models: f-20, f-21, f-22 g-20, g-21, g-22 - hydra-cell.eu · models: f-20, f-21, f-22 g-20, g-21,...

W0122A

Models: F-20, F-21, F-22 G-20, G-21, G-22

INSTALLATION & SERVICEF20-991-UK00A

Wanner International Ltd8/9 Fleet Business Park Sandy Lane, Church Cr, Hants, GU52-8BF

Telephone: +44 (0) 1252 816847Fax: +44 (0) 1252 629242Email: [email protected]

� F�0-991-UK00A

Max PressureMetallic: F/G-�0:1000psi(70bar);

F/G-�1/��:1500psi(100bar)Non-Metallic: AllModels:�50psi(17bar)

Capacity @ Max Pressurerpm gpm I/min

F/G-�0-X 1750 0.96 3.63F/G-�0-E 1750 0.73 �.76F/G-�0-S 1750 0.55 �.08F/G-�0-B 1750 0.33 1.�5F/G-�0-G 1750 0.�0 0.76

Delivery @ Max Pressurerevs/galrevs/liter

F/G-�0-X 18�3 500F/G-�0-E �397 659F/G-�0-S 318� 906F/G-�0-B 5303 1400F/G-�0-G 8750 �30�

Max Inlet Pressure 100psi(7bar)

Max TemperatureMetallicHeads: �50°F(1�1°C)–consultfactoryfor

temperaturesabove160°F(71°C)Non-MetallicHeads: 140°F(60°C)

Inlet Port F-�0:1/�inchNPTG-�0:1/�inchBSPT

Discharge Port F-�0:3/8inchNPTG-�0:3/8inchBSPT

F-�0:5/8inchhollowshaftforNEMA 56CShaft Diameter

C-Facemotor(withfeet)F-�1/��:5/8inchG-�0:19mmforIEC80B5Flangemotor(withfeet)G-�1/��:19mm

Shaft Rotation Bi-directional

Bearings Radialball

Oil Capacity 1/8USquart(0.1�liters)

Weight MetallicHead:1�lbs(5.5kg)Non-MetallicHead:9lbs(4.1kg)

F/G-20 ContentsPage

Specifications..........................................................................�

Dimensions.............................................................................4

Installation...............................................................................7

Maintenance..........................................................................11

Service(FluidEnd)...............................................................1�

Service(HydraulicEnd)........................................................15

Troubleshooting.....................................................................18

F/G-20 Specifications

Calculating Required Horsepower (kW)*

+5.5xrpm

63,000

gpmxpsi

1,460= electricmotorHP*

+5.5xrpm

84,4�8

lpmxbar

511= electricmotorkW*

* rpmequalspumpshaftrpm.HP/kWisrequiredapplicationpower.Usecautionwhensizingmotorswithvariablespeeddrives.

Note:Performanceandspecificationratingsapplytoallconfigurationsunlessspecificallynotedotherwise.

3 F�0-991-UK00A

2.0

1.0

4.0

0.5

1.5

3.5

2.5

3.0

0

RPM0 200 400 600 800 1000 1200 1400 1600 1800

F/G-20-E

F/G-20-S

F/G-20-B

F/G-20-G

F/G-20-X100 PSI (7 bar)500 PSI (35 bar)1000 PSI (70 bar)1500 PSI (100 bar)

Gal

lons

per

Min

ute

1.2

1.0

0.8

0.6

0.4

0.2

Lite

rs p

er M

inut

e

1750

W0133

RPM

0

Lift

(feet

of w

ater

)

Lift

(cm

of w

ater

)

0

0.520

40

100

60

80

1.0

1.5

2.0

2.5

3.0

3.5

4.0

200 400 600 800 1000 1200 1400 1600 1800

1750

F/G-20-EF/G-20-SF/G-20-BF/G-20-G

F/G-20-X

W0131

Performance Net Positive Suction Head – NPSHr

Dry Lift

F/G-20 Specifications

RPM

0

NPS

Hr (

feet

of w

ater

)

NPS

Hr (

met

ers

of w

ater

)

1750

2

1

2

3

4

5

6

4

6

8

10

12

14

16

18

20

22

0 200 400 600 800 1000 1200 1400 1600 1800

F/G-20-XF/G-20-EF/G-20-SF/G-20-BF/G-20-G

W0132

Note:Performanceandspecificationratingsapplytoallconfigurationsunlessspecificallynotedotherwise.

4 F�0-991-UK00A

F/G-20 DimensionsF-20/G-20 Models with Metallic Pumping Head

F-20/G-20 Models with Non-Metallic Pump Head

Brass

316StainlessSteel

Hastelloy®C

Kynar®

Polypropylene

3.25(82.6)

0.25(6.4)

0.65(16.5)

0.72(18.3)

3.64(92.5)

8.38(213)

2.93(74.4)

4.15(105)

9.72(247)

2.20(55.9)

Inlet F-20: 1/2" NPTG-20: 1/2" BSPT

Outlet F-20: 3/8" NPTG-20: 3/8" BSPT

F-20: 5/8" ID (for NEMA 56C)G-20: 19 mm ID (for IEC 80)

Ø0.42(10.7)

Ø6.50(165)

Ø5.870(149)

W0129

3.25(82.6)

0.25(6.4)

0.65(16.5)

0.72(18.3)

3.64(92.5)

8.63(219.2)

2.93(74.4)

4.15(105)

9.97(253.2)

2.20(55.9) Ø0.42

(10.7)

Ø6.50(165)

Ø5.870(149)



F-20: 5/8" ID (for NEMA 56C)G-20: 19 mm ID (for IEC 80)

W0130

Inches(mm)

5 F�0-991-UK00A



Brass

316StainlessSteel

Hastelloy®C

Kynar®

Polypropylene

2.25(57.2)

3.45(87.6)

Ø0.50(12.7)

2.12(53.8)

5.18(132)

8.93(227)

Ø0.33(8.4)

(thru hole 2 places)

(thru hole)

0.72(18.3)

0.65(16.5)

4.98(127)

2.93(74.4)

4.50(114)

0.96(24.4) 1.91

(48.5)


Outlet F-21: 3/8 NPTG-21: 3/8 BSPT

F-21: Ø5/8"G-21: Ø19 mm

W0134

2.25(57.2)

3.45(87.6)

Ø0.50(12.7)

2.12(53.8)

5.18(132)

9.18(233.2)

Ø0.33(8.4) (thru hole)

0.72(18.3)

0.65(16.5)

4.98(127)

2.93(74.4)

4.50(114)

0.96(24.4) 1.91

(48.5)



F-21: Ø5/8"G-21: Ø19 mm

(thru hole 2 places)

W0135

Inches(mm)

6 F�0-991-UK00A



Brass

316StainlessSteel

Hastelloy®C

Kynar®

Polypropylene

7.09(180)

0.65(16.5)

0.72(18.3)

8.38(213)

2.93(74.4)

4.15(105)

9.72(247)

5.63(143)

Ø6.50(165)

Ø5.870(149)

Ø0.42(10.7)(4 x)



F-22: Ø5/8"G-22: Ø19 mm

W0137

7.09(180)

0.65(16.5)

0.72(18.3)

8.63(219.2)

2.93(74.4)

4.15(105)

9.97(253.2)

5.63(143)

Ø6.50(165)

Ø5.870(149)

Ø0.42(10.7)(4 x)



F-22: Ø5/8"G-22: Ø19 mm

W0138

Inches(mm)

F/G-20 InstallationSafety Precautions

General remarks

These safety / installation instructions contain fundamental information and precautionary notes and must be kept available to all associated with the operation of the pump. Please read them thoroughly prior to installation, electrical connection and commissioning of the unit. It is imperative that all other operating instructions relating to the components of individual units are followed.

These safety / installation instructions do not take local regulations into account. The operator must ensure that such regulations are observed by all, including the personnel carrying out the installation.

Each pump must be labeled by the end user to warn of any hazards that the system process may produce; e.g. corrosive chemicals or hot process etc.

All personnel involved in the operation, maintenance, inspection and installation of the pump must be fully qualified to carry out the work. The personnel’s responsibilities, competence and supervision must be clearly defined by the operator. To the extent that if the personnel in question is not already in possession of the requisite know how, appropriate training and instruction must be provided. In addition, the operator is responsible for ensuring that the contents of the operating instructions are fully understood by all the responsible personnel.

When installing a Hydra-Cell pump in conjunction with a motor or motor and frequency controller the relevant manuals must be referred to for electromagnetic compatibility. The installation should conform to EN 61800 and EN 60204.

All safety instructions in this manual and all relevant local health and safety regulations must be followed.

Attention must be paid to the weight of the pump before attempting to lift either manually or selecting appropriate lifting equipment.

F�0-991-UK00A

7 F�0-991-UK00A

F/G-20 InstallationLocationNOTE: The numbers in parentheses are the Reference Numbers on the illustrations found later in this manual and in the Parts Manual.

Locatethepumpasclosetothesupplysourceaspossible.

Installitinalightedcleanspacewhereitwillbeeasytoinspectandmaintain.Allowroomforcheckingtheoillevel,changingtheoil,andremovingthemanifold(3)andvalveplate(�1).

MountingThepumpshaftcanberotatedineitherdirection.Topreventvibration,securelyattachthepumpormotortoarigidbase.

On a belt-drive system, align the sheaves accurately: pooralignmentwasteshorsepowerandshortensthebeltandbearinglife.Makesurethebeltsareproperlytightened,asspecifiedbythebeltmanufacturer.

Onadirect-drivesystem,aligntheshaftsaccurately.

Onaclose-coupledsystem,coatthemotorshaftliberallywithLoctite®NickelAnti-Seize#77164.

W0128

Important PrecautionsAdequate Fluid Supply.Toavoidcavitationandprematurepumpfailure,besurethatthepumpwillhaveanadequatefluidsupplyandthattheinletlinewillnotbeobstructed.See“InletPiping”.

Positive Displacement. This is a positive-displacementpump.Toavoidseveresystemdamageifthedischargelineeverbecomesblocked,installareliefvalvedownstreamfromthepump.See“DischargePiping”.

Safety Guards. Install adequate safety guards over allpulleys,belts,andcouplings.Followallcodesandregulationsregardinginstallationandoperationofthepumpingsystem.

Shut-Off Valves.Neverinstallshut-offvalvesbetweenthepumpanddischargepressureregulator,or in theregulatorbypassline.

Freezing Conditions.Protectthepumpfromfreezing.SeealsotheMaintenanceSection.

ConsulttheFactoryforthefollowingsituations:

• Extremetemperatureapplications(above160°Forbelow40°F)

• Pressurefeedingofpumps• Viscousorabrasivefluidapplications• Chemicalcompatibilityproblems• Hotambienttemperatures(above110°F)• Conditionswherepumpoilmayexceed�00°Fbecause

ofacombinationofhotambient temperatures,hot fluidtemperature,andfullhorsepowerload—anoilcoolermayberequired

8 F�0-991-UK00A

F/G-20 InstallationInlet Piping (Suction Feed)CAUTION: When pumping at temperatures above 160° F (71°C), use a pressure-feed system.

Installdraincocksatanylowpointsofthesuctionline,topermitdraininginfreezingconditions.

Provideforpermanentortemporaryinstallationofavacuumgaugetomonitortheinletsuction.Tomaintainmaximumflow,vacuumatthepumpinletshouldnotexceed7in.Hg(180mmHg).Do not supply more than one pump from the same inlet line.

Supply TankUseasupplytankthatislargeenoughtoprovidetimeforanytrappedairinthefluidtoescape.Thetanksizeshouldbeatleasttwicethemaximumpumpflowrate.

Isolatethepumpandmotorstandfromthesupplytank,andsupportthemseparately.

Install a separate inlet line from the supply tank to eachpump.

Installtheinletandbypasslinessotheyemptyintothesupplytankbelowthelowestwaterlevel,ontheoppositesideofthebafflefromthepumpsuctionline.

Ifalinestrainerisusedinthesystem,installitintheinletlinetothesupplytank.

To reduce aeration and turbulence, install a completelysubmergedbaffleplatetoseparatetheincomingandoutgoingliquids.

Installavortexbreakerinthesupplytank,overtheoutletporttothepump.

Placeacoveroverthesupplytank,topreventforeignobjectsfromfallingintoit.

Hose and RoutingSize thesuction lineat leastonesize larger than thepumpinlet,andsothatthevelocitywillnotexceed1-3ft/sec(0.3to0.9m/s):Forpipeininches:Velocity(ft/sec)=0.408xGPM/PipeID�Forpipeinmm:Velocity(m/sec)=�1.�xLPM/PipeID�Keepthesuctionlineasshortanddirectaspossible.Useflexiblehoseand/orexpansionjointstoabsorbvibration,expansion,orcontraction.Ifpossible,keepthesuctionlinelevel.Donothaveanyhighpointstocollectvaporunlessthesehighpointsarevented.Toreduceturbulenceandresistance,donotuse90°elbows.If turnsarenecessary in thesuction line,use45°elbowsorarrangesweepingcurvesintheflexibleinlethose.Ifablockvalveisused,besureitisfullyopenedsothattheflowtothepumpisnotrestricted.TheopeningshouldbeatleastthesamediameterastheinletplumbingID.Do not use a line strainer or filter in the suction line unlessregularmaintenanceisassured.Ifused,itshouldhaveafree-flowareaofatleastthreetimesthefree-flowareaoftheinlet.Installpipingsupportswherenecessarytorelievestrainontheinletlineandtominimizevibration.

Inlet Piping (Pressure Feed)Provideforpermanentortemporaryinstallationofavacuum/pressure gauge to monitor the inlet vacuum or pressure.Pressureatthepumpinletshouldnotexceed�50psi(173bar);ifitcouldgethigher,installaninletpressureregulator.Do not supply more than one pump from the same inlet line.

Inlet CalculationsAcceleration HeadCalculating the Acceleration Head

Usethefollowingformulatocalculateaccelerationheadlosses.SubtractthisfigurefromtheNPSHa,andcomparetheresulttotheNPSHroftheHydra-Cellpump.

Ha=(LxVxNxC)÷(KxG)

where:

Ha=Accelerationhead(ftofliquid)L=Actuallengthofsuctionline(ft)—notequivalentlengthV=Velocityofliquidinsuctionline(ft/sec)[V=GPMx(0.408

÷pipeID�)]N=RPMofcrankshaftC=Constantdeterminedbytypeofpump—use0.6�8forthe

F/G-�0/�1/��Hydra-CellpumpK=Constant to compensate for compressibility of the fluid

—use:1.4forde-aeratedorhotwater;1.5formostliquids;�.5forhydrocarbonswithhighcompressibility

G= Gravitationalconstant(3�.�ft/sec�)

Friction LossesCalculating Friction Losses in Suction Piping

When following the above recommendations (under “inletPiping”) for minimum hose/pipe I.D. and maximum length,frictionallossesinthesuctionpipingarenegligible(i.e.,Hf=0) ifyouarepumpingawater-likefluid.

When pumping more-viscous fluids such as lubricating oils,sealants,adhesives,syrups,varnishes,etc.,frictional lossesinthesuctionpipingmaybecomesignificant.AsHfincreases,theavailableNPSH(NPSHa)willdecrease,andcavitationwilloccur.

Ingeneral,frictionallossesincreasewithincreasingviscosity,increasingsuction-linelength,increasingpumpflowrate,anddecreasing suction-line diameter. Changes in suction-linediameterhavethegreatestimpactonfrictionallosses:a�5%increase in suction-line diameter cuts losses by more thantwotimes,anda50%increasecutslossesbyafactoroffivetimes.

Consultthefactorybeforepumpingviscousfluids.

9 F�0-991-UK00A

F/G-20 InstallationMinimizing Acceleration Head and Frictional LossesTominimizetheaccelerationheadandfrictionallosses:

• Keepinletlineslessthan1ft(0.3m)long(suctionstabilizerrequiredforlongerinletlines)

• Useatleast5/8”(16mm)I.D.inlethose• Usesofthose(low-pressurehose,noncollapsing) for the

inletlines• Minimizefittings(elbows,valves,tees,etc.)• Use a suction stabilizer on the inlet.

Net Positive Suction HeadNPSHamustbeequal toorgreater thanNPSHr. If not, thepressureinthepumpinletwillbelowerthanthevaporpressureofthefluid—andcavitationwilloccur.

Calculating the NPSHa

UsethefollowingformulatocalculatetheNPSHa:

NPSHa=Pt+Hz-Hf-Ha-Pvp

where:

Pt=Atmosphericpressure

Hz=Verticaldistancefromsurfaceliquidtopumpcenterline(ifliquidisbelowpumpcenterline,theHzisnegative)

Hf=Frictionlossesinsuctionpiping

Ha=Accelerationheadatpumpsuction

Pvp = Absolute vapor pressure of l iquid at pumpingtemperature

NOTES:

• In good practice, NPSHa should be � ft greater thanNPSHr

• AllvaluesmustbeexpressedinfeetofliquidAtmospheric Pressure at Various Altitudes

Altitude Pressure Altitude Pressure (ft) (ft of H2O) (ft) (ft of H2O) 0 33.9 1500 3�.1

500 33.3 �000 31.51000 3�.8 5000 �8.�

Discharge PipingNote: Consult the Factory before manifolding two or more pumps together.

Hose and RoutingUsetheshortest,most-directrouteforthedischargeline.

Selectpipeorhosewithaworking pressure ratingofatleast1.5timesthemaximumsystempressure.EXAMPLE:Selecta1500psi(103bar)W.P.-ratedhoseforsystemstobeoperatedat1000psi(69bar)gaugepressure.

Useabout6ft(1.8m)offlexiblehosebetweenthepumpandrigidpipingtoabsorbvibration,expansionorcontraction.

Supportthepumpandpipingindependently.Sizethedischargelinesothatthevelocityofthefluidwillnotexceed7-10ft/sec(�-3m/sec):

Forpipeininches:Velocity(ft/sec)=0.408xGPM/PipeID�

Forpipeinmm:Velocity(m/sec)=�1.�xLPM/PipeID�

Pressure RegulationInstall a pressure regulator or unloader in the discharge line.Bypasspressuremustnotexceed thepressure limitofthepump.

Sizetheregulatorsothat,whenfullyopen,itwillbelargeenoughtorelievethefullcapacityofthepumpwithoutoverpressurizingthesystem.

Locatethevalveasclosetothepumpaspossibleandaheadofanyothervalves.

Adjustthepressureregulatingvalvetonomorethan10%overthemaximumworkingpressureofthesystem.Donotexceedthemanufacturer’spressureratingforthepumporregulator.

Routethebypasslinetothesupplytank,ortothesuctionlineas far as possible from the pump (to reduce the chance ofturbulence).

Ifthepumpwillbeoperatingforalongtimewiththedischargeclosedand fluidbypassing, installa thermalprotectorset totripat140°Finthebypassline(topreventseveretemperaturebuildupinthebypassedfluid).

CAUTION: Never install shutoff valves in the bypass line or between the pump and pressure regulator or relief valve.

Provideforpermanentortemporaryinstallationofapressuregaugetomonitorthedischargepressureatthepump.

Foradditionalsystemprotection,installasafetyreliefvalveinthedischargeline,downstreamfromthepressureregulator.

10 F�0-991-UK00A

F/G-20 InstallationInitial Start-Up Procedure1. Turnonpowertothepumpmotor.�. Checktheinletpressureorvacuum.Tomaintainmaximum

flow,inletvacuummustnotexceed7in.Hg.Inletpressuremustnotexceed�50psi(17.3bar).

3. Listenforanyerraticnoiseandlookforunsteadyflow.4. Ifthesystemhasanairlockandthepumpfailstoprime:

a. Turnoffthepower.b. Removethepressuregaugeorplugfromtheteefittingatthepumpoutlet(refertotheillustrationonpage3).NOTE: Fluid may come out of this port when the plugis removed. Provide an adequate catch basin for fluidspillage, if required. Fluid will come out of this portwhen the pump is started, so we recommend that youattach adequate plumbing from this port so fluid willnot be sprayed or lost. Use high-pressure-rated hoseand fittings from this port. Take all safety precautionsto assure safe handling of the fluid being pumped.c. Jogthesystemonandoffuntilthefluidcomingfromthisportisair-free.d. Turnoffthepower.e. Removetheplumbingthatwastemporarilyinstalled,andreinstallthepressuregaugeorplug.

5. Adjust the discharge pressure regulator to the desiredoperating and bypass pressures. Do not exceed themaximumpressureratingofthepump.

6. After the pressure regulator is adjusted, set the “pop-off”safety reliefvalveat100psihigher than thedesiredoperatingpressure.

7. PumpsfittedwithPTFEdiaphragmsrequire�psi(0.14bar)minimuminletpressure.

Before Initial Start-UpBeforeyoustartthepump,besurethat:

• Allshut-offvalvesareopen,andthepumphasanadequatesupplyoffluid.

• Allconnectionsaretight.• Theoil reservoirbeneath thereservoirdiaphragm(71) is

completely full. NOTE: The reservoir is filled and sealedatthefactory.Ifyouareunsureabouttheoillevel,removethecover(70)andslowlyliftthediaphragm(71).RefertoServiceProcedure#6,“FillandSealtheOilReservoir”,intheFluid-EndServiceSection.

• Thereliefvalveontheoutletofthepumpisadjustedsothepumpstartsunderminimumpressure.

• All pulleys and belts are properly aligned, and belts aretensionedaccordingtospecification.

• Allpulleysandbeltshaveadequatesafetyguards.

11 F�0-991-UK00A

F/G-20 MaintenanceNOTE: The numbers in parentheses are the Ref. Nos. on the illustrations in the Parts Manual.

PeriodicallyChangetheoilafterthefirst100hoursofoperation,thenchangeaccordingtotheguidelinesbelow.Whenchanging,removethedrainplug(69),Allowalloilandcontaminanttodrainout.

Hours Between Oil Changes @ Various Process Fluid Temperatures

<90°F <139°F <180°F Pressure RPM (32°C) (60°C) (82°C)

Metallic Pump Head <1000psi(70bar) <1�00 6,000 4,000 �,000

<1800 3,000 �,000 1,500

<1500psi(100bar) <1�00 3,000 �,000 1,500<1800 1,500 1,000 1,000

Non-Metallic Pump Head <�50psi(17bar) <1�00 3,000 �,000 —

<1800 1,500 1,000 —

NOTE: Minimum oil viscosity for proper hydraulic end lubrication is 16-20 cST (80-100 SSU).

CAUTION:Donot turn thedriveshaftwhile theoil reservoirisempty.

Thereshouldbenotrappedairundertheoilreservoirdiaphragm(71). Refer to Service Procedure #6, “Fill and Seal the OilReservoir”,intheFluid-EndServiceSection.

Use the appropriate Hydra-Oil for the application (contactWannerEngineeringifindoubt).

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.

Checktheinletpressureorvacuumperiodicallywithagauge.

CAUTION:Protectthepumpfromfreezing.Referalsotothe“ShutdownProcedure”.

Shutdown Procedure During Freezing TemperaturesTake 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. Adjustthedischargepressureregulatingvalvesothepumprunsunderminimumpressure.Stopthepump.

�. Drainsupplytank;openanydraincocksinsystempipingandcollectdrainage.Drainasmuchfluidfromthepumpmanifoldand plumbing attached directly to the pump manifold bylooseningfittingsorremovingplugsorgauges.

3. Closedraincocks insystempipingandtightenorreplaceanyfittings,gaugesorplugs.

4. Fillsupplytankwithenoughantifreezetofillsystempipingandpump.NOTE: Disconnect the system return line from the supplytank and connect it to a separate reservoir.

5. Startthepumpandallowittorununtilthesystemisfilledwithantifreeze.NOTE: If the system has an airlock andthe pump fails to prime, follow step 4 of the Initial Start-up Procedure to clear the air.

6. Whenmostlyantifreezeisflowingfromthesystemreturnline,stopthepump.Connect thesystemreturn linebacktothesupplytankandcirculatetheantifreezeforashortperiod.

7. It isalsogoodpractice tochange theoil in thehydraulicendbeforestorageforanextendedperiod.Thiswillremoveany accumulated condensation and sediment from theoil reservoir. Drain and refill the hydraulic end with theappropriate Hydra-Oil and operate the pump for a shortperiodtoassuresmoothperformance.

1� F�0-991-UK00A

W0124

F/G-20 Service (Fluid End)

Bolt Torque SpecificationsF-20/21/22 G-20/21/22

Ref. No. (in-lbs) (Ncm)1 90 1,017

�0 14 158�� 10 113�3 14 158

W0126

SeeHydraulicEndforpumphousings

W0125

W0123

13 F�0-991-UK00A

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 alleasily-serviceablepartsofthepump.Repairproceduresforthehydraulicend(oilreservoir)ofthepumpareincludedinalatersectionofthemanual.

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. Removealleightbolts(1)aroundthemanifold.b. Removethemanifold(3).c. Inspectthemanifoldforwarpingorweararoundtheinlet

andoutletports.Ifwearisexcessive,replacethemanifoldorreturnittoWannerEngineeringforresurfacing.Tocheckifthemanifoldiswarped,placeastraightedgeacrossit.Awarpedmanifoldshouldbereplaced.

2. Inspect Valves (4-17)Theinletandoutletvalveassembliesaredifferent(theinlet valve is larger) and face in opposite directions.Inspecteachvalveasfollows:

a. Checkthespringretainers(4,17),andreplaceifworn.b. Check the valve springs (5,16). If shorter than a

new spring, replace them (do not just stretch the oldspring).

c. Check the valve poppets (6,15). If worn excessively,replacethem.

d. Removethevalveseats(9,13).AseatpullerisincludedintheWannerToolKit.Inspectthevalveseatsforwear,andreplaceifnecessary.AnewO’ring(8,1�)shouldbeinstalled.

e. Check thedampeningwashers (10,11), and replace ifworn.

f. Reinstallthevalveassemblies:• Cleanthevalveportsandshoulderswithemerycloth,andlubricatethemwithlubricatinggelorpetroleumjelly(donotusepetroleumproductswheninstallingEPDMO-rings).• InstalltheO-rings(8,1�)onthevalveseats(9,13).• Inlet Valve.Insertthespringretainer(17)intothevalveplate,theninsertthespring,valve,Tetraseal,valveseat,anddampeningwasher(16-11).AflatO-ring[Tetraseal](14) goesbetweentheretainerandseat.• Outlet Valve.Insertthedampeningwasher,valveseat,Tetraseal,valve,andspring,thentheretainer.InstalltheflatO-ringbetweentheretainerandseat.

3. Inspect and ReplaceDiaphragm (22)

a. Usea3-mmAllenwrenchtoremovethetwocapscrews(�0) fromthevalveplate(�1).

b. Liftthediaphragmbyoneedge,andturnthepumpshaftuntilthediaphragmmovesupto“topdeadcenter”.Thiswillexposemachinedcrossholesintheplungershaftbehindthediaphragm.NOTE: If the pump has a hollow shaft, use the shaftrotator from the Wanner Tool Kit.

c. Insert the plunger holder (from the Wanner Tool Kit)throughoneof themachinedcrossholes, tohold thediaphragmup.Thepropersize tool is included in theWannerToolKit. (Don’t remove the tooluntil thenewdiaphragmisinstalledinstep“G”below).

d. Unscrewthediaphragm.Usean8-mmor5/16-in.open-endwrench,andturncounterclockwise.

e. Inspectthediaphragmcarefully.Adamageddiaphragmgenerally indicates a pumping system problem, andreplacingonly thediaphragmwill not solve the largerproblem.Inspectthediaphragmforthefollowing:• Small puncture.Usuallycausedbyasharpforeignobjectinthefluid,orbyaniceparticle.• Diaphragm pulled away from the sides. Usuallycaused by fluid being frozen in the pump, or byoverpressurizationofthepump.• Diaphragm becoming stiff and losing flexibility.Usuallycausedbypumpingafluidthatisincompatiblewiththediaphragmmaterial.• Diaphragm edge chewed away. Usuallycausedbyoverpressurizingthesystem.CAUTION: If a diaphragm has ruptured and foreignmaterial or water has entered the oil reservoir, donot operate the pump. Check the diaphragm, thenflush the reservoir completely (as outlined below)and refill it with fresh oil. Never let the pump standwith foreign material or water in the reservoir, or withthe reservoir empty.

f. Clean away any spilled oil. Apply Loctite #�4�Threadlocker to thethreadsof thenewdiaphragm(ortheoldone,asappropriate).

g. Installthediaphragmandtightento10in-lbs.

14 F�0-991-UK00A

4. Flush Contaminant fromHydraulic End (only if adiaphragm has ruptured)

a. With the valve plate and manifold still removed (seeabove), remove the oil drain cap (69), and the oilreservoircover(70)anddiaphragm(71).Allowalloilandcontaminanttodrainout.

b. Fill the reservoir with kerosene or solvent, manuallyturnthepumpshafttocirculatethekerosene,anddrain.Disposeofthiscontaminatedfluidproperly.CAUTION: If you have an EPDM diaphragm, or if foodgrade oil is in the reservoir, do not use kerosene orsolvents. Instead, flush with the same lubricant thatis in the reservoir. Pumps with an EPDM diaphragmhave an “E” as the 7th digit of the Model No.

c. Repeattheflushingprocedure(step“b”above).d. Fillthereservoirwithfreshoil,manuallyturnthepump

shafttocirculatetheoil,anddrainonceagain.e. Refill the reservoir. If the oil appears milky, there is

still contaminant in the reservoir. Repeat the flushingprocedureuntiltheoilappearsclean.

5. Prime the Hydraulic Cella. With the pump horizontal, fill the reservoir with the

appropriateHydraoilfortheapplication.b. All air in the oil within the hydraulic cell (behind the

diaphragm)mustbeforcedoutbyturningtheshaft—andthuspumpingthepiston.Ashaftrotator is includedintheWannerToolKit.Turn the shaft until a bubble-free flow of oil comesfrombehind thediaphragm.Watch theoil level in thereservoir; if it gets too low during priming, air will bedrawnintothepiston(insidethehydraulicend).Thiswillcausethepumptohavealossinflow,andyouwillhavetostartoveragainwithprimingthehydrauliccell.Filloilreservoir completely. Add diaphragm seal and installcoverplate.

c. Wipeexcessoilfromthecoverplateanddiaphragm.

F/G-20 Service (Fluid End)6. Fill and Seal the Oil Reservoir

a. The oil reservoir diaphragm (71) protrudes down intothepumphousingapproximately1/4to3/8in.Addoil,ifrequired,sothatwhenthediaphragmisset intothereservoirallairispushedout.Takecarenottoallowanyoiloverflowtogetbetweenthepumphousing(6�or66)andthecover(54).Thismayresultinanapparentoilleaklater,whenthepumpisputintouseandheatsup.

b. Installthecover(70)usingthefourbolts.c. Wipeoffanyexcessoilthatgotsqueezedoutontothe

outsideofthepumphousing.NOTE:Thediaphragm(71)willflexupanddownslightlyasthepumpoperates.Theventholesinthereservoircover(70)allowthisactiontofreelyoccur.

7. Reinstall Valve Plate (21) andManifold (3)

a. Reinstallthevalveplate(�1),withthevalveassembliesinstalledasoutlinedabove,onto thediaphragmplate(�4).

b. ReinstalltheO-rings(18,19)ontothevalveplate(�1).Usepetroleumjellyorlubricatinggeltoholdtheminplace(donotusepetroleumproductswheninstallingEPDMO-rings).

c. Reinstallthemanifoldontothevalveplate.d. Insertallbolts(1)aroundtheedgeofthemanifold,and

alternately tighten opposite bolts until all are secure.Torqueto90in.-lbs.

e. Recheckallboltsfortightness.

15 F�0-991-UK00A

F/G-20 Service (Hydraulic End)

Bolt Torque SpecificationsF-20/21/22 G-20/21/22

Ref. No. (in-lbs) (Ncm)50 35 3965� 14 1587� 10 11375 35 396

W0127

F/G-�1andF/G-��ShaftandKeyway

F/G-20 and F/G-22 Pump Housing

F/G-�0HollowShaft

SeeFluidEndforPistonAssembly

F/G-21Pump Housing

F/G-�0Only

16 F�0-991-UK00A

NOTE: The numbers 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 thehydraulicend(oilreservoir)ofthepump.

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.

Dependingontherepairyouareattempting,youmayormaynothavetoremovethemotorfromadirect-drivepump/motorunit.

Internalpistoncomponents(�6-3�)canbeservicedwithoutremovingthemotororcrankshaft.Themotorandcrankshaftmust be removed to service the connecting rod (59), piston(33),crankshaft(58),frontbearing(60),backbearing(57),orseal(56).

To Service Piston Without Removing Motor or Crankshaft

1. Disassemble PistonRemovethemanifold,valveplate,diaphragmplateanddiaphragm, and drain the oil from the pump (see theFluid-EndServiceSection):

a. Remove the snap ring (�6) from the piston, using astandard#1snap-ringpliers.

b. Pulloutthevalveplunger(�9).Thisalsoremovesthewasher(�7)andspring(�8).

c. (31),andpullthecylinderoutofthepiston.Becarefulnottodamagethepiston.

d. Inspectallparts,andreplacetheO-ringandanyotherpartsthatarewornormaybedamaged.

2. Reassemble Pistona. Tipthepumpsothepistonisupright.b. Droptheball(3�)intotheopeninginthebottomofthe

piston.c. Insertthevalveplunger(�9)intothevalvecylinder(31).

Slidethespring(�8)overtheplunger,insidethevalvecylinder.

d. Slidetheassembledvalvecylinder,plunger,andspring(�8-31)intothepiston(33).

e. Insertthewasher(�7)overtheplunger.f. Usingthesnap-ringpliers,insertthesnapring(�6)into

thepiston.

To Remove Motor from Direct-Coupled Unit (F20)

1. Disassemble Motor fromPump

a. Removethefourboltsandflatwashersthatsecurethepumpandmotortogether.

b. Installtwooftheboltsintothethreadedholesinthepumpflange(51).

c. Alternatelyturntheboltsclockwiseuntilthepumpandmotorseparate.

2. Reassemble Motor to Pumpa. Thoroughlycleanthemotorshaftandthehollowpump

shaft.b. Apply a liberal amount of Loctite Nickel Anti-Seize

#77164tothepumpshaft.c. Installtheshaftkeyintothemotorshaftkeyway.d. Slidethemotorshaftintothehollowpumpshaft.

CAUTION:Whenassembling thispump to thedirect-coupledmotor,becarefulthattheshaftkeyremainsinthemotorshaftkeywayanddoesnotrideupthekeywayandcontacttheshaftseal(whichwouldcauseprematuresealfailure).Incorrectkeyplacementcouldalsocausethehollowpumpshafttofail.Use a screwdriver to move the shaft key back in themotorshaftkeywayasthemotorandpumparedrawntogether.

e. Reinstallthefourboltsandflatwashers.


17 F�0-991-UK00A

To Service Remainder of Hydraulic End

1. Remove Pump Housinga. Remove themanifold,valveplate,anddiaphragm,as

outlinedintheFluid-EndServiceSection.b. Draintheoilfromthepumphousingbyremovingthedrain

plug(69),andtheoilreservoircover(70)anddiaphragm(71).

c. Standthepumponend,withthedriveshaftup.d. Removethebolts(5�)thatsecurethecover(54)tothe

housing(6�or66).Usea5-mmsocketwrench.SavetheO-rings(53).

e. RemovethecoverandthecoverO-ring(55).f. Remove the crankshaft (58) by pulling it through the

connectingrod(59).

2. Remove and Replace PistonToremovethepiston(33),firstremovetheconnectingrod(59)andpin(61)bypressingthepinthroughtheconnectingrod.Reversetheprocesstoreinstallthepiston.RefertoSteps5and6belowtoreplacethediaphragmandreassemblethepump.

3. Reassemble Housing andCasting

NOTE:Inspecttheshaftseal(56)beforecontinuing.Ifitlooksdamagedinanyway,replaceit.Referto“ReplaceShaftSeal”below.

a. Standthepumponend.b. Withthepistonandconnectingrodinplace,reinstallthe

crankshaftbythreadingitthroughtheconnectingrod.c. Reinstall thecover,coverO-ring,andbolts(with their

O-rings).

4. Replace Shaft Seala. Pressthebackbearing(57)andseal(56)outofthecover

(54).Discardtheseal.b. Apply a coating of Loctite High-Performance Pipe

Sealant With PTFE, or a comparable product, to theoutersurfaceofanewsealandtheinsidesurfaceoftheopeninginthebackcover(54)wherethesealwillrest.

c. Pressthenewsealintothebackcover.d. Inspectthebearing(57).Ifpittedordamaged,replace

it.

5. Reinstall Diaphragma. Screwtheplungerpuller(fromtheWannerToolKitor

RepairKit)intotheplunger(�9).Pullouttoexposethecrossholeintheplunger.Rotatetheshaftuntilthepistonisattopdeadcenter.

b. Insert the diaphragm wrench (from the Wanner ToolKit),or similardowel-typeobject, through theplungerhole— tohold theplungeraway from thediaphragmplate(�4),andtokeeptheplunger fromturningwhenthediaphragmisbeinginstalled.

c. ApplyasmallamountofLoctite#�4�tothethreadsofthediaphragm(besurethethreadsareclean).

d. Setthediaphragm(��)ontheplunger(�9),ridge-sideout.Screwthediaphragmontotheplunger.

e. Holdthediaphragmwrench,andtightenthediaphragmto10in.-lbsoftorque.

f. Fillthereservoirwithfreshoilandprimethepump,asoutlinedintheFluid-EndServiceSection.

6. Reassemble PumpFillandsealtheoilreservoir,thenreassemblethepumpasoutlinedintheFluid-EndServiceSection.


18 F�0-991-UK00A

F/G-20 TroubleshootingCavitation• Inadequatefluidsupplycausedby:

– Inletlinecollapsedorclogged– Cloggedlinestrainer– Inletlinetoosmallortoolong– Airleakininletline– Wornordamagedinlethose– Suctionlinetoolong– Toomanyvalvesandelbowsininletline– NPSHaislessthanNPSHr

• Fluidtoohotforinletsuctionpipingsystem.• Airentrainedinfluidpipingsystem.• Aerationandturbulenceinsupplytank.• Inletsuctionvacuumtoohigh.

Symptoms of Cavitation• Excessivepumpvalvenoise• Prematurefailureofspringorretainer(4,5,16,17)• Volumeorpressuredrop• Rough-runningpump

Drop in Volume or PressureAdropinvolumeorpressurecanbecausedbyoneormoreofthefollowing:

• Airleakinsuctionpiping• Cloggedsuctionlineorsuctionstrainer• Suctionlineinletabovefluidlevelintank• Inadequatefluidsupply• PumpnotoperatingatproperRPM• Reliefvalvebypassingfluid• Wornpumpvalveparts• Foreignmaterialininletoroutletvalves• Lossofoilprimeincellsbecauseoflowoillevel• Ruptureddiaphragm(��)• Cavitation• Warpedmanifoldfromoverpressurizedsystem• O - r i n g s f o r c e d o u t o f t h e i r g r o o v e s f r o m

overpressurization• Airleakinsuctionlinestrainerorgasket• Crackedsuctionhose.• Emptysupplytank• Excessiveaerationandturbulenceinsupplytank• Abrasivesinthefluid• Valveincompatiblewithcorrosivesinthefluid• Pumprunningtoofast• Wornandslippingdrivebelt(s)• Wornspraynozzle(s)

Pump Runs Rough• Wornpumpvalves• Airlockinoutletsystem• Oillevellow• Wrongweightofoilforcoldoperatingtemperatures(change

tolighterweight)• Cavitation• Airinsuctionline• Restrictionininlet/suctionline• Hydrauliccellsnotprimedafterchangingdiaphragm(��)• Foreignmaterialininletoroutletvalve• Damageddiaphragm(��)• Brokenvalvespring(5,16)

Premature Failure of Diaphragm (22)• Frozenpump• Puncturebyaforeignobject• Elastomerincompatiblewithfluidbeingpumped• Pumprunningtoofast• Excesspressure

Water in Oil Reservoir• Condensation• Ruptureddiaphragm(��)• Hydraulic cell not properly primed after diaphragm (��)

replacement• Frozenpump

Strong Water PulsationsNOTE: Small pulsations are normal with a single-acting pump.

• Foreignobjectlodgedinpumpvalve• Lossofprimeinhydrauliccellbecauseoflowoillevel• Airinsuctionline• Valvespring(5,16)broken• Cavitation• Aerationorturbulenceinsupplytank

19 F�0-991-UK00A

Valve Wear• Normalwear

Pump Runs, But Fluid Doesn’t Flow• Unitair-locked

Loss of Oil• Externalseepage• Ruptureofdiaphragm(��)• Frozenpump• Wornshaftseal• Oildrain,fillcap,oroilreservoircoverloose• Valveplateandmanifoldboltsloose

Premature Failure of Valve Spring or Retainer• Cavitation• Foreignobjectinthepump• Pumprunningtoofast• Spring/retainer material incompatible with fluid being

pumped

F/G-20 Troubleshooting

�0

Limited WarrantyWannerEngineering,Inc.extendstotheoriginalpurchaserofequipmentmanufacturerdbyitandbearingitsname,alimitedone-yearwarrantyfromthedateofpurchaseagainstdefects in material or workmanship, provided that theequipmentisinstalledandoperatedinaccordancewiththerecommendationsandinstructionsofWannerEngineering,Inc.WannerEngineering,Inc.willrepairorreplace,atitsoption, defective parts without charge if such parts arereturnedwith transportationchargesprepaid toWannerEngineering, Inc., 1�04 Chestnut Avenue, Minneapolis,Minnesota55403.

Thiswarrantydoesnotcover:

1. The electric motors (if any), which are covered bythe separate warranties of the manufacturers of thesecomponents.

�. Normalwearand/ordamagecausedbyor related toabrasion, corrosion, abuse, negligence, accident, faultyinstallationortamperinginamannerwhichimpairsnormaloperation.

3. Transportationcosts.

This limited warranty is exclusive, and is in lieu of anyotherwarranties(expressor implied) includingwarrantyofmerchantabilityorwarrantyof fitness foraparticularpurpose and of any noncontractual liabilities includingproduct liabilities based on negligence or strict liability.Every form of liability for direct, special, incidental orconsequential damages or loss is expressly excludedanddenied.

©�004WannerEngineering,Inc.PrintedinUSAF�0-991-UK00A4/2017

Wanner International Ltd8/9 Fleet Business Park Sandy Lane, Church Cr, Hants, GU52-8BF


Wanner Pumps LtdFlat A, 21/F, Chatham Commercial Building,399 Chatham Road North, Hungnom, Kowloon, Hong Kong

Telephone: (852) 3428 6534Fax: (852) 3188 9145Email: [email protected]

Wanner Engineering, Inc.1204 Chestnut Avenue, Minneapolis, MN 55403


models: f-20, f-21, f-22 g-20, g-21, g-22 - hydra-cell.eu · models: f-20, f-21, f-22 g-20, g-21,...

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