HYCON HWP2 User manual

HWP2/HWP3/HWP4
Hydraulic Submersible
Pumps 2”-3”-4”
HWP2 from serial No. 6459
HWP3 from serial No. 6364
HWP4 from serial No. 6597
Revised
21.02.2019
Prior to Operation
We thank you for choosing a
HYCON submersible pump.
To ensure smooth operation
and long-lasting performance
of your pump, we recommend
you to study this operating
manual carefully and pay spe-
cial attention to the chapters
about
Safety and Service
Precautions
We hope you will be satisfied
with your new HYCON sub-
mersible pump.
Best regards
HYCON A/S
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk

1
Contents
Page
Safety Precautions.............................................................................................. 2
Oil Flow and Pressure ......................................................................................... 3
Useful Information regarding the Use of the Pump ............................................... 4
Starting Instructions ........................................................................................... 6
Technical Data ................................................................................................... 7
Dimensions ........................................................................................................ 8
Connection to Hydraulic Power Sources ............................................................... 9
Service and Maintenance ...................................................................................10
Oil Types ..........................................................................................................10
EC-Declaration of Conformity ............................................................................ 11
Warranty Terms ............................................................................................... 12
Spare Parts List ................................................................................................ 13
HYCON A/S
Vester Hassingvej 33
DK-9320 Hjallerup
Denmark
Tel: [phone]
Fax: [phone]
Mail [e-mail]
www.hycon.dk

2
Safety Precautions
Read the pump and power source operating manuals prior to use.
Check the oil flow to the submersible pump (see technical data). Please also refer
to page 4. A too high oil flow can cause the velocity on the pump to be too high
and thereby involve a risk of defects.
Make sure that the quick-release couplings are properly connected and locked.
When disconnecting the couplings during operation, there is a risk of motor de-
fects.
Make sure that hose couplings and water hose are properly connected and
locked.
A fine jet of oil at pressure can penetrate the skin. It is therefore important never
to use your fingers to check for oil leaks and never to hold your face close to su-
spected leaks –use a piece of cardboard instead. If oil has penetrated the skin,
you should get medical treatment immediately.
Always use approved hoses. Contact your dealer, if necessary.
The operator must pay extra attention and show caution when working in difficult
working areas, such as slopes and other dangerous nature of the ground. Do not
reach too far with the submersible pump, but always maintain a good footing and
keep your balance. In excavations there is always a risk of earth slips.
The operator must always use protective goggles, earplugs, hard hat and shoes
when operating the submersible pump.
Inspection or cleaning of the submersible pump and change or disconnection of
hoses may never be done while the pump is connected to the powerpack.
Always connect hoses to the submersible pump before starting the powerpack. Be
sure that all couplings are tight.
The pump may not be operated if the oil temperature is above 80 C°. Operation
at higher temperatures may result in the pump (the motor) getting warmer than
normal and the operator risks getting burnt on it.
To avoid all personal injury and damage to material, all repair, maintenance and
service work must be carried out by authorized or properly trained persons only.

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A submersible pump not in use should always be kept in a safe and dry place.
Always use hoses, couplings and spares as such recommend by HYCON A/S.
Always mount the hoses correctly, so that the pump runs the right way. If the
pump runs the wrong way there is a risk of defects that are not covered by
warranty.
Repairs may only be carried out by experienced personnel.
Make sure that all couplings are cleaned before connection.
Always disconnect the hydraulic circuit before connecting or disconnecting the
pump. If this is not done, there is a risk of damage to the quick release couplings
or the motor or the hydraulic system getting superheated.
Oil Flow and Pressure
Your new HYCON submersible pump is designed for a certain oil flow, working pres-
sure and maximum pressure. A too high oil flow and/or a too high pressure results in
overload of the pump, meaning that the lifetime of your new HYCON tool will not be
as expected, and that your service and repair costs will be too high.
It is important to check that the pump is not supplied with an oil flow beyond its de-
sign capacity, that the working pressure is correct and that the maximum allowed
pressure is not exceeded.
On page 6 you will find the technical data, and on page 8 there is a guide to connec-
tion to hydraulic power sources and how to ensure that the submersible pump is not
overloaded.
IMPORTANT

4
Useful Information regarding the Use of the Pump
The HYCON submersible pump is compact and light and offers high performance.
The 2” pump weighs only 7.7 kg and pumps up to 35 m³ per hour, the 3” pump
weighs only 11 kg and pumps up to 84 m³ per hour and the 4” pump weighs 26.7 kg
and pumps up to 127 m³ per hour. Only hydraulic submersible pumps have such
high performance in relation to size.
HYCON submersible pumps are perfect tools for pumping all kinds of fluids –
especially dirty fluids. The pumps are VORTEX pumps, which are designed specifical-
ly to pump dirty fluids, without a need for extra maintenance and without reducing
the lifetime of the pump and its components.
The 2” pump can pump solids up to ø38 mm, the 3” pump solids up to ø63 mm and
the 4” pump solids up to ø74 mm.
The pump can be used for many purposes and in many connections. In this respect
an important feature of the pump is that it will not give any sparks. The construction
of the pump allows it to run dry without damage.
The drop in the curves is when the pump meets the pressure limit of 172 bar
pressure. Example the 2” pump at 30 lpm will not be able to pump more than 35
m3/h but will have that flow up to a lift height (Head) of 10 meters, before
decreasing in pumped flow.
Pumping Capacity HWP2
30 lpm
20 lpm

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Pumping Capacity HWP3
Pumping Capacity HWP4
30 lpm
20 lpm
40 lpm
30 lpm

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The pump can also be connected to excavators and other machines. We recommend
the use of a HYCON oil flow divider to protect the pump against a too high oil supply,
a too high pressure and backwards rotation. Please refer to page 8.
Starting Instructions
START
Mount a water hose.
Connect hoses –clean couplings before connection.
Get a good footing before you start pumping.
Lower the pump into the fluid. Make sure that the water hose is fixed.
Set the power source on ”ON”.
STOP
Set the power source on ”OFF”.
For operation in sensitive environments,
you should only use bio-degradable oil.

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Technical Data
2” Pump
3” Pump
4” Pump
Weight w/o hoses
7.7 kg
11 kg
26.7 kg
Oil flow
20-30 l.p.m.
20-30 l.p.m.
30-40 l.p.m.
Working pressure nominal
90-140 bar
120-140 bar
120-150 bar
Pressure relief valve in
power source
Max. 172 bar
Max. 172 bar
Max. 172 bar
Max. return pressure
40 bar
40 bar
40 bar
Max. oil temperature
80°C
80°C
80°C
Max. water temperature
80°C
80°C
80°C
Max. solid size
ø38 mm
ø63 mm
ø74 mm
Max. pumping capacity
35 m³/hour
84 m³/hour
127 m³/hour
Max. head
30 m
20 m
22 m
Connection water hose
2” thread
internal
BSP
3” thread
internal
BSP
4” thread
internal
BSP
May run dry
Yes
Yes
Yes

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Dimensions
HWP2
HWP3
HWP4

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Connection to Hydraulic Power Sources
The submersible pump can be connected to various hydraulic power sources, such as
excavators, trucks, loaders, tractors etc., and of course HYCON powerpacks, the de-
sign of which ensures your new HYCON pump the absolute best working conditions.
It is important that the submersible pump is not subjected to an oil flow and a work-
ing pressure beyond its design capability. Please refer to the ID-tag.
Check the oil flow and the working pressure by means of test equipment. The test
equipment should comprise a pressure gauge, a flow meter and a valve for adjust-
ment of pressure.
Make sure that:
the oil supply is not too high
the working pressure is not too high
the return pressure is not too high
the pressure relief valve is not set higher than 172 bar
the internal diameter of the hoses is sufficient (min. ½”)
all couplings are in order
the power source is equipped with an oil filter of min. 25 Micron
Hoses with too small internal diameter and/or defect couplings cause the pump to
work with incorrect working pressure.
Your dealer can help you check this.
If the output of the power source is too high:
the power source must be adjusted to correct output
or you can choose to mount a HYCON oil flow divider to protect the pump
against overload
or you can choose one of our HYCON powerpacks. Your dealer can guide you
in choosing the right powerpack.
In case of doubt, please contact your dealer or HYCON A/S.