Fill-rite FR405 User Manual

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Page 1

Owner's ManualOwner's Manual

Owner's Manual

Owner's ManualOwner's Manual

SERIES FR400 DIAPHRAGM

PUMP

For Industrial Fluid Transfer

For models:For models:

For models:

For models:For models:

FR405, FR410, FR412, FR205, FR210, FR212 (DC)FR405, FR410, FR412, FR205, FR210, FR212 (DC)

FR405, FR410, FR412, FR205, FR210, FR212 (DC)

FR405, FR410, FR412, FR205, FR210, FR212 (DC)FR405, FR410, FR412, FR205, FR210, FR212 (DC)

& FR450, FR450E, FR452 (AC)& FR450, FR450E, FR452 (AC)

& FR450, FR450E, FR452 (AC)

& FR450, FR450E, FR452 (AC)& FR450, FR450E, FR452 (AC)

Model FR410

Patent #5,219,274

Page 2

DANGER

EXPLOSION PROOF MOTOR OPTION: Electrical wiring should be done by a licensed electrician in accordance with approved electrical codes. Motor should be properly grounded and a rigid conduit should be used when installing electrical wiring. Improper use or installation of this product can cause serious bodily injury or death.

DANGER

Not for use with fluids thatNot for use with fluids that

Not for use with fluids that

Not for use with fluids thatNot for use with fluids that have a flash point below 100°Fhave a flash point below 100°F

have a flash point below 100°F

have a flash point below 100°Fhave a flash point below 100°F (37.8°C, ie: gasoline, alcohol).(37.8°C, ie: gasoline, alcohol).

(37.8°C, ie: gasoline, alcohol).

(37.8°C, ie: gasoline, alcohol).(37.8°C, ie: gasoline, alcohol). Refer to NFPA 325M (FireRefer to NFPA 325M (Fire

Refer to NFPA 325M (Fire

Refer to NFPA 325M (FireRefer to NFPA 325M (Fire Hazard Properties of Flam-Hazard Properties of Flam-

Hazard Properties of Flam-

Hazard Properties of Flam-Hazard Properties of Flammable Liquids, Gases, andmable Liquids, Gases, and

mable Liquids, Gases, and

mable Liquids, Gases, andmable Liquids, Gases, and Volatile Solids) for flashVolatile Solids) for flash

Volatile Solids) for flash

Volatile Solids) for flashVolatile Solids) for flash points of common liquids.points of common liquids.

points of common liquids.

points of common liquids.points of common liquids. Static electricity buildup andStatic electricity buildup and

Static electricity buildup and

Static electricity buildup andStatic electricity buildup and discharge could result in arcdischarge could result in arc

discharge could result in arc

discharge could result in arcdischarge could result in arc and explosion.and explosion.

and explosion.

and explosion.and explosion.

SAFETY INSTRUCTIONS

1. 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.

2. Never disassemble YOKE ASSEMBLY (see item 12).

This is under extreme pressure and injury could result.

3. Tank or barrel should be anchored to prevent tipping in both the full and empty conditions.

4. The pump motor is equipped with thermal overload protection. 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 without warning if power is on.

OPTIONS

•1" polypropylene ball valve/nozzle

•Buna-N or EPDM hose

•Telescoping steel suction tube

• 820 electronic digital meter (for thin or thick viscosities)

•2" NPT or 2" buttress inlet bung adapter

•1" FNPT straight and 90o inlet/outlet fittings available

•Wraparound tubular mounting frame

•Santoprene diaphragms

•12 VDC, 24 VDC, 115 VAC/60 Hz, 230 VAC/50 Hz available

TECHNICAL INFORMATION

Design Features

•1" FNPT straight inlet and 90o outlet standard

•15 PSIG maximum outlet pressure

•2600 RPM, 1/4 HP motor:

•12 VDC, rated at 20 amps

•24 VDC, rated at 10amps

•115 VAC/60 Hz rated at 2.0 amps

•230 VAC/50 Hz rated at 1.1 amps

•Thermal overload protection of the motor

•Positive displacement/self-priming design

•Unaffected by particulate materials up to 0.100"

diameter in the pumped fluids

•Flow easily controlled by outlet throttling from

maximum to zero

•Pump may run dry without damage

•Handles viscosities from 1.0 CPS to 3000 CPS

(SAE 140 gear oil at 68

•Minimum shear (agitation) of pumped fluids

•Does not include inlet strainer

•Minimum operating temperature: -10ºF (-23ºC)

•Maximum operating temperature: 130ºF (54ºC)

•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

WARNING

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 FR400 is 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.

Fluid Compatibility

The FR400 Series pump is compatible with the following fluids:

• Ethylene Glycol, Hydraulic Oil, Motor Oil, Water

The FR400 Series pump is fluids:

NOTNOT

NOT compatible with the following

NOTNOT

• 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.

Fluorocarbon Polypropylene

FilCon

Stainless Steel

Buna-N

Page 3

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 90o 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.

Mounting Holes

Adapters are available to fit the pump to a 2" bung and a selection of standard bung fittings common in the petroleum, chemical and agricultural markets.

Use pipe compound or Teflon® tape on all threaded fittings (except 2" bung threads if present).

Electrical Installation

DANGER

Not for use with fluids thatNot for use with fluids that

Not for use with fluids that

Not for use with fluids thatNot for use with fluids that have a flash point belowhave a flash point below

have a flash point below

have a flash point belowhave a flash point below 100°F (37.8°C, ie: gasoline,100°F (37.8°C, ie: gasoline,

100°F (37.8°C, ie: gasoline,

100°F (37.8°C, ie: gasoline,100°F (37.8°C, ie: gasoline, alcohol). Refer to NFPAalcohol). Refer to NFPA

alcohol). Refer to NFPA

alcohol). Refer to NFPAalcohol). Refer to NFPA 325M (Fire Hazard Proper-325M (Fire Hazard Proper-

325M (Fire Hazard Proper-

325M (Fire Hazard Proper-325M (Fire Hazard Properties of Flammable Liquids,ties of Flammable Liquids,

ties of Flammable Liquids,

ties of Flammable Liquids,ties of Flammable Liquids, Gases, and Volatile Solids)Gases, and Volatile Solids)

Gases, and Volatile Solids)

Gases, and Volatile Solids)Gases, and Volatile Solids) for flash points of commonfor flash points of common

for flash points of common

for flash points of commonfor flash points of common liquids. Static electricityliquids. Static electricity

liquids. Static electricity

liquids. Static electricityliquids. Static electricity buildup and discharge couldbuildup and discharge could

buildup and discharge could

buildup and discharge couldbuildup and discharge could result in arc and explosion.result in arc and explosion.

result in arc and explosion.

result in arc and explosion.result in arc and explosion.

Circuit Breakers (AC only)

Power to the unit should be supplied from a dedicated circuit breaker. No other equipment should be powered from this breaker. Provision must be made to break both

legs of any AC circuit.

Dimensions

DANGER

DC ONLY: DC ONLY:

DC ONLY: Connect cable to 12 volt DC power supply as

DC ONLY: DC ONLY: follows, paying special attention to wire colors:

Pump Cable

Positive Red Negative Black

CALIBRATION

If a meter is used, calibrate according to the instructions in the meter’s Owner's Operation & 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.

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ASSEMBLY/DISASSEMBLY

NOTE: Pump should be thoroughly flushed prior to disassembly.

Motor/Gear Assembly Removal (Refer to exploded

view of pump)

1. If possible, 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.

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. lbs. 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. tighten screws to 50 in. lbs.

Hand start and

DO NOT DISASSEMBLE GEAR ASSEMBLY.DO NOT DISASSEMBLE GEAR ASSEMBLY.

DO NOT DISASSEMBLE GEAR ASSEMBLY. Planet

DO NOT DISASSEMBLE GEAR ASSEMBLY.DO NOT DISASSEMBLE GEAR ASSEMBLY. 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 serviced without removing motor and oil from pump body by removing one at a time 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

5. Insert four screws (item 11) and o-rings (item 42) into diaphragm as shown and tighten to 35 in. lbs. of torque.

6. Install pump covers (item 4). Hand start and tighten screws (item 20) to 50 in. lbs.

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 pressure exceeds 15psi (1 bar). Instead, submerge 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. lbs. (items 19, 20, & 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 level.

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. lbs. to prevent internal leakage.

NOTE: If external screws (items 19, 20, & 23) are removed,

hand start and tighten to 50 in. lbs.

Page 5

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

•Maximum of 30 minute duty cycle, not for continuous operation

•9 inches of mercury dry vacuum

•Suction lift: 10' for water. The lift in feet is equivalent to the vertical distance from the surface of the fluid in the tank. to the inlet of the 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 (lpm)

7.6 15.1

) T E E

F (

E S

O H

G R A

H C S

I D

I " 1

F O

T G N

E L

4 6 8 10121416

FLOW in GALLONS PER MINUTE (gpm)

225 cps (30 wt Oi l @ 78° F)

308 cps (30 wt Oi l @ 69° F) 560 cps (30 wt Oil @ 56° F)

30.3 37.9 45.4 53 60.6

22.7

15.2

13.7

12.2

10.7

9.1

7.6

665 cps (30 wt Oil @ 49° F)

2420 cps (30 wt Oil @ 22° F)

4.6

1.5

6.1

NOTES:

) S

1. SUCTION LOSSES.

R E T E

( E

S O H E G R

A H C S

I D

I " 1

F O

H T

G N E

Test pump was mounted on a 55 gallon drum of oil, 1/2 full. A SOTERA 1" suction pipe was used.

FILL-RITE

A longer or smaller diameter inlet pipe will lower the flow rate.

2. VERTICAL HEAD LOSSES.

Test hose was horizontal with pump. Add 3 feet of hose for each 1 foot of vertical rise.

3. OTHER LOSSES. Elbows, quick-disconnects,

swivels, and check valves in outlet or inlet hoses will restrict the flow. Add the estimated length of hose for each component used.

1" SureStop + 0.5 feet Other 1" disconnects + 13.0 feet 1" Check Valves + 8.7 feet

1" Elbow + 2.6 feet

Page 6

SERIES 400 PUMP PARTS LIST

ITM. PART NO. NO. DESCRIPTION QTY.

1a 400G9453 12 VDC Motor no gear

1b 400G9734 12 VDC Motor with gears Opt.

1c 400G9486 115 VAC 60 Hz Motor no gear

1d 400G9735 115 VAC 60 Hz Motor with gears Opt.

2a 400F6846 Motor Assembly - 12 VDC EXP PROO

2b 200G7237 Motor Assembly - 24 VDC EXP PROO

2c 400F7351 Motor Assembly - 115 VAC EXP PROOF Opt.

2d 400G7186 Motor Assembly - 230 VAC EX P PROOF O pt.

3 400F6567 Pump Body 1 4 400F6568 Pump Cover 2 5 400F6569 Flange, straight 1 6 400F6924 Gasket Inlet Flange 2 7 400F6571 Check Valve - Inlet 4 8 35F6588 O-ring (-117) (Included w/Item 7) 4 9 400F6589 Check Valve - Outlet 4

10 400F7238 Diaphragm Assembly - FilCon™ 2

(Includes Items 7, 8, 9) 400F6917 Diaphragm Assembly - Santoprene™ Opt. (Includes Items 7, 8, 9)

11 400F6795 #10-24 x 1/2 THMS 8 12 400F6781 Yoke Assembly 1 13 400F6800 Drive Shaft 1 14 400F6819 Eccentric Bushing 1 15 400F6827 Bearing Ring 1 16 400F6880 Thrust Plate 1 17 400F6579 Bearing Plate 1 18 400F6693 Shaft Bushing 2 20 400F0267 1/4-20 x 3/4 PHMS 30 21 6U100 Nozzle, Aluminum 1 22 400F6679 90° Flange with brass inserts 1 23 400F6817 1/4-20 x 2-1/4 HHMS 2 24 400F6557 Gear Assembly (Included w/Item 1 or 2) 1 25 400G7494 #6-32 x 1/2 FHMS (Incl. w/Item 1 or 2) 6 26 400F6692 Gasket Motor Flange 1 27 400F6563 Drive Gear (Included w/Item 1 or 2) 1 28 1200F6440 Drive Key (Included w/Item 1 or 2) 1 29 400G9104 Shaft Seal (Included w/Item 1 or 2) 1 30 400F6818 Sight Cap, Polypropylene 2 31 400F6813 O-ring (-022) 2 32 400F8517 Nameplate 1 33 400F6758 Logo Plate 2 34 1200F7207 Cable 20 feet (DC Only) 20 FT

35a 400G9736 Nozzle Holder, Aluminum Nozzle Opt.

35b 400G9737 Nozzle Holder, Poly Nozzle Opt.

36 400F6566 Gear Housing (Included w/Item 1 or 2) 1 37 400G7006 Ball Valve Nozzle, 1", Poly Nozzle Opt. 39 700F3123 1" x 12' EPDM Hose Opt.

400F3140 1" x 12' Nyall Hose Opt. 40 700F6748 Nozzle Cover (Explosive Proof motor) Opt. 41 600F2220 5/16-18 x 3/4 HHCS Opt. 42 400G8887 O-Ring (007) 8

43a 400G9140 Bung Adapter - NPT Opt.

43b 400F6528 Bung Adap ter - Buttress O pt.

44 400F0237

400F7320 Power Cord (115 VAC Only) (Not Shown) Opt.

650G7185 Power Cord (230 VAC Only) (Not Shown) Opt.

400F1855 Suction Pipe, Polypropylene (Not Shown) Opt.

nti-Dr ip Sp out Op t.

Opt.

Opt. Opt.

WHEN ORDERING REPAIR PARTS, BE SURE TO GIVE REPLACEMENT PART NUMBER, DATE OF MANUFACTURE 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, & 42)

Page 7

DATE STAMP

1b 1d

35a

35b

EXPLOSION PROOF

MOTOR OPTION

43b

43a

12V, 24V, 115V, 230

WITH GEARS

CAUTION: NEVER disassemble Yoke Assembly. This is under extreme spring tension and injury could result.

WHEN ORDERING REPAIR PARTS, BE SURE TO GIVE REPLACEMENT 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

Page 8

TROUBLESHOOTING GUIDE

PROBLEM POSSIBLE CAUSE SOLUTION

Pump won’t prime •Suction line problem •Check for leaks in suction line.

•Leaky check valves •Check for dirt or damaged check valves and replace.

•Check valves improperly installed •Check for proper installation.

•Outlet plugged •Check for blockage and clear.

•Motor not operating •Check power source.

•Repair or replace motor.

•Stripped or damaged gears •Check gear assembly and drive gear for damage. Replace complete assembly if necessary.

Pump hums but will •Motor faulty •Replace motor. not operate •Gear mechanism jammed •Check for free rotation of the gears.

Low pump capacity •Low voltage •Check power source.

•Leaky suction line •Repair leaks.

•Dirt in check valves •Dismantle and clean.

•Faulty check valves •Install repair kit.

•One or both diaphragms leaking •Install repair kit.

•One piston screw loose •Install new yoke assembly.

•Piston retainer screws loose •Install new yoke assembly.

•Debris ingested •Add inlet screen.

Motor overheats •Pumping hot fluids •Shorten duty cycle.

•Motor faulty •Replace motor.

Fluid leakage •Faulty or missing gaskets •Install all gaskets specified in parts list.

•Loose bolts •Torque all bolts to 50 in. lbs.

•Cracked component •Replace defective component.

•Piston retainer screws loose •Install new yoke assembly.

Page 9

NOTES

Page 10

PRODUCT WARRANTY

Tuthill Transfer Systems (“Manufacturer”) warrants to each consumer buyer of its Fill-Rite products (the “Buyer”), from the date 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

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 authorized 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.

400F3394 REV. 8

www. tuthill.com

8825 Aviation Drive Fort Wayne, In diana USA 46809 Tel 260 747-7524 Fax 260 747-3159