Hydra-Cell T100S Installation, Operation & Maintenance Manual
Installation, Operation & Maintenance
177-998D
T100 Series High Pressure
Model: T100S
1204 Chestnut Avenue, Minneapolis, MN 55403
Tel: (612) 332-5681 Fax: (612) 332-6937
Toll-free fax [US only]: (800) 332-6812
www.hydra-cell.com/metering
email: sales@wannereng.com
W0542B
T100 Series High Pressure - Contents
W0542B
Page
Component Identication ........................................................2
Specications ..........................................................................2
Dimensions .............................................................................4
Installation ...............................................................................6
Maintenance ............................................................................9
Service (Fluid End) ................................................................10
Service (Hydraulic Section) ...................................................11
Service (Power End) .............................................................14
Troubleshooting .....................................................................16
Oil Level Monitor ...................................................................17
Fluid End Parts ......................................................................18
Hydraulic Section Parts ........................................................ 20
Power End Parts .................................................................. 22
Torque Specications ............................................................24
T100S Tool Kit Parts .............................................................25
Pump Storage .......................................................................25
Replacement Parts Kits ....................................................... 26
Warranty ................................................................................27
Component Identication
Oil Fill Cap
with Dipstick
Outlet
Fluid End
Oil Fill Cap
Hydraulic Section
Inlet
T100 Series High - Specications
Power End
Float Switch &
Sight Glass
Crankshaft
Oil Drain Plug
Maximum Pressure: 5000 psi (345 bar)
Flow Capacities @ Maximum Pressure
rpm gpm I/min BPD
T100S 450 26.0 98.4 891
Delivery
Pressure psi (bar) gal/rev liter/rev
500 (34) 0.066 0.249
2500 (172) 0.063 0.237
5000 (345) 0.059 0.222
rpm
450 maximum
20 0 m ini mum (contact factory for speeds less than 200)
Maximum Discharge Pressure
Metallic Heads: 5000 psi (345 bar)
Maximum Inlet Pressure 500 psi (34 bar)
Operating Temperature
Maximum: 180 F (82.2 C)
Minimum: 40 F (4.4 C)
(consult factory for temperatures outside this range)
Maximum Solids Size 800 microns
Input Shaft Left or Right Side
Inlet Ports 2 inch Class 300 FF ANSI Flange
Discharge Ports 1-1/4 inch Class 2500 RTJ ANSI Flange
Shaft Diameter 3 inch (76.2 mm)
Shaft Rotation Uni-directional (see rotation arrows)
T100 Series High Specications (Cont’d)
Oil Capacity 18 US quarts (17 liters) - blank back cover
20.5 US quarts (19.4 liters) - oil level back cover
Weight (dry)
Metallic Heads: 1100 lbs (499 kg)
Fluid End Materials
Diaphragm Follower Screw: 316 Stainless Steel
Outlet Valve Retainer: 316 Stainless Steel
Plug-Outlet Valve Port: 316 Stainless Steel
Inlet Valve Retainer: 316 Stainless Steel
Power End Materials
Crankshaft: Forged Q&T Alloy Steel
Connecting Rods: Ductile Iron
Crossheads: 12L14 Steel
Crankcase: Ductile Iron
Bearings: Spherical Roller/Journal (main)
Steel Backed Babbit (crankpin)
Bronze (wristpin)
2
177- 9 9 8 D
T100S
RPM
200 225 325 375 425 450
10.0
32.5
30.0
27.5
25.0
22.5
20.0
17.5
15.0
12.5
Liters Per Minute
Gallons Per Minute
35.9
W0540B
275 400350300250
75.0
80.0
85.0
90.0
95.0
70.0
40.0
45.0
50.0
55.0
60.0
65.0
100.0
110.0
115.0
120.0
105.0
500 psi (34 bar)
2500 psi (172 bar)
5000 psi (345 bar)
RPM
12
NPSHr (feet of water
)
NPSHr (meters of water)
13
14
15
16
17
18
3.75
4
4.25
4.5
4.75
5
5.25
W0541B
5.5
T100S
200 350 450300 400 500250
T100 Series - High Specications (Cont’d)
Performance
Net Positive Suction Head –
NPSHr
Calculating Required
Horsepower (kW)*
gpm x psi
1,460
l/min x bar
* HP/kW is required application power.
Attention!
511
=
electric motor HP*
=
electric motor kW*
When sizing motors with variable speed drives (VFDs), it is
very important to select a motor and a VFD rated for constant
torque inverter duty service and that the motor is rated to
meet the torque requirements of the pump throughout desired
speed range.
3
177- 9 9 8 D
T100 Series High Pressure - Dimensions
W0529B
3.50
(89)
4.83
(123)
Ø 3.00
(76)
0.75 X 0.75 Keyway
(19.05 X 19.05)
Minimum full key
29.11
(739)
16.50
(419)
Center of mass
42.55 (1081)
W0530B
inches
(mm)
Front View
Top View
4
177- 9 9 8 D
T100 Series High - Dimensions (Cont’d)
Center of mass
Outlet:
ASME 16.5
18.6
(473)
1-1/4˝ Class 2500 lbs RTJ
(4X 1-8 UNC-2B)
Both Sides
inches
(mm)
12.30
(312)
5.54
(141)
Inlet:
ASME B16.5
2˝ Class 300 lbs FF
(8X 5/8-11 UNC-2B)
Both Sides
2.22
(56)
4 X Ø0.88
(22.23)
Mounting Holes
Center of mass
13.92
(354)
10.92
(277)
Side View
20.80
(528)
W0531B
4.09
(104)
8.2
(208)
8.27
(210)
14.1
(358)
Bottom View
5
W0532B
12.06
(306)
3/4-14 NPT
177- 9 9 8 D
T100 Series High Pressure - Installation
MINIMUM LIQUID LEVEL
VORTEX
BREAKER
WEIR
PLATE
FEED IN
LINE VELOCITY
5-15 FT/SEC.
LONG-RADIUS
ELBOW
SUCTION LINE
VELOCITY 1-3 FT/SEC.
FULL-OPENING
VALV E
ECCENTRIC REDUCER
W/ FLAT SIDE UP
(OPTIONAL)
SUCTION
STABILIZER
AMPLE NPSHA
PUMP FLUID
CYLINDER
LINE VELOCITY
3-10 FT/SEC.
MINIMUM NUMBER OF ELBOWS
WITH AMPLE PIPE SUPPORTS
(OPTIONAL)
PULSATION
DAMPENER
RELIEF VALVE W/
10 PERCENT MAX.
PRESSURE
ACCUMULATION
PRESSURE
GAUGE
PRESSURE
GAUGE
Typical Installation
START-UP AND
CAPACITY-CONTROL
VALV E
W0511A
CHECK VALVE
65 psi cracking pressure
OIL LEVEL
MONITOR
Location
Locate the pump as close to the uid supply source as
possible.
Install it in a lighted clean space where it will be easy
to inspect and maintain. Allow room for checking the oil
level, changing the oil (drain plug on the bottom of pump),
and removing the pump head components (inlet and
discharge retainer plates, manifold, and related items).
Rigging Provisions and
Procedures
Lift pump by attaching rigging to all four eyebolts (14).
Adjust attachment lengths to keep pump level during lifting.
CA UTION: Ey e b o l t s ar e ra t e d to lif t th e we i g h t of the
pump only. Also see center of mass references in
the Dimension Drawings Section.
Mounting
CAUTION: The pump shaft rotation direction is
indicated by arrows on the pump housing.
To prevent vibration, mount the pump and motor securely
on a level rigid base.
On a belt-drive system, align the sheaves accurately;
poor alignment wastes horsepower and shortens the
belt and bearing life. Make sure the belts are properly
tightened, as specied by the belt manufacturer.
On a direct-drive system, align the shafts accurately.
Unless otherwise specied by the coupling manufacturer,
maximum parallel misalignment should not exceed 0.015
in. (0.4 mm) and angular misalignment should be held
to 1° maximum. Careful alignment extends life of the
coupling, pump, shafts, and support bearings. Consult
coupling manufacturer for exact alignment tolerances.
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” and consult NPSH chart.
Positive Displacement. This is a positive-displacement pump. Install a
relief valve downstream from the pump. See “Discharge Piping”.
Safety Guards. Install adequate safety guards over all pulleys, belts, and
couplings. Follow all local codes and regulations regarding installation
and operation of the pumping system.
Shut- O Valves. Never install shut-o valves between the pump and
discharge pressure regulator, relief valve, or in the regulator bypass line.
Freezing Conditions. Protect the pump from freezing. See also the
Maintenance Section.
Vacuum at Outlet. Do not allow a vacuum at the pump outlet during
shutdown. A vacuum can damage the diaphragm at start-up. If there is a
vacuum at the pump outlet, allow atmospheric pressure at the outlet for
30 minutes before starting. Wanner Engineering recommends installing
an outlet check valve with a 65 psi (4.5 bar) cracking pressure to prevent
a vacuum condition during shutdown.
Consult the Factory for the following situations:
• Fluid temperature applications – above 180° F (82° C) or below 40° F (4.4° C)
• Pressure feeding of pumps over 500 psig (34.5 bar)
• Viscous uid applications above 100 Cps
• Chemical compatibility problems
• Hot ambient temperatures – above 110° F (43° C)
• Conditions where pump oil may exceed 200° F (93° C) because of a
combination of hot ambient temperatures, hot uid temperature, and
full horsepower load — an oil cooler may be required
• Pump rpm less than 200
6
177- 9 9 8 D
T100 Series High - Installation (Cont’d)
Accessories
Consult installation drawing below for typical system components.
Contact Wanner Engineering or the distributor in your area for
more details.
Inlet Piping (Suction Feed)
Install drain cocks at any low points of the suction line, to permit
draining in freezing conditions.
Provide for permanent or temporary installation of a vacuum
gauge to monitor the inlet suction. To maintain maximum ow,
NPSHA must exceed NPSHR (See chart in Specications
Section). D o no t supply more than one pump fr o m th e sa m e
inlet line if possible.
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 ve times the maximum pump ow rate (in gpm or lpm).
For example: at a maximum rate of 45 gpm, since trapped air
takes ve minutes to escape from water, 5 x 45 = 225 gallons
for a recommended supply tank size.
Isolate the pump and motor stand from the supply tank, and
support them separately.
Install a separate inlet line from the supply tank to each pump.
Install the inlet and bypass lines so they empty into the supply
tank below the lowest water level, on the opposite side of the
bae from the pump suction line.
If a line strainer is used in the system install it in the inlet line
to the supply tank.
To reduce aeration and turbulence, install a completely submerged
bae plate to separate the incoming and outgoing liquids.
Install a vortex breaker in the supply tank, over the outlet port
to the pump.
Place a cover over the supply tank, to prevent foreign objects
from falling into it.
Hose and Routing
Size the suction line at least one size larger than the pump inlet,
and so that the velocity will be 1-3 ft/sec (0.3 to 0.9 m/s):
For pipe in inches: Velocity (ft/sec) = 0.408 x GPM/Pipe ID2
For pipe in mm: Velocity (m/sec) = 21.2 x LPM/Pipe ID2
Keep the suction line as short and direct as possible.
Use exible hose and/or expansion joints to absorb vibration,
expansion, or contraction.
If possible, keep suction line level. Do not have any high points
collecting vapor unless high points are vented.
To reduce turbulence and resistance, do not use 90° elbows.
If turns are necessary in the suction line, use 45° elbows or
arrange sweeping curves in the exible inlet hose.
If a block valve is used, be sure it is fully opened so that the ow
to the pump is not restricted. The opening should be at least the
same diameter as the inlet plumbing ID.
Do not use a line strainer or lter in the suction line unless
regular maintenance is assured. If used, choose a top loading
basket. It should have a free-ow area of at least three times
the free-ow area of the inlet.
Install piping supports where necessary to relieve strain on the
inlet line and to minimize vibration.
Inlet Piping (Pressure Feed)
Provide for permanent or temporary installation of a vacuum/
pressure gauge to monitor the inlet vacuum or pressure.
Pressure at the pump inlet should not exceed 500 psi (34.5 bar);
if it could get higher, install an inlet pressure reducing regulator.
Do no t su p p l y more than one pu m p fr o m th e same inlet li n e .
Inlet Calculations
Acceleration Head
Calculating the Acceleration Head
Use the following formula to calculate acceleration head losses.
Subtract this gure from the NPSHa, and compare the result to
the NPSHr of the Hydra-Cell pump.
Ha = (L x V x N x C) ÷ (K x G)
where:
Ha = Acceleration head (ft of liquid)
L = Actual length of suction line (ft) — not equivalent length
V = Velocity of liquid in suction line (ft/sec) [V = GPM x (0.408
÷ pipe ID
N = RPM of crank shaft
C = Constant determined by type of pump — use 0.066 for
the T100S Hydra-Cell pumps
K = Constant to compensate for compressibility of the uid —
use: 1.4 for de-aerated or hot water; 1.5 for most liquids;
2.5 for hydrocarbons with high compressibility
G = Gravitational constant (32.2 ft /sec
Friction Losses
Calculating Friction Losses in Suction Piping
When following the above recommendations (under “Inlet
Piping”) for minimum hose/pipe I. D. and maximum length,
frictional losses in the suction piping are negligible (i.e., Hf = 0)
if you are pumping a water-like uid.
When pumping more-viscous uids such as lubricating oils,
sealants, adhesives, syrups, varnishes, etc., frictional losses in
the su c t i o n piping ma y bec ome signi c an t . As Hf increase s , th e
available NPSH (NPSHa) will decrease, and cavitation will occur.
In general, frictional losses increase with increasing viscosity,
increasing suction-line length, increasing pump ow rate, and
decreasing suction-line diameter. Changes in suction-line
diameter have the greatest impact on frictional losses: a 25%
increase in suction-line diameter cuts losses by more than two
times, and a 50% increase cuts losses by a factor of ve times.
Consult the factory before pumping viscous uids.
Minimizing Acceleration Head and Frictional Losses
To minimize the acceleration head and frictional losses:
• Keep inlet lines less than 6 ft (1.8 m) or as short as possible
2
)]
2
)
7
177- 9 9 8 D
T100 Series High - Installation (Cont’d)
• Use at least 2.5 in. (63 mm) I.D. inlet hose
• Use suction hose (low-pressure hose, non collapsing) for
the inlet lines
• Minimize ttings (elbows, valves, tees, etc.)
• Use a suction stabilizer on the inlet.
Net Positive Suction Head
NPSHa must be equal to or greater than NPSHr. If not, the
pressure in the pump inlet will be lower than the vapor pressure
of the uid — and cavitation will occur.
Calculating the NPSHa
Use the following formula to calculate the NPSHa:
NPSHa = Pt + Hz - Hf - Ha - Pvp
where:
Pt = Atmospheric pressure
Hz = Vertical distance from liquid surface to pump center line
(if liquid is below pump center line, the Hz is negative)
Hf = Friction losses in suction piping
Ha = Acceleration head at pump suction
Pvp = Absolute vapor pressure of liquid at pumping temperature
Notes:
• In good practice, NPSHa should be 2 ft greater than NPSHr
• All values must be expressed in feet of liquid
Atmospheric Pressure at Various Altitudes
Altitude Pressure Altitude Pressure
(ft) (ft of H
0 33.9 1500 32.1
500 33.3 2000 31.5
1000 32.8 5000 28.2
O) (ft) (ft of H2O)
2
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. EX AMPLE: Select
a 1500 psi W.P.-rated hose for systems to be operated at 1000
psi-gauge pressure.
Use exible hose between the pump and rigid piping to absorb
vibration, expansion or contraction.
Support the pump and piping independently. Size the discharge line
so that the velocity of the uid will be 3-10 ft/sec (1-3 m/sec):
For pipe in inches: Velocity (ft/sec) = 0.408 x GPM/Pipe ID2
2
For pipe in mm: Velocity (m/sec) = 21.2 x LPM/Pipe ID
Pressure Relief
In stal l a pressure relie f val ve in th e disc harg e line . Bypass
pressure must not exceed the pressure limit of the pump.
Size the relief 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.
Route the bypass line to the supply tank. See the diagram showing
a typical installation at the beginning of the Installation Section.
If the pump may be run for a long time with the discharge closed
and uid bypassing, install a thermal protector in the bypass line
(to prevent severe temperature buildup in the bypassed uid).
CAUTION: Never install shuto valves in the bypass line
or between the pump and pressure relief valve.
Install a pressure gauge in the discharge line.
Va c uum at Ou t l e t . Do not allow a vacuum at the pump outlet during
shutdown. A vacuum can damage the diaphragm at start-up. If
there is a vacuum at the pump outlet, allow atmospheric pressure
at the outlet for 30 minutes before starting. Wanner Engineering
recommends installing an outlet check valve with a 65 psi cracking
pressure to prevent a vacuum condition during shutdown.
Oil Level Monitoring. Oil level is sensed by the back cover
oat switch (48) and can be used to control the pump system
operation.
Before Initial Start-Up
Before you start the pump, be sure that:
• Pump is stored at a temperature between 40-180 F (4.4-82.2 C)
for a minimum of 24 hours before start up.
• All shuto valves are open, and the pump has an adequate
supply of uid.
• All connections are tight.
• The oil level is within the marking on the dipstick. Add oil as
needed. The oil level can also be viewed through the sight
glass (42) on the back cover (12). The oil level is OK when
the oat (48) is in the middle of the sight glass.
• Connect the oat switch (if used). See Float Switch Section.
• Test the oat switch by removing the side port plug (50) and
manipulating the oat up and down using a suitable tool
(screwdriver). Reinstall side port plug (50).
CAUTION: Take care not to drop tool inside pump.
• The relief valve on the pump outlet is adjusted so the pump
starts under minimum pressure.
• All shaft couplings or drive pulleys have adequate safety guards.
Initial Start-Up
1. Pump must be at or above 40 F (4.4 C) for 24 hours prior to
starting.
2. Open the bypass line start-up and capacity-control valve so the
pump may be started against negligible discharge pressure.
3. Turn on power to the pump motor.
4. Ch e c k the inlet pressure or va c u um. To maint a i n maximu m ow,
inlet vacuum must not exceed 7 in. Hg at 70° F (180 mm Hg at
21° C). Inlet pressure must not exceed 500 psi (34.5 bar).
5. Listen for any erratic noise, and look for unsteady ow. If the
pump does not clear, refer to the Troubleshooting Section.
6. If the system has an air lock and the pump fails to prime:
a. Turn o the power.
b. Remove the pressure gauge from the tee tting at the
pump outlet (see installation diagram).
8
177- 9 9 8 D
T100 Series High - Installation/Maintenance
Initial Start-Up (Cont’d)
Note: Fluid may come out of this port when the plug
is removed. Provide an adequate catch basin for uid
spillage, if required. Fluid will come out of this port
when the pump is started, so we recommend that you
attach adequate plumbing from this port so uid will
not be sprayed or lost. Use high-pressure-rated hose
and ttings from this por t. Take all safety precautions
to assure safe handling of the uid being pumped.
c. Jog the system on and o until the uid coming from this
port is air-free.
d. Turn o the power.
e. Remove the plumbing that was temporarily installed, and
reinstall the pressure gauge or plug.
7. Adjust the bypass line valve to the desired operating pressure.
Do not exceed the maximum pressure rating of the pump.
8. After the system pressure is adjusted, verify the safety relief
valve setting by closing the bypass line valve until the relief
valve opens.
Note: Fluid may come out of the safety relief valve.
Provide an adequate catch basin for uid spillage. Take
all safety precautions to assure safe handling of the
spillage.
9. Reset the bypass line valve to obtain the desired system pressure.
10. Provide a return line from the relief valve to the supply tank,
similar to the bypass line.
Maintenance
Note: The numbers in parentheses are the Reference
Numbers shown in the Parts Section of the manual.
Daily
Check the oil level and the condition of the oil with the pump
turned o. The oil level should be within the marking on the
dipstick or when the oat is in the middle of the sight glass. Add
oil as needed or use continuous monitor.
Use the appropriate Hydra-Oil for the application (contact
Wanner Engineering if in doubt).
CAUTION: If you are losing oil but don’t see any external
leakage, or if the oil becomes discolored and contaminated,
one of the diaphragms (73) may be damaged. Refer to the
Fluid-End Service Section. Do not operate the pump with
a damaged diaphragm.
Do no t le a ve contaminated oil in th e pu m p ho u sing or leav e
the housing empty. Remove contaminated oil as soon as
discovered, and replace it with clean oil.
Periodically
Change the oil after the rst 500 hours of operation;
and then every 2000 hours or six months, whichever
comes rst.
Note: Hydra-Cell T100S Series Pumps come standard with
10W30 motor oil.
Minimum oil viscosity for proper hydraulic end lubrication
is 10-20 cST at 212°F (100°C).
Use of an oil cooler is recommended when process uid
and/or hydraulic end oil exceeds 180°F (82°C).
When changing oil, remove drain plug (40) at the bottom of the
pump so all oil and accumulated sediment will drain out.
Check the inlet pressure or vacuum periodically with a gauge. If
vacuum at the pump inlet exceeds NPSHR, check the inlet piping
system for blockages. If the pump inlet is located above the
su p p l y tank, chec k th e u i d supply le vel and re p l enish if to o lo w.
Inspect pump for hydraulic oil or process uid leaks.
Shutdown Procedure During
Freezing Temperatures
Take all safety precautions to assure safe handling of the
ui d be i n g pu m p e d . Prov i d e ad e q u a t e ca t c h basins for u i d
drainage and use appropriate plumbing from drain ports,
etc., wh e n u shing the pump an d system with a co m p a t i b l e
antifreeze. Drain ports are located in the manifold.
Recommended Tools and
Supplies
The following tools and supplies are recommended for servicing
the T100S Pump:
10 mm hex socket with extension
30 mm hex socket
46 mm hex socket
3/4 in. hex socket
8 mm box-end wrench
13 mm open-end wrench
9/16 in. box-end wrench
3 mm hex wrench
4 mm hex wrench
6 mm hex wrench
8 mm hex wrench
3/8 in. hex wrench
Torx T30
Flathead screwdriver
No. 3 Phillips-head screwdriver
Internal retaining ring pliers
8 in. adjustable wrench
Torque wrench, adjustable from 250 to 450 ft-lbs (339 to 610 N-m)
Pipe wrench
Loctite 242
New Hydra-Oil
Wanner T100S Tool Kit (see T100S Tool Kit Parts)
9
177- 9 9 8 D
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