Heat Pump User Manual

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL

POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO

1of 29

DOCUMENT NBR. :

PED-010

REVISION:

EFFECTIVE

DATE:

08-24-2004

POLARIS SERIES TBM 200 LH ( 8" ) TYPE PHO / PBO / PVO

ELECTRO-SUBMERSIBLE PUMP

PUMP TYPE: TBM 200 LH ( 8" ) TYPE ( )

POLARIS PART NBR.: 700.200.05.

HP / V / Hz / Poles: / / /

INSULATION: F  H  SUPER H 

EXPLOSION PROOF: Y  N 

EQUIPMENT OPTIONS:

POWER CABLE: ADDITIONAL (FEET)

VITON MOTOR O-RINGS 

VITON SEAL ELASTOMERS 

“SEAL GUARD” 

“SLURRY BOSS” 

“MOTOR SENTRY” 

SS MOTOR FLANGE 

COAL TAR EPOXY 

PUMP SERIAL NUMBER:

DATE:

CUSTOMER:

CUSTOMER P.O. NBR.

SHIPPED TO:

Summary of content (50 pages)

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 1of 29 EFFECTIVE DATE: 08-24-2004 POLARIS SERIES TBM 200 LH ( 8" ) TYPE PHO / PBO / PVO ELECTRO-SUBMERSIBLE PUMP PUMP TYPE: TBM 200 LH ( 8" ) TYPE ( POLARIS PART NBR.: 700.200.05.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 2of 29 EFFECTIVE DATE: TABLE OF CONTENTS SECTION 1.0 INTRODUCTION SECTION 2.0 WARRANTIES SECTION 3.0 SAFETY SECTION 4.0 MECHANICAL INSTALLATION 4.1 RECEIVING INSPECTION 4.2 STORAGE 4.2.1 4.2.2 4.2.3 4.3 HANDLING 4.4 MECHANICAL SEAL INSPECTION 4.5 PUMP SET UP / MOUNTING 4.5.1 4.5.2 4.5.3 4.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 SECTION 6.0 08-24-2004 PRE START UP CHECK PUMP START UP PUMP SHUT DOWN TROUBLE SHOOTING WET END INSTALLATION 7.1 7.2 7.3 SECTION 8.0 EFFECTIVE DATE: OPERATION 6.1 6.2 6.3 6.4 SECTION 7.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 1.0 4of 29 EFFECTIVE DATE: 08-24-2004 INTRODUCTION Your new Series TBM pump has been designed and manufactured to perform for many years with a minimum of maintenance. However, parts will wear and need replacing eventually. The period between maintenance will greatly depend on the service and your maintenance program.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 2.0 5of 29 EFFECTIVE DATE: 08-24-2004 WARRANTIES Seller warrants that the products covered by this contract conform to applicable drawings and specifications accepted in writing by Seller, will be free from defects in material and workmanship, will be merchantable and will perform in accordance with the detailed specifications accepted in writing by Seller.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 3.0 6of 29 EFFECTIVE DATE: 08-24-2004 SAFETY Do not install the equipment other than in accordance with the instructions contained in this manual. When required information cannot be found in this manual, contact the nearest POLARIS PUMPS representative. This instruction book should be read completely before starting installation, maintenance or operation.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 4.0 7of 29 EFFECTIVE DATE: 08-24-2004 INSTALLATION 4.1 RECEIVING INSPECTION The unit must be inspected immediately upon arrival and any irregularities and damages due to shipment must be reported to the carrier and POLARIS PUMPS. A copy of this manual is included in the shipment. Put this manual a safe, accessible place for ready reference when required.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 8of 29 EFFECTIVE DATE: 08-24-2004 4.2.2 USED PUMP STORAGE A used pump should be completely disassembled and all parts cleaned and inspected. All unpainted metal surfaces should be coated with grease or suitable protectant. All previously painted parts should be touched up or repainted. Reassemble the pump as per Sections 7.0 and store as per Section 4.2.1. 4.2.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 4.5 9of 29 EFFECTIVE DATE: 08-24-2004 PUMP SET UP / MOUNTING 4.5.1 CABLE AND CHAIN SUSPESION Pumps of SERIES TBM are fitted with integral lifting lugs sized to accommodate the dead weight of the pump assembly. Verify the weight of your specific pump before making lifting cable or chain selection. See relevant general arrangement drawings (Section 8.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 10of 29 EFFECTIVE DATE: 08-24-2004 4.6.2 PRIMARY SEAL FLUSH The seal flush / cooling water to the outboard mechanical seal is automatically supplied if the pump is running. Be aware that if the pump is operated in applications where the sump can be pumped dry, a minimum water level must be present to prevent the mechanical seal from dry running.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 5.0 11of 29 EFFECTIVE DATE: 08-24-2004 ELECTRICAL INSTALLATION 5.1 GENERAL Power supply and electrical work must be as per local and national codes. All wiring and installation of cables, relays, disconnects, etc., should be performed by qualified personnel. Check that main line voltage and frequency agree with the specifications on the motor data plate.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 6.0 12of 29 EFFECTIVE DATE: 08-24-2004 OPERATION 6.1 PRE-START UP CHECK A pre-start up check should always be performed prior to putting your pump into service. The following procedures should be adhered to as a minimum. • POWER SUPPLY Double-check and confirm that the power supply voltage and frequency match with the pump data plate.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 6.2 13of 29 EFFECTIVE DATE: 08-24-2004 PUMP START UP Whenever possible, start the pump in clear liquid to prime discharge piping and/or hoses. If flexible hoses are used, make sure that they are not pinched since the pressure developed by the pump may not be enough to force them open. Lower the pump slowly into the material to be pumped.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 6.3 14of 29 EFFECTIVE DATE: 08-24-2004 PUMP SHUT DOWN Never stop the pump while pumping solids through the system. This will plug the piping. Lift the pump into clear fluid for as long as it takes to flush the entire system of any slurry. IMPORTANT If you operate and store your pump in environments subject to below-freezing temperatures: 1.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 6.4 15of 29 EFFECTIVE DATE: 08-24-2004 TROUBLE SHOOTING 6.4.1 FAULT TRACING To carry out fault tracing on electrical equipment, a multi-meter, test lamp and wiring diagram are required. Fault tracing must be done with the power disconnected unless checks cannot be performed without power to the motor.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 - 16of 29 EFFECTIVE DATE: 08-24-2004 FAULT SIGNAL AT THE STARTER, PUMP CAN BE STARTED MANUALLY Check for faulty level-control system components (start or high water sensors). Clean or replace as required. Check for faulty control equipment. Check that all connections are intact. Check relay and actuator windings.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 - 17of 29 EFFECTIVE DATE: 08-24-2004 PUMP IS EXPECTED TO STOP BUT KEEPS RUNNING If the pump has been running satisfactory and is capable of emptying the sump to the control stop level, check for leakage in discharge piping and connections. Leakage water may be re-circulated back into the sump. Check that the impeller or suction is not clogged.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 - 18of 29 EFFECTIVE DATE: 08-24-2004 PUMP IS RUNNING WITH REDUCED FLOW This can be caused by either pump and / or system related problems. Check your system set-up: Verify that all piping connections are tight and that there are no leaks in the discharge line. Check that any valves are fully open and operable and the discharge line and valves are not clogged.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 7.0 19of 29 EFFECTIVE DATE: 08-24-2004 WET END INSTALLATION Inspect and inventory all parts before you begin assembly. Clean all parts and remove protective coatings as required. Inspect the motor module for any visual damage paying particular attention to the shaft end and mechanical seal.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 7.1 TBM 200 LH - TYPE PHO 20of 29 EFFECTIVE DATE: 08-24-2004 Drawing A0207 and A0210 Apply "Never-Seize" to the motor shaft end. Position Flinger Gasket (Item 060.2) onto shaft. Insert Drive Key (Item 113) into the key seat. Slide Flinger (Item 110) onto the shaft. Position Impeller Gasket (Item 060.1) against the Impeller flinger.
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POLARIS PUMPS - SERIES TBM - 200 LH TYPE PHO ITEM ITEM ITEM 151 PART NUMBER QTY. DESCRIPTION EXT. DESC.1 A0210 (Rev.0) 1/2 MODEL1 MODEL 2 WT.(lbs) 375.57 826.37 MTL. DWG. # C0182 151.200.05.00240 1 KIT, WET END - BASIC 101 101.012.05.00213 1 IMPELLER RH, 5V TBM 200LH PHO, PBO, PVO A532 CL III TP. A 102 102.012.05.00215 1 CASING VOLUTE TBM 200LH PHO, PBO, PVO A532 CL III TP. A D0184 103 103.012.05.00217 1 LINER SUCTION TBM 200LH PHO, PBO, PVO A532 CL III TP.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 7.2 TBM 200 LH - TYPE PBO 23of 29 EFFECTIVE DATE: 08-24-2004 Drawing A0208 and A0211 Apply "Never-Seize" to the motor shaft end. Position Flinger Gasket (Item 060.2) onto shaft. Insert Drive Key (Item 113) into the key seat. Slide Flinger (Item 110) onto the shaft. Position Impeller Gasket (Item 060.1) against the Impeller flinger.
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POLARIS PUMPS - SERIES TBM - 200 LH TYPE PBO ITEM ITEM ITEM 151 PART NUMBER QTY. DESCRIPTION EXT. DESC.1 A0211 (Rev.0) 1/2 MODEL1 MODEL 2 WT.(lbs) 375.57 826.37 MTL. DWG. # C0182 151.200.05.00240 1 KIT, WET END - BASIC 101 101.012.05.00213 1 IMPELLER RH, 5V TBM 200LH PHO, PBO, PVO A532 CL III TP. A 102 102.012.05.00215 1 CASING VOLUTE TBM 200LH PHO, PBO, PVO A532 CL III TP. A D0184 103 103.012.05.00217 1 LINER SUCTION TBM 200LH PHO, PBO, PVO A532 CL III TP.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 7.3 TBM 200 LH - TYPE PVO 26of 29 EFFECTIVE DATE: 08-24-2004 Drawing A0209 and A0212 Apply "Never-Seize" to the motor shaft end. Position Flinger Gasket (Item 060.2) onto shaft. Insert Drive Key (Item 113) into the key seat. Slide Flinger (Item 110) onto the shaft. Position Impeller Gasket (Item 060.1) against the Impeller flinger.
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POLARIS PUMPS - SERIES TBM - 200 LH TYPE PVO ITEM ITEM ITEM 151 PART NUMBER QTY. DESCRIPTION EXT. DESC.1 A0211 (Rev.0) 1/2 MODEL1 MODEL 2 WT.(lbs) 375.57 826.37 MTL. DWG. # C0182 151.200.05.00240 1 KIT, WET END - BASIC 101 101.012.05.00213 1 IMPELLER RH, 5V TBM 200LH PHO, PBO, PVO A532 CL III TP. A 102 102.012.05.00215 1 CASING VOLUTE TBM 200LH PHO, PBO, PVO A532 CL III TP. A D0184 103 103.012.05.00217 1 LINER SUCTION TBM 200LH PHO, PBO, PVO A532 CL III TP.
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL POLARIS - SERIES TBM 200 LH ( 8” ) - TYPE PHO / PBO / PVO DOCUMENT NBR. : REVISION: PED-010 1 8.0 29of 29 EFFECTIVE DATE: 08-24-2004 APPENDIX 8.1 PUMP GENERAL ARRANGEMENT DRAWING, TBM 200 LH – PHO, PBO, PVO TBM 200 LH – 40 / 50 / 60 HP MOTOR TBM 200 LH – 75 / 100 / 125 HP MOTOR 8.1.1 8.1.2 8.1.3 PUMP PERFORMANCE CURVE - TYPE PHO PUMP PERFORMANCE CURVE - TYPE PBO PUMP PERFORMANCE CURVE - TYPE PVO 8.
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''#" *"&% %)* ## *"&% % ' ( *"&% #" % . % $ # "% # % &#-'! ) +*- )* (.
PAGE 36
RECEIVING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 37
RECEIVING AND HANDLING ACCEPTANCE #*-*0"#'4 $).+ / /#$. ,0$+( )/ !* +/$)" .#$+( )/ !-*( /# /- ).+*-/ /$*) *(+ )4 ! )4 *! /# "** . '' !*- $) /# $'' *! ' $)" *- 3+- .. - $+/ - ( " */# ,0 )/$/4 $. .#*-/ * )*/ +/ /# ( 0)/$' /# !- $"#/ *- 3+- .. " )/ ( & . ) ++-*+-$ / )*/ /$*) *) 4*0- !- $"#/ $'' *- 3+- .. - $+/ ! )4 *) ' '*.. *- ( " $. $. *1 - ' / - )*/$!4 4*0- !- $"#/ *- 3+- .. " )/ / *) ) - ,0 ./ #$( /* ( & ) $).+ /$*) 2$'' ..$.
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#&' $#+ & & %) & ! "(' & )" ( #" # $)!$ ' " !$ & ' . " #+ #" ( #"' " ' #$ & ( " ( ! ' )" ( #" # $ ( ' .
PAGE 39
When removing impeller warm slightly with a torch and pry impeller off evenly with either small pry bars or a wheel puller. When the submersible pump motor leaves the factory it is ready for installation. No adjustment, venting or oil filling is required. For THREE PHASE motors the only connection to the motor lead cable is the power supply. For SINGLE PHASE motors the motor lead cable and power supply must be properly connected at the Control Box.
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With proper application and installation of monitoring devices, periodic inspection of motor seals is not required. Should a malfunction occur the motor has been equipped with a moisture detection system and thermal protection which will provide advance warning of impending failure allowing the user to plan a maintenance program before failure occurs. 1.
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1. Loosen four bolts, securing lead cable connector (1), two complete turns. CABLE CONNECTOR 2. Attempt to break the cable connector seal thus relieving gas pressure within the motor. If gas pressure is not relieved loosen the bolts another turn and try again. Continue this process until the pressure is relieved and/or the cap is removed. Be extremely careful until the cable connector assembly is removed. MOISTURE SENSORS (2) 3.
PAGE 42
Alternating Current Thermostats are automatic reset for use in a normally closed circuit where the thermostat is connected in series with the holding coil of the magnetic starter. Thermostats provide Over Temperature Protection 2" in accordance with NEMA MG 1Ć12.53. When the motor is so marked locked rotor protection is not provided by the winding over temperature protector. It is suggested that over current protection be used in the motor starter to insure locked rotor protection.
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"& .'$, + * &'%"& $ . $- + & % 0 &0/! * *'% &'%"& $ %"&-+ ,' &'%"& $ ($-+ $$ ,0( 2 '&,*'$+ * " &," " 0 +( " " '%('& &, &-% * /!" ! '$$'/+ ,! '*% , 2 /! * ,! + * * ($ 0 &-% *+ & $ ,, *+ "& " ,". ' ,! 2 +-(($0 $"& .
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Normally open load contacts close and normally closed load contacts open when the sensor probes detect the influx of moisture within the motor. # A normally closed pushbutton and neon indicating lamp are provided as means of checking the moisture sensing components.
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STANDARD REPLACEMENT SEAL CROSS REFERENCE PURCHASING SPECIFICATIONS a Crane Type Seal 2 2 1- %."*'$ 2 2 2 1- %."*'$ 2 2 1- %."*'$ 2 2 1- %."*'$ 2 2 1- %."*'$ 2 2 1- %."*'$ 2 2 1- %."*'$ 2 2 1- %."*'$ 2 2 1- %."*'$ 2 2 1- %.
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#% " ( ( % ' $ % " &! # ! # $ % & & & $ "! ## % & & & $ "! ## % & & & $ "! ## % & & $ "! ## % & & & $ "! ## % & & & $ "! ##
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ENGINEERING STANDARD PROCEDURE IMPELLER INSTALLATION – TECH BULLETIN DOCUMENT NBR. : REVISION: PED-016 1of 2 EFFECTIVE DATE: 1 09-26-2003 1.0 SCOPE: The purpose of this Engineering Standard Document is to define the procedure to be followed in installing the Impeller and Impeller Lock Screw. 2.0 METHOD: 2.1 – Impeller Installation Clean all parts prior to impeller installation. Apply “Never Seize” or similar to Impeller bore, Shaft and Key. Install Impeller onto Shaft.
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ENGINEERING STANDARD PROCEDURE IMPELLER INSTALLATION – TECH BULLETIN DOCUMENT NBR. : REVISION: PED-016 2of 2 EFFECTIVE DATE: 1 09-26-2003 2.3 – Impeller Cap Installation Remove all oil or grease from Impeller Screw. Install O-rings onto Impeller Screw and Impeller Cap (Model PHO) or Shaft Adapter (Models PBO, PVO). Insert Impeller Screw and apply Thread Locker to the Impeller Screw and shaft-end internal threads. Use Devcon SuperLock 2271 High Strength Stud Lock Grade or equivalent. 2.
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ENGINEERING STANDARD PROCEDURE IMPELLER INSTALLATION – TECH BULLETIN DOCUMENT NBR. : REVISION: PED-017 1.0 1of 1 EFFECTIVE DATE: 0 09-16-2003 SCOPE: Assembly Pre-Load / Bolt Torque requirements for Metric Fasteners of Grades A2-70 (304L) A4-70 (316L) and 8.8, for Sizes M4 to M20. 2.0 METHOD: ASSEMBLY TORQUE / ASSEMBLY PRE-LOAD SIZE TIGHTENING TORQUE CLASS ASSEMBLY PRE-LOAD lb/ft [lb/in] kN lbf M4 2.20 1.622 [19.46] 2.73 612.23 M5 4.20 3.097 [37.16] 4.47 1002.44 7.40 5.45 [65.