CAT Pumps 280, Installation And Start-Up Information

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TORQUE CHART
Pump Item Torque
Pump Model Thread Tool Size [P/N] in. lbs. ft. lbs. Nm
PISTON ROD NUT
284 ...................................M4 M8 Hex [25052] 25 2.0 3
280, 290, ..........................M6 M10 Hex [25082] 55 4.4 6
323, 333, 390,
430, 10 FR
1020, 1520, 2020 .............M7 M10 Hex [25082] 115 9.4 13
25 FR ...............................M8 M13 Hex [25324] 115 9.4 13
6020, 6040 ......................M14 M24 Hex [44046] 390 32.5 44
6024, 6044 ......................M10 M17 Hex [25083] 220 18.1 25
MANIFOLD STUD/NUT AND CYLINDER BOLTS
280, 284, 290, ..................M8 M12 Hex 115 9.4 13
323, 333, 390,
430
10 FR ..............................M10 M17 Hex [25083] 220 18.1 25
25 FR ..............................M12 M19 Hex 350 28.9 39
6020, 6024, .....................M16 M24 Hex [44046] 565 47.0 64
6040, 6044
BUBBLE OIL GAUGE
........................................M28 Oil Gauge Tool [44050] 45 3.6 5
MOUNTING SCREWS
280, 290, 333, 430 ...........M8 M13 Hex [25324] 100-115 8.3-9.5 12-13
520, 623, 820, 1010 ........M10 M17 Hex [25083] 205 17.1 24
25 FR ..............................M12 M19 Hex 285-345 23.7-28.8 34-40
CONNECTING ROD SCREWS
3 FR, 4 FR, 5 FR..............M7 M10 Hex [25082] 95 7.96 11
10 FR, 25 FR ...................M8 M13 Hex [25324] 130 10.8 15
60 FR ..............................M10 M17 Hex [25083] 390 32.5 44
INLET CONDITION CHECK-LIST
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 40 PSI (2.8 BAR).
Negative suction up to –8.5 PSI (–0.5 BAR) can be achieved with optimum
plumbing conditions.
❏
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
on the pump inlet line.
❏
Inspect and clean inlet filters on a regular schedule to avoid flow restriction.
❏
A pressure gauge is recommended to monitor the inlet pressure and should be
mounted AS CLOSE TO THE PUMP INLET as possible. Short term, intermittent
cavitation will not register on a standard gauge. A pressure transducer is
necessary to accurately read inlet pressure.
❏
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 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.
TECHNICAL BULLETIN REFERENCE CHART
No. Subject Models
001 Long to Short Cylinders 10FR
002 Inlet Pressure VS Liquid Temperature All Models
003 Power Unit Drive Packages 3PFR - 68PFR, 10FR - 60FR
005 “B” Manifold and Stepped Valve Seat 10FR
008 Motor Pulley Selection Chart 3PFR - 15PFR, 3FR - 25FR
009 Piston Rod and Seal 25FR
012 Sleeve-Type Piston Pump V-Packing Inserters 3FR, 4FR, 10FR, 25FR, 60FR
016 Bac-Cup Piston Assemblies 290, 323, 333, 430, 623
017 Shimming of Discharge Manifolds 3FR, 4FR, 10FR, 25FR
020 Quiet Valve Kits 280, 333, 430, 623, 820, 1010
021 Piston Rod, Sleeve and Seal 1020, 1520, 2020, 2520
024 Lubrication of Lo-Pressure Seals All Models
025 Four Screw Crankcase Cover 333 and 430
026 Threaded Style Oil Gauge and Crankcase Cover 280, 290, 333, 430, 10FR
030 Flanged Nut Discharge Manifold 280, 323, 333, 390, 430
033 Crankcase and Rear Cover 270, 279, 280, 290
034 Servicing Crankcase Section 3FR, 4FR, 10FR, 25FR
036 Cylinder and Plunger Reference Chart All Models
037 Machined Piston Assembly 323, 333, 623
038 Blue Dot Seal and Wick 323, 4FR, 10FR
039 Flat Valves VS Quiet Valves 390
042 Four Screw Crankcase Cover 623, 820, 1010
063 Hi-Temp, Cooled Inlet Renamed 2520C
064 By-Pass Hose Sizing All Unloaders/Regulators
074 Torque Chart Piston and Plunger Pumps
077 Oil Drain Kit All Models (except 2SF/4SF)
084 Eye-Bolt Relocation 60FR, 60PFR, 68PFR