Hydra-Cell P100 Installation, Operation & Maintenance Instructions Manual

Page 1

P100 Metering Pump

Installation, Operation & Maintenance

P100-991-2400C

1204 Che stnut Avenue, Minneapo lis, MN 55403 Tel: (612) 332-5681 Fax: (612) 332-6937 Toll-fre e fax [US only]: (800) 332-6812 www.hydra-cell.com/metering email: [email protected]

W0032B

Metallic pump shown

Page 2

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)

P100-991-2400C

Page 3

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

P100-991-2400C

Page 4

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

9.36

(237.8)

0.26

(6.7)

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)

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)

Plastic

Pump Head

10.09

(256 .3)

10.09

(256 .3)

10.09

(256 .3)

P100-991-2400C

Page 5

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)

P100-991-2400C

Page 6

P100 Installation (Cont’d)

Safety Precautions

General remarks

These safety / installation instructions contain fundamental information and precautionary notes and must be kept available to all associated with the operation of the pump. Please read them thoroughly prior to installation, electrical connection and commissioning of the unit. It is imperative that all other operating instructions relating to the components of individual units are followed.

These safety / installation instructions do not take local regulations into account. The operator must ensure that such regulations are observed by all, including the personnel carrying out the installation.

Each pump must be labeled by the end user to warn of any hazards that the system process may produce; e.g. corrosive chemicals or hot process etc.

All personnel involved in the operation, maintenance, inspection and installation of the pump must be fully qualied to carry out the work. The personnel’s responsibilities, competence and supervision must be clearly dened by the operator. To the extent that if the personnel in question is not already in possession of the requisite know how, appropriate training and instruction must be provided. In addition, the operator is responsible for ensuring that the contents of the operating instructions are fully understood by all the responsible personnel.

When installing a Hydra-Cell pump in conjunction with a motor or motor and frequency controller the relevant manuals must be referred to for electromagnetic compatibility. The installation should conform to EN 61800 and EN 60204 as applicable.

All safety instructions in this manual and all relevant local health and safety regulations must be followed.

Attention must be paid to the weight of the pump before attempting to lift either manually or selecting appropriate lifting equipment.

Inlet Piping

CA UT ION : Wh en pumpi ng at t emp era tures above 160° F (71°C),

use a pressure-feed system.

Provide for permanent or temporary installation of a compound pressure gauge to monitor the inlet pressure. To maintain maximum ow, vacuum at the pump inlet should not exceed 7 in. Hg (180 mm Hg).

Note: PTFE diaphragms require a minimum suction

pressure of 15 psi.

Do not supply more than one pump from the same inlet line.

Supply Tank

Use a supply tank that is large enough to provide time for any trapped air in the uid to escape. The tank size should be at least twice the maximum pump ow rate.

Install a separate inlet line from the supply tank to each pump.

Place a cover over the supply tank, to prevent foreign objects from falling into it.

Hose Sizing and Routing

To minimize acceleration head and frictional losses, size the suction line at least one size larger than the pump inlet, and keep the suction line as short and direct as possible.

Recommendations:

• Keep inlet lines less than 3 ft. (1 m) long

• Use at least 5/8” (16 mm) I.D. inlet hose

• Minimize ttings (elbows, valves, tees, etc.)

Support the pump and piping independently.

Inlet Piping (Pressure Feed)

Provide for permanent or temporary installation of a pressure gauge to monitor the inlet pressure. Pressure at the pump inlet should not exceed 250 psi (17.3 bar). For higher pressures install a pressure reducing valve. Do not supply more than one pump

from the same inlet line.

Note: System back pressure must exceed the pump inlet pressure by at least 15 psi (1 bar) in order to prevent ow

thru.

Discharge Piping

Hose and Routing

Use the shortest, most-direct route for the discharge line.

Select pipe or hose with a working pressure rating of at least

1.5 times the maximum system pressure. Example: Select a 1500 psi (103 bar) W.P. rated hose for a system to be operated at 1000 psi (69 bar) gauge pressure.

Support the pump and piping independently.

Pressure Regulation

Install a pressure relief valve in the discharge line. Bypass pressure must not exceed the pressure limit of the pump.

Size the valve so that, when fully open, it will be large enough to relieve the full capacity of the pump without overpressurizing the system.

Locate the valve as close to the pump as possible and ahead of any other valves.

Adjust the pressure relief valve to no more than 10% over the maximum working pressure of the system. Do not exceed the manufacturer’s pressure rating for the pump or valve.

Route the bypass line to the supply tank.

CA UT ION: Never in sta ll shut o󰀨 valves in th e by pas s line or between the pump and pressure regulator or relief valve.

Provide for permanent or temporary installation of a pressure gauge to monitor the discharge pressure at the pump.

Minimum Discharge Pressure

To ensure proper capacity control, a minimum discharge pressure of 50 psi (3.5 bar) is recommended.

P100-991-2400C

Page 7

P100 Installation (Cont’d)

Initial Start-Up Procedure

Note: Th e nu mbe rs in pa ren these s ar e Re fer enc e Nu mbe rs located in the Parts List exploded views of this manual.

Note: The oil reservoir in the pump housing is lled and sealed at the factory. To check the oil level, remove the cover (70) and slowly lift the diaphragm (71). Also see Fill and Seal the Oil Reservoir Paragraph in the Fluid End Service Section.

Before starting the pump, be sure that:

1. All shut-o󰀨 valves are open, and pump has adequate supply of uid.

2. All connections are tight.

3. Oil reservoir beneath diaphragm (71) is completely full.

4. Open priming valve on system back pressure valve so pump

starts under minimum pressure. See Typical Metering Installation drawing.

Turn on power to pump motor and:

1. Check inlet pressure or vacuum. To maintain maximum ow, pump inlet should be under ooded suction conditions at all times. Inlet pressure must not exceed 250 psi (17.3 bar).

2. Observe any erratic noise or ow.

3. Jog pump on and o󰀨 until uid coming from priming valve

is air-free.

4. Close priming valve.

5. Perform pump calibration. See Calibration Procedure.

Calibration

Not e: Ea ch me ter in g pu mp or pu mp syst em must be ca libra ted to dete rmi ne th e pu mp spee d re quire d fo r th e de sired ow ra te.

Accurate calibration system conditions. When calibrating the pump or system, it is useful to plot capacity curves for future reference. Observe on the curve, that pump capacity decreases slightly as discharge pressure increases.

In order to achieve the best possible results, perform calibration under actual process conditions. Follow these steps:

1. Run pump for 20 minutes at actual process conditions. If process system cannot be used, circulate back to supply tank through pressure relief valve (see Typical Metering Installation drawing). If required system pressure is less than 50 psi (3.5 bar) back pressure valve must be installed and set to produce minimum of 50 psi (3.5 bar) pressure at pump head.

2. Determine maximum pump speed required for all system conditions that need to be satised. Measure pump delivery at this maximum speed using system calibration cylinder, ow meter, or similar container. This is the “rated capacity” for pump.

3. Measure pump delivery at 100%, 75%, 50%, 25%, and 10% of maximum speed just determined. Let pump run for 5 minutes at each speed setting before taking capacity measurement.

depends on pump discharge pressure and

P100 Maintenance

Periodically

CAUT ION: Do not turn th e dr ive sh aft whi le the oi l reser voi r

is empty.

CAUTION: Do not leave contaminated oil in the pump housi ng or le ave th e hous ing empty. Re move cont ami nated oil as soon as discovered and replace with clean oil.

1. Check inlet pressure periodically with gauge.

2. Change oil according to hours guidelines in table.

3. Change oil as follows:

a. Remove drain plug (69), and allow oil and contaminants to drain completely. Catch oil and dispose of properly.

b. Use suitable Hydra-Oil for the application and pump components.

c. There should be no trapped air under oil reservoir diaphragm (71). Also see: Fill and Seal the Oil Reservoir Paragraph in the Fluid End Service

Section.

Pump Operation Hours Between Oil Changes

at Various Process Fluid Temperatures

Pressure (32°C) (60°C) (82°C)

Metallic Pump Head

<1000 psi (70 bar) 6,000 4,000 2,000 <1500 psi (100 bar) 3,000 2,000 1,500

Non-Metallic Pump Head

<250 psi (17 bar) 3,000 2,000 —

Note: Minimum oil viscosity for proper hydraulic end lub ric atio n is 16 - 20 cS T (8 0-100 SSU ). P- Serie s r e pla cem ent parts kits (complete kits and diaphragm kits) include suitable oil for each P Series pump conguration.

CAUTION: If you are losing oil but don’t see any external leakage, or if the oil becomes discolored and contaminated,

the diaphragm (22) may be damaged. Refer to the Fluid End

Service and Troubleshooting Sections. Do not operate the

pump with a damaged diaphragm.

<90°F <139°F <180°F

P100-991-2400C

Page 8

P100 Fluid End Service

Note: The reference numbers in parentheses are shown

in the Fluid End Parts List.

This se ction ex plain s ho w to di sasse mble an d in spect all easily serviceable parts of the pump uid end.

CAUTION: Disassembly of the hydraulic end of the pump should be performed only by a qualied technician. For assistance, contact Wanner Engineering (612-332-5681) or

the distributor in your area.

1. Remove Support Plate (2)/

Manifold (3)

Not e: Suppo r t Pl ate is used on non- m eta ll ic pu mp s on ly.

a. Remove eight bolts (1) around support plate (2)/manifold (3), b. Remove support plate/manifold. c. Inspect support plate/manifold for warping or wear around

inlet and outlet ports. If wear is excessive, replace or return to Wanner Engineering for resurfacing.

Place a straightedge across manifold to check if it is

warped. If warped replace.

2. Inspect Valves (4-17)

The inlet and outlet valve assemblies are di󰀨erent (inlet

va lve is la rger) an d fa ce oppo site direct ions. Inspe ct each

valve assembly as follows: a. Check spring retainers (4,17), and replace if worn. b. Check valve springs (5,16). If shorter than new spring,

replace (do not stretch old spring). c. Check valve discs (6,15). If worn excessively, replace. d. Remove valve seats (9,13) with seat puller provided in

Wanner Tool Kit (Part No. A03-175-1105). Inspect valve seats for wear, and replace if necessary.

New O-rings (8,12) should be installed. e. Check dampening washer (10), and replace if worn. f. Reinstall inlet and outlet valve assemblies:

• Clean valve ports and shoulders with emery cloth, and

lubricate with lubricating gel or petroleum jelly (do not use

petroleum products when installing EPDM O-rings).

• Install O-rings (8,12) on valve seats (9,13).

• Inlet Valve. Insert spring retainer (17) into valve plate

(21). Then in sert spr ing (16), valve (15), Tetra Se al ® (14)

and valve seat (13)..

• Outlet Valve. Insert dampening washer (10), valve

seat (9) (for non-metallic retainers only), Tetra Seal® (7),

valve (6), spring (5), and spring retainer (4).

3. Inspect and Replace

Diaphragm (22)

Note: Oil escaping from behind diaphragm is

possible during the following steps.

a. Use 3 mm Allen wrench to remove two capscrews (20)

from valve plate (21).

b. Lift diaphragm (22) by one edge, and turn pump shaft

(use the shaft rotator from the Wanner Tool Kit)

until diaphragm moves up to “top dead center”. This will expose machined cross holes in plunger shaft behind diaphragm.

c. Insert plunger holder (from the Wanner Tool Kit) through

one of machi ne d cr oss ho les to hold di aphra gm up. Don’t remove tool until new diaphragm is installed in step g below.

d. Unscr ew diaphr ag m (22). Use 8 mm or 5/16 in . open- end

wrench and turn counterclockwise.

e. Inspect diaphragm (22) carefully. A damaged diaphragm

generally indicates a pumping system problem. Replacing diaphragm will not solve the larger problem. Inspect diaphragm for the following:

• Puncture. Usually caused by sharp foreign object in uid.

• Diaphragm pulled away from sides. Usually caused by uid being frozen in pump, or by over-pressurization of pump.

• Diaphragm becoming sti󰀨 and losing exibility.

Usually caused by pumping uid that is incompatible with diaphragm material.

• Diaphragm edge chewed away. Usually caused by over-pressurizing system.

CAUTION: If a diaphragm has ruptured and foreign

mat er ial or wa ter ha s en ter ed the oi l re ser voi r, do not operate the pump. Check the diaphragm, then ush the reservoir completely (see Flush Contaminant from Hy dr aul ic End pa ragra ph) an d rell it wi th fres h oil. Ne ve r le t the pump st and wit h fo reign mat eri al or water in the reservoir, or with the reservoir empty.

f. Clean away any spilled oil. Apply Loctite® 242 thread

locker to threads of new diaphragm (22) (or old one).

g. Insta ll diaphr ag m (22) an d ti ghten to 10 in -lb s (113 N-c m).

P100-991-2400C

Page 9

P100 Fluid End Service (Cont’d)

4. Flush Contaminant from

Hydraulic End

(Only if diaphragm has ruptured)

a. With valve plate and manifold still removed (see above),

remove drain plug (69), four screws (72), cover (70), and oil diaphragm (71). Allow all oil and contaminant to drain out.

b. Fill reservoir with compatible solvent. Manually turn pump

shaft to circulate compatible solvent and drain. Use the shaft rotator provided in Wanner Tool Kit (Part No. A03175-1105). Dispose of contaminated uid properly.

CA UT ION: If you have an EPDM di aph ragm, or if food

grade oil is in the reservoir, do not use kerosene or solvents. Instead, ush with the same lubricant that is in the reservoir.

c. Repeat step b ushing procedure. d. Fill reservoir with fresh oil and manually turn pump shaft

to circulate oil. Drain oil.

Note: P Series replacement parts kits (complete kits

and diaphragm kits) include the correct oil for each specic P Series pump conguration.

e. Rell reservoir with fresh oil. If oil appears milky, there is

still contaminant in reservoir. Repeat steps c and d until oil appears clean.

5. Prime Hydraulic Cell

a. I f ne cessa r y, wi th pump hori zo ntal, re mo ve fo ur screw s (72),

cover (70), and oil diaphragm (71).

b. Fill pump housing reservoir (62) with correct Hydra oil for

application.

Note: P Series replacement parts kits (complete kits

and diaphragm kits) include the correct oil for each specic P Series pump conguration.

c. Air behind the diaphragm must be forced out by turning

shaft and pumping piston. Any air in the hydraulic end will cause the pump to have loss in ow and re-priming will be necessary.

d. Turn sh aft unt il bubb le- free o w of oil co me s fr om behi nd

diaphragm. Use the shaft rotator provided in Wanner Tool Kit (Part No. A03-175-1105). Make sure oil level in reservoir doesn’t get to low. Add oil as necessary. If oil

gets too lo w, ai r wi ll be dr aw n into hy dr aulic side of pi ston. e. When oil is bubble-free, refresh oil reservoir. f. Install oil diaphragm and cover, using four screws. g. Wipe o󰀨 excess oil on pump housing.

6. Reinstall Valve Plate (21) and Support Plate (2) / Manifold (3)

Not e: Suppo r t Pl ate is used on non- m eta ll ic pu mp s on ly.

a. Reinstall valve plate (21) on diaphragm plate (24). b. Reinstall O-rings (18,19) on valve plate (21). Use

petroleum jelly or lubricating gel to hold them in place (do not use petroleum products when installing EPDM

O-rings). c. Reinstall support plate (2) / manifold (3) onto valve plate. d. Insert eight bolts (1) around edge of manifold, and

alternately tighten opposite bolts until all are secure.

Torque to 90 in-lbs (1017 N-cm). e. Recheck all bolts for tightness.

7. Fill Oil Reservoir

a. I f ne cessa r y, wi th pump hori zo ntal, re mo ve fo ur screw s (72),

cover (70), and oil diaphragm (71). The oil diaphragm

extends into pump housing reservoir approximately

1/4 in. to 3/8 in. b. Add oil so that when diaphragm is set in reservoir all air

is pushed out. Take care not to allow any oil overow.

This may result in an apparent oil leak when the pump is

put into use. c. Install reservoir cover (70) using four screws (72). d. Wipe o󰀨 excess oil on pump housing.

Note: Th e oi l di aph ragm wi ll ex up an d down sligh tly

as the pump operates. The vent holes in the cover

allow this to freely occur. Do not block vent holes.

P100-991-2400C

Page 10

W0039A

Outlet

Valve

Plastic

Retainer

Metal

Retainer

Plastic

Retainer

Inlet

Valve

Metal

Retainer

Detail “B”

(Valve Assemblies)

P100 Fluid End Parts List

W0040A

Detail C

(Nonmetallic

Pump Head)

W0038A

Detail A

(Piston Assembly)

W0037A

Piston Assembly

(see Detail A)

Valve Assemblies

(see Detail B)

(see Detail C)

Bolt Torque Specications

Ref. No. in-lbs N-cm

1 90 1,017

20 14 158 22 10 113 23 14 158

P100-991-2400C

Page 11

P100 Fluid End Parts List (Cont’d)

Ref. Quantity/ No. Part Number Description Pump

1 G20-024-2011 Bolt, Hex-hd, SST................................8

2 F20-100-1033 Plate, Manifold support* ......................1

3 F20-004-1010 Manifold, Brass, NPT ..........................1

F20-004-1012 Manifold, 316 SST, NPT ......................1

F20-004-1017 Manifold, Hastelloy C, NPT .................1

F20-004-1050 Manifold, Polypropylene, NPT ............1

F20-004-1053 Manifold, PVDF, NPT ..........................1

G20-004-1010 Manifold, Brass, BSPT ........................1

G20-004-1012 Manifold, 316 SST, BSPT ....................1

G20-004-1017 Manifold, Hastelloy C, BSPT ...............1

G20-004-1050 Manifold, Polypropylene, BSPT ..........1

G20-004-1053 Manifold, PVDF, BSPT ........................1

4 D03-023-1017 Retainer, Outlet valve spring,

Hastelloy C ..........................................1

D03-023-2317 Retainer, Outlet valve spring,

polypropylene ......................................1

D03-023-2318 Retainer, outlet valve spring, PVDF ....1

5 D03-022-3113 Valve Spring, Outlet, Hastelloy C ........1

D03-022-3114 Valve Spring, Outlet, Elgiloy ................1

6 D03-021-1011 Outlet Valve, Nitronic...........................1

D03-021-1017 Outlet Valve, Hastelloy C ....................1

D03-021-3300 Outlet Valve, Ceramic .........................1

7 D03-092-2110 Tetra Seal®, Outlet, Buna-N ...............1

D03-092-2111 Tetra Seal®, Outlet, FKM ....................1

D03-092-2112 Tetra Seal®, Outlet, neoprene ............1

D03-092-2113 Tetra Seal®, Outlet, EPDM .................1

D03-035-2119 Tetra Seal®, Outlet, PTFE ..................1

8 D03-035-2112 O-ring, Outlet valve seat, neoprene ....1

D03-035-2113 O-ring, Outlet valve seat, EPDM .........1

D03-035-2118 O-ring, Outlet valve seat, PTFE ..........1

D25-046-2110 O-ring, Outlet valve seat, Buna-N .......1

D25-046-2111 O-ring, Outlet valve seat, FKM ...........1

9 D03-020-1001 Valve Seat, Outlet, 316 SST ................1

D03-020-1017 Valve Seat, Outlet, Hastelloy C ...........1

D03-020-3300 Valve Seat, Outlet, ceramic .................1

D15-020-2016 Valve Seat, Outlet, tungsten carbide ..1

10 D03-125-2317 Washer, Outlet dampening,

polypropylene ......................................1

D03-125-2318 Washer, Outlet dampening, PVDF ......1

12 D10-035-2110 O-ring, Inlet valve seat, Buna-N..........1

D10-035-2111 O-ring, Inlet valve seat, FKM ..............1

D10-035-2112 O-ring, Inlet valve seat, neoprene .......1

D10-035-2113 O-ring, Inlet valve seat, EPDM ............1

D10-035-2118 O-ring, Inlet valve seat, PTFE .............1

13 D10-020-1011 Valve Seat, Inlet, 316 SST ..................1

D10-020 -1017 Valve Seat, Inlet, Hastelloy C ..............1

D10-020 -3300 Valve Seat, Inlet, ceramic ...................1

14 D10-092-2110 Tetra Seal®, Inlet, Buna-N ..................1

D10-092-2111 Tetra Seal®, Inlet, FKM .......................1

D10-092-2112 Tetra Seal®, Inlet, neoprene ...............1

D10-092-2113 Tetra Seal®, Inlet, EPDM ....................1

D10-092-2118 Tetra Seal®, Inlet, PTFE .....................1

Ref. Quantity/ No. Part Number Description Pump

15 D10-021-1011 Inlet Valve, Nitronic .............................1

D10-021-1017 Inlet Valve, Hastelloy C .......................1

D10-021-3300 Inlet Valve, Ceramic ............................1

16 D10-022-3117 Valve Spring, Inlet, Elgiloy...................1

D10-022-3123 Valve Spring, Inlet, Hastelloy C ...........1

17 D10-023-1017 Retainer, Inlet valve spring,

Hastelloy C ..........................................1

D10-023-2327 Retainer, Inlet valve spring,

polypropylene ......................................1

D10-023-2328 Retainer, Inlet valve spring, PVDF ......1

18 F20-074-2110 O-ring, Inlet manifold, Buna-N ............1

F20-074-2111 O-ring, Inlet manifold, FKM .................1

F20-074-2112 O-ring, Inlet manifold, neoprene .........1

F20-074-2113 O-ring, Inlet manifold, EPDM ..............1

F20-074-2118 O-ring, Inlet manifold, PTFE ...............1

19 D10-034-2110 O-ring, Outlet manifold, Buna-N .........1

D10-034-2111 O-ring, Outlet manifold, FKM ..............1

F20-073-2112 O-ring, Outlet manifold, neoprene ......1

F20-073-2113 O-ring, Outlet manifold, EPDM ...........1

F20-073-2118 O-ring, Outlet manifold, PTFE ............1

20 G20-029-2010 Cap Screw, Soc-hd .............................2

21 F20-003-1010 Valve Plate, Brass ...............................1

F20-003-1012 Valve Plate, 316 SST ...........................1

F20-003-1017 Valve Plate, Hastelloy C ......................1

F20-003-1050 Valve Plate, Polypropylene .................1

F20-003-1053 Valve Plate, PVDF ...............................1

22 D03-018-1212 Diaphragm, Neoprene .........................1

D03-018-1213 Diaphragm, EPDM ..............................1

D03-018-1215 Diaphragm, FKM .................................1

D03-018-1218 Diaphragm, PTFE ...............................1

D03-018-1220 Diaphragm, Buna-N ............................1

D03-018-1225 Diaphragm, Aas .................................1

23 G20-088-2010 Cap-Screw, Soc-hd .............................2

24 F20-002-1010 Diaphragm Plate..................................1

25 D03-075-2110 O-ring, Diaphragm plate, Buna-N .......1

26 D03-048-2210 Snap Ring ............................................1

27 D03-049-1000 Washer ................................................1

28 D03-045-3110 Spring, Sleeve valve............................1

D03-045-3111 Spring, Sleeve valve for PTFE

diaphragm ...........................................1

29 D03-044-1000 Valve Plunger ......................................1

30 D03-034-2110 O-ring, Valve cylinder, Buna-N ...........1

31 D03-043-1000 Valve Cylinder .....................................1

32 D10-015-3010 Ball ......................................................1

33 D03-014-1004 Piston** ................................................1

34 D03-014-1210 Piston Assembly**(1) ...........................1

* For use with Non-Metallic Pump Head models only. ** Non Kel-Cell. (1) Piston Assembly includes: items 26 through 33.

P100-991-2400C

Page 12

W0042A

P100 Hydraulic End Parts Lists

Ref. Quantity/ No. Part Number Description Pump

52 G20-086-2010 Screw, Cap, hex-hd, ange .................6

53 F20-036-2110 O-ring, Back cover screw, Buna-N .....6

54 G2 0-131-1010 Cover ...................................................1

55 F20-037-2110 O-ring, Cover, Buna-N ........................1

56 F20-031-2110 Seal, Buna-N .......................................1

57 D03-010-2910 Back Bearing .......................................1

58 F20-009-1003 (X) Hollow Shaft, 5/8” ID .....................1

59 D03-132-1000 Connecting Rod ..................................1

60 F20-010-2910 Front Bearing .......................................1

61 D03-133-1000 Pin .......................................................1

62 G20-001-1033 Pump Housing ....................................1

65 D10-085-2210 Key, Shaft ............................................1

69 D10-038-2210 Plug, Drain ...........................................1

70 F20-105-1020 Cover/Nameplate, Oil reservoir, SST ..1

71 F20-091-1010 Gasket, Oil reservoir ...........................1

72 G20-090-2010 Screw, Cap, hex-hd .............................4

Hydraulic End Service

CAUTION: Disassembly of the hydraulic end of the pump should be performed only by a qualied technician. For assistance, contact Wanner Engineering (612-332-5681) or

the distributor in your area.

Bolt Torque Specications

Ref. No. in-lbs N-cm

52 14 158

72 10 113

P100-991-2400C

Page 13

P100 Reducer Parts List

Ref. Quantity/ No. Part Number Description Pump

1 P100 Pump Assembly, NPT ............ Ref

P100 Pump Assembly, BPST .......... Ref

2 112-580 Shaft, P100/P200. ...............................1

3 D10-085-2210 Key, 0.1875 SQ x 1.00 LG, Steel .........1

4 D25-085-2210 Key, 1/4 SQ x 1.40 LG .........................1

5 112-555 Input Flange Kit, NEMA 56C Adapter .1 112-558 Input Flange Kit, IEC 63 B5 Adapter ...1 112-559 Input Flange Kit, IEC 71 B5 Adapter ...1

6 112-411 Reducer, 5:1 ratio ...............................1

112-410 Reducer, 7.5:1 ratio ............................1

112-409 Reducer, 10:1 ratio .............................1

112-408 Reducer, 15:1 ratio .............................1

112-407 Reducer, 20:1 ratio .............................1

112-405 Reducer, 30:1 ratio .............................1

112-404 Reducer, 40:1 ratio .............................1

112-403 Reducer, 50:1 ratio .............................1

112-402 Reducer, 60:1 ratio .............................1

Ref. Quantity/ No. Part Number Description Pump

7 F20-120-1030 Adapter, P100 Pump ...........................1

8 100-914 Screw, 5/16-18 x .75, HHCS ...............4

9 G20-089-2020 Screw, M5 x 16 mm, FHS....................6

10 100- 659 Screw, 1/4-20 UNC-2A x 1, HHCS, sst . 4

11 112-090 Baseplate, P100 ..................................1

12 100-915 Washer, at, sst, 5/16 ..........................4

13 100-063 Locknut, 1/4-20, sst .............................4

14 100-663 Washer, at, 1/4, sst ............................8

W0043A

* Note: item consists of: one selected flange kit,

with spacer, four studs and four nuts.

P100-991-2400C

Page 14

P100 Troubleshooting

Problem Probable Cause Solution

No power. Supply correct power according to motor requirements.

Motor/Pump

Does Not

Operate:

No Deliver y

Blown fuse/tripped circuit breaker.

Shaft coupling to pump not in place.

Current overload - motor. Motor not rated for pump operating conditions - install proper motor.

Thermal overload - motor. Motor not rated for pump and/or ambient operating conditions - supply

Faulty motor drive/controller. Repair/replace.

Faulty motor. Repair/replace.

Low liquid level in supply tank (if low-level shut-o󰀨 is used).

Supply tank empty. Fill tank.

Loss of prime Re-prime using Initial Start-Up Procedure.

Inlet line or strainer clogged. Clear debris and ush, or replace.

Inadequate supply pressure at pump inlet.

Inlet line too restrictive. Increase inlet line diameter and/or decrease inlet line length.

Fluid viscosity too high. Reduce viscosity if possible (by heat or some other means). Increase inlet

Vapor lock/cavitation. Increase inlet pressure. Decrease uid temperature.

Pump valves held open or worn out.

System relief valve actuating. Adjust relief valve, or repair, clean, or replace with new relief valve.

Replace/reset, eliminate circuit overload.

Install proper coupling hardware (see parts list).

cooling or install proper motor.

Fill tank.

Increase supply pressure by raising uid level in tank, raising tank, or pressurizing suction tank.

line diameter and/or decrease inlet line length. Increase supply pressure.

Clear debris and ush, or replace (see Fluid End Service)

Delivery Too

Low and/or

Erratic

Delivery Too

High and/or

Erratic.

Review all Probable Causes and Solutions in Problem 2 No Delivery above.

Air leak(s) in inlet line. Locate all leaks and repair.

System back pressure too low. Adjust back pressure valve to higher setting. Install back pressure valve if

none in system.

Pumped uid characteristics changed.

Inlet supply pressure changed. Monitor inlet supply pressure (at the pump) to determine if it is too low,

Pump OK - Calibration system or ow meter error.

Oil condition in pump hydraulic end changed.

System back pressure too low. Adjust back pressure valve to higher setting. Install back pressure valve if

Inlet supply pressure changed. Monitor inlet supply pressure (at the pump) to determine if it is too high,

Pump OK - Calibration system or ow meter error.

Monitor supply tank temperature to determine if uid is too hot (leading to cavitation) or too cold (increasing uid viscosity). Stabilize temperature at suitable level to resolve problem. Check for entrapped air in the uid supply system.

causing a starved condition/cavitation. Stabilize pressure at suitable level to resolve problem.

Evaluate components and repair/correct problem(s).

Check oil level - if low evaluate for source of leakage. Consult factory for hydraulic end service.

Change oil per recommended guidelines in maintenance section.

none in system.

causing a “ow-through” condition. Stabilize pressure at suitable level to resolve problem.

Evaluate components and repair/correct problem(s).

P100-991-2400C

Page 15

P100 Replacement Parts Kits

TO ORDER REPLACEMENT PARTS KIT: A Replacement Parts Kit contains 9 digits corresponding to customer-specied design options.

Order

Digit Code Description

1-2 Pump Conguration P1 For all P100 Pumps

3 Kit Designator K Complete Fluid End Kit* D Diaphragm Kit* V Valve Kit

4-5 Pump Head Version 52 Standard

6 Spring Retainers/Dampening Washers

B Brass M For PVDF pump head

P For Polypropylene pump head S For 316 Stainless Steel pump head T For Hastelloy® C pump head X Not included in Diaphragm Kit

7 Diaphragm & O-ring Material

A Aas/PTFE O-rings (Synthetic Oil) E EPDM (EPDM Compatible Oil) X FKM (Synthetic Oil) S FKM (Food Contact Oil) J PTFE (Food Contact Oil) W PTFE (Synthetic Oil) P Neoprene (Synthetic Oil) R Neoprene (Food Contact Oil) T Buna-N (Synthetic Oil) F Buna-N (Food Contact Oil)

8-9 Check Valve Material (Valve Spring / Valve & Seat)

SS Elgiloy / 316 SST TT Hastelloy® C / Hastelloy® C SC Elgiloy / Ceramic TC Hastelloy® C / Ceramic XX Not included in Diaphragm Kit

* Includes Hydraulic End Oil

6 953

Kit Contents

Kit Designator

Part Number† Description Qty K D V

D03 -018 -_ __ Diaphragm 1 • • F20- 073-_ __ O-ring, outlet manifold 1 • • • F2 0- 074- ___ O-ring, inlet manifold 1 • • • D03-035-___ O-ring, outlet valve seat 1 • • D03-020-___ Valve seat, outlet 1 • • D03-021- __ _ Valve, outlet 1 • • D03-022-_ __ Valve spring, outlet 1 • • ‡D03-092-___ Tetra Seal®, outlet 1 • • D03-023-__ _ Retainer, outlet valve spring 1 • • D03-125-_ __ Washer, outlet dampening 1 • • D11-0 35 -__ _ O -ring, inlet valve seat 1 • • D10-020-___ Valve seat, inlet 1 • • D10- 021-__ _ Valve, inlet 1 • • D10- 022-___ Valve spring, inlet 1 • • ‡D10-092-_ __ Tetra Seal®, inlet 1 • • D10- 023-___ Retainer, inlet valve spring 1 • • A01-113-3400 Thread locker 1 • •

Hydraulic End Oil (0.5 qt) • •

† Last four digits of part numbers with –_ _ _ refer to specic material

of construction.

‡ Not included with metal spring retainers.

P100 Tool Kit

The P100 Tool Kit (Part No. A03-175-1105) contains the tools listed below. These tools are used to assist in the repair and maintenance of the P100. See the maintenance sections of this manual for specic application.

Ref. Quantity/ No. Tool Part No. Tool Description Kit

1 A03-125-1020 Holder, Plunger ...................................1

2 A03-195-1200 Rotator, Shaft ......................................1

3 A03-196-1000 Lifter, Plunger ......................................1

4 A03-124-1200 Lever Assembly ..................................1

7 A03-126-1500 Tool Box ..............................................1

P100-991-2400C

Page 16

P100 Warranty

Limited Warranty

Wanner Engineering, Inc. extends to the original purchaser of equipment manufactured by it and bearing its name, a limited one-year warranty from the date of purchase against defects in material or workmanship, provided that the equipment is installed and operated in accordance with the recommendations and instructions of Wanner Engineering, Inc. Wanner Engineering, Inc. will repair or replace, at its option, defective parts without charge if such parts are returned with transportation charges prepaid to Wanner Engineering, Inc., 1204 Chestnut Avenue, Minneapolis, Minnesota 55403.

This warranty does not cover:

1. The electric motors (if any), which are covered by the separate warranties of the manufacturers of these components.

2. Normal wear and/or damage caused by or related to abrasion, corrosion, abuse, negligence, accident, faulty installation or tampering in a manner which impairs normal

operation.

3. Transportation costs.

This limited warranty is exclusive, and is in lieu of any other warranties (express or implied) including warranty of merch an tabil it y or wa rra nt y of t ness for a particu lar purp ose and of any non-contractual liabilities including product liabilities based on negligence or strict liability. Every form of liability for direct, special, incidental or consequential damages or loss is expressly excluded and denied.

Wanner Engineering, Inc.

World Headquarters & Manufacturing

Wanner Engineering, Inc 1204 Chestnut Avenue, Minneapolis, MN 55403 USA Phone: 612-332-5681 ● Fax: 612-332-6937 Toll-Free Fax (USA): 800-332-6812 Email: [email protected] www.Hydra-Cell.com

207 US Highway 281 Wichita Falls, TX 76310 USA Phone: 940-322-7111 Toll-Free Fax: 800-234-1384 Email: [email protected] www.Hydra-Cell.com

Latin American Ofce

São Paulo, Brazil Phone: +55 (11) 4081-7098 Email: [email protected] www.Hydra-Cell.com

Wanner International Ltd.

Wanner International Ltd Hampshire - United Kingdom Phone: +44 (0) 1252 816847 Email: [email protected]m www.Hydra-Cell.eu

Wanner Pumps Ltd.

Wanner Pumps Ltd. Kowloon - Hong Kong Phone: +852 3428 6534 Email: [email protected] www.WannerPumps.com

Shanghai - China Phone: +86-21-6876 3700 Email: [email protected] www.WannerPumps.com

P100-991-2400C 8/2005, Revised 3/2016