Hydra-Cell P100 Installation, Operation & Maintenance Instructions Manual

TM

P100 Metering Pump

Installation, Operation & Maintenance

P100-991-2400C

1204 Che stnut Avenue, Minneapo lis, MN 55403
Tel: [phone] Fax: [phone]
Toll-fre e fax [US only]: [phone]
www.hydra-cell.com/metering
email: [e-mail]

W0032B

Metallic pump shown

P100 Contents

W0032B

Page

Operation ................................................................................2

Specications ..........................................................................2

Dimensions .............................................................................4

Installation ...............................................................................5

Calibration ...............................................................................7

Maintenance ............................................................................7

Fluid End

Service .................................................................................8

Parts List .............................................................................10

Hydraulic End Parts List ........................................................12

Reducer Parts List.................................................................13

Troubleshooting .....................................................................14

Replacement Parts Kits ........................................................15

Warranty ................................................................................16

Hydra-Cell Metering Solutions Pumps are hydraulically­actuated, hydraulically-balanced diaphragm metering pumps
that exceed API 675 performance standards of ±1% steady state
accuracy, ±3% linearity and ±3% repeatability.

Due to their multiple diaphragm design, the P Series
metering pumps, with the exception of the P100, provide virtually
“pulse-free” linear ow. Unlike conventional single diaphragm
metering pumps, this linear ow reduces the need for pulsation
dampeners and increases the reliability, performance, and
safety of the metering pump system.

Pump operation and plunger activation are accomplished
through a crankshaft (P100, P200 and P300) or wobble plate
(P400, P500 and P600). Horizontal disk check valves allow for
the pumping of particulates that ordinarily collect on vertical
ball check valves common to conventional metering pumps.

P Series pumps utilize speed to adjust ow rate through a
motor and variable-frequency drive (VFD), eliminating the need
for mechanical adjustment.

Component Identication

Reducer

Outlet

Inlet

Pump Assembly
Fluid End

Oil Cover/ID Plate

Pump Assembly
Hydraulic End

P100 SpecicationsP100 Operation

Diaphragms per Liquid End 1 (non Kel-Cell pistons)

Flow Control Electronic variable speed drive

Steady State Accuracy ±1%

Linearity ±3%
Repeatability ±3%

Maximum Pressure

Metallic Heads: 1500 psi (103 bar)
Non-Metallic Heads: PVDF: 350 psi (24 bar)
Polypropylene: 250 psi (17 bar)

Maximum Inlet Pressure 250 psi (17 bar)

Fluid Operating Temperatures*

Metallic Head: 250°F (121°C)
Non-Metallic Head: 140°F (60°C)
* Consult factory for correct component selection for
temperatures from 160˚F (71˚C) to 250˚F (121˚C).

Inlet Port 1/2 inch NPT or BSPT

Discharge Port 3/8 inch NPT or BSPT

Maximum Solids 200 microns

Shaft Rotation Bi-directional

Materials Used See Replacement Parts Kits Section

for individual pump materials.

Oil Capacity 1/8 US quart (0.12 liters)

Weight (less motor)

Metallic Heads: 21.2 lbs (9.6 kg)
Non-Metallic Heads: 19.1 lbs (8.7 kg)

2

P100-991-2400C

P100 Specications (Cont’d)

Performance Maximum Flow at Designated Pressure - Imperial *

All Pumps (gph) Metallic Pump Heads Only (gph)

100 psi 250 psi 500 psi 1000 psi 1500 psi

1.086 (½) 1.077 (¾) 1.058 (¾) 1.015 (¾) 0.981 (¾) 30 60:1

1.316 (½) 1.300 (¾) 1.273 (¾) 1.220 (¾) 1.184 (¾) 36 50:1

1.630 (½) 1.628 (½) 1.607 (¾) 1.535 (¾) 1.492 (¾) 45 40:1

2.192 (½) 2.182 (½) 2.148 (½) 2.056 (½) 2.000 (¾) 60 30:1

2.643 (½) 2.626 (½) 2.582 (½) 2.473 (½) 2.405 (½) 72 25:1

3.318 (½) 3.291 (½) 3.232 (½) 3.099 (½) 3.014 (½) 90 20:1

4.444 (½) 4.400 (½) 4.316 (½) 4.141 (½) 4.028 (½) 120 15:1

6.695 (½) 6.618 (½) 6.483 (½) 6.226 (½) 6.057 (½) 180 10:1

8.947 (½) 8.836 (½) 8.651 (½) 8.311 (½) 8.085 (½) 240 7.5:1

13.45 (½) 13.27 (½) 12.99 (½) 12.48 (½) 12.14 (¾) 360 5:1

17.95 (½) 17.71 (½) 17.32 (½) 16.65 (¾) 16.20 (¾) 480 7.5:1

26.96 (½) 26.58 (½) 25.99 (¾) 24.99 (¾) 24.31 (1) 720 5:1

*Capacity data shown is for pumps with elastomeric diaphragms. Consult factor y for performance characteristics of pumps with PTFE diaphragms.

( ) Required Motor hp

Performance Maximum Flow at Designated Pressure - Metric *

All Pumps (lpm) Metallic Pump Heads Only (lpm)

7 bar 17 bar 34 bar 69 bar 103 bar

3.425 (0.18) 3.396 (0.18) 3.337 (0.18) 3.203 (0.18) 3.095 (0.55) 25 60:1

4.150 (0.18) 4.102 (0.18) 4.016 (0.18) 3.850 (0.18) 3.735 (0.55) 30 50:1

5.140 (0.18) 5.135 (0.18) 5.068 (0.18) 4.841 (0.25) 4.708 (0.55) 37.5 40:1

6.916 (0.18) 6.884 (0.18) 6.777 (0.18) 6.486 (0.25) 6.307 (0.25) 50 30:1

8.336 (0.18) 8.283 (0.18) 8.145 (0.18) 7.801 (0.25) 7.587 (0.25) 60 25:1

10.47 (0.18) 10.38 (0.18) 10.20 (0.18) 9.774 (0.25) 9.507 (0.25) 75 20:1

14.02 (0.18) 13.88 (0.18) 13.61 (0.18) 13.06 (0.37) 12.71 (0.37) 100 15:1

21.12 (0.18) 20.88 (0.18) 20.45 (0.18) 19.64 (0.37) 19.11 (0.37) 150 10:1

28.22 (0.18) 27.87 (0.18) 27.29 (0.18) 26.22 (0.37) 25.50 (0.37) 200 7.5:1

42.43 (0.18) 41.87 (0.18) 40.96 (0.18) 39.37 (0.37) 38.30 (0.55) 300 5:1

56.63 (0.37) 55.86 (0.37) 54.64 (0.37) 52.53 (0.55) 51.10 (0.55) 400 7.5:1

85.04 (0.37) 83.85 (0.37) 81.98 (0.55) 78.84 (0.55) 76.70 (0.55) 600 5:1

*Capacity data shown is for pumps with elastomeric diaphragms. Consult factor y for performance characteristics of pumps with PTFE diaphragms.

( ) Required Motor kW

Pump

rpm

Pump

rpm

Gear

Ratio

Gear

Ratio

Motor

rpm

1800

3600

Motor

rpm

1500

3000

3

P100-991-2400C

5.75

(146.1)

7.27

(184.7)

5.40

(137.2)

4.50

(114.3)

Ø0.41

(10.4)

(4X)

0.78

(19.8)

5.40

(137.2)

7.90

(200.6)

2.10

(53.3)

3.47

(88.1)

1/2" NPT or
1/2" BSPT

3/8" NPT or
3/8" BSPT

E

9.36

(237.8)

A

B

C

F

D

H

0.26

(6.7)

G

W0035A

P100 Dimensions

P100 Models: Metallic and Non-Metallic

Input

Frame Size

NEMA 56C

IEC 63 B5

IEC 71 B5

A B C D E

9.93 (252.2)

9.42 (239)

9.81 (249.2)

Ø 6.54

(Ø 166)

Ø 5.51

(Ø 140)

Ø 6.30

(Ø 160)

Dimensions in Inches (Millimeters)

Ø 4.50

(Ø 114.3)

Ø 3.74

(Ø 95)

Ø 4.33

(Ø 110)

(Ø 15.7)

(Ø 11)

(Ø 14)

Ø .62

Ø .43

Ø .55

Ø 6.92

(Ø 175.8)

Ø 6.74

(Ø 171.3)

Ø 6.74

(Ø 171.3)

(Square

Key)

0.187 (4.75)

0.157 (4)

0.196 (5)

F

Metallic

Pump Head

(2 87. 4)

(275. 3)

(285.5)

G H

11. 36

10.84

11. 24

Plastic

Pump Head

11. 61

(294.9)

11. 09

(281.7)

11. 49

(291. 8)

Metallic

Pump Head

9.84 (250)

9.84 (250)

9.84 (250)

Plastic

Pump Head

10.09

(256 .3)

10.09

(256 .3)

10.09

(256 .3)

4

P100-991-2400C

P100 Installation

W0323A

(To process)

Pulsation

Dampener

(Optional)

Relief

Valve

Flanges & Manifolds

Ball Valve

Y-Strainer

Isolating

Valve

Calibration

Cylinder

Pressure

Gauge

Back Pressure

Valve

P-Series

Metering Pump

Typical Metering Installation

Controllers
& Motors

Location

Locate the pump as close to the supply source as possible.

Install the pump system in a lighted clean space where it will be
easy to inspect and maintain.

Motor and Controller

The P Series pump shaft can rotate in either direction,

therefore direction of motor shaft rotation is not critical.

Flow rate is determined by motor speed, which is controlled
using an inverter duty constant torque motor and VFD. Flow
rate functions can also be easily controlled using the Hydra-Cell
Control Freak and appropriate motor.

Accessories

Consult installation drawing below for typical metering uid
system components. Contact Wanner Engineering or the
distributor in your area for more details.

Important Precautions

Adequate Fluid Supply. To avoid cavitation and
premature pump failure, be sure that the pump will have
an adequate uid supply and that the inlet line will not be
obstructed. See Inlet Piping.

Positive Displacement. This is a positive-displacement
pump. To avoid severe system damage if the discharge line
ever becomes blocked, install a relief valve downstream
from the pump. See Discharge Piping.

Safety Guards. Follow all codes and regulations regarding
installation and operation of the pumping system.

Shut-O󰀨 Valves. Never install shut-o󰀨 valves between
the pump and relief valve, or in the regulator bypass line.

Consult the Factory for the following situations:

• Extreme temperature applications (above 160°F or
below 40°F)

• Pressure feeding of pumps

• Viscous or abrasive uid applications

• Chemical compatibility problems

• Hot ambient temperatures (above 110°F)

5

P100-991-2400C