Hydra-Cell T100S Installation, Operation & Maintenance Manual Download Page 1

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W0542B

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: [email protected]

T100 Series High Pressure

Model: T100S

177-998D

Installation, Operation & Maintenance

Summary of Contents for T100S

Page 1: ...e 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 T100 Series High Pressure Model T100S 177 998D Installation Operation Maintenance ...

Page 2: ...llation 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 Specifications 24 T100S Tool Kit Parts 25 Pump Storage 25 Replacement Parts Kits 26 Warranty 27 T100 Series High Specifications Cont d Oil Capacity 18 US quarts 17 liters blank back cover 20 5 ...

Page 3: ...r 13 14 15 16 17 18 3 75 4 4 25 4 5 4 75 5 5 25 W0541B 5 5 T100S 200 350 450 300 400 500 250 Net Positive Suction Head NPSHr T100 Series High Specifications Cont d Attention 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 throug...

Page 4: ...998D 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 Top View Front View inches mm ...

Page 5: ... 5 54 141 12 30 312 18 6 473 Inlet ASME B16 5 2 Class 300 lbs FF 8X 5 8 11 UNC 2B Both Sides 14 1 358 Outlet ASME 16 5 1 1 4 Class 2500 lbs RTJ 4X 1 8 UNC 2B Both Sides Center of mass 20 80 528 8 27 210 12 06 306 4 X Ø0 88 22 23 Mounting Holes 4 09 104 W0532B 2 22 56 Center of mass 3 4 14 NPT inches mm ...

Page 6: ...D 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 VALVE 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 GAUG...

Page 7: ... 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 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 p...

Page 8: ...4 Checktheinletpressureorvacuum Tomaintainmaximumflow 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 flow 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 off the power b Remove the pressure gauge from...

Page 9: ...l Periodically Change the oil after the first 500 hours of operation and then every 2000 hours or six months whichever comes first Note Hydra Cell T100S Series Pumps come standard with 10W30 motor oil 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 b...

Page 10: ...nd Service Outlet Check Valve Disassembly Note Removal of Inlet Check Valves first will make removal of Outlet Check Valves easier a Remove two eyebolts 14 and ten cap screws 98 around three discharge retainer plates 96 b Remove three discharge retainer plates with assembled outlet valve port plugs 93 backup rings 95 O rings 94 and outlet valve retainers 92 c Check outlet valve port plugs backup r...

Page 11: ...erial or water has entered the oil reservoir do not operate the pump Check all diaphragms then flush the reservoir completely and refill it with fresh oil Never let the pump stand with foreign material or water in the reservoir or with the reservoir empty c Remove the diaphragm 73 and inspect it carefully for any abnormal conditions A ruptured diaphragm generally indicates a pumping system problem...

Page 12: ...bolts 177 058 from T100 High Pressure Tool Kit in place of two Setscrews 56 on top of diaphragm plate Hydraulic Section Disassembly Cont d Diaphragm Plate Disassembly WARNING Manifold 88 and assembled parts weigh over 200 pounds and are a two man lift Use care in handling to prevent personal injury or damage to equipment a Slide manifold assembly away from diaphragm plate 52 following steps a thro...

Page 13: ...nt Hydraulic Section Assembly T100 High Hydraulic Section Service Cont d Diaphragm Plate Assembly a Replace diaphragm plate gasket 24 if damaged CAUTION Ensure plungers 53 are lubricated with oil before assembly Dry plungers and cylinders can bind on start up b See Hydraulic Section Parts Illustration Carefully slide diaphragm plate 52 and assembled parts along pump studs flush with Power End of p...

Page 14: ...rankshaft by reaching into rear of crankcase 2 around crankshaft 1 Push connecting rod assembly away from journal on the crankshaft Move as far forward as possible d Repeat removal for three sets Crankshaft Removal a Remove six cap screws 16 from one side of pump attaching seal and bearing assembly assembled items 6 7 9 11 15 17 and 18 to the crankcase 2 b Carefully remove crankshaft 1 with seal a...

Page 15: ... handling to prevent personal injury or damage to equipment Crankshaft Installation a Install one seal and bearing assembly to either side of crankcase 2 using six screws 15 Crankshaft 1 will be installed on opposite side b Place remaining seal and bearing assembly on following end of crankshaft Note No shimming of crankshaft is necessary End play of crankshaft should be between 0 010 in minimum t...

Page 16: ...elief valve bypassing fluid Worn pump valve parts Foreign material in inlet or outlet valves Loss of oil prime in cells because of low oil level Ruptured diaphragm Cavitation Warped manifold from overpressurized system O rings forced out of their grooves from overpressurization Air leak in suction line strainer or gasket Cracked suction hose Empty supply tank Excessive aeration and turbulence in s...

Page 17: ...ions of the manual for float switch set up and use Note The oil level should always be visible between the high and low oil marks viewed on sight glass 42 If the oil level reaches the high or low mark the float switch will be activated Low Closed Open Normal Closed Closed Open Closed Low Open Open Normal Closed Open High Black Common Yellow High Oil Level Red Low Oil Level Black Common Yellow Whit...

Page 18: ...ail A 92 See Detail A 100 14 98 97 96 94 95 93 99 88 Inlet Valve Outlet Valve Detail A 102 103 104 105 106 107 Metalic 107 108 103 103 T100 Series High Fluid End Parts W0542B Fluid End Note for torque values refer to the Torque Specification Table ...

Page 19: ... 177 014 01 Plug Drain 316 SST 3 100 D10 047 2110 O ring Buna N 3 D10 047 2111 O ring FKM 3 101 177 116 Screw Cap hex hd M20 250 mm 8 102 177 202 01 Valve Seat 17 4 SST HT 6 177 202 02 Valve Seat Hastelloy C 6 177 202 05 Valve Seat Nitronic 6 103 177 254 03 Ring Back up PVDF 6 or 12 177 254 04 Ring Back up 6 or 12 104 177 253 01 O ring Buna N 6 177 253 02 O ring FKM 6 105 177 208 01 Valve 17 4 SST...

Page 20: ...66 54 59 53 58 72 57 65 56 55 24 52 W0534E 74 73 82 75 80 84 76 85 83 81 87 86 T100 Series High Hydraulic Section Parts W0542B Rear View Hydraulic Section Note for torque values refer to the Torque Specification Table ...

Page 21: ...77 906 Cartridge Air Bleed valve 3 66 177 904 Cartridge Underfill valve 3 69 177 905 Cartridge Overfill valve 3 72 177 234 Tube Bias spring 3 73 177 266 01 Diaphragm Buna N 3 177 266 02 Diaphragm FKM 3 74 177 176 01 Screw Flat hd M6 x 1 0 x 16 mm Aus 3 75 177 238 Ring Diaphragm back up 3 76 177 916 Diaphragm Rod Assembly 3 80 177 223 Spring Bias 3 81 177 258 Diaphragm Stop 3 82 177 263 Clamp Diaph...

Page 22: ...ing rod end cap sleeve and two bolts 3 13 48 12 1 8 3 5 29 23 28 4 27 51 45 32 20 21 25 15 14 17 7 6 11 18 9 15 10 2 19 24 W0535B 43 41 49 44 42 46 47 16 50 36 37 40 39 38 35 8 3 3 31 T100 Series High Power End Parts W0542B Power End Note for torque values refer to the Torque Specification Table ...

Page 23: ... 12 mm 4 21 177 118 Setscrew M12 15 mm 4 23 G10 082 2010 Setscrew M6 10 mm 3 24 177 013 Gasket Diaphragm plate Ref 25 D03 039 1030 Cap Oil fill with o ring 1 27 177 031 Washer Spherical 3 28 177 030 Spring Belleville 3 29 177 047 Screw Shoulder M16 30 mm 3 31 177 036 Key Crankshaft 1 Ref Quantity No Part Number Description Pump 32 177 912 Dipstick 1 35 209 701 Fitting 5 8 Tube 1 36 209 711 Tube 5 ...

Page 24: ... 311 Plug 3 4 in NPT SST 50 177 459 Plug 1 2 14 NPT 53 450 ft lbs 610 242 177 229 Cylinder S 54 300 ft lbs 407 177 231 Plug Diaphragm plate 59 50 ft lbs 68 G10 024 2010 Screw Cap soc hd M10 90 mm 65 75 ft lbs 101 177 906 Cartridge Air Bleed valve 66 30 ft lbs 41 177 904 Cartridge Underfill valve 69 105 in lbs 12 177 905 Cartridge Overfill valve 74 60 in lbs 7 242 177 176 Screw Flat hd M6 x 1 0 x 1...

Page 25: ... 52 only Do not use to lift entire pump Attempting to lift entire pump with Eyebolt 8 may cause personal injury or damage to equipment CAUTION If the pump is to be stored more than six months take the following steps to protect against corrosion After Shut Down of the pump 1 Drain all process fluid from pump Do not drain oil from the pump CAUTION Do not store the pump without oil in the reservoir ...

Page 26: ...itronic 50 T Hastelloy C X Not included in Diaphragm Kit 11 Valve Springs E Elgiloy T Hastelloy C X Not included in Diaphragm Kit 12 Valve Spring Retainers H 17 7 Stainless Steel M PVDF P Polypropylene S 316 SST T Hastelloy C X Not included in Diaphragm Kit Part Number Description Quantity 177 260 __ Diaphragm 3 177 238 Ring Back up 3 100 217 __ O ring 3 T100 High Pressure Kit D Contents Part Numb...

Page 27: ... 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 wa...

Page 28: ...111 Toll Free Fax 800 234 1384 Email sales wannereng com www Hydra Cell com Latin American Office São Paulo Brazil Phone 55 11 4081 7098 Email sales wannereng com www Hydra Cell com Wanner Engineering Inc Wanner International Ltd Hampshire United Kingdom Phone 44 0 1252 816847 Email sales wannerint com www Hydra Cell eu Wanner International Ltd Wanner Pumps Ltd Kowloon Hong Kong Phone 852 3428 653...

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