Tuthill 6000 Kurzanleitung

Service Manual #67

Installation and Service

Instructions

6000, 7000 & 8000 Series

Magnetically Coupled Pumps

Service Manual # 67

Page 2of 36

Table of Contents

Section Description Page

1General Description 4

2The Pumping Principle 5

3Proper Installation 5

4Pressure Limitations 6

5Magnet Temperature Limitations 7

6Optional Equipment 7

7Method Of Drive 8

8Location 8

9Strainer Protection 8

10 Startup 9

11 Pump Disassembly Procedure -6110 & 7110 Pumps 9

12 Pump Disassembly Procedure -6200 Pumps 11

13 Pump Disassembly Procedure -6210 Pumps 13

14 Pump Disassembly Procedure -6300, 7200 & 8200 Pumps 15

15 Pump Disassembly Procedure -6310, 7210 & 8210 Pumps 16

16 Pump Assembly Procedure -6110 & 7110 Pumps 18

17 Pump Assembly Procedure -6200 Pumps 20

18 Pump Assembly Procedure -6210 Pumps 22

19 Pump Assembly Procedure -6300, 7200 & 8200 Pumps 24

20 Pump Assembly Procedure -6310, 7210 & 8210 Pumps 26

21 Troubleshooting 34

22 Material Returns 35

!WARNING

The magnets in magnetically coupled pumps create very strong magnetic fields. Special care must

be taken with the following:

Pacemakers -Magnets can upset the timing of pacemakers. These magnets should be kept away

from all pacemakers. Because of the health risks involved the importance of this cannot be

overstated.

Credit Cards -Magnets can scramble the information on a credit card’s magnetic tape.

Computers, Computer Tapes and Computer Disks -Magnets can scramble the information on

the memory device.

Watches -Magnets can affect the workings of traditional mechanical spring driven watches as well

as chip and electronically controlled designs.

Electronic Instruments -Sensitive electronic instruments and devices may change calibration or

be damaged by a powerful magnetic field.

Explosive Atmosphere -Rare earth magnets and magnetic materials may create sparks through

contact in handling. Never handle rare earth magnets in explosive atmospheres because sparking

may ignite the atmosphere.

Note: This manual replaces Service Manuals #66, 77 & 88.

Service Manual # 67

Page 3of 36

!WARNING

Magnetically coupled pumps (SEALLESS -as defined by the Hydraulic Institute) do not contain any

dynamic seals. The possibility of leakage is therefore greatly reduced.

However, all materials are subject to wear and stress which can eventually lead to a failure,

resulting in leakage. Without proper safeguards, leakage of hazardous fluids is potentially

dangerous and can cause serious injury or death, or create an environmental hazard.

Users must understand and deal with this potential danger regardless which manufacturer’s pump is

used. If the fluid being pumped is hazardous, appropriate monitoring must be employed to provide

early warning of any leakage. If you are unsure of the methods available to monitor your application,

you should contact capable engineering firms for design guidance.

Magnetically coupled pumps may decouple and must be stopped to re-engage. Operation of a

decoupled unit may destroy the magnets and will result in a serious danger of explosion when

handling fluids with a low flash point because of very rapid heat buildup.

Magnetically coupled pumps are not designed to be run dry.

!WARNING

Failure to follow these instructions could result in serious bodily injury or death.

Do not attempt to work on any Tuthill pump installation before completing the steps below.

Disconnect the drive so that it cannot be started while work is being performed.

Review the Material Safety Data Sheet (MSDS) applicable to the liquid being pumped to

determine its characteristics and the precautions necessary to ensure safe handling.

Vent all pressure within the pump through the suction or discharge lines.

All Tuthill pumps contain residual hydraulic oil from the factory production test. Determine if this is

compatible with the fluid you are pumping. If the fluid is incompatible, consult the factory.

Service Manual # 67

Page 4of 36

Section 1: General Description

The Tuthill 6000, 7000 & 8000 Series pumps are magnetically-coupled versions of the Tuthill 4000 &

ST Series pumps. These pumps operate on the internal gear pumping principle described below.

These pumps do not contain any dynamic seals, thus eliminating any possibility of shaft seal

leakage. The available models are shown in Table 1.

max

speed

(inch)

(mm)

(usgpm)

(lpm)

(rpm)

(psi)

(bar)

6113

1/2

1.7

1800

500

34.5

6114

1/2

1800

500

34.5

6115

5.5

1800

500

34.5

6202

1800

100

6.9

6203

1 1/4

1800

100

6.9

6204

1 1/2

140

1800

100

6.9

6205

1 1/2

235

1800

100

6.9

6206

318

1800

100

6.9

6302

1800

200

13.8

6303

1 1/2

1800

200

13.8

6304

1 1/2

114

1800

200

13.8

6305

189

1500

200

13.8

6306

2 1/2

303

1500

200

13.8

6307

135

511

1200

200

13.8

7114

2.8

1800

200

13.8

7115

5.6

1800

200

13.8

7202

1200

150

10.3

7203

1 1/2

1200

150

10.3

7204

1 1/2

1200

150

10.3

7205

125

1000

150

10.3

7206

2 1/2

201

1000

150

10.3

7207

341

800

150

10.3

8202

1800

200

13.8

8203

1 1/2

1800

200

13.8

8204

1 1/2

114

1800

200

13.8

8205

189

1500

200

13.8

8206

2 1/2

303

1500

200

13.8

8207

135

511

1200

200

13.8

* metric ports not available in these sizes

max pressure

cast iron

stainless steel

carbon steel

Materials of

Construction pump

size std port size max capacity

Table 1 -Models Available

Service Manual # 67

Page 5of 36

Section 2: The Pumping Principle

Figure 1 -Internal Gear Pumping Principle

Tuthill 6000, 7000 & 8000 Series pumps employ the internal gear pumping principle (see Figure 1).

There are only two moving parts. Pumping action is based on a rotor, idler gear and crescent-

shaped partition cast integral with the cover.

Power applied to the rotor is transmitted to the idler gear with which it meshes. The space between

the outside diameter of the idler and the inside diameter of the rotor is sealed by the crescent.

As the pump starts, the teeth come out of mesh, increasing the volume. This creates a partial

vacuum, drawing the liquid into the pump through the suction port.

The liquid fills the spaces between the teeth of the idler and the rotor and is carried past the

crescent partition through the pressure side of the pump.

When the teeth mesh on the pressure side, the liquid is forced from the spaces and out through the

discharge port.

Section 3: Proper Installation

Unsatisfactory pump installations are usually characterized by poor suction conditions for the

specific liquid being handled. Suction conditions should be minimized to prevent vaporization of the

liquid. If vacuum conditions force the liquid to vaporize, cavitation will occur, resulting in loss of

capacity, premature wear and noisy operation.

For optimum pump performance, the suction line must be at least as large as the corresponding

pump port. It should be as short as possible in order to avoid excessive pressure drops and must

be airtight. The placement of a strainer on the suction side of the pump will restrict any solids or

abrasives from entering the pump which could cause internal damage.

Note: Pipe line friction increases at a rapid rate with an increase in viscosity. For a given pump and

motor, larger pipe lines are necessary to maintain the same pump pressure when changing from a

thin fluid to a thick one.

When handling high viscosity liquids, the speed of the pump must be reduced and the size of the

lines increased to prevent cavitation.

Service Manual # 67

Page 6of 36

Under no conditions should the pump be used to support external piping loads. Piping and other

equipment should be independently supported.

The discharge line must be designed with the maximum pressure rating of the pump in mind.

Excessive pressure could cause damage to your motor and/or pump. If a pressure relief valve has

not been supplied with the pump, some other means of pressure protection must be utilized. This

could include in-line safety valves, pressure shutdown switches or other similar devices.

Every pump installation should have a good foundation. Its structure should be sufficiently strong to

hold the pump rigid and to absorb any strain or shock that may be encountered. The installation

should be leveled, checked for proper piping alignment, and then fastened securely.

Pumps should be filled with fluid at installation and should never be allowed to run dry.

6000, 7000 & 8000 Series pumps have internal venting which makes them directional. The direction

of rotation is specified from the shaft end of the pump. Unless otherwise specified, rotation is

assumed to be clockwise (CW), which places the suction port on the right side of the pump when

viewed from the shaft end. Operation of the pump in a direction other than specified can cause

damage to both the pump and magnets.

Consult Tuthill personnel whenever unusual conditions of speed, pressure, vacuum or viscosity are

encountered.

The Tuthill pump is a positive displacement pump. As the pump rotates, liquid is positively

delivered to the discharge side of the pump. If the discharge line is closed off, pressure will

increase until the magnets de-couple, the drive equipment stalls and/or fails, the pump breaks or

ruptures, or the piping bursts. This could result in serious bodily injury or death. To prevent this

from happening, the use of a pressure relief valve is required. A relief valve that directs the flow back

to the supply tank is recommended.

Pumps shipped from the factory with relief valves are assembled for clockwise or counterclockwise

rotation as originally specified. The adjusting screw must always point toward the suction line. If

you want to change rotation, the relief valve assembly must be removed and turned 180°, and the

bracket must be rotated 180°.

Section 4: Pressure Limitations

Standard models have pressure ratings as shown in Table 1. Standard canisters are designed to

withstand the maximum rated discharge pressure of the pump. The internal venting arrangement

will normally result in a pressure in the canister that is less than the discharge pressure.

!WARNING

Exceeding the maximum canister pressure may cause a canister failure resulting in the release of

the fluid being pumped. Refer to the Optional Equipment section for options available for safely

addressing this concern.

Consult the factory regarding any applications where the canister pressure is in question.

Service Manual # 67

Page 7of 36

Section 5: Magnet Temperature Limitations

Standard pumps are supplied with magnets constructed of Neodymium-Iron-Boron. These magnets

cannot exceed a maximum temperature of 250° F (120° C). Operation above the maximum

temperature will result in a permanent reduction in magnet strength. Samarium-Cobalt magnets are

available as an option and have a maximum temperature rating of 500° F (260° C). Generally, all

magnets subjected to temperatures above their maximum rating will lose a portion or all of their

magnetic strength.

To prevent damage to the magnets, use of a temperature sensor is recommended. Refer to Section

6: Optional Equipment for further details.

Section 6: Optional Equipment

Sensing equipment must be installed to immediately shut down the system when any abnormality

is detected.

Secondary Control

This feature converts the outer pump adapter into a secondary control chamber. In the

event of fluid leakage from the primary chamber, this option provides a temporary backup

system for preventing leakage into the environment, with proper sensing devices. Use of

secondary control is recommended when handling hazardous or toxic fluids. Secondary

control cannot be expected to contain pressure or significant fluid loss.

Provided with this option are two tapped ports in the outer pump adapter, which will

accommodate various sensors:

•Leak Sensor -Installed into the lower tapped port, it monitors for fluid within the

secondary containment chamber to indicate inner canister failure.

•Temperature Sensor -Installed into the upper tapped port, it monitors canister

temperature to help prevent magnet damage due to excessive heat.

•Cooling Jacket -Utilizes both tapped ports and the secondary control chamber to

disperse heat from the canister and magnets.

Pumps must be inspected weekly to verify the integrity of the secondary control feature.

More frequent inspection may be necessary, dependent on the specific application.

Bracket Access

This option incorporates two access holes in the pump bracket to provide a direct passage

to the inner magnet for use as follows:

•Pressure Sensor -monitors pressure in the inner canister.

•Flush -allows for flushing of canister chamber.

•Drain -allows for draining of canister chamber.

Service Manual # 67

Page 8of 36

Section 7: Method Of Drive

Direct drive through a traditional flexible coupling is recommended. However, do not expect the

flexible coupling to compensate for misalignment. Contact the coupling manufacturer to determine

the maximum amount of misalignment which the coupling can tolerate.

All pump and motor units must be properly aligned during assembly and periodically checked since

misalignment may occur later due to changing conditions.

Pipe strain can force the pump and motor shaft out of alignment. Therefore, all piping to the pump

must be properly supported. Do not allow the pump to act as a pipe support.

Provide for proper expansion of pipes when handling hot liquids. Allow pump to reach operating

temperatures and then re-check alignment.

Provide sufficient clearance, 1/16 -1/18 inches (1.5 -3 mm) between coupling halves with shaft in

closest operating position.

Never depend upon sight or feel. Use proper gauges when aligning a pump.

Never operate pump without all guards in place.

Section 8: Location

The pump should be located as close to the source of supply as conditions permit and if possible,

below the level of the liquid in the reservoir. When necessary to locate the pump in a pit, provisions

should be made to safeguard against flooding. Care must be taken to properly support the suction

and discharge piping so that no strain is put on the pump due to either weight or expansion. Piping

strain can result in misalignment, hot bearings, worn couplings, and vibration. It is important that

the piping used be clean and free of chips or scales.

Section 9: Strainer Protection

Strainers are used to remove contaminated particles from the fluid system and extend pump life.

Every pump should be protected from these particles by a strainer in the suction line.

Strainer size and mesh of screen is determined by rate of flow and viscosity of fluid. Consult

strainer manufacturer for recommendations.

Never use a strainer with built-in automatic by-pass on the suction line set to open under 30 inch

(750 mm) Hg. vacuum.

Install strainer according to the designated direction of flow.

Have strainer accessible for servicing.

Use a duplex type strainer when shutdown during service is not permitted.

Provide a vacuum gauge in the suction line for determining when the strainer requires cleaning.

Make certain strainer baskets are properly reinforced so as not to collapse under 30 inch (750 mm)

Hg. vacuum.

Service Manual # 67

Page 9of 36

Section 10: Startup

!WARNING

Follow all precautions outlined in the Material Safety Data Sheet (MSDS) applicable to the liquid

being pumped to ensure safe handling.

All Tuthill pumps contain residual hydraulic oil from the factory production test. Determine if this is

compatible with the fluid you are pumping. If the fluid is incompatible, consult the factory.

Prior to starting the pump double check the following:

•Pressure and vacuum gauges should be installed as close as possible to the pump.

•Rotate pump shaft to ensure it turns freely without binding.

•Recheck alignment and ensure all guards are in place.

•Make sure piping is independently supported and no strain is being transmitted to the pump.

•Make sure the safety relief valve is installed correctly.

•Open suction and discharge gate valves.

•Check for any leaks once gate valves are open.

•Check pump rotation.

After completing these checks the pump can be started.

!CAUTION

The pump should not be run dry. If after approximately 60 seconds there is no discharge of liquid,

stop the pump and investigate the possible cause. Failure to comply with this could cause severe

damage to magnets, bushings and/or metal parts.

Section 11: Pump Disassembly Procedure -6110 & 7110 Pumps

Refer to Figure 3 (6110) & Figure 4 (7110).

Although some minor disassembly is possible with the complete pump/motor assembly still in

place, it is recommended that the pump/motor unit be disconnected and moved to a maintenance

area.

!WARNING

Residual pumped fluid will be present in the pump. Follow all precautions outlined in the Material

Safety Data Sheet (MSDS) applicable to the liquid being pumped to ensure safe handling.

Service Manual # 67

Page 10 of 36

1. Remove piping from the ports.

2. Mark cover and housing before disassembly to ensure proper reassembly.

3. Remove the cover screws, cover and idler.

4. Inspect the following parts carefully for deep grooves, scratches or other damage:

•The end face of the rotor

•The O.D. of the idler

•The I.D. of the idler.

•Both faces of the idler.

•The O.D. of the idler pin.

•The inside surfaces of the cover including the crescent.

5. Check for signs of wear. A decrease in capacity is generally caused by the abrasive action of

foreign materials in the liquid, resulting in excessive end clearances. End clearance can be

reduced by changing to a thinner cover gasket. To adjust the end clearance, see assembly

procedure.

!CAUTION

The pump must be separated from the magnet coupling if further disassembly is required. Follow

the instructions below.

The housing, rotor and inner magnet can be removed by hand.

DO NOT PLACE HAND OR FINGERS BETWEEN THE HOUSING AND ADAPTER. The magnets

are extremely strong and will attract all metallic objects and can be the source of pinch points. Do

not wear watches or other metallic jewelry when working with magnets. See warning on Page 2.

Failure to follow proper procedures or use appropriate tools could result in injury to you or damage

to either personal property or the pump.

6. Remove the housing screws.

7. Remove the pump head assembly from the adapter, making sure to pull it straight off.

8. Remove the canister from the housing. The canister will probably contain pumping residue.

Use care when removing, making sure to pull the canister straight off. Inspect the canister I.D.

and O.D. for evidence of contact or wear.

9. Set the housing, rotor and inner magnet assembly face-down. Remove the retaining ring, inner

magnet and key.

10. Set the magnet down on a clean, non-magnetic surface. Inspect the magnet sleeve for

evidence of damage or excessive wear and cover with a cloth to prevent contamination.

11. Check the shaft O.D. for any burrs and remove to prevent damage to the housing bushing.

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