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Hydra-Cell D66 Installation Operation & Maintenance

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Installation, Operation & Maintenance
D66-991-2400 Rev G
Models: D66, G66
W0577A
W0578B
1204 Chestnut Avenue, Minneapolis, MN
55403
T e l : ( 6 1 2 ) 3 3 2 - 5 6 8 1
F a x : ( 6 1 2 ) 3 3 2 - 6 9 3 7
Toll-free fax [US only]: (800) 332-6812
www.hydra-cell.com
email: sales@wannereng.com

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  • Page 1 Installation, Operation & Maintenance D66-991-2400 Rev G Models: D66, G66 W0577A W0578B 1204 Chestnut Avenue, Minneapolis, MN 55403 T e l : ( 6 1 2 ) 3 3 2 - 5 6 8 1 F a x : ( 6 1 2 ) 3 3 2 - 6 9 3 7 Toll-free fax [US only]: (800) 332-6812 www.hydra-cell.com...
  • Page 2 Note that Non-Metallic Heads: 120°F (49°C) - consult factory for motor manufacturers typically de-rate the service factor to 1.0 temperatures above 120°F (49°C) when operating with a VFD. D66-991-2400 Rev G...
  • Page 3 Net Positive Suction Head – NPSHr 264.9 70.0 D/G-66 227.1 60.0 200 PSI (14 bar) D/G-66 700 PSI (48bar) 189.3 50.0 151.4 40.0 113.6 30.0 75.7 20.0 37.9 10.0 1000 Revolutions Per Minute 900 1000 Revolutions Per Minute D66-991-2400 Rev G...
  • Page 4 1-1/2” 18.44 3.37 (468.31) (85.58) 1.46 (37.13) (12.73) 1.71 13.62 (43.55) (345.86) 16.22 Ø 2.00 (412.05) (50.82) 7.12 (180.85) Oil Drain 8.84 (224.41) 3/8” NPT Inlet 2 1/2” 9.87 6.50 6.81 (21.08) (250.70) (165.10) (172.97) 11.53 (292.86) D66-991-2400 Rev G...

  • Page 5: Safety Precautions

    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 as applicable.

  • Page 6: Equipment Precautions

    — an oil cooler may be required Pressure Gauge Pressure Regulator Discharge Baffle Line W0571B Suction Line Vacuum Pressure Inlet Gauge To Tank Bypass Line D66-991-2400 Rev G...
  • Page 7 Subtract this figure from the NPSHa, and compare the result to Supply Tank the NPSHr of the Hydra-Cell pump. Use a supply tank that is large enough to provide time for any Ha = (L x V x N x C) ÷ (K x G) trapped air in the fluid to escape.

  • Page 8: Discharge Piping

    For additional system protection install safety relief valve in discharge line downstream from pressure regulator. Atmospheric Pressure at Various Altitudes Altitude Pressure Altitude Pressure (ft) (ft of H (ft) (ft of H 33.9 1500 32.1 33.3 2000 31.5 1000 32.8 5000 28.2 D66-991-2400 Rev G...

  • Page 9: Initial Start-Up Procedure

    8. Provide return line from relief valve to supply tank, similar to bypass line from pressure regulator, never back to suction CAUTION: Protect the pump from freezing. Refer also to line. the “Shutdown Procedure”. D66-991-2400 Rev G...

  • Page 10: Tools And Supplies

    5. Start pump and allow it to run until system is filled with • Wanner D66/G66 Tool Kit, P/N A03-191-1100 antifreeze. • 3/4-in box end wrench Note: If the system has an air lock and the pump fails •...
  • Page 11 (8), valve seat toward the valve plate. Place 1 3/4-in hex socket or 2” schedule 40 pipe onto legs of the valve retainer. Tap the tool until the valve retainer bottoms out. D66-991-2400 Rev G...
  • Page 12 FHCS (17) into valve plunger (61). Tighten FHCS to 144 in.-lbs (16 N-m). Warning do not overtighten as this can cause damage to valve plunger (61). j. Repeat steps a. thru i. for all five diaphragms (20). D66-991-2400 Rev G...
  • Page 13 Slowly turn pump shaft by hand and watch for bubbles at oil reservoir fill opening. This will take several rotations. When no more bubbles come out and reservoir level has dropped about 1” (25 mm), hydraulic cells are primed. e. Replace reservoir (30) and complete installation. D66-991-2400 Rev G...
  • Page 14 CAUTION: These parts are heavy and may need a second person or a lifting device to remove them. h. Remove bearing adjustment plate (48) from the cylinder housing (23) and inspect the bearing cup (51A). Inspect all parts for wear and replace if necessary. D66-991-2400 Rev G...
  • Page 15 (54). Install shaft rotator/seal inserter (from the D/G-66 Tool Kit) over the cam assembly shaft. Using mallet, tap shaft rotator/seal inserter to push two seals into the pump housing (35). Wipe off excess sealant. D66-991-2400 Rev G...
  • Page 16 D/G-66 Fluid End Parts - Metallic TORQUE/LOCTITE REQUIREMENTS ITEM# TORQUE LOCTITE# 90 FT-LBS 180 FT-LBS 65 FT-LBS 12 FT-LBS 609, 567 65 FT-LBS D66-991-2400 Rev G...
  • Page 17 O-Ring, Buna-N ........5 D40-047-2111 O-Ring, FKM ........5 D40-047-2113 O-Ring, EPDM ........5 19 D66-017-1010 Follower, SS 316 .........5 D66-017-1011 Follower, Hastelloy C276 .....5 20 D66-018-2320 Diaphragm, Buna-N, 4” .......5 D66-018-2315 Diaphragm, FKM, 4” ......5 D66-018-2313 Diaphragm, EPDM, 4” ......5 D66-991-2400 Rev G...
  • Page 18 D/G-66 Fluid End Parts - Non-Metallic TORQUE/LOCTITE REQUIREMENTS ITEM# TORQUE LOCTITE# 65 FT-LBS 150 FT-LBS 20 FT-LBS 12 FT-LBS 609, 567 D66-991-2400 Rev G...
  • Page 19 Diaphragm, EPDM, 4” ......5 21 D66-016-1010 Plunger ..........5 22 D25-076-2210 Street Elbow, 3/8 NPT Brass ....1 23 D25-077-2210 Pipe, Nipple, 3/8 NPT ......1 24 D25-078-2210 Pipe, Cap, 3/8 NPT ......1 25 D66-002-1020 Cylinder Housing .........1 26 D40-054-2010 Lockwasher, 5/8 ........4 D66-991-2400 Rev G...
  • Page 20 D/G-66 Hydraulic End Parts TORQUE/LOCTITE REQUIREMENTS ITEM# TORQUE LOCTITE# D66-991-2400 Rev G...
  • Page 21 Valve Cylinder ........5 64 D40-041-1010 Retainer, Ball ........5 65 D10-015-3010 Ball, .1875 Dia ........10 66 D66-014-1010 Piston ..........5 67 D40-013-1010 Foot .............5 68 D40-050-1010 Retainer, Foot ........5 69 D66-014-1210 Piston Assembly ........5 70 D66-014-1209 Foot Piston Assembly ......5 D66-991-2400 Rev G...
  • Page 22 Delivery Too High and/or Inlet supply pressure changed. Monitor inlet supply pressure (at the pump) to determine if it is too high, Erratic. causing a “flow-through” condition. Stabilize pressure at suitable level to resolve problem. D66-991-2400 Rev G...
  • Page 23 TO ORDER REPLACEMENT PARTS KIT: A Replacement Parts Kit contains 11 digits corresponding to customer-specified design options. Order Digit Code Description Kit Contents Pump Configuration For all D66 Pumps Kit Designator For all G66 Pumps Part Number* Description Kit Designator Complete Fluid End Kit...

  • Page 24: Limited Warranty

    Shanghai - China excluded and denied. All liability of Wanner shall terminate Phone: +86-21-6876 3700 one (1) year from the date of purchase of the equipment. Email: sales@wannerpumps.com www.WannerPumps.com © 2016 Wanner Engineering, Inc. Printed in USA D66-991-2400 Rev G...
  • Page 25 Installation, Operation & Maintenance D66-991-2410 Rev A Models: D66, G66 Serial Number 455218 and Above 1204 Chestnut Avenue, Minneapolis, MN 55403 T e l : ( 6 1 2 ) 3 3 2 - 5 6 8 1 F a x : ( 6 1 2 ) 3 3 2 - 6 9 3 7 Toll-free fax [US only]: (800) 332-6812 www.hydra-cell.com...
  • Page 26 Note that Non-Metallic Heads: 120°F (49°C) - consult factory for motor manufacturers typically de-rate the service factor to 1.0 temperatures above 120°F (49°C) when operating with a VFD. D66-991-2410 Rev A...

  • Page 27: Net Positive Suction Head

    D/G-66 Specifications Performance Net Positive Suction Head – NPSHr 70.0 D/G-66 65.0 60.0 55.0 50.0 45.0 40.0 35.0 30.0 25.0 20.0 15.0 10.0 1000 900 1000 Revolutions per Minute 250 PSI 500 PSI 1000 PSI D66-991-2410 Rev A...
  • Page 28 613.16 Outlet 1-1/2 SAE 18.84 478.54 3.45 87.63 18.44 468.38 1.46 37.08 12.70 13.62 1.71 345.95 43.43 Ø2.00 50.80 16.22 411.99 8.84 224.54 7.12 180.85 Inlet 2-1/2 SAE 9.87 250.70 21.08 6.88 6.50 174.75 165.10 11.53 292.86 D66-991-2410 Rev A...
  • Page 29 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 as applicable.
  • Page 30 — an oil cooler may be required Pressure Gauge Pressure Regulator Discharge Baffle Line W0571B Suction Line Vacuum Pressure Inlet Gauge To Tank Bypass Line D66-991-2410 Rev A...
  • Page 31 Subtract this figure from the NPSHa, and compare the result to Supply Tank the NPSHr of the Hydra-Cell pump. Use a supply tank that is large enough to provide time for any Ha = (L x V x N x C) ÷ (K x G) trapped air in the fluid to escape.
  • Page 32 For additional system protection install safety relief valve in discharge line downstream from pressure regulator. Atmospheric Pressure at Various Altitudes Altitude Pressure Altitude Pressure (ft) (ft of H (ft) (ft of H 33.9 1500 32.1 33.3 2000 31.5 1000 32.8 5000 28.2 D66-991-2410 Rev A...
  • Page 33 If the pump inlet is located above the supply tank, check the fluid supply level and replenish if too low. CAUTION: Protect the pump from freezing. Refer also to the “Shutdown Procedure”. D66-991-2410 Rev A...
  • Page 34 5. Start pump and allow it to run until system is filled with • Wanner D66/G66 Tool Kit, P/N A03-191-1100 antifreeze. • 3/4-in, and 1 1/8-in (non-metallic only) hex socket Note: If the system has an air lock and the pump fails •...
  • Page 35 (54), valve seat toward the valve plate. Place 1 3/4-in hex socket or 2” schedule 40 pipe onto legs of the valve retainer. Tap the tool until the valve retainer bottoms out. D66-991-2410 Rev A...
  • Page 36 FHSC (53) into valve plunger (32). Tighten FHSC to 144 in.-lbs (16 N-m). Warning do not overtighten as this can cause damage to valve plunger (32). j. Repeat steps a. thru i. for all five diaphragms (50). D66-991-2410 Rev A...
  • Page 37 This will take several rotations. When no more bubbles come out and reservoir level has dropped about 1” (25 mm), hydraulic cells are primed. e. Replace oil fill cap with O-ring (2) and complete installation. D66-991-2410 Rev A...
  • Page 38 Remove bearing adjustment plate (42) from the cylinder housing (48) and inspect the bearing cup (90A). Inspect all parts for wear and replace if necessary. D66-991-2410 Rev A...
  • Page 39 (7). Install shaft rotator/seal inserter (from the D/G-66 Tool Kit) over the cam assembly shaft. Using mallet, tap shaft rotator/seal inserter to push two seals into the pump housing (1). Wipe off excess sealant. D66-991-2410 Rev A...
  • Page 40 D/G-66 Fluid End Parts - Metallic TORQUE/LOCTITE REQUIREMENTS ITEM# TORQUE LOCTITE# 12 FT-LBS 65 FT-LBS 180 FT-LBS 90 FT-LBS 65 FT-LBS D66-991-2410 Rev A...
  • Page 41 Screw, 1/2 HHCS ........9 61 D66-029-2019 Screw, 1/2” SHCS .......5 62 D25-038-2210 Fitting, Plug Pipe, 3/8 NPT, Brass ..1 D25-038-2211 Fitting, Plug Pipe, 3/8 NPT, 316 SST ..1 63 D40-125-2310 Washer, Dampening, Celcon ....10 D40-125-2318 Washer, Dampening, PVDF ....10 D66-991-2410 Rev A...
  • Page 42 D/G-66 Fluid End Parts - Non-Metallic TORQUE/LOCTITE REQUIREMENTS ITEM# TORQUE LOCTITE# 12 FT-LBS 20 FT-LBS 65 FT-LBS 150 FT-LBS D66-991-2410 Rev A...
  • Page 43 Spring, 17-7 PH .........10 D40-022-3118 Spring Elgiloy ........10 D40-022-3119 Spring, Hastelloy .......10 69 D40-123-1010 Washer, Valve Spring, SS316 ...10 D40-123-1017 Washer, Valve Spring, Hastelloy ..10 70 D66-023-2310 Valve Spring Retainer, Celcon ..10 D66-023-2328 Valve Spring Retainer, PVDF ....10 D66-991-2410 Rev A...
  • Page 44 D/G-66 Hydraulic End Parts TORQUE/LOCTITE REQUIREMENTS ITEM# TORQUE LOCTITE# D66-991-2410 Rev A...
  • Page 45 Guide, Disc Spring ......1 45 D40-075-3110 Spring Disc Adjusting Plate ....4 46 D35-116-1010 Backup Washer ........1 48 D66-002-1020 Cylinder Housing .........1 90 D66-007-1220 Cam Assembly ........1 91 D66-014-1210 Piston Assembly ........5 92 D66-014-1209 Foot Piston Assembly ......5 D66-991-2410 Rev A...
  • Page 46 Delivery Too High and/or Inlet supply pressure changed. Monitor inlet supply pressure (at the pump) to determine if it is too high, Erratic. causing a “flow-through” condition. Stabilize pressure at suitable level to resolve problem. D66-991-2410 Rev A...
  • Page 47 TO ORDER REPLACEMENT PARTS KIT: A Replacement Parts Kit contains 11 digits corresponding to customer-specified design options. Order Digit Code Description Kit Contents Pump Configuration For all D66 Pumps Kit Designator For all G66 Pumps Part Number* Description Kit Designator Complete Fluid End Kit...
  • Page 48 Shanghai - China excluded and denied. All liability of Wanner shall terminate Phone: +86-21-6876 3700 one (1) year from the date of purchase of the equipment. Email: sales@wannerpumps.com www.WannerPumps.com © 2022 Wanner Engineering, Inc. Printed in USA D66-991-2410 Rev A...

This manual is also suitable for:

G66

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