owner's manual - Oasis Car Wash Systems

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OWNER’S MANUAL

OASIS CAR WASH SYSTEMS 800-892-3537 · www.oasiscarwashsystems.com

Installation

Revised 04/01/08

1.3

Installation

Revised 04/01/08

1.5

Installation

Revised 04/01/08

1.4

REVERSE OSMOSIS OPERATION Once your Oasis RO System is on-line, the day to day operation is very simple. You should check the salt level in the brine tank daily and add salt as required. Once per week test to ensure the water is free of chlorine. This can be checked from the test cock located on top of the carbon filter. You should also check the water for hardness to ensure the proper operation of the water softener. Water must be at zero grains hardness. During normal operation, the system will operate automatically and does not require any further attention. The Oasis RO System is basically two systems in one. The first system produces pure water. The other system delivers the pure water to the wash bays.

RO MEMBRANE SYSTEM The RO Membrane is nothing more than a very fine filter. This filter (membrane) is so fine that it simply removes the minerals from the water and allows only the pure water to pass (permeate) through the membrane. Since the membrane is so fine, a pump must be used to pressurize the water to approximately 200 PSI to force the water through the membrane. As with any filter, after time the membrane could become clogged (fouled) with minerals, grease or dirt and not allow any further passage of the pure water through the membrane and into the holding tank. Since the membranes are very fine and fouling can occur, a water softener is used to soften the incoming water and the carbon filter is used to remove the chlorine. Chlorine will damage the membrane, and prolonged exposure can cause permanent damage. To keep fouling from happening, a certain amount of water must be used to flush past the surface of the membrane and rinse the build-up of minerals from the membrane surface. This water is then recirculated through the membrane pump system and used over. After several passes by the membrane, the recirculating water becomes very saturated with minerals. It must therefore be discarded. To ensure smooth continuous operation, an orifice is located in the recirculation system and a controlled amount of water is rejected from the system to drain (reject water) on a continuous basis as long as the membrane pump is running. The amount of reject water is controlled by the orifice located in the plumbing in the lower portion of panel. See schematic for its location. The amount of reject water is set at the factory and should only be changed after consultation with the factory. The amount of water going to drain can be monitored in the REJECT WATER FLOW METER. The pure water (PRODUCT WATER) that permeates through the membrane is then stored in the stainless steel product water holding tank. As the water level reaches the top of the tank a float switch will shut off the membrane pump, thus stopping the production of pure water. Once the water level is reduced a sufficient amount, the float switch will start the membrane pump and once again fill the tank with pure water. If you operate the Oasis system 24 hours per day you will find that the water softener will regenerate at approximately 2 o'clock AM. The system will receive city water to the Oasis system during the time that the water softener regeneration takes place. This should be avoided. Do not allow the storage system to run at this time, as it will cause membrane damage. The normal regeneration time is about 2 hours. You may wish to check the softener manual for more detailed information concerning the operation of the water softener.

DELIVERY SYSTEM OPERATION The Delivery System consists of a pump capable of producing pressure up to approximately 150 PSI using the water from the pure water holding tank. The electric control panel and wash bay switches control the pump. Should the water level fall below the low water level switch in the water holding tank, the delivery pump shuts off until the water level is restored.

INSTALLATION & OPERATION INSTRUCTIONS This Oasis RO system is pre-plumbed and wired for easy installation and start-up. Once this system is on-line, very little preventative maintenance is required. 1. Chlorine test weekly. The chlorine level should remain at zero to prevent permanent damage to the RO Membranes. 2. Water hardness test weekly. The water hardness should remain at zero, to prevent premature fouling of the RO Membranes. 3. Sediment filter checked weekly (visual inspection).

INSTALLATION 1. Select a location where the required utilities are easily accessible. 2. Check the incoming water pressure prior to installing the RO System. Should the water pressure be less than 40 PSI, a booster pump may be required (consult factory). If the incoming water pressure exceeds 100 PSI it will be necessary to install a pressure-reducing valve. 3. Normal electrical requirements for this system are 240/480 volt 3-phase 10/20-amp service. Controls are located in the main electrical enclosure. 4. Make the drain line connection (1/2 inch) to a floor drain near the RO system. Should a drain not be available in close proximity to the RO system, you can run the drain line overhead to a drain located elsewhere in the building (Max height 8' above base). Please refer to sketch for the location of this connection. 5. The final connection to make is the pure water connection from each wash bay to the RO manifold located on the upper right end of JETSTREAM MODULE.

START UP INSTRUCTIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

19. 20. 21.

22.

23. 24.

Charging the system with water is the first step in starting up the RO system. Check to be sure that the manual service valve is in the off position (customer supplied). Make sure the power is turned off. Install a temporary jumper wire between terminal number 5 and number 76 (solenoid valve). Remove sediment filter and housing, being careful to not lose the o-ring. Turn off the 3-phase contactor for RO storage pump. Turn on the power to control panel. Partially open the service valve to flush the dust out of the charcoal tank. If this step is skipped, you may cause the sediment filter to foul prematurely. Allow charcoal filter to flush slowly for approximately fifteen minutes. Close the service valve therefore shutting off the water supply, turn off control power and then remove the jumper between terminal number 5 and number 76. Reinstall the sediment filter and housing. Turn on control power. Caution! Make sure water softeners have been regenerated before charging system (water should test 0 grains hardness). Make sure the ½” permeate pure water hose is connected to the bottom plumbing of the pure water holding tank. Turn off the RO 3-Phase contactor. This will enable the storage pump and allow water to flow and expel all air from the system (air bubbles can be seen through flow meters on front door). The upper float switch in the pure water holding tank must be in the down position. Turn on the service valve slowly, checking for air bubble again in flow meters. Now check pump for correct rotation by watching shaft (may seen at about mid position of storage pump), while someone else bumps RO pump contactor momentarily. See pump for correct rotation. CAUTION! Do not run pump for more than 5 seconds in the event rotation is wrong, as this can cause sever damage to the pump. When the rotation is correct, the PUMP CONTACTOR can now be turned to run position. The high-level float switch must be in the down position for the pump to run. There is about an 8 second delay before the pump will start. Once the system is producing water, adjust the pressure to about 200 PSI. See Schematic for pressure regulator location. Water should begin to fill the pure water holding tank Make sure the high-level float switch will shut the system down automatically. Manually raise this switch by hand, which should shut down the system. Again lower the high-level float switch and the system will restart after the 8-second delay. While the storage tank is filling, use the water test kits. Take a sample of water from the water sample valve and check for chlorine and hardness. It is extremely important that the RO membrane(s) be supplied with chlorine-free, soft water. Both of the readings should be zero. If they are not, discard the water in the storage tank until the water becomes pure. After the storage tank has filled with pure water, make sure the hand valve in the supply line to the delivery pump from the storage tank is fully open. The RO System is now in full automatic operation.

TROUBLE SHOOTING GUIDE 1) Product flow is less than normal, pressure normal and water with water temperature at approximately 78 deg F * CAUSE:

RO membrane(s) fouled.

* SOLUTION:

Membrane(s) should be cleaned. CONSULT FACTORY.

2) Product flow higher than normal and pressure normal with water temperature at approximately 78 deg F * CAUSE:

Membrane(s) damaged.

* SOLUTION:

Repair or replace. The membrane life is approximately three to five years depending on service duty.

3) Storage pump will not start. * CAUSE:

a) Control panel circuit breaker has tripped. b) Motor overload has tripped. c) Float switch is stuck or defective. d) Motor has become defective. e) High-level float switch is stuck or defective.

* SOLUTION:

a) Reset circuit breaker. b) Reset motor overload. c) Repair or replace. d) Repair or replace. e) Repair or replace.

5) Delivery pump will not start. * CAUSE:

a) Control panel circuit breaker has tripped. b) Motor overload has tripped. c) Motor has become defective. d) Pressure switch is not working. e) Low water level in holding tank. f) Low-water switch is defective.

* SOLUTION:

a) Reset circuit breaker. b) Reset motor overload. c) Repair or replace. e) Repair or replace.

6) No delivery pressure. * CAUSE:

a) See step number 5. b) Insufficient amount of water in storage tank. c) Delivery pump is damaged. d) Pump is running in the wrong direction.

* SOLUTION:

a) See step number 5. b) Allow time for tank to fill. c) Repair or replace pump. d) Change motor rotation if required, at time of installation only.

7) No storage pressure. * CAUSE:

a) Low incoming water pressure. b) Float switch is defective. c) Lost power to pump. d) Pump is running in the wrong direction. e) Motor has become defective. f) System water leaks.

* SOLUTION:

a) Incoming water pressure should be between 40 and 100 PSI. b) Repair or replace. c) Replace fuse or reset overload. d) Change motor rotation if required at time of installation only. f) Repair or replace. g) Repair or replace failed plumbing.

8) Storage pump short cycles on and off. * CAUSE:

a) Sediment filter dirty. b) Insufficient water flow/pressure.

* SOLUTION:

a) Replace. b) Check incoming water supply (40-100 PSI required).

DLA9, DLA12, DLA16, DLA26 Operating instructions

Combination contactor - motor circuit-breaker

FPTC 407714 P0001-07/97

ABB Control Inc.

23 AC 1000.6 – 7/98

15 lb.in. 9 lb.in. 9 lb.in.

Warning ! The operation, installation and servicing of this appliance must be carried out by a qualified electrician applying the relevant rules of the art, installation standards and safety regulations. Before operating the contactors, check that control voltage complies with the data on the coil mounting bracket. Connection to other control voltage can destroy the coil. Do not touch live parts. Danger !.

24 AC 1000.6 – 7/98

ABB Control Inc.

®

5CP Plunger Pump

5CP2120W 5CP2140WCS 5CP2150W

Models

SPECIFICATIONS MODEL 5CP2120W FEATURES Superior Design ● ● ● ● ● ●

Triplex plunger design gives smoother liquid flow. Hi-Pressure Seals are completely lubricated and cooled by the liquids being pumped. Inlet and discharge valve assemblies interchange for easier maintenance. Lubricated Lo-Pressure Seals provides double protection against external leakage. Oil bath crankcase assures optimum lubrication. Close tolerance concentricity of the ceramic plunger maximizes seal life.

Quality Materials ● ● ● ● ● ● ● ●

Precision design 304 stainless steel valves and seats are hardened and polished for ultimate seating and extended valve life. Forged brass manifolds for strength and corrosion resistance. Special blend W770 manifold offers washout and freeze protection for car wash applications. Special concentric, high-density, polished, solid ceramic plungers provide a true wear surface and extended seal life. Specially formulated, CAT PUMP exclusive, Hi-Pressure Seals offer unmatched performance and seal life. Die cast aluminum crankcase provides high strength, minimum weight and precision tolerance control. Chrome-moly crankshaft gives unmatched strength and surface hardness. Oversized crankshaft bearings with greater loading capacity mean longer bearing life.

U.S. Measure

Metric Measure

Flow ...............................................................4.0 GPM Pressure Range......................................100-2500 PSI RPM ..............................................................950 RPM Bore....................................................................0.787" Stroke .................................................................0.709" Weight ...........................................................19.14 lbs.

(15 L/M) (7-175 BAR) (950 RPM) (20 mm) (18 mm) (8.7 kg)

MODEL 5CP2140WCS Flow ...............................................................4.0 GPM Pressure Range......................................100-2500 PSI RPM ............................................................1725 RPM Bore....................................................................0.787" Stroke .................................................................0.394" Weight ...........................................................19.14 lbs.

MODEL 5CP2150W Flow ...............................................................5.0 GPM Pressure Range.......................................100-2000 PSI RPM ............................................................1725 RPM Bore....................................................................0.787" Stroke .................................................................0.472" Weight ...........................................................19.14 lbs.

● ● ●

Convenient “press-in” style seal case for ease in servicing. Wet-end is easily serviced without entering crankcase, requiring less time and effort. Valve assemblies are accessible without disturbing piping, for quick service. Preset packings mean no packing gland adjustment is necessary, reducing maintenance costs.

Inlet Pressure Range (950 RPM) .............– 5 to 60 PSI Inlet Pressure Range (1725 RPM) ...Flooded to 60 PSI Crankcase Capacity ............................................17 oz. Max. Liquid Temperature ....................................160°F

WARNING

(– 0.35 to 4 BAR) (Flooded to 4 BAR) (0.51 L) (71°C)

Above 130°F call CAT PUMPS for inlet conditions and elastomer recommendations.

Inlet Ports (2)................................................1/2" NPTF Discharge Ports (2) ......................................3/8" NPTF Shaft Diameter....................................................0.787" Dimensions ....................................10.35 x 10.0 x 5.78"

(1/2" NPTF) (3/8" NPTF) (20 mm) (263 x 254 x 147 mm)

ELECTRIC HORSEPOWER REQUIREMENTS MODEL

FLOW

U.S. GPM 2120W 4.0 Alternate 5.0 2140WCS 4.0 2150W 5.0

L/M 15 19 15 19

DETERMINING THE PUMP R.P.M.

All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility for the operation of a customer’s high pressure system.

(19 L/M) (7-140 BAR) (1725 RPM) (20 mm) (12 mm) (8.7 kg)

COMMON SPECIFICATIONS

Easy Maintenance ●

(15 L/M) (7-175 BAR) (1725 RPM) (20 mm) (10 mm) (8.7 kg)

DETERMINING THE REQUIRED H.P. DETERMINING MOTOR PULLEY SIZE

PRESSURE MOTOR PULLEY SIZE PSI PSI PSI PSI Using 1725 RPM Motor 1200 1500 2000 2500 & 8" Std. Pump Pulley BAR BAR BAR BAR RPM Pulley 85 105 140 175 O.D. 3.3 4.1 5.5 6.9 950 4.3 4.1 5.1 6.9 N/A 1188 5.5 3.3 4.1 5.5 6.9 1725 Direct 4.1 5.1 6.9 N/A 1725 Direct Rated G.P. M. Rated R.P. M.

=

“Desired” G.P. M. “Desired” R.P. M.

GPM x PSI 1460

=

Electric Brake H. P. Required

Motor Pulley O.D. Pump R.P.M.

=

Pump Pulley O.D. Motor R.P.M.

See complete Drive Packages [Inclds: Pulleys, Belts, Hubs, Key] Tech Bulletin 003. Refer to pump Service Manual for repair procedure, additional technical information and pump warranty.

“Customer confidence is our greatest asset”

PARTS LIST ITEM

PART NUMBER 5CP2120W MATL

2 5 8 10 11 15 20 25 30 32 33 37 38 40 48 49 50 51 53 64 65 70 75 88 90 98 99 100 106 120 121 125 139 162 163 164 166 167 168 172 174 185 188

196 250 255 260

30057 96031 126542 46910 14028 43222 14480 48742 46928 — — 46798 14179 92241 44428 92519 125824 25625 23170 46940 14044 48617 46746 48458 46838 43328 45697 46841 46730 48394 ◆ 48432 ✝ 48201 46749 43305 45153 ◆ 48429 46843 13978 14329 ◆ 48904 43307 44936 46667 22179 48361 43358 44938 ◆ 48908 43725 43723 43750 44565 17615 15855 ◆ 48431 43849 48245 87872 126513 22187 118672 30243 30611

STL STZP STCP R AL NBR NBR STL TNM FCM — — — NBR — NBR STZP STCP R STCP NBR AL NBR AL CM BBNP NBR S S CC NBR FPM EPDM SSL PVDF NBR FPM EPDM BB NBR FPM EPDM SNG FPM HT BBCP D NBR FPM EPDM S S S PVDF NBR FPM EPDM BBCP W770 STZP STCP R BBCP STCP STZP STZP

5CP2140WCS MATL 30057 96031 126542 46910 14028 43222 14480 48742 — 48203 48224 46798 14179 92241 44428 92519 125824 25625 23170 46940 14044 48617 46746 48458 46838 43328 45697 46841 46730 48394 ◆ 48432 ✝ 48201 46749 43305 45153 ◆ 48429 46843 13978 14329 ◆ 48904 43307 44936 46667 22179 48361 43358 44938 ◆ 48908 43725 43723 43750 44565 17615 15855 ◆ 48431 43849 48245 87872 126513 22187 118672 30243 30611

STL STZP STCP R AL NBR NBR STL TNM — FCM AL — NBR — NBR STZP STCP R STCP NBR AL NBR AL CM BBNP NBR S S CC NBR FPM EPDM SSL PVDF NBR FPM EPDM BB NBR FPM EPDM SNG FPM HT BBCP D NBR FPM EPDM S S S PVDF NBR FPM EPDM BBCP W770 STZP STCP R BBCP STCP STZP STZP

DESCRIPTION 30057 96031 126542 46910 14028 43222 14480 48742 46982 — — 46798 14179 92241 44428 92519 125824 25625 23170 46940 14044 48617 46746 48458 46838 43328 45697 46841 46730 48394 ◆ 48432 ✝ 48201 46749 43305 45153 ◆ 48429 46843 13978 14329 ◆ 48904 43307 44936 46667 22179 48361 43358 44938 ◆ 48908 43725 43723 43750 44565 17615 15855 ◆ 48431 43849 48245 87872 126513 22187 118672 30243 30611

STL STZP STCP R AL NBR NBR STL TNM FCM — — — NBR — NBR STZP STCP R STCP NBR AL NBR AL CM BBNP NBR S S CC NBR FPM EPDM SSL PVDF NBR FPM EPDM BB NBR FPM EPDM SNG FPM HT BBCP D NBR FPM EPDM S S S PVDF NBR FPM EPDM BBCP W770 STZP STCP R BBCP STCP STZP STZP

265

30637 STZP 30659 —

30637 STZP 30659 —

30637 STZP 30659 —

275

30944 STL

30944 STL

30944 STL

283 298 299 300

34334 34970 34980 816650 33628 31628 ◆ 31648 31638

— STZP STZP W770 NBR FPM EPDM* HT

34334 34970 34980 816650 33628 31628 ◆ 31648 31638

— STZP STZP W770 NBR FPM EPDM* HT

QTY

5CP2150W MATL

34334 34970 34980 816650 33628 31628 ◆ 31648 31638

— STZP STZP W770 NBR FPM EPDM* HT

Key (M6x6x25) Screw, Sems HHC (M8x16) Screw, Sems HHC (M8x16) Cover, Bearing O-Ring, Bearing Cover - 70D Seal, Oil, Crankshaft Bearing, Ball Rod, Connecting Assy [10/01] Crankshaft, Dual End Crankshaft, Single End Cover, Bearing Blind Cap, Oil Filler, Domed O-Ring, Oil Filler Cap - 70D Gauge, Oil, Bubble w/Gasket - 80D Gasket, Flat, Oil Gauge - 80D Screw, Sems HHC (M6x16) Screw, Sems HHC (M6x16) Plug, Drain (1/4"x19BSP) O-Ring, Drain Plug - 70D Cover, Rear O-Ring, Rear Cover Crankcase Pin, Crosshead Rod, Plunger Seal, Oil, Crankcase - 70D Slinger, Barrier Washer, Keyhole (M18) Plunger (M20x50) Washer, Seal - 90D Washer, Seal - 90D Washer, Seal Retainer, Plunger w/Stud (M6) Retainer, Seal Seal, LPS w/S-Spg Seal, LPS w/SS-Spg Seal, LPS w/SS-Spg Case, Seal (Press-in-style) O-Ring, Seal Case - 70D O-Ring, Seal Case O-Ring, Seal Case Seal, HPS w/S Seal, HPS w/SS Seal, HPS 2-Pc w/S-Support Plug, Inlet (1/2"NPT) Back-up-Ring, Seat O-Ring, Seat - 70D O-Ring, Seat - 70D O-Ring, Seat Seat Valve Spring Retainer, Spring O-Ring, Valve Plug - 75D O-Ring, Valve Plug - 70D O-Ring, Valve Plug - 75D Plug, Valve Manifold, Head - W770 Screw, HSH (M8x70) Screw, HSH (M8x70) Plug, Discharge (3/8"NPT) Protector, Shaft Mount, Direct Assembly, Angle Rail - B (Inclds: 28499, 30900, 30910, 30920) (Belt Drive Only) Mount, Angle Assy-Retro Fit Kit, Complete Mounting (Inclds: 30611, 30633, 118672) (Belt Drive Only) Hub & Key Assy (M20 w/M6 Keyway) [See Drive Packages, Tech Bulletin 003] Kit, Oil Drain Clutch, Assy, Single Groove, 20mm, 12VDC Clutch, Assy, Dual Groove, 20mm, 12VDC Head, Complete Kit, Seal (Inclds: 98, 106, 121, 125) Kit, Seal (Inclds: 98, 106, 121, 125) Kit, Seal (Inclds: 98, 106, 121, 125) Kit, Seal (Inclds: 98, 106, 121, 125)

1 8 8 2/1 2 2 2 3 1 1 1 1 1 1 1 4 4 1 1 1 1 1 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1 6 6 6 6 6 6 6 6 6 6 6 6 1 8 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

EXPLODED VIEW

Models 5CP2120W, 5CP2140WCS, 5CP2150W

October 2006 5CP2120W MATL 310 350 400 — —

30821 31821 ◆ 31162 30696 7850 — 6107

NBR FPM EPDM STZP BB — —

5CP2140WCS MATL 30821 31821 ◆ 31162 30696 7850 8026ES-8042ES 6107

5CP2150W MATL

NBR 30821 FPM 31821 EPDM ◆ 31162 STZP 30696 BB 7850 — 8026ES-8042ES — 6107

NBR FPM EPDM STZP BB — —

Kit, Valve (Inclds: 162,163,164,166,167,168,172) Kit, Valve (Inclds: 162,163,164,166,167,168,172) Kit, Valve (Inclds: 162,163,164,166,167,168,172) Plier, Reverse Modular Unloader (See Individual Data Sheet) BD Motors (See Individual Data Sheet) Oil, Bottle (21 oz) ISO 68 Multi-viscosity Hydraulic (Fill to specified crankcase capacity prior to start-up)

2 2 2 1 1 1 1

Bold print part numbers are unique to a particular pump model. Italics are optional items. ◆ Silicone oil/grease required. ✝ Production parts are different than repair parts. R Components comply with RoHS Directive. [ ] Date of latest production change. W770 effective with 97 production. *Review material codes for individual items (HT generally may be used as alternate). See Tech Bulletins 002, 003, 024, 036, 043, 053, 060, 061, 064, 073, 074, 077, 078 and 083 for additional information. MATERIAL CODES (Not Part of Part Number): AL=Aluminum BB=Brass BBCP=Brass/Chrome Plated BBNP=Brass/Nickel Plated CC=Ceramic CM=Chrome-moly D=Acetal EPDM=Ethylene Propylene Diene Monamer FBB=Forged Brass FCM=Forged Chrome-moly FPM=Fluorocarbon HS=High Strength HT=Hi-Temp (EPDM Alternative) NBR=Medium Nitrile (Buna-N) PVDF=Polyvinylidene Fluoride S=304SS SNG=Special Blend (Buna) SSL=316SS/Low Carbon STL=Steel W770=Special Alloy STCP=Steel/Chrome Plated STZP=Steel/Zinc Plated TNM=Special High Strength

Models 5CP2120W, 5CP2140WCS, 5CP2150W

10 1

9 3

4

5

6

11 7 12

2

8

10

1

2 3

4

5

Die cast aluminum crankcase means high strength, lightweight, and excellent tolerance control. Oversized crankshaft bearings provide extended bearing life and pump performance. Chrome-moly crankshaft provides unmatched strength and surface hardness for long life. Matched high strength connecting rods noted for strength and superior bearing quality. The plunger rods with hardened surfaces offer wear resistance and Zamak crossheads for high load capacity.

6

7

8

9

The stainless steel slinger provides back-up protection for the crankcase seal, keeping pumped liquids out of the crankcase. Special concentric, high-density, polished, solid ceramic plungers provide a true wear surface and extended seal life. Manifolds are a high tensile strength forged W770 alloy for long term, continuous duty. 100% wet seal design adds to service life by allowing pumped liquids to cool and lubricate on both sides.

10 Stainless steel valves, seats and springs provide corrosion-resistance, ultimate seating and extended life. 11 Specially formulated, CAT PUMP exclusive, Hi-Pressure Seals offer unmatched performance and seal life. 12 Press-in style seal case offers alignment and support for seals and “no tools” servicing.

Products described hereon are covered by one or more of the following U.S. patents 3558244, 3652188, 3809508, 3920356, 3930756 and 5035580

CAT PUMPS (U.K.) LTD.

World Headquarters CAT PUMPS 1681 - 94th Lane N.E. Minneapolis, MN 55449 - 4324 Phone (763) 780-5440 — FAX (763) 780-2958 e-mail: [email protected] www.catpumps.com

1 Fleet Business Park, Sandy Lane, Church Crookham FLEET, Hampshire, GU52 8BF, England Phone Fleet 44 1252-622031 — Fax 44 1252-626655 e-mail: [email protected]

N.V. CAT PUMPS INTERNATIONAL S. A. The Pumps with Nine Lives

Heiveldekens 6A, B-2550 Kontich, Belgium Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51 e-mail: [email protected] www.catpumps.be

International Inquiries

CAT PUMPS DEUTSCHLAND GmbH

FAX (763) 785-4329 e-mail: [email protected]

Buchwiese 2, D-65510 Idstein, Germany Phone 49 6126-9303 0 — Fax 49 6126-9303 33 e-mail: [email protected] www.catpumps.de PN 993100 Rev D 9618

CP PLUNGER PUMP SERVICE MANUAL

®

3CP MODELS: 3CP1120, 3CP1130, 3CP1140 5CP MODELS: 5CP2120W, 5CP2140WCS, 5CP2150W, 5CP3120, 5CP3120G1, 5CP3130G1, 5CP5120, 5CP5150G1, 5CP6120, 5CP6120G1, 5CP6140, 5CP6150 7CP MODELS: 7CP6170 INSTALLATION AND START-UP INFORMATION Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only with the proper selection, installation of plumbing, and operation of the pump and accessories. SPECIFICATIONS: Maximum specifications refer to individual attributes. It is not implied that all maximums can be performed simultaneously. If more than one maximum is considered, check with your CAT PUMPS supplier to confirm the proper performance and pump selection. Refer to individual pump Data Sheet for complete specifications, parts list and exploded view. LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications (3CP-10 oz., 5CP-17 oz., 7CP-38 oz.). DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE. Change initial fill after 50 hours running period. Thereafter, change oil every 3 months or 500 hour intervals. Additional lubrication may be required with increased hours of operation and temperature. PUMP ROTATION: Pump was designed for forward rotation to allow optimum lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil level is increased slightly above center dot to assure adequate lubrication. PULLEY SELECTION: Select size of motor pulley required to deliver the desired flow from Horsepower Requirement and Pulley Selection Chart (refer to Tech Bulletin 003 or individual Data Sheet). DRIVE SELECTION: The motor or engine driving the pump must be of adequate horsepower to maintain full RPM when the pump is under load. Select the electric motor from the Horsepower Requirement Chart according to required pump discharge flow, maximum pressure at the pump and drive losses of approximately 3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper engine size. MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit drainage of crankcase oil. An uneven mounting surface will cause extensive damage to the pump base. To minimize piping stress, use appropriate flexible hose to inlet and discharge ports. Use the correct belt; make sure pulleys are aligned. Excessive belt tension may be harmful to the bearings. Hand rotate pump before starting to be certain shaft and bearings are free moving. LOCATION: If the pump is used in extremely dirty or humid conditions, it is recommended pump be enclosed. Do not store or operate in excessively high temperature areas or without proper ventilation. INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual before starting system. DO NOT STARVE THE PUMP OR RUN DRY. Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over 130°F. Elastomer or RPM changes may be required. See Tech Bulletin 002 or call CAT PUMPS for recommendations. C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in applications with stressful inlet conditions such as high temperatures, booster pump feed, long inlet lines or quick closing valves.

DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or system. Install a Pulsation Dampener on the discharge head or in the discharge line as close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator) is properly precharged for the system pressure (see individual Data Sheet). A reliable Pressure Gauge should be installed near the discharge outlet of the high pressure manifold. This is extremely important for adjusting pressure regulating devices and also for proper sizing of the nozzle or restricting orifice. The pump is rated for a maximum pressure; this is the pressure which would be read at the discharge manifold of the pump, NOT AT THE GUN OR NOZZLE. Use PTFE thread tape or pipe thread sealant (sparingly) to connect accessories or plumbing. Exercise caution not to wrap tape beyond the last thread to avoid tape from becoming lodged in the pump or accessories. This condition will cause a malfunction of the pump or system. PRESSURE REGULATION: All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). The primary pressure device must be installed on the discharge side of the pump. The function of the primary pressure regulating device is to protect the pump from over pressurization, which can be caused by a plugged or closed off discharge line. Over pressurization can severely damage the pump, other system components and can cause bodily harm. The secondary safety relief device must be installed in-line between the primary device and the pump or on the opposite side of the manifold head. This will ensure pressure relief of the system if the primary regulating device fails. Failure to install such a safely device will void the warranty on the pump. When the high pressure system is left running with the trigger gun off, the by-pass liquid can be routed to drain or to the pump inlet. If routed to the pump inlet, the by-pass liquid can quickly develop excessive heat and result in damage to the pump. A THERMO VALVE installed in the by-pass line is recommended to protect the pump. An AUTO SHUT-OFF ASSEMBLY may also be used. NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure regulating device to compensate. Replace nozzle and reset regulating device to system pressure. PUMPED LIQUIDS: Some liquids may require a flush between operations or before storing. For pumping liquids other than water, contact your CAT PUMPS supplier. STORING: For extended storing or between use in cold climates, drain all pumped liquids from pump and flush with antifreeze solution to prevent freezing and damage to the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech Bulletin 083).

WARNING All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility for the operation of a customer’s high pressure system. Products described hereon are covered by one or more of the following U.S. patents 3558244, 3652188, 3809508, 3920356, 3930756 and 5035580

CAT PUMPS (U.K.) LTD.

World Headquarters CAT PUMPS 1681 - 94th Lane N.E. Minneapolis, MN 55449 - 4324 Phone (763) 780-5440 — FAX (763) 780-2958 e-mail: [email protected] www.catpumps.com

®

The Pumps with Nine Lives

1 Fleet Business Park, Sandy Lane, Church Crookham FLEET, Hampshire, GU52 8BF, England Phone Fleet 44 1252-622031 — Fax 44 1252-626655 e-mail: [email protected]

N.V. CAT PUMPS INTERNATIONAL S. A. Heiveldekens 6A, B-2550 Kontich, Belgium Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51 e-mail: [email protected] www.catpumps.be

International Inquiries

CAT PUMPS DEUTSCHLAND GmbH

FAX (763) 785-4329 e-mail: [email protected]

Buchwiese 2, D-65510 Idstein, Germany Phone 49 6126-9303 0 — Fax 49 6126-9303 33 e-mail: [email protected] www.catpumps.de PN 33009 Rev J 7709

All Models

3CP1120, 5CP2120W, 7CP6170

5CP3120, 5CP5120, 5CP5150

Removal of Valve Plugs

Valve Plug and O-Ring

Valve Plug, O-Ring and Back-up Ring

CAUTION: Before commencing with service, shut off drive (electric motor, gas or diesel engine) and turn off water supply to pump. Relieve all discharge line pressure by triggering gun or opening valve in discharge line. After servicing is completed, turn on water supply to pump, start drive, reset pressure regulating device and secondary valve, read system pressure on the gauge at the pump head. Check for any leaks, vibration or pressure fluctuations and resume operation.

SERVICING THE VALVES 1. Remove the hex Valve Plugs (top discharge, bottom inlet). 2. Examine the O-Ring under the plug for cuts or distortion. Replace if worn. Lubricate new O-Rings before installing. NOTE: The 5CP3120, 5CP5120 and 5CP5150 have both an O-Ring and Back-up Ring on the Valve Plug. 3. Grasp Spring Retainer by the tab at the top with a pliers and remove from each valve chamber. Usually the valve assembly will remain together while being removed. To separate the valve assembly, insert a screw-driver into the side of the Spring Retainer and press on the back side of the Valve to begin separation, then between the Spring Retainer and Seat to separate completely. If the valve assembly separates during removal, remove the Spring and Valve with a needle nose pliers. With a reverse pliers, remove the Seat from each valve chamber. Then, with a small screwdriver, carefully remove the O-Ring at the bottom of the valve chamber. NOTE: The 5CP2120W, 5CP6120 and 7CP6170 have an O-Ring and Back-up Ring on each Seat.

4. Examine all valve parts for pitting, gouges or wear and replace with preassembled Valve Assembly. Service kit contains Spring Retainers, Springs, Valves, Seats, Back-up Rings and O-Rings. NOTE: Inlet and discharge valve parts are interchangeable. Two Valve Kits are needed for complete valve change. 5. Grasp new Valve Assembly by the tab at the top with a pliers, immerse in oil and push into each valve chamber. Be certain valve assembly is completely seated in valve chamber. NOTE: For certain applications apply liquid gasket to the o-ring crevices and seal surfaces. See Tech Bulletin 053 for model identification. NOTE: EPDM elastomers require Silicone-base lubricant. 6. Apply Loctite® 242® to the threads of each Valve Plug, thread into valve port and torque per chart.

3CP1120, 5CP2120W, 7CP6170

5CP3120, 5CP5120, 5CP5150

All Models

Removal of Valve Assembly

Removal of Valve Assembly

Removal of Valve Seat O-Ring

3CP1120, 5CP3120, 5CP5120

5CP2120W, 5CP6120, 7CP6170

All Models

Complete Valve Assembly

Complete Valve Assembly

Removal of Socket Head Screws

SERVICING THE PUMPING SECTION Disassembly

Reassembly

1. Using an allen wrench, remove the Socket Head Screws from the Manifold Head.

1. Generally Plungers do not need to be replaced. Clean plungers and remove any foreign material with a nonabrasive cleaner.

2. Rotate Crankshaft by hand to start separation of Manifold Head from Crankcase. 3. Insert two flat head screwdrivers on opposite sides to further separate Manifold Head from Crankcase. Support the underside of the Manifold Head and tap lightly with a mallet on the backside of the Manifold Head. CAUTION: KEEP MANIFOLD PROPERLY ALIGNED WITH CERAMIC PLUNGERS WHEN REMOVING TO AVOID DAMAGE TO THE PLUNGERS. 4. Remove the Seal Retainer from each plunger rod and examine for wear.

2. Install Seal Retainer over Plungers with small tab facing down and holes facing forward towards manifold head. 3. Rotate the crankshaft so the two outside plungers are extended the same distance. 4. Lightly lubricate the Plungers and carefully slide the Manifold Head onto the Plungers supporting from the underside. On the high pressure V-Packing models or larger manifolds, it may be necessary to gently tap with a soft mallet until the Manifold Head is flush with the Crankcase. 5. Replace Socket Head Screws and torque per chart.

5. Examine Ceramic Plunger for cracks or scoring. Refer to SERVICING THE PLUNGERS if replacement is needed.

3CP1120, 5CP2120W, 5CP6120

5CP3120, 5CP5120, 5CP5150, 7CP6170

All Models except 7CP6170

Seal Arrangement

Seal Arrangement

Plunger Arrangement

SERVICING THE PLUNGERS Disassembly 1. To service the plungers, it is necessary to remove the manifold head. Follow disassembly procedure for SERVICING THE PUMPING SECTION. 2. Remove the Seal Retainer from each plunger rod. 3. Using a wrench, loosen the Plunger Retainer about three to four turns. 4. Push the Ceramic Plunger back towards the crankcase to separate from the Plunger Retainer and proceed with unthreading the Plunger Retainer by hand. 5. Remove the Plunger Retainer, Seal Washer, Ceramic Plunger, Keyhole Washer and Barrier Slinger from each Plunger Rod. 6. On the model 7CP6170 remove the Plunger Retainer, Stud, Gasket, O-Ring, Back-up Ring, Ceramic Plunger and Barrier Slinger from each Plunger Rod. Reassembly 1. Visually inspect Crankcase Oil Seals for deterioration or leaks and contact factory for assistance with replacement. 2. Replace Barrier Slinger if damaged and slide onto Plunger Rod with concave side away from Crankcase. 3. Examine Seal Washer for cuts or wear and replace as needed. 4. On the model 7CP6170 examine Gaskets, O-Rings and Back-up Rings for cuts or wear and replace as needed. 5. Examine Plunger Retainers and Studs for wear or damaged threads and replace as needed. 6. On the model 7CP6170 install Gaskets first, then O-Rings and Back-up Rings onto the Plunger Retainer. NOTE: Lubricate O-Rings and Back-up Rings for ease in installation and to reduce possible damage.

7. All other models, lubricate and install Seal Washer onto Plunger Retainer. 8. On the model 7CP6170 apply Loctite® 242® to one end of threaded Plunger Retainer Stud and secure to Plunger Retainer. 9. Examine Ceramic Plungers for scoring, scale build-up, chips or cracks and replace as needed. Generally the ceramic plungers do not need to be replaced. 10. Slide Plunger Retainer Assembly into flat end of Ceramic Plunger. 11. Apply Loctite ® 242 ® to exposed threaded end of Plunger Retainer. 12. Install Ceramic Plunger with Plunger Retainer onto each Plunger Rod shoulder and thread Plunger Rod. Torque to specifications per chart. NOTE: Ceramic Plungers can only be installed in one direction. Counterbore end of Ceramic Plunger to fit over Plunger Rod shoulder. 13. Install Seal Retainers with small tabs facing down and holes facing forward towards manifold head. 14. Proceed with servicing the seals or remounting of Manifold Head as described.

SERVICING THE SEALS AND V-PACKINGS Disassembly

V-Packing Models:

1. Remove the Manifold Head as described in SERVICING THE PUMPING SECTION.

1. Lubricate each seal chamber in manifold head.

2. Place the Crankcase side of manifold facing up and with a reverse pliers, remove the Lo-Pressure Seal from the Seal Case. 3. Using a reverse pliers, remove the press-in style Seal Case from the Manifold Head. 4. Remove the O-Ring from O.D. of Seal Case. Hi-Pressure Seal Models 3CP1120, 3CP1130, 3CP1140, 5CP2120W, 5CP2140WCS, 5CP2150W, 5CP6120, 5CP6120GI The Hi-Pressure Seal is generally easily removed from the manifold without any tools. If extremely worn, a reverse pliers may be used. V-Packing Models 5CP3120, 5CP3120G1, 5CP3130G1, 5CP5120, 5CP5150G1, 7CP6170 The V-Packings and Male Adapter are easily removed from the manifold without any tools.If extremely worn, a reverse pliers may be used. Reassembly NOTE: If your pump has been built with special seals and O-Rings, service with same type. Refer to pump Data Sheet for correct parts or kits. Hi-Pressure Seal Models:

NOTE: For certain applications apply liquid gasket to the O-Ring crevices and seal surfaces. See Tech Bulletin 053 for model identification. NOTE: EPDM elastomers require silicone-base lubricant. 2. Insert Male Adapter with notches down and “v” side up and press completely into each seal chamber by hand. 3. Lubricate V-Packings and install one at a time with grooved side down into each seal chamber. 4. Examine Seal Case O-Ring and replace if worn. Lubricate new O-Rings before installing. 5. Press Seal Case into each seal chamber until completely seated. Lo-Pressure Seal-All Models: 1. Examine Lo-Pressure Seals for wear to the internal ridges, outer surfaces or for broken springs and replace as needed. 2. Install Lo-Pressure Seal into Seal Case with garter spring down. 3. All Models: Install Seal Retainer over Plungers with small tabs facing down and holes facing forward towards manifold head. 4. Replace Manifold Head onto pump as described under SERVICING THE PUMPING SECTION and torque per chart.

1. Lubricate each seal chamber in manifold head. NOTE: For certain applications apply liquid gasket to the O-Ring crevices and seal surfaces. See Tech Bulletin 053 for model identification. NOTE: EPDM elastomers require silicone-base lubricant. 2. Carefully square Hi-Pressure Seal into position by hand with the grooved side down (metal back facing out) and press into each seal chamber until completely seated. 3. Examine Seal Case O-Rings and replace if worn. Lubricate new O-Ring before installing. 4. Press the Seal Case into each seal chamber until completely seated.

SERVICING THE CRANKCASE SECTION 1. While Manifold Head, Plungers and Seal Retainers are removed, examine Crankcase Oil Seals for leaking and wear. 2. Check for any signs of leaking at Rear Cover, Drain Plug, Bubble Gauge and Dipstick (7CP6170). 3. Check oil level and for evidence of water in oil. Change crankcase oil on a regular schedule. See Preventative Maintenance Check-List. 4. Rotate Crankshaft by hand to feel for smooth bearing movement. 5. Examine Crankshaft Oil Seal externally for drying, cracking or leaking. 6. Contact CAT PUMPS or your local distributor if crankcase service is evidenced.

Loctite and 242 are registered trademarks of the Henkel Corporation.

INLET CONDITION CHECK-LIST PREVENTATIVE MAINTENANCE CHECK-LIST Check

Daily Weekly 50 hrs. 500 hrs.* 1500 hrs.** 3000 hrs.**

Clean Filters

x

Oil Level/Quality

x

Oil Leaks

x

Water Leaks

x

Belts, Pulley

x

Plumbing

x

Initial Oil Change

x

Oil Change

x

Seal Change

x

Valve Change

x

Accessories

x

* If other than CAT PUMPS special cutstom-blend multi-viscosity ISO68 hydraulic oil is used, change cycle should be every 300 hours. ** Each system’s maintenance cycle will be exclusive. If system performance decreases, check immediately. If no wear at 1500 hours, check again at 2000 hours and each 500 hours until wear is observed. Valves typically require changing every other seal change. Duty cycle, temperature, quality of pumped liquid and inlet feed conditions all effect the life of pump wear parts and service cycle. ** Remember to service the regulator/unloader at each seal servicing and check all system accessories and connections before resuming operation. Refer to service DVD for additional assistance.

TORQUE CHART Pump Item Pump Model

Torque in. lbs. ft. lbs. Nm

Thread

Tool Size [P/N]

Plunger Retainer

M6

M10 Hex [25082]

55

4.6 6.2

Manifold Screw

M8

M6 Allen [30941]

115

9.58 13

Valve Plugs 3CP, 5CP 7CP

M22 M26

M24 Hex [44046] M27 Hex [44045]

870 870

72.5 98 72.5 98

Bearing Cover Screws 3CP 5CP, 7CP

M6 M8

M10 Hex./Phil. [25082] M13 Hex [25324]

50 115

4.0 5.4 9.58 13

Rear Cover Screws

M6

M10 Hex./Phil. [25082]

50

4.0 5.4

Connecting Rod Screws

M7

M10 Hex [25082}

95

8.0

11

Bubble Oil Gauge

M28 Oil Gauge Tool [44050]

45

3.8

5

Direct Mount Bolts

M8

115

9.58 13

M13 Hex [25324]

TECHNICAL BULLETIN REFERENCE CHART No.

Subject

002

Inlet Pressure VS Liquid Temperature

Models All Models

003

Power Unit Drive Packages

3PFR - 68PFR, 10FR - 60FR

024

Lubrication of Lo-Pressure Seals

All Models

036

Cylinder and Plunger Reference Chart

All Models

043

LPS and HPS Servicing

All Plunger Models

060

Baffle Assembly

34170

064

By-Pass Hose Sizing

All Unloaders/Regulators

074

Torque Chart

Piston and Plunger Pumps

077

Oil Drain Kit

All Models (except 2SF/4SF)

078

Field Retrofit Mounting

5CP

083

Winterizing a Pump

All Models

Review Before Start-Up Inadequate inlet conditions can cause serious malfunctions in the best designed pump. Surprisingly, the simplest of things can cause the most severe problems or go unnoticed to the unfamiliar or untrained eye. REVIEW THIS CHECK-LIST BEFORE OPERATION OF ANY SYSTEM. Remember, no two systems are alike, so there can be no ONE best way to set-up a system. All factors must be carefully considered. INLET SUPPLY should exceed the maximum flow being delivered by the pump to assure proper performance. ❏ Open inlet shut-off valve and turn on water supply to avoid starving pump. DO NOT RUN PUMP DRY. ❏ Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over 130°F. Elastomer or RPM changes may be required. See Tech Bulletin 002 or call CAT PUMPS for recommendations. ❏ Avoid closed loop systems especially with high temperature, ultra-high pressure or large volumes. Conditions vary with regulating/unloader valve. ❏ Low vapor pressure liquids, such as solvents, require a booster pump and C. A.T. to maintain adequate inlet supply. ❏ Higher viscosity liquids require a positive head and a C. A.T. to assure adequate inlet supply. ❏ Higher temperature liquids tend to vaporize and require positive heads and C. A.T. to assure adequate inlet supply. ❏ When using an inlet supply reservoir, size it to provide adequate liquid to accommodate the maximum output of the pump, generally a minimum of 6-10 times the GPM (however, a combination of system factors can change this requirement); provide adequate baffling in the tank to eliminate air bubbles and turbulence; install diffusers on all return lines to the tank. INLET LINE SIZE should be adequate to avoid starving the pump. ❏ Line size must be a minimum of one size larger than the pump inlet fitting. Avoid tees, 90 degree elbows or valves in the inlet line of the pump to reduce the risk of flow restriction and cavitation. ❏ The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on SUCTION systems to avoid collapsing. ❏ The simpler the inlet plumbing the less the potential for problems. Keep the length to a minimum, the number of elbows and joints to a minimum (ideally no elbows) and the inlet accessories to a minimum. ❏ Use pipe sealant to assure air-tight, positive sealing pipe joints. INLET PRESSURE should fall within the specifications of the pump. ❏ Acceleration loss of liquids may be increased by high RPM, high temperatures, low vapor pressures or high viscosity and may require pressurized inlet and C. A.T. to maintain adequate inlet supply. DO NOT USE C.A.T. WITH SUCTION INLET. ❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet pressure and a C. A.T. for certain applications. With adequate inlet plumbing, most pumps will perform with flooded suction. Maximum inlet pressure is 60 PSI (4 BAR). ❏ After prolonged storage, pump should be rotated by hand and purged of air to facilitate priming. Disconnect the discharge port and allow liquid to pass through pump and measure flow. INLET ACCESSORIES are offered to protect against over pressurization, contamination or temperature and control flow. ❏ A shut-off valve is recommended to facilitate maintenance. ❏ Installation of a C. A.T. is essential in applications with stressful conditions such as high temperatures, booster pump feed or long inlet lines. Do not use C. A.T. with negative inlet pressure. ❏ A stand pipe can be used in some applications to help maintain a positive head at the pump inlet line. ❏ Inspect and clean inlet filters on a regular schedule to avoid flow restriction. ❏ A pressure transducer is necessary to accurately read inlet pressure. Short term, intermittent cavitation will not register on a standard gauge. ❏ All accessories should be sized to avoid restricting the inlet flow. ❏ All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction. ❏ Optional inlet protection can be achieved by installing a pressure cut off switch between the inlet filter and the pump to shut off pump when there is no positive inlet pressure. BY-PASS TO INLET Care should be exercised when deciding the method of by-pass from control valves. ❏ It is recommended the by-pass be directed to a baffled reservoir tank, with at least one baffle between the by-pass line and the inlet line to the pump. ❏ Although not recommended, by-pass liquid may be returned to the inlet line of the pump if the system is properly designed to protect your pump. When a pulsation dampener is used, a PRESSURE REDUCING VALVE must be installed on the inlet line (BETWEEN THE BY-PASS CONNECTION AND THE INLET TO THE PUMP) to avoid excessive pressure to the inlet of the pump. It is also recommended that a THERMO VALVE be used in the by-pass line to monitor the temperature build-up in the by-pass loop to avoid premature seal failure. ❏ A reinforced, flexible, low pressure hose rated up to 300 PSI should be used for routing by-pass back to the pump inlet. ❏ Caution should be exercised not to undersize the by-pass hose diameter and length. Refer to Technical Bulletin 064 for additional information on the size and length of the by-pass line. ❏ Check the pressure in the by-pass line to avoid over pressurizing the inlet. ❏ The by-pass line should be connected to the pump inlet line at a gentle angle of 45° or less and no closer than 10 times the pump inlet port diameter e.g. 1-1/2" port size = 15" distance from pump inlet port.

Handy Formulas to Help You

HOSE FRICTION LOSS PRESSURE DROP IN PSI PER 100 FT OF HOSE WITH TYPICAL WATER FLOW RATES Hose Inside Diameters, Inches

Water* Flow Gal/Min

1/4

5/16

3/8

1/2

5/8

3/4

1"

0.5 16 5 2 1 54 20 7 2 2 180 60 25 6 2 3 380 120 50 13 4 2 4 220 90 24 7 3 5 320 130 34 10 4 6 220 52 16 7 1 8 300 80 25 10 2 10 450 120 38 14 3 15 900 250 80 30 7 20 1600 400 121 50 12 25 650 200 76 19 30 250 96 24 40 410 162 42 50 600 235 62 60 370 93 *At a fixed flow rate with a given size hose, the pressure drop across a given hose length will be directly proportional. A 50 ft. hose will exhibit one-half the pressure drop of a 100 ft. hose. Above values shown are valid at all pressure levels.

WATER LINE PRESSURE LOSS PRESSURE DROP IN PSI PER 100 FEET Steel Pipe—Nominal Dia.

Water GPM

Brass Pipe—Nominal Dia. 1/4 3/8 1/2 3/4 1 11/4 11/2

Copper Tubing O.D. Type L 1/4 3/8 1/2 5/8 3/4 7/8

8.5 1.9

6.0 1.6

120 13 2.9 1.0

30 7.0 2.1

20 5.6 1.8

400 45 10 3.4 1.3

60 14 4.5 1.1

40 11 3.6

94 20 6.7 2.6

1/4 3/8 1/2 3/4

1 2 3 5 8 10 15 25 40

1 1 /4 1 /2 1

1

150 36 12 2.8

100 28 9.0 2.2

230 50 17 6.1 3.0

330 86 28 6.7 1.9

220 62 21 5.2 1.6

500 120 40 15 6.5

520 130 43 10 3.0

320 90 30 7.8 2.4

180 56 22 10

270 90 21 6.2 1.6

190 62 16 5.0 1.5

120 44 20

670 240 56 16 4.2 2.0

470 150 40 12 3.8 1.7

330 110 50

66 17 8.0

39 11 5.0

550 200 88

37

17

23

11

52

29

40

19

210 107

48

61

28

60 80 100

RESISTANCE OF VALVES AND FITTINGS Nominal Pipe Inside Size Diameter Inches Inches

Equivalent Length of Standard Pipe in Feet Gate Valve

Globe Valve

Angle Valve

45˚ Elbow

90˚ Elbow

180˚ Close Ret

Tee Thru Run

Tee Thru Branch

1/2 3/4 1 11/4 11/2

0.622 0.824 1.049 1.380 1.610

0.41 0.54 0.69 0.90 1.05

18.5 24.5 31.2 41.0 48.0

9.3 12.3 15.6 20.5 24.0

0.78 1.03 1.31 1.73 2.15

1.67 2.21 2.81 3.70 4.31

3.71 4.90 6.25 8.22 9.59

0.93 1.23 1.56 2.06 2.40

3.33 4.41 5.62 7.40 8.63

2

2.067 2.469 3.068 4.026

1.35 1.62 2.01 2.64

61.5 73.5 91.5 120.0

30.8 36.8 45.8 60.0

2.59 3.09 3.84 5.03

5.55 6.61 8.23 10.80

12.30 14.70 18.20 23.90

3.08 3.68 4.57 6.00

11.60 13.20 16.40 21.60

2 1/2 3 4

Arriving at a total line pressure loss, consideration should then be given to pressure loss created by valves, fittings and elevation of lines. If a sufficient number of valves and fittings are incorporated in the system to materially affect the total line loss, add to the total line length, the equivalent length of line of each valve or fitting.

TYPICAL RESERVOIR TANK RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY Supply Line

Bypass Line (from regulator or unloader)

→ D











MIN. 4"

(Dia of pipe)

T X

Level Sensing Device



1.5 x D (Min.)

Flexible Hose to Pump





FILTER

MIN. 4"

Minimum Liquid Level

Bypass Line (from regulator or unloader)

Minimum Two Baffles Sealed at Bottom

Q. How can I find the RPM needed to get specific GPM (Gallons Per Minute) I want? Rated RPM A. Desired RPM = Desired GPM x Rated GPM Q. I have to run my pump at a certain RPM. How do I figure the GPM I’ll get? Rated GPM A. Desired GPM = Desired RPM x Rated RPM Q. Is there a simple way to find the approximate horsepower I’ll need to run the pump? A. Electric Brake GPM x PSI = Horsepower Required 1460

(Standard 85% Mech. Efficiency)

Q. What size motor pulley should I use? Pump RPM A. Pump Pulley (Outer Diameter) x Motor/Engine RPM

(Consult Engine Mfr.)

Q. How do I calculate the torque for my hydraulic drive system? GPM x PSI A. Torque (ft. lbs.) = 3.6 RPM

(

)

Avoid Cavitation Damage

One or several of the conditions shown in the chart below may contribute to cavitation in a system resulting in premature wear, system downtime and unnecessary operating costs. CONDITION Inadequate inlet line size Water hammering liquid acceleration/ deacceleration Rigid Inlet Plumbing Excessive Elbows in Inlet Plumbing Excessive Liquid Temperature

SOLUTION Increase line size to the inlet port or one size larger ● Install C.A.T. Tube ● Move pump closer to liquid supply ●

Use flexible wire reinforced hose to absorb pulsation and pressure spikes ● Keep elbows to a minimum and less than 90° ●

Use Thermo Valve in bypass line Do not exceed pump temperature specifications ● Substitute closed loop with baffled holding tank ● Adequately size tank for frequent or high volume bypass ● Pressure feed high temperature liquids ● Properly ventilate cabinets and rooms Air Leaks in Plumbing ● Check all connections ● Use PTFE thread tape or pipe thread sealant ● Size tank according to pump output — Agitation in Supply Tank Minimum 6-10 times system GPM ● Baffle tank to purge air from liquid and separate inlet from discharge High Viscosity Liquids ● Verify viscosity against pump specifications before operation ● Elevate liquid temperature enough to reduce viscosity ● Lower RPM of pump ● Pressure feed pump ● Increase inlet line size ● Perform regular maintenance or use clean Clogged Filters filters to monitor build up ● Use adequate mesh size for liquid and pump specifications ● ●

DIAGNOSIS AND MAINTENANCE One of the most important steps in a high pressure system is to establish a regular maintenance program. This will vary slightly with each system and is determined by various elements such as the duty cycle, the liquid being pumped, the actual specifications vs rated specifications of the pump, the ambient conditions, the inlet conditions and the accessories in the system. A careful review of the necessary inlet conditions and protection devices required before the system is installed will eliminate many potential problems. CAT PUMPS are very easy pumps to service and require far less frequent service than most pumps. Typically, only common tools are required, making in-field service convenient, however, there are a few custom tools, special to certain models, that do simplify the process. This service manual is designed to assist you with the disassembly and reassembly of your pump. The following guide will assist in determining the cause and remedy to various operating conditions. You can also review our FAQ or SERVICE sections on our WEB SITE for more facts or contact CAT PUMPS directly. PROBLEM

PROBABLE CAUSE

SOLUTION

Low pressure

•Worn nozzle. •Belt slippage. •Air leak in inlet plumbing. •Pressure gauge inoperative or not registering accurately. •Relief valve stuck, partially plugged or improperly adjusted. •Inlet suction strainer (filter) clogged or improperly sized. •Abrasives in pumped liquid. •Leaky discharge hose. •Inadequate liquid supply. •Severe cavitation. •Worn seals. •Worn or dirty inlet/discharge valves.

•Replace with properly sized nozzle. •Tighten belt(s) or install new belt(s). •Tighten fittings and hoses. Use PTFE liquid or tape. •Check with new gauge. Replace worn or damaged gauge. •Clean/adjust relief valve. Replace worn seats/valves and o-rings. •Clean filter. Use adequate size filter. Check more frequently. •Install proper filter. •Replace discharge hose with proper rating for system. •Pressurize inlet and install C.A.T. •Check inlet conditions. •Install new seal kit. Increase frequency of service. •Clean inlet/discharge valves or install new valve kit.

Pulsation

•Faulty Pulsation Dampener. •Foreign material trapped in inlet/discharge valves.

•Check precharge. If low, recharge, or install a new dampener. •Clean inlet/discharge valves or install new valve kit.

•Worn V-Packings, Hi-Pressure or Lo-Pressure Seals. •Worn adapter o-rings. •Humid air condensing into water inside the crankcase. •Excessive wear to seals and V-Packings.

•Install new seal kit. Increase frequency of service. •Install new o-rings. •Install oil cap protector. Change oil every 3 months or 500 hours. •Install new seal kit. Increase frequency of service.

Knocking noise •Inlet supply •Bearing •Pulley

•Inadequate inlet liquid supply. •Broken or worn bearing. •Loose pulley on crankshaft

•Check liquid supply. Increase line size, pressurize or install C.A.T. •Replace bearing. •Check key and tighten set screw.

Oil leak •Crankcase oil seals. •Crankshaft oil seals and o-rings. •Drain plug •Bubble gauge •Rear cover •Filler cap

•Worn crankcase oil seals. •Worn crankshaft oil seals or o-rings on bearing cover. •Loose drain plug or worn drain plug o-ring. •Loose bubble gauge or worn bubble gauge gasket. •Loose rear cover or worn rear cover o-ring. •Loose filler cap or excessive oil in crankcase.

•Replace crankcase oil seals. •Remove bearing cover and replace o-rings and/or oil seals. •Tighten drain plug or replace o-ring. •Tighten bubble gauge or replace gasket. •Tighten rear cover or replace o-ring. •Tighten filler cap. Fill crankcase to specified capacity.

Pump runs extremely rough •Inlet conditions •Pump valves •Pump seals

•Restricted inlet or air entering the inlet plumbing •Stuck inlet/discharge valves. •Leaking V-Packings, Hi-Pressure or Lo-Pressure seals.

•Correct inlet size plumbing. Check for air tight seal. •Clean out foreign material or install new valve kit. •Install new seal kit. Increase frequency of service.

•Scored plungers. •Over pressure to inlet manifold. •Abrasive material in the liquid being pumped. •Excessive pressure and/or temperature of pumped liquid. •Running pump dry. •Starving pump of adequate liquid.

•Replace plungers. •Reduce inlet pressure per specifications. •Install proper filtration at pump inlet and clean regularly. •Check pressure and inlet liquid temperature. •DO NOT RUN PUMP WITHOUT LIQUID. •Increase hose one size larger than inlet port size. Pressurize and install C.A.T. •Replace manifold. Check liquid compatibility.

Water leak •Under the manifold •Into the crankcase

Premature seal failure

•Eroded manifold.

®

7 Frame Plunger Pump

530 550

Models SPECIFICATIONS

U.S. Measure

Metric Measure

Flow ...........................................................5.0 GPM Pressure Range.............................100 to 2500 PSI RPM .......................................................1100 RPM Bore..............................................................0.708" Stroke...........................................................0.945"

(19 L/M) (7 to 175 BAR) (1100 RPM) (18 mm) (24 mm)

MODEL

FEATURES Superior Design ● ● ● ● ● ●

Triplex plunger design gives smoother liquid flow. Hi-Pressure Seals or V-Packings are completely lubricated and cooled by the liquid being pumped. Inlet and discharge valve assemblies interchange for easier maintenance. Lubricated Lo-Pressure Seals provide double protection against external leakage. Oil bath crankcase assures optimum lubrication. Close tolerance concentricity of the ceramic plunger maximizes seal life.

Quality Materials ● ● ● ● ● ● ●

● ●

MODEL 550 Flow ...........................................................5.0 GPM Pressure Range.............................100 to 3000 PSI RPM .......................................................1415 RPM Bore..............................................................0.630" Stroke...........................................................0.945"

(19 L/M) (7 to 210 BAR) (1415 RPM) (16 mm) (24 mm)

COMMON SPECIFICATIONS Inlet Pressure Range ..................Flooded to 60 PSI Crankcase Capacity ......................................25 oz. Maximum Liquid Temperature .......................160°F

(Flooded to 4 BAR) (0.75 L) (71°C)

For temperatures above 130°F call CAT PUMPS for inlet conditions and elastomer recommendations.

Precision design 304 stainless steel valves and seats are hardened and polished for ultimate seating and extended valve life. Forged brass manifold is strong and corrosion resistant. Special concentric, high-density, polished, solid ceramic plungers provide a true wear surface and extended seal life. Specially formulated, CAT PUMP exclusive, Hi-Pressure Seals or V-Packings offer unmatched performance and seal life. Die cast aluminum crankcase provides high strength, minimum weight and precision tolerance control. Chrome-moly crankshaft gives unmatched strength and surface hardness. Oversized crankshaft bearings with greater capacity mean longer bearing life.

Inlet Ports (2) ..........................................1/2" NPTF (1/2" NPTF) Discharge Ports (2).................................3/8" NPTF (3/8" NPTF) Shaft Diameter ..............................................0.945" (24 mm) Weight........................................................25.5 lbs. (11.5 kg) Dimensions................................13.6 x 9.61 x 6.41" (346 x 244 x 163 mm)

ELECTRIC HORSEPOWER REQUIREMENTS MODEL

530

Easy Maintenance ●

530

Wet end is easily serviced without entering crankcase, requiring less time and effort. Valve assemblies are accessible without disturbing piping, for quick service. Preset packings mean no packing gland adjustment is necessary, reducing maintenance costs.

WARNING All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility for the operation of a customer’s high pressure system.

550

FLOW

U.S. GPM 5.0 4.5 4.0 5.0 4.0 3.0

L/M 19.0 17.0 15.0 19.0 15.0 11.4

DETERMINING THE PUMP R.P.M. DETERMINING THE REQUIRED H.P. DETERMINING MOTOR PULLEY SIZE

PRESSURE PSI PSI PSI 1800 2150 2500 BAR BAR BAR 125 150 175 6.2 7.4 8.6 5.6 6.6 7.7 5.0 5.9 6.9 6.2 7.4 8.6 5.0 5.9 6.9 3.7 4.4 5.2

MOTOR PULLEY SIZE

PSI Using 1725 RPM Motor 3000 & Std. 10" Pulley O.D. BAR RPM Pulley 210 O.D. N/A 1100 6.3 N/A 990 5.6 N/A 880 5.0 10.3 1415 8.0 8.3 1130 6.4 6.2 850 5.0

Rated G.P. M. Rated R.P. M.

=

“Desired” G.P. M. “Desired” R.P. M.

GPM x PSI 1460

=

Electric Brake H. P. Required

Motor Pulley O.D. Pump R.P.M.

=

Pump Pulley O.D. Motor R.P.M.

See complete Drive Packages [Inclds: Pulleys, Belts, Hubs, Key] Tech Bulletin 003. Refer to pump Service Manual for repair procedure, additional technical information and pump warranty.

“Customer confidence is our greatest asset”

PARTS LIST ITEM 2 5 8 9 10 11 15 20 25 31 32 33 37 38 40 48 49 50 51 53 56 64 65 69 70 75 88 90 96 97

PART NUMBER 530 MATL 550 MATL 30067 92519 43223 815280 12393 43222 43221 48863 43220 828710 43211 14177 92241 44428 92520 25625 23170 43217 44836 45056 43240 43237 43229 43227 43228 43328 45697 43232 43235 17399 14160 45891 104360 45686 45687 43239 43243 44926 — 45683 20285 11693 43245 44925 — — — — 22179 43248 43249 44383 43722 43825 43721 43824 43751 43823 44564 17617 11691 43851 45417 46868 45550 43633 43256 30243 30645 30611 30660 30206 33000 34334 34628 34630 34959 812183 30488 — 30820 31820 30696 43257 44050 6575 6107

STL STZP AL FBR NBR NBR STL TNM FCM — ABS NBR — NBR STZP STCP NBR AL NBR AL POP CM ZZCP STZP NBR S S CC PTFE NBR FPM CU S PVDF PVDF — NBR FPM — BB NBR FPM SNG FPM — — — — BBCP PTFE NBR FPM S S S S S S PVDF NBR FPM BBCP BBCP S STZP BB STCP STZP STZP STZP — F STL — STZP STZP STZP BBCP NBR — NBR NBR STZP STZP STZP — —

30067 92519 43223 815280 12393 43222 43221 48863 43220 828710 43211 14177 92241 44428 92520 25625 23170 43217 44836 45056 43240 43237 43229 43227 43228 43328 45697 43311 43235 17399 14160 45891 104360 45686 45687 43313 43316 — 106660 45684 20285 11693 — — 43320 43319 46287 43318 22179 43248 43249 44383 43722 — 43721 — 43751 — 44564 17617 11691 43851 45547 46868 45550 43633 43256 30243 30645 30611 30660 30206 33000 34334 34628 34630 34959 812184 30610 31610 30820 31820 30696 43257 44050 6575 6107

STL STZP AL FBR NBR NBR STL TNM FCM — ABS NBR — NBR STZP STCP NBR AL NBR AL POP CM ZZCP STZP NBR S S CC PTFE NBR FPM CU S PVDF PVDF — NBR — FPM BB NBR FPM — — BB PTFE HT BB BBCP PTFE NBR FPM S — S — S — PVDF NBR FPM BBCP BBCP S STZP BB STCP STZP STZP STZP — F STL — STZP STZP STZP BBCP NBR HT NBR NBR STZP STZP STZP — —

DESCRIPTION

QTY

Key (M8x7.5x25) 1 Screw, HHC Sems (M6x16) 8 Cover, Bearing 2 Shim, Bearing Cover (2-pc) 1 O-Ring, Bearing Cover 2 Seal, Oil 2 Bearing, Roller 2 Rod, Assy, Connecting [6/02] 3 Crankshaft, Dual End 1 Protector, Oil Cap w/Gasket 1 Cap, Oil Filler 1 O-Ring, Filler Cap - 70D 1 Gauge, Oil, Bubble w/Gasket - 80D 1 Gasket, Flat, Oil Gauge - 80D 1 Screw, HHC Sems (M6x20) 4 Plug, Drain (1/4"x19BSP) 1 O-Ring, Drain Plug - 70D 1 Cover, Rear 1 O-Ring, Rear Cover - 70D 1 Crankcase (M10) 1 Pan, Oil 1 Pin, Crosshead 3 Rod, Plunger 3 Washer, Oil Seal 3 Seal, Oil, Crankcase 3 Slinger, Barrier 3 Washer, Keyhole (M18) 3 Plunger (M18x77 and M16x77) 3 Back-up-Ring, Plunger Retainer 3 O-Ring, Plunger Retainer - 80D 3 O-Ring, Plunger Retainer - 70D 3 98 Gasket, Plunger Retainer 3 99 Retainer, Plunger w/Stud 3 100 Retainer, Seal, Rear 3 Retainer, Seal, Adapter, Front 3 101 Wick, Long Tab 3 106 Seal, LPS w/S-Spg 3 Seal, LPS w/SS-Spg 3 Seal, LPS w/S-Spg 3 120 Case, Seal 3 121 O-Ring, Seal Case - 70D 3 O-Ring, Seal Case 3 125 Seal, HPS w/S 3 Seal, HPS w/SS 3 126 Adapter, Female 3 127 V-Packing 6 V-Packing 6 128 Adapter, Male 3 139 Plug (1/2" NPT) 1 162 Back-up-Ring, Seat 6 163 O-Ring, Seat - 80D 6 O-Ring, Seat - 70D 6 164 Seat, Q.V. 6 Seat, F.V. 6 166 Valve, Q.V. 6 Valve, F.V. 6 167 Spring, Q.V. 6 Spring, F.V. 6 168 Retainer, Spring 6 172 O-Ring, Valve Plug - 90D 6 O-Ring, Valve Plug - 90D 6 174 Plug, Valve 6 185 Head, Manifold (M10F) 1 187 Stud, Manifold (M10x35) 4 194 Nut, Flanged (M10) 4 196 Plug, Discharge (3/8" NPT) 1 250 Protector, Shaft 1 255 Kit, Direct Mounting 1 260 Rail, Angle, Assy A-U.S. (Inclds: 30635 [2.09"], 31129, 990777, 30910, 30920) 1 Rail, Angle, Assy B-U.S. (Inclds: 28499 [2.95"], 30900, 30910, 30920) 1 265 Kit, Mounting (Inclds: 30645, 30206, 33000, 30067, 43256) 1 269 Pulley (10") [See Drive Packages, Tech Bulletin 003] 1 274 Hub “H”, M24 (Keyway M8) [See Drive Packages, Tech Bulletin 003] 1 283 Kit, Oil Drain 1 298 Clutch Assy, Single Groove, 24mm, 12VDC 1 Clutch Assy, Dual Groove, 24mm, 12VDC 1 Clutch Assy, Eight Groove Poly L, 24mm, 12VDC 1 299 Head, Complete 1 300 Kit, Seal (Inclds: 97, 101, 106, 121, 125 or 127) 1 Kit, Seal, HT (Inclds: 97. 101, 106, 121, 125) 1 310 Kit, Valve , Q.V. (Inclds: 162-164, 166, 167, 168, 172) 2 Kit, Valve , F.V. (Inclds: 162-164, 166, 167, 168, 172) 2 350 Plier, Reverse 1 351 Tool, Seal Case Removal 1 352 Tool, Oil Gauge Removal 1 — Plunger Pump Service DVD 1 — Oil, Bottle (21 oz.) ISO 68 Multi-Viscosity Hydraulic 1 (Fill to specified crankcase capacity prior to start-up) Bold print part numbers are unique to a particular pump model. Italics are optional items. [ ] Date of latest production change. Refer to Tech Bulletins 002, 003, 008, 024, 027, 035, 036,0 43, 045, 051, 053, 054, 067, 074, 077 and 083 for additional information. MATERIAL CODES (Not Part of Part Number): AL=Aluminum ABS=ABS Plastic BB=Brass BBCP=Brass/Chrome Plated CC=Ceramic CM=Chrome-Moly CU=Copper F=Cast Iron FBR=Fiber FCM=Forged Chrome-moly FPM=Fluorocarbon HT=Hi-Temp NBR=Medium Nitrile (Buna-N) POP=Polypropylene PTFE=Pure Polytetrafluoroethylene PVDF=Polyvinylidene Fluoride S=304SS SNG=Special Blend (Buna) STCP=Steel/Chrome Plated STL=Steel STZP=Steel/Zinc Plated TNM=Special High Strength ZZCP=Zamak/Chrome Plated

EXPLODED VIEW

Models 530, 550 May 2006

Models 530, 550

8

10 11 7

8

1

9 6

5

12

4

3

2

10

Model 530 shown

1

Die cast aluminum crankcase means high strength, lightweight, and excellent tolerance control.

5

Special high strength plunger rods with Zamak crossheads for longevity and corrosion resistance.

2

Oversized crankshaft bearings provide extended bearing life and pump performance.

6

3

Chrome-moly crankshaft provides unmatched strength and surface hardness for long life.

The stainless steel slinger provides back-up protection for the crankcase seal, keeping pumped Liquids out of the crankcase.

7

4

Matched high strength connecting rods are for superior strength and bearing quality.

8 9

Special concentric, high-density, polished, solid ceramic plungers provide a true wear surface and extended seal life. Manifolds are a high tensile strength forged brass for long term, continuous duty.

life by allowing pumped liquids to cool and lubricate on both sides. 10 Stainless steel valves, seats and springs provide corrosion-resistance, ultimate seating and extended life. 11 Specially formulated, CAT PUMP exclusive, Hi-Pressure Seals/V-Packings offer unmatched performance and seal life. 12 Crossheads are 360° supported for uncompromising alignment.

100% wet seal design adds to service

Products described hereon are covered by one or more of the following U.S. patents 3558244, 3652188, 3809508, 3920356, 3930756 and 5035580

CAT PUMPS (U.K.) LTD.

World Headquarters CAT PUMPS 1681 - 94th Lane N.E. Minneapolis, MN 55449 - 4324 Phone (763) 780-5440 — FAX (763) 780-2958 e-mail: [email protected] www.catpumps.com

1 Fleet Business Park, Sandy Lane, Church Crookham FLEET, Hampshire, GU52 8BF, England Phone Fleet 44 1252-622031 — Fax 44 1252-626655 e-mail: [email protected]

N.V. CAT PUMPS INTERNATIONAL S. A. The Pumps with Nine Lives

Heiveldekens 6A, B-2550 Kontich, Belgium Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51 e-mail: [email protected] www.catpumps.be

International Inquiries

CAT PUMPS DEUTSCHLAND GmbH

FAX (763) 785-4329 e-mail: [email protected]

Buchwiese 2, D-65510 Idstein, Germany Phone 49 6126-9303 0 — Fax 49 6126-9303 33 e-mail: [email protected] www.catpumps.de PN 993112 Rev C 5608

5, 7, 15PFR PLUNGER PUMP SERVICE MANUAL

®

5 FRAME: 310, 340, 350, 311, 341, 351, 317, 347, 357 5 FRAME OEM: 30, 31, 34, 35, 42HS, 43HS, 45

7 FRAME: 530, 550 7 FRAME OEM: 51, 53, 55, 56, 57, 58, 59, 60, 70 15 FRAME: 650, 651, 660, 661,1050, 1051, 1057

INSTALLATION AND START-UP INFORMATION Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only with the proper selection, installation of plumbing and operation of the pump and accessories. SPECIFICATIONS: Maximum specifications refer to individual attributes. It is not implied that all maximums can be performed simultaneously. If more than one maximum is considered, check with your CAT PUMPS supplier to confirm the proper performance and pump selection. Refer to individual pump Data Sheets for complete specifications, parts list and exploded view.

DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to avoid deadhead overpressure condition and severe damage to the pump or system.

LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications [5PFR-18 oz., 7PFR-25 oz., 15PFR-42oz.]. DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE. Change initial fill after 50 hours running period. Thereafter, change oil every 3 months or 500 hour intervals, whichever comes first.

A reliable Pressure Gauge should be installed near the discharge outlet of the high pressure manifold. This is extremely important for adjusting pressure regulating devices and also for proper sizing of the nozzle or restricting orifice. The pump is rated for a maximum pressure; this is the pressure that is read at the discharge manifold of the pump, NOT AT THE GUN OR NOZZLE.

PUMP ROTATION: Pump was designed for forward rotation to allow optimum lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil level is increased slightly above center dot to assure adequate lubrication. PULLEY SELECTION: Select size of motor pulley required to deliver the desired flow from Horsepower Requirement and Pulley Selection Chart (refer to Tech Bulletin 003 or individual Data Sheet). DRIVE SELECTION: The motor or engine driving the pump must be of adequate horsepower to maintain full RPM when the pump is under load. Select the electric motor from the Horsepower Requirement Chart according to required pump discharge flow, maximum pressure at the pump and drive losses of approximately 3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper engine size. MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit drainage of crankcase oil. An uneven mounting surface will cause extensive damage to the pump base. To minimize piping stress, use appropriate flexible hose to inlet and discharge ports. Use the correct belt; make sure pulleys are aligned. Excessive belt tension may be harmful to the bearings. Hand rotate pump before starting to be certain shaft and bearings are free moving. LOCATION: If the pump is used in extremely dirty or humid conditions, it is recommended pump be enclosed. Do not store or operate in excessively high temperature areas or without proper ventilation. INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual before starting system. DO NOT STARVE THE PUMP OR RUN DRY. Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over 130°F. Elastomer or RPM changes may be required. See Tech Bulletin 002 or call CAT PUMPS for recommendations. C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in applications with stressful inlet conditions such as high temperatures, booster pump feed, long inlet lines or quick closing valves.

Install a Pulsation Dampening device on the discharge head or in the discharge line as close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator) is properly precharged for the system pressure (see individual Data Sheet).

Use PTFE thread tape or pipe thread sealant (sparingly) connect accessories or plumbing. Exercise caution not to wrap tape beyond the last thread to avoid tape from becoming lodged in the pump or accessories. This condition will cause a malfunction of the pump or system. PRESSURE REGULATION: All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). The primary pressure device must be installed on the discharge side of the pump. The function of the primary pressure regulating device is to protect the pump from over pressurization, which can be caused by a plugged or closed off discharge line. Over pressurization can severely damage the pump, other system components and can cause bodily harm. The secondary safety relief device must be installed between the primary device and pump. This will ensure pressure relief of the system if the primary regulating device fails. Failure to install such a safely device will void the warranty on the pump. When the high pressure system is left running with the trigger gun off, the by-pass liquid can be routed to drain or to the pump inlet. If routed to the pump inlet, the by-pass liquid can quickly develop excessive heat and result in damage to the pump. A THERMO VALVE installed in the by-pass line is recommended to protect the pump. An AUTO SHUT-OFF ASSEMBLY may also be used. NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure regulating device to compensate. Replace nozzle and reset regulating device to system pressure. PUMPED LIQUIDS: Some Liquids may require a flush between operations or before storing. For pumping liquids other than water, contact your CAT PUMPS supplier. STORING: For extended storing or between use in cold climates, drain all pumped liquids from pump and flush with antifreeze solution to prevent freezing and damage to the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech Bulletin 083).

WARNING All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility for the operation of a customer’s high pressure system. Products described hereon are covered by one or more of the following U.S. patents 3558244, 3652188, 3809508, 3920356, 3930756 and 5035580

CAT PUMPS (U.K.) LTD.

World Headquarters CAT PUMPS 1681 - 94th Lane N.E. Minneapolis, MN 55449 - 4324 Phone (763) 780-5440 — FAX (763) 780-2958 e-mail: [email protected] www.catpumps.com

1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet Hampshire GU52 8BF, England Phone Fleet 44 1252-622031 — Fax 44 1252-626655 e-mail: [email protected]

N.V. CAT PUMPS INTERNATIONAL S. A. The Pumps with Nine Lives

Heiveldekens 6A, 2550 Kontich, Belgium Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51 e-mail: [email protected] www.catpumps.be

International Inquiries

CAT PUMPS DEUTSCHLAND GmbH

FAX (763) 785-4329 e-mail: [email protected]

Buchwiese 2, D-65510 Idstein, Germany Phone 49 6126-9303 0 — Fax 49 6126-9303 33 e-mail: [email protected] www.catpumps.de PN 30002 Rev K 7311

Removal of Valve Plugs

Examination of O-Ring and Back-up-Ring on Valve Plug

Removal of Valve Assembly

CAUTION: Before commencing with service, shut off drive (electric motor, gas or diesel engine) and turn off water supply to pump. Relieve all discharge line pressure by triggering gun or opening valve in discharge line. After servicing is completed, turn on water supply to pump, start drive, reset pressure regulating device and secondary valve, read system pressure on the gauge at the pump head. Check for any leaks, vibration or pressure fluctuations and resume operation.

SERVICING THE VALVES Reassembly

Disassembly NOTE: Usually the valve assembly will remain together while being removed.

1. Examine Spring Retainers for internal wear or breaks in the structure and replace as needed.

1. Remove the hex Valve Plugs (top discharge, bottom inlet).

2. Examine Springs for fatigue or breaks and replace as needed.

2. Examine the O-Ring under the Valve Plug for cuts or distortion and replace if worn. Lubricate new O-Rings before installing.

3. Examine Valves and Seats for grooves, pitting or wear and replace as needed.

NOTE: On Models 43HS, 45, 56, 57, 59, 60, 70 there is an extended Valve Plug with O-Ring and Back-up-Ring. Install the Back-up-Ring, then the O-Ring into the groove at the end of the Valve Plug (refer to Tech Bulletin 058). 3. Grasp Spring Retainer by tab at the top with pliers and remove from valve chamber. 4. To separate the valve assembly, insert a screwdriver into the side of the Retainer and press on the back side of the Valve to begin separation, then between the Retainer and Valve Seat to separate completely. 5. If the valve assembly separates during removal, remove the Spring and Valve with a needle nose pliers. 6. Using a reverse pliers, remove the Valve Seat from the manifold chamber.

4. Examine Seat and Valve Plug O-Rings for cuts or wear and replace as needed. Lubricate and install new O-Ring onto outside diameter of Seat and Valve Plugs. NOTE: Inlet and discharge valve parts are interchangeable. Two Valve Kits are needed for complete valve change. 5. Grasp new Valve Assembly by tab at top with pliers and push into valve chamber. Be certain Valve Assembly is completely seated in valve chamber. NOTE: For certain applications apply liquid gasket to the O-Ring crevices and seal surfaces (refer to Tech Bulletin 053). NOTE: For Corrosion Resistant Models remember to install the Coil Spring between the Valve Plug and Retainer (refer to Tech Bulletin 046). 6. Apply Loctite 242 to the threads of the Valve Plug, thread into manifold port and torque per chart.

Y X Order of parts in Valve Assembly

Removal of Seal Cases from Manifold Head

Removal of High Pressure Seals

V-P Models

Y X H.P.S. Models Seal and V-Packing Arrangement

X Installation of Male Adapter

Order of Packings [MA, VP, FA]

SERVICING THE SEALS Disassembly

Reassembly

1. Remove the Manifold Head as described in SERVICING THE PLUNGERS section.

V-Packing Models:

2. Place Manifold Head on work surface with crankcase side up.

1. Lubricate seal chamber in the manifold. NOTE: For certain applications apply liquid gasket to the O-Ring crevices and seal surfaces (refer to Tech Bulletin 053).

3. On 5PFR and 7PFR plunger pumps prior to May of 1989, remove Snap Ring and Lo-Pressure Seal from each Seal Case. Discard Snap Rings (refer to Tech Bulletin 054).

2. Insert Male Adapter with notches down and “v” side up and press completely into chamber by hand.

4. On 5PFR and 7PFR plunger pumps after May of 1989, remove Lo-Pressure Seal from each Seal Case.

3. Lubricate V-Packings and install one at a time with grooved side down.

5. On 15PFR plunger pumps, remove Snap Ring and Lo-Pressure Seal from each Seal Case.

4. Install Female Adapter with grooved side down.

6. Remove Seal Case from each seal chamber. Remove O-Ring from outside diameter of Seal Case. 7. Hi-Pressure Seal Models: The Hi-Pressure Seal is generally easily removed from the manifold without any tools. If extremely worn a reverse pliers may be used.

5. Examine Seal Case O-Ring and replace if worn. Lubricate new O-Rings before installing. 6. Thread Seal Case into manifold and tighten with special seal case tool. Torque per chart.

8. V-Packing Models: The Female Adapter, V-Packings and Male Adapter are easily removed from manifold without any tools. If extremely worn a reverse pliers may be used.

C

Separating Manifold Head from Crankcase

Removal of Manifold Head from Crankcase

Removal of Seal Retainers and Wicks

Ceramic Plunger and Retainer Arrangement

Proper Alignment of Ceramic Plungers for reassembly

Hi-Pressure Seal Models:

SERVICING THE PLUNGERS

1. Lubricate seal chamber in manifold.

Disassembly

NOTE: For certain applications apply liquid gasket to the O-Ring crevices and seal surfaces (refer to Tech Bulletin 053). 2. Carefully square Hi-Pressure Seal into position by hand with the grooved side down (metal back facing out). NOTE: When alternate materials, the fit of the special materials may be snug and require gently driving the LPS into position with a cylinder of the same diameter to assure a square seating and no damage to the LPS. 3. Examine Seal Case O-Ring and replace if worn. Lubricate new O-Ring before installing. 4. Secure Hi-Pressure Seal into position by threading Seal Case into manifold. Tighten Seal Case with special seal case tool. Torque per chart. Lo-Pressure Seal - All Models: 1. Examine Lo-Pressure Seals for wear or broken springs and replace if necessary. 2. Install Lo-Pressure Seal into each seal case with garter spring down. 3. On 5PFR and 7PFR plunger pumps do not use Snap Ring (refer to Tech Bulletin 054). 4. On 15PFR plunger pumps install Snap Ring into each Seal Case. 5. Install the Seal Retainer with new Wick onto each plunger rod with tab down and wick out. 6. Rotate Crankshaft by hand so the two outside plungers are extended equally. 7. Lightly lubricate the Ceramic Plunger, then carefully slide the Manifold Head over the Ceramic Plunger, supporting it from the underside to avoid damage to the plungers or seals. Press the Manifold Head into the Crankcase until flush. 8. Replace two (2) Lockwashers, two (2) Socket Head Screws for (4) Flange Nuts and torque per chart.

1. Using an M8 allen wrench on the 5PFR pumps, a M14 hex tool on the 7PFR pumps, or a M17 hex tool on the 15PFR pumps, remove the two (2) Socket Head Screws, and two (2) Lockwashers or four (4) Flanged Nuts. 2. Rotate Crankshaft by hand to start separation of Manifold head from Crankcase. 3. Insert two flat head screwdrivers on opposite sides to further separate Manifold Head from Crankcase or support the underside of the Manifold Head and tap lightly with a mallet on the backside of the Manifold Head. CAUTION: KEEP MANIFOLD PROPERLY ALIGNED WITH CERAMIC PLUNGERS WHEN REMOVING TO AVOID DAMAGE TO EITHER PLUNGERS OR SEALS. 4. Remove Oil Pan and slide out Seal Retainer with Wick. 5. Using an M12 hex tool on the 5, 7 and 15PFR pumps, or an M11 hex tool on the OEM 5, and 7PFR pumps, loosen the Plunger Retainer about three to four turns. 6. Push the Ceramic Plunger back towards the Crankcase to separate it from the Plunger Retainer and proceed with unthreading the Plunger Retainer by hand. 7. Remove the Plunger Retainer, O-Ring, Back-up-Ring and Gasket. Stud may stay on Plunger Rod or come off with Plunger Retainers. 8. Remove the Ceramic Plunger, Keyhole Washer and Barrier Slinger from Plunger Rod. Reassembly 1. Visually inspect Crankcase Oil Seals for deterioration or leaks. Contact CAT PUMPS for assistance with replacement. See SERVICING THE CRANKCASE section. 2. Examine Barrier Slingers and Keyhole Washers for damage. Slide onto Plunger Rod with concave side away from Crankcase. 3. Examine Ceramic Plunger for scoring, scale build-up, chips or cracks and replace as needed. 4. Slide Ceramic Plunger over each Plunger Rod. NOTE: Ceramic Plunger can only be installed in one direction (front to back). Do not force onto rod. 5. Examine O-Ring and Back-up-Ring on Plunger Retainer and replace if cut or worn. Lubricate O-Rings for ease of installation and to avoid damage to the O-Rings.

PREVENTATIVE MAINTENANCE CHECK-LIST Check

Daily Weekly 50 hrs.

Clean Filters

500 hrs.* 1500 hrs.** 3000 hrs.**

x

Oil Level/Quality

x

Oil Leaks

x

Water Leaks

x

Belts, Pulley

x

Plumbing

x

Initial Oil Change

x

Oil Change

x

Seal Change

x

Valve Change

x

Accessories

6. Install new Gasket, then O-Ring, then Back-up-Ring onto each Plunger Retainer. NOTE: OEM models have a longer Plunger Retainer Stud. 7. Apply Loctite 242 to exposed threads of Stud and thread Plunger Retainer onto Plunger Rod. Torque per chart.

x

* If other than CAT PUMPS special multi-viscosity ISO68 oil is used, change cycle should be every 300 hours. ** Each system’s maintenance cycle will be exclusive. If system performance decreases, check immediately. If no wear at 1500 hours, check again at 2000 hours and each 500 hours until wear is observed. Valves typically require changing every other seal change. Duty cycle, temperature, quality of pumped liquid and inlet feed conditions all effect the life of pump wear parts and service cycle. ** Remember to service the regulator/unloader at each seal servicing and check all system accessories and connections before resuming operation. Refer to video for additional assistance.

8. Install the seal Retainer with NEW Wick onto each rod with tab down and wick out. NOTE: Do not lubricate wicks at initial start-up. Operate for 10 to 15 minutes to allow grease from LPS to penetrate the plunger surface, then lubricate as needed.

TECHNICAL BULLETIN REFERENCE CHART No.

Subject

Models

003 Power Unit Drive Packages

3PFR - 68PFR, 10FR - 60FR

024 Lubrication of Lo-Pressure Seals

All Models

9. Rotate Crankshaft by hand so the two outside plungers are extended equally.

027 Spring Retainer

5PFR, 7PFR, 15PFR

032 Shaft Extension and Manifold Port

310, 317, 323, 530, 550

10.Lightly lubricate the Ceramic Plungers, then carefully slide the Manifold Head over the Ceramic Plungers supporting it from the underside to avoid damage to the Ceramic Plungers or Seals. On the high pressure V-Packing models or larger manifolds, it may be necessary to gently tap with a soft mallet until the manifold is flush with the crankcase.

035 Servicing Crankcase Section

7PFR - 60PFR

036 Cylinder and Plunger Reference Chart

All Models

043 LPS and HPS Servicing

All Plunger Models

047 Blind Bearing Shaft Cover

Gearbox Plunger Pumps

11.Replace two (2) Lockwashers, two (2) Socket Head Screws or four (4) Flanged Nuts and torque per chart.

048 Extended Valve Plug

7PFR and 15PFR

049 Stainless Steel Hardware

3PFR7, 5PFR7, 15PFR7

051 M10 Manifold and Crankcase

7PFR and OEM

045 One-Piece S.S. Plunger Retainer w/Stud

5PFR, 7PFR, 15PFR

046 Valve Plug with Coil Spring

317, 347, 357, 1057

052 Plunger Rod and Stud

3PFR, 5PFR, 15PFR, 35PFR, 60PFR

SERVICING THE CRANKCASE SECTION

053 Liquid Gasket

All Plunger NAB-S.S. Models

1. While Manifold, Plungers and Seal Retainers are removed, examine Crankcase Oil Seals for leaking and wear.

054 2 Piece Seal Retainer

5PFR and 7PFR

2. Check for any signs of leaking at Bearing Covers, Rear Cover, Drain Plug or Bubble Gauge.

058 Forged Manifold and Extended Valve Plugs

56, 57, 59, 60

060 Baffle Assembly

34170

061 Installation and Adjustment Procedure

8100

062 Manifold and Seal Case

650 and 651

064 By-Pass Hose Sizing

All Unloaders/Regulators

3. Check oil level and for evidence of water in oil.

067 S.S. Plunger Retainer

3PFR, 5PFR, 7PFR

4. Rotate Crankshaft by hand to feel for smooth bearing movement.

072 Manifold Head and V-Packing

1050, 1051, 1057

073 Hi-Temp HPS

3PFR, 5PFR, 2SF

5. Examine Crankshaft Oil Seals externally for drying, cracking or leaking.

074 Torque Chart

Piston and Plunger Pumps

077 Oil Drain Kit

All Models (except 2SF/4SF)

083 Winterizing a Pump

All Models

6. Consult CAT PUMPS or your local distributor if crankcase service is evidenced.

See Section I of the Plunger Pump Service Video for additional information.

INLET CONDITION CHECK-LIST

TORQUE CHART Pump Item Pump Model

Thread

Tool Size [P/N]

Review Before Start-Up Torque in. lbs. ft. lbs. Nm

PLUNGER RETAINER OEM Models ....................................M6 All Standard Models.........................M6

M11 Hex [44044] M12 Hex

55 55

4.4 4.4

6 6

MANIFOLD HEAD BOLTS 5PFR

30, 31, 34, 35....................M10 310, 340, 350 311, 341, 351 317, 347, 357

M8 Allen [25052]

220

18.1

25

5PFR

42HS, 43HS, 45................M10

M8 Allen [33046]

220

18.1

25

7PFR

510, 530, 550....................M10 56, 57, 58, 59, 60, 70

M14 Hex [25053]

220

18.1

25

15PFR 650, 651, 660, 661............M10 1050, 1051, 1057

M17 Hex [25083]

220

18.1

25

30, 31, 34, 35....................M22 310, 311, 317 340, 341, 347 350, 351, 357 42HS

M24 Hex [44046]

870

72.3

98

5PFR

43HS, 45...........................M25

M24 Hex [44046]

520

43.4

59

7PFR

530, 550 ........................3/4" SPT 51, 55, 56, 57, 58 59, 60, 70

M27 Hex [44045]

870

72.3

98

15PFR 650, 651, 660, 661 ........3/4" SPT 1050, 1051, 1057

M27 Hex [44045]

870

72.3

98

VALVE PLUGS 5PFR

CRANKCASE COVER / BEARING COVER SCREWS 5PFR

30, 31, 34, 35.....................M6 310, 340, 350 317, 347, 357 311, 341, 351

M10 Hex/Phil. [25082]

50

4.0

6

5PFR

42HS, 43HS, 45.................M6 ...........................................M8

M10 Hex/Phil. [25082] M13 Hex [25324]

50 115

4.0 9.4

6 13

7PFR

51, 53, 55, 56, 57,..............M6 59, 60, 70

M10 Hex [25082]

115

9.4

13

15PFR 650, 1050...........................M6

M10 Hex [25082]

50

4.0

5.7

30, 31, 34, 35 ....................N/A 310, 311, 317 340, 341, 347 350, 351, 357 42HS, 43HS, 45 ................N/A

1/2" Soc. Drive [33004] 354

29.5

40

1/2" Soc. Drive [33005] 354

29.5

40

51, 53, 55, 56, ...................N/A 57, 58, 59, 60, 70 530, 550

1/2" Soc. Drive [33005] 354

29.5

40

15PFR 650, 651, 660, 661 ............N/A 1050, 1051, 1057 ..............N/A

1/2" Soc. Drive [33006] 346 1/2" Soc. Drive [33006] 390

28.8 32.5

39 44

Oil Gauge Tool [44050]

45

3.6

5

M13 Hex [25324] M17 Hex [25083]

115 240

9.4 19.7

13 29

SEAL CASE 5PFR

7PFR

BUBBLE OIL GAUGE All Models .......................................M28 MOUNTING BOLTS 5PFR, 7PFR ....................................M8 15PFR ..........................................M10

Inadequate inlet conditions can cause serious malfunctions in the best designed pump. Surprisingly, the simplest of things can cause the most severe problems or go unnoticed to the unfamiliar or untrained eye. REVIEW THIS CHECK-LIST BEFORE OPERATION OF ANY SYSTEM. Remember, no two systems are alike, so there can be no ONE best way to set-up a system. All factors must be carefully considered. INLET SUPPLY should exceed the maximum flow being delivered by the pump to assure proper performance. ❏ Open inlet shut-off valve and turn on water supply to avoid starving the pump. DO NOT RUN PUMP DRY. ❏ Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over 130°F. Elastomer or RPM changes may be required. See Tech Bulletin 002 or call CAT PUMPS for recommendations. ❏ Avoid closed loop systems especially with high temperature, ultra-high pressure or large volumes. Conditions vary with regulating/unloader valve. ❏ Low vapor pressure liquids, such as solvents, require a booster pump and C. A.T. to maintain adequate inlet supply. ❏ Higher viscosity liquids require a positive head and a C. A.T. to assure adequate inlet supply. ❏ Higher temperature liquids tend to vaporize and require positive heads and C. A.T. to assure adequate inlet supply. ❏ When using an inlet supply reservoir, size it to provide adequate liquids to accommodate the maximum output of the pump, generally a minimum of 6-10 times the GPM (however, a combination of system factors can change this requirement); provide adequate baffling in the tank to eliminate air bubbles and turbulence; install diffusers on all return lines to the tank. INLET LINE SIZE should be adequate to avoid starving the pump. ❏ Line size must be a minimum of one size larger than the pump inlet fitting. Avoid tees, 90 degree elbows or valves in the inlet line of the pump to reduce the risk of flow restriction and cavitation. ❏ The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on SUCTION systems to avoid collapsing. ❏ The simpler the inlet plumbing the less the potential for problems. Keep the length to a minimum, the number of elbows and joints to a minimum (ideally no elbows) and the inlet accessories to a minimum. ❏ Use pipe sealant to assure air-tight, positive sealing pipe joints. INLET PRESSURE should fall within the specifications of the pump. ❏ Acceleration loss of liquids may be increased by high RPM, high temperatures, low vapor pressures or high viscosity and may require pressurized inlet and C. A.T. to maintain adequate inlet supply. DO NOT USE C. A.T. WITH SUCTION INLET. ❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet pressure and a C. A.T. for certain applications. With adequate inlet plumbing, most pumps will perform with flooded suction. Maximum inlet pressure is 60 PSI (4 BAR). ❏ After prolonged storage, pump should be rotated by hand and purged of air to facilitate priming. Disconnect the discharge port and allow liquid to pass through pump and measure flow. INLET ACCESSORIES are designed to protect against overpressurization, control inlet flow, contamination or temperature and provide ease of servicing. ❏ A shut-off valve is recommended to facilitate maintenance. ❏ Installation of a C. A.T. is essential in applications with stressful conditions such as high temperatures, booster pump feed or long inlet lines. Do not use C. A.T. with negative inlet pressure. ❏ A stand pipe can be used in some applications to help maintain a positive head at the pump inlet. ❏ Inspect and clean inlet filters on a regular schedule to avoid flow restriction. ❏ A pressure transducer is necessary to accurately read inlet pressure. (Short term, intermittent cavitation will not register on a standard gauge.) ❏ All accessories should be sized to avoid restricting the inlet flow. ❏ All accessories should be compatible with the solution being pumped to prevent premature failure or malfunction. ❏ Optional inlet protection can be achieved by installing a pressure cutoff switch between the inlet filter and the pump to shut off pump when there is no positive inlet pressure. BY-PASS TO INLET Care should be exercised when deciding the method of by-pass from control valves. ❏ It is recommended the by-pass be directed to a baffled reservoir tank, with at least one baffle between the by-pass line and the inlet line to the pump. ❏ Although not recommended, by-pass liquid may be returned to the inlet line of the pump if the system is properly designed to protect your pump. A PRESSURE REDUCING VALVE must be installed on the inlet line (BETWEEN THE BY-PASS CONNECTION AND THE INLET TO THE PUMP) to avoid excessive pressure to the inlet of the pump. It is also recommended that a THERMO VALVE be used in the by-pass line to monitor the temperature build-up in the by-pass loop to avoid premature seal failure. ❏ A low-pressure, flexible cloth braid (not metal braid) hose should be used from the by-pass connection to the inlet of the pump. ❏ Caution should be exercised not to undersize the by-pass hose diameter and length. Refer to Technical Bulletin 64 for additional information on the size and length of the by-pass line. ❏ Check the pressure in the by-pass line to avoid overpressurizing the inlet. ❏ The by-pass line should be connected to the pump inlet line at a gentle angle of 45° or less and no closer than 10 times the pump inlet port diameter e.g. 1-1/2" port size = 15" distance from pump inlet port.

Handy Formulas to Help You

HOSE FRICTION LOSS PRESSURE DROP IN PSI PER 100 FT OF HOSE WITH TYPICAL WATER FLOW RATES Hose Inside Diameters, Inches

Water* Flow Gal/Min

1/4

5/16

3/8

1/2

5/8

3/4

1"

0.5 16 5 2 1 54 20 7 2 2 180 60 25 6 2 3 380 120 50 13 4 2 4 220 90 24 7 3 5 320 130 34 10 4 6 220 52 16 7 1 8 300 80 25 10 2 10 450 120 38 14 3 15 900 250 80 30 7 20 1600 400 121 50 12 25 650 200 76 19 30 250 96 24 40 410 162 42 50 600 235 62 60 370 93 *At a fixed flow rate with a given size hose, the pressure drop across a given hose length will be directly proportional. A 50 ft. hose will exhibit one-half the pressure drop of a 100 ft. hose. Above values shown are valid at all pressure levels.

WATER LINE PRESSURE LOSS PRESSURE DROP IN PSI PER 100 FEET Steel Pipe—Nominal Dia.

Water GPM

Brass Pipe—Nominal Dia. 1/4 3/8 1/2 3/4 1 11/4 11/2

Copper Tubing O.D. Type L 1/4 3/8 1/2 5/8 3/4 7/8

8.5 1.9

6.0 1.6

120 13 2.9 1.0

30 7.0 2.1

20 5.6 1.8

400 45 10 3.4 1.3

60 14 4.5 1.1

40 11 3.6

94 20 6.7 2.6

1/4 3/8 1/2 3/4

1 2 3 5 8 10 15 25 40

1 1 /4 1 /2 1

1

150 36 12 2.8

100 28 9.0 2.2

230 50 17 6.1 3.0

330 86 28 6.7 1.9

220 62 21 5.2 1.6

500 120 40 15 6.5

520 130 43 10 3.0

320 90 30 7.8 2.4

180 56 22 10

270 90 21 6.2 1.6

190 62 16 5.0 1.5

120 44 20

670 240 56 16 4.2 2.0

470 150 40 12 3.8 1.7

330 110 50

66 17 8.0

39 11 5.0

550 200 88

37

17

23

11

52

29

40

19

210 107

48

61

28

60 80 100

RESISTANCE OF VALVES AND FITTINGS Nominal Pipe Inside Size Diameter Inches Inches

Equivalent Length of Standard Pipe in Feet Gate Valve

Globe Valve

Angle Valve

45˚ Elbow

90˚ Elbow

180˚ Close Ret

Tee Thru Run

Tee Thru Branch

1/2 3/4 1 11/4 11/2

0.622 0.824 1.049 1.380 1.610

0.41 0.54 0.69 0.90 1.05

18.5 24.5 31.2 41.0 48.0

9.3 12.3 15.6 20.5 24.0

0.78 1.03 1.31 1.73 2.15

1.67 2.21 2.81 3.70 4.31

3.71 4.90 6.25 8.22 9.59

0.93 1.23 1.56 2.06 2.40

3.33 4.41 5.62 7.40 8.63

2

2.067 2.469 3.068 4.026

1.35 1.62 2.01 2.64

61.5 73.5 91.5 120.0

30.8 36.8 45.8 60.0

2.59 3.09 3.84 5.03

5.55 6.61 8.23 10.80

12.30 14.70 18.20 23.90

3.08 3.68 4.57 6.00

11.60 13.20 16.40 21.60

2 1/2 3 4

Arriving at a total line pressure loss, consideration should then be given to pressure loss created by valves, fittings and elevation of lines. If a sufficient number of valves and fittings are incorporated in the system to materially affect the total line loss, add to the total line length, the equivalent length of line of each valve or fitting.

TYPICAL RESERVOIR TANK RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY Supply Line

Bypass Line (from regulator or unloader)

→ D











MIN. 4"

(Dia of pipe)

T X

Level Sensing Device



1.5 x D (Min.)

Flexible Hose to Pump





FILTER

MIN. 4"

Minimum Liquid Level

Bypass Line (from regulator or unloader)

Minimum Two Baffles Sealed at Bottom

Q. How can I find the RPM needed to get specific GPM (Gallons Per Minute) I want? Rated RPM A. Desired RPM = Desired GPM x Rated GPM Q. I have to run my pump at a certain RPM. How do I figure the GPM I’ll get? Rated GPM A. Desired GPM = Desired RPM x Rated RPM Q. Is there a simple way to find the approximate horsepower I’ll need to run the pump? A. Electric Brake GPM x PSI = Horsepower Required 1460

(Standard 85% Mech. Efficiency)

Q. What size motor pulley should I use? Pump RPM A. Pump Pulley (Outer Diameter) x Motor/Engine RPM

(Consult Engine Mfr.)

Q. How do I calculate the torque for my hydraulic drive system? GPM x PSI A. Torque (ft. lbs.) = 3.6 RPM

(

)

Avoid Cavitation Damage

One or several of the conditions shown in the chart below may contribute to cavitation in a system resulting in premature wear, system downtime and unnecessary operating costs. CONDITION Inadequate inlet line size Water hammering liquid acceleration/ deacceleration Rigid Inlet Plumbing Excessive Elbows in Inlet Plumbing Excessive liquid Temperature

SOLUTION Increase line size to the inlet port or one size larger ● Install C.A.T. Tube ● Move pump closer to liquid supply ●

Use flexible wire reinforced hose to absorb pulsation and pressure spikes ● Keep elbows to a minimum and less than 90° ●

Use Thermo Valve in bypass line Do not exceed pump temperature specifications ● Substitute closed loop with baffled holding tank ● Adequately size tank for frequent or high volume bypass ● Pressure feed high temperature liquids ● Properly ventilate cabinets and rooms Air Leaks in Plumbing ● Check all connections ● Use PTFE thread tape or pipe thread sealant ● Size tank according to pump output — Agitation in Supply Tank Minimum 6-10 times system GPM ● Baffle tank to purge air from liquid and separate inlet from discharge High Viscosity Liquids ● Verify viscosity against pump specifications before operation ● Elevate liquid temperature enough to reduce viscosity ● Lower RPM of pump ● Pressure feed pump ● Increase inlet line size ● Perform regular maintenance or use clean Clogged Filters filters to monitor build up ● Use adequate mesh size for liquid and pump specifications ● ●

DIAGNOSIS AND MAINTENANCE One of the most important steps in a high pressure system is to establish a regular maintenance program. This will vary slightly with each system and is determined by various elements such as the duty cycle, the liquid being pumped, the actual specifications vs rated specifications of the pump, the ambient conditions, the inlet conditions and the accessories in the system. A careful review of the necessary inlet conditions and protection devices required before the system is installed will eliminate many potential problems. CAT PUMPS are very easy pumps to service and require far less frequent service than most pumps. Typically, only common tools are required, making in-field service convenient, however, there are a few custom tools, special to certain models, that do simplify the process. This service manual is designed to assist you with the disassembly and reassembly of your pump. The following guide will assist in determining the cause and remedy to various operating conditions. You can also review our FAQ or SERVICE sections on our WEB SITE for more facts or contact CAT PUMPS directly. PROBLEM

PROBABLE CAUSE

SOLUTION

Low pressure

•Worn nozzle. •Belt slippage. •Air leak in inlet plumbing. •Pressure gauge inoperative or not registering accurately. •Relief valve stuck, partially plugged or improperly adjusted. •Inlet suction strainer (filter) clogged or improperly sized. •Abrasives in pumped liquid. •Leaky discharge hose. •Inadequate liquid supply. •Severe cavitation. •Worn seals. •Worn or dirty inlet/discharge valves.

•Replace with properly sized nozzle. •Tighten belt(s) or install new belt(s). •Tighten fittings and hoses. Use PTFE liquid or tape. •Check with new gauge. Replace worn or damaged gauge. •Clean/adjust relief valve. Replace worn seats/valves and o-rings. •Clean filter. Use adequate size filter. Check more frequently. •Install proper filter. •Replace discharge hose with proper rating for system. •Pressurize inlet and install C.A.T. •Check inlet conditions. •Install new seal kit. Increase frequency of service. •Clean inlet/discharge valves or install new valve kit.

Pulsation

•Faulty Pulsation Dampener. •Foreign material trapped in inlet/discharge valves.

•Check precharge. If low, recharge, or install a new dampener. •Clean inlet/discharge valves or install new valve kit.

•Worn V-Packings, Hi-Pressure or Lo-Pressure Seals. •Worn adapter o-rings. •Humid air condensing into water inside the crankcase. •Excessive wear to seals and V-Packings.

•Install new seal kit. Increase frequency of service. •Install new o-rings. •Install oil cap protector. Change oil every 3 months or 500 hours. •Install new seal kit. Increase frequency of service.

Knocking noise •Inlet supply •Bearing •Pulley

•Inadequate inlet liquid supply. •Broken or worn bearing. •Loose pulley on crankshaft

•Check liquid supply. Increase line size, pressurize or install C.A.T. •Replace bearing. •Check key and tighten set screw.

Oil leak •Crankcase oil seals. •Crankshaft oil seals and o-rings. •Drain plug •Bubble gauge •Rear cover •Filler cap

•Worn crankcase oil seals. •Worn crankshaft oil seals or o-rings on bearing cover. •Loose drain plug or worn drain plug o-ring. •Loose bubble gauge or worn bubble gauge gasket. •Loose rear cover or worn rear cover o-ring. •Loose filler cap or excessive oil in crankcase.

•Replace crankcase oil seals. •Remove bearing cover and replace o-rings and/or oil seals. •Tighten drain plug or replace o-ring. •Tighten bubble gauge or replace gasket. •Tighten rear cover or replace o-ring. •Tighten filler cap. Fill crankcase to specified capacity.

Pump runs extremely rough •Inlet conditions •Pump valves •Pump seals

•Restricted inlet or air entering the inlet plumbing •Stuck inlet/discharge valves. •Leaking V-Packings, Hi-Pressure or Lo-Pressure seals.

•Correct inlet size plumbing. Check for air tight seal. •Clean out foreign material or install new valve kit. •Install new seal kit. Increase frequency of service.

•Scored plungers. •Over pressure to inlet manifold. •Abrasive material in the liquid being pumped. •Excessive pressure and/or temperature of pumped liquid. •Running pump dry. •Starving pump of adequate liquid.

•Replace plungers. •Reduce inlet pressure per specifications. •Install proper filtration at pump inlet and clean regularly. •Check pressure and inlet liquid temperature. •DO NOT RUN PUMP WITHOUT LIQUID. •Increase hose one size larger than inlet port size. Pressurize and install C.A.T. •Replace manifold. Check liquid compatibility.

Water leak •Under the manifold •Into the crankcase

Premature seal failure

•Eroded manifold.

OWNER’S MANUAL INSTALLATION AND OPERATING INSTRUCTIONS REPAIR PARTS LIST

Signature 2000 High Pressure Booster Pump 60 Hz. 1/2 through 3 HP

1218 0894 NC

STA-RITE INDUSTRIES, DELAVAN, WISCONSIN 53115 © 2006, Sta-Rite Industries

S327 (Rev. 1/8/07)

READ AND FOLLOW SAFETY INSTRUCTIONS! This is the safety alert symbol. When you see this symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury: DANGER warns about hazards that will cause serious personal injury, death or major property damage if ignored. WARNING warns about hazards that can cause serious personal injury, death or major property damage if ignored. CAUTION warns about hazards that will or can cause minor personal injury or property damage if ignored. The word NOTICE indicates special instructions which are important but not related to hazards.

ELECTRICAL SAFETY

WARNING

Hazardous voltage. Can shock, burn, or cause death.

GENERAL SAFETY To avoid risk of serious bodily injury and property damage, read safety instructions carefully before installing pump. Do not allow pump or any system component to freeze. To do so may damage system and will void warranty.

Some models of pump are supplied with 3-connector grounding type cord. Connect only to properly grounded, GFCI protected outlet. Do not lift pump by electrical cord.

Risk of electric shock. To avoid fatal shocks, proceed as follows if pump needs servicing. A. Disconnect power to pump outlet box before pulling pump cord plug. After plug is pulled, let pump cool for 20 minutes before attempting to work on it. B. Take extreme care when changing fuses. To reduced chance of fatal electrical shocks, DO NOT stand in water or put your finger in the fuse socket. C. Ground electrical outlet box. D. Use only Ground Fault Circuit Interrupter (GFCI) protected grounded outlet for cord plug.

Pump is nonsubmersible. Keep motor dry at all times. Do not wash motor. Do not immerse. Protect motor from wet weather.

Ground pump before connecting to power supply.

If using extension cord, use only UL approved indoor/outdoor, 3-wire, grounding type cord. Do not allow any part of cord or receptacle ends to sit in water or damp locations.

Never run pump dry. Running pump dry can damage internal parts, overheat pump (which can cause burns to people handling or servicing pump), and will void warranty. Do not pump chemicals or corrosive liquids with pump.

Unplug pump before servicing. Hazardous Pressure. Burn Hazard. Do not touch an operating motor. Modern motors can operate at high temperatures. To avoid burns when servicing pump, allow it to cool for 20 minutes after shut-down before handling.

A. Use high pressure reinforced type discharge hose ONLY. See parts list for available hose, nozzle and fittings. A high pressure relief valve is recom-mended. B. DO NOT use garden hose with High Pressure Booster pump. Garden hose will not stand the discharge pressure produced and will fail. C. High pressure discharge stream is dangerous. To avoid injury, DO NOT aim the discharge stream at any person or animal. D. BE SURE that the pump suction pipe pressure plus the pump discharge pressure does not exceed the pressure rating of hose and fittings. See Table I for pump discharge pressure ratings.

Follow local and/or national plumbing and electrical codes when installing. Hazardous Pressure. DO NOT run the pump with discharge shutoff, as hose may burst or pump may be damaged due to high temperatures.

2

INSPECT THE SHIPMENT

INSTALLATION

The high pressure booster pump has been carefully inspected and packaged to assure safe delivery. Inspect the pump and fittings and report to the carrier any items which are damaged or missing.

The pump is designed to boost city water pressure or water pressure from a private water system. Use this high pressure stream to wash down milk parlors, barns, garages and driveways, or for fire protection. The pump is portable with a convenient carrying handle. If an existing pressure water system is to be used as a water supply, it can be connected with available fittings and 3/4" or 1" high pressure hose to the pump inlet. A special heavy duty 3/4" or 1" suction hose with fittings is available as an accessory. If pump is permanently mounted on wall, use a 3/4" or 1" pipe or heavy-duty hose for suction line. 20 GPM models require one-inch discharge hose to reduce friction losses and 30 GPM models require 1-1/4".

TABLE I - DISCHARGE PRESSURE No. of Stages

Discharge Pressure PSI at Rated Flow

Discharge Pressure PSI at No Flow

GPM

HP

7

1/2

9

90

130

7

3/4

12

123

173

7

1

16

162

229

10

1/2

6

74

113

10

3/4

8

97

147

10

1

10

134

188

10

1

11

146

202

10

1-1/2

14

173

206

10

2

16

197

260

20

1

7

75

110

20

1-1/2

9

97

143

20

2

11

123

175

20

3

15

195

250

30

1

5

59

75

30

1-1/2

6

71

91

30

2

7

81

106

30

3

11

129

167

Hazardous pressure. Pump body may explode if pressures exceed rated limits. Maximum inlet pressure is 80 PSI. Maximum discharge pressure is 315 PSI. Warranty is void if these pressure limits are exceeded.

HIGH PRESSURE BOOSTER PUMP INSTALLATION INSTRUCTIONS These instructions cover high pressure booster pump installations as shown below: From pressurized house service

Suction

*For total discharge pressure, add this pressure to suction pipe pressure. For example, an HP7C pump taking suction from a 100 psi water service line will produce 130 + 100 = 230 psi total discharge pressure at 0 GPM flow. If suction pressure drops to 50 psi, discharge pressure will drop to 180 psi. NOTE: Model numbers that include an “S” (HPS7C, HPS10D, etc) have a stainless steel suction, discharge assembly, and capscrews. Model numbers ending in “3” (HP7C3, HPS10C3, etc) have 3-phase motors. Models numbers ending in “T” have TEFC motors.

Discharge

1208 0894

Figure 1 – Connection to house service.

Water tank or reservoir

Suction

Discharge

1207 0894

Figure 2 – Connection to water reservoir.

3

Size the inlet according to the chart below:

Priming Plug Tee

90 Elbow Male Pipe to Male Hose Adapter

Ave. GPM

Threaded Inlet Size

Recommended Inlet Line Size

Recommended Discharge Line Size

7 10 20 30

3/4" NPT 3/4" NPT 1" NPT 1-1/4" NPT

1" 1" 1-1/4" 1-1/2"

1" 1" 1-1/4" 1-1/2"

Female Hose Connection

15 Feet Maximum

High Pressure Hose

An inlet strainer will prevent suspended debris from clogging pump.

Male Hose Connection

The internal running surfaces of the pump and seals require water lubrication for good, consistent operation. Allowing pump to run dry will severely damage pump and seals.

Water Supply

Install a pressure gauge in pump inlet line. Keep at least two pounds per square inch pressure (2 PSI) in inlet line whenever pump is operating. If this is not possible, consult customer service representative.

Gun Nozzle Weeping Type ONLY Foot Valve 1210 0894

LUBRICATION

Figure 3 – Cistern or shallow well installation.

It is not necessary to lubricate pump or motor. The motor is equipped with sealed ball bearings, lubricated for the life of the bearing. The mechanical shaft seal in the pump is self-lubricating and requires no adjustment. Disassemble pump to replace seal (See “Maintenance”, Pages 8 to 9).

Service Line

To Power

Gate Valve or Hose Bibb Male Pipe to Male Hose Adapter

OPERATION NOTICE: Observe the following precautions when operating the pump:

High Pressure Hose with two Female Connections

1. Keep the motor dry! Do not direct stream from pump discharge onto the motor! 2. Male Pipe to Male Hose Adapter (Suction)

Hazardous pressure. Do not run the pump with discharge shutoff, as hose may burst or pump may be damaged due to high temperatures.

3. Do not use a standard trigger gun with this pump. Use only trigger guns with an automatic weeping feature. These are available as accessories and are provided with three nozzles. The smallest nozzle restricts the flow, allowing use of a smaller water source. The two larger nozzles are used if the water source will supply the pump’s full capacity.

Gun Nozzle Weeping Type ONLY

Male Pipe to Male Hose Adapter (Discharge) Female Hose Connection

4. Do not run pump dry; to do so may damage the seal. 5. To avoid internal damage to pump, Do not operate with water temperature above 175 degrees F.

High Pressure Hose

1209 0894

Figure 4 – Wall mounted to pressurized service line. To reduce friction losses to a minimum, inlet (suction) line should be short and have as few elbows as possible. 4

Disconnect power before working on pump, motor, pressure switch, or wiring.

Single Phase, ODP Motor Dual-voltage motors (motors that can operate at either 115 or 230 volts), are set at the factory to 230 volts. Do not change motor voltage setting if line voltage is 230 volts, or if you have a single voltage motor.* NOTE: Never wire a 115 volt motor to a 230 volt line.

3. Move and attach the plug at the 115 volt position. The plug will now cover 2 metal tabs. The arrow on the plug will point to 115V. 4. Attach the power lead wires to the power lead terminals. Make sure the wires are secure. 5. Attach the ground wire to the green ground screw 6. Reinstall the Motor end cover Go to Wiring Connections below.

REMOVE MOTOR END COVER

DIAL TYPE VOLTAGE SELECTOR

MOTOR SWITCH SETTINGS

If you have a dual-voltage motor, and will connect it to 115 volts, follow the procedure below. Ground Screw End Cover Screws

Voltage Change Dial

Power Lead Terminals

Motor End Cover

Figure 5 – Removing Motor End Cover Figure 7 – Voltage set to 230 volts, Dial Type

You will need to remove the motor end cover to change the voltage setting. Your motor terminal board (located under the motor end cover) should look like one of those below.

To change to 115 volts: 1. Make sure power is off. 2. Turn the dial counter-clockwise until 115 shows in the dial window. 3. Attach the power lead wires to the power lead terminals. Make sure the wires are secure. 4. Attach the ground wire to the green ground screw 5. Reinstall the Motor end cover Go to Wiring Connections below.

PLUG TYPE VOLTAGE SELECTOR Ground Screw Voltage Change Plug

Power Lead Terminals

Figure 6 – Voltage set to 230 volts, Plug Type To change to 115 volts: 1. Make sure power is off. 2. Pull the plug straight up.

*Models with power cords are pre-wired for 115 volts. This includes models HP7D-02 and HP7C-02. 5

ELECTRICAL

WIRING CONNECTIONS 1. Install, ground, wire and maintain this pump in compliance with the National Electrical Code (NEC) or the Canadian Electrical Code (CEC) and with all local codes and ordinances that apply. Consult your local building inspector for local information. 2. Make sure that the voltage, frequency and phase (single phase or three phase) of the power supply agree with that stamped on the motor nameplate. If in doubt, check with the power company. 3. Some models are equipped with three phase motors. Three phase motors require magnetic starters and can run in either direction, depending on how they are connected to the power supply. NOTICE: Dual voltage motors without cords are factory wired for 230 volts. If necessary, reconnect the motor for 115 volts, as shown. All cord connected motors are wired for 115 volts (See Page 5). Do not alter the wiring in single voltage motors. Install, ground, wire, and maintain your pump in comliance with the National Electrical Code (NEC) or the Canadian Electrical Code (CEC), as applicable, and with all local codes and ordinances that apply. Consult your local building inspector for code information. NOTICE: Clamp the power cable to prevent strain on the terminal screws. NOTICE: Your Motor Terminal Board (under the motor end cover) looks like one of those shown above. Do not change motor wiring if line voltage is 230 volts. Connect power supply as shown for your supply voltage. NOTICE: Some models are equipped with three phase motors. Three phase motors require magnetic starters and can run in either direction, depending on how they are connected to the power supply.

Ground motor before connecting to electrical power supply. Failure to ground motor can cause severe or fatal electrical shock hazard. Explosion hazard. Do not ground to a gas supply line. To avoid dangerous or fatal electrical shock, turn OFF power to motor before working on electrical connections. Supply voltage must be within ±10% of nameplate voltage. Incorrect voltage can cause fire or serious damage to motor and voids warranty. If in doubt consult a licensed electrician. Use wire size specified in Wiring Chart (Table II, Page 7). If possible, connect pump to a separate branch circuit with no other appliances on it. Wire motor according to diagram on motor nameplate. If nameplate diagram differs from diagrams above, follow nameplate diagram.

For All 3-phase and TEFC Motors: Follow the wiring diagram on the motor junction box or on the motor nameplate.

6

To Check For Proper Rotation – 3 Phase Motors

Models without cord and plug:

Risk of electrical shock. 1. Be sure power is disconnected to motor when working on electrical connections. 2. Remove the motor end cover, exposing motor shaft. Momentarily start pump. If hookup is correct, the shaft will rotate clockwise. 3. If rotation is not clockwise, reverse any two leads to the starter. The rotation will now be correct.

1. Connect ground wire first. Connect the ground first, then to green grounding terminal provided under motor canopy (see Figures 6 and 7) identified as GRD. Make ground connection to this terminal. Do not connect motor to electrical power supply until unit is permanently grounded; otherwise serious or fatal electrical shock hazard may be caused. 2. For best ground connection, connect to a grounded lead in the service panel or to a metal underground water pipe or well casing at least 10 ft. long. If plastic pipe or insulated fittings are used, run ground wire directly to the metal well casing or use ground electrode furnished by the power company.

GROUNDING THE MOTOR Ground the pump permanently using a wire of size and type specified by local or National Electrical Code. Models (HP7C and HP7D Series Only) with factory installed cord and plug: Risk of electric shock. This equipment is only for use on 115V and is equipped with an approved 3-conductor cord and 3-prong, grounding-type plug. To reduce the risk of electric shock, be certain that it is connected to a properly grounded, grounding-type receptacle. Do not modify or remove plug. Make sure pump circuit meets National Electrical Code. To avoid dangerous electrical shock hazard, keep cord dry at all times.

TABLE II - RECOMMENDED FUSING AND WIRING Branch Fuse Rating Amps

Motor Type

Motor H.P.

Volts/ Phase

Max. Load Amps

ODP ODP

1/2 1/2

115/230/1 230/460/3

12.4/ 6.2 3.1/1.55

20/15 15/15

12/14 14/14

Wire Length 101-200’ AWG Wire Size 10/14 14/14

ODP ODP

3/4 3/4

115/230/1 230/460/3

14.8/7.4 3.6/1.8

20/15 15/15

12/14 14/14

8/14 14/14

6/14 14/14

ODP ODP

1 1

115/230/1 230/460/3

19.2/9.6 4.7/2.35

25/15 15/15

10/14 14/14

8/14 14/14

6/12 14/14

ODP ODP ODP ODP ODP ODP ODP ODP

1-1/2 1-1/2 1-1/2 2 2 2 3 3

115/230/1 230/1 230/460/3 115/230/1 230/1 230/460/3 208-230/1 200-230/460/3

24/12 12.0 6.8/3.4 26/13 10.4 6.0/3.0 15.0 11.5/5.8

30/15 15 15/15 35/20 15 15/15 20 15/15

10/14 14 14/14 8/12 14 14/14 12 14/14

6/12 14 14/14 6/12 14 14/14 12 14/14

6/12 12 14/14 4/10 14 14/14 10 12/14

TEFC TEFC

1 1

115/230/1 208-230/460/3

18/9 4.8/2.4

25/15 15/15

10/14 14/14

8/14 14/14

8/12 14/14

TEFC TEFC

1-1/2 1-1/2

230/1 208-230/460/3

10.4 6.0/3.0

15 15/15

14 14/14

14 14/14

12 14/14

TEFC TEFC

2 2

230/1 208-230/460/3

11.7 7.0/3.5

15 15/15

14 14/14

10 14/14

8 14/14

TEFC TEFC

3 3

230/1 208-230/460/3

7.0/3.5

15/15

14/14

14/14

14/14

7

0’-100’

201-300’ 8/14 14/14

screwdriver by the handle and short capacitor terminals together. Do not touch metal screwdriver blade or capacitor terminals. 3. Unscrew the overload and move it aside. Do not disconnect wires. Slide 7/16" open end wrench in behind spring loaded centrifugal switch as shown. Place on motor shaft flats to hold shaft stationary. 4. With one 7/16" wrench in place on motor shaft, place second wrench on shaft hex at pump end and unscrew impeller stack by turning counter-clockwise. 5. Once loose from motor shaft, hold shaft by snap ring using a pliers or similar tool, and pull stack from shell. You may have to apply a back and forth motion to break stack loose from shell. To assemble with replacement impeller stack, keep pump in the vertical position, motor down, and reverse instructions 1 through 5. Assembly hints: A. Apply a soapy water solution to suction and dischage O-Rings to ease seating of shell. B. Make sure mechanical shaft seal spring is in proper position on motor shaft. C. On three-phase models, apply Loctite No. 271 to motor shaft threads before reinstalling stack.

MAINTENANCE Pump Disassembly Hazardous voltage. Can shock, burn or cause death. Disconnect power to pump before servicing. Tools required: 1. 7/16" open end wrench (2 required). 2. Flat blade screwdriver with insulated handle. 3. Work bench with vise recommended. 4. Pliers or similar tool. 5. Pipe wrench. Impeller Stack Changeout (See Figure 8) Remove pump from service and mount vertically in vise (if available) motor side down. Hold at center of motor. It may be desirable to wrap motor with a shop rag to protect outside surface. Proceed as follows: 1. Attach pipe wrench to flats on discharge connection and turn clockwise to remove (left hand threads). 2. Remove screws holding motor canopy and remove canopy. Pull straight off as shown. Leave switch wires attached (if present). Capacitor voltage may be hazardous. To discharge capacitor, hold insulated handle

1

Remove with clockwise rotation.

Discharge Connection

4 Torque discharge connection to 80 - 100 ft-lbs at reassembly

Remove with Counter-clockwise rotation.

Snap Ring Impeller Stack

3

7/16" Open End Wrench 7 / 16

Overload Protector (Moved for access)

Overload screw (remove)

Capacitor

Centrifugal Switch View A-A Motor end view with canopy removed

See View A-A

3

Disconnect from power source. A

2

1211 0605

Motor Canopy

Figure 8 – Impeller stack changeout. 8

5

Mechanical Seal Changeout (refer to Figures 8 and 9)

polished face of seat and press into seal cavity using a 3/4" socket or a piece of 3/4" standard pipe.

This procedure is best completed with the pump held in a vertical position, motor down. First complete “Disassembly” instructions 1 through 5 under “Impeller Stack Changeout.” (see Figure 8).

D. Be sure polished surface of seat is free of dirt and has not been damaged by insertion. Remove excess soapy water. Dispose of cardboard washer.

6. Remove 4 capscrews holding pump body to motor. Pump handle will come off with top capscrews.

12. Installation of rotating half and spring:

7. Unscrew pump shell from pump body, turning clockwise (left hand threads).

A. Reinstall pump body on motor using extreme caution not to hit ceramic portion of seal on motor shaft. Reattach pump body to motor using capscrews. Be sure to reinstall pump handle at this time.

8. Remove mechanical shaft seal spring and rotating half from motor shaft. Use care not to scratch motor shaft when removing rotating half. 9. Remove pump body from motor and place on flat surface, face down. Again, use care not to scratch motor shaft.

B. Inspect shaft to make sure that it is clean.

10. Use a screwdriver to push ceramic seat out from seal cavity as shown.

D. Lubricate inside diameter of rotating half with soapy water and slide onto motor shaft (sealing face first).

C. Clean face of rotating half of seal with a clean cloth.

11. Installation of ceramic seat: A. Turn pump body over so seal cavity is up; clean cavity thoroughly.

E. Place spring over motor shaft so it rests on rotating half.

B. Clean polished surface of ceramic seat with a clean cloth.

13. To complete reassembly from this point, reverse instructions 1 through 5 under “Impeller Stack Changeout.”

C. Lubricate outside rubber surface of seat with soapy water. Place cardboard washer over

7

NOTICE: Lubricate suction and discharge O-Rings with soapy water for easier installation of shell.

Remove shell; turn clockwise.

10 Push ceramic seat out of pump body

8 Rotating Half of Mechanical Seal

Rotating Half

12

9 Remove Pump Body

11 3/4" pipe or 3/4" socket with extender

Cardboard washer (supplied w/seal)

Polished Face

6 Ceramic Seat

Torque bolts to 15 - 27 Ft-lbs during reassembly.

Figure 9 – Mechanical seal changeout. 9

1212 0605

1

2 3 4 5

6

10

7

THE FOLLOWING ACCESSORIES MAY BE ORDERED FOR HIGH PRESSURE BOOSTER PUMPS Hose 6’-3/4" w/Female Ends (150 PSI Rating) Hose 25’-3/4" w/Male & Female Ends (150 PSI Rating) Adapter 3/4" NPT x 3/4" Hose Nozzle - High Pressure Suction Vacuum Relief Valve

PKG 83

7A

PKG 84 PKG 85 PKG 86 PKG 96

8 1206 0605 NCBSW/NB

5 9

Figure 9 – Exploded view.

REPAIR PARTS LIST

Key No. 1 1 2 3 4 5 6 7 7 7A 8 8 9 10 # #

Description Motor - 115/230 Volt, 1 Phase Motor - 230/460 Volt, 3 Phase Handle (†) Water Slinger Pump Body O-Ring Shaft Seal Assembly Pump Stack (7 GPM Pump) Pump Stack (10 GPM Pump)†† Nylatron Bearing (included with Key No. 9) Pump Shell (7 GPM Pump) Pump Shell (10 GPM Pump)††† Discharge Assembly Capscrew - 3/8 x 16 x 1-1/2" Cord Connector** Cord**

Qty.

HP7C-02 HP7C3-02 HP10C-02 HP10C3-02 1/2 HP

HP7D-02 HP7D3-02 HP10D-02 HP10D3-02 3/4 HP

HP7E-02 HP7E3-02 HP10E-02 HP10E3-02 HP10E311-02 1 HP

HP10F-02 HP10F3-02 1-1/2 HP

1 1 1 1 1 2 1 1 1

J218-590PKG AP100CH C54-21 17351-0009 C2-85 U9-430 U109-118 P325-422 P325-425

J218-596PKG AP100DL2 C54-21 17351-0009 C2-85 U9-430 U109-118 P325-423 P325-426

J218-601PKG AP100EH C54-21 17351-0009 C2-85 U9-430 U109-118 P325-424 P325-439

J218-883APKG AP100FH – 17351-0009 C2-85 U9-430 U109-118 – P325-428

J218-628APKG AP100GH – 17351-0009 C2-85 U9-430 U109-118 – P325-429

1 1 1 1 4 1 1

W31112 P56-430SSL P56-460SSL C152-3 U30-982ZP U71-7 U17-402

W31112 P56-431SSL P56-461SSL C152-3 U30-982ZP U71-7 U17-1238

W31112 P56-432SSL P56-469SSL C152-3 U30-982ZP – –

W31112 – P56-452SSL C152-3 U30-982ZP – –

W31112 – P56-432SSL C152-4 U30-982ZP – –

# Not Illustrated. ** Included with Model Numbers HP7C-01 and the HP7D Series Model Numbers. † Handle comes with HP7 series and HP10E series. †† Model HP10E311-02 uses Part Number P325-362. ††† Model HP10E311-02 uses Part Number P56-404SSL.

10

SHP10G3-02 HP10G-02 HP10G3-02 2 HP

1 2 3 4

5

9

6

THE FOLLOWING ACCESSORIES MAY BE ORDERED FOR HIGH PRESSURE BOOSTER PUMPS Hose 6’-3/4" w/Female Ends (150 PSI Rating) Hose 25’-3/4" w/Male & Female Ends (150 PSI Rating) Adapter 3/4" NPT x 3/4" Hose Nozzle - High Pressure Suction Vacuum Relief Valve

6A

PKG 83 PKG 84 PKG 85 PKG 86 PKG 96

7 1206 0605 NHW/NB

4 8

Figure 10 – Exploded view.

REPAIR PARTS LIST

Key No. 1 1 2 3 4 5 6 6 6A 7 7 8 9

Description Motor - 115/230 Volt, 1 Phase Motor - 230/460, 3 Phase Water Slinger Pump Body O-Ring Shaft Seal Assembly Pump Stack (7 GPM) Pump Stack (10 GPM) Nylatron Bearing (included with Key No. 9) Pump Shell (7GPM) Pump Shell (10GPM) Discharge Assembly Capscrew 3/8 x 16 x 1-1/2", S.S.

Qty.

HPS7C-01 HPS7C3-01 HPS10C-01 HPS10C3-01 1/2 HP

HPS7D-01 HPS7D3-01 HPS10D-01 HPS10D3-01 3/4 HP

HPS7E-01 HPS7E3-01 HPS10E-01 HPS10E3-01 1HP

HPS10F-01 HPS10F3-01 1-1/2 HP

HPS10G-01 HPS10G3-01 2 HP

1 1 1 1 2 1 1 1

J218-590PKG AP100CH 17351-0009 C2-86SS U9-430 U109-118 P325-422R P325-425R

J218-596PKG AP100DL2 17351-0009 C2-86SS U9-430 U109-118 P325-423R P325-426R

J218-601PKG AP100EH 17351-0009 C2-86SS U9-430 U109-118 P325-424R P325-439R

J218-883APKG AP100FH 17351-0009 C2-86SS U9-430 U109-118 – P325-428R

J218-628APKG AP100GH 17351-0009 C2-86SS U9-430 U109-118 – P325-429R

1 1 1 1

W31112 P56-430SSL P56-460SSL C152-4

W31112 P56-431SSL P56-461SSL C152-4

W31112 P56-432SSL P56-469SSL C152-4

W31112 – P56-452SSL C152-4

W31112 – P56-432SSL C152-4

4

S25983

S25983

S25983

S25983

S25983

11

1

2 3 4 5

6

10

7

THE FOLLOWING ACCESSORIES MAY BE ORDERED FOR HIGH PRESSURE BOOSTER PUMPS Hose 6’-3/4" w/Female Ends (150 PSI Rating) Hose 25’-3/4" w/Male & Female Ends (150 PSI Rating) Adapter 3/4" NPT x 3/4" Hose Nozzle - High Pressure Suction Vacuum Relief Valve

PKG 83

7A

PKG 84 PKG 85 PKG 86 PKG 96

8 1206 0605 NCBSW/NB

5 9

Figure 11 – Exploded view.

REPAIR PARTS LIST

Key No. Description 1 1 1 1 1 2 3 4 5 6 7 7A 8 9 10

Motor - 115/230 Volt, 1 Phase Motor - 230 Volt, 1 Phase Motor - 230/460 Volt, 3 Phase Motor - 230 Volt, 1 Phase, TEFC Motor - 208-230/460 Volt, 3 Phase, TEFC Handle Water Slinger Pump Body O-Ring Shaft Seal Assembly Pump Stack Nylatron Bearing (included with Key No. 9) Pump Shell Discharge Assembly Capscrew - 3/8 x 16 x 1-1/2"

Qty.

HP20E-02 HP20E3-02 1 HP

1 1 1

J218-601PKG – AP100EH

J218-883APKG J218-628APKG – A100GSL AP100FH AP100GH

– AE100HLL AP100HL

1







J218-1035

1 1 1 1 2 1 1

– C54-21 17351-0009 C2-85A U9-430 U109-118 P325-602R

– C54-21 17351-0009 C2-85A U9-430 U109-118 P325-431R

– C54-21 17351-0009 C2-85A U9-430 U109-118 P325-432R

J218-1036 C54-21 17351-0009 C2-85A U9-430 U109-118 P325-718R

1 1 1 4

W31112 P56-433SSL C152-3A U30-982ZP

W31112 P56-434SSL C152-3A U30-982ZP

W31112 P56-452SSL C152-3A U30-982ZP

W31112 P56-620SSL C152-3A U30-982ZP

12

HP20F-02 HP20F3-02 1-1/2 HP

HP20G-02 HP20G3-02 2 HP

HP20H-01 HP20H3-01 HP20HT-02 HP20H3T-02 3 HP

1 2 3 4

5

9

6

THE FOLLOWING ACCESSORIES MAY BE ORDERED FOR HIGH PRESSURE BOOSTER PUMPS Hose 6’-3/4" w/Female Ends (150 PSI Rating) Hose 25’-3/4" w/Male & Female Ends (150 PSI Rating) Adapter 3/4" NPT x 3/4" Hose Nozzle - High Pressure Suction Vacuum Relief Valve

6A

PKG 83 PKG 84 PKG 85 PKG 86 PKG 96

7 1206 0605 NHW/NB

4 8

Figure 12 – Exploded view.

REPAIR PARTS LIST

Key No. Description 1 1 1 1 1 2 3 4 5 6 6A 7 8 9

Motor - 115/230 Volt, 1 Phase Motor - 230 Volt, 1 Phase Motor - 230/460 Volt, 3 Phase Motor - 230 Volt, 1 Phase, TEFC Motor - 208-230/460 Volt, 3 Phase, TEFC Water Slinger Pump Body O-Ring Shaft Seal Assembly Pump Stack Nylatron Bearing (included with Key No. 8) Pump Shell Discharge Assembly Capscrew 3/8 x 16 x 1-1/2"

Qty.

HPS20E-01 HPS20E3-01 1HP

HPS20F-01 HPS20F3-01 1-1/2 HP

HPS20G-01 HPS20G3-01 2 HP

HPS20H-01 HPS20H3-0 HPS20HT-01 HPS20H3T-01 3 HP

1 1 1

J218-601PKG – AP100EL2

J218-883APKG – AP100FH

J218-628APKG A100GSL AP100GH

– AE100HLL AP100HL

1







J218-1035

1 1 1 2 1 1

– 17351-0009 C2-86SSA U9-430 U109-118 P325-440R

– 17351-0009 C2-86SSA U9-430 U109-118 P325-431R

– 17351-0009 C2-86SSA U9-430 U109-118 P325-432R

J218-1036 17351-0009 C2-86SSA U9-430 U109-118 P325-718R

1 1 1 4

W31112 P56-470SSL C152-4A S25983

W31112 P56-434SSL C152-4A S25983

W31112 P56-452SSL C152-4A S25983

W31112 P56-620SSL C152-4A S25983

13

1

2 3 4 5

6

10

7

THE FOLLOWING ACCESSORIES MAY BE ORDERED FOR HIGH PRESSURE BOOSTER PUMPS Hose 6’-3/4" w/Female Ends (150 PSI Rating) Hose 25’-3/4" w/Male & Female Ends (150 PSI Rating) Adapter 3/4" NPT x 3/4" Hose Nozzle - High Pressure Suction Vacuum Relief Valve

7A

PKG 83 PKG 84 PKG 85 PKG 86 PKG 96

8 1206 0605 NCBSW/NB

5 9

Figure 13 – Exploded view.

REPAIR PARTS LIST

Key No. Description 1 1 1 1 1 2 3 4 5 6 7 7A 8 9 10

Motor - 115/230 Volt, 1 Phase Motor - 230 Volt, 1 Phase Motor - 230/460 Volt, 3 Phase Motor - 230 Volt, 1 Phase, TEFC Motor - 208-230/460 Volt, 3 Phase, TEFC Handle Water Slinger Pump Body O-Ring Shaft Seal Assembly Pump Stack Nylatron Bearing (included with Key No. 9) Pump Shell Discharge Assembly Capscrew - 3/8 x 16 x 1-1/2"

Qty.

HP30E-02 HP30E3-02 HP30ET-02 HP30E3T-02 1 HP

HP30F-02 HP30F3-02 HP30FT-02 HP30F3T-02 1-1/2 HP

HP30G-02 HP30G3-02 HP30GT-02 HP30G3T-02 2 HP

1 1 1

J218-601PKG – AP100EH

J218-883APKG – AP100FH

J218-628APKG A100GSL AP100GH

– AE100HLL AP100HL

1

A100FL-T

AE100GL-T

AE100G5L-T

J218-1035

1 1 1 1 2 1 1

AP100FL-T C54-21 17351-0009 C2-85B U9-430 U109-118 P325-719R

AP100GL-T C54-21 17351-0009 C2-85B U9-430 U109-118 P325-720R

AP100G5L-T C54-21 17351-0009 C2-85B U9-430 U109-118 P325-721R

J218-1036 C54-21 17351-0009 C2-85B U9-430 U109-118 P325-722

1 1 1 4

W31112 P56-621SSL C152-3B U30-982ZP

W31112 P56-622SSL C152-3B U30-982ZP

W31112 P56-434SSL C152-3B U30-982ZP

W31112 P56-615SSL C152-3B U30-982ZP

14

HP30H-02 HP30H3-02 HP30HT-02 HP30H3T-02 3 HP

1 2 3 4

5

9

6

THE FOLLOWING ACCESSORIES MAY BE ORDERED FOR HIGH PRESSURE BOOSTER PUMPS Hose 6’-3/4" w/Female Ends (150 PSI Rating) Hose 25’-3/4" w/Male & Female Ends (150 PSI Rating) Adapter 3/4" NPT x 3/4" Hose Nozzle - High Pressure Suction Vacuum Relief Valve

6A

PKG 83 PKG 84 PKG 85 PKG 86 PKG 96

7 1206 0605 NHW/NB

4 8

Figure 14 – Exploded view.

REPAIR PARTS LIST

Key No. Description 1 1 1 1 1 2 3 4 5 6 6A 7 8 9

Motor - 115/230 Volt, 1 Phase Motor - 230 Volt, 1 Phase Motor - 230/460 Volt, 3 Phase Motor - 230 Volt, 1 Phase, TEFC Motor - 208230/460 Volt, 3 Phase, TEFC Water Slinger Pump Body O-Ring Shaft Seal Assembly Pump Stack Nylatron Bearing (included with Key No. 9) Pump Shell Discharge Assembly Capscrew 3/8 x 16 x 1-1/2"

Qty.

HPS30E-01 HPS30E3-0 HPS30ET-01 HPS30E3T-01 1HP

HPS30F-01 HPS30F3-01 HPS30FT-01 HPS30F3T-01 1-1/2 HP

HPS30G-01 HPS30G3-01 HPS30GT-01 HPS30G3T-01 2 HP

HPS30H-01 HPS30H3-01 HPS30HT-01 HPS30H3T-01 3 HP

1 1 1

J218-601PKG – AP100EH

J218-883APKG – AP100FH

J218-628APKG A100GSL AP100GH

– AE100HLL AP100H

1

A100FL-T

AE100GL-T

AE100G5L-T

J218-1035

1 1 1 2 1 1

AP100FL-T 17351-0009 C2-86SSB U9-430 U109-118 P325-719R

AP100GL-T 17351-0009 C2-86SSB U9-430 U109-118 P325-720R

AP100G5L-T 17351-0009 C2-86SSB U9-430 U109-118 P325-721R

J218-1036 17351-0009 C2-86SSB U9-430 U109-118 P325-722R

1 1 1 4

W31112 P56-621SSL C152-4B S25983

W31112 P56-622SSL C152-4B S25983

W31112 P56-434SSL C152-4B S25983

W31112 P56-615SSL C152-4B S25983

15

LIMITED WARRANTY Sta-Rite Industries, warrants to the original consumer of the products listed below, that they will be free from defects in material and workmanship for the Warranty Period from the date of original installation or manufacture as noted. Product

Warranty Period

Water Systems Products – jet pumps, small centrifugal pumps, submersible pumps and related accessories

whichever occurs first: 1 year from date of original installation, or 2 years from date of manufacture

Hydro-Flow Filters

1 year from date of purchase

Signature 2000® Fibrewound Tanks

5 years from date of original installation

Pro-SourceTM Steel Pressure Tanks

5 years from date of original installation

Pro-SourceTM Epoxy-Lined Tanks

3 years from date of original installation

Sump/Sewage/Effluent Products

1 year from date of original installation, or 2 years from date of manufacture

Our warranty will not apply to any product that has been subject to negligence, misapplication, improper installation or maintenance. In the event a three phase submersible motor is operated with single phase power through a phase converter, or if three-leg ambient compensated, extra-quick trip overload relays of recommended size are not used, our warranty is void. Buyer’s only remedy and Sta-Rite Industries’ only duty is to repair or replace defective products (at Sta-Rite Industries’ choice). Buyer agrees to pay all labor and shipping charges associated with this warranty and to request warranty service through the installing dealer as soon as a problem is discovered. If warranty service is requested more than 30 days after the Warranty Period has ended, it will not be honored. STA-RITE INDUSTRIES SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER. THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE WARRANTY PERIOD PROVIDED HEREIN. Certain states do not permit the exclusion or limitation of incidental or consequential damages or the placing of limitations on the duration of an implied warranty, therefore, the limitations or exclusions herein may not apply. This warranty sets forth specific legal rights and obligations, however, additional rights may exist, which may vary from state to state. Supersedes all previous publications.

Sta-Rite Industries, 293 Wright St., Delavan, WI 53115

HydroMinder Model 506 Package Contains: 1. Proportioner with U-clamp for mounting 2. Float with chain 3. Suction tube with foot valve -- 9 ft. 4. Discharge tube -- 2 ft. 5. Metering tip kit (14 tips) 6. Production information sheet

THANK YOU FOR YOUR INTEREST IN OUR PRODUCTS Please use this equipment carefully and observe all warnings and cautions. ******************************************************************** NOTE ***********************************************************************

WEAR

protective clothing and eyewear when dispensing chemicals or other materials.

ALWAYS

observe safety and handling instructions of the chemical manufacturers.

ALWAYS

direct discharge away from you or other persons or into approved containers.

ALWAYS

dispense cleaners and chemicals in accordance with manufacturer's instructions. Exercise CAUTION when maintaining your equipment.

KEEP

equipment clean for proper operation.

WEAR

protective clothing and eyewear when working in the vicinity of all chemicals, filling or emptying equipment or changing metering tips.

ALWAYS

re-assemble equipment according to instruction procedures. Be sure all components are firmly screwed or latched into position.

ATTACH

only to tap water outlets (85 PSI maximum).

Through proper care and maintenance, this equipment will serve your toughest cleaning jobs.

Installation: 1. Select a metering tip (see next three sections) and insert it into the suction stub on the eductor body. 2. Attach the end of the discharge tube with the clamp and flooding ring to the discharge barb on the eductor. Since the HydroMinder 506 does not have a siphon breaker, you may want to drill a small hole (1/8" or 1/4" ID) in the discharge tube, above the highest solution level and below the discharge end of the eductor. This will allow the discharge tube to drain after each cycle. 3. Mount the unit in a level position on the side of the reservoir. The U-clamp may be repositioned or removed as necessary. 4. Insert the foot valve end of the suction tube into the concentrate container. (The level of the concentrate must be below the level of the eductor, or the proportioner will continue to siphon concentrate after it is turned "off".) 5. Slide the open end of the suction tube over the suction stub. 6. Adjust the bead chain length to position the float at the desired level of solution. To prevent foaming, be certain that the solution level will always be above the point of discharge. Be sure float mechanism is not hampered by water turbulence caused by discharging solution. It may be necessary to baffle the float from the discharge in order for the unit to work properly. 7. Install a minimum 1/2-inch ID water hose between the inlet threads and the water spigot. Minimum water pressure required to properly operate the proportioner is 25 PSI (flowing).

Measurement of Concentration: You can determine the dispensed water-to-product ratio for any metering tip size and product viscosity. All that is required is to operate the primed dispenser for a minute or so and note two things: the amount of dispensed water/product mixture, and the amount of concentrate used in preparation of the solution dispensed. The water-to-product ratio is then calculated as follows: Dilution (X) = Amount of Mixed Solution — Amount of Concentrate Drawn Amount of Concentrate Drawn Dilution ratio, then, equals X parts water to one part concentrate (X:1). If the test does not yield the desired ratio, choose a different tip and repeat the test. Alternative methods to this test are 1) pH (using litmus paper), and 2) titration. Contact your concentrate supplier for further information on these alternative methods and the materials required to perform them.

APPROXIMATE DILUTIONS AT 40 PSI FOR WATER-THIN PRODUCTS (1.0 CP) Tip Color No Tip Grey Black Beige Red White Blue Tan Green Orange Brown Yellow Purple Pink

Orifice Size .187 .128 .098 .070 .052 .043 .040 .035 .028 .025 .023 .020 .014 .010

(Std. Drill Number) (3/16) (30) (40) (50) (55) (57) (60) (65) (70) (72) (74) (76) (79) (87)

Ratio 4:1 5:1 6:1 8:1 17:1 23:1 25:1 36:1 48:1 64:1 75:1 90:1 120:1 240:1

Metering Selection: Metering TipTip Selection: CONVERSION CHART: final concentration ofthe thedispensed dispensed liquid is TheThe final concentration ofRatio liquid is Equivalents toopenrelated to both the size of the metering tip related to both the size of Standard the metering tip opening Measures ing (orifice) andviscosity the viscosity of liquid the liquid being (orifice) and the of the being sisiphoned. If product viscosity is noticeably greater Oz./Gal.is noticeably phoned. If product viscosity greater Ratio % than of water, consult the procedure for than thatthat of water, consult for 128the procedure 1:1the first 50.0MeaMeasurement of Concentration on page surement of Concentration on the first page 64 water-to-product 2:1 33.3 to to achieve desired achieve your your desired water-to-product ratio.ratio. For 32 use the4:1 For water-thin products, at20.0 right water-thin products, use the chartchart at right asas a 21 factors 14.3 a guideline. Because aswater inlet water guideline. Because such such factors as 6:1 inlet pres16affectcan 8:1 11.1 pressure and temperature affect dilution sure and temperature can dilution ratios, the ratios, the figures listed below are only approxi14 9:1 10.0 figures listed below are only approximate. Test the mate. Test you the are actual dilution you 8 16:1are 5.9 actual dilution achieving using the achieving Measureusing the Measurement proce6of Concentration 24:1 4.0 ment of Concentration procedure for best results. dure for best results. Two undrilled, are Two undrilled, clear tips supplied for tips drilling 4are 32:1 clear 3.0 supplied for drilling sizes not listed. sizes not listed. 3 48:1 2.0 2 1 1/2 1/4

64:1 128:1 256:1 512:1

1.5 0.8 0.4 0.2

Operation: Open the water supply ball valve. When the solution in the reservoir reaches the level set by the float, the valve will close. This will stop the water flow and siphoning of concentrate. When withdrawal of solution from the reservoir causes the level to drop more than 1-1/2 inches, the valve will open, and the reservoir will be refilled to the previous, pre-set level. This cycle will be repeated automatically until the supply of concentrate is depleted. The ball valve should be fully closed when changing metering tips or concentrate container, when reservoir is drained, or when the unit is not in use. Troubleshooting: Problem

Probable Cause

Remedy

1. No discharge

a. No water b. Defective magnetic valve assembly c. Excessive water pressure

a. Open water inlet b. Replace assembly

a. Clogged foot valve b. Metering tip or eductor clogged c. Low water pressure d. Discharge tube or flooding ring not in place

a. Clean or replace foot valve b. Clean* or replace

a. Valve parts dirty or defective b. Magnet spring too short c. Clogged valve orifice

a. Clean or replace

a. Diluted solution being siphoned into container b. Water being siphoned into container

a. Replace or repair foot valve

2. No concentrate draw

3. Failure of unit to turn off

4. Backflow into concentrate

c. Install regulator if pressure exceeds 85 PSI

c. Minimum 25 PSI flowing required d. Check position: Replace discharge tube if flooding ring is missing.

b. Replace c. Clean or replace

b. Replace eductor

* In hard water areas, scale may form at the discharge of the eductor. This scale may be removed by soaking the eductor in a descaling solution or by running the descaling solution through the system. If descaling solution is educted through the system, flush the unit by educting water only before returning the system to regular use.

HydroMinder Model 506 Parts Diagram/List a KEY PART NO. b 1 2 3 4

238100 506500 502000 10080500

5

5030-K

6

6655-P

6

7 8 9 10 11 12

520000 505600 440121 690015 5057-A 5058-9A

7

13 14 15 16 17 18

10076301 250006 519000 5043-A 507200 360900

c 4 d e f

h

k 1

2

3

m

18

n

8

5

15

8

DESCRIPTION strainer washer hose swivel ball valve magnet parts kit: a. screw, b. washer, c. magnet cover, d. Magnet cap, e. magnet assembly, f. magnet spring,g. magnet yoke mounting bracket kit (specify model 506): includes Z Bracket, U clamp, lockwashers, screws and thumbscrews valve parts kit: h.valve guide ("bonnet"), k. armature spring, m. armature, n. diaphram water valve body street elbow eductor assembly metering tip (kit) discharge tube assembly suction tube assembly (includes 13 & 14) foot valve, Viton ceramic weight nipple float assembly (includes #17 chain) bead chain nipple

9 10 4g 12 14

17 16 11

13

MILLENIUM INSTALLATION MANUAL NTR 735 B/E Simple Automation Control Module (MAS)

MAS INSTALLATION MANUAL

NTR 735 B

Table of contents

1. INTRODUCTION

1

2. HARDWARE DESCRIPTION

2

3. INSTALLATION

6

4. CONNECTION

7

5. USER SAFETY AND PROTECTION OF EQUIPMENT

10

1. Introduction The MILLENIUM series has been designed for use in domestic, office and industrial applications. Each module can be used to manage all the sensors and actuators in the installation. A display on the front panel can be used to check the state of your system at any time. The MILLENIUM series is characterised by : • Ease of programming and parameter entry • WINDOWS-based programming software • Compact size • EEPROM module backup • Realtime clock as standard • Output with high breaking capacity

The MILLENIUM series has been designed for simple automation control modules (examples : lighting, air conditioning, irrigation, doors, barriers, simple safety systems, greenhouses, ventilation). The realtime clock allows equipment to be programmed in hours or minutes.

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MAS INSTALLATION MANUAL

NTR 735 B

2. Hardware description 2.1

Part numbers

Codes 89 750 001 89 750 002 89 750 003 89 750 013 89 750 004 89 750 005 89 750 015

2.2

Part numbers Power supply

Inputs Type 100 - 240V AC 100 - 240V AC

MAS 6 RCA MAS 10 RCA MAS 10 RCD 24V DC 24V DC MAS 10 TCD MAS 20 RCA 100 - 240V AC 100 - 240V AC MAS 20 RCD 24V DC 24V DC MAS 20 TCD

No. 4 6 6 6 12 12 12

Outputs Dimensions Weight Type No. mm kg RELAY 2 RELAY 4 71.2 x 90 x 55 0.2 RELAY 4 TRANSISTOR 6 RELAY 8 RELAY 8 124.6 x 90 x 55 0.32* TRANSISTOR 8

Description of power supplies

Description Power supply Micro-cuts Current peak

Maximum consumption

Typical consumption

Code MAS x RCA MAS x xCD MAS x RCA MAS x xCD 240V AC 24 V DC MAS 6 RCA, MAS 10 RCA, MAS 10 RCD, MAS 10 TCD, *MAS 20 RCA, *MAS 20 RCD, *MAS 20 TCD, MAS 6 RCA, MAS 6 RCA, MAS 10 RCA, MAS 10 RCA, MAS 10 RCD, MAS 10 TCD, *MAS 20 RCA, *MAS 20 RCA, *MAS 20 RCD, *MAS 20 TCD,

264V AC 264V AC 28,8V DC 28,8V DC 264V AC 28,8V DC 28,8V DC 240V AC 120V AC 240V AC 120V AC 24V DC 28,8V DC 240V AC 120V AC 24V DC 24V DC

Specification 100 - 240V AC, +10% -15%, 50/60 Hz 24V DC, +20% -15% 10ms 5ms ≤ 1.5 A t < 0.3 ms ≤ 7 A t < 0.2 ms 3 VA 4 VA 3W 2W 8 VA 7W 5W Active I/O : 2.5 VA Deactivated I/O : 1.5 VA Active I/O : 2 VA Deactivated I/O : 1.2 VA Active I/O : 3 VA Deactivated I/O : 1.5 VA Active I/O : 2.5 VA Deactivated I/O : 1.2 VA Active I/O : 2 W Deactivated I/O : 0.3 W Active I/O : 2 W Deactivated I/O : 0.3 W Active I/O : 5 VA Deactivated I/O : 1.5 VA Active I/O : 4 VA Deactivated I/O : 1.2 VA Active I/O : 5 W Deactivated I/O : 0.3 W Active I/O : 5 W Deactivated I/O : 0.3 W

* Without special connection modules.

Simple Automation Control Module (MAS) ntr_735b_e_mas_installation_manual.doc

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MAS INSTALLATION MANUAL 2.3

NTR 735 B

Description of inputs

Description Input voltage Input impedance Level 0 Level 1 Response time Galvanic isolation Status indication

Description of AC inputs 100 - 240V AC, +10% -15%, 50/60 Hz ≥ 800 k Ohms ≤ 40V AC ≥ 80V AC 25 ms min, 130 ms max. No LCD display

Description Input voltage Current consumption Level 0 Level 1 Response time

Description of DC inputs 24V DC +20% -15% 5 mA ≤ 4V ≥ 18V 15 ms ± 5 ms (I 01 – I 08) 30 ms ± 10 ms (I 09 – I 12) No LCD display

Galvanic isolation Status indication

Description MAS 10 RCD MAS 20 RCD Number of bits Resolution Conversion time Input voltage Input impedance Precision Default Offset/ Gain

Temp. dependent derating

Description of analogue inputs 6 Inputs: I 01 – I 06 8 Inputs: I 01 – I 08 8 (10000 / 250) mV 15 ± 5ms 0 – 10V DC 150 k Ohms max. ± 5% Offset = 0 Gain = 1 These values can be changed by the program ± 3 LSB on the authorised range

Simple Automation Control Module (MAS) ntr_735b_e_mas_installation_manual.doc

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MAS INSTALLATION MANUAL 2.4

Description of relay outputs

Description Max. operating voltage Max. operating current Minimum load Response time Type of contact Status indication

Category of use AC15 (electromagnet) DC13 (electromagnet) (L/R = 150 ms) AC14 (electromagnet) AC12 (resistive) DC12 (resistive)

2.5

NTR 735 B

Description of relay outputs 250V AC, 30V DC 8A / point 10mA at 5V DC ≤ 10ms Gold-plated silver LCD display

Max. operating voltage 250V AC 30V DC 250V AC 250V AC / 110V AC 30V DC

Power consumption Durability in steady state (number of operations) 450 VA 100 000 10 W 100 000 750 VA 2000 VA / 1100 VA 192 W

100 000 100 000 / 30 000 100 000

Max. ops / hour 600 360 600 1800 1800

Description of transistor outputs

Description Operating voltage Rating current / terminals Minimum load Max. inductive load Resistive load Response time Ton/Toff, Toff/Ton Open circuit current leakage Status indication Isolation circuit

Description of transistor outputs 5-24V DC (+ 20 % - 5 %) 1 A / terminal (8-24V DC) 0.1A / terminal (5-8V DC) 1.0 mA 1 A / 24V DC (24 W) 0.125 A / 24V DC (3.0 W) ≤ 1 ms ≤ 0.1 mA / 24 V DC LCD display None

Simple Automation Control Module (MAS) ntr_735b_e_mas_installation_manual.doc

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MAS INSTALLATION MANUAL 2.6

NTR 735 B

General description

Description Programming Program capacity Program backup Data backup Clock backup LCD display Real time clock accuracy

Specification Logic block or function block 64 blocks or 1500 bytes Via internal EEPROM or optional external EEPROM module 20 days at 25° C (via capacitor) 20 days at 25° C (via capacitor) Display unit with 4 lines of 10 characters. 5 seconds / day

Climatic conditions : Type Operating temperature Storage temperature Humidity Degree of protection Environment

Standard

Amplitude 0/55 °C -30/70 °C 35 - 85% relative humidity, without condensation IP 20 No corrosive gases. Minimum dust

Mechanical protection : Type Resistance to vibrations Direct mounting

IEC Standard 60068-2-6

Resistance to vibrations Mounted on DIN rail

60068-2-6

Resistance to shocks

60068-2-27

Type Dielectric strength

Standard EN 60730-1

Insulation resistance

EN 60730-1

Safety class Certifications

Conformity

Amplitude 10- 57 Hz: 0.15 mm Constant amplitude Acceleration 57- 150 Hz 19.6 m/ s² X, Y, Z : 10 times (80 minutes in each direction) 10- 57 Hz: 0.075 mm Constant amplitude Acceleration 57- 150 Hz: 9.8 m/s² X, Y, Z : 10 times (80 minutes in each direction) Acceleration : 147m/s², duration: 11 ms X, Y, Z : 3 times in each direction

Amplitude 3750V AC > 1 min between the following points : Power supply terminals / input / output terminals Between the relay outputs Between the terminals and the DIN 43880 control box or equivalent 7 Mohm at 500V DC between the following points : Power supply terminals / input / output terminals Between the relay outputs Between the terminals and the DIN 43880 control box or equivalent II CE Low Voltage directive 73/23/EEC EMC directive 89/336/EEC UL/ cUL

UL 508 EN60730- 1 EN61010- 1 EN50081- 1 EN50082- 1 EN50082- 2

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MAS INSTALLATION MANUAL

NTR 735 B

3. Installation L

N NC NC

1

2

3

IN

POWER AC 100/240V

4

5

6

Ref. Description of front panel Programming port 1 EEPROM backup module 2 Fixing holes, ∅ : 4.2 mm Power supply terminals 3 Input terminals 4 LCD display 5 Menu keys 6 Output terminals 7 DIN rail mounting 8

AC INPUT

ESC

OK

MAS 10 RCA RELAY OUTPUT

3.1

DIN rail mounting

The modules can be mounted on a 35 mm DIN rail (DIN EN 50022). 3.2

Panel mounting

Recommended diameter of fixing screws : M4. 3.3

Screw terminal connection

The end of the wire should be fitted with a ferrule. 3.4

Mounting instructions

The MILLENIUM series can be installed anywhere, but the following points should be taken into consideration. Do not install if : the atmosphere is excessively dusty, conductive, corrosive, gas-laden, damp, wet or inflammable, or subject to excessive heat*, excessive shocks or vibrations. Do not install the module in water or near any possible leaks. Protect the module from external debris during installation. Separate the cables and power equipment as far as possible. The MILLENIUM series module should be installed in cabinets which adhere to standard DIN 43880.

!



For sufficient module ventilation, allow a space of 10 mm between the front of the module and the cabinet door, and likewise between the base of the cabinet and the bottom of the module. 4

6 10 L

N

NC NC

1

2

3

AC INPUT

POWER DC 24V

1

2

3

4

5

IN

6

7

10

11 12

MAS 20 TCD

90

89 750 015

CROUZET AUTOMATISMES

9

DC INPUT

ESC

OK

8

REF :

MADE IN JAPAN

(A) (B)

MODEL :

MAS 10 RCA 89 750 002

6

CROUZET AUTOMATISMES

MODEL :

10 5

SERIAL :

REF :

4

MADE IN JAPAN

SERIAL :

POWER AC 100/240V

IN

OK

MAS 20 TCD

MAS 10 RCA TRANSISTOR OUTPUT

RELAY OUTPUT

4

6

10 55

71

10 124.6

55

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MAS INSTALLATION MANUAL

NTR 735 B

4. Connection 4.1

Connection instructions The MILLENIUM series has been designed with ease of connection in mind. A technician or engineer with experience of national and local electrical standards should be able to connect MILLENIUM series modules to the sensors and actuators without difficulty. • The input and output cables should not be in the same wiring harness. • Keep the input/output wiring harnesses well away from the power wiring harnesses. • Use cables which are suitable for the application.

! 4.2

Conductor cross-section

!

For the inputs / outputs use conductors : 0.13 mm² - 3.31 mm² (26 - 12 AWG). Strip back the conductor by 7 ± 0.5 mm. Undo the terminal screw to its maximum before inserting a conductor. To be sure of correct connection, insert the wire fully in the terminal and tighten the screws.

Maximum tightening torque 0.5 Nm (5kgfcm). Do not coat the conductor ends with tin to prevent them breaking.

4.3

Power supply For an AC power supply, the phase should be connected to the L terminal and the Neutral to the N terminal. Never connect the phase to the N terminal, as the user could receive a dangerous electric shock. For a DC power supply, the positive conductor should be connected to the ‘+’ terminal and the negative conductor to the ‘-’ terminal. The power supply terminals should not be connected to the other module terminals.

Simple Automation Control Module (MAS) ntr_735b_e_mas_installation_manual.doc

02/2000 - 7/10

MAS INSTALLATION MANUAL 4.4

NTR 735 B

Wiring diagram, MAS 6-10

POWER : AC

FR GB D IT SP NL

INPUT : AC L

N

100-240 VAC 50/60 Hz Ambient temperature : 0 + 55 °C

1,0 A

External contact only

L

POWER : DC

N

NC

NC

INPUT : DC

1

2

Les bornes “L“ et “N“ ne sont pas réversibles. “L“ and “N“ terminals are not reversible. “L“ und “N“ - Anschlüße sind nich tauschbar. I morsetti “L“ e “N“ non sono invertibili. Los bornes “L“ y “N“ no están reversibles. De klemmen “L“ en “N“ zijn niet omkeerbaar.

3 4 INPUTS

5

6

NPN _

+

24 VDC + 20 % - 15 % Ambient temperature : 0 + 55 °C

+

External contact only

1,0 A

+

POWER : DC

INPUT : DC

-

(A)

(B)

1

2

3 4 INPUTS

5

6

_

PNP

_

24 VDC + 20 % - 15 %

ANA 1,0 A

Ambient temperature : 0 + 55 °C

External contact only

+

-

(A)

(B)

1

2

3 4 INPUTS

5

6

OUTPUT : RELAY 7 mm

Resistive load : 8 A 250 VAC 30 VDC Inductive load : 125 VAC : 245 VA (1/3 hp) 250 VAC : 367 VA (1/2 hp)

OUT1

OUT2

OUT3

OUT4

10 A

+

26-12 AWG 0.13-3.31 mm²

or

OUTPUT : TRANSISTOR FR GB D IT SP NL

Resistive load : 1A / 8-24 Vcc ; 0,1A / 5-8 Vcc

Le 0V est à relier à la borne “-“ de l’alimentation du Millenium. Connect the 0V to “-“ terminal of Millenium power supply. +5VDC to Der Nulleiter ist mit der “-“ Klemme der Millenium+24VDC Stromversorgung zu verbinden. Lo 0V deve essere collegato al morsetto “-“ dell’ alimentazione del Millenium. 5V ≤ 0,3A 12/24V ≤ 2A El 0V se ha de conectar al borne “-“ de alimentación del Millenium. De 0V is verbonden aan de “-“ klem van de voeding.

Inductive load : 1A / 24 Vcc (24W)

OUT1

OUT2

OUT3

OUT4

0V

Simple Automation Control Module (MAS) ntr_735b_e_mas_installation_manual.doc

02/2000 - 8/10

MAS INSTALLATION MANUAL 4.5

NTR 735 B

Wiring diagram, MAS 20

POWER : AC

100-240 VAC 50/60 Hz Ambient temperature : 0 + 55 °C

External contact only

L

NC

NC

1

2

3

4

External contact only

5

6 7 INPUTS

Les bornes “L“ et “N“ ne sont pas réversibles. “L“ and “N“ terminals are not reversible. “L“ und “N“ - Anschlüße sind nich tauschbar. I morsetti “L“ e “N“ non sono invertibili. Los bornes “L“ y “N“ no están reversibles. De klemmen “L“ en “N“ zijn niet omkeerbaar.

8

9

10

11

12

NPN +

+

_

1,0 A _ +

POWER : DC

N

INPUT : DC

24 VDC + 20 % - 15 % Ambient temperature : 0 + 55 °C

N

1,0 A

L

POWER : DC

FR GB D IT SP NL

INPUT : AC

-

(A)

(B)

1

2

3

4

INPUT : DC

5

6 7 INPUTS

8

9

10

11

12

PNP

TOR

ANA

_

24 VDC + 20 % - 15 % TOR + ANA

1,0 A

Ambient temperature : 0 + 55 °C

TOR

External contact only +

OUTPUT : RELAY

-

(A)

(B)

1

2

3

4

5

6 7 INPUTS

8

Resistive load : 8 A 250 VAC 30 VDC

9

10

11

12

Inductive load : 125 VAC : 245 VA (1/3 hp) 250 VAC : 367 VA (1/2 hp) 7 mm

OUT1

OUT2

OUT3

OUT4

OUT5

10 A

OUT6

OUT7

OUT8

10 A

+

+

or

or

26-12 AWG 0.13-3.31 mm² OUTPUT : TRANSISTOR FR GB D IT

SP

NL

Resistive load : 1A / 8-24 Vcc ; 0,1A / 5-8 Vcc

Inductive load : 1A / 24 Vcc (24W)

Le 0V est à relier à la borne “-“ de l’alimentation du Millenium. Connect the 0V to “-“ terminal of Millenium power supply. Der Nulleiter ist mit der “-“ Klemme der Millenium-Stromversorgung zu verbinden. Lo 0V deve essere collegato +5VDC OUT1 OUT2 OUT3 OUT4 al morsetto “-“ dell’ to alimentazione del Millenium. +24VDC El 0V se ha de conectar al borne “-“ de alimentación 5V ≤ 0,3A del Millenium. 12/24V ≤ 2A De 0V is verbonden aan de “-“ klem van de voeding. 0V

OUT5

OUT6

OUT7

OUT8

Simple Automation Control Module (MAS) ntr_735b_e_mas_installation_manual.doc

02/2000 - 9/10

MAS INSTALLATION MANUAL

NTR 735 B

5. User safety and protection of equipment • This manual contains all the diagrams and explanations which will guide the user in installing and using MILLENIUM products correctly. This manual should be read and understood prior to use or installation. • If you have any doubts while installing MILLENIUM products or require any further information, consult your Crouzet distributor. • This manual may be amended without prior notification.

This manual is intended for use by competent personnel trained in installation of this equipment as defined in the following European directives : Machinery (98/37/EEC) Low voltage (73/23/EEC) EMC (89/336/EEC). Installation and electrical connections must be performed by a qualified technician. This manual uses the symbols below to highlight information relating to the safety of personnel and the protection of equipment. Where these symbols appear, the associated comments should be read and understood. The symbols are :

The identified danger will cause material damage.

!

The identified danger is liable to cause material damage.

• In no circumstances can Crouzet Limited be held responsible for damage arising as a result of installing or using this equipment. • All examples and diagrams in this manual are intended to aid comprehension. Their application is entirely the responsibility of the user. Crouzet Limited will not accept any responsibility for actual use of this product based on these examples. • It is up to the user to assess the suitability of this product for his applications. • In the event of product malfunction, the integral safety features should prevent dangerous situations. • Never modify or repair MILLENIUM products. • Check that MILLENIUM products comply with existing national and local standards.

Simple Automation Control Module (MAS) ntr_735b_e_mas_installation_manual.doc

02/2000 - 10/10

DIGITAL I/O MODULE MOUNTING BOARDS FOR “M” SERIES MINIATURE MODULES NOTES: DIMENSIONS: INCHES (MILLIMETERS) TOLERANCE: +0.020 (+.50)

PB24MD SCREW TERMINAL LOGIC SUPPLY BARRIER STRIP

REPLACEABLE 1A LOGIC SUPPLY FUSE

2.200˝ (55.88) 0.750˝ (19.05)

POWER BARRIER STRIP

0.400˝ (10.16)

WIRE INSERTION SIDE

2

8.000˝ (203.19)

1.700˝ (43.18)

1 2

3

4

5

6

7

8

9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24

1 R1

RESISTOR NETWORK

2.600˝ (66.04)

HOLD-DOWN BAR 1 R3

1

2

3

4

5

6

7

8

9

10

11

12

24

23

22

21

20

19

18

17

16

15

14

13

LED STATUS INDICATOR (24 PLCS)

R2

6.000˝ (152.40)

3-32 NYLON STANDOFF

1

REPLACEABLE 5A LINE FUSE (24 PLCS)

Y AC INPUT W DC INPUT

SWAGED STANDOFF 0.15 (3.8) DIA

B AC OUTPUT R DC OUTPUT

CROUZET PB-24MD 48 47 46 45 44 43 42 41

0.250˝ (6.35)

NOTES: DIMENSIONS: INCHES 9MILLIMETERS) TOLERANCE: +0.020 (+.50) NOTES: 1) 2) 3) 4)

5) 6)

40 39 38 37 36 35 34 33

32 31 30 29 28 27 26 25

0.294˝ (7.46) SIGNAL INPUT/OUTPUT 50 TRACE (0.1˝ CENTERS) MALE CARD EDGE.

MATING CONNECTOR IS BERG66317-150 OR EQUIVALENT. SPECIFY SUFFIX ‘C’ FOR OPTIONAL 65823-093 OR EQUIVALENT MALE PIN CONNECTOR FOR PARALLEL-TO-THE-BOARD CABLE CONNECTION. SPECIFY SUFFIX ‘V’ FOR OPTIONAL CIRCUIT ASSEMBLY CA-50H-2B-SR OR EQUIVALENT MALE PIN CONNECTOR FOR PERPENDICULAR-TO-THE-BOARD CABLE CONNECTION. 4-40 TERMINAL STRIPS ACCEPT WIRE SIZES FROM 26 TO 14 AWG . OPTIONAL JUMPERS ARE AVAILABLE TO INTERCONNECT BARRIER STRIP ORDER “JM8” PHOENIX MKD51.5 5.08mm SERIES (OR EQUIVALENT) SCREW TERMINAL BLOCKS STANDARD. SPECIFY SUFFIX “A” FOR BOARD-MOUNTED PHOENIX MSTBVA 1.5/16-G-5.08 (OR EQUIVALENT) MALE CONNECTOR. SPECIFY SUFFIX “B” FOR BOARD-MOUNTED PHOENIX MSTBVA 1.5/16-G-5.08 (OR EQUIVALENT) MALE CONNECTOR AND MATING PHOENIX MSTBVA 1.5/16-ST-5.08 (OR EQUIVALENT) FEMALE. SCREW-TERMINAL PLUG-IN CONNECTOR. LITTLE FUSE 251001 OR EQUIVALENT. LITTLE FUSE 251005 OR EQUIVALENT. POWER BARRIER STRIP 1 + LOGIC SUPPLY TERMINAL STRIP

2

3

4

5

6

7

8

9

10

11 12

13 14

15 16

17 18

19 20

21 22

23 24

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

5 4 3 2 1

48 47

46 45

4

42 41

40 39

38 37

36 35

34 33

32 31

30 29

28 27

26 25

25 27 29 31 33 35 50 PIN 37 CONNECTOR 39 41 43 45 47 49

ALL EVEN PINS 2-50 1 3 5 7 9 50 PIN 11 CONNECTOR 13 15 17 19 21 23

43

POWER BARRIER STRIP

Products and specifications subject to change without notice.

Consult factory for application assistance. 204 Airline Drive, Suite 300, Coppell, Texas 75019 / Tel: (800) 677-5311 / FAX: (800) 677-3865 / www.crouzet-usa.com

2-47

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[Change]

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Water Safety & Flow Control

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HOME > Search > N55B

N55B Water Pressure Reducing Valves Size(s) :

1/2 to 1 in. (15 to 25mm)

Description: Series N55B Water Pressure Reducing Valves are used in commercial and residential applications to reduce incoming water pressure for protection of plumbing system components and to reduce water consumption. It consists of a bronze body construction integral stainless steel strainer, thermoplastic seat, bronze sealed spring cage for waterworks pit installations and thermal expansion bypass. The N55B is available with either threaded, solder, PEX or CPVC end connections. Maximum Working Pressure: 400psi (27.6 bar), Adjustable Reduced Pressure Range: 25 to 75psi (172 to 517 kPa), Standard Pressure Setting: 50psi (345 kPa).

Model/UPC Code UPC 098268204728

Part # 0008235

Description 3/4 N55B G M1

OEM Division

ES-N55B

For Residential and Commercial Applications Job Name

–––––––––––––––––––––––––––––––––––––––––––

Contractor ––––––––––––––––––––––––––––––––––––––––––––

Job Location –––––––––––––––––––––––––––––––––––––––––

Approval

Engineer –––––––––––––––––––––––––––––––––––––––––––––

Contractor’s P.O. No. –––––––––––––––––––––––––––––––––––

Approval –––––––––––––––––––––––––––––––––––––––––––––

Representative

–––––––––––––––––––––––––––––––––––––––––––––

––––––––––––––––––––––––––––––––––––––––

Series N55B-M1 Water Pressure Reducing Valves*

N55BU-M1

Sizes: 1/2" – 1" (15 – 25mm) Series N55B-M1 Water Pressure Reducing Valves are designed to reduce incoming water pressure to a sensible level to protect plumbing system components and reduce water consumption. This series is suitable for water supply pressures up to 400psi (27.6 bar) and may be adjusted from 25 to 75psi (172 – 517kPa). The standard setting is 50psi (345kPa). All parts are quickly and easily serviceable without removing the valve from the line. The standard bypass feature permits the flow of water back through the valve into the main when pressures, due to thermal expansion on the outlet side of the valve, exceed the pressure in the main.

Features • Double union inlet & outlet connections (option DU) • Integral stainless steel strainer • Thermoplastic seat • Bronze body construction • Serviceable in line • Bypass feature controls thermal expansion pressure** • Sealed spring cage on all models for waterworks pit installations

Models N55B-M1 N55BU-M1 N55BU-S-M1 N55BDU-M1 N55BDU-S-M1 N55BDU-PEX-M1 N55BDU-CPVC-M1

NPT threaded female inlet x NPT female outlet NPT threaded union inlet x NPT female outlet Solder union inlet x NPT female outlet Double Union – NPT threaded union female inlet and outlet Double Union – Solder union inlet and outlet Double Union – PEX union inlet and outlet Double Union – CPVC union inlet and outlet

Reinforced Diaphragm

Threaded, solder, PEX or CPVC ends

Thermal Expansion Bypass

Integral Stainless Steel Strainer

Thermoplastic Seat

Specifications Standard Specifications: A Water Pressure Reducing Valve with integral strainer shall be installed in the water service pipe near its entrance to the building where supply main pressure exceeds 60psi (413 kPa) to reduce it to 50psi (345 kPa) or lower. The valve shall feature a bronze body suitable for water supply pressures up to 400psi (27.6 bar). Provision shall be made to permit the bypass flow of water around the valve back into the main when pressures, due to thermal expansion on the outlet side of the valve, exceed the pressure in the main. Water Pressure Reducing Valve with built-in bypass check valves will be acceptable. Approved valve shall be listed to ASSE 1003 and IAPMO and certified to CSA B356. Valve shall be a Watts Regulator Company Series N55B-M1. * A water saving test program concluded that reducing the supply pressure from 80 – 50psi (551 – 346kPa) resulted in a water savings of 30%. ** Bypass will not work if inlet pressure is above 150psi (10.34 bar).

Lead Free Specifications: A Water Pressure Reducing Valve with integral strainer shall be installed in the water service pipe near its entrance to the building where supply main pressure exceeds 60psi (413 kPa) to reduce it to 50psi (345 kPa) or lower. The valve shall feature a bronze body where suitable for water supply pressures up to 400psi (27.6 bar). The combined metal components of the valve contacted by potable water shall contain less than one half of one percent (0.5%) lead by weight. Provision shall be made to permit the bypass flow of water around the valve back into the main when pressures, due to thermal expansion on the outlet side of the valve, exceed the pressure in the main. Water Pressure Reducing Valve with built-in bypass check valves will be acceptable. Approved valve shall be listed to ASSE 1003 and IAPMO and certified to NSF 61-8 and CSA B356. Valve shall be a Watts Regulator Company Series LF N55B-M1.

Watts product specifications in U.S. customary units and metric are approximate and are provided for reference only. For precise measurements, please contact Watts Technical Service. Watts reserves the right to change or modify product design, construction, specifications, or materials without prior notice and without incurring any obligation to make such changes and modifications on Watts products previously or subsequently sold.

Materials

Capacity Bronze Thermoplastic Bronze Stainless steel Reinforced EPDM Elastomer

Pressure Drop

Body: Seat: Cage: Integral Strainer: Diaphragm: Valve Disc:

Pressure — Temperature Temperature Range: 33°F – 180°F (5°C – 82°C) Maximum Working Pressure: 400psi (27.6 bar) Adjustable Reduced Pressure Range: 25 – 75psi (172 – 517kPa) Standard Reduced Pressure Setting: 50psi (345kPa)

Standards

kPa

psi

0

0

34.5

5

68.9

10

103.4

15

137.8

20

172.3

3

⁄4 " 20mm 1 ⁄2" 15mm

25

Meets requirements of ASSE Standard 1003; (ANSI A112.26.2) and CSA Standard B356. Certified by NSF to ANSI/NSF Standard 61-8 (LF N55B-M1 Models only). Listed by IAPMO and City of Los Angeles.

1" 25mm

0 0

10 37.3

20 75.7

30 113.6

40 gpm 151.4 lpm

Flow

Options Add Suffix

G GG LP

Gauge tapping Gauge tapping and 160psi (11 bar) gauge Low Pressure Range 10-35psi (69-241kPa)

FNPT

Add Preffix

Lead Free† construction

LF †

The combined metal components of this product contacted by potable water contain less than one half of one percent (0.5%) of lead by weight.

ENPT

Dimensions – Weights

FSWEAT

ESWEAT FPEX C FEMALE NPT THREAD BOTH ENDS OF BODY

EPEX FCPVC D A A+E A+E+E

G

ECPVC

ABOVE VALVE SHOWN WITH SINGLE NPT UNION CONNECTION ON INLET VALVES MAY BE ORDERED WITH 0,1,OR 2 UNION CONNECTIONS USING ANY COMBINATION OF NPT, SOLDER, PEX OR CPVC CONNECTIONS REQUIRED “F” DIMENTIONS ARE APPROXIMATE ENGAGEMENT LENGTHS.

SIZE (DN)

DIMENSIONS A

in. 12

⁄ ⁄ 1

34

mm

in.

C mm

7 16

in. 9 16

D mm

in. 11 16

mm

15 3 / 88 4 ⁄ 116 1 ⁄ 43 20 37/16 88 49⁄16 116 111⁄16 43 25 41/8 105 49⁄16 116 111⁄16 43

ENPT in. mm

ESWEAT in. mm

58

5 8 7 8

⁄ / /

5 8 3 4

16 16 20

/ / 1

Water Safety & Flow Control Products

ES-N55B

0608

15 21 26

EPEX in. 13 16 15 16

/ /

11⁄8

mm

WEIGHT ECPVC in. mm 9 16 13 16

21 / 15 24 / 21 29 11/16 26

FNPT in. 1 2 9 16

mm

/ 13 / 14 11/16 17

FSWEAT in. mm

in.

1 2 3 4

5 8 5 8

/ 13 / 19 15/16 23

FPEX mm

/ 16 / 16 13/16 21

FCPVC in. mm 12

G in.

mm

lbs

kg

14

⁄ 13 2 ⁄ 57 1.5 .68 ⁄ 18 21⁄4 57 1.5 .68 15⁄16 23 21⁄4 57 1.75 .79 34

USA: 815 Chestnut St., No. Andover, MA 01845-6098; www.watts.com Canada: 5435 North Service Rd., Burlington, ONT. L7L 5H7; www.wattscanada.ca

© Watts Regulator Company, 2006

IS-N55B-M1

Watts Series N55B-M1 1 ⁄2" - 1" (15-25mm)

Installation Instructions 1. The valve should be installed by a licensed contractor in accordance with local codes and ordinances. This valve should be installed where it is accessible with sufficient clearance for cleaning, service, or adjustment. 2. Before installing the valve, be sure that the pipe ends are reamed and threads are cut to size. For valves with Quick-Connect tailpieces refer to "Quick-Connect Installation" instructions below. 3. Flush the lines to remove all loose scale, dirt and other foreign matter that can damage or clog the valve.

N55BU-M1

4. Install the regulator with the arrow on the body pointing in the direction of the flow. 5. Regulator may be installed vertically or horizontally (upright or inverted). 6. Start Up — Open cold water supply then hot water supply. Inspect for leaks. Note: The valve should be inspected annually to assure maximum life and performance.

N55BDU-QC-M1

Quick-Connect Installation

Typical Installation TO SILL COCK

To Connect

WATTS PRESSURE GAUGE (2 PLACES)

11/2 in. (38.1mm) 1

/2 in.Pipe (12.7mm)

WATER METER SUPPLY

WATTS SHUTOFF VALVE (2 PLACES)

3

1 /4 in. (44.45mm) WATTS BACKFLOW PREVENTER

WATTS PRESSURE REGULATOR

TO FIXTURES 3

/4 in.Pipe (19.05mm)

17/8 in. (47.63mm)

Series Installation

1 in.Pipe (25.4mm)

Series installations are recommended where very high supply pressure must be reduced to a very low downstream pressure. Reducing the pressure in stages eliminates whistling and noise.

1. Mark pipe as shown. This is pipe insertion depth.

TO SILL COCK

PEX tubing only WATTS PRESSURE GAUGE (2 PLACES)

2. Clean pipe end.

Collet clip

WATER METER SUPPLY

WATTS SHUTOFF VALVE (2 PLACES)

WATTS BACKFLOW PREVENTER

TO FIXTURES

WATTS PRESSURE REGULATORS (2 PLACES)

Pipe Stiffener

Parallel Installation

Mark

Tail Piece

3. If using PEX tubing, insert pipe stiffener (provided) into end of pipe.

4. Push tubing into tailpiece up to mark. 5. Insert collet clip.

To Disconnect

TO SILL COCK

Parallel installations are recommended where high flow or low flow demand is intermittent/occasional. They are also used for installations where service cannot be interrupted. WATTS PRESSURE GAUGE ( 2 PLACES )

WATER METER SUPPLY

WATTS SHUT-OFF VALVE ( 6 PLACES )

WATTS BACKFLOW PREVENTER

WATTS PRESSURE REGULATOR ( 2 PLACES )

TO FIXTURES

Collet depressed

1. Remove collet clip.

2. Depress collet. 3. Pull tubing from tailpiece.

Maintenance Instructions

SEAT/STEM MODULE

• To clean strainer or replace seat/stem module shut off supply, loosen Locknut and Lock Seal and back off Adjusting Screw. • Remove Spring Cage, Spring, Washer and Slip Ring. Grasp Stem Nut with fingers or pliers and lift module from body. • Replace module and reassemble valve.

Stem Nut Adjusting Screw Lock Nut Lock Seal

Strainer

Spring Washer

• Readjust pressure setting.

Adjustment

Spring Spring Cage

Regulator is factory preset to 50psi (344 kPa). To adjust pressure setting, loosen the lock nut and turn the adjusting bolt clockwise to increase pressure, counter clockwise to decrease pressure.

Stem Nut Slip Ring

Note: Use a pressure gauge downstream to adjust and verify the pressure setting.

Seat/Stem Module

By-Pass Feature*

Strainer

This regulator has a built-in thermal expansion by-pass feature. This feature prevents downstream pressure from rising to more than 10psi above the supply pressure. * By-Pass will not work if inlet pressure is above 150psi (10.3 bar).

Troubleshooting Repair Kit

High System Pressure If the downstream system pressure is higher than the set pressure under no flow conditions, the cause could be thermal expansion, pressure creep or dirt/debris on the seat.

KIT NO. 1 ⁄2 – 1 N55B-RK

Thermal expansion occurs whenever water is heated in a closed system. The system is closed when supply pressure exceeds 150psi, or a check valve or backflow preventer is installed in the supply piping.

in.

SIZE mm

ORDERING CODE

KIT INCLUDES

⁄2, 3⁄4, 1

15, 20, 25

0007723

Seat/Stem Module

1

You must make provisions for pressure relief protection of your plumbing system and components. The use of a relief valve such as the Watts 530C, BRV, Governor 80, or 3L or potable water expansion tank such as the Watts DET, PLT or DETA may be required. To determine if this is the result of thermal expansion, try briefly opening the cold water tap. If the increased pressure is caused by thermal expansion, the pressure will immediately be relieved and the system will return to the set pressure. Watts offers a pressure test gauge, model 276H300 to assist you in determining if you have high water pressure. Watts 276H300 The 276H300 when attached to a hose bibb registers the highest pressure reading over the period of time it is left on the system.

Limited Warranty: Watts Regulator Company warrants each product to be free from defects in material and workmanship under normal usage for a period of one year from the date of original shipment. In the event of such defects within the warranty period, the Company will, at its option, replace or recondition the product without charge. This shall constitute the sole and exclusive remedy for breach of warranty, and the Company shall not be responsible for any incidental, special or consequential damages, including without limitation, lost profits or the cost of repairing or replacing other property which is damaged if this product does not work properly, other costs resulting from labor charges, delays, vandalism, negligence, fouling caused by foreign material, damage from adverse water conditions, chemical, or any other circumstances over which the Company has no control. This warranty shall be invalidated by any abuse, misuse, misapplication or improper installation of the product. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties that are imposed by law are limited in duration to one year. Some States do not allow limitations on how long an implied warranty lasts, and some States do not allow the exclusion or limitation of incidental or consequential damages. Therefore the above limitations may not apply to you. This Limited Warranty gives you specific legal rights, and you may have other rights that vary from State to State. You should consult applicable state laws to determine your rights.

Water Safety & Flow Control Products

IS-N55B-M1

0730

USA: 815 Chestnut St., No. Andover, MA 01845-6098; www.watts.com Canada: 5435 North Service Rd., Burlington, ONT. L7L 5H7; www.wattscanada.ca

EDP# 1915391

©Watts Regulator Co., 2007

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owner's manual - Oasis Car Wash Systems

OWNER’S MANUAL OASIS CAR WASH SYSTEMS 800-892-3537 · www.oasiscarwashsystems.com Installation Revised 04/01/08 1.3 Installation Revised 04/01/...

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