Entire Manual
Contents
1. INSTALLATION amp SERVICE WANNER ENGINEERING INC X 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 H G 25 Contents Page SPeCiiCAtlONs zez2 ist de eiietepscs teases etait cae iend 2 Dimensio S aaa T a beast sada eee hese aia n 4 Instalati sea n a a nea a aeara Bee 5 Maintenance nicah es a a a 9 Service Fluid End penre end saaa sienna neiden sisa 10 Service Hydraulic End cc eeceeeeeeeeeeeeeeeeeeeeeeeteeeeereee 15 Troubleshooting 5 ccsisceseessecenescapceneteeseesicensasceaestaccanersuneesane 18 H G 25 Specifications Max Pressure Metallic 1000 psi 70 bar Non Metallic 250 psi 17 bar Capacity Max Pressure rpm gpm l min H G 25 X 1050 20 0 76 H G 25 E 1150 20 2 77 H G 25 S 1150 15 6 59 H G 25 1150 11 6 44 Calculating Required Horsepower kW Delivery Max Pressure revs gal revs liter H G 25 X 52 14 H G 25 E 57 15 H G 25 S 74 19 H G 25 99 26 Max Inlet Pressure Metallic 250 psi 17 bar Non Metallic 50 psi 3 5 bar Max Temperature Metallic 250 F 121 C consult factory for temperatures above 160 F 71 C Non Metallic Polypropylene 120 F 49 C Kynar 140 F 60 C Inlet Port H 25 1 1 2 inch NPT G 25 1 1 2 inch BSPT H 25 1 inch NPT G 25 1 inch BSPT 1 1 8 inch 28 58 mm Discharge Port Shaft Diameter2. NOTE The numbers in parentheses are the Reference Numbers on the exploded view illustrations found 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 pump head manifold valve plate and related items Mounting The pump shaft can be rotated in either direction To prevent vibration securely attach the pump and motor to a level 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 Unless otherwise specified by the coupling manufacturer maximum parallel misalignment should not exceed 0 015 in 0 4 mm and angular misalignment should be held to 1 maximum Careful alignment extends life of the coupling pump shafts and support bearings Consult coupling manufacturer for exact alignment tolerances Pressure Gauge Pressure Regulator Vacuum Pressure Gauge 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 D
3. Shaft Rotation Bi directional Bearings Tapered roller Oil Capacity 2 5 US quarts 2 4 liters Weight Metallic Heads 125 Ibs 56 8 kg Non Metallic Heads 90 lbs 40 9 kg 50 x rpm _ 9PMXPSi_ electric motor HP 63 000 1 460 50 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 G25 991 2400 5 1 04 H G 25 Specifications Gallons Per Minute RPM 200 400 600 800 1000 1200 24 0 88 0 84 0 22 0 8 8 80 0 HIG 25 X 7 20 0 d 76 0 72 0 200 PSI 14 bar 18 0 500 PSI 35 bar 68 0 1000 PSI 70 bar j 64 0 16 0 60 0 56 0 14 0 52 0 48 0 12 0 44 0 40 0 10 0 36 0 32 0 8 0 28 0 24 0 6 0 20 0 16 0 4 0 12 0 8 0 2 0 4 0 0 0 Liters Per Minute Net Positive Suction Head NPSHr 2 7 0 22 3 T H G 25 X 20 H G 25 E H G 25 S 6 0 H G 25 1 18 16 5 0 a g s Z 14 a 5 4 0 2 8 12 2 x b D 10 3 0 a 8 2 0 6 4 1 0 2 0 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 Dry Lift Lift feet of water RPM Lift meters of water 200 400 600 RPM 0 800 10
4. 52 into a spring retainer 51 e Install two O rings 52 on the valve cylinder 55 f Slide the assembled valve cylinder plunger and spring 53 55 into the spring retainer 51 Install an O ring 56 on the spring retainer 51 Slide the complete cylinder and retainer assembly 51 56 into the piston assembly 59 i Insert a return spring 50 into the piston assembly j Repeat the above procedure for the other two pistons ze 4 Reassemble Pump Housing and Cylinder Housing NOTE Inspect the shaft seals 64 before continuing If they look damaged in any way replace them remove by pounding them out from inside the pump housing Both seals should be replaced at the same time Clean the seal bore in the housing using emery cloth or ScotchBrite a Place the cylinder housing 25 face down on a flat surface b Insert the assembled pistons 50 59 into the cylinder housing c Note the location of the outer ring of holes in the cylinder casting and in the pump housing flange in particular the holes where bolts 26 will be installed Screw threaded studs from the Wanner Tool Kit into two of the four threaded holes in the cylinder housing Use opposite holes d Stand the camshaft assembly 62 on the cylinder housing 25 CAUTION The pilot bearing MUST be properly nested in the bearing race during assembly If misaligned the bearing will be damaged and the pump will fail within the first h
5. Usually caused by fluid being frozen a With the pump horizontal and the fluid end head in the pump or by overpressurization of the pump removed fill the reservoir with the appropriate Hydra oil Diaphragm becoming stiff and losing flexibility for the application Have a catch basin for oil that leaks Usually caused by pumping a fluid that is incompatible from behind the diaphragms when priming Catch the oil with the diaphragm material and dispose of it properly do not reuse it diaphragm is operated at temperatures below its rated b All air in the oil within the hydraulic cell behind the capability diaphragms must be forced out by turning the shaft and Diaphragm edge chewed away Usually caused by thus pumping the piston A shaft rotator is included in overpressurizing the system the Wanner Tool Kit Turn the shaft until a bubble free Inspect the plunger 23 for any rough surfaces or edges flow of oil comes from behind all the diaphragms Watch Do not remove the plunger from the valve plunger 54 the oil level in the reservoir if it gets too low during Smooth the surfaces and edges as necessary with emery priming at ull be drawn Into the pistons inside the cloth or a fine file hydraulic end and will cause the pump to run rough CAUTION If a diaphragm has ruptured and foreign C Wipe excess oil from the cylinder casting 24 and material or water has entered the oil reservoir do diaphragms 20 not operate the pump Che
6. and collect drainage 3 Close draincocks in system piping and replace manifold plug 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 extended 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 G25 991 2400 5 1 04 H G 25 Service Fluid End Models with Non Metallic Pump Head e G7 36 A Cii 35 28 a i ok Il TA Oo Lbs ae d 10 G25 991 2400 5 1 04 H G 25 Service Fluid End Models with Metallic Pumping Head lt With brass external centerbolt models use 8 with all other models use 3 With cast iron pump heads use 17 and not 10 with all other heads use 10 and not 17 Not required on all pumps Valv
7. end of the tool Apply a heavier coat of grease between the seals and press them together Apply a coating of Loctite High Performance Pipe Sealant With Teflon or a comparable product to the outer surface of both seals and the inside surface of the opening in the pump housing where the seals will rest Apply a light film of grease to the drive shaft Slide the seal protector tool with the two seals over the end of the shaft Slide the seal inserter tool from the Wanner Tool Kit over the seal protector tool and press the seals completely into place Tap the tool with a soft mallet to firmly seat the seals 6 Adjust Camshaft Endplay a b If the three set screws 24 are in the cylinder housing 25 remove and clean them Insert the centerbolt 1 into the hole in the center of the cylinder housing Turn it in to move the bearing adjusting plate 61 and cup tight against the bearing cone Back out the centerbolt two full turns then turn it back in again until it is tight against the adjusting plate 61 Back out the centerbolt exactly 1 4 of a turn With a plastic mallet or a regular mallet and wooden board to prevent damage to the shaft rap the end of the shaft three or four times This will provide about 0 006 in 0 15 mm endplay in the shaft Apply removable threadlocker to the threads of the three cleaned set screws 24 Screw the three set screws 24 into the cylinder housing until they contact the bear
8. for unsteady flow If the pump does not clear refer to the Troubleshooting Section 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 5 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 safety relief valve at 100 psi 7 bar higher than the desired operating pressure To verify this setting adjust the discharge pressure regulator upward until the relief valve opens Follow the recommendations in the above NOTE step 4b for handling the fluid that will come from the relief valve Reset the discharge pressure regulator
9. 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 3 ft 1 m long e Use at least 1 1 2 in 88 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 G25 991 2400 5 1 04 H G 25 Installation 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 5
10. maintain maximum flow vacuum at the pump inlet should not exceed 7 in Hg at 70 F 180 mm Hg at 21 C 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 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 Amaximum of 3 feet 1 m is recommended Use flexible hose and or expansion j
11. reduce the chance of turbulence and cavitation If the pump may be run for a long time with the discharge closed and fluid bypassing install a thermal protector in the bypass line to prevent severe 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 G25 991 2400 5 1 04 H G 25 Installation Before Initial Start Up Before you start the pump be sure that All shutoff valves are open and the pump has an adequate supply of fluid All connections are tight The oil level is 1 4 in 6 mm above the cast surface in the upper oil reservoir The relief valve on the pump outlet 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 belts and shaft couplings have adequate safety guards Initial Start Up Procedure 1 2 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 at 70 F 180 mm Hg at 21 C Inlet pressure must not exceed 250 psi 17 bar Listen for any erratic noise and look
12. when you disassemble the pump e Remove the bolts 26 that secure the housing to the cylinder casting The piston return springs 50 will force the cylinder casting and housing apart f Lift off the housing 30 g Inspect the cam and bearings 62 and the bearing race in the rear of the housing If the bearings are pitted or binding or if the housing race is worn contact Wanner Engineering 2 Disassemble Pistons a With the pump housing removed see above turn the unit over and set it on a flat surface piston side down b With diaphragms removed see the Fluid End Service Section reinsert a follower screw 19 into the hole in one of the valve plungers 54 Tap the screw lightly with a hammer the plunger 23 should slip off the valve plunger 54 The hydraulic piston assembly 50 59 can now be disassembled Inspect all parts and replace all O rings and any other parts that are worn or damaged c Repeat step b for the remaining pistons NOTE When you reassemble the hydraulic piston use new plungers 23 They are press fit onto the valve plungers 54 and are generally not reusable 16 3 Reassemble Pistons a Drop a ball 58 into each opening in the bottom of a piston assembly 59 b Insert a retaining washer 57 and O ring 56 to hold the ball in place c Insert a valve plunger 54 into a valve cylinder 55 Slide a spring 53 over the plunger inside the valve cylinder d Insert an O ring
13. 0 4 000 3 000 2 000 lt 1000 psi 70 bar lt 800 4 000 3 000 2 000 lt 1200 2 000 1 500 1 000 Non Metallic Pump Head lt 250 psi 17 bar lt 800 4 000 3 000 i lt 1200 2 000 1 500 _ NOTE Minimum oil viscosity for proper hydraulic end lubrication is 16 20 cST 80 100 SSU NOTE Use of an oil cooler is recommended when process fluid and or hydraulic end oil exceeds 180 F 82 C for Metallic Pump Head models or when hydraulic end oil exceeds 180 F 82 C for Non Metallic Pump Head models CAUTION Do not turn the drive shaft while the oil reservoir is empty Check the inlet pressure or vacuum periodically with a gauge If vacuum at the pump inlet exceeds 7 in Hg 180 mm Hg check the inlet piping system for blockages If the pump inlet is located above the supply tank check the fluid supply level and replenish if too low CAUTION Protect the pump from freezing Refer also to the Shutdown Procedure 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 remove plug 4 from manifold
14. 00 1200 G25 991 2400 5 1 04 H G 25 Dimensions Models with Metallic Pumping Head Brass Cast Iron 316 Stainless Steel Nickel Alloy Hastlloy CW12MW B 432 13 8 es 350 g Oil Fill Cap 0 25 2 00 Outlet 6 4 50 8 H 25 1 NPT Keyway G 25 1 BSPT 1 125 28 58 us Inlet ee E Fl EE H 25 1 1 2 NPT y G 25 1 1 2 BSPT 3 8 18 NPT 5 63 Drain Port a 0 25 6 4 E A 2 25 0 42 4 57 2 lt a e 982 sit wat a6 Sot Width 4 4 6 8 a br 144 lt 173 10 0 a 254 gt oa gt Models with Non metallic Pump Head Kynar Polypropylene 17 4 F 444 3 2 14 2 0 50 81 3 7 362 12 7 0 50 a OilFilCap a27 Outlet 0 25 H 25 1 NPT ea G 25 1 BSPT Keyway 1 125 28 58 Inlet H 25 1 1 2 NPT 5 eq a G 25 1 1 2 BSPT 3 8 18 NPT 5 63 Drain Port os 0 25 6 4 A 2 25 gt 0 42 Slot Width ETRS 67 2 lt x 242 sit idt a6 Sot Width 3 4 45 6 8 86 4 7 lt ai 173 10 0 10 0 ii 254 g lt 254 gt 4 G25 991 2400 5 1 04 H G 25 Installation Location
15. 00 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 hose with a working pressure rating of at least 1 5 times the maximum system pressure EXAMPLE Select a 1500 psi W P rated hose for systems to be operated at 1000 psi 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
16. and complete installation d When compressed air is being used to prime insert a clean air hose to the pump inlet and restrict the pump outlet Turn the shaft a quarter turn and then apply air pressure into the manifold to put pressure on the diaphragms This will force air out from inside the pistons and you will see bubbles at the reservoir opening Repeat for several rotations until no more air bubbles come out and the reservoir level has dropped about 1 25 mm The hydraulic cells are now primed e Replace the oil fill cap and complete installation 6 Reinstall Valve Plate 18 Manifold 7 a Reinstall the valve plate 18 with the valve assemblies installed as outlined above onto the cylinder casting b Reinstall the O rings between the valve plate and manifold See illustrations to determine which O rings to use depending on pumping head material Use petroleum jelly or lubricating gel to hold them in place c Reinstall the manifold onto the valve plate Be sure the drain plug 4 is at the bottom of the manifold If the pumping head is non metallic support plate 43 is also required d Insert all bolts 5 washers 6 and nuts 31 around the edge of the manifold and the centerbolt 1 with washer 2 Hand tighten e H 25 external centerbolt models only Install the centerbolt 1 with its washer 2 and tighten it Torque to 60 N m Model H 25 e Torque centerbolt to 45 ft lbs f Alternately tigh
17. ck all diaphragms then d Ensure that the oil is 1 inch 25 mm from the top of the flush the reservoir completely as outlined below fill port and refill it with fresh oil Never let the pump stand e Replace oil fill cap 27 with foreign material or water in the reservoir or with the reservoir empty Install a new diaphragm or reinstall the old one as appropriate ridge side out Clean the screw 19 and remove any oil from it Apply medium strength threadlocker to the screw Reinstall the screw the follower 21 and a new O ring 20 Tighten to 18 in Ibs 2 0 N m Repeat the above inspection procedure and replacement if necessary with the other two diaphragms 13 5B Priming the Hydraulic Cells for Kel Cell Pumps NOTE Providing oil prime to Kel Cell fitted pumps requires pressure be applied to the diaphragms This can be done manually with the system head pressure or with pressurized air if available Review all methods below to determine the procedure most suitable G25 991 2400 5 1 04 H G 25 Service Fluid End Method 1 system head pressure ess than 2 psi a Install the valve plate 16 but without the outlet valves installed or else remove the outlet valves leave the seats installed onto the cylinder housing Tighten the two socket head screws 41 b Fillthe reservoir with appropriate Hydra oil to the fill port c With a blunt pointer eraser end of pencil reach in through each outle
18. e Assemblies with metal spring retainers Er comm i 11 G25 991 2400 5 1 04 H G 25 Service Fluid End NOTE The numbers in parentheses are the Ref Nos on the illustrations 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 CAUTION Do not disassemble the hydraulic end unless you are a skilled mechanic For assistance contact Wanner Engineering TEL 612 332 5681 or FAX 612 332 6937 or the distributor in your area CAUTION The four bolts 26 that screw through the back of the housing into the cylinder casting hold the casting over the hydraulic end of the pump Do not remove them except when repairing the hydraulic end 1 Remove Manifold 7 Valve Plate 18 a Remove all nuts 31 and bolts 5 around the manifold Do not remove the four bolts 26 that are installed through the back of the pump housing b With a 3 8 in 10 mm hex Allen wrench remove the centerbolt 1 and its washer 2 in the center of the manifold CAUTION Do not turn the pump drive shaft while the manifold and valve plate are off the pump except when removing diaphragms or repriming the hydraulic cells c Remove the manifold 7 and support plate 43 Support plate 43 is used only with non metallic pump head d Inspect the manifold for warpi
19. ent manually turn the diaphragm up The proper size tool is included in the the pump shaft to circulate the kerosene and drain Wanner Tool Kit CAUTION If you have EPDM diaphragms or if food Remove the screw 19 O ring 20 and follower 21 in grade oil is in the reservoir do not use kerosene or the center of the diaphragm solvents Instead flush with the same lubricant that Remove the diaphragm and inspect it carefully A is in the reservoir Pumps with EPDM diaphragms ruptured diaphragm generally indicates a pumping have an E as the 7th digit of the Model No system problem and replacing only the diaphragm will c Repeat the flushing procedure step b not solve the larger problem Inspect the diaphragm for d Fill the reservoir with fresh oil manually turn the pump the following shaft to circulate the oil and drain once again Half moon marks Usually caused by cavitation of the e Refill the reservoir If the oil appears milky there is still pump refer to the Troubleshooting section e Concentric circular marks Usually caused by cavitation of the pump refer to the Troubleshooting section Small puncture Usually caused by a sharp foreign object in the fluid or by an ice particle Diaphragm pulled away from the center screw or from contaminant in the reservoir Repeat the flushing procedure until the oil appears clean 5A Prime the Hydraulic Cells on Standard Pumps the cylinder sides
20. il runs out past the diaphragms with socket head screws 41 but do not tighten completely Leave a gap between the valve plate and the cylinder housing Turn the shaft 2 3 turns to finish forcing out air behind the diaphragms The hydraulic cells are now primed Now finish tightening the valve plate with the two socket head screws and add pump manifold c Wipe excess oil from around the pump head d Check that the oil level is 1 inch 25 mm from the top of the fill port e Replace the oil fill cap and complete installation 14 Method 2 head pressure greater than 2 psi This simple and clean method of priming the Hydra cells requires an inlet head pressure of at least 5 feet 1 5 m or 2 psi 14 bar The pressure source is required to hold the diaphragms back while the piston moves so as to force out the air Completely assemble the pump and fill the reservoir with the appropriate Hydra oil to the fill port a When tank head pressure is being used to prime install the pump back into the system and connect the tank supply line to pump inlet Pump discharge line may be connected at this time but end of line must be open to allow air to pass out b Slowly turn the pump shaft by hand and watch for bubbles exiting the oil reservoir fill opening This will take several rotations when no more bubbles come out and the reservoir level has dropped about 1 25 mm the hydraulic cells are primed c Replace the oil fill cap
21. ing adjusting plate 61 Remove the centerbolt 1 17 7 Install Plungers NOTE If the plungers 23 have been removed from the valve plungers 54 do not reuse them Install new ones instead a b Rotate the pump shaft so the piston is in the top dead center position Place a plunger on the exposed screw end of the plunger guide tool from the Wanner Tool Kit The larger diameter side of the plunger should face the tool Screw the guide with the plunger into the valve plunger 54 until tight Hold the single bottom handle of the guide and turn the double top handle to force the plunger to seat on the valve plunger This is a press fit when installed the plunger should be tight against the shoulder of the valve plunger NOTE Do not remove the plunger guide until the diaphragm is installed see below Install the diaphragm as outlined below then repeat the procedure for the other two plungers and diaphragms 8 Reinstall Diaphragms a With the plunger guide tool still screwed into the valve plunger 54 pull the valve plunger up until the cross holes in the valve plunger are exposed Insert the plunger holder from the Wanner Tool Kit through the top hole to hold the plunger 23 away from the cylinder housing and to keep the valve plunger from turning when the diaphragm is being installed Place the diaphragm 22 onto the plunger 23 ridge side out Center the diaphragm follower 21 on
22. isplacement 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 installation 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 71 C or below 40 F 5 C Pressure feeding of pumps Viscous or abrasive fluid applications Chemical compatibility problems Hot ambient temperatures above 110 F 43 C Conditions where pump oil may exceed 200 F 93 C because of a combination of hot ambient temperatures hot fluid temperature and full horsepower load an oil cooler may be required TO TANK G25 991 2400 5 1 04 H G 25 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
23. ll the O ring 11 on the valve seat 12 NOTE Some pumps use plastic dampening washers 38 between the valve seat 12 and the manifold 7 or valve plate 18 Refer to the illustrations on page 11 and the fluid end exploded views in the Parts Manual e Inlet 3 center valves Insert the spring retainer 16 into the valve plate then insert the spring valve and valve seat 14 13 12 If the pump has plastic spring retainers a flat O ring 15 goes between the retainer and seat e Outlet 3 outer valves Insert the valve seat valve and spring then the retainer If the pump has plastic retainers install the flat O ring between the retainer and seat If the pump has metal spring retainers in the outlet valves position them so a leg does not point toward the center of the pump refer to the illustration INSTALLING OUTLET VALVES ON VALVE PLATE WRONG Retainer leg pointing toward center of pump G25 991 2400 5 1 04 H G 25 Service Fluid End 3 Inspect and Replace Diaphragms 22 a Lift the diaphragm by one edge and turn the pump shaft 4 Flush Contaminant from Hydraulic End only if a diaphragm has ruptured until the diaphragm pulls up This will expose machined cross holes in the valve plunger shaft behind the a Remove the oil drain cap 34 and allow all oil and diaphragm contaminant to drain out Insert an Allen wrench through one of the holes to hold b Fill the reservoir with kerosene or solv
24. ng or wear around the inlet and outlet ports If wear is excessive replace the manifold To check if the manifold is warped remove the O rings and place a straightedge across it A warped manifold should be replaced e Remove the three socket head cap screws 39 with a 3 16 in 5 mm hex Allen wrench f Inspect the valve plate in the same manner as the manifold NOTE Plastic valve plates and manifolds should also be inspected for cracks and replaced if necessary 12 2 Inspect Valves 11 16 38 The three inlet and three outlet valve assemblies in the pump are identical but face in opposite directions Inspect each valve as follows a Check the spring retainer 16 and replace if worn b Check the valve spring 14 If it is shorter than a new spring replace it don t just stretch the old spring c Check the valve poppet 13 If worn excessively replace it NOTE If your pump has plastic spring retainers there is a tetra seal flat O ring 15 between the retainer 16 and valve seat 12 d Remove the valve seat 12 Aseat remover is included in the Wanner Tool Kit On cast iron valve plates be careful not to break the metal ridge around the O ring groove Inspect the valve seat for wear and replace it if necessary Install a new O ring 11 e Reinstall the valve assemblies e Clean the valve ports and shoulders with emery cloth and lubricate them with lubricating gel or petroleum jelly e Insta
25. oints 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 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 Loctite is a registered trademark of Loctite Corporation Teflon is a registered trademark of E 1 DuPont de Nemours amp Co Inc Scotchbrite is a registered trademark of 3M Company 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 17 bar if it could get higher install an inlet pressure reducing 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
26. ours of operation e Using grease to retain it install the O ring 65 and slide the housing 30 down over the shaft and onto the threaded studs from step c Be sure the holes in the housing and the cylinder housing are properly aligned f Install washers 6 and nuts 31 on the threaded studs but don t tighten yet You may want to insert two or more bolts 5 into the unthreaded holes of the housing and cylinder housing to help align the parts G25 991 2400 5 1 04 H G 25 Service Hydraulic End g Alternately tighten the nuts 31 to evenly draw the housing down to the cylinder housing Be sure the O ring 65 stays in place Also as you tighten the nuts keep checking the shaft alignment by turning the shaft use the rotator in the Wanner Tool Kit If the shaft begins to bind and become difficult to turn back off the nuts and realign the shaft When the pump housing is tight against the cylinder housing you should be able to turn the shaft smoothly After all the nuts 31 are tightened insert cap screws 26 with washers 6 into the two unused threaded holes in the housing Then remove the two threaded studs and replace them with the other two cap screws and washers Turn the shaft again to check its alignment 5 Replace Shaft Seals a Apply a thin film of grease on the seal protector tool part of the Wanner Tool Kit Slide both seals onto the tool with the spring side of the seals toward the open
27. r 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 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 Worn and slipping drive belt s e Worn spray nozzle s e Cracked cylinder casting 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 Cavitation e Air in suction line e Restriction in inlet suction line e Hydraulic cells not primed after changing diaphragm e Foreign material in inlet or outlet valve Damaged diaphragm e Fatigued or broken valve spring e Brocken piston return spring insed hydraulic end Premature Failure of Diaphragm Frozen pump e Puncture by a foreign object Elastomer incompatible with fluid being pumped Pump running too fast e Excess pressure e Cavitation e Broken piston return spring 50 Water or Process Fluid in Oil Re
28. servoir Condensation e Ruptured diaphragm e Hydraulic cell not properly primed after diaphragm replacement Frozen pump e Diapragm screw O ring 18 missing or cracked e Cracked cylinder casting Strong Water or Process Fluid Pulsations NOTE Small pulsations are normal in single acting pumps with multiple pumping chambers 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 13 broken e Cavitation e Aeration or turbulence in supply tank G25 991 2400 5 1 04 H G 25 Troubleshooting Valve Wear Normal wear from high speed operation Cavitation Abrasives in the fluid Valve incompatible with corrosives in the fluid Pump running too fast Loss of Oil External seepage Rupture of diaphragm Frozen pump Diapragm screw O ring 18 missing or cracked Worn shaft seal Oil drain piping or fill cap 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 Excessive inlet pressure 19 G25 991 2400 5 1 04 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 20 Limited Warranty Wanner Engineering Inc ex
29. t valve port and push the follower diaphragm backwards Note the air bubbles coming out at the oil fill port Now turn the shaft about 1 2 turn d Repeat depressing diaphragms and rotating shaft approx 4 6 times until no more air bubbles escape and the oil has dropped about 1 inch 25 mm from the top of the fill port The hydraulic cells are now primed Replace the oil fill cap e Install outlet valve assemblies in each outlet valve port See Parts Manual for correct assembly order You may have to tip pump head upward in order to keep the valve centered on the seat and allow the retainer to fit all the way into port flush f Install manifold 6 and complete installation Alternative Method 1 With the pump horizontal and the fluid end head removed fill the reservoir with the appropriate Hydra oil for the application Have a catch basin for oil that leaks from behind the diaphragms when priming Catch the oil and dispose of it properly do not reuse it a All air in the oil within the hydraulic piston behind the diaphragms must be forced out by turning the shaft and thus pumping the piston A shaft rotator is included in the Hydra Cell Tool Kit Keep pressure on the diaphragms while turning the shaft until a bubble free flow of oil comes from behind all the diaphragms Maintain the oil level in the reservoir Do not allow oil level to be lower than the reservoir b Quickly attach the loaded valve plate 16 before the o
30. ten opposite bolts 5 until all are secure Torque to 45 ft lbs Model G 25 e Alternately tighten opposite bolts 5 until all are secure Torque to 60 N m f Torque the centerbolt to 60 N m G25 991 2400 5 1 04 H G 25 Service Hydraulic End Kel Cell Qty per piston 4 G25 991 2400 5 1 04 15 H G 25 Service Hydraulic End NOTE The numbers in parentheses are the Ref Nos on the illustrations in the Parts Manual CAUTION Do not disassemble the hydraulic end unless you are a skilled mechanic For assistance contact Wanner Engineering TEL 612 332 5681 or FAX 612 332 6937 or the distributor in your area CAUTION The four bolts 26 that screw through the back of the housing into the cylinder casting 25 hold the casting to the pump housing Do not remove them except when repairing the hydraulic end NOTE The following service procedures refer several times to the Wanner Tool Kit We strongly urge you not to try to repair the hydraulic end of the pump without using the tools in this kit available from Wanner or your local distributor 1 Remove Pump Housing a Remove the head of the pump and the diaphragms as outlined in the Fluid End Service Section b Drain the oil from the pump housing by removing the drain plug 34 c Set the hydraulic end of the pump face down on the cylinder casting 25 d Check the shaft for sharp burrs Smooth any burrs to prevent scarring the housing seals 64
31. tends 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 loss is expressly excluded and denied 2004 Wanner Engineering Inc Printed in USA G25 991 2400 5 1 04
32. the diaphragm Place the O ring 20 onto the follower screw 19 Apply a small amount of threadlocker to the threads of the follower screw Insert the follower screw with O ring through the diaphragm follower 21 and diaphragm 22 and screw it into the valve plunger 54 Hold the plunger holder and torque the follower screw to 18 in lbs 2 0 N m Repeat the above procedure for the plungers and diaphragms of the other two cylinders Fill the reservoir with fresh oil and prime the pump as outlined in the Fluid End Service Section 9 Reassemble Pump Head Reassemble the pump head as outlined in the Fluid End Service Section G25 991 2400 5 1 04 H G 25 Troubleshooting Cavitation e Inadequate fluid supply because 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 and elbows in inlet line 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 vacuum too high Symptoms of Cavitation e Excessive pump valve noise e Premature failure of spring or retainer e Volume or pressure drop e Rough running pump e Premature failure of diaphragms e Piston return spring failure insed hydraulic end Drop in Volume or Pressure A drop in volume or pressure can be caused by one o
33. 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 0 066 for the H 25 and G 25 Hydra Cell pumps 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 with 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
34. to the desired system pressure Provide a return line from the relief valve to the supply tank similar to the bypass line from the pressure regulator G25 991 2400 5 1 04 H G 25 Maintenance NOTE The numbers in parentheses are the Reference Numbers on the exploded view illustrations found in this manual and in the Parts Manual Daily Check the oil level and the condition of the oil The oil level should be 1 4 in 6 mm above the cast surface in the upper oil reservoir 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 one of the diaphragms 22 may be damaged Refer to the Fluid End Service Section Do not operate the pump witha 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 Periodically Change the oil after the first 100 hours of operation and then according to the guidelines below When changing remove the drain plug cap 34 at the bottom of the pump so all oil and accumulated sediment will drain out Hours Between Oil Changes Various Process Fluid Temperatures lt 90 F 32 C lt 180 F 82 C lt 139 F Pressure RPM 60 C Metallic Pump Head lt 650 psi 45 bar lt 800 6 000 4 500 3 000 lt 120
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