Polaris TBM 200 LH User's Manual
Contents
1. r H LOAD 5 MDICATOR LIGAT SENSOR PROBE CONTIMUTY TEST BUTTON MOISTURE DETECTION p LA R IS POLARIS 5 NTR L THER PROOF Pump n Hard hon POLARIS Hard hon ENGINEERING STANDARD PROCEDURE 1of 2 IMPELLER INSTALLATION TECH BULLETIN DOCUMENT NBR PED 016 REVISION 1 EFFECTIVE 09 26 2003 DATE 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 Using a grease remover or solvent remove all grease oil or preservative from the shaft end internal threads and dry 2 2 Impeller Blocking Position an Open End or Box Open End Wrench Using one of the Strainer Bolts as shown Place a piece of Wood between the Impeller and Wrench Note Reverse Wrench Location to opposite side for Impeller removal O NEWB 08 15 02 pt ADDED250LH 09 26 03 CHANGE DESCRIPTION APPV D DATE POLARIS Pump n Hard hon ENGINEERING STANDARD PROCEDURE 2of 2 IMPELLER INSTALLATION TECH BULLETIN DOCUMENT NBR PED 016 REVISION 1 EFFECTIVE 09 26 2003 DATE 2 3 Impeller Cap Installation Remove all oil or grease fr2. ise _ s ww pue mono monos emos som ee 3 L m 3 3 j s 1 ma j samanan 3 enone s 3 ome ma p 1 me j 2 SEE TABLE BELOW FOR COMPLETE PUMP PART NUMBERS AND MOTOR DETAILS ESTIMATED WEIGHT TOTAL POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 2901 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PBO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 8 0 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 PUMP PERFORMANCE CURVE TYPE PHO 8 1 2 PUMP PERFORMANCE CURVE TYPE PBO 8 1 3 PUMP PERFORMANCE CURVE TYPE PVO 8 2 RELIANCE ELECTRIC Application Installation amp Operation Manual Duty Master Submersible Motors 8 2 MOISTURE DETECTION RELAY 8 4 IMPELLER INSTALLATION BOLT TORQUE SPECIFICATIONS REVISIONS REV CHANGE DESCRIPTION DATE 0 NEW RELEASE 8 AUG 01 1 ADDED BOLT TORQUE SPECIFICAT
3. ALL MOTOR AMO CABLE LOSSES 2 WALID FOR 75 HP FRAME 360 100 STANDARD MOTOR n 50 25 T 800 1200 1600 2000 2400 2800 3200 FLOW U S G P M BHP AMPS Bl 0 bl 50 Ll 30 1 FEET EFF F x 10 POLARIS Pump Hard thon PUMP MODEL TBM 200 LH PBO PERFORMANCE FOR CLEAR WATER AND 12 SG APPROVED BY LORRELT OTHER DUMOITKEUINS ANDOR SOLOS EFFELT WIRE TO WATER EFFICIENCY ALL MOTOR AMO CABLE LOSSES 2 WALID FOR 75 HP FRAME 360 100 STANDARD MOTOR 50 25 T 800 1200 1600 2000 2400 2800 3200 FLOW U S G P M BHP AMPS Bl 0 bl 50 Ll 30 1 FEET EFF F x 10 100 n 50 25 POLARIS Pump n Hard PUMP MODEL TBM 200 LH PVO PERFORMANCE FOR CLEAR WATER AND 12 SG APPROVED BY LORRELT OTHER DUMOITKEUINS ANDOR SOLOS EFFELT WIRE TO WATER EFFICIENCY INCLUOING ALL MOTOR AMO CABLE LOSSES 2 WALID FOR 75 HP FRAME 360 STANDARD MOTOR T 800 1200 1600 2000 2400 2800 3200 FLOW U S G P M BHP AMPS Bl 0 bl 50 Ll 30 1 Application Installation and Operation Of Reliance Tandem Seal Single and Polyphase Duty Master A C Submersible Pump Motors UL Listed for Class Groups C and D in Water or Sewage
4. Sew 06 s ses fastener screw m 1 0 ew emer rom ew 3 00 j j re mamana 5 mun am pue mms mono m e pw mm m sama 1 1 1 00 12 s ise ws pue p remos crue ue emos rae 3 L m 3 j 1 ma LLL I 3 Se 3 ome ma j 1 I
5. F WIRING BY OTHERS 7 CONTROL ENCLOSURE FIGURE 3 MOISTURE SENSING CIRCUIT TYPICAL WIRING DIAGRAM LEAD COLOR CODING BLACK WHITE RED ORANGE GREEN LEAD LEAD LEAD LEAD LEAD Polyphase T4 Ground Power Control Cable STANDARD REPLACEMENT SEAL CROSS REFERENCE 0010 R MAX RECTANGULAR RING T CUP MOUNTED RING SEAT RING SEAT SEAT PURCHASING SPECIFICATIONS Spring d e g 12 A 1 250 pmi Ceramic BP1C1 1 15 16 1 875 47 64 1 1 16 116 3 8 1 7 16 2 3 16 1 500 Ceramic Ceramic BP1C1 2 3 16 2 125 47 64 1 1 8 1 9 6 1 16 1 11 16 2 3 16 1 750 lutem lun Lou Ceramic BP1C1 2 5 8 2 500 E UM 5 138 1 16 7 16 1 15 16 2 7 8 ip 2 000 2 000 ceramic 278 2750 Ceramic BP1C1 2 7 8 2 750 49164 1 hu ue 7 16 2 3 16 3 3 16 12 E 2 250 Cup Ceramic BP1C1 3 1 8 3 125 49 64 1 11 16 2 1 4 1 16 1 2 3 7 16 3 7 16 12 G 3 00 E Cup Ceramic BP1C1 4 00 4 125 2 687 2 062 2 687 0 06 0 56 3 19 4 50 18 F 2 75 21 Cup Ceramic BP1C1 3 75 3 500 0 796 1 125 1 75 0 03 0 595 2 94 4 12 18 G 3 00 Cup Ceramic BP1C1 4 00 3 875 0 796 1 125 1 75 0 06 0 56 3 19 4 50 2 75 E Cup Ceramic BP1C1 3 75 3 50 0 796 1 125 1 75 0 06 0 56 2 94 4 12 m ETC NON CUT ESCRETOEUCSEUCEEUSECI STANDARD REPLACEMENT O RING CROSS REFERENCE 421900 D W Materi
6. Leads are tagged for easy identification A con nection diagram is provided in the lead chamber Motors can be connected for either high or low voltages Some motor ratings are built as single voltage units and as such are not reconnectable The motor lead cable assembly for Submersible Pump Motors has 3 marked power leads plus two ground leads two thermal leads and two moisture sensing probe leads in standard cable lengths of 25 feet Leads are brought through an epoxy sealed con nector providing a mechanically strong water tight seal The cap and cable assembly are available from Reliance Electric as a replacement part as sembly When replacing the lead wire cap care should betaken notto nick or damage the O ring seal Replace any damaged or nicked O rings WHEN REPLACEMENT CABLE ASSEMBLY IS REQUIRED ORDER FROM RELIANCE ELEC TRIC CO USING MOTOR IDENTIFICATION NUMBER MAINTENANCE 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 GENERAL NOTES ALL PARTS 1 Reliance Submersible Motors utilize an explosion proof Class Groups C and D tandem seal design with an oil chamber separate from the winding
7. SEE TABLE BELOW FOR COMPLETE PUMP PART NUMBERS AND MOTOR DETAILS ESTIMATED WEIGHT TOTAL POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 2601 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PBO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 7 3 TBM 200 LH TYPE PVO 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 Hoist the Volute Casing Item 102 into position and insert into the motor flange spigot Apply Never Seize to the Socket Head Cap Screws and insert with Lock Washers Items 040 1 040 4 through the motor flange into the Casing and tighten Slide the Impeller Item 101 onto the shaft Position the O rings Item 062 2 062 3 onto the Shaft Adapter Item 108 and the same into the impeller bore lining up the groove in the cap face with the key Position O Ring Item 062 1 onto the Impeller Lock Screw Item 040 3 apply Locktite and insert into the shaft end and tighten Refer to Appendix 8 4 for Impeller Lock Screw Torque and Procedure Apply Never Seize to the adapter thread and screw on the Shaft Extension Item 109 Tighten the shaft extension via the wrench flats on the outboard end Position the O ring Item 062 4 into the shaft exte
8. Meg ohm meter check the insulation between the phases and ground If the phase amp readings are too high or uneven or a ground fault is detected contact POLARIS PUMPS POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 17of 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 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 CAUTION Disconnect and lock out the main power supply before working in the intake area of the pump Failure to do so can result in serious injury Clean out and remove any objects that may have clogged the impeller and inspect the pump components for any visual damage Inspect the sump area and remove any oversized material and debris Inspect pump strainer for excessive wear and replace if required Check that the impeller and casing are not worn and need to be replaced Check the impeller running clearance and adjust as required Check for faults in the level control equipment Clean and inspect the level sensor probes and perform a function test Check the level control relay contactor and holding circuit Replace any faulty components Check the location
9. NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 4 5 4 6 DATE 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 oee relevant general arrangement drawings Section 8 0 or bills of materials for weight information 4 5 2 OPTIONAL LIFTING SUSPENSION BAIL MOUNTING Optional lifting bails are available for all pumps of SERIES TBM for applications where a single lifting cable or chain is preferred 4 5 3 FLOOR MOUNTING When Pumps are operated resting on the pump stand on the sump floor they must rest on a horizontal surface that prevents the pump from tipping over and burying itself A chain or cable with limited slack can be utilized to prevent this PIPING 4 6 1 DISCHARGE HOSE DISCHARGE PIPING Flexible heavy duty non collapsible discharge hose is preferred All rigid piping must be independently supported Pump casing should never bear the weight of the piping Non collapsible expansion type joints are recommended on the discharge side of the pump for rigid pipe installations POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 10of 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 4 6 2 PRIMARY SEAL FL
10. Short Time Duty 15 minutes in Air A C MOTORS ew You Can Trust Instruction Manual B 3629 12 April 1996 TABLE OF CONTENTS Page RECEIVING AND HANDLING assu usuras quito dear dta aad wa 1 MPT D wampu 2 MAINTENANCE ESO REVUES TUE BP Cen TERRE asus ex 4 5 THERMAL PROTECTION SYSTEM 5 6 MOISTURE DETECTION SYSTEM 6 7 LEAD COLOR CODING ad turas IA pid E stents 8 STANDARD REPLACEMENT SEAL CROSS REFERENCE 9 STANDARD REPLACEMENT RING CROSS REFERENCE 9 STANDARD REPLACEMENT SNAP RING CROSS REFERENCE 10 IMPORTANT It is important that these instructions be studied by the personnel installing and operating this equipment Read thoroughly before starting Keep these instructions for future reference A IMPORTANT The motors specified in this instruction book are U L listed for application in Class Groups C and D explosion proof environments All repairs other than lead reconnects and outer seal replacement shall be performed by an authorized Reliance service facility Any other repairs performed by the customer or non Rel
11. area 2 Wound Stators Reliance Submersible Mo tors utilize a wound stator which has been pressed into the frame The stator insulation system has been designed for the tempera ture and electrical rating involved If the motor failure is analyzed to encompass a winding failure return the motor to an authorized Re liance Electric Service Shop 3 Encapsulated Lead Connector Assembly The lead connector assembly has been especially encapsulated to insure integrity of the motor The connector can be removed from the motor in order to reconnect leads Should the lead connector assembly be damaged or the integrity of the encapsulation be in question it is required that a replace ment lead connector assembly be ordered from Reliance Electric Company MOTOR MAY CONTAIN GAS UNDER PRESSURE DUE TO HIGH TEMPERA TURES FROM OPERATION WITHOUT BEING SUBMERGED DISASSEMBLY MAY CAUSE BODILY INJURY FOR ASSIS TANCE CONTACT A RELIANCE OFFICE 4 Hardware All hardware is stainless steel and should be replaced with the same type 5 Ifthe Conduit Connection is used a corrosion resistant conduit such as stainless steel is recommended 6 When replacement cable assembly is required order from Reliance Electric Industrial Co using motor identification number MECHANICAL REPAIRS U L listed motors must be returned to an authorized Reliance Electric Service Facility for repairs other than to replace the outer seal See
12. motor However proper consideration of the application will prevent such an overload With reference to the diagram in figure 1 the following load conditions should be noted A Below level 1 bottom of the pump fluid is not pumped and no load is reflected to the motor B One pump should always be sized sufficient ly large to draw the well down even under maximum flow conditions The maxi mum amount of time the motor will operate fully loaded and uncovered is the amount of time required to draw the well down from level Z2 top of the motor to the bottom of the pump C Time described in B above should not be greater than 15 minutes if full motor name plate horsepower is required for this opera tion See Application Instructions D The above application notes do not make allowance for a The heat exchanger effect of the attached pump It is pumping a relatively cool fluid and will remove some heat b The motor does not operate fully loaded completely in gas It is fully loaded as the motor is being uncovered c If the well is being drawn down from the top of the motor and maximum flow conditions exist the influent flow will usually provide excellent cooling of the pump motor 2 14 FIGURE 1 INSTALLATION IMPORTANT Read this manual thoroughly before installa tion 1 The user must select a motor starter and over current protection suitable for this motor and its application Co
13. motor interchange any two motor leads at the starter To reverse direction of rotation of a SINGLE PHASE motor the proper connections must be made in the motor connection chamber refer to the W D s supplied in the motor connection chamber and Control Box Lif ing eyes are supplied for purpose of installation and servicing Do not use motor lead cables for lifting means Normal care should be exercised to prevent mechani cal damage to the seal the frame and the insulated cable WARNING LIFT MOTOR ONLY USING BOTH ATTACHMENT POINTS EYENUTS amp EYEBOLTS MUST BE SEATED amp IN LINE AS SHOWN BELOW PREFERRED METHOD USE SPREADER BAR STARTING CAUTION Surface temperature of motor enclosure may reach temperatures which can cause discomfort or injury to personnel acci dentally coming into contact with hot sur faces When installing protection should be provided by user to protect against accidental contact with hot surface On initial start up the motor and pump should be checked for proper rotation prior to final application The unit is designed to protect all power connec tions against moisture All Reliance Submersible Pump Motors have a lead connection chamber THREE PHASE dual voltage motors have 9 motor leads and SINGLE PHASE dual voltage motors have 8 motor leads in this chamber All Submersible Pump Motors have 2 thermal pro tector leads and 2 moisture sensing probe leads in this chamber
14. necessary by adding or subtracting casing gaskets Slide strainer and gaskets into the casing bore Position the Pump Stand Item 112 over the strainer insert Never Seize coated Socket Head Cap ocrews and Lock Washers Items 040 2 040 4 and tighten Apply Never Seize to the Countersunk Head Cap Screws ltem 040 5 insert the Intake Screen Item 111 and screws into the strainer and tighten Apply Never Seize to the shaft extension thread and screw on the Solids Mixer Item 106 Tighten using a plastic or rubber hammer POLARIS Pus h Mand hon m mi WET END ASSEMBLY EXPLOSION 200 DRAWING MER 208 REV 1 EFFELTIVE DATE 08 09 01 FOR BILL OF MATERIALS PARTS LIST SEE A0211 POLARIS Pump n Hard hon POLARIS PUMPS SERIES TBM 200 LH TYPE PBO A0211 Rev 0 1 2 PaRTNowseR a m _ sem pee ioo a ewm 5 vom ue memes pee nman pee nooo 3 xv e sama 3 e 7 4 s
15. note on Table of Content page To inspect the outer seal proceed as follows 1 Remove outer snap ring 3 replace as needed 2 Remove rotating outer seal 4 replace as needed 3 Approved lubricating and insulating oil shall meet Reliance approved source sheet 4824 18 AF Manufacturers materials currently meeting this specification are as follows MANUFACTURER S IDENTIFICATION ITEM MANUFACTURER OF MATERIAL 1 Sun Oil Company Sun Fleet Regular SAE 10W 2 Standard Oil Co Sohio 62 SAE 10W 3 Shell Oil Company Rotella 10 SAE 10W MOTOR INSPECTION After assembly run motor in shaft down position for 30 seconds minimum to minute maximum to allow seals to seat then check for oil leakage In some cases a slight oil mist will appear around the seal Wipe clean after test PAINTING AND SHIPPING Before painting motor cover exposed seal Remove any paper tape etc from seal area before crating motor These motors can be shipped in shaft up or shaft down position Care must be taken that exposed seal is not damaged during shipment Carton must protect exposed seal from dirt dust and damage ELECTRICAL REPAIRS CABLE CONNECTOR 2 MOISTURE SENSORS 2 OUTER SEAL OUTER SNAP RING LEAD RECONNECT The cable connector assembly may be removed to reconnect the leads without negating the U L listing or the warranty MOTOR MAY CONTAIN GAS UNDER PRESSURE DUE TO HIGH TEMP
16. of the stop level probe to ensure it is not set too low PUMP STARTS AND STOPS REPEATEDLY Check if the back flow from the discharge pipe is enough to raise the sump level to the level controller starting probe If so positioning a rubber flap valve in the discharge pipe close enough to the pump will minimize back flow Check that the distance between start and stop level probes is not too short Check that the contactor does not break its self holding function Check the voltage in the control circuit in relation to the rated voltage on the coil Check the functioning of the stop sensor probe The voltage drop in the line during the start up surge can cause the contactor self holding function to break POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 18of 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 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 Check your system head requirement The pump flow will reduce if the point of discharge has been raised or additional piping has been added Check your pump Verify proper direction of rotation Chec
17. power leads Induced voltage can cause false moisture signals CONTACT OPERATION Normally open load contacts close and normally closed load contacts open when the sensor probes detect the influx of moisture within the motor TEST PROCEDURE A normally closed pushbutton and neon indicating lamp are provided as means of checking the moisture sensing components When the pushbutton is depressed the indicating lamp will be illuminated to indicate A power is supplied to the control B the control is operative and C wiring to the moisture sensing probes in the motor is intact This procedure should be performed periodically to confirm integrity of circuit SIGNAL DEVICES The signal device may be audible bell buzzer horn or siren or visible incandescent or neon lamp or both a signal device of your choice may be obtained from your local electrical supply house SYSTEM OPERATION It is recommended that upon indication by warn ing light etc of outer seal failure that the motor be removed from the installation and the oil and outer seal be replaced as soon as possible If reconditioning is not performed within a 30 day period it is recommended that the inner seal be thoroughly inspected and replaced if required When ordering parts or reporting trouble give oales Office complete Nameplate Data TEST RESISTOR MOISTURE SENSORS NORMALLY OPEN 1 SIGNAL CIRCUIT WIRING BY WARRICK
18. 0 LH Types PBO and PVO Allen wrenches 5 8 14 mm 8 mm 5 mm Open ended wrench 2 or 51 mm Plastic or Rubber Hammer Never Seize or Molykote Locktite POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 2001 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PBO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 71 TBM 200 LH TYPE PHO 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 Hoist the Volute Casing Item 102 into position and insert into the motor flange spigot Apply Never Seize to the Socket Head Cap Screws and insert with Lock Washers Items 040 1 040 4 through the motor flange into the Casing and tighten olide the Impeller Item 101 onto the shaft Position the O ring Item 062 2 onto the Impeller Cap Item 107 and the same into the impeller bore lining up the groove in the cap face with the key Position O Ring Item 062 1 onto the Impeller Lock Screw Item 040 3 apply Locktite and insert into the shaft end and tighten Refer to Appendix 8 4 for Impeller Lock Screw Torque and Procedure Position Casing Gaskets Item 060 3 onto Strainer Item 103 aligning the holes To verify the impeller running clearanc
19. D TIGHTENING TORQUE ASSEMBLY PRE LOAD Ib ft Ib in 1 622 19 46 3 097 37 16 1002 44 5 45 65 40 1415 08 4126 40 n lt e n lt 11414 88 18389 40 ABOVE TORQUE PRE LOAD VALUES ARE BASED ON A COEFFICIENT OF FRICTION OF 0 14 Anti seize Lubricant 90 NEW UB 08 15 02 A ADDED250LH 09 26 03 CHANGE DESCRIPTION APPV D DATE
20. DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 1 0 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 Series TBM pumps are heavy duty Electro submersible pumps featuring motor armatures with a nominal service factor up to 2 depending on pump wet end and motor combination Pumps with standard motors are designed to operate completely submersed in liquids with pH values from 6 14 and temperatures not exceeding 40 C 104 F Higher temperatures and or dry running applications will require H or Super H insulation and or an optional water jacket Motor modules of series TBM can be ordered in standard configuration or as explosion proof units per Class 1 Groups C amp D Temperature code T3C UL Listed File No E10822 CSA Certified File No LR19467 15 Frames 140 180 210 250 amp 360 CSA Certified File No LR19467 15 Frame 320 This manual has been compiled to help you minimize your maintenance and speed repairs when required Read and understand this manual Please provide the Serial Number of your equipment if additional manuals are needed WHEN ORDERING PARTS ALWAYS REFER TO PUMP SERIAL NUMBER THIS NUMBER IS FOUND ON THE NAMEPLATE ON THE PUMP POLARIS Pump n Hard hon INSTALLATI
21. E ENCLOSURE Line voltages are nominal values and may be anywhere from nominal minus 15 to nominal plus 10 TYPE 2800 XXX MOTOR MOISTURE DETECTOR CONTROL INSTALLATION All type 2800 XXX controls are identified by a specific component number which follows the format 2800 XXX where the X s are replaced by numbers and letters indicative of the A C supply line voltage and frequency contact configuration and enclosure Each control has a data label on the right hand side of the terminal block In addition each enclosed control has another data label on the outside of the enclosure cover Mount the control on a vertical surface with the transformer on the left hand side and accomplish all indicated wiring Terminals on the control are numbered and are in the same relative position as the terminals shown on the wiring diagram Terminal pair 1 2 must be continuously energized from an A C supply line of electrical character istics shown on the data label Contacts must be wired into the electrical load circuit s of the warning devices as required Each contact used for load duty must be wired in series with the load and that series branch circuit connected across a power source compatible with the load Wiring must be provided from the moisture detector sensor probe leads of the RELIANCE ELECTRIC motor designated W1 and W2 to terminals 9 and 10 of the 2800 XXX control Control leads should not be installed in the same conduit as
22. E PBO 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 Hoist the Volute Casing Item 102 into position and insert into the motor flange spigot Apply Never Seize to the Socket Head Cap Screws and insert with Lock Washers Items 040 1 040 4 through the motor flange into the Casing and tighten Slide the Impeller Item 101 onto the shaft Position the O rings Item 062 2 062 3 onto the Shaft Adapter Item 108 and the same into the impeller bore lining up the groove in the cap face with the key Position O Ring Item 062 1 onto the Impeller Lock Screw Item 040 3 apply Locktite and insert into the shaft end and tighten Refer to Appendix 8 4 for Impeller Lock Screw Torque and Procedure Apply Never Seize to the adapter thread and screw on the Shaft Extension Item 109 Tighten the shaft extension via the wrench flats on the outboard end Position the O ring Item 062 4 into the shaft extension thread relief Position Casing Gaskets Item 060 3 onto Strainer Item 103 aligning the holes To verify the impeller running clearance compare the depth from the top of the strainer to the gaskets with the depth from the casing face to the impeller vanes The total difference should be 1 32 1 16 Adjust as
23. ECTIVE 08 24 2004 DATE 63 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 After the pump has been shut down completely drain wet end water jacket and piping Failure to do so will result in serious damage to your equipment 2 Be aware that the motor seal oil can thicken during cold storage to the point where it will be too viscous and can not provide adequate lubrication for start up Pre heat the pump as required before start up 3 Be aware that certain elastomer components lip seals o rings etc must not be operated if their temperature is below 4 F 20 C Pre heat the pump as required before start up POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 150 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 6 4 DATE 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 If a fault is detected be sure to keep all personnel clear of the pump when the pow
24. ERA TURES FROM OPERATION WITHOUT BEING SUBMERGED DISASSEMBLY MAY CAUSE BODILY INJURY FOR ASSIS TANCE CONTACT A RELIANCE OFFICE PROCEDURE 1 Loosen four bolts securing lead cable connector 1 two complete turns 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 3 Remove cable connector and reconnect to desired voltage as shown on connection diagram inside the cable connector 4 Insulate connectors with 4824 13 AU heat shrinkable plastic If the 4824 13 AU shrink able plastic is not available tape may be used but it should be an oil resistant type Enough wraps should be used to insure the buildup will be sufficient to prevent the connector from breaking through the insulation The following procedure should be employed Five layers of plastic elec trical tape followed by two layers electrical grade woven adhesive tape such as Mystik 7020 or 3M 27 for oil and abrasion resistance 5 Place O ring over fit and coat fit with Chevron SRI grease not excessive 6 Place cable connector back on motor install four bolts and tighten THERMAL PROTECTION SYSTEM THERMAL PROTECTION A IMPORTANT Reliance Submersible Pump Motors are equipp
25. HARGE PIPING DISCHARGE HOSE 4 6 2 PRIMARY SEAL FLUSH PIPING 46 3 OPTIONAL WATER JACKET PIPING 4 6 4 OPTIONAL WATER JET RING SECTION 5 0 ELECTRICAL INSTALLATION 5 1 GENERAL 5 2 MOISTURE DETECTION RELAY THERMAL PROTECTION 5 3 INSTALLATION REFER TO THE RELIANCE ELECTRIC MOTOR INSTALLATION amp MAINTENANCE MANUAL FOR DUTY MASTER SUBMERSIBLE MOTORS SECTION 8 2 POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 3of 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PBO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE SECTION 6 0 OPERATION 6 1 PRE START UP CHECK 6 2 PUMP START UP 6 3 PUMP SHUT DOWN 6 4 TROUBLE SHOOTING SECTION 7 0 WET END INSTALLATION T 1 TBM 200 LH Type PHO Open Suction Strainer 7 2 TBM 200 LH Type PBO Open Suction Strainer Solids Mixer Attachment 7 3 TBM 200 LH Type PVO Open Suction Strainer Shredder Attachment SECTION 8 0 APPENDIX 8 1 PUMP GENERAL ARRANGEMENT DRAWING TBM 200 LH PVO 8 11 PUMP PERFORMANCE CURVE TYPE PHO 8 1 2 PUMP PERFORMANCE CURVE TYPE PBO 8 1 3 PUMP PERFORMANCE CURVE TYPE PVO 8 2 RELIANCE ELECTRIC MOTOR INSTALLATION amp MAINTENANCE MANUAL FOR DUTY MASTER SUBMERSIBLE MOTORS 8 3 MOISTURE DETECTION RELAY 8 4 IMPELLER INSTALLATION BOLT TORQUE REQUIREMENTS POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL POLARIS SERIES TBM 200 LH 8 TYPE PHO
26. IONS 24 AUG 04 T PS 310 12 20 4 4 C 25 LL N a rn Z ud lt gt UT P m EE x e om CJ 4 3 l z n E CE pe E iui 2 4 c Yz T Lr b E E 1 3 8 un Ln 4 i 21 75 zx 1 i NOTE Lal H amp D 1 OLARIS 200 LH PHO mu m P U M P S tn Pump n Hard ho 466 85 387 30 12 20 47 i w E 2 Cr 7 1 gt or Pn ES 2 I p i un c E CI E C m E CE pe E iui 2 4 1 c en x Lr a un ia 1 Sol un Ln ERO Capa 105 27 35 E 1 i NOTE H n T T 1 BNO 27 56 44122123 5 Hard hon 200 LH PBO 1365 1075 TEM 200 LH PVU 23694 1117 16 12 01 FEET EFF F x 10 POLARIS Pump n Hard PUMP MODEL TBM 200 LH PHO PERFORMANCE FOR CLEAR WATER AND 12 SG APPROVED BY LORRELT OTHER DUMOITKEUINS ANDOR SOLOS EFFELT WIRE TO WATER EFFICIENCY
27. ON OPERATION AND MAINTENANCE MANUAL 5of 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PBO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 2 0 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 These warranties extend for a period of twelve 12 months from the date of purchase by Buyer Buyer s exclusive remedy and Seller s sole duty under these warranties is to repair or replace the product Normal wear and tear on Seller s product shall not constitute a warranty defect THERE ARE NO OTHER WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THOSE SET FORTH ABOVE THE WARRANTY OF MERCHANTABILITY IS LIMITED TO THE PERIOD SPECIFIED ABOVE These warranties are contingent upon the product being stored installed maintained and operated in accordance with good engineering practices and the instructions contained in the Operating and Maintenance Manual Failure to do so shall operate to void all warranties Seller s total responsibility for damages whether arising in contract or tort arising out of or relating to the performance of the product or the warranties hereunder shall be strictly limited to the contract price for the product In no event shall S
28. POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL POLARIS SERIES TBM 200 LH 8 TYPE PBO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 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 C SEAL GUARD SLURRY BOSS MOTOR SENTRY SS MOTOR FLANGE E COAL TAR EPOXY 0 PUMP SERIAL NUMBER DATE CUSTOMER CUSTOMER P O NBR SHIPPED TO POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 2of 29 POLARIS SERIES TBM 200 LH 8 PHO PBO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 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 421 NEW PUMP AND EQUIPMENT STORAGE 42 2 USED PUMP STORAGE 4 2 3 SPARE PARTS STORAGE 4 3 HANDLING 4 4 MECHANICAL SEAL INSPECTION 4 5 PUMP SET UP MOUNTING 4 5 1 CABLE AND CHAIN SUSPENSION 4 5 2 OPTIONAL LIFTING SUSPENSION BAIL MOUNTING 4 5 3 FLOOR MOUNTING 4 6 PIPING 4 61 DISC
29. S PUMPS when the equipment is to be removed from storage and put into service Failure to notify POLARIS PUMPS will result in your warranty being void Your new pump will arrive ready for use Close off all flush and cooling water inlet ports and cooling water exhaust ports on water jackets Suitable covers out of plywood or plastic must be installed on the suction entrance and discharge to provide adequate protection against dirt dust and nesting animals The main power and control cable ends must be protected by means of suitable shrink on boots or similar to prevent the ingress of moisture during storage Equipment should be stored in a dry location and situated on an even surface with no strains applied If stored outdoors the equipment must be covered with a waterproof tarp secured to the equipment or skid POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 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 3 SPARE PARTS STORAGE opare parts may not arrive at your site with adequate protection for long t
30. THERMOSTATS P1 amp P2 Normally Closed Thermostat Leads normally open thermostats are not acceptable to UL 1 Starter Holding Coil 2 Holding Coil Contacts N O FIGURE 2 TYPICAL THERMAL PROTECTOR WIRING DIAGRAM MOISTURE DETECTION SYSTEM MOISTURE SENSING PROBES A IMPORTANT Reliance Submersible Pump Motors are with moisture detection equipped devices Failure to properly connect or utilize this system voids motor warranty Moisture sensing probes leads marked Wj and must be used in conjunction with an induction relay This device will detect moisture entering the oil chamber due to failure of the outer seal and when properly connected to a warning device will needed maintenance requires periodic test provide notification of Integrity of system CONTROLS AND SIGNAL DEVICES A control and signal device not supplied by Reliance must be installed at the job site to complete the moisture detection system Compatible controls are available from Charles Warrick Co Normandy Court Royal Oak Michigan 48073 810 549 4900 CONTROL SELECTION AND ORDERING FOR CHARLES F WARRICK CO CONTROLS ORDER BY COMPONENT NUMBER 2800 XXX A C SUPPLY LINE VOLTAGE amp FREQUENCY 115V 50 60 H2 230V 50 60Hz 480V 50 60Hz CONTACT CONFIGURATION TERMINAL PAIR 34 56 78 8 3 4 C NO e N C NEMA TYP
31. TYPE PHO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 3 0 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 The equipment is capable of trouble free operation when properly installed operated and maintained These instructions present the basic information and methods required for proper installation and maintenance This pump has been designed to provide safe and reliable service however as with all equipment of this type the operator s must exercise good judgment and proper safety practices to avoid damage to the equipment and surroundings and to avoid personal injury The instructions in this manual are intended for personnel with a general training in operation and maintenance of centrifugal pumps and electric motors It is assumed that your safety department has established a safety program based upon a thorough analysis of industrial hazards Before installing operating or performing maintenance on the pump and associated components described in this manual it is suggested that the safety program be reviewed to ensure that it covers the hazards arising from rotating and electrical machinery In general all personnel should be
32. USH 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 If the sump level falls below the minimum requirement the higher than normal seal temperatures can cause the seal faces to crack due to thermal shock once the sump water level rises back and quenches the hot seal faces Refer to the general arrangement drawing of your pump Section 8 0 for the minimum sump level requirement and install suitable level controls 4 6 3 OPTIONAL WATER JACKET PIPING An optional water jacket must be installed if the pump is operated in applications where the sump can be pumped dry below the minimum water level and the pump remains running for periods exceeding 15 minutes This is to prevent overheating and subsequent burnout of the stator windings Cooling water should be 3 GPM at 60 P S I maximum pressure at a temperature not exceeding 40 C 104 Water must be clean so that no sand etc is pumped into the water jacket POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL POLARIS SERIES TBM 200 LH 8 TYPE PHO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 50 ELECTRICAL INSTALLATION 51 GENERAL Power supply and electrical work must be
33. adhered to as a minimum e POWER SUPPLY Double check and confirm that the power supply voltage and frequency match with the pump data plate e WIRING Double check all power and control cable connections Check and confirm that all ground leads are connected and properly grounded e CONTROL SYSTEM Double check that all control equipment is powered up and operational e CABLES Inspect both power and control cables for visual damage such as cuts and tears in the jacket e OIL LEVEL Double check the motor seal oil level e ROTATION CHECK Correct rotation is counter clock wise as viewed from the pump intake side In case of wrong rotation switch two of the three main power leads Do not run the pump in air longer than required to verify proper rotation e COOLING AND FLUSH WATER Double check all connections hoses and piping and ensure that the water supply is turned on for applications requiring motor cooling Visually confirm that the cooling water is circulating and exiting through the exhaust opening of the water jacket prior to start up POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 13of 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 6 2 DATE 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
34. al Compound Number 60 FU 3 750 0 139 BUNAN National Seal No B 46A 72 FU 4 500 0 125 BUNAN Parker Seal N 219 7 94 FU 5 875 0 125 BUNA N Precision Rubber No 1197 6 250 0 125 Crane Packing 2561 124 FU 7 750 0 125 BUNAN 144 FU 9 000 0 125 BUNAN 168 FU 10 500 0 125 BUNAN 12 000 0 125 13 000 0 140 15 000 0 140 TO BE USED AT 9 1 2 I D 3 32 NOM THICKNESS STANDARD REPLACEMENT SNAP RING CROSS REFERENCE Part No Waldes 47174 5 T Catalog Number 1 156 010 050 002 1 1 4 5108 125 H 420 Stainless 015 B 1 387 010 050 002 1 1 2 5108 150 H 420 Stainless 015 1 637 013 062 003 1 3 4 5108 177 420 Stainless 020 D 1 850 013 062 003 2 5108 200 H 420 Stainless 4020 E 2 081 015 078 003 2 1 4 5108 225 H 420 Stainless 025 H 2 543 015 093 003 2 3 4 5100 275 H 420 Stainless 025 F 2 75 020 093 003 3 5100 300 H 420 Stainless 030 3 006 020 093 003 3 1 4 5100 325 H 420 Stainless 030 NOTE Outer shaft seal must be in liquid when motor is operated whether motor is submerged or in air Seals cannot be run in a dry environment without a significant reduction in seal life 10 1 33 84 MING HOLES FOR 40 SCREWS OUTER SEAL LEAKAGE INDICATOR LI AL SUPPLY LINE 1 t
35. 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 Prior to installation of any wiring inspect both main power and control cable for possible cuts and tears 5 2 MOISTURE SENSOR RELAY Failure to install operate the specified Motor Moisture Detection Relay and not connecting the thermal over load wiring will void your Warranty POLARIS PUMPS requires the use of a Warrick Controls Type 2810 moisture detection relay This relay must be purchased with your pump as an integral part of the package to validate your warranty oee Section 8 3 for dimensional information and wiring diagram 5 3 INSTALLATION All activities related to the electrical installation maintenance and operation and service of the motor module must be in accordance with the RELIANCE ELECTRIC Application Installation amp Operation Manual Duty Master Submersible Motors Section 8 2 of this pump manual POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 120129 POLARIS SERIES TBM 200 LH 8 TYPE PHO PBO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 6 0 OPERATION 61 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
36. e compare the depth from the top of the strainer to the gaskets with the depth from the casing face to the impeller vanes The total difference should be 1 32 1 16 Adjust as necessary by adding or subtracting casing gaskets Slide strainer and gaskets into the casing bore Position the Pump Stand Item 112 over the strainer insert Never Seize coated Socket Head Cap ocrews and Lock Washers Items 040 2 040 4 and tighten Apply Never Seize to the Countersunk Head Cap Screws ltem 040 5 insert the Intake Screen Item 111 and screws into the strainer and tighten POLARIS Pus h Mand hon m m i has WET END ASSEMBLY EXPLOSION FOR BILL OF MATERIALS PARTS LIST SEE 200 LH PHO 0210 DRAWING MER 0207 REV 1 EFFECTIVE DATE 08 09 01 POLARIS Pump n Hard hon POLARIS PUMPS SERIES TBM 200 LH TYPE PHO A0210 Rev 0 1 2 I Jj mamana muon mw se x ue pee noon pee nooo 3 e sama 3 00 11 11 I
37. ed with thermal protection devices Failure to properly connect or utilize this system voids motor warranty Thermostat leads marked P1 amp P2 must be con nected in series with the stop button of the 3 wire pilot circuit of the magnetic motor controller so that the thermostat will open the circuit before dangerous temperatures are reached 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 1 12 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 MOTOR CONTROLLER MAY HAVE AUTO MATIC OR MANUAL OVERLOAD RESET DISCONNECT ALL POWER LEADS TO MOTOR WHEN PERFORMING ANY WORK ON MOTOR OR DRIVEN EQUIPMENT A MANUAL MOMENTARY START SWITCH IS REQUIRED TO PREVENT AU TOMATIC RESTART OF MOTOR WHEN THERMOSTAT RESETS If current through the thermostat will exceed the values listed in Figure 2 an intermediate control circuit relay must be used to reduce the current or the thermostat will not work properly Alternating Current Volts Continuous Inrush Amperes Amperes 110 120 3 0 30 220 240 1 5 15 440 480 0 75 7 5 550 600 0 6 6 0 STARTER STOP START
38. eller be liable for any incidental or consequential damages such as lost profits loss of use of productive facilities or equipment expenses or damages incurred in reliance on the product s performance or lost production whether suffered by buyer or any third party Seller warrants that the products comply with OSHA standards on drive guard design and construction if applicable in effect at the time of manufacture and makes no other warranty with respect to any other standards Seller shall not be responsible for failure of parts to fit properly due to deterioration of or modification to Buyer s existing equipment for which such parts are furnished Seller makes no warranty or guarantee that the product supplied hereunder will comply with the performance of Buyer s existing equipment seller reserves the right to furnish substitutes for material not available or whose use is restricted The use of a non OEM components or b non OEM pump spare parts and or c non approved modifications to the product and or d failure to install a moisture detection relay and or e failure to connect the thermal overload protection wiring will operate to void all warranties We reserve the right to change the design construction or material of any part without incurring the obligation of installing such changes on pumps already delivered POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 6of 29 POLARIS SERIES TBM 200 LH 8
39. er is turned on A qualified electrician must perform all electrical work Obey all local codes and regulations and follow recommended safety procedures The following Checklist is designed to aid in identifying possible faults assuming the pump has been in operation and functioned previously All activities related to the electrical installation maintenance and operation and service of the motor module must be in accordance with the RELIANCE ELECTRIC Application Installation amp Operation Manual Duty Master Submersible Motors Section 8 2 of this pump manual FAULT SIGNAL AT THE STARTER If the stator temperature is too high check that the pump motor is completely submerged or that the water supply to the water jacket is turned on during operation and that the impeller rotates freely In case of a moisture sensor fault check the condition of the oil and check for water in the motor housing and oil sump Make sure the overload protection is reset POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 16of 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PBO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 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 w
40. erm storage unless it was specified in your parts order It is the customer s responsibility to ensure that all spare parts are prepared and packaged for long term storage Components such as mechanical seal assemblies and parts should be left in their original sealed containers The long term storage of elastomer rubber parts must be given consideration since elastomers may have a short shelf live under certain circumstances 4 3 HANDLING Use care when moving pumps Sling pumps so that any protruding components will not be damaged Do not use choke type sling or chain arrangements for skids or containers Make sure that the lifting equipment is rated to safely handle the weight of the pump and auxiliary equipment See relevant general arrangement drawings Section 8 0 or bills of materials for weight information 4 4 MECHANICAL SEAL INSPECTION The pump was checked during assembly and testing for proper alignment of the pump components Rough handling during shipment storage or preparation for installation could cause damage to mechanical seals POLARIS PUMPS are equipped with tandem mechanical seals and should be checked for any oil leakage on the wet end side This is to ensure that the seal faces did not receive any damage during shipment storage or preparation for installation POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 9of 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PVO DOCUMENT
41. guided by all the basic rules of safety associated with the equipment and the process It should be understood that the information contained in this manual does not relieve operating and maintenance personnel of the responsibility of exercising normal good judgment in operation and care of the pump and its components P eL Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL POLARIS SERIES TBM 200 LH 8 TYPE PHO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 4 0 DATE 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 lt is important that the entire contents of this manual are studied before installation Pump parts and accessories may be packed inside shipping container or attached to skids in individual packages Inspect all containers crates and skids before discarding 4 2 STORAGE 4 2 1 NEW PUMP AND EQUIPMENT STORAGE If your new pump is to be stored for a long period before use the following procedures must be adhered to in order for POLARIS PUMPS to extend the normal warranties Notify POLARIS PUMPS that the equipment is to be stored and that the storage procedures will be followed Notify POLARI
42. h communications UNPACKING If facilities for the shelter of equipment are not available repack motor and store shaft down until ready for use After unpacking and inspecting to see that all parts have been received in good condition turn the motor shaft by hand to be sure that there are no obstructions to free rotation The motor should be checked for oil leaks after being removed from the crate If positive indication of an oil leak is found around the shaft seal or drive end bracket notify the nearest Reliance Electric Sales Office APPLICATION All Reliance Submersible Pump Motors include thermal devices as standard These devices are required by UL on all motors 1 HP and larger listed Class Groups C and D These devices are not recognized by UL for motors less than 1 HP but are included by Reliance for additional motor protection Motors less than 1 HP are supplied with a cautionary label and are suitable on applications where vapor or gas ignition temperatures exceed 280 C These motors are listed for Class I Group D only Reliance Electric stocks common ratings through 100 HP continuous duty submerged in liquid 15 minutes duty in air at nameplate horsepower Designs through 250 HP and special continuous in air ratings are also available Continuous in Air Designs have a 1 0 Service Factor Normally there are four conditions during which a submersible sewage pump may be operated in gases or vapors 1 W
43. hen the wet well is being dewatered 2 When the pump motor assembly is being lowered down the guiderails The flow from the pump is needed during the installation process to insure that solids are cleared from the discharge flange area to insure proper seating 3 When low level cutoff controls fail 4 When low level sensors are positioned at the bottom of the pump assembly NOTE Outer shaft seal must be in liquid when motor is operated whether motor is submerged or in air Seals cannot be run in a dry environment without a significant reduction in seal life If seal is to be run in a dry environment a special design seal must be supplied Standard seals applied in dry seal applications will not be covered by warranty CONTINUOUS OPERATION GASES OR VAPORS It is the driven equipment manufacturer s responsibility to insure this motor product is properly applied Horsepower requirements are a function of pump design impeller size amp head and flow conditions In gas operating time is a function of pit size pump capacity and flow conditions Only the pump manufacturer can insure that the pump motor is properly applied for continuous in gas or vapor operation As with any motor product it is essential that proper consideration be given to the load characteristics to insure the motor product will not be overloaded Should such an overload occur thermostats embedded in the windings will provide a signal to deenergize the
44. iance service facilities negates the U L listing and motor warranty Copyright Reliance Electric Industrial Company 1996 Revisions to this manual require Hazardous Approval Engineering and or UL approval Reliance and DutyMaster are registered trademarks of Reliance Electric Industrial Company RECEIVING AND HANDLING ACCEPTANCE Thoroughly inspect this equipment before accepting shipment from the transportation company If any of the goods called for in the bill of lading or express receipt are damaged or the quantity is short do not accept them until the freight or express agent makes an appropriate notation on your freight bill or express receipt If any concealed loss or damage is discovered later notify your freight or express agent at once and request him to make an inspection We will assist you in collecting claims for loss or damage in shipment however this willingness on our part does not remove the transportation company s responsibility in reimbursing you for collection of claims or replacement of material Claims for loss or damage in shipment must not be deducted from the Reliance Electric invoice nor should payment of the Reliance Electric invoice be withheld awaiting adjustment of such claims as the carrier guarantees safe delivery If considerable damage has been incurred and the situation is urgent contact the nearest Reliance Electric Sales Office for assistance Please keep a written record of all suc
45. indings Test actuator switch for contact in both manual and automatic mode PUMP CAN NOT BE STARTED MANUALLY NO VOLTAGE TO PUMP Check that the main power switch is on Check for control voltage to the starter equipment and that all fuses are intact Check that all supply line phases are live and that all fuses are intact and properly fitted Check that the overload protection relay is reset Check for breaks in the motor cable PUMP CAN NOT BE STARTED MANUALLY VOLTAGE IS GOING TO PUMP If this is the case some oversized material or other debris may have jammed the impeller solids mixer or shredder CAUTION Disconnect and lock out the main power supply before working in the intake area of the pump Failure to do so can result in serious injury Clean out and remove any objects that may have jammed the impeller and inspect the pump components for any visual damage Inspect the sump area and remove any oversized material and debris Inspect pump strainer for excessive wear and replace if required PUMP CAN BE STARTED MOTOR PROTECTION TRIPS Check that the overload protection is not set too low or is defective Check the breaker set point vs the amperage on the motor data plate and adjust or replace overload protection relay as required Check for free rotation of the impeller If it is not easily rotated or feels tight check for tramp material within the pump Using an Amp meter check the current on all three phases Using a
46. k the pump intake area to ensure that the impeller strainer and mixer or shredder is not clogged Visually inspect the wet end components for wear The performance of the pump can be significantly reduced if casing and impeller have experienced excessive wear Check the impeller running clearance and adjust if required Replace parts as required POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 1901 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PBO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 7 0 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 Remove any protective coatings from the shaft end and check to make sure that the tapped hole in the end of the shaft and the key seat are free of any shavings and dirt Prior to the physical assembly of the wet end familiarize yourself with all of the components and the assembly sequence by reading the assembly instructions and the enclosed explosion drawings Based on your particular pump model and size gather the necessary tools as per the following tool list TOOL REQUIREMENTS Series TBM 200 LH Type PHO Allen wrenches 5 8 14 mm 6 mm Plastic or Rubber Hammer Never Seize or Molykote Locktite Series TBM 20
47. mana v pue mw xum oe Sem pee noon stan pee nooo 3 meesewwems e sama 3 s Sew s onomea 15 sa ee 17 A L 7 exer ou rem 0m ew 7 eme me ue 7 em memes em 3 LLL I s rara m 2 s fastener screw onomea 06
48. nsion thread relief Position Casing Gaskets Item 060 3 onto Strainer Item 103 aligning the holes To verify the impeller running clearance compare the depth from the top of the strainer to the gaskets with the depth from the casing face to the impeller vanes The total difference should be 1 32 1 16 Adjust as necessary by adding or subtracting casing gaskets Slide strainer and gaskets into the casing bore Position the Pump Stand Item 112 over the strainer insert Never Seize coated Socket Head Cap screws and Lock Washers Items 040 2 040 4 and tighten Apply Never Seize to the Socket Head Cap Screws Item 040 6 insert the Stationary Shredder Item 105 and screws into the strainer Insert Set screws 040 7 into stationary shredder Apply Never Seize to the shaft extension thread and screw on the Rotating Shredder Item 104 Tighten using a plastic or rubber hammer Adjust shredder clearance to 0 5 mm 0 020 using the set screws and tighten the socket head cap screws POLARIS Pus h Mand hon m mi 2 im ANG 05 ma d WET END ASSEMBLY EXPLOSION FOR BILL OF MATERIALS PARTS LIST SEE 200 LH PVO 0212 DRAWING MER 0209 REV 1 EFFECTIVE DATE 08 09 01 POLARIS Pump n Hard hon POLARIS PUMPS SERIES TBM 200 LH TYPE PVO A0211 Rev 0 1 2 G I j ma
49. nsult motor starter application data as well as the National Electric Code and or other local codes 2 Maximum submergence of motor is not to exceed 200 feet in depth and or 200 P S I at motor seal 3 Thermal Protectors must be connected Leads marked P1 and P2 See Figure 2 4 Moisture Sensing Probes must be con nected Leads marked W1 and W2 See Figure 3 5 Check your power supply against final nameplate connection voltage If required the impeller should be heated slight ly before pressing it on the shaft Under no circumstances should the impeller be driven on by pounding as this will damage the seal 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 Motor will operate successfully with frequency not more than 596 and voltage not more than 1096 above or below nameplate data Performance within this range will not necessarily be the same as the established performance at exact rated voltage and frequency All submersible pump motors will operate in either direction of rotation To reverse direction of a THREE PHASE
50. om 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 4 Lock Screw Installation Align and insert the Impeller Cap or Shaft Adapter into the Impeller Counter Bore Insert the Lock Screw into Motor Shaft and tighten using a Torque Wrench or Allen Wrench with suitable extension See Table below for required Torque 2 5 Impeller Lock Screw Torque Requirements TBM 50LH 100LH 1 2 13 UNC 55 ft lbs 75 Nm TBM 150LH 5 8 11 UNC 110 ft Ibs 150 Nm TBM 200LH 3 47 10 UNC 200 ft Ibs 275 Nm TBM 250LH 3 47 10 UNC 200 ft Ibs 275 Nm TBM 75MH 5 87 11 UNC 110 ft Ibs 150 Nm TBM 100MH 5 87 11 UNC 110 ft Ibs 150 Nm TBM 150MH 3 47 10 UNC 200 ft lbs 275 Nm TBM 200MH 3 47 10 UNC 200 ft Ibs 275 Nm BB 08 15 02 A ADDED250LH 09 26 03 CHANGE DESCRIPTION APPV D DATE P U M P S Pump Hard hon ENGINEERING STANDARD PROCEDURE 1of 1 IMPELLER INSTALLATION TECH BULLETIN DOCUMENT NBR PED 017 REVISION 0 EFFECTIVE 09 16 2003 DATE 1 0 SCOPE Assembly Pre Load Bolt Torque requirements for Metric Fasteners of Grades A2 70 304L 4 70 316L and 8 8 for Sizes M4 to M20 2 0 METHOD ASSEMBLY TORQUE ASSEMBLY PRE LOA
51. s 06 s onomea 15 fastener 1 3 emer L 7 ew samasaa 3 eme sa I J j C rie mamana pe nooo wwe m o 3 SELL I 14 s j Jj T 1 mamas am ee 3 Lex 3 s LLL 3 ma LLL I j SEE TABLE BELOW FOR COMPLETE PUMP PART NUMBERS AND MOTOR DETAILS ESTIMATED WEIGHT TOTAL POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL 23of 29 POLARIS SERIES TBM 200 LH 8 TYPE PHO PVO DOCUMENT NBR PED 010 REVISION 1 EFFECTIVE 08 24 2004 DATE 72 TBM 200 LH TYP
52. the pressure developed by the pump may not be enough to force them open Lower the pump slowly into the material to be pumped Mixture density can be monitored via a current meter Higher current draw of the pump will indicate higher density and therefore higher production rate The mixture density can be controlled by raising or lowering the pump into the material Be aware of the mixture characteristics for your specific application It is important that you maintain a pipeline velocity above the critical settling velocity of the solids mixture being pumped to prevent the solids from settling out and clogging the discharge line Never stop the pump while pumping solids through the system This will plug the piping Before shut down raise the pump into clean water and completely flush the discharge line During the initial few days of operation while all parts are still new observe the discharge gauge readings as well as the motor amperage draw If a flow meter is available monitor the pump output as well These readings should be taken and recorded periodically and will help you to establish an inspection and maintenance schedule Keeping track of your pumps performance will make it easier to identify problems before they become serious and cause undue damage POLARIS Pump n Hard hon INSTALLATION OPERATION AND MAINTENANCE MANUAL POLARIS SERIES TBM 200 LH 8 TYPE PHO DOCUMENT NBR PED 010 REVISION 1 EFF
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