BLACKHAWK! V-2 Technical Document

V-2 Pneumatic Piston Pump™
Installation Manual and Operating Instructions
1097 Hill Avenue, Glen Ellyn IL 60137
blackhawkco.com | 630.469.4916

Scan the QR code above to view further
technical data and documentaon for
the V-2 Pneumac Piston Pump

Overview ......................................2
Preinstallation .................................4
1. Unpack..........................................4
2. Gather tools.....................................4
3. Measure the well depth...........................5
4. Uncoil the rod ...................................5
5. Choosing the riser pipe ...........................6
6. Lay out the pump system .........................7
Installation ....................................8
1. Assemble the downhole components ..............8
2. Install the vanstone flange .......................8
3. Lower the pump into the well......................8
4. Inspect the well seal .............................8
5. Lower the piston into the well.....................9
6. Measure length of the rod and cut............... 10
7. Install the top head driver with ferrule and nut.... 12
Start Up ......................................14
1. Turn on the actuator ........................... 14
2. Complete installation .......................... 14
Maintenance ..................................16
Troubleshooting Guide .........................18
Appendix .....................................20
Contents

Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 2
Overview
1
3
2
5
6
7
8
10
9
4
Driver Components:
1.) Piston Cylinder Cap
2.) Manifold
3.) Air Valve
4.) Piston Cylinder
5.) Piston Cylinder Head
6.) Splash Plate
 7.)StungBox
 8.)BrassOilerPlate
 9.)AutoOiler
10.) Driver Rod Connect

PreintstallationInstallationStartupMaintenance
Troubleshooting Guide Preintstallation
Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 3
11
12
13
14
Driver Components:
11.) Drive Piston
12.) Nose Seal
 13.)StungBoxCartridge
14.) Drain Hose
Note: See appendix for individual part numbers

Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 4
Preinstallation
1. UNPACK
a. Verify the shipment has all the necessary materials that were ordered.
If any required material is missing, call [phone].

2. GATHER TOOLS
a. Source all the tools required for

• (2) Pipe wrenches
• Adjustable wrench
• Channel-lock pliers
• Small vice-grip pliers
• 
socket
• (4) Open-end wrenches
⸰
⸰
⸰
⸰
• (1) Allen wrench
⸰6 mm
• Hacksaw
• Measuring tape
• Electrical tape
• Air-cylinder oil
• Teflon-type tape
• Silicone Spray lubricant
• Dark ink marker


• Eye protection
• Gloves
• Additional PPE required by site
regulations and requirements

PreintstallationInstallationStartupMaintenance
Troubleshooting Guide Preintstallation
Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 5
3. MEASURE THE WELL DEPTH
a. Verify the depth of the well and record it.

measuring the riser-pipe length.
4. UNCOIL ROD
 
walking out the coiled rod uncoiling the
rod as you walk.
CAUTION: The rod is under tension, use
gloves and eye protecon when handling
the rod.



6
5
4
7
3
1
2
Piston Assembly Components:
1.) Rod Connect Nut
2.) Rod Connect Ferrule
3.) Piston Rod Connect
 4.)CheckBall
 5.)PistonCage
 6.)PistonTransion
 7.)U-CupSeals(x2)

5. CHOOSING THE RISER PIPE
a. The riser pipe for the pump will be
provided by the customer.
b. The manufacturer recommends
HDPE DR11 tubing for standard
wells or Stainless-Steel pipe for
elevated-temperature sites.
c. Riser pipe diameters and lengths
vary, depending on the customer’s
needs and the depth of the well.
d. The riser pipe can be connected to
the pump system in a number of
ways depending on the type of riser
pipe used and customer preference.
e. The manufacturer can provide these


• Threaded NPT stainless-steel
connections
• Heat butt fuse HDPE connections
• PPE Compression fittings for
HDPE pipe (not recommended
for wells longer than 100 feet in
length)
• NEVER use glued fittings
Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 6
1 2 3
Riser Pipe Connector Types:
1.) NPT Threaded Pipe
 2.)HDPEHeatBuFused
3.) PPE Compression

PreintstallationInstallationStartupMaintenance
Troubleshooting Guide Preintstallation
Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 7
6. LAY OUT THE DOWNHOLE COMPONENTS
OF THE PUMP SYSTEM
a. Lay out the pump system.
b. The well seal will be at the top and a stain-
less-steel pipe nipple will be threaded into


it slips down the well.
 
screen and pump barrel.
⸰If the ID of the riser pipe or the connec-
tions is smaller than the piston’s diameter,
then a pipe nipple will be added to the
top of the pump barrel for maintenance
purposes.
d. The middle gap is where you will connect
the riser pipe. The length of the riser pipe is
dependent on the length of the well, minus
the lengths of the pump barrel and the pipe
nipples provided.

Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 8
Installation
3. LOWER THE DOWNHOLE
COMPONENTS INTO THE WELL
a. Carefully slide the pump barrel into the well,


 
4. INSPECT THE WELL SEAL
 
b. There are typically 3 ports on each well seal. One port is the actuator mount.
At this port you will install the close nipple and discharge tee.
• A pipe union can be installed above the tee for ease of future
maintenance.
c. The other two ports can be used for monitoring and drainage. The larger port

1. ASSEMBLE THE DOWNHOLE COMPONENTS
a. Tightly secure the compression nut to the piston rod connect.

• If the ID of the riser pipe or connections is smaller than the OD of the piston,
the piston must be first inserted into the pump barrel and drive rod inserted
through riser pipe, connections and tubing prior to assembly of the
downhole.
• Use plumber’s tape on all threaded connections of the riser pipe to ensure the
connections do not leak.
2. INSTALL THE VANSTONE FLANGE
 
of the well casing.
b. Place the rubber gasket on top of the

Flange Components:
1.) Rubber Gasket
 2.)VanstoneFlange
 3.)WellCasing
1
2
3

PreintstallationInstallationStartupMaintenance
Troubleshooting Guide Intstallation
Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 9
5. LOWER THE PISTON INTO THE WELL
 


the pump barrel.
• Refer to step 1b if the ID of the riser
pipe or connections is smaller than
the OD of the piston
b. Hand pump the drive rod to ensure the
piston is pumping liquid. You will start to

liquid entering the riser pipe.

Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 10
6. MEASURE LENGTH OF THE ROD AND CUT
SeeRodCungDiagramonnextpageforreference.
 See Step 1.
b. Mark the rod at the top of the tee or pipe union with a marker. See Step 2.
c. Pull 3 to 4 feet of rod from the well. See Step 3.

union.Clamp vice grips to the tape. NOTE: This secures the drive rod at the
surface and prevents rod from dropping into the well. See Step 4.
 
and make a second mark. See Step 4.
 
Cut on both sides to ensure the rod does not split. See Step 4.
g. When cut correctly, there will be an 8 inch gap between the top of the piston

the stroke.

PreintstallationInstallationStartupMaintenance
Troubleshooting Guide Intstallation
Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 11
Rod Cung Diagram
Step 1 Step 2 Step 3 Step 4
Mark Rod
Mark
Cut Point
Mark
Cut Rod
Clamp
20”
8”
20”

Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 12
Seeguresonnextpageforreference.
a. Retrieve the ferrule and nut from the actuator. They will be loosely fastened to
the actuator’s rod to motor connect. See Step 1.

outward, onto the rod. Then lower the ferrule onto the drive rod. See Step 1.
c. Retrieve the actuator and slide the drive rod into motor connect with the ferrule
and nut below it. See Step 2.


ferrule will have mushroomed out and there will be a faint white line where the
ferrule has dug into the rod. See Step 2.
 

 
leaks.
 

7. INSTALL THE TOP HEAD DRIVER WITH FERRULE AND NUT

PreintstallationInstallationStartupMaintenance
Troubleshooting Guide Intstallation
Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 13
Step 1
Step 2

Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 14
Start Up
2. COMPLETE INSTALLATION
a. The pump in now installed and ready for use.
1. TURN ON ACTUATOR
Seegureonnextpageforreference.
 

c. Turn on air supply.


stainless-steel drive rod.
 
minute. This will lengthen seal life and reduce maintenance frequency.

PreintstallationInstallationStartupMaintenance
Troubleshooting Guide Startup
Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 15
3
4
1
2
Startup Components:
 1.)SpeedControlMuers
 2.)AirFilterRegulator
 3.)AirSupplyBallValve
4.) Drain Hose
Air Supply
Discharge Line

Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 16
Maintenance
PERIODIC CHECKS
• Check pump back pressure at the discharge tee.
⸰

• Check liquid discharge rate at the discharge tee.
⸰

• Check air leakages at actuator drive motor.
⸰
• 
⸰
REPLACING SEALS IN THE ACTUATOR DRIVE MOTOR.
• 
• The actuator’s drive motor has a number of seals in it and they will wear over
time.
• The cylinder nose seal cartridge, located below the actuator cylinder, is a critical
seal.
⸰If this seal starts to leak air, pressure cannot be built up in the cylinder and the
actuator will not reciprocate. Replace cylinder seals at this time.
REPLACING STUFFING BOX SEALS.
• 

• 
⸰
⸰Seal life depends on discharge pressure, stroke speed, grit and temperature of
liquid.
⸰
port. 

PreintstallationInstallationStartupMaintenance
Troubleshooting Guide Maintenance
Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 17
REPLACING PISTON SEALS.
• Piston seals will wear over time.
⸰Once the seals wear, there will be a loss of liquid discharge mea-
sured at the discharge tee. Replace piston seals at this time.
LUBRICATION OF STUFFING BOX SEALS
• Grease Zerk Fitting
⸰
⸰DO NOT use auto grease gun or over grease, this will cause the

• Auto Oiler System
⸰Use 6-month auto oiler fitting.
⸰Replace oiler cartridge and battery when oiler bladder runs dry.
CAUTION AND RECOMMENDATIONS
• DO NOT operate pump with the discharge valve closed or discharge

• DO NOT scratch the actuator’s drive motor stainless steel piston

• DO NOT use CLR or comparable chemicals on the aluminum
components of the actuator drive motor.
• 
• Recommend industrial compressed air quality for supply air.
• 
at the discharge tee will result in faster seal wear.
• Recommend use of synthetic grease, synthetic spray lubricant, or
3-in-1 oil for lubrication. WD-40 is not recommended.

Blackhawk Technology Company
V-2PneumaticPistonPumpI&O-10365 | 20220811 18
Troubleshooting Guide
1. DRIVER NOT RECIPROCATING OR STUTTERING WHILE IN USE
a. Air Supply Issues
• Check that the air supply is on.
• Check that all the air supply connections are sound.
• Check that there is between 40 - 120 PSI of air supply pressure, increase air
pressure to the driver at the regulator as needed.
b. Air Cylinder Seals Worn Out
• The driver’s air cylinder seals will wear down and need to be replaced over
time.
• Air will most likely be leaking from the cylinder’s nose seal cartridge.
⸰

 
• Verify that the dischage valve is in the open position.
• Relieve pressure in the discharge line.
• Check for and remove any obstructions in the discharge pipe.
• 
⸰

2. DRIVER RECIPROCATING BUT NOT PUMPING LIQUID
 
• Liquid level in the riser pipe will take time until it is filled to the level of the
discharge tee
• Find the time it takes the liquid to reach the tee
⸰


• Remove pump system from the well
• Check riser pipe and connections for leaks
• Tighten all connections