TapFlo PTL Series, Manual

Page 1: ...PTL Low Pressure Hose Pumps Original Instruction 2023 1 Read this instruction manual carefully before you install and operate the pump Pump models PTL PXTL 9 13 17 25 30 45 IOM manual...

Page 2: ...e 11 1 5 Foundation 11 1 6 Environment 11 1 7 Suction and discharge piping 11 1 7 1 Connection of suction pipe 12 1 7 2 Connection of discharge pipe 12 1 8 Health and safety 12 1 8 1 Protection 12 1 8...

Page 3: ...2 8 Actions in emergency 19 3 MAINTENANCE 20 3 1 Inspections 20 3 2 When the pump is new or reassembled 20 3 2 1 Performance test 20 3 3 Routine inspection 20 3 4 Complete inspection 21 3 5 Location o...

Page 4: ...4 Tightening torques 48 6 5 Permitted loads on manifolds 49 7 ATEX supplementary manual 50 7 1 Potentially explosive atmospheres ATEX 50 7 2 Operating limits 50 7 3 Construction materials use restrict...

Page 5: ...pflo PTL Hose Pumps 4 7 18 Earth connection of the pump and other equipment 57 7 19 Antistatic surface 57 7 20 Paint thickness 58 7 21 Inspection 58 8 WARRANTY 59 8 1 Warranty form 59 8 2 Returning pa...

Page 6: ...2 EC of European Parliament and of the Council of 17 May 2006 on machinery amending Directive 95 16 EC Directive 2014 30 EU of the European Parliament and of the Council of 26 February 2014 on the har...

Page 7: ...h the relevant Union harmonisation legislation Directive 2006 42 EC of European Parliament and of the Council of 17 May 2006 on machinery Directive 2014 34 EU of the European parliament and of the cou...

Page 8: ...S The object of the declaration described above is in conformity with the relevant Union harmonisation legislation Directive 2006 42 EC of European Parliament and of the Council of 17 May 2006 on mach...

Page 9: ...manual This is what they say This symbol stands next to all safety instructions in this instruction manual where danger to life and limb may occur Observe these instructions and proceed with utmost ca...

Page 10: ...PTL Hose pumps 9 0 4 Nameplate The nameplate is made in the below design It is made of AISI 304 stainless steel and placed on the pump stand or discharge flange bracket Nameplate dimensions are 38 x...

Page 11: ...ts of the pump that are in contact with the pumped liquid 1 2 Receiving inspection Although precaution is taken by us when packing and shipping we urge you to carefully check the shipment on receipt M...

Page 12: ...Check that the feet of the pump motor unit stand well on each of them The surface on which the foundation stands must be flat and horizontal If the unit is fitted on a steel structure make sure that...

Page 13: ...the discharge side in order to protect the pump from water hammer effect that can be created in the discharge pipeline If overpressure in the discharge line is possible an appropriate pressure safety...

Page 14: ...emperature changes and do not exceed the maximum temperature specified when the pump was ordered See also general max temperatures based on water in chapter 6 Data Ambient temperature limits are form...

Page 15: ...check valve on the discharge side in order to protect the pump from water hammer effect that can be created in the discharge pipeline The suction line should be as short and straight as possible A gat...

Page 16: ...ectric power The electric power absorbed by the motor can be measured by means of a wattmeter or an amp gauge 1 10 2 Optional instruments The optional instruments can indicate if pump is working in an...

Page 17: ...ble electric switchboard equipped with a knife switch and suitable safety devices e g motor breaker switches in the power circuit Safety devices against overloads must also protect the motors Make sur...

Page 18: ...ee section 6 4 Tightening torque s After approximately one week of operation the torque should be checked again This is important to prevent possible leakage Starting the electrical motor makes the pu...

Page 19: ...at is to avoid any problems due to water hammering It is therefore advised to install a check valve on the discharge to protect the pump If a suction shutoff valve has been installed it is advisable t...

Page 20: ...urn recycle recovery of WEEE and minimize any potential effects of EEE on the environment and human health due to the presence of hazardous substances The WEEE marking applies only to countries within...

Page 21: ...specific pump speed This information is useful for checking performance in the future as wear takes place You will be able to set schedules for maintenance of the pump and to select spare parts to be...

Page 22: ...e losses on suction side Check change installation on suction side Too viscous liquid Check if pump speed is proper for viscosity Air in liquid Seal suction line check refill container Hose is blocked...

Page 23: ...sassembly should be performed only by qualified personnel There should always be at least two persons present during disassembly Each operation to be fulfilled with the machine must always be carried...

Page 24: ...r specific maintenance actions Fig 3 6 1 Unscrew the front cover mounting bolts 141 and remove them with their washers 142 Fig 3 6 2 Remove the front cover 12 Fig 3 6 3 Unscrew the front connection br...

Page 25: ...3 6 8 Remove the rear connection bracket 170R Fig 3 6 9 Unscrew the gear motor mounting bolts 112 and remove them with their washers 114 Fig 3 6 10 Remove both keys 161 from the shaft Fig 3 6 11 Unscr...

Page 26: ...h their washers 925 NOTE During assembly use blue Loctite 243 on the screw thread Fig 3 6 16 Remove the brackets 94 from the rollers Fig 3 6 17 Take apart the roller assembly Fig 3 6 18a PTL9 PTL17 Fo...

Page 27: ...t fills the pump housing Make sure that suction and discharge valves are closed before draining Pump size PTL9 13 PTL17 PTL25 PTL30 PTL45 Casing volume L 0 6 1 3 3 5 8 20 Fig 3 7 1 Place a drip pan un...

Page 28: ...pump operating conditions the more repeatable the hose life will be See 4 3 Hose leak detector In order to avoid costly downtime of the pump it is recommended to inspect the hose after about 90 of th...

Page 29: ...nd retract the bracket so that there is no pressure on the hose anymore NOTE Do not loosen the screws on the other side of the rotor Fig 3 9 5b PTL30 PTL45 On the side where the roller is NOT pressing...

Page 30: ...clamp bands 271 Fig 3 9 8 Remove the clamp bands 271 and the inserts 70 form the hose Clean the inserts 70 and pump casing 11 Fig 3 9 9 Clean the new hose 15 thoroughly before assembly Assemble the n...

Page 31: ...otor and rotate the roller 180 Fig 3 9 14 PTL30 PTL45 Remove the cover and install the missing roller assembly without any shims Fig 3 9 15 Set the roller pressure according to the Roller Adjustment p...

Page 32: ...nd safety Fig 3 10 1 Remove the front cover mounting bolts 141 leaving two of them partially fastened to avoid accidental falling off of the pump Fig 3 10 2 Check condition of casing gasket 18 and rev...

Page 33: ...cosity This operation can be done without complete pump disassembly NOTE Proceed with this procedure only after familiarizing oneself with the instructions at the beginning of chapter 3 Maintenance an...

Page 34: ...rk on the bracket Tighten the roller bracket mounting screws Fig 3 9 5b PTL30 PTL45 Re tighten the roller bracket mounting screws 941 Fig 3 9 6 Reassemble the front cover 12 and run the pump Fig 3 9 7...

Page 35: ...wer Fig 3 9 9b PTL30 PTL45 Repeat steps 3 9 6 and 3 9 7 and check the vacuum Add extra shims as long as the vacuum reading is 0 6 bar or lower Fig 3 9 10a PTL9 PTL25 Adjust the loose roller bracket to...

Page 36: ...lacement interval h Pos 50 A Pos 50 B Pos 922 PTL9 8700 25600 75500 PTL13 8700 25600 75500 PTL17 7300 27400 7450 PTL25 5850 PTL30 12500 PTL45 20000 3 13 Shaft bearings assembly PTL9 PTL17 Fig 3 13 1 P...

Page 37: ...t can be easily directed to the righ without any modifications By using the code 2 when ordering the pump the housing will be installed in the right direction Fig 3 14 3 Upwards direction directing ca...

Page 38: ...re details see the Mobile Pump Solutions nfo letter under this LINK 4 2 Frequency inverters The frequency inverters are used regulate the motor speed and therefore the capacity of the pump They can be...

Page 39: ...risk of improper operation increases possibility of breakdown and voids warranty terms 5 1 Exploded view PTL9 PTL17 For interactive exploded view go HERE 5 2 Spare parts list PTL9 PTL17 Pos Q ty Descr...

Page 40: ...1 Casing gasket NBR 19 1 Shaft screw A4 70 191 1 Retaining washer AISI 304L 270 2 Hose cover NBR 271 2 Clamp band AISI 316L 50 2 Bearing Steel 51 1 Distance sleeve Steel 52 1 Shaft circlip big Zinc p...

Page 41: ...ounting nuts A4 12 1 Front cover Polycarbonate AISI 3046 121 1 Front cover reinforcement ring AISI 304L 122 1 Front cover gasket NBR 141 11 163 Bracket mounting bolt A4 70 142 11 163 Bracket mounting...

Page 42: ...TL45 4 8 for PTL25 4 for PTL30 and PTL45 5 Only for PTL30 and PTL45 6 Polycarbonate non ATEX pumps AISI 304 ATEX pumps 5 5 Stocking recommendation Even at normal operation some elements in the pump wi...

Page 43: ...or PTL9 13 3 for PTL17 Roller spare parts KIT 16 013 92S 16 017 92S 16 025 92S 16 030 92S 16 045 92S Click above links for interactive exploded views Pos Description Q ty 92 Roller 2 921 Roller shaft...

Page 44: ...erial of hose E EPDM N NBR nitrile rubber R NR standard W EPDM FDA S NR FDA F NBR FDA VI Special executions 1 Optional insert material S AISI 316L standard T PTFE P PE AST L PP 2 Inlet outlet directio...

Page 45: ...rmance curves are based on water at 20 C Other circumstances might change the performance See below how the capacity will change at different viscosities and suction lifts Intermittent duty 1 hour sto...

Page 46: ...58 Max suction lift m Ft 9 29 5 9 29 5 9 29 5 9 29 5 9 29 5 9 29 5 Maximum pump speed rpm 50 Hz 187 187 187 138 104 93 Ma liquid temperature C F 80 176 80 176 80 176 80 176 80 176 80 176 Min ambient...

Page 47: ...B 132 132 188 5 20 5 20 7 40 C 133 133 188 5 24 5 24 7 40 D 223 223 313 8 78 8 78 12 32 E 219 219 291 8 62 8 62 11 46 F 129 129 166 5 08 5 08 6 54 G 190 190 251 7 48 7 48 9 88 H 210 210 269 8 27 8 27...

Page 48: ...395 539 669 15 55 21 22 26 34 F 225 310 374 8 86 12 20 14 72 G 346 424 533 13 62 16 69 20 98 H 376 460 571 14 80 18 11 22 48 I 219 276 346 8 62 10 87 13 62 J 340 415 510 13 39 16 34 20 08 K 320 446 5...

Page 49: ...f preventive maintenance contact Tapflo for interval proposals Although pump applications vary a general guideline is to re torque the pump every two weeks PTL30 PTL45 PTL9 PTL25 Item Bolt pos Name TP...

Page 50: ...lds We recommend not to exceed the following loads and forces reacting on the manifolds Pump size Direction Load Nm Force Nm PTL9 PTL13 X 110 Y 90 5 Z 85 5 PTL17 X 330 Y 160 5 Z 80 5 PTL25 X 240 Y 180...

Page 51: ...that may be exposed to gas T4 135 C Gb Db high protection level ATEX classification of complete unit depends on used drive Check if the ATEX marking of the delivered pump corresponds to the marking of...

Page 52: ...used Only a metal cover is allowed 7 4 Pumped liquids Pumped liquid must be chemically compatible and not cause exothermic reaction with lubricant nor with any of pump materials of construction The pu...

Page 53: ...automatically stops the pump It is strongly recommended to establish preventive maintenance procedures as outlined in chapter 3 9 Hose replacement Description Leak sensor is a 4 pin normally open NO...

Page 54: ...ements of EN 60079 14 and EN 60079 25 standards Coperative instruments Use ia isolation barriers for the connection e g Baumber PROFSI3 B25100 ALG LS Function M12 A4 pin Va 1 GND 0V 3 NO NC 4 2 Use an...

Page 55: ...of a 3 wire line Intrinsically safe ia electrical specification Ui 45V Ii 110mA Pi 750mW Ci 0 1nF m Li 1 F m The connection of temperature sensor in intrinsically safe execution ia must comply with t...

Page 56: ...the designated positions on the top or bottom of the pump casing In particular the temperature sensor must be placed on the pump outlet If you anticipate frequently changing the pumping direction it i...

Page 57: ...usual noises Pump size Replacement interval h Pos 50 A Pos 50 B Pos 922 PTL9 5800 17100 50300 PTL13 5800 17100 50300 PTL17 4850 18300 5000 PTL25 3950 PTL30 8350 PTL45 13300 7 13 Foreign objects in pum...

Page 58: ...oes not exceed the nominal working temperatures specified by the gear motor manufacturer An optional external cooling system may be required The pump can be supplied with or without a gearmotor When c...

Page 59: ...part the thickness of the paint layer must not exceed 2mm 7 21 Inspection Check below points before every pump start or at least once a day when operating pump in continuous duty Pump tightness If su...

Page 60: ...ate of pump installation Pump type Serial No see name plate or stamped on pump housing Description of the fault The installation Liquid emperature C Viscosity cPs Spec grav kg m3 pH value Content of p...

Page 61: ...r other documents specifically made available to Tapflo before entering into this agreement c high quality materials are used in the construction of the pumps and that machining and assembly are carri...

Page 62: ...lt in accordance with standard CE normative and are tested where applicable by Tapflo Approval and tests by other control authority are for the customer s account The products shall not be considered...

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