Wanner Engineering Hydra-Cell G-25 Installation Service
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Wanner Engineering Hydra-Cell G-25 Installation Service

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Installation & Service
G25-991-2400B
Models: G-25, H-25
W0452
WANNER ENGINEERING, INC.
1204 Chestnut Avenue, Minneapolis, MN 55403
TEL: (612) 332- 5681 FA X: (612) 332- 6937
TOLL-FREE FAX [US only]: (800) 332-6812
www.hydra-cell.com
email: sales@wannereng.com

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  • Page 1 Installation & Service G25-991-2400B Models: G-25, H-25 W0452 WANNER ENGINEERING, INC. 1204 Chestnut Avenue, Minneapolis, MN 55403 TEL: (612) 332- 5681 FA X: (612) 332- 6937 TOLL-FREE FAX [US only]: (800) 332-6812 www.hydra-cell.com email: sales@wannereng.com...
  • Page 2 G/H-25 Contents Page Specifications................ Dimensions................4 Installation................5 Maintenance................9 Service.(Fluid.End)..............10 Service.(Hydraulic.End)............15 Troubleshooting..............18 G/H-25 Specifications Calculating Required Max Pressure. .. Metallic:. 1000.psi..(70.bar). Horsepower (kW)* . Non-Metallic:. 50.psi..(17.bar) Capacity @ Max Pressure. rpm. gpm. I/min. gpm.x.psi 50.x.rpm =.. electric.motor.HP* .

  • Page 3: Net Positive Suction Head

    G/H-25 Specifications Performance Net Positive Suction Head – NPSHr 1000 1200 24.0 88.0 H/G-25-X 84.0 H/G-25-E 22.0 H/G-25-S H/G-25-I 80.0 H/G-25-X 76.0 20.0 72.0 H/G-25-E 200 PSI (14 bar) 18.0 500 PSI (35 bar) 68.0 1000 PSI (70 bar) 64.0 16.0 60.0 56.0...
  • Page 4 G/H-25 Dimensions Models with Metallic Pumping Head Brass Cast.Iron 316.Stainless.Steel Nickel.Alloy.(Hastelloy.CW1MW) 17.01 (432) 9.44 13.2 (240) (336) Oil Fill Cap 0.25 2.25 Outlet (6.4) (57) H-25: 1" NPT Keyway G-25: 1" BSPT Ø1.125 (28.55) Inlet H-25: 1 1/2" NPT 11.58 (294) G-25: 1 1/2"...

  • Page 5: Important Precautions

    G/H-25 Installation Location Important Precautions NOTE: The numbers in parentheses are the Reference Numbers on the exploded view illustrations found later in Adequate Fluid Supply.. To. avoid. cavitation. and. this manual and in the Parts Manual. premature.pump.failure,.be.sure.that.the.pump.will.have. an.adequate.fluid.supply.and.that.the.inlet.line.will.not.be. Locate.the.pump.as.close.to.the.supply.source.as.possible. obstructed...See.“Inlet.Piping”. Install.it.in.a.lighted,.clean.space.where.it.will.be.easy.to.inspect.
  • Page 6 G/H-25 Installation Inlet Piping (Suction Feed) Inlet Piping (Pressure Feed) CAUTION: When pumping at temperatures above 160° F Provide.for.permanent.or.temporary.installation.of.a.vacuum/ (71° C), use a pressure-feed system. pressure. gauge. to. monitor. the. inlet. vacuum. or. pressure.. . Pressure.at.the.pump.inlet.should.not.exceed.50.psi.(17.bar);..if. Install.draincocks.at.any.low.points.of.the.suction.line,.to.permit. it.could.get.higher,.install.an.inlet.pressure.reducing.regulator. draining.in.freezing.conditions. Do.not.supply.more.than.one.pump.from.the.same.inlet.line. Provide.for.permanent.or.temporary.installation.of.a.vacuum.

  • Page 7: Discharge Piping

    G/H-25 Installation Minimizing Acceleration Head and Frictional Losses Discharge Piping To.minimize.the.acceleration.head.and.frictional.losses: NOTE: Consult the Factory before manifolding two or more •.. Keep.inlet.lines.less.than.3.ft.(1.m).long pumps together. •.. Use.at.least.1-1/.in..(38.mm).I.D..inlet.hose Hose and Routing •.. Use.soft.hose.(low-pressure.hose,.non.collapsing).for.the. inlet.lines Use.the.shortest,.most-direct.route.for.the.discharge.line. •.. Minimize.fittings.(elbows,.valves,.tees,.etc.) Select.pipe.or.hose.with.a.working pressure rating.of.at.least. •. Use a suction stabilizer on the inlet. 1.5.times.the.maximum.system.pressure..EXAMPLE:..Select.a.

  • Page 8: Before Initial Start-Up

    G/H-25 Installation Before Initial Start-Up Initial Start-Up Procedure Before.you.start.the.pump,.be.sure.that: 1.. Turn.on.power.to.the.pump.motor. .. Check.the.inlet.pressure.or.vacuum..To.maintain.maximum. •.. All.shutoff.valves.are.open,.and.the.pump.has.an.adequate. flow,.inlet.vacuum.must.not.exceed.7.in..Hg.at.70°.F.(180. supply.of.fluid. mm.Hg.at.1°.C)..Inlet.pressure.must.not.exceed.50.psi. •.. All.connections.are.tight. (17.bar). •.. The.oil.level.is.1/4.in..(6.mm).above.the.cast.surface.in.the. 3.. Listen.for.any.erratic.noise,.and.look.for.unsteady.flow...If.the. upper.oil.reservoir. pump.does.not.clear,.refer.to.the.Troubleshooting.Section. •.. The.relief.valve.on.the.pump.outlet.is.adjusted.so.the.pump. 4.. If.the.system.has.an.air.lock.and.the.pump.fails.to.prime: starts.under.minimum.pressure. a.. Turn.off.the.power. •.. All. pulleys. and. belts. are. properly. aligned,. and. belts. are. b..
  • Page 9 G/H-25 Maintenance Shutdown Procedure During NOTE: The numbers in parentheses are the Reference Numbers on the exploded view illustrations found in this Freezing Temperatures manual and in the Parts Manual. Take all safety precautions to assure safe handling of the Daily fluid being pumped.
  • Page 10 G/H-25 Service (Fluid End) Models with Non-Metallic Pump Head W0195B G5-991-400B...
  • Page 11 G/H-25 Service (Fluid End) Models with Metallic Pumping Head † With brass external-centerbolt models, use #8; with all other models, use #3. ‡ With cast iron pump heads, use #17 and not #10; with all other heads, use #10 and not #17. Not included with brass pump heads.
  • Page 12 G/H-25 Service (Fluid End) 2. Inspect Valve Assemblies NOTE: The numbers in parentheses refer to the parts illustrations. (parts 11-16, and 38) This. section. explains. how. to. disassemble. and. inspect. all. easily-serviceable. parts. of. the. pump.. Repair. procedures. for. NOTE: The three inlet and three outlet valve assemblies the.hydraulic.end.(oil.reservoir).of.the.pump.are.included.in.a.
  • Page 13 G/H-25 Service (Fluid End) 3. Inspect and Replace 4. Flush Contaminant from Diaphragms (22) Hydraulic End (use if diaphragm has ruptured) a...Lift.diaphragm.().by.one.edge,.and.turn.pump.shaft. until.diaphragm.pulls.up..This.will.expose.machined.cross. a.. Remove. oil. drain. cap. (34). and. allow. all. oil. and. holes.in.valve.plunger.shaft.behind.diaphragm. contaminants.to.drain.out..Replace.oil.drain.cap. b... Insert. Allen. wrench. through. one. of. holes,. to. hold. b..
  • Page 14 G/H-25 Service (Fluid End) 5B. Prime Hydraulic Cells Hydra-cells requires an inlet head pressure of at least 5 feet (1.5 m) or 2 psi (.14 bar). This pressure is on Kel-Cell Pumps (Cont’d) required to hold the diaphragms back while the piston moves to force out the air.
  • Page 15 G/H-25 Service (Hydraulic End) Kel-Cell Models W0197B Quantity per piston: 4 G5-991-400B...
  • Page 16 G/H-25 Service (Hydraulic End) 3. Reassemble Pistons (66) NOTE: The numbers in parentheses are the Reference Numbers used in the Parts Manual illustrations. a...Drop. ball. (58). into. each. opening. in. bottom. of. piston. CAUTION: Do not disassemble the hydraulic end unless assembly.(59).
  • Page 17 G/H-25 Service (Hydraulic End) 7. Install Plungers (23) h.. Alternately.tighten.four.cap.screws.to.evenly.draw.pump. housing.and.cylinder.housing.together..Be.sure.O-ring.(65). NOTE: Install new plungers if they have been removed stays.in.place. from the valve plungers (54). Do not reuse. i.. While. tightening. cap. screws,. frequently. check. shaft. a...Rotate.pump.shaft.so.piston.(66).is.in.top-dead-center. alignment.by.turning.shaft.with.rotor.(from.Wanner.Tool. position. Kit)..If.shaft.begins.to.bind.and.is.hard.to.turn,.back.off.
  • Page 18 G/H-25 Troubleshooting Cavitation Pump Runs Rough •. Inadequate.fluid.supply.because: •. Worn.pump.valves —.Inlet.line.collapsed.or.clogged •. Airlock.in.outlet.system —.Clogged.line.strainer •. Oil.level.low —.Inlet.line.too.small.or.too.long •. Wrong.weight.of.oil.for.cold.operating.temperatures.(change. to.lighter.weight) —.Air.leak.in.inlet.line •. Cavitation —.Worn.or.damaged.inlet.hose •. Air.in.suction.line —.Suction.line.too.long •. Restriction.in.inlet/suction.line —.Too.many.valves.and.elbows.in.inlet.line •. Hydraulic.cells.not.primed.after.changing.diaphragm •. Fluid.too.hot.for.inlet.suction.piping.system. •. Foreign.material.in.inlet.or.outlet.valve •. Air.entrained.in.fluid.piping.system. •. Damaged.diaphragm •.
  • Page 19 G/H-25 Troubleshooting Valve Wear •. Normal.wear.from.high-speed.operation •. Cavitation •. Abrasives.in.the.fluid •. Valve.incompatible.with.corrosives.in.the.fluid •. Pump.running.too.fast Loss of Oil •. External.seepage •. Rupture.of.diaphragm •. Frozen.pump •. Diaphragm.screw.O-ring.(18).missing.or.cracked •. Worn.shaft.seal •. Oil.drain.piping.or.fill.cap.loose. •. Valve.plate.and.manifold.bolts.loose Premature Failure of Valve Spring or Retainer •. Cavitation •.
  • Page 20 Every. form. of. liability. for. direct,. special,. incidental. or. consequential. damages. or. loss. is. expressly. excluded. and.denied. WANNER ENGINEERING, INC. 1204 Chestnut Avenue, Minneapolis, MN 55403 TEL: (612) 332- 5681 FA X: (612) 332- 6937 TOLL-FREE FAX [US only]: (800) 332-6812 www.hydra-cell.com...

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