Fill-rite FR405 User's Manual
Contents
1. F SERIES 400 PUMP PARTS LIST ITM PART 6 _ 400r6924 Gasket Inlet Flange 2 8 _ 35F6588 O ring 117 Included wiltem 7 9 400F6589 Check Valve Outlet 4 4 10 400F7238 Diaphragm Assembly FilCon 2 eee Includes Items 7 8 9 ey 400F6917 Diaphragm Assembly Santoprene Opt eee Includes Items 7 8 9 ed 8 _25 40007494 6 32 x 1 2 FANS Incl wiltem tor2 Ball Valve Nozzle 1 Poly Nozzle 1x12 EPDM Hose __ 400F3140 __ 1 x12 Nyall Hose a2 aoocsee7 Onno 007 6 ___ zoor7a2o___ Power Gord 115 VAC Only Not Shown Opt 65067185 _ Power Cord 230 VAC Only Not Shown Opt _ 400F1855 Suction Pipe Polypropylene Not Shown Opt WHEN ORDERING REPAIR PARTS BE SURE TO GIVE REPLACEMENT PART NUMBER DATE OF MANUFAC TURE AND PUMP MODEL NUMBER THIS WILL ENSURE THAT THE CORRECT REPLACEMENT PART IS SUPPLIED 400KTF6862 Series 400 Repair Kit Includes Items 6 11 24 28 amp 42 EXPLOSION PROOF MOTOR OPTION CAUTION NEVER disassemble Yoke Assembly This is under extreme spring tension and injury could result WHEN ORDERING REPAIR PARTS BE SURE TO GIVE RE PLACEMENT PART NUMBER DATE OF MANUFACTURE AND PUMP SERIES NUMBER THIS WILL ENSURE THAT THE CORRECT REPLACEMENT PART IS SUPPLIED TOLL FREE CUSTOMER CARE NUMBER 800 634 2695 TROUBLESHOOTING GUIDE e Chec e Chec eChec e Chec e Chec Repa Pump won t prime Suction l2. and tighten to 35 in lbs of torque 6 Install pump covers item 4 Hand start and tighten screws item 20 to 50 in Ibs 7 Install motor item 1 and gear assembly item 24 Be sure gasket item 26 is in place Rotate motor until drive shaft slips in hole in gear assembly Tighten screws item 20 to 50 in Ibs of torque 8 Fill with approximately 16 ounces of automotive grade SAE 30W oil through one of the holes for sight caps item 30 To further disassemble pump 9 Remove motor and drain oil if complete disassembly is required 10 Remove four screws item 19 and lockwashers item 21 holding bearing plate item 17 11 Remove bearing plate item 17 and thrust plate item 16 12 Remove drive shaft item 13 bearing item 14 bearing ring 15 and yoke assembly item 12 Assemble in reverse order See step 4 through step 8 above for additional assembly instructions Hand start and tighten screws to 50 in Ibs MAINTENANCE To keep pump running at its best periodically perform the following procedures Refer to exploded view drawing of pump Chemical Applications Do not allow chemical to remain in the pump for any extended period of time whereby the chemicals are allowed to dry out Thoroughly rinse pump and meter by flushing the pump with water or appropriate flushing fluid DO NOT USE PRESSURIZED WATER OR PRESSURIZED AIR to flush your pump Damage to the equipment can occur if flush water
3. buildup and discharge could result in arc and explosion Mounting Holes Circuit Breakers AC only XE A Power to the unit should be supplied from a dedicated Adapters are available to fit the pump to a 2 bung anda circuit breaker No other equipment should be powered selection of standard bung fittings common inthe petroleum from this breaker Provision must be made to break both chemical and agricultural markets legs of any AC circuit Use pipe compound or Teflon tape on all threaded fittings except 2 bung threads if present Dimensions Electrical Installation EXPLOSION PROOF MOTOR OPTION Electrical wiring should be done by alicensed electrician in accordance with approved electrical codes Motor should be prop erly grounded and arigid con duit should be used when in stalling electrical wiring Im proper use or installation of this product can cause seri ous bodily injury or death DC ONLY Connect cable to 12 volt DC power supply as follows paying special attention to wire colors Pump Cable CALIBRATION Positive Red Negative If a meter is used calibrate according to the instructions in the meter s Owner s Operation amp Safety Manual If pump is to be mounted on a vehicle it is recommended that permanent wiring and connections be made to vehicle power system which includes a 30 amp slow blow fuse ASSEMBLY DISASSEMBLY NOTE Pump should be thoroughly flushed prior to disa
4. FILL RITE Owner s Manual SERIES FR400 DIAPHRAGM PUMP For Industrial Fluid Transfer For models FR405 FR410 FR412 FR205 FR210 FR212 DC amp FR450 FR450E FR452 AC Model FR410 Patent 5 219 274 EXPLOSION PROOF MOTOR OPTION Electrical wiring should be done by a licensed electrician in accordance with approved electrical codes Motor should be prop erly grounded and arigid con duit should be used when in stalling electrical wiring Im proper use or installation of this product can cause seri ous bodily injury or death Not for use with fluids that have a flash point below 100 F 37 8 C ie gasoline alcohol Refer to NFPA 325M Fire Hazard Properties of Flam mable Liquids Gases and Volatile Solids for flash points of common liquids Static electricity buildup and discharge could result in arc and explosion Use Teflon tape to seal all joints to avoid leakage of fluids being pumped Leaking of caustic and or hazardous fluids could result in severe injuries Never disassemble YOKE ASSEMBLY see item 12 This is under extreme pressure and injury could result Tank or barrel should be anchored to prevent tipping in both the full and empty conditions The pump motor is equipped with thermal overload pro tection If overheated it will shut itself off without any damage to the windings Be sure to turn off the pump power if this occurs As the motor cools it will start witho
5. PS to 3000 CPS SAE 140 gear oil at 68 F e Minimum shear agitation of pumped fluids e Does not include inlet strainer e Minimum operating temperature 10 F 23 C e Maximum operating temperature 130 F 54 C e Overall dimensions 14 35 6 cm long x 8 25 21cm high x 8 75 22 2 cm deep 30 minute duty cycle not for continuous operation Fluid Compatibility The FR400 Series pump is compatible with the following fluids e Ethylene Glycol Hydraulic Oil Motor Oil Water The FR400 Series pump is NOT compatible with the following fluids e Acetone Ammonia Gasoline Bleach Chlorine Hydro chloric Acid Ink MEK If in doubt about compatibility of a specific fluid contact the supplier of the fluid to check for any adverse reactions to the wetted materials shown in the parts list Stainless Steal PBN INSTALLATION The basic pump is furnished with 1 NPT threaded openings in the inlet and outlet flanges Flanges are available as a straight outlet or a 90 angle design which can be rotated four ways to accommodate different installation needs Both inlet and outlet flanges include four 1 4 20 threaded holes spaced 1 7 8 between centers for secure mounting Not for use with fluids that have a flash point below 100 F 37 8 C ie gasoline alcohol Refer to NFPA 325M Fire Hazard Proper ties of Flammable Liquids Gases and Volatile Solids for flash points of common liquids Static electricity
6. he surface of the fluid in the tank tothe inlet ofthe pump PLUS the friction losses through the vertical and horizontal runs of pipe all elbows and other fittings Systems should be designed to require a minimum amount of suction lift SERIES 400 DIAPHRAGM PUMP TYPICAL FLOW RATE FOR VARIOUS VISCOSITIES FLOW in LITERS PER MINUTE lom 0 7 6 15 1 22 7 30 3 37 9 45 4 53 60 6 50 15 2 NOTES fe tae oy _ SUCTION LOSSES and LU Lu Test pump was mounted on a 55 HI 40 122 fy gallon drum of oil 1 2 full A a FILL RITE 1 suction pipe was used ep O 35 10 7 en A longer or smaller diameter inlet er O pipe will lower the flow rate Ek 30 9 1 z 05 2 VERTICAL HEAD LOSSES 25 76 amp Test hose was horizontal with oO T pump Add 3 feet of hose for each 2 1 foot of vertical rise QO 20 et 5 a a 3 OTHER LOSSES T 15 46 5 Elbows quick disconnects 5 fe swivels and check valves I 40 3 O in outlet or inlet hoses 5 T will restrict the flow Z 5 Add the estimated length of hose ig 1 5 Z for each component used al 0 0 Wi Other 1 disconnects 13 0 feet 0 2 4 6 8 10 12 14 16 1 Check Valves 8 7 feet 1 Elbow 2 6 feet FLOW in GALLONS PER MINUTE gpm ere ees 225 CPS 30 wt Oil 78 F m 308 cps 30 wt Oil 69 F emmmmmn 665 cps 30 wt Oil 49 F 560 cps 30 wt Oil 56 F 2420 cps 30 wt Oil 22
7. ine problem e Leaky check valves e Check valves improperly installed e Outlet plugged e Motor not operating k for leaks in suction line k for dirt or damaged check valves and replace k for proper installation k for blockage and clear k power source ir or replace motor e Stripped or damaged gears Check gear assembly and drive gear for damage Replace complete assembly if necessary Pump hums but will Motor faulty not operate e Gear mechanism jammed e Replace motor e Check for free rotation of the gears Low pump capacity Low voltage e Leaky suction line e Dirt in check valves e Faulty check valves e One or both diaphragms leaking e One piston screw loose e Check power source e Repair leaks e Dismantle and clean e Install repair kit e Install repair kit e Install new yoke assembly e Piston retainer screws loose e Install new yoke assembly e Debris ingested e Add inlet screen Motor overheats e Pumping hot fluids e Shorten duty cycle e Motor faulty e Replace motor Fluid leakage e Faulty or missing gaskets e Loose bolts e Cracked component e Piston retainer screws loose e Install all gaskets specified in parts list e Torque all bolts to 50 in Ibs e Replace defective component e Install new yoke assembly NOTES FILL RITE Tuthill Transfer Systems Manufacturer warrants to each consumer buyer of its Fill Rite products the Buyer from the date
8. of invoice or sales receipt that goods of its manufacture Goods will be free from defects of material and workmanship Duration of this warranty is as follows Heavy Duty Products Two years Standard Duty Products One year Economy Duty Products One year Cabinet pumps Parts and Accessories One year Manufacturer s sole obligation under the foregoing warranties will be limited to either at Manufacturers option replacing or repairing defective Goods subject to limitations hereinafter provided or refunding the purchase price for such Goods theretofore paid by the Buyer and Buyer s exclusive remedy for breach of any such warranties will be enforcement of such obligations of Manufacturer If Manufacturer so requests the return of the Goods the Goods will be redelivered to Manufacturer in accordance with Manufacturer s N TUTHILL 400F3394 REV 8 Transfer Systems instructions F O B Factory The remedies contained herein shall constitute the sole recourse of the Buyer against Manufacturer for breach of warranty IN NO EVENT SHALL MANUFACTURER S LIABILITY ON ANY CLAIM FOR DAMAGES ARISING OUT OF THE MANUFACTURE SALE DELIVERY OR USE OF THE GOODS EXCEED THE PURCHASE PRICE OF THE GOODS The foregoing warranties will not extend to Goods subjected to misuse neglect accident or improper installation or maintenance or which have been altered or repaired by anyone other than Manufacturer or its authori
9. pressure exceeds 15psi 1 bar Instead sub merge the suction tube or inlet adapter in clean water and dispense water by operating the pump Dispose of the flush water properly After flushing pump air to remove as much water as possible All Applications on annual basis or as needed 1 Tighten all external screws to 50 in Ibs items 19 20 amp 23 NOTE NEVER EXCEED 50 IN LB TORQUE WHEN TIGHTENING SCREWS 2 Drain oil through sight caps and replace oil with approximately 16 ounces of automotive grade SAE 30W through one of the sight cap holes The oil level should be level with the bottom edge of the sight caps item 30 located on the front of the pump body NOTE Always check oil level when the pump is evel 3 Check the four 10 24 x 1 2 machine screws item 11 holding the diaphragm in place If loose tighten screws to 35 in los to prevent internal leakage NOTE If external screws items 19 20 amp 23 are removed hand start and tighten to 50 in Ibs REPAIR Pumps being returned for service must be triple rinsed and accompanied by an MSDS sheet indicating the chemicals fluids which have been pumped Pumps not adhering to these specifications may be refused service at either the repair shop or the factory Performance e Maximum of 30 minute duty cycle not for continuous operation 9 inches of mercury dry vacuum e Suction lift 10 for water The lift in feet is equivalent to the vertical distance from t
10. s sembly Motor Gear Assembly Removal Refer to exploded view of pump 1 Ifpossible position pump with sight caps item 30 down 2 Remove four screws item 20 and lift out motor gear assembly 3 Drain oil from pump if additional maintenance to pump is required Gear Assembly Replacement 1 Remove six screws item 25 and pull gear assembly item 24 from motor 2 Pull drive gear item 27 and key item 28 from motor shaft DO NOT DISASSEMBLE GEAR ASSEMBLY Planet gears and ring gear are marked for proper assembly and must not be altered Diaphragm Assembly Check Valve Replacement NOTE Diaphragm and check valve assemblies can be ser viced without removing motor and oil from pump body by removing one at atime with diaphragm facing up Care must be taken not to contaminate oil 1 Loosen cover item 4 screws item 20 slightly and drain fluid trapped in the pumping chamber Then remove screws and covers 2 Remove retainer screws item 11 and o rings item 42 3 Remove diaphragm assemblies items 7 8 9 and 10 by pulling check valves out of pump body starting with outlet valves first item 9 at top of pump 4 Install new diaphragm check valve assembly noting ball location in relation to flow O rings are on inlet valves at bottom of pump Lubricate O rings before inserting into pump body See Figure 1 Figure 1 0 5 Insert four screws item 11 and o rings item 42 into diaphragm as shown
11. ut warning if power is on This pump should not be used to fuel aircraft This pump is not suited for use with fluids for human consumption GENERAL DESCRIPTION The Fill Rite Series FR400is a double action diaphragm pump using a patented spring driven positive displacement mechanism The flow rate with low viscosity material is up to 13 GPM 49 LPM The ultimate in chemical handling capability is provided with stainless steel polypropylene polyester and fluorocarbon wetted parts OPTIONS 1 polypropylene ball valve nozzle Buna N or EPDM hose e Telescoping steel suction tube 820 electronic digital meter for thin or thick viscosities e 2 NPT or 2 buttress inlet bung adapter 1 FNPT straight and 90 inlet outlet fittings available Wraparound tubular mounting frame e Santoprene diaphragms 12VDC 24 VDC 115 VAC 60 Hz 230 VAC 50 Hz available TECHNICAL INFORMATION Design Features e1 FNPT straight inlet and 90 outlet standard 15 PSIG maximum outlet pressure e 2600 RPM 1 4 HP motor e12 VDC rated at 20 amps 24 VDC rated at 10amps e115 VAC 60 Hz rated at 2 0 amps e 230 VAC 50 Hz rated at 1 1 amps e Thermal overload protection of the motor e Positive displacement self priming design e Unaffected by particulate materials up to 0 100 diameter in the pumped fluids e Flow easily controlled by outlet throttling from maximum to zero e Pump may run dry without damage e Handles viscosities from 1 0 C
12. zed representative THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY FITNESS FOR PURPOSE OF ANY OTHER TYPE WHETHER EXPRESS OR IMPLIED No person may vary the foregoing warranties and remedies except in writing signed by a duly authorized officer of Manufacturer Warranties or remedies that differ from the foregoing shall not otherwise be binding on Manufacturer The Buyer s acceptance of delivery of the Goods constitutes acceptance of the foregoing warranties and remedies and all conditions and limitations thereof 8825 Aviation Drive Fort Wayne Indiana USA 46809 Tel 260 747 7524 Fax 260 747 3159
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