Hydra-Cell T Series User manual

Rev. A 14/10/2019 1
ATEX
T & Q-Series pumps
Directive 2014/34/EU
Covers – Category 2 Zone 1 requirements
Rev: A Date of issue: 14/10/2019

Rev. A 14/10/2019 2
Contents
1. Wanner and the ATEX Directive 2014/34/EU .................................................................................3
2. Operating Conditions ...................................................................................................................... 4
3. Drive Motors ...................................................................................................................................5
4. Protection Concept .........................................................................................................................5
5. Specific Conditions of Use............................................................................................................... 5
6. Markings of Conformity – Category 2 Zone 1 ................................................................................. 7
7. Earth Continuity Checks & Procedure............................................................................................. 9
8. Oil level monitoring device installation. ....................................................................................... 11
8.1 Electrical installation.............................................................................................................12
9. Installation and Putting into Service.............................................................................................13
10. Maintenance and Testing .........................................................................................................16
Appendix 1: Type Certificate.................................................................................................................17
Appendix 2: Maximum Pressure Values of all Models .........................................................................22

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1. Wanner and the ATEX Directive 2014/34/EU
ATEX Directive 2014/34/EU is a directive adopted by the European Union (EU) to
harmonise the technical and legal requirements in the Member States for products
intended for use in potentially explosive atmospheres. The Directive covers electrical
and non-electrical equipment and became mandatory in April 2016 when adopted by
the EU.
The Directives are known as ATEX from the French title of the 2014/34/EU directive:
Appareils destinés à être utilisés en ATmosphères EXplosives.
Wanner has worked with an outside specialist agency called Intertek in order to obtain
ATEX Certification for the T&Q-Series Hydra-Cell pumps, carrying out a
comprehensive risk assessment and compiling the Technical File. Intertek is
accredited by UKAS (the UK Accreditation Service) and authorised to carry out product
safety testing and Certification of equipment under European Directives such as ATEX
as well as under the international IECEx scheme. See Apendix 1 “Type Examination
Certificate.”
Certificate Number:
ITS14ATEX18067X
Compliance with the Essential Health and Safety Requirements has been assured by
compliance with standards:
EN 80079-36:2016
EN 80079-37:2016
T & Q-Series Hydra-Cell ATEX Certification covers the supply from Wanner of bare
shaft pumps and not complete pump and electric motor sets.

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2. Operating Conditions
The normal operating environment is an outdoor or indoor above ground industrial
environment in which flammable dust or gas could be present.
The intended maximum external ambient operating temperature is +40°C.The
minimum permitted temperatures (both ambient and operating) are defined by the
below table:
Diaphragm Material
Minimum service temperature (°C)
Aflas
30
EPDM
-20
FKM
5
HNBR
-5
This is the maximum temperature range for T-Series Hydra-Cell pump with ATEX.
Wanner has obtained Type Certification, for conditions outside the pump as follows:-
II 2G Ex h IIC T5…T4 Gb X
Group II (Zone 1)
Category 2 G (gasses)
T5…T4 (auto ignition temperature dependent on process temperature)
Process Temperature
Resultant T-class TX
Less than or equal to 49°C
T5
Less than or equal to 82°C
T4
Note – Process liquid temperatures above 82°C are not permitted for this
equipment.
Hydra-Cell pumps are not intended for pumping explosive atmospheres in normal
operation. Where the liquid being pumped is flammable or where the supply tank is
vented to an explosive atmosphere measures must be taken to ensure the pump head
is fully flooded with liquid during normal operation.

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3. Drive Motors
T & Q-Series Hydra-Cell ATEX Certification covers the supply of bare shaft pumps
only and not complete pump and motor sets.
The supplier of the drive motor and motor control system must provide over current
and short circuit protection that is capable of shutting down the pump before the motor
produces more than 100% of the input power limit of the power-end.
The input power limit can be calculated using the Hydra-Cell standard power
requirements formula (see product specification sheets on website) at maximum
speed and pressure for any given pump .
4. Protection Concept
T & Q Series Hydra-Cell pumps are protected by constructional safety and control of
ignition source.
Constructional safety is ensured by splash lubrication. Control of ignition source is
used in the form of an oil level monitoring float switch which ensures the presence of
the protective liquid (lubricant).
5. Specific Conditions of Use
Hydra-Cell pumps are not intended for pumping explosive atmospheres in normal
operation. Where the liquid being pumped is flammable or where the supply tank is
vented to an explosive atmosphere measures must be taken to ensure the pump head
is fully flooded with liquid during normal operation.
The pump must be operated in conjunction with an external safety relief valve which
must be set at or below the maximum operating pressure of the pump.
The liquid and ambient temperature limits in the table in section 2 must be
respected.
An NPSHa calculation taking into account acceleration head losses must be
performed by the operator and compared with the NPSH requirement of the pump
before installation to guard against operating the pump in conditions of cavitation.
The operator is responsible for checking the selected materials of construction for
resistance to the liquids to be pumped.

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The lubricating oil in the pump should be changed in accordance with the guidelines
stated in the pump Installation, Operation and Maintenance manual. The type of oil
recommended and the frequency of the oil change can vary in accordance with the
pump materials of construction, the duty, shaft speed, discharge pressure and the
process liquid temperature.
Only officially sanctioned genuine lubricants must be used. The below lubricants are
permitted for use in ATEX T & Q series pumps:
Oil code
(digit 13 of
pump model
code)
Description
Suitable for use
with diaphragm
materials
Re-ordering part
numbers
A
10w30 standard duty
All except EPDM
A01-114-3430
A01-114-3431
A01-114-3432
A01-114-3433
B
40wt
All except EPDM
A01-114-3440
A01-114-3441
A01-114-3442
A01-114-3443
D
EPDM compatible
All
A01-114-3402
A01-114-3403
E
Food contact
All except EPDM
A01-114-3410
A01-114-3411
H
15w50 high-temp
severe-duty synthetic oil
All except EPDM
A01-114-3416
A01-114-3421
T&Q Series Hydra-Cell pumps are not suitable for total immersion in liquid.
Only genuine replacement parts and mechanical components must be used. The
chemical and mechanical characteristics of genuine parts only have been considered
as part of the risk assessment to ensure explosion safety within the parameter of the
ATEX classification herein.
Alteration or modification of the pump is only permitted with the express permission
of Wanner International.

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6. Markings of Conformity – Category 2 Zone 1
The pump nameplate is Stainless steel and text clearly marked as below in figure 1.
Figure 1 - ATEX nameplate markings
The nameplate will be positioned on the top of the crankcase. It is fixed with pop
rivets to the main crankcase illustrated on the next page in figure 2.

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Figure 2 – Component positions
An earth stud is fitted to every T and Q-Series Hydra-Cell ATEX certified pump and
must be connected to ground during installation.
For some T100 models there is also a secondary earthing point on an ‘ear’ projecting
from the back cover gasket. This should also be connected to electrical ground.
Earth Stud
Oil Drain
Sight Glass
Oil level monitor
Nameplate
Access hole for testing float switches
Secondary earth
(T100 Only)

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7. Earth Continuity Checks & Procedure.
Checking Procedure.
The 2 cables connected to the PAT tester are connected, one to the manifold of the
pump and the other to the earth stud, as described in the pictures below.
The ‘earth bond’ is then measured on the deflection meter, when the red earth button
is pressed on the PAT tester.
Values of below 0.1 ohms can be expected and as such are acceptable. The actual
value is recorded against the pump serial number in the ATEX register.
PAT tester connected to pump 1

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PAT tester in operation 1

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8. Oil level monitoring device installation.
ATEX T and Q series pumps are supplied with an Ex d flameproof level sensor
which is used to monitor the level of oil in the pump and detect a change in level
caused by diaphragm rupture. This should be connected to an approved motor
shutdown system.
There are two different versions available: A 2-point magnetic float reed switch and a
continuous level sensor.
2 point float switch, P/N 177-453-01
The float switch is fitted with 2 floats and 4 normally closed reed switches. When the
oil level is nominal, all switches will be closed circuit. If the oil level becomes too
high the upper float switches will create an open circuit condition. If the oil level
becomes too low the lower float switches will create an open circuit condition. The
switches should be installed as part of a control loop which ensures that any switch
creating an open circuit condition will result in a shutdown of the pump within less
than 1 minute. Configuring the control loop so that there is a small delay of less than
1 minute will enable testing of the switch during pump operation without inadvertently
shutting down the pump.
Both switch points are pre-set and will trigger at the correct limiting oil levels if the
switch is installed at the factory.

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8.1 Electrical installation
The connecting wires to the printed circuit board must be between 16 to 22AWG
(Metric capacity 1.5mm2) with 6mm stripped ends. The earth wire should be
connected to the screw point in the head using the crimp terminal provided. EXd
flameproof cable gland for enclosures with internal volume ≥ 0.5 litres and suitable
for gas, zone, temperature and cable type being used. IP6x glands must be used in
dust environments.
When using conduit a stopping box must be fitted no more than 50mm from the
sensor head. The stopping box and conduit must be installed in accordance with
clause 13.2.2 EN60079-1.
A cable strain relief can be made by passing the cable through the nylon washer and
fixing a cable tie tight to the cable, leaving a minimum of 70mm after the cable tie.
The electrical supply to all the switches must be connected through a protection
device to limit excess current should a fault occur. A fast blow 1A fuse can be used
to limit the total current drawn by all the switches together. If each switch point is
fused individually the sum of all the fuse links must not exceed 1Amp. The fuse must
be placed in a position where it protects the cable and the sensor should a fault
occur.
After connecting the earth, supply and output wires, screw the lid down hand-tight,
keep applying torque by hand until the lid cannot be turned any further. Tighten the
lidlocking screw so the lid cannot be accidentally removed.

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9. Installation and Putting into Service.
Inlet Piping (Suction Feed)
If there is a possibility of freezing conditions, 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 flow, NPSHA must exceed NPSHR (See chart in Specifications Section). Do not supply more than one
pump from the same inlet line if possible. Where this is unavoidable, give due consideration to the use of suction
stabilisers.
Hose and Routing
Size the suction line so that the velocity will be no more than 0.9 m/s:
For pipe in mm: Velocity (m/sec) = 21.2 x LPM/Pipe ID2
Keep the suction line as short and direct as possible.
Where possible, use flexible hose and/or expansion joints to absorb vibration, expansion, or contraction.
If possible, keep suction line level. If possible, avoid any high points collecting vapor unless high points are vented.
To reduce turbulence and resistance, avoid the use of 90° elbows where possible. If turns are necessary in the
suction line, use 45° elbows or arrange sweeping curves in the flexible inlet hose.
If a block valve is used, be sure it is fully opened so that the flow 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 filter in the suction line unless regular maintenance is assured. If used, choose a top
loading basket. It should have a free-flow area of at least three times the free-flow 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. Where possible, avoid supplying more than one pump from the same inlet line. Where
multiple pumps must be installed from the same line give due consideration to ensuring the fluid velocity does not
exceed 0.9m/s at any point in the suction line and install suction stabilisers to minimise suction line pulsation.
Inlet Calculations
Acceleration Head
Calculating the Acceleration Head
Use the following formula to calculate acceleration head losses. Subtract this figure 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 (m) — not equivalent length
V = Velocity of liquid in suction line (m/sec) [V = LPM x (21.2 ÷ pipe ID2)]
N = rpm of crank shaft
C = Constant determined by type of pump — use 0.066 for the T100 Hydra-Cell pumps, use 0.04 for the
Q155 Hydra-Cell pumps.
K = Constant to compensate for compressibility of the fluid — use: 1.4 for de-aerated or hot water; 1.5 for
most liquids; 2.5 for hydrocarbons with high compressibility
G = Gravitational constant (9.81m/s2)
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 fluid.
When pumping more-viscous fluids such as lubricating oils, sealants, adhesives, syrups, varnishes, etc.; frictional
losses in the suction piping may become significant. As Hf increases, the available NPSH (NPSHa) will decrease,
and cavitation will occur.
In general, frictional losses increase with increasing viscosity, increasing suction-line length, increasing pump flow
rate, and decreasing suction-line diameter. Changes in suction-line diameter have the greatest impact on frictional

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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 five times.
Consult the factory before pumping viscous fluids.
Minimizing Acceleration Head and Frictional Losses
To minimize the acceleration head and frictional losses, where possible:
• Keep inlet lines less than 6 ft (1.8 m) or as short as possible
• Use at least 4 in. (102 mm) I.D. inlet hose
• Use suction hose (low-pressure hose, non collapsing) for the inlet lines
• Minimize fittings (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 fluid — 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:
NPSHa must be at least 1m greater than NPSHr
All values must be expressed in metres of liquid
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.
Where possible, use flexible hose between the pump and rigid piping to absorb vibration, expansion or contraction.
Support the pump and piping independently. Where possible, size the discharge line so that the velocity of the fluid
will be 1-3 m/sec
Pressure Relief
Install a pressure relief valve in the discharge 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
over pressurizing the pump.
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 pump.
Do not route the bypass line directly back to the pump suction port.
If the pump may be run for a long time with the discharge closed and fluid bypassing, install a thermal protector in
the bypass line (to prevent severe temperature buildup in the bypassed fluid).
CAUTION: Never install shutoff valves in the bypass line or between the pump and pressure relief valve.
Install a pressure gauge in the discharge line.
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 4.5 bar cracking
pressure where necessary to prevent a vacuum condition during shutdown.
Oil Level Monitoring. Oil level is sensed by the back cover float switch and can be used to control the pump
system operation.
Before Initial Start-Up

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Before you start the pump, be sure that:
• Pump is stored at a temperature above the minimum service temperature for a minimum of 24 hours before
start up.
• All shutoff valves are open, and the pump has an adequate supply of fluid.
• All connections are tight.
• The oil level is correct. 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 float (48) is in the middle of the sight glass.
• Connect the float switch. See Float Switch Section.
• Test the float switch by removing the side port plug (50) and manipulating the float 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 minimum temperature specified in diaphragm temperature limits table for 24 hours
prior to starting.
2. Open the bypass line start-up and capacity-control valve (if required) so the pump may be started against
negligible discharge pressure.
3. Turn on power to the pump motor.
4. Check the inlet pressure or vacuum. To maintain maximum flow, inlet vacuum must not exceed 0.24 bar at 21°
C. Inlet pressure must not exceed 500 psi (34 bar).
5. Listen for any erratic noise, and look for unsteady flow.
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 the tee fitting at the pump outlet (if installed), or remove the plug / blanking
flange from the unused side of the pump discharge.
Note: Fluid may come out of this port when the plug is removed. Provide an adequate catch basin for fluid
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 fluid will not be sprayed or lost. Use high-pressure-rated hose
and fittings from this port. Take all safety precautions to assure safe handling of the fluid being pumped.
c. Jog the system on and off until the fluid coming from this port is air-free.
d. Turn off 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 fluid 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.

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10. Maintenance and Testing
Hydra-Cell pumps should only be maintained by competent engineers authorised to
perform the procedures being carried out.
As part of the regular maintenance procedure for the pump, the following routine
checks must be made.
1. Check the pressure relief / bypass valve is functioning as intended.
2. All head and casing bolts are secured (refer to torque values).
3. Check for electrical conductivity for the pump frame to ground.
4. Check the integrity of the external shaft seals and pump head O rings.
Please refer to the T-Series Hydra-Cell Installation / Service manual and supplements
for more detailed instructions on maintenance and checking methods.
The pump casing must have cooled down to ambient temperature before
disassembling the pump.
The bearings in the pump have a limited lifetime. Each T-Series pump datasheet has
curves showing pressure and speed limits corresponding to rated L10 bearing life of
16,000 and 25,000 hours. The bearings should be replaced according to the
instructions in the Installation, Operation and Maintenance manual after the L10
bearing life has expired. Failure to replace the bearings after the lifetime has
expired can result in bearing failure, leading to excessive heat generation and
the pump temperature exceeding the certified temperature class.
The oil level float switches are a critical part of the explosion protection of the pump
and they should be tested for correct operation at regular intervals. The pump is
provided with an access hole on the back cover which enables the floats to be
exercised without disassembly of the pump. A flat bladed screwdriver or similar blunt
tool can be inserted through the access hole. This should be done while the pump is
running. Push the lower float downwards with the screwdriver until it hits the
mechanical stop and hold the float down until the control system initiates a pump
shutdown. The pump should then be re-started and the upper float should be lifted
and held upwards against the stop until the control system initiates a pump shutdown.
If either float fails to initiate a shutdown then the pump should be manually stopped
and not used again until the control system loop is confirmed as working correctly.
This proof test of the shutdown system should take place at least once every 18
months and records of the testing should be maintained by the operator.

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Appendix 1: Type Certificate

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