HP D-04, G-04 User Manual

INSTALLATION & SERVICE

INDUSTRIAL PUMPS

Models: D-04, G-04

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

D/G-04 Contents

Page

Specifications......................................................................... 2

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

Installation.............................................................................. 5

Maintenance .......................................................................... 9

Service (Fluid End) .............................................................. 10

Service (Hydraulic End)....................................................... 14

Troubleshooting ................................................................... 17

D/G-04 Specifications

Max Pressure 2,500 psi (170 bar) Capacity @ Max Pressure

rpm gpm I/min D/G-04-X 1750 2.9 11.0 D/G-04-E 1750 2.1 7.8 D/G-04-S 1750 1.6 6.1

Delivery @ Rated Pressure

revs/gal

500 psi 1500 psi 2500 psi D/G-04-X 565 583 603 D/G-04-E 761 795 833 D/G-04-S 921 972 1,093

revs/liter

35 bar 100 bar 170 bar D/G-04-X 149 154 159 D/G-04-E 201 211 224 D/G-04-S 244 257 287

Max Inlet Pressure 500 psi (35 bar) Max Temperature 250°F (121°C) – consult factory for

temperatures above 160°F (71°C)

Inlet Port D-04: 1/2 inch NPT

G-04: 1/2 inch BSPT

Discharge Port D-04: 1/2 inch NPT

G-04: 1/2 inch BSPT

Shaft Diameter 7/8 inch (22.22 mm) Shaft Rotation Bi-directional Bearings Ball bearings Oil Capacity 1.1 US quarts (1.05 liters) Weight 37 lbs (16.8 kg)

Calculating Required Horsepower (kW)*

6 x rpm

63,000

6 x rpm

84,428

* rpm equals pump shaft rpm. HP/kW is required application power. Use caution when sizing motors with variable speed drives.

gpm x psi

1,460 –

gpm x bar

511 –

psi – 500

(

bar – 35

(

electric motor HP*

)

electric motor kW*

)

2 D04-991-2400 5/1/04

D/G-04 Specifications

Performance Net Positive Suction Head –

0 200 400 600 800 1000 1200 1400 1600 1800

3.33

3.00

2.66

500 PSI (35 bar) 1500 PSI (100 bar) 2500 PSI (170 bar)

2.33

RPM

D/G-04-X

12.5

1750

11.25

8.75

NPSHr

D/G-04-X D/G-04-E D/G-04-S

3.5

1750

3.0

2.5

2.0

2.00

1.66

Gallons per Minute

1.33

1.00

0.66

0.33

D/G-04-E

D/G-04-S

7.5

6.25

Liters per Minute

5.0

3.75

2.5

1.25

NPSHr (feet of water)

0 200 400 600 800 1000 1200 1400 1600 1800

RPM

Dry Lift

8.0

7.0

6.0

5.0

4.0

3.0

Lift (feet of water)

2.0

1.0

D/G-04-X D/G-04-E D/G-04-S

200 400 600 800 10001200 14001600 1800

RPM

240

1750

220 200

180 160

140 120 100

1.5

NPSHr (meters of water)

1.0

0 .5

Lift (cm of water)

80 60

40 20

3 D04-991-2400 5/1/04

D/G-04 Dimensions

D/G-04 Models with Metallic Pumping Head

Brass 304 Stainless Steel 316 Stainless Steel

8.71

(221.2)

4.25

(108)

0.75

(19.1)

10.38

(263.7)

(57.2)

2.75

(69.9)

2.25

2.75

(69.9)

3.35

(85.1)

7.01

(178)

0.75

(19.1)

0.189

(4.8)

4.250

(107.9)

2.25

(57.2)

1.73

(43.9)

Good Key

0.875

(22.23)

1.71

(43.4)

9.93

(252.2)

Outlet

5.00

(127)

Inlet

D-04: 1/2" NPT G-04: 1/2" BSPT

6.55

(166)

3.52

(89.4)

4.97

(126)

4 D04-991-2400 5/1/04

D/G-04 Installation

NOTE: The numbers in parentheses are the Reference Numbers on the illustrations in the Parts Manual.

Location

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 rotate in either direction.To prevent vibration, securely attach the pump to a rigid base.

On a belt-drive system, align the sheaves accurately; poor alignment wastes horsepower and shortens the belt and bearing life. Make sure the belts are properly tightened, as specified by the belt manufacturer.

On a direct-drive system, align the shafts accurately. Unless otherwise specified by the coupling manufacturer, maximum parallel misalignment should not exceed .015” and angular misalignment should be held to 1 degree maximum. Careful alignment extends life of the coupling, pump, shafts, and support bearings. Consult coupling manufacturer for exact alignment tolerances.

On a close-coupled system, coat the motor shaft liberally with anti-seize.

Important Precautions

Adequate Fluid Supply. To avoid cavitation and

premature pump failure, be sure that the pump will have an adequate fluid supply and that the inlet line will not be obstructed. See “Inlet Piping”.

Positive Displacement. This is a positive-displacement pump. To avoid severe system damage if the discharge line ever becomes blocked, install a relief valve downstream from the pump. See “Discharge Piping”.

Safety Guards. Install adequate safety guards over all pulleys, belts, and couplings. Follow all codes and regulations regarding 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 (4°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

5 D04-991-2400 5/1/04

D/G-04 Installation

Inlet Piping (Suction Feed)

CAUTION: When pumping at temperatures above 160° F (71

° C), use a pressure-feed system.

Install draincocks at any low points of the suction line, to permit draining in freezing conditions.

Provide for permanent or temporary installation of a vacuum gauge to monitor the inlet suction. To maintain maximum flow, vacuum at the pump inlet should not exceed 7 in. Hg at 3 gpm and 70° F (180 mm Hg at 11.4 liters/min and 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.

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 500 psi (34 bar); if it could get higher, install an inlet pressure regulator.

Do not supply more than one pump from the same inlet line.

Inlet Calculations

Acceleration Head

Calculating the Acceleration Head

Use the following formula to calculate acceleration head losses. Subtract this figure from the NPSHa, and compare the result to the NPSHr of the Hydra-Cell pump.

Ha = (L x 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 ÷

N=RPM of crank shaft C=Constant determined by type of pump — use 0.066 for the

K= Constant to compensate for compressibility of the fluid —

G=Gravitational constant (32.2 ft/sec2)

pipe ID

D-04 and G-04 Hydra-Cell pumps

use: 1.4 for de-aerated or hot water; 1.5 for most liquids;

2.5 for hydrocarbons with high compressibility

)]

Hose Size and Routing

Use the shortest, most-direct route from the supply tank to the pump. If elbows are needed, 45° are recommended. Any restrictions in the inlet piping may cause pump output to drop.

Do not install any 90

• Use flexible noncollapsible hose between the pump and rigid piping or supply tank. This will absorb vibration, and allow for expansion or contraction.

• Use the largest practical hose. The smallest permissible size is 5/8 in. (16 mm) I.D.

• All valves, fittings, and unions must also have 5/8-in. (16 mm) minimum I.D. Do not exceed 5 feet of hose and piping between and supply tank and the pump inlet.

• Support the pump and piping independently.

• Make sure all joints are sealed and tight, to prevent the pump

from drawing air into the inlet.

• 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.

Loctite is a registered trademark of Loctite Corporation. Teflon is a registered trademark of E. I. DuPont de Nemours & Co. Inc.

° elbows in the pump inlet.

6 D04-991-2400 5/1/04

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