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 (D-03, G-03) or motor (M-03, M-23, G-13) to a rigid base.

• Belt-Drive Systems: 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.
• Direct-Drive Systems: 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.
• Close-Coupled Systems: Coat the motor shaft liberally with anti-seize.

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" section for details.

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" section.

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.  Refer to the Maintenance Section for specific procedures.

Consult the Factory for the following situations:

• Extreme temperature applications (above 160°F or below 40°F)
• Pressure feeding of pumps
• Viscous or abrasive fluid applications
• Chemical compatibility problems
• Hot ambient temperatures (above 110°F)
• Conditions where pump oil may exceed 200°F (an oil cooler may be required)

   

Caution: When pumping at temperatures above 160° F (71° C), use a pressure-feed system.

• Install drain cocks 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.
• With PTFE diaphragms, the inlet must be flooded.

• Use a supply tank 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, install it in the inlet line to the supply tank.
• To reduce aeration and turbulence, install a completely submerged baffle plate to separate 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.

Size the suction line at least one size larger than the pump inlet so that velocity will not exceed 1-3 ft/sec (0.3 to 0.9 m/sec).

• Keep the suction line as short and direct as possible.
• Use flexible hose and/or expansion joints to absorb vibration, expansion, or contraction.
• If possible, keep the suction line level. Do not have high points to collect vapor unless they are vented.
• To reduce turbulence and resistance, do not use 90° elbows. Use 45° elbows or sweeping curves in flexible inlet hose if turns are necessary.
• If a block valve is used, ensure it is fully opened; 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 at least three times the free-flow area of the inlet.
• Install piping supports where necessary to relieve strain on the inlet line and minimize vibration.

• Provide for permanent or temporary installation of a vacuum/pressure gauge to monitor the inlet.
• Pressure at the pump inlet should not exceed 250 psi (17.3 bar); if it could get higher, install an inlet pressure regulator.
• Do not supply more than one pump from the same inlet line.

Acceleration Head

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

Where:

• Ha: Acceleration head (ft of liquid)
• L: Actual length of suction line (ft)
• V: Velocity of liquid in suction line (ft/sec) [V = GPM × (0.408 ÷ pipe ID²)]
• N: RPM of crank shaft
• C: Constant (0.066 for M-03, D-03, M-23, G-03 and G-13)
• K: Constant for fluid compressibility (1.4 for de-aerated/hot water; 1.5 for most liquids; 2.5 for high-compressibility hydrocarbons)
• G: Gravitational constant (32.2 ft/sec²)

Friction Losses

Frictional losses in the suction piping are negligible (Hf = 0) for water-like fluids when following minimum hose I.D. and maximum length recommendations.

For more-viscous fluids (lubricating oils, sealants, etc.), frictional losses may become significant, decreasing NPSHa and causing cavitation. Frictional losses increase with increasing viscosity, suction-line length, and flowrate, or decreasing line diameter.

Consult the factory before pumping viscous fluids.

• Keep inlet lines less than 3 ft (1 m) long.
• Use at least 5/8 in. (16 mm) I.D. inlet hose.
• Use soft, non-collapsing, low-pressure hose for inlet lines.
• Minimize fittings (elbows, valves, tees, etc.).
• Use a suction stabilizer on the inlet.

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:

Where:

• Pt: Atmospheric pressure
• Hz: Vertical distance from surface liquid to pump center line (if liquid is below pump center line, 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:

• In good practice, NPSHa should be 2 ft greater than NPSHr.
• All values must be expressed in feet of liquid.

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.
• Use approximately 6 ft (1.8 m) of flexible hose between the pump and rigid piping to absorb vibration and expansion.
• Support the pump and piping independently.
• Size the discharge line so that the velocity will not exceed 7-10 ft/sec (2-3 m/sec).

Pressure Regulation

• Install a pressure regulator or unloader in the discharge line.
• Bypass pressure must not exceed the pressure limit of the pump.
• Locate the regulator as close to the pump as possible and ahead of any other valves.
• Adjust the regulator to no more than 10% over the maximum working pressure of the system.
• Route the bypass line to the supply tank, or to the suction line as far from the pump as possible (to reduce the effects of downtime and turbulence).
• If the pump will be operating with the discharge closed for long periods, install a thermal protector in the bypass line, to trip at 140° F (60° C).
• For additional system protection, install a safety relief valve in the discharge line, downstream from the pressure regulator.

CAUTION: Never install shut-off valves in the bypass line or between the pump and the pressure regulator/relief valve.

Before you start the pump, be sure that:

• All shut-off valves are open, and the pump has an adequate supply of fluid.
• All connections are tight.
• The oil level is 3/4 in. (20 mm) from the top of the fill port.
• The relief valve on the outlet of the pump 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 and belts have adequate safety guards.

• 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 (17.3 bar).
• Listen for any erratic noise and look for unsteady flow.
• If the system has an air lock and the pump fails to prime:
  • Turn off the power.
  • Open one outlet port.
  • Briefly restart the system and operate it until fluid comes out the outlet port.
  • Turn off the power and reinstall the outlet port 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 "pop-off" safety relief valve at 100 psi (6.9 bar) higher than the desired operating pressure.

NOTE: The numbers in parentheses are the Ref. Nos. on the illustrations in the Parts Manual.

• Check the oil level and the condition of the oil. The oil level should be 3/4 in. (20 mm) from the top of the fill port.
• Use the appropriate Wanner Hydra-Oil brand motor 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 (17) may be damaged. Refer to the 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.

Change the oil after the first 100 hours of operation, then change according to the guidelines below. When changing, remove the drain plug (60). Allow all oil and contaminant to drain out.

Hours Between Oil Changes @ Various Process Fluid Temperatures

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

CAUTION: Do not turn the drive shaft while the oil reservoir is empty.

If the pump is to be lifted or stored for a long period (more than six months), or if it is to be exposed to freezing temperatures, follow this procedure:

• Flush the pump with a solution of water and a rust-inhibitor.
• Stop the pump.
• Drain the liquid from the pump and suction/discharge lines.
• Fill the pump with an antifreeze/water solution if it will be exposed to freezing temperatures.
• To facilitate restarting, follow step 4 of the Initial Start-up Procedure to clear any air locks.
• When antifreeze is flowing from the system return line, stop the pump. Connect the return line back to the supply tank and circulate for a short period.
• It is good practice to change the oil in the Hydraulic End before storage to remove accumulated condensation and sediment. Drain and refill with appropriate Hydra-Oil and operate for a short period.

CAUTION: Protect the pump from freezing. Refer also to the "Shutdown Procedure".

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.

Note: The numbers in parentheses are the Ref. Nos. on the illustrations in the Parts Manual.

Important: Fluid End Service is different for Kel-Cell and non Kel-Cell versions. Before performing Fluid End Service, determine your version:

• Kel-Cell versions: Indicated by a "K" in digit 5 of the pump model number.
• Non Kel-Cell versions: Indicated by an "A" or "D" in digit 5 of the pump model number.

• Remove all eight bolts (1) around the manifold.
• Remove the manifold (3).
• Inspect the manifold for warping or wear around the inlet and outlet ports. If wear is excessive, replace the manifold. To check for warping, remove the O-rings (4) and place a straightedge across the surface. A warped manifold should be replaced.
• Remove the two socket-head capscrews (14).
• Inspect the valve plate in the same manner as the manifold.

The three inlet and three outlet valve assemblies are identical but face in opposite directions. Inspect each valve as follows:

• Check the spring retainer (10), and replace if worn.
• Check the valve spring (8). If it is shorter than a new spring, replace it (do not stretch the old spring).
• Check the valve poppet (7). If worn excessively, replace it.
• Remove the valve seat (6). A seat puller is included in the Wanner Tool Kit. Inspect the valve seat for wear and replace if necessary. A new O-ring (5) should be installed.
• Check the dampening washer (11), and replace if worn.
• Reinstall the valve assemblies:
  • Clean the valve ports and shoulders with emery cloth, and lubricate them with lubricating gel or petroleum jelly.
  • Install the O-ring (5) on the valve seat (6).
  • Inlet Valves (3 lower valves): Insert the spring retainer (10) into the valve plate, then insert the spring, valve, tetra seal, valve seat with O-ring, and dampening washer (8, 7, 9, 6, 11). A flat O-ring [tetra seal] (9) goes between the plastic spring retainer and seat.
  • Outlet Valves (3 upper valves): Install the three outlet valve assembly components in reverse order as the inlet valves.