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Belanger® Equipment Owners Manual

DuraFlo™ 18 GPM Pumping Stations

Copyright 2013

Belanger, Inc

®

This manual and the accompanying equipment are protected by United States trademark, copyright, and patent laws. You
may make one copy of this manual. Do not make additional copies of this manual or electronically transmit it in any form
whatsoever, in whole or in part, without the prior written permission of Belanger, Inc.

®

The registered trademarks used in this document are the property of their respective owners. The use of such trademarks is
for reference purposes only and does not imply sponsorship or approval of Belanger, Inc.

®

by these companies or any

companies affiliated with their respective owners.

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Summary of Contents for DuraFlo

Page 1: ...Box 5470 Northville MI 48167 5470 Customer Service Phone 248 349 7010 Fax 248 380 9681 www Belangerinc com 18 GPM 18 GPM 18 GPM 18 GPM Pumping Stations Pumping Stations Pumping Stations Pumping Stations DuraFlo DuraFlo DuraFlo DuraFlo ...

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Page 3: ...make additional copies of this manual or electronically transmit it in any form whatsoever in whole or in part without the prior written permission of Belanger Inc The registered trademarks used in this document are the property of their respective owners The use of such trademarks is for reference purposes only and does not imply sponsorship or approval of Belanger Inc by these companies or any c...

Page 4: ......

Page 5: ...ted Limited Warranty 3 Operational Warning 4 Important Safety Information 5 Safety Symbols and Signal Words 5 IMPORTANT Safety Information MUST READ 6 Safety Warnings 7 Introduction 8 Specifications 9 Requirements 9 Operating Envelope Dimensions 10 Connections Overview 11 Assembly 12 Installation 14 Initial Startup 14 Plumbing Overview 15 Pipe System Overview 15 ...

Page 6: ...10 Fax 248 380 9681 1MANUL375 Table of Contents Maintenance 18 Routine Procedures 18 Powder Coating Maintenance 19 Trouble Shooting Guide 22 Drive Belt Replacement and Tightening 23 Pumping Station Float Valve Seal Replacement Kit 105884 26 Replacement Parts 36 Hydra Cell Industrial Pump Manual 39 ...

Page 7: ...ty Hydrofluoric Acid Ammonium Bi flouride Bromic Acid Muriatic Acid Sulfonic Acid Phosphoric Acid Hydrogen Cyanide Hydrochloric Acid Sodium Hydroxide and Chlorinated Solvents 5 Seller makes no warranty express or implied with respect to the design or operation of any entire system in which Seller s goods sold hereunder are mere components 6 In no event shall Seller be liable for any incidental spe...

Page 8: ...agraph 8 Limited Warranty of the Belanger Terms and Conditions of Sales describes the potential limitation of warranty due to your chemical selection 4 This warranty shall be void for all equipment failures and premature component wear caused by the use of corrosive chemicals in the wash process The following list includes some but not all of the particularly corrosive chemicals that if used in co...

Page 9: ...ignal words used in this manual and on warning labels tell you the seriousness of particular safety hazards The precautions that follow must be followed to prevent death injury or damage to the equipment This signal word is used to alert you to a hazard or unsafe practice which WILL RESULT IN DEATH OR SERIOUS INJURY This alerts you to a hazard or unsafe practice which COULD RESULT IN DEATH OR SERI...

Page 10: ...release of hazardous energy while employees perform servicing and maintenance activities The standard outlines measures for controlling hazardous energies electrical mechanical hydraulic pneumatic chemical thermal and other energy sources Note Reference the OSHA standard 29 CFR 1910 331 to 29 CFR 1910 335 for safe work practices to protect employees working on electrical circuits and equipment Thi...

Page 11: ...Y OVERHEAD ROTATING AND OR MOVING COMPONENTS COULD RESULT IN SERIOUS INJURY OR DEATH BE AWARE OF FOREIGN OBJECTS IN THE AREA SURROUNDING A ROTATING PIECE OF EQUIPMENT OBJECTS MAY BECOME TANGLED WITH EQUIPMENT AND COULD RESULT IN SERIOUS INJURY OR DEATH BE AWARE OF HAZARDS ASSOCIATED WITH EQUIPMENT INSTALLED ON THE FLOOR THAT MAY BE A TRIP HAZARD It is imperative to your safety and the safety of ot...

Page 12: ...lity Another benefit of the industrial duty motors is the pre lubricated double shielded oversized bearings to accommodate varying belt loads and tensions The industrial duty motor also provides a high efficiency energy design This design uses class F copper windings that allow the motor to operate at higher temperatures than normal and still maintain durability The DuraFlo product line has the tr...

Page 13: ...et Size 1 NPT 100 psi Max Water Inlet Pressure Outlet Size 18 GPM 1 MJIC Weight With 10 hp 545 Lb Dry or With 15 hp 685 Lb Dry DISCONNECT AND LOCKOUT ELECTRICAL POWER AND DISSIPATE ANY OTHER POTENTIALLY HAZARDOUS ENERGY SOURCES ACCORDING TO 29 CFR 1910 147 AND THE EXAMPLE PROVIDED IN 1910 147 APPENDIX A BEFORE SERVICING ANY EQUIPMENT Always wear safety glasses when performing maintenance on any eq...

Page 14: ...0 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Specifications Operating Envelope Dimensions Note Be sure to leave adequate space around the DuraFlo pumping station to allow for service and maintenance on the belts pump and motor 21 65 34 ...

Page 15: ...sing the wash Pumping Station Water Inlet 1 NPT F into bulkhead Max Inlet Pressure 100 psi Inlet Float Valve 3 4 NPT F Valve 50 GPM 60 PSI Tank Overflow Port 1 barbed hose fitting to drain Pumping Station Bypass Line Pump Inlet Hose 2 ID x 2 3 8 OD Pressure Relief Unloader Valve Outlet 1 2 Plug Pumping Station Water Outlet 1 MJIC Pump Inlet Hose 2 ID x 2 3 8 OD Pressure Relief Unloader Valve Inlet...

Page 16: ...feed line Install the connection to the float valve inlet 3 4 FNPT with flexible hose Note At the fluid inlet a minimum 1 feed to the float valve is required Recommended 1 barbed hose fittings field supplied Main water feed typically 2 3 4 flexible hose required field supplied Reducer field supplied Shut off valve field supplied Recommended 1 minimum 3 4 copper copper field supplied Outlet plumbin...

Page 17: ...e from the unloader valve to any hard piping solenoid or tees Hose MUST be rated for a minimum pressure of 1500 PSI Remember that the plumbing has direct bearing on pressure at the nozzle massive pressure drops are common to an incorrectly installed system 3 Install 3 phase wiring in accordance with any and all local and national codes direction is reversible Use caution this machine starts automa...

Page 18: ...e Wanner Hydra Cell section in this manual for the initial startup procedures for the pump 3 Verify that the water inlet valve flow rate is set correctly and does not exceed 100 psi 4 Verify that all hose fittings and clamps are tight 5 Flush out the component that is connected to the DuraFlo pumping station before installing any nozzles Note Check the drive belt tension after the first 8 hours of...

Page 19: ...PM 113 5 LPM 1 81 125 1 0 31 0 68 047 7 3 2 23 40 GPM 151 4 LPM 3 04 21 14 7 4 48 1 15 079 9 8 2 99 0 51 035 7 0 2 13 Note Velocity should not exceed 15 feet 4 6 meters per second in a correctly installed system 1 2 13 mm 3 4 19 mm 1 25 4 mm 1 1 4 31 8 mm 1 1 2 38 1 mm 2 50 8 mm Tee side 4 1 2 5 1 5 6 1 8 7 2 1 8 2 4 12 3 7 90oF Ell 23oC Ell 1 1 2 5 2 6 2 3 4 8 4 1 2 4 1 2 6 1 8 45oF Ell 11oC Ell ...

Page 20: ... 5 LPM 3 57 246 15 1 4 6 1 27 088 9 8 2 99 0 49 034 6 5 1 98 40 GPM 151 4 LPM 2 11 145 13 0 3 96 0 81 056 8 8 2 68 Note Velocity should not exceed 15 feet 4 6 meters per second in a correctly installed system 1 2 13 mm 3 4 19 mm 1 25 4 mm 1 1 4 31 8 mm 1 1 2 38 1 mm 2 50 8 mm Tee side 4 1 2 5 1 5 6 1 8 7 2 1 8 2 4 12 3 7 90oF Ell 23oC Ell 1 1 2 5 2 6 2 3 4 8 4 1 2 4 1 2 6 1 8 45oF Ell 11oC Ell 3 4...

Page 21: ... GPM 113 5 LPM 2 18 150 12 3 3 75 0 32 022 5 4 1 65 40 GPM 151 4 LPM 3 61 249 16 3 4 97 0 52 036 7 3 2 23 Note Velocity should not exceed 15 feet 4 6 meters per second in a correctly installed system 1 2 13 mm 3 4 19 mm 1 25 4 mm 1 1 4 31 8 mm 1 1 2 38 1 mm 2 50 8 mm Tee side 4 1 2 5 1 5 6 1 8 7 2 1 8 2 4 12 3 7 90o F Ell 23o C Ell 1 1 2 5 2 6 2 3 4 8 4 1 2 4 1 2 6 1 8 45o F Ell 11o C Ell 3 4 2 1 ...

Page 22: ...ses Verify that all nozzles are clean and free of debris in the orifice Check all hoses for leaks Verify the operation of the float valve Remove any large debris or objects that may constrict or block the inlet screen from the holding tank Weekly Check belt tension Check whether the belts are worn or have a tendency to slip Replace belts Belanger Part No 1BELT595 for the 10 HP Pump Station and 1BE...

Page 23: ...ose dirt or debris DO NOT use a power washer or high pressure water as this can wear and cause harm to the powder coated surface 2 Using a mild detergent and warm water clean the powder coat surface with a soft cloth sponge or a soft natural bristle brush DO NOT use water heated to a temperature above 140 F as this can wear and cause harm to the powder coated surface 3 Rinse the sponge or soft bru...

Page 24: ...Clean the surface by washing it with a detergent and a non scratch scrub sponge Use a solution of warm water and non abrasive pH neutral pH 5 8 detergent to clean material prior to painting Thoroughly rinse and dry the surface If solvents are needed to remove marks a soft cloth dampened with Isopropyl Alcohol may be used Solvents containing esters ketones or chlorinated solvents must not be used w...

Page 25: ... paint at each end of the stroke Patience On a warm day if each coat has been allowed to dry before the next application it should be possible to rub the paint down after about 30 minutes If it starts to drag and ball the paint leave it to dry further It will now have to be rubbed right back to a smooth surface again which may take another hour More patience is required The thinner the coats of pa...

Page 26: ...bration in tank Inadequate fluid level in tank Shut off machine to allow fluid to cool off Purge airlines to remove bubbles Make sure tank is sitting level Increase fluid level Drop in volume or pressure Air leak in suction line Worn un loader valve Empty supply tank Slipping drive belt Worn Low Level Switch Replace suction lines Replace un loader valve Belanger Part No 1VALVE WA715 Refill fluid s...

Page 27: ... two bolts on the pivot side A1 and A2 and two bolts on the adjustment side B1 and B2 NOTE For steps 4 and 5 see the image below 4 Loosen the adjustment Jam Nut C 5 To replace the belts lower the adjustment screw D with one wrench while holding nut E with another wrench A2 Pivot Back Side B2 Adjustment Front Side A1 Pivot Back Side B1 Adjustment Front Side The Above Image is a LOWER RIGHT View Bol...

Page 28: ... shown below NOTE NOTE THE PUMP STATION USES BX STYLE BELTS A 4 2 SMALL PULLEY AND 860 2500 RPM MOTOR THE PULLEY SPAN IS 14 THESE NUMBERS CROSS REFERENCE TO 7 2 LB BELT TENSION FOR NEW BELTS AND 4 9 LB FOR USED BELTS ON THE GOODYEAR CHART SUPPLIED WITH THE TENSION GAUGE Span Scale set this o ring at 14 Deflection Force Scale 5V 5VX 4 4 6 7 1750 3000 8 8 3001 4000 500 1749 5 6 10 2 13 2 8 5 15 2 B ...

Page 29: ...deflection force scale 12 At this point the back belt tension should read 7 lbs for a new belt or 5 lbs for a used belt 13 Tighten bolt B2 and rotate the large pump pulley CCW 2 turns 14 Tighten adjustment screw D until the front belt is at 7 lbs for a new belt or 5 lbs for a used belt 15 Tighten fasteners B1 A1 and B2 16 Check the tension of the other belts It should be 7 2lbs for a new belt or 5...

Page 30: ...llowing Kit Includes the Parts Shown Below Qty Description Image 1 Teflon Cup 1 Standard Disc 1 Top Follower Required Tools Description Example Remarks 1 2 Open End Box Wrench Needle Nosed Pliers 12 Adjustable Wrench Removing the Existing Stem Assembly 1 Remove the Float Rod by removing the Cap Screw from the Float Rod Connector using a 1 2 wrench 2 Remove the Down Spout Float Rod Down Spout Cap S...

Page 31: ... Bulkhead fitting on the tank 4 Remove the two upper pins and Cotter Pins Remove the pin that connects the Link to the Lever and the pin that connects the Lift to the Lever 5 Loosen the Jam Nut and remove the Lift from the Stem then remove the Jam Nut from the Stem 6 Loosen the Lock Nut from the Bonnet and remove the nut and the Swivel Yoke Lever Lift Cotter Pins Upper Pins Link Loosen this Jam Nu...

Page 32: ...Existing Stem Assembly 7 Using an adjustable wrench loosen and remove the Bonnet 8 Slide the Stem Assembly out from the Valve Body Disassemble the Stem Assembly Components 1 Loosen and remove the Stem as shown by the dotted arrow Doing so will free the Cup Seal and Top Follower Discard the old Cup Seal but keep the Top Follower Loosen the Bonnet from here Bonnet Stem Assembly Body Top Follower Cup...

Page 33: ...mponents 2 Loosen then remove the Bottom Follower and black Standard Disc Discard the old Standard Disc Reassemble the Stem Assembly Components 1 Install the new Standard Disc and tighten the Bottom Follower onto the Piston OLD Stem Assembly Black Leather Cup OLD Style Top Follower Flat Surface NEW Stem Assembly White Teflon Cup NEW Style Top Follower Extruded Surface Standard Disc Bottom Follower...

Page 34: ... Fax 248 380 9681 1MANUL375 Maintenance Pumping Station Float Valve Seal Replacement Kit 105884 Reassemble the Stem Assembly Components 2 Install the new Teflon Cup Top Follower and Stem as shown below tighten them into position Teflon Cup Seal with Extruded Top Follower Standard Disc Bottom Follower ...

Page 35: ...lle MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 31 Maintenance Pumping Station Float Valve Seal Replacement Kit 105884 Reassemble the Valve with a Rebuilt Stem Assembly 1 Insert a rebuilt Stem Assembly 2 Re install the Bonnet and tighten it into place Bonnet Stem Assembly ...

Page 36: ... Float Valve Seal Replacement Kit 105884 Reassemble the Valve with a Rebuilt Stem Assembly 3 Re install the Swivel Yoke and Lock Nut and then tighten them both into place 4 Re install the Jam Nut and the Lift and then tighten them both into place 5 Re install the Lever Pins and Cotter Pins Jam Nut Lift Nut Upper Pins Cotter Pins Lever Swivel Yoke Lock Nut ...

Page 37: ...8 349 7010 Fax 248 380 9681 33 Maintenance Pumping Station Float Valve Seal Replacement Kit 105884 Reassemble the Valve with a Rebuilt Stem Assembly 6 Re install the valve to its location on the tank 7 Re install the Down Spout 8 Re install the Float Rod and Cap Screw Cap Screw Float Rod Down Spout ...

Page 38: ... and best operation of the valve it is suggested that the Float Arm Assembly be set to a 45 or slightly greater angle The valve will not operate properly with the arm at a 90 angle If the Down Tube extends below the surface of the liquid the valve may become air bound and not close properly A small drilled hole approximately 1 8 has been drilled in the lower neck of the valve body above the thread...

Page 39: ...Loosen the Lock Nut shown below and rotate the Float Arm until it is properly centered 2 Tighten the Lock Nut General The valve should be inspected at regular intervals to ensure that it works freely and has not been clogged by residue from the solution in the tank especially if it has not been used on a regular basis Minor leakage is acceptable between the Stem and Bonnet when the valve is operat...

Page 40: ...1MANUL375 Maintenance Replacement Parts Pumping Station Overview Frame Assembly 110445 110444 Included as part of Frame Assembly 110445 1WASHR FL706 4 1FSTNR HH522 4 1WASHR LC456 4 1CAP084 6 102373 1WASHR FL810 2 1NUT JM333 2 1CAP152 6 1CAP084 6 1CAP152 6 Mount the Unloader Valve Here Part Number 110446 1FSTNR ST500 2 ...

Page 41: ...970 1BLKHD PL760 1ELECT SW550 1RSRVR852 TANK 1BLKHD PL765 1ELBOW PL970 101865 1RSRVR852 TANK 1BLKHD PL760 1ELBOW BR390 1SCREN450 1NIPPL PL865 101865 1CLAMP933 4 1HOSE875 36 1PUMP937 1FTTNG BH833 1PLUG BR691 1NIPPL BR934 9436 1ELBOW BR508 1MCONC BR757 110448 1ELBOW BR390 1MCONC BR710 1CLAMP922 2 1REDUC BR275 1ELBOW BR363 1GAUGE821 1WASHR FL415 4 1NUT LC212 4 1VALVE WA715 1CLAMP295 2 1FSTNR SH413 4 ...

Page 42: ...C216 4 KEYSTOCK 10 HP 5 16 SQUARE X 2 3 8 LONG 15 HP 3 8 SQUARE x 2 7 8 LONG 1PUMP937 KEYSTOCK 1 4 SQUARE X 1 13 16 LONG 1RETNR670 14 1WASHR FL185 14 1WASHR LC115 14 1FSTNR SH058 14 1PLSTC GD112 1BELT595 2 10 HP 1BELT598 2 15 HP 1PULLY545 1BSHNG954 10 HP 1BSHNG956 15 HP 1BSHNG626 1PULLY788 1DECAL083 1PLSTC GD110 ATTACH THE MOTOR TO FRAME HERE 4 ATTACH PART NUMBER 1PUMP937 TO FRAME HERE 4 ATTACH PA...

Page 43: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 39 Hydra Cell Industrial Pump Manual ...

Page 44: ...DURAFLO 18 GPM PUMPING STATIONS 40 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 45: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 41 Hydra Cell Industrial Pump Manual ...

Page 46: ...DURAFLO 18 GPM PUMPING STATIONS 42 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 47: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 43 Hydra Cell Industrial Pump Manual ...

Page 48: ...DURAFLO 18 GPM PUMPING STATIONS 44 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 49: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 45 Hydra Cell Industrial Pump Manual ...

Page 50: ...DURAFLO 18 GPM PUMPING STATIONS 46 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 51: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 47 Hydra Cell Industrial Pump Manual ...

Page 52: ...DURAFLO 18 GPM PUMPING STATIONS 48 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 53: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 49 Hydra Cell Industrial Pump Manual ...

Page 54: ...DURAFLO 18 GPM PUMPING STATIONS 50 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 55: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 51 Hydra Cell Industrial Pump Manual ...

Page 56: ...DURAFLO 18 GPM PUMPING STATIONS 52 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 57: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 53 Hydra Cell Industrial Pump Manual ...

Page 58: ...DURAFLO 18 GPM PUMPING STATIONS 54 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 59: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 55 Hydra Cell Industrial Pump Manual ...

Page 60: ...DURAFLO 18 GPM PUMPING STATIONS 56 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 61: ...DURAFLO 18 GPM PUMPING STATIONS 1MANUL375 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 57 Hydra Cell Industrial Pump Manual ...

Page 62: ...DURAFLO 18 GPM PUMPING STATIONS 58 Belanger Inc PO BOX 5470 Northville MI 48167 5470 Ph 248 349 7010 Fax 248 380 9681 1MANUL375 Hydra Cell Industrial Pump Manual ...

Page 63: ......

Page 64: ...DuraFlo 18 GPM Pump Stations 1MANUL375 Belanger Inc P O Box 5470 Northville MI 48167 5470 Customer Service Phone 248 349 7010 Fax 248 380 9681 ...

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