TechnaFlo Manual Cover - PFI FLOWTEKNIK miniaturepumper/technaflo... · Pumping of viscous liquids with Gear Pumps (reference) Gear pumps are well suited for pumping of viscous liquids

TechnaFlo Product Manual

P – D – T Series Pumps

Birkdale Close, Manners Industrial Estate Ilkeston, Derbyshire, DE7 8YA, England Tel + 44 (0) 115 9325226 Fax + 44 (0) 115 9324816 Email: [email protected] Website: www.tuthill.com

Index

1. Viscosity handling characteristics 2. Viscosity speed limits 3. D, T & P Series product matrix 4. Magset 5. Safety instructions 6. Materials of construction 7. PEEK data sheet 8. PPS data sheet 9. 316 Stainless steel data sheet P Series 10. Installation operation & maintenance instructions

P Series 11. P series on a 63 Frame motor

D Series

12. Installation operation & maintenance instructions D Series 13. D Series service pack instructions 14. D Series pumphead 15. D Series explosion 16. D Series on a 63 frame motor 17. D Series on a 71 frame motor

T Series

18. Installation operation & maintenance instructions

T Series 19. T Series service pack instructions 20. T Series pumphead 21. T Series explosion 22. T Series on a 71 frame motor 23. T Series on a 80 frame motor

24. Motor wiring diagram 25. Atex certificate

Tuthill Pump Group Concord Operations

Viscosity Handling Characteristics Guide Viscosity Conversion Table (reference) Saybolt Universal (SSU)

Centistokes Centipoises Typical liquids at 70°F

31 1.00 0.8 Water 35 2.56 2.05 Kerosene 50 7.40 5.92 No. 2 Fuel Oil 80 15.70 12.60 No. 4 Fuel Oil

100 20.20 16.20 Transformer Oil 200 43.20 34.60 Hydraulic Oil 300 65.40 52.20 SAE 10W Oil 500 110 88 SAE 10 Oil

1,000 200 173 SAE 20 Oil 2,000 440 352 SAE 30 Oil 5,000 1,080 880 SAE 50 Oil

10,000 2,160 1,760 SAE 60-70 Oil 50,000 10,800 8,800 Molasses B

100,000 21,600 17,300 Molasses C * Centipoises are given for oil of 0.8 specific gravity. Relationship: centistokes x specific gravity = centipoises. Pumping of viscous liquids with Gear Pumps (reference) Gear pumps are well suited for pumping of viscous liquids if the following rules are observed. (1) Pump speed (RPM) must be reduced. Use speed reduction table below as a guide. (2) Suction and discharge lines must be increased by at least one, or better two pipe sizes over the size of the pump ports. (3) Horsepower of the motor must be increased over whatever power would be required for pumping water under the same pressure and flow.

Speed Reduction % Increase in Horsepower Viscosity in SSU

Recommended speed (RPM)

Viscosity in SSU

50 1725

Pressure

30 500 1000 5000 10,000 50,000 100,000500 1500 2 --- 30 60 120 200 300 400

1000 1300 20 --- 25 50 100 160 260 3505,000 1000 40 --- 20 40 80 120 220 300

10,000 600 60 --- 15 30 60 105 180 25050,000 400 80 --- 12 25 50 90 150 200

100,000 200 100 --- 10 20 40 80 120 150

Viscosity / RPM 1023-02Effective May 2002 Replace New

RECOMMENDED MAXIMUM SPEED U, D, & T SERIES

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

0.02

0.04

0.08

0.11

0.23

0.38

0.57

0.68 0.8 0.99 1.2 1.3 1.6 2 2.3 2.6 5.3 7.9 8 12

PUMP SIZE ML/REV

SPEE

D (R

PM)

10,000 CPS

5,000 CPS

1,000 CPS

100 CPS

1 CPS

P - SERIES D - SERIES T - SERIESTYPE EXTERNAL GEAR EXTERNAL GEAR EXTERNAL GEAR

MATERIAL PPS 316 S/STEEL 316 S/STEEL

MATERIAL OPTIONS

HASTELLOY SHAFTS

HASTELLOY, TITANIUM, ALLOY

20

HASTELLOY, TITANIUM

CAVITY FIXED FIXED FIXED

FLOW (ml/Rev) .38 to 1.2 .11 to 2.3 2.6 to 12.0

MAX FLOW 3.2 L/Min 6.1 L/Min 32.0 L/Min

MAX PRESSURE 10 Bar 17 Bar 17 Bar

SYSTEM PRESSURE

20 Bar 34 Bar 34 Bar

MAX TEMPERATURE

65°C 176°C 176°C

PORTS 1/8" NPT1/8" NPT or 1/4"

NPT3/8" or 3/4" NPT

PORT OPTIONS NO YES YES

GEAR MATERIALS

PPS or PTFEPPS, PEEK, PTFE, LCP, KYNAR or SS

PPS, PEEK, LCP or SS

BEARING MATERIALS

PPSPPS, PEEK, PTFE, CARBON or LCP

PPS, PEEK, PTFE, CARBON or LCP

PPS

"O" RING MATERIALS

AS REQUIRED AS REQUIRED AS REQUIRED AS REQUIRED

RELIEF VALVE OPTIONAL OPTIONAL OPTIONAL NONE

PRODUCT MATRIX

RATINGS BASED ON CLEAN WATER, AMBIENT TEMPERATURE, 0 Bar and 2800 RPM

SHAFT EXTENDED FULLY FORWARDS (Motors with Shaft end Play only)

DRIVE MAGNET

MAGNET SETTING DIMENSION = M

PUMP SERIES MAGNET SETTING (M) in “mm” B, D, PD, BX 2.16 to 2.29

M, T 5.99 to 6.10 TX 3.56 to 3.68

MAGNET “DROP” SETTING (FAILURE TO SET MAGNET CORRECTLY WILL RESULT IN PUMP DAMAGE)

MATERIALS OF CONSTRUCTION MODEL P-SERIES D-SERIES T-SERIES

WETTED COMPONENTS PPS with 316 SS, HASTELLOY

or TITANIUM TRIM 316 SS, HASTELLOY or

TITANIUM 316 SS, HASTELLOY or

TITANIUM GEARS PPS PPS, PEEK, PTFE, LCP PPS or PEEK

BEARINGS PPS PPS, PEEK, PTFE, CARBON, or

LCP PPS, PEEK,

CARBON

O-RINGS VITON, EPR, NITRILE, or

NEOPRENE VITON, PTFE, EPR, NITRILE, or

NEOPRENE VITON, PTFE, EPR, NITRILE, or

NEOPRENE

MAGNETS ENCAPSULATED CERAMIC or

SAMARIUM COBALT ENCAPSULATED CERAMIC or

SAMARIUM COBALT ENCAPSULATED CERAMIC or

SAMARIUM COBALT 316 SS: 316 Stainless Steel PPS: Polyphenylene Sulfide PEEK: PolyEtherEtherKetone

Preliminary Product Data

RTP 2285 HF TFE 15Polyetheretherketone (PEEK)

Carbon FiberPTFE Lubricated

High Flow

As a specialty compounder RTP Company custom formulates thermoplastic compounds to meet specific customer and application requirements. Standard product data sheets are intended to showcase our capabilities to modify and enhance polymers and to provide comparative information on the effects of various additives.

Compound Properties English SI Metric

Color Natural/Black Natural/Black Injection Pressure 12000 - 18000 psi 83 - 124 MPa Injection Cylinder Temperature 650 - 730 °F 343 - 388 °C Mold Temperature 325 - 425 °F 163 - 218 °C Properties & Average Values of Injection Molded Specimens

Permanence RTP 2285 HF TFE 15 RTP 2285 HF TFE 15ASTM

Test

Specific Gravity 1.49 D792Molding Shrinkage, 1/8 in (3.18 mm) section 0.005 in/in 0.5 % D955Water Absorption, 24 hrs @ 23°C 0.12 % 0.12 % D570 Mechanical

Impact Strength, Izod, notched 1/8 in (3.18 mm) section 85 J/m D256Impact Strength, Izod, unnotched 1/8 in (3.18 mm) section 641 J/m D256Tensile Strength 234 MPa D638Tensile Elongation 1.3 % 1.3 % D638Tensile Modulus 31010 MPa D638Flexural Strength 345 MPa D790Flexural Modulus 24120 MPa D790 Electrical

Volume Resistivity 1E5 ohm-cm D257

1.49

1.6 ft-lb/in

12 ft-lb/in34000 psi

4.5 psi x 106

50000 psi3.5 psi x 106

1E5 ohm-cm

Thermal

Deflection Temperature @ 264 psi (1.82 MPa) 288 °C D648Flammability* V-0 @ 1/16 in ** V-0 @ 1.5 mm ** D3801 Notes

Data herein is typical and not to be construed as specifications. Unless otherwise specified, all data listed is for natural or black colored materials. Pigments can affect properties. * This rating is not intended to reflect hazards of this or any other material under actual fire conditions. ** Per testing performed by RTP Company.

Data are obtained from specimens molded under carefully controlled conditions from representative samples of the compound described herein. Properties may be materially affected by molding techniques applied and by the size and shape of the item molded. No assurance can be implied that all molded articles will have the same properties as those listed.

No information supplied by RTP Company constitutes a warranty regarding product performance or use. Any information regarding performance or use is only offered as suggestion for investigation for use, based upon RTP Company or other customer experience. RTP Company makes no warranties, expressed or implied, concerning the suitability or fitness of any of its products for any particular purpose. It is the responsibility of the customer to determine that the product is safe, lawful and technically suitable for the intended use. The disclosure of information herein is not a license to operate under, or a recommendation to infringe any patents.

RTP Company • 580 East Front Street • Winona, MN 55987 • 507-454-6900

550 °F

Preliminary Product Data

RTP 1385 TFE 15Polyphenylene Sulfide (PPS)

Carbon FiberPTFE Lubricated

As a specialty compounder RTP Company custom formulates thermoplastic compounds to meet specific customer and application requirements. Standard product data sheets are intended to showcase our capabilities to modify and enhance polymers and to provide comparative information on the effects of various additives.

Compound Properties English SI Metric

Color Natural/Black Natural/Black Injection Pressure 10000 - 15000 psi 69 - 103 MPa Injection Cylinder Temperature 550 - 610 °F 288 - 321 °C Mold Temperature 275 - 350 °F 135 - 177 °C Properties & Average Values of Injection Molded Specimens

Permanence RTP 1385 TFE 15 RTP 1385 TFE 15ASTM

Test

Specific Gravity 1.54 D792Molding Shrinkage, 1/8 in (3.18 mm) section 0.001 in/in 0.1 % D955Molding Shrinkage, 1/4 in (6.35 mm) section 0.001 in/in 0.1 % D955Water Absorption, 24 hrs @ 23°C 0.02 % 0.02 % D570 Mechanical

Impact Strength, Izod, notched 1/8 in (3.18 mm) section 53 J/m D256Impact Strength, Izod, unnotched 1/8 in (3.18 mm) section 320 J/m D256Tensile Strength 164 MPa D638Tensile Elongation 0.5 % 0.5 % D638Tensile Modulus 26180 MPa D638Flexural Strength 236 MPa D790Flexural Modulus 21360 MPa D790Compressive Stength 131 MPa D695Hardness, Rockwell R 123 123 D785 Electrical

Volume Resistivity 1E5 ohm-cm D257

1.54

1 ft-lb/in

6 ft-lb/in23800 psi

3.8 psi x 106

34200 psi3.1 psi x 106

19000 psi

1E5 ohm-cm

Thermal

Deflection Temperature @ 264 psi (1.82 MPa) 266 °C D648Deflection Temperature @ 66 psi (0.45 MPa) 260 °C D648Flammability* V-0 @ 1/16 in ** V-0 @ 1.5 mm ** D3801Coefficient of Linear Thermal Expansion, Flow Direction 1.6 cm/cm/°C x 10-5 D696Thermal Conductivity, Through-plane 0.36 W/m-K C177 Notes

Data herein is typical and not to be construed as specifications. Unless otherwise specified, all data listed is for natural or black colored materials. Pigments can affect properties. * This rating is not intended to reflect hazards of this or any other material under actual fire conditions. ** Per testing performed by RTP Company.

Data are obtained from specimens molded under carefully controlled conditions from representative samples of the compound described herein. Properties may be materially affected by molding techniques applied and by the size and shape of the item molded. No assurance can be implied that all molded articles will have the same properties as those listed.

No information supplied by RTP Company constitutes a warranty regarding product performance or use. Any information regarding performance or use is only offered as suggestion for investigation for use, based upon RTP Company or other customer experience. RTP Company makes no warranties, expressed or implied, concerning the suitability or fitness of any of its products for any particular purpose. It is the responsibility of the customer to determine that the product is safe, lawful and technically suitable for the intended use. The disclosure of information herein is not a license to operate under, or a recommendation to infringe any patents.

RTP Company • 580 East Front Street • Winona, MN 55987 • 507-454-6900

510 °F500 °F

0.9 in/in/°F x 10-5

2.5 BTU-in/hr-ft²-°F

316 Stainless Steel:

316 Stainless Steel is used when the product will be exposed to a corrosive environment. Edstrom Industries uses 316 stainless steel in applications where high levels of chlorine or hydrochloric acid are added to the drinking water. 316 stainless steel is also used when the product is connected to other equipment, such as chlorinators or bottle fillers, and spills or fumes may contact the sheet metal. Edstrom Industries uses 316 stainless steel for animal drinking valves, fittings, and tubing in room distribution systems and rack manifolds. 316 stainless steel is specified at any location where the drinking water may flow through. This is done in case the customer adds chlorine to the water, or if the customer uses tap water. (Tap water may be acidic and have high levels of organic material, which can cause corrosion.)

316 stainless steel contains molybdenum, and the nickel content in 316 is 10% (compared to the 8% nickel content found in 314 stainless steel). Molybdenum, in conjunction with chromium, provides superior resistance to corrosion due to chlorides. The increased nickel content aids in repassivation of the passive film in case of damage.

Note, however, that 316 stainless steel is subject to attack if very high levels of chlorine are used for extended periods of time. If 50 PPM and above is used in the system and let stand in the system for longer than 3 or 4 hours, pitting will occur, as the chlorides will attack it, especially in cracks and crevices.

316 stainless steel is non-magnetic. Its machinability is similar to 304 stainless steel, and its material cost is 50% to 100% more than 303 or 304 stainless steel.


P Series Installation, Operation, Safety & Warranty Information

WARNING SAFETY INSTRUCTIONS CAUTION

1. Gear pumps can produce high differential pressures that may cause system damage and expose personnel to hazards associated with an unintentional release of fluid. Exceeding design limits may cause pump to burst and may cause pump and/or motor to fail. 2. Pumphead and motor & drive are designed to be operated together. Before any disassembly, disconnect power to motor and do not allow pumphead to be pressurized. 3. Do not pressurize or operate pump unless the pump/motor assembly contains a complete set of correctly installed fasteners in good condition. Each threaded hole must contain a fastener. 4. Do not operate pump/motor unless it is secured in its desired location. 5. Do not modify any part of pump/motor assembly. Modification may weaken pressure-containing parts and create hazards to personnel. Use only factory-authorized replacement or repair parts. 6. Do not allow pump to be subjected to an internal pressure approaching its burst pressure of 600 psig at room temperature. Internal pressure (measured at either suction or discharge ports) should not exceed 300 psig (safety factor of 2.0). Specific codes, standards, operating practices and conditions may dictate a lower internal pressure (higher safety factor). Verify leak-tight installation of fluid connections prior to operation where leakage could be hazardous. 7. Do not exceed a fluid temperature of 150°F. Fluid temperatures above 100°F reduce the strength of pressure-containing parts. At 150°F pump burst pressure is 500 psig. 8. The pump should not be used where the pumped fluid causes corrosion to metal pressure-containing parts of attacks the pump seals or plastic body. These conditions will cause a significant reduction in the ability of the pump to contain pressurized fluid and may cause hazardous leakage. Motor & Drive Assemblies 1. In normal operation electric motors may develop surface temperatures that will burn the skin. 2. Electric motors produce waste heat that must not be allowed to accumulate in the surrounding air. Unless otherwise specified, an electric motor will operate continuously without overheating at its published performance limit at an ambient (air) temperature not exceeding 40°C (104°F). 3. Electric motors are not liquid tight and should not be exposed to sprays, splashes, drips or immersion, nor should they be exposed to the weather. 4. Do not block motor ventilation openings (if present). Do not allow objects to enter motor openings. 5. Motor must be disconnected from power supply immediately if any condition prevents motor rotation. AC Motors 1. AC motors must be operated only from the power source(s) (voltage and frequency) specified on the motor nameplate. 2. Connect dual voltage motors to power source according to connection diagram on motor nameplate. 3. Thermally protected motors (see motor nameplate) automatically turn themselves off when winding temperature exceeds allowable limits; however, motor will restart without warning when winding temperature drops, unless power source is disconnected from motor. Thermal overload protection must not be relied upon to control motor under any but abnormal or unexpected conditions. Permanent Magnet (brush-type) DC (PMDC) Motors (Including AC/DC series-wound (universal) motors) 1. PMDC motors are designed to operate over a range of speeds by varying the input voltage; unless otherwise specified, a PMDC motor may be operated at input voltage in the range specified by the motor rating (see nameplate). 2. Regardless of input voltage, motor current may exceed the motor rating only for intermittent duty applications. Operation with excessive motor current may result in motor overheating. 3. Continuous duty current limits for PMDC motors are based upon a power supply form factor of 1.0 (ripple free). 4. PMDC motors are not thermally protected (motor will not automatically turn itself off when overheated). Brushless DC (BLDC) Motors 1. BLDC motors are designed to operate over a range of speeds by varying the input voltage; do not operate motor beyond input voltage range of motor (see nameplate). 2. Regardless of input voltage, motor current must never exceed the value specified for the motor; even momentary operation with excessive motor current may cause permanent damage to motor. 3. Power supply ripple and noise (peak-to-peak) must never exceed 10% of the input voltage supplied; otherwise, permanent damage to motor will result.

INSTALLATION Pump Installation & Plumbing – Locate the pump as close and below the liquid source as possible. Suction and Discharge lines should be as large as the pump ports and as short as possible. If long suction runs are required, use larger tubing. Avoid any restrictions; valves, elbows or sharp turns whenever possible to avoid loss of flow or performance.

P Series IOM 4001-02 Effective May 2002 Replace New Page 1 of 2

P Series…continued Fitting Installation – Apply a paste-type thread sealant no more than 3 threads from the end of the fitting before assembling to pump ports (1/8 NPT). Do not use Teflon® Tape. Tighten fittings no more than 5 total turns and no more than 2 turns beyond finger-tight, whichever is less. The use of plastic fittings is highly recommended to reduce the likelihood of cracked ports. Take care not to damage or misalign the pumphead when installing the fittings. Hold the pumphead, not the motor, to resist the wrenching torque. Filters – On the suction side a filter of 25 microns or less is desirable. If the system is closed loop recirculating the filter must be placed on the discharge side. The smallest micron filter should be used without restricting flow or performance.

OPERATION Magnetic Coupling – Magnetic coupling makes the “zero leak” feature possible. It also offers protection from damage caused by excessive pressures or foreign particles wedged in the gear teeth. Decoupling occurs when the two magnets are forced out of pole-to-pole alignment. 1. If the pump decouples, the motor will continue to operate at no load speed but the gears in the pump will stop rotating. 2. To recouple, stop the motor completely and restart. 3. If decoupling persists, check the system for excessive pump pressure. If this does not correct the problem, the pump will have to be disassembled, check for foreign particles wedged in the gear teeth. Disassemble and clean parts thoroughly following repair procedure. After reassembly, rotate motor fan, Pump and Motor should rotate freely with no magnet rub or internal friction. 4. Operating pressure – The differential pressure across the pump should be set well below the decoupling pressure (See catalog for decoupling pressures). This will prevent inadvertent decoupling caused by transient pressure surges. Internal Bypass – Use a screwdriver to adjust. Adjustment may be made while the pump is operating. The bypass pressure is adjusted higher by turning the adjusting screw clockwise, and lowered by turning counter-clockwise. The bypass pressure should be set below the normal decoupling pressure and above the operating pressure. See catalog for factory set bypass pressure. Self-Priming – Tuthill pumps are capable of self-priming, make certain the gears are “wetted” with the pumping fluid. Running Dry - Dry running will cause permanent damage; make certain there is fluid in the pump while in operation. Running in Reverse – The inherent design of these gear pumps require that the pump be run in clockwise rotation. Intermittent reverse rotation for purging may be acceptable. Continuous reverse rotation (counter-clockwise) is not recommended and premature failure will occur.

PRODUCT WARRANTY Tuthill Pump Company of California (“Manufacturer”) a subsidiary of Tuthill Corporation warrants to each buyer of its products (the “Buyer”) for a period of 12 months from date of manufacture that goods of its manufacture (“Goods”) will be free from defects of material and workmanship. Manufacturer’s sole obligation under the foregoing warranties will be limited to either, at Manufacturer’s option, replacing or repairing defective Goods or refunding the purchase price for such Goods theretofore paid by the Buyer, the Buyer’s exclusive remedy for breach of any of such warranties will be enforcement of such obligations of Manufacturer. If Manufacturer so requests the return of the Goods, the Goods will be redelivered to Manufacturer in accordance with Manufacturer’s instructions F.O.B. factory. The remedies contained herein shall constitute the sole recourse of the Buyer against Manufacturer for breach of warranty. IN NO EVENT SHALL MANUFACTURER BE LIABLE FOR CONSEQUENTIAL DAMAGES NOR SHALL MANUFACTURER’S LIABILITY ON ANY CLAIM FOR DAMAGES ARISING OUT OF THE MANUFACTURE, SALE, DELIVERY OR USE OF THE GOODS EXCEED THE PURCHASE PRICE OF THE GOODS. The foregoing warranties will not extend to Goods subjected to misuse, neglect, accident or improper installation or maintenance or which have been altered or repaired by anyone other than Manufacturer or its authorized representative. THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY, FITNESS FOR PURPOSE AND OF ANY OTHER TYPE, WHETHER EXPRESS OR IMPLIED. The warranty specified herein shall apply to this contract, but it is specifically understood that Goods sold hereunder are not warranted for wear or for operation with erosive or corrosive fluids unless specifically stated in our acknowledgment. No product or part shall be deemed to be defective by reason of failure to resist wear or erosive or corrosive action of any fluid and Buyer shall have no claim whatsoever against Manufacturer therefore. No person may vary the foregoing warranties and remedies except in writing signed by a duly authorized officer of Manufacturer. Warranties or remedies that differ from the foregoing shall not otherwise be binding on Manufacturer. The Buyer’s acceptance of delivery of the Goods constitutes acceptance of the foregoing warranties and remedies, and all conditions and limitations thereof.

IMPORTANT INFORMATION For your protection, please read and observe the following instructions. Transportation companies assume all liability from the time of shipment is received by them until the time it is delivered to the consumer. Our liability ceases at the time of shipment. All shipments leaving our plant have been carefully inspected. If a shipment arrives with the crating or packaging damaged, have the carrier note the condition on the receipt. Check as soon as possible for concealed damage. If it is found that the shipment has been damaged in transit, please Do Not return to us, but notify and file a claim with the carrier at once. FAILURE TO FOLLOW THIS PROCEDURE WILL RESULT IN THE REFUSAL BY THE CARRIER TO HONOR ANY CLAIMS WITH A CONSEQUENT LOSS TO THE CONSUMER. If UPS or Parcel Post has been damaged, retain the damaged material and notify us at once. We will file a claim. Goods may not be returned for credit unless authorized by our sales department.

P Series IOM 4001-02 Effective May 2002 Replace New Page 2 of 2


D, T & U Series Installation, Operation, Safety & Warranty Information




D, T, U Series IOM 4000-02Effective May 2002 Replace New Page 1 of 2

D, T & U Series…continued Fitting Installation – Apply a paste-type thread sealant or Teflon® tape (two wraps maximum) no more than 3 threads from the end of the fitting before assembling to pump ports. Tighten fittings no more than 5 total turns and no more than 2 turns beyond finger-tight, whichever is less. Take care not to damage or misalign the pumphead when installing the fittings. Hold the pumphead, not the motor, to resist the wrenching torque. Filters – On the suction side a filter of 25 microns or less is desirable. If the system is closed loop recirculating the filter may be placed on the discharge side. The smallest micron filter should be used without restricting flow or performance.

OPERATION Magnetic Coupling – Magnetic coupling makes the “zero leak” feature possible. It also offers protection from damage caused by excessive pressures or foreign particles wedged in the gear teeth. Decoupling occurs when the two magnets are forced out of pole-to-pole alignment. 1. If the pump decouples, the motor will continue to operate at no load speed but the gears in the pump will stop rotating. 2. To recouple, stop the motor completely and restart. 3. If decoupling persists, check the system for excessive pump pressure. If this does not correct the problem, the pump will have to be disassembled, check for foreign particles wedged in the gear teeth. Disassemble and clean parts thoroughly following repair procedure. After reassembly, rotate motor fan, Pump and Motor should rotate freely with no magnet rub or internal friction. 4. Operating pressure – The differential pressure across the pump should be set well below the decoupling pressure (See catalog for decoupling pressures). This will prevent inadvertent decoupling caused by transient pressure surges. Internal Bypass – Use a screwdriver to adjust. Adjustment may be made while the pump is operating. The bypass pressure is adjusted higher by turning the adjusting screw clockwise, and lowered by turning counter-clockwise. The bypass pressure should be set below the normal decoupling pressure and above the operating pressure. See catalog for factory set bypass pressure. (T & U Series are not available with internal bypass.) Self-Priming – Tuthill pumps are capable of self-priming, make certain the gears are “wetted” with the pumping fluid. Running Dry - Dry running will cause permanent damage; make certain there is fluid in the pump while in operation. Running in Reverse – The inherent design of these gear pumps require that the pump be run in clockwise rotation. Intermittent reverse rotation for purging may be acceptable. Continuous reverse rotation (counter-clockwise) is not recommended and premature failure will occur. Do not operate U-Series in reverse rotation, may result in reduced performance.





D SERVICE PAK INSTRUCTIONS

Suggested Service Pak Tools 60129-1 Bearing Extractor Tool 60158-1 Medium Blade Screwdriver 60098-2 Bearing Installation Tool 60157-1 Bypass Nut Driver 60154-1 T10 Torx Driver Optional Rubber Gloves 60155-1 T15 Torx Driver Optional Masking Tape 60169-1 Hex Key Wrench 9/64″ 60149-1 D Series Tool Kit

(Includes all tools shown above) Service Pak includes: 2 Gears, 3 O-Rings, 5 Bearings, Silicone Lubrication and Instruction Sheet.

WARRANTY WILL NOT EXTEND TO GOODS ALTERED OR REPAIRED BY ANYONE OTHER THAN THE MANUFACTURER OR AUTHORIZED REPRESENTATIVE

NOTE: Service Paks are designed to be installed by someone familiar with precision mechanical assemblies and tools. Observe reasonable safety precautions, including the use of safety eyewear when performing the steps listed below. IMPORTANT: Check the Service Pak parts you have received. Tuthill has changed the Driven Magnet to a “slip fit” design for the Driving Gear Assembly (12). This design does not require a Magnet Clamp Screw (5). If you have received a Service Pak with the “slip fit” design and your Pump has a Magnet Clamp Screw (5) design Driven Magnet (7) you will need to contact the factory and order a “slip fit” Driven Magnet (7). See pictorials at the end of these instructions. DISASSEMBLY INSTRUCTIONS (Refer to pages 3 and 4) 1. Provide a clean surface for work area. 2. Remove three Mounting Screws (3) and separate Pumphead from Drive Housing. 3. Note: If the Gears are not being replaced and will be reused, after removing the Cap (16) in the next step mark

the Gears orientation with a permanent marker. This will allow the Gears to be reassembled in the same orientation.

4. Note: Remove two cap screws (17) with a 9/64 Hex Socket Wrench. Models manufactured prior to 2001 use a T20 Torx Driver.

5. Remove two Cap Screws (17) in the Cap (16) holding the other parts in place and remove the Cap (16), Driven Gear (13), Cavity Plate (15) and two Dowel Pins (14). If the pump is furnished with a Bypass take care not to damage the Poppet (20) sealing surface. Remove Poppet Assembly (20) from Bypass Adjusting Screw (18). Turn Bypass Nut (19) counter-clockwise 1 ½ turns. Hold Bypass Nut (19) against rotation and turn Bypass Adjusting Screw (18) counter-clockwise to remove from Cap (16).

6. Remove six Mounting Plate Screws (1) and remove the Mounting Plate (2) and Magnet Cup (4). 7. Note: Instructions for “slip fit” Design. Pull the Driven Magnet (7) off the Driving Gear Assembly (12) shaft (no

Screw is used in this design). 8. Note: Instructions for Magnet Clamp Screw Design. To prevent damage to the Driving Gear (12) REMOVE

Cap (16) BEFORE installing or removing the Magnet Clamp Screw (5). NEVER install or remove the Magnet Clamp Screw (5) with Cap (16) in place. Hold the Driven Magnet (7), Magnet Clamp (6), and Magnet Hub (8) from rotation and turn Magnet Clamp Screw (5) clock-wise (left hand threads) to remove.

9. Note: Magnet Clamp (6) and Magnet Hub (8) are not part of a DX Driven Magnet (7). 10. Remove three O-Rings (9) from the Cap (16) and Body (10). O-Rings (9) may be removed with a blast of

compressed air or with a sharp pin. 11. Important: Do not nick or scar the sides of the bearing bores in the steps below. 12. Clamp the Bearing Extractor Tool in a vise and screw the Bearing (11) on the tool and gently tap with a soft mallet

while supporting and pulling the Cap (16) or Body (10) to free the Bearing (11). Repeat process until all five Bearings (11) are removed. See Figure 1.

13. Inspect all parts for damage and wear. If wear on Cap (16), Cavity Plate (15) and Body (10) is excessive rebuilding the pump may not be recommended (consult factory).

ASSEMBLY INSTRUCTIONS (Refer to pages 3 and 4) A. Clean all parts. Any foreign material clinging to the Driven Magnet (7) can be removed with masking tape.

Title: D Service Pak Instructions Page 1 of 4 Document: 70016-1 Date: 05/03/06 Revision: H

ECO 50-7029 File name: Service Pak Instructions


B. Using the Installation Tool press five new Bearings (11) into the Cap (16) and Body (10). Bearings (11) should be .002/.005 below the face of the Cap (16) and Body (10). See Figure 2.

C. Apply a thin coat of silicone lubricant (furnished in Service Pak) to three new O-Rings (9) and install in the Cap (16) and Body (10) O-Ring grooves. Omit silicone lubricant if it is incompatible with your pumped fluid.

D. Note: Instructions for “slip fit” Design. Install Driving Gear Assembly (12); then slip fit Driven Magnet (7) on shaft (no screw required for this design).

E. Note: Instructions for Magnet Clamp Screw Design. Install Driving Gear Assembly (12), Magnet Hub (8), Driven Magnet (7), Magnet Clamp (6) and Magnet Clamp Screw (5). Hold Driven Magnet (7) to prevent rotation and tighten Magnet Clamp Screw (5) counter-clockwise (left hand threads) to 200 in/oz torque (a rubber glove can be used to facilitate holding the Driven Magnet (7).

F. Note: When performing the following assembly operations DO NOT apply forces to the Driven Magnet (7). Pushing or pulling the Driven Magnet (7) may damage the Driving Gear Assembly (12).

G. Install two Dowel Pins (14) into Body (10) and slip the Cavity Plate (15) over the Dowel Pins (14) against the Body (10) face. The Cavity Plate (15) will fit properly in only one orientation. The Screw holes in the Body (10) and Cavity Plate (15) must align.

H. Install Driven Gear Assembly (13) with the longer shaft extension into the Body (10). I. If pump is furnished with a Bypass, install Bypass Adjusting Screw (18) through the Bypass Nut (19) and turn

clockwise until the Bypass Adjusting Screw (18) is flush with the Bypass Nut (19). Attach Poppet Assembly Spring (20) onto the Bypass Adjusting Screw (18).

J. Align Cap (16) with the Driving (12) and Driven (13) Gear Assembly shafts and Dowel Pins (14). Assemble carefully and make certain the Poppet Assembly (20) goes fully into the Poppet hole and seats. See Figure 3.

K. Install two Cap Screws (17) in Cap (16) and torque alternately to 640 in/oz. L. Rotate the Driven Magnet (7) by hand to check for any binding during rotation. The Driven Magnet (7) should turn

freely. If there is binding determine and remove cause. M. Install Magnet Cup (4) and Mounting Plate (2) with six Mounting Plate Screws (1). Turn alternately until tight to

320 in/oz. N. Assemble Pumphead to Motor and Drive Housing with three Mounting Screws (3). Pump/Motor assembly is now

complete. O. Note: New parts may exhibit slight interference with mating surfaces. An initial “run-in” period may be required to

allow the gears to seat. Rebuilt pumps may initially decouple below normal differential pressure or produce less than normal flow-rate until mating parts have fully seated during initial period of operation.

Reference numbers on Pages 3 and 4

1. Mounting Plate Screws 2. Mounting Plate 3. Pump Mounting Screws 4. Magnet Cup 5. Magnet Clamp Screw 6. Magnet Clamp 7. Driven Magnet 8. Magnet Hub 9. O-Ring 10. Body 11. Bearing 12. Driving Gear Assembly 13. Driven Gear Assembly 14. Dowel Pin 15. Cavity Plate 16. Cap 17. Cap Screw 18. Bypass Adjusting Screw 19. Bypass Nut 20. Bypass Spring, Guide & Poppet Assembly

Title: D Service Pak Instructions Page 2 of 4 Document: 70016-1 Date: 05/03/06 Revision: H

ECO 50-7029 File name:D Service Pak Instructions

CC

D SERIES DIMENSIONAL DRAWING

IlkestonDerbyshireEngland

TUTHILLPUMP GROUP

UNCONTROLLED COPY WILL NOT BE UPDATED


D, T & U Series Installation, Operation, Safety & Warranty Information





D, T & U Series…continued Fitting Installation – Apply a paste-type thread sealant or Teflon® tape (two wraps maximum) no more than 3 threads from the end of the fitting before assembling to pump ports. Tighten fittings no more than 5 total turns and no more than 2 turns beyond finger-tight, whichever is less. Take care not to damage or misalign the pumphead when installing the fittings. Hold the pumphead, not the motor, to resist the wrenching torque. Filters – On the suction side a filter of 25 microns or less is desirable. If the system is closed loop recirculating the filter may be placed on the discharge side. The smallest micron filter should be used without restricting flow or performance.

OPERATION Magnetic Coupling – Magnetic coupling makes the “zero leak” feature possible. It also offers protection from damage caused by excessive pressures or foreign particles wedged in the gear teeth. Decoupling occurs when the two magnets are forced out of pole-to-pole alignment. 1. If the pump decouples, the motor will continue to operate at no load speed but the gears in the pump will stop rotating. 2. To recouple, stop the motor completely and restart. 3. If decoupling persists, check the system for excessive pump pressure. If this does not correct the problem, the pump will have to be disassembled, check for foreign particles wedged in the gear teeth. Disassemble and clean parts thoroughly following repair procedure. After reassembly, rotate motor fan, Pump and Motor should rotate freely with no magnet rub or internal friction. 4. Operating pressure – The differential pressure across the pump should be set well below the decoupling pressure (See catalog for decoupling pressures). This will prevent inadvertent decoupling caused by transient pressure surges. Internal Bypass – Use a screwdriver to adjust. Adjustment may be made while the pump is operating. The bypass pressure is adjusted higher by turning the adjusting screw clockwise, and lowered by turning counter-clockwise. The bypass pressure should be set below the normal decoupling pressure and above the operating pressure. See catalog for factory set bypass pressure. (T & U Series are not available with internal bypass.) Self-Priming – Tuthill pumps are capable of self-priming, make certain the gears are “wetted” with the pumping fluid. Running Dry - Dry running will cause permanent damage; make certain there is fluid in the pump while in operation. Running in Reverse – The inherent design of these gear pumps require that the pump be run in clockwise rotation. Intermittent reverse rotation for purging may be acceptable. Continuous reverse rotation (counter-clockwise) is not recommended and premature failure will occur. Do not operate U-Series in reverse rotation, may result in reduced performance.





TX SERVICE PAK INSTRUCTIONS

Suggested Service Pak Tools 60130-1 Bearing Extractor Tool 60152-1 Phillips Screwdriver 60020-1 Bearing Installation Tool Optional Rubber Gloves 60151-1 Medium Blade Screwdriver Optional Masking Tape 60150-1 T Series Tool Kit (Includes all tools shown above)

Service Pak includes: 2 Gears, 4 O-Rings, 5 Bearings, Silicone Lubrication and Instruction Sheet.

WARRANTY WILL NOT EXTEND TO GOODS ALTERED OR REPAIRED BY ANYONE OTHER THAN THE MANUFACTURER OR AUTHORIZED REPRESENTATIVE

NOTE: Service Paks are designed to be installed by someone familiar with precision mechanical assemblies and tools. Observe reasonable safety precautions, including the use of safety eyewear when performing the steps listed below. IMPORTANT: To prevent damage to the Driving Gear Assembly (17) REMOVE Cap (6) BEFORE installing or removing the Magnet Screw (15). NEVER install or remove the Magnet Screw with Cap (6) in place. DISASSEMBLY INSTRUCTIONS 1. Provide a clean surface for work area. 2. Remove two Pump Mounting Screws (1) and one Pump Mounting Screw (2) and separate Pumphead from Drive

Housing. 3. With a permanent marker mark the relative positions of the Mounting Plate (3), the Body (4), the Cavity Plate (5)

and the Cap (6) orientation for ease in reassembly. 4. Note: If the Gears are not being replaced and will be reused, after removing the Cap (6) in the next step mark the

Gear orientation with a marker. This will allow the Gears to reassembled in the same orientation. 5. Remove two Pump Screws (7) and three Pump Screws (8) in the Cap (6) holding the other parts in place and

remove the Cap, Driven Gear Assembly (9), Cavity Plate (5) and two Dowel Pins (10). 6. Remove Clamp Plate Screws (11); remove the Clamp Plate (13) and Magnet Cup (12). 7. Hold the Driven Magnet (14), and turn Magnet Screw (15) counter-clockwise to remove. Note: Pumps produced

prior to 1995 utilized left-hand threads for the Magnet Screw (15), remove by turning clockwise. Pumps produced after 1995 utilized right-hand threads.

8. Remove four O-Rings (19, 20, 21) from the Cap (6) and Body (4). O-Rings may be removed with a blast of compressed air or with a sharp pin.

9. Complete disassembly of Body (4), Mounting Plate (3) and Driving Gear Assembly (17). 10. Important: Do not nick or scar the sides of the bearing bores in the steps below. 11. Note: Mark the location of the Bearing (18) lubrication grooves with a permanent marker on the Cap (6) and Body

(4) before removing the Bearings. The Bearing lubrication grooves should be as far away from the inlet (suction) port as possible.

12. Clamp the Bearing Extractor Tool in a vise and screw the Bearing (18) on the tool and gently tap with a soft mallet while supporting and pulling the Cap (6) or Body (4) to free the Bearing. Repeat process until all five Bearings are free. If necessary remove Bearings by carefully breaking out the bearing material with a small chisel and mallet.

See figure 2. 13. Inspect all parts for damage and wear. If wear on Cap (6), Cavity Plate (5) and Body (4) is excessive rebuilding

the pump may not be recommended (consult factory). ASSEMBLY INSTRUCTIONS A. Clean all parts. Any foreign material clinging to the Driven Magnet (14) can be removed with masking tape. B. Align the Bearing (18) lubrication grooves with the marks made during Bearing removal in step 12. C. Using the Installation Tool press five new Bearings into the Cap (6) and Body (4). Bearings should be .002/.005

below the face of the Cap (6) and Body (4). See figure 3.

Title: D Service Pak Instructions Page 1 of 3 Document: 70012-1 Date: 5/31/06 Revision: J

ECO 50-7065 File name:D Service Pak Instructions


D. Omit silicone lubricant if it is incompatible with your pumped fluid. E. Using alignment marks made in step 3 during disassembly carefully assemble the Mounting Plate (3) and Body (4)

together with a slight twisting action until fully seated taking care not to dislodge or pinch the O-Ring. F. Install Driving Gear Assembly (17), Magnet Pin (16), Driven Magnet (14),and Magnet Screw (15). Hold Driven

Magnet to prevent rotation and tighten Magnet Screw clockwise to 960 in/oz torque (a rubber glove can be used to facilitate holding the Driven Magnet).

G. Note: When performing the following assembly operations DO NOT apply forces to the Driven Magnet (14). Pushing or pulling the Driven Magnet may damage the Driving Gear Assembly (17).

H. Confirm the presence of the plastic plug located in the lower Dowel Pin (10) hole of the Body (4). This is to prevent the Dowel Pin from slipping out. Install two Dowel Pins into Body (4) and slip the Cavity Plate (5) onto the Dowel Pins against the Body (4) face. The Cavity Plate (5) will fit properly in only one orientation. All the Screw holes in the Body (4) and Cavity Plate must align.

I. Install Driven Gear Assembly (9). J. Align Cap (6) with the Driving (17) and Driven (9) Gear Assembly shafts and Dowel Pins (10). K. Install two Pump Screws (7) and three Pump Screws (8) in Cap (6) and torque alternately to 640 in/oz. L. Rotate the Driven Magnet (14) by hand to check for any binding during rotation. The Driven Magnet should turn

freely. If there is binding determine and remove cause. M. Orient Clamp Plate (13) so that protruding Pump Screws (7) are aligned with the clearance holes provided in the

Clamp Plate. Install the Magnet Cup (12) and Clamp Plate with Clamp Plate Screws (11) and torque alternately to 320 in/oz.

N. Assemble Pumphead to Motor and Drive Housing with three Pump Mounting Screws (1 & 2). Pump/Motor assembly is now complete.

O. Note: New parts may exhibit slight interference with mating surfaces. An initial “run-in” period may be required to allow the gears to seat. Rebuilt pumps may initially decouple below normal differential pressure or produce less than normal flow-rate until mating parts have fully seated during initial period of operation.

Reference numbers on page 3:

1. Pump Mounting Screw (to mount pumphead to housing, 2 ea.) 2. Pump Mounting Screw (to mount pumphead to housing, 1 ea.) 3. Mounting Plate (316 SST) 4. Body 5. Cavity Plate 6. Cap 7. Pump Screw (through cap, cavity plate & body into mounting plate, 2 ea.) 8. Pump Screw (through cap & cavity plate into body, 3 ea.) 9. Driven Gear Assembly 10. Dowel Pin 11. Clamp Plate Screws 12. Magnet Cup 13. Clamp Plate 14. Driven Magnet 15. Magnet Screw 16. Magnet Pin 17. Driving Gear Assembly 18. Bearings 19. O-Ring 20. O-Ring 21. O-Ring

Title: T Service Pak Instructions Page 2 of 3 Document: 70012-1 Date: 5/31/06 Revision: J

ECO 50-7065 File name:T Service Pak Instructions

PLEASE CLARIFY THIS DIMENSION

X

IlkestonDerbyshireEngland

TUTHILLPUMP GROUP

UNCONTROLLED COPY WILL NOT BE UPDATED

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SCHEMI DI COLLEGAMENTO MOTORE TRIFASETHREE.PHASES MOTOR CONNECTION DIAGRAM

SCHEMAS DE BRANCHEMENT MOTEUR TRIPHASES

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24

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