Pompetravaini TBAK Series User manual

(Rev. 2.0_10-2010)
DISASSEMBLY AND
ASSEMBLY INSTRUCTIONS
FOR MAGNETIC DRIVE
MULTISTAGE SELF-PRIMING
CENTRIFUGAL
PUMPS
TBK - TBAK

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps
2
INTRODUCTION
These instructions are f or the m aintenance per sonnel f or m aintenance and/or r epair of the indic ated pum p s eries.
Disassembly and assembly procedures should be carried out by qualified personnel. Prior to working on the pumps the
maintenance person should be fully knowledgeable of the material outlined in this manual. Instructions relating to safety
of operation, installation and m aintenance will be f ound in the “ OPERATING MANUAL F OR CENTRIFUGAL PUMPS”
and in the “ DISASSEMBLY AND ASSEMBLY INST RUCTIONS F OR SELF -PRIMING MULT ISTAGE CENT RIFUGAL
PUMPS” which is usually supplied with the pump or it can be requested from your POMPETRAVAINI representative.
CAUTION!
Pumps series TBK and TBAK create a high magnetic field. Personnel should take proper precautions i
f
they are wearing pace-makers or if they are using instrumentation sensitive to magnetic fields.
The listed below minimum distances must be kept:
- When the magnetic rotor parts are disassembled:
users of pace-maker = 2 meters
floppy disk; magnetic cards, etc. = 1 meter
- When the magnetic rotor is mounted in the pump:
users of pace-maker = 1 meter
floppy disk; magnetic cards, etc. = 0,5 meter
Proper attire is necessary prior to beginning any work on the pum ps. Therefore, for your safety, always wear safety hat,
eyeglasses, gloves, shoes etc. and be sure to have proper tools necessary for the work to be done.
Do not f orce or s ubject pum p or any of its c omponents to s udden s hocks or violent im pact. Do not dam age w ith
markings or scratches the mechanical seal surface areas, the engagement surfaces and sealing areas. Do not damage
gaskets, and O-Rings. Do not leave in the pump foreign matter such as screws, nuts, bolts, washers, rags, etc.
When requesting spare parts or technical inf ormation f or the pum p, always quote the pum p m odel num ber and s erial
number which is printed on the pump nameplate: therefore it is recommended not to remove the pump nameplate or, in
case this action will be necessary, write the serial number on the pump (for example on the flange).
Should additional inf ormation be r equired, pleas e do not hes itate to c ontact PO MPETRAVAINI or the closest
representative. Should there be any difficulties in repairing the pum p, it is recommended to send the pum p for repair to
POMPETRAVAINI or the local authorised representative.
POMPETRAVAINI will not and c annot be r esponsible f or w ork done on the pum p by the c ustomer or non-authorised
personnel.
NOTE: Pump parts are identified by item numbers (VDMA). Item numbers can be found in the parts list under chapter
10 and cross-referenced with the sectional drawings under chapter 11.
All drawings given in these instructions are only schematics and not certified.
INDEX
1 - Actions to be taken prior pump disassembly
2 - “TBK” pump s eries dis assembly to r eplace
bushing
3 - “TBK” pump series bushing support assembly
4 - “TBK” and “ TBAK” pum p s eries s upport
disassembly
5 - Complete disassembly for pumps series “TBK”
6 - Complete disassembly for pumps series “TBAK”
7 - Internal m agnet r otor dis assembly f or “ TBK”
and “TBAK” pumps series
8 - Assembly of “TBK” and “TBAK” pumps series
9 - Spare parts
10 - Parts list
11 - Typical sectional drawings
The liquids and gas handled by the pum ps and als o their par ts c ould be potentially danger ous for
persons and envir onment: provide their eventual disposal in c onformity with the law s into f orce and a
proper environment management.
The pr esent m anual is not as signed for pum ps subjected to the ATEX 94/9/CE directive. In case the
pump is assigned in environments subjected to the application ATEX 99/92/CE directive or in case the
pump is provided with a nam eplate indicating the AT EX stamp, it s trictly forbidden proceed to start up
the pumps but necessary to consult POMPETRAVAINI for clarifications.
For pumps subjected to the ATEX 94/9/CE directive it is available a dedicated integrative manual.
In preparing this manual, every possible effort has been m ade to hel p t he c ustomer and operat or with t he proper i nstallation an d operat ion of t he
pump. Should you find errors, misunderstandings or discrepancies please do not hesitate to bring them to our attention.

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps 3
1 – ACTION TO BE TAKEN PRIOR PUMP DISASSEMBLY
Prior starting disassembly activities it is required:
- Shut down the pump following usual shut down procedures.
- Disconnect electric motor from electric supply in order to make sure that it may accidentally start up.
- Close valves installed on pump suction and discharge.
- Wait and make sure that temperature is equal to ambient temperature prior to start any activity.
- Unlock the drain plug in order to drain completely the spiral casing.
Follow extra carefully this procedure in case pumped liquid is dangerous by contact or by inhalation.
At this regard it is mandatory to be provided with proper safety wear.
- Disassembly pipes and auxiliary connections in case connected to pump.
Remove coupling guard and, if present, spacer coupling.
- Loose the s upport foot VDMA 183 and, depending on needs , it is possible take away pump casing from piping and
baseplate and/or remove the electric motor.
2 – “TBK” PUMP SERIES DISASSEMBLY TO REPLACE BUSHING
Loosen s crews VDMA 901 and ex tract the
bushing s upport VDMA 355 and its bushing
VDMA 310 or 310.3 ( in f unction if pum p
execution is /1 or /2) by means, if necessary,
of the s ame s crews as ex tractors in the
threaded holes available in the support self.
Later on, by m eans of a suitable extractor,
extract the bushing support (see fig. 1 or 2).
In case of ex ecution /2 als o c heck the wear
of ceramic coated bushing VDMA 521 and if
necessary r eplace it loos ening the s crew
VDMA 914.5 and r emoving the washer
VDAM 554.
400.2
355
940.4
905
901
903
914.5
554.7
554
521
310.3
ØD
210.1903.1
107
ØD
310
F ig. 1 – Pumps series TBK/2 F ig. 2 – Pumps series TBK/1
3 – “TBK” PUMP SERIES BUSHING SUPPORT ASSEMBLY
Check wear of bushing VDMA 310 or 310.3 (in function of
execution /1 or /2) and, if nec essary, r eplace it w ith a
spare one: check the bushing internal diameter is the right
one for pump type indicated in obj ect (see fig. 1 or 2 and
tab. 1), then press it in the bushing support VDMA 355.
For execution /1 dr ill in the bus hing 3 radial holes Ø5 mm
at 120°, having c are that one hole is located in upper
position.
For ex ecution /2 dr ill in the bushing 1 crossing hole Ø3
mm loc ated in upper pos ition in c orrespondence of the
hole present in the bushing support VDMA 355.
After having loc ated the gas ket VDMA 400.2, assembly
the bus hing s upport on the dis charge casing VDMA 107
and tight the screws VDMA 901.
Tab. 1 - Dimensions of bus hings ( VDMA 310 or 310.3)
internal diam eters alr eady pr essed in bushing
support VDMA 355 (see fig. 1 or 2)
Construction /2 Construction /1
PUMPS SERIES ØD
VDMA 310.3
ØD
VDMA 310
TBK 200 --- --- 16 D7 +0,068
+0,050
TBK 290 ÷ 310 24 E8 22 D7 +0,086
+0,065
TBK 400 30 E8
+0,073
+0,040 --- ---
TBK 500 --- --- 28 D7 +0,086
+0,065
TBK 650 30 E8 +0,073
+0,040 --- ---

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps
4
4 – “TBK” and “TBAK” PUMP SERIES SUPPORT DISASSEMBLY
(See fig. 5 and typical sectional drawings under chapter 11).
Remove stud nuts VDMA 902 and separate the s upport VDMA 330 f rom c asing c over VDAM 161 over coming the
magnets attraction force avoiding to damage the external rotor magnets VDMA 818.2.
To dis assembly the ex ternal m agnetic r otor w ith s mall s ize dr agging ( sealing c ontainer Ø 75, see fig. 6 and 10) is
necessary to remove the adaptor ring VDMA 502 loosening the grub screw VDMA 904.
Loosen screw VDMA 900.1 and remove the junk ring VDMA 550.1.
Extract then the fly wheel VDMA 132 with the external magnetic rotor VDMA 818.2.
Remove the half elastic coupling from pum p drive end and, unscrewing the s crews VDMA 914.4, r emove the ex ternal
bearing cover VDMA 360.1, the elastic ring VDMA 935 and circlip VDMA 932.1.
Loosen screws VDMA 900 and extract the internal bearing cover VDMA 360.2.
Apply now a strong pressure on the primary shaft VDMA 210 drive end to extract the bearing VDMA 320 and remove the
same shaft with bearing VDMA 320.1 from the support VDMA 330.
Remove circlip VDMA 932 and if necessary remove from shaft also bearing VDMA 320.1.
Verify that all parts are undam aged and w ear or tear scratches are not pr esent: if necessary replace thos e par ts with
original spare parts before starting assembly, executing each step reverse to disassembly steps.
5 - COMPLETE DISASSEMBLY FOR PUMPS SERIES “TBK”
Complete pump disassembly becomes necessary if , f or example, the pum p does not per form as ex pected due to an
excessive wear of impellers VDMA 230 and/or suction and discharge elements VDMA 109 and 114.
Replacing or machining the worn-out parts will be a question of economics and /or time available to complete the rapair.
This c hapter w ill c onsider the dis assembly of a pump without non-drive end s leeve bear ing hous ing and dr ive end
bearing and mechanical s eal hous ing ( see f ig. 3) : dis assembly and as sembly of thes e c omponents have been
addressed in chapters 2 – 3 – 4.
NOTE: where the mechanic is not f amiliar with the pump, it is advisable to draw a reference line along the pum p. Mark
each part with its location, rotation and assembly sequence; however the main components are already marked at
the ex ternal upper par t w ith r eference logs to pr ovide the pr oper pos ition (see the attached “Disassembly and
assembly instructions for self-priming multistage centrifugal pumps”).
Disassembly work should be carried out w ith proper tools and using suitable disassembly sequence to pr event f urther
damage to the pump parts.
940.4
905
903
310.2
ØD2
ØD1
310.5230
161210.1 903.1 940.2 114 109 310.1 562.2 818G
107 400.1 106 412914.1 914 914.2940.1
550
920562.1
Fig. 3
Pumps series TBK

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps 5
Loosen and r emove the tie- bolts VDMA 905, place the pump in vertical position onto a suitable base with the discharge
casing VDMA 107 on the top.
Remove once for all the tie-bolts (VDMA 905) nuts and washers and loosen the tie-bolts from the casing cover VDMA 161.
Remove the discharge casing VDMA 107 and its gasket VDMA 400.1, the discharge element VDMA 114 and its gasket,
the open im peller VDMA 230, the k ey VDMA 940.2 the s uction element VDMA 109 and its gasket. Go on f ollowing the
same sequence as many times as is the num ber of stages of the pum p. Remove the suction casing VDMA 106 and its
gasket.
Take precautions not the dam age the s haft VDMA 210.1 and plac e it in a bench vice vertically and with the drive side
upward in order to disassemble the internal magnetic coupling assembly (see chapter 7).
6 - COMPLETE DISASSEMBLY FOR PUMPS SERIES ”TBAK”
Complete pump disassembly becomes necessary if , f or example, the pum p does not per form as ex pected due to an
excessive wear of impellers VDMA 230 and/or suction and discharge elements VDMA 109 and 114.
Replacing or machining the worn-out parts will be a question of economics and /or time available to complete the rapair.
This chapter will consider the dis assembly of a pum p without drive end bearing and mechanical seal housing (see fig.
4): disassembly and assembly of this component have been addressed in chapter 4.
NOTE: where the mechanic is not f amiliar with the pump, it is advisable to draw a reference line along the pum p. Mark
each part with its location, rotation and assembly sequence; however the main components are already marked at
the ex ternal upper par t w ith r eference logs to pr ovide the pr oper pos ition (see the attached “Disassembly and
assembly instructions for self-priming multistage centrifugal pumps”).
Disassembly work should be carried out w ith proper tools and using suitable disassembly sequence to pr event f urther
damage to the pump parts.
940.1
ØD
ØD1
412 914 914.2 550
920
107 914.1
562.2161 818G903.1230.2 109310.1940.2 114
106
925
903 940.4905 400.1149 230 562.1
521
310
210.1
Loosen and r emove the tie- bolts VDMA 905, plac e the pump in vertical position onto a s uitable bas e with the s uction
casing VDMA 106 on the top.
Remove once for all the tie-bolts (VDMA 905) nuts and washers and loosen the tie-bolts from the casing cover VDMA 161.
Remove the suction casing VDMA 106 and its gasket VDMA 400.1.
Loosen the impeller nut VDMA 925 ( pay attention to the lef t-handed thr eading) and r emove the c entrifugal im peller
VDMA 230.2.
Remove the diffuser VDMA 149, its gasket and its sleeve bearing VDMA 310.
Remove the shaft VDMA 210.1 the spacer sleeve VDMA 521 and the key VDMA 940.4.
Remove the s uction elem ent VDMA 114 and its gas ket VD MA 400.1, r emove the open im peller VDMA 230, the key
VDMA 940.2, the discharge element VDMA 109 and its gasket. Go on following the same sequence as many times as is
the number of stages of the pump. Remove the discharge casing VDMA 107 and its gasket.
Take precautions not the dam age the s haft VDMA 210.1 and plac e it in a bench vice vertically and with the drive side
upward in order to disassemble the internal magnetic coupling assembly (see chapter 7).
Fig. 4
Pumps series TBAK

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps
6
7 – INTERNAL MAGNET ROTOR DISASSEMBLY FOR “TBK” AND “TBAK” PUMPS SERIES
A particular attention it is required during disassembly because silicon carbide inserts, that are very fragile, may break,
chip off or going out of their seats.
562.1
818.4
818 818.1 818.5 818.3 818.2562.2 818.6
412914.1 914
900.1
550.1
940.3
914.3914.2940.1 550 920 132
161
Undo VDMA 914 screws and remove the VDMA 813.3 cover and its sealing VDMA 412 O-Ring, undo the VDMA 920 nut
and the VDMA 550 washer.
Remove the internal magnet rotor VDMA 818.1 with the external cover VDMA 818.5.
Remove the body VDMA 161 with the rotor support bush VDMA 818: If it is nec essary to s eparate thes e tw o
components , undo VDMA 914.1 screws.
Remove VDMA 940.1 shaft key, slip off the VDMA 818.6 rotor bush and the internal cover VDMA 818.4.
Look carefully the magnet bushes f or s cratches or beginning of s eizure m arks, eventually r eplace with or iginal s pare
parts.
Clean all the c omponents and pr oceed to as sembly them reversing the s tep f or the dis assembly. T he values f or the
torque wrench for the magnet screws are reported on the Tab. 2.
It is fundamental to lubricate all silicon carbide components that are in contact.
Screw
Diameter
In contact with
pumped liquid Dry
Tab. 2
Maximum torque wrench setting for magnet
component screws.
M5
M6
M8
M10
M12
M16
4 Nm
7 Nm
16 Nm
32 Nm
55 Nm
65 Nm
4,5 Nm
7,5 Nm
18 Nm
Fig. 5
Drawing of internal magnet
rotor.
(the dotted line shows
external magnetic rotor
component)

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps 7
8 – ASSEMBLY OF “TBK” AND “TBAK” PUMPS SERIES
Check that all the pump components are in good condition, clean them with the proper clearing product.
If hydraulic components (VDMA 230 and 230.2 im pellers, VDMA 109 e 114, elem ents.) could be re-installed but require
machine tooling, please follow the included “Assembly and Disassembly of self-priming centrifugal pumps” instructions.
In case of assembly of old components with new original spare part sit is necessary to check full compatibility no matter
if old components have been machined or not.
For suggested spare parts please read chapter 9.
About bus h inner diam eter pleas e r efer to tab 3 values c onsidering pum p type and bus h VDMA num ber. Pr oceed to
assembly the pum p following the “ Assembly and Dis assembly of self-priming centrifugal pum ps” instructions reversing
the indic ated s teps of dis assembly. Be c areful about s equential s teps and components reference point for assembly
position.
Once pump assembly is completed, connect the pum p to s upporting assembly completed with external magnetic rotor,
being aware of the strong attraction between the two parts.
Finally make the pump r otating by ac ting by hand on VDMA 210 dr ive s haft. Pum p s hould r otate f reely w ithout
generating any noise and or crackling.
PUMPS SERIES ØD
VDMA 310
ØD1
VDMA 310.1
ØD2
VDMA 310.2
TBK & TBAK 200 --- --- 18 B9 18
TBK & TBAK 290 ÷ 310 24 E8 24 B9 28
TBK & TBAK 400 30 B9
+0,212
+0,160 ---
TBK & TBAK 500 32 B9 32
Tab. 3
Bush internal diameter (VDMA
310 or 310.1 or 310.2) already
pressed on VDMA 109 or 149
elements (see fig. 3 or 4)
TBK & TBAK 650
30 E8
+0,073
+0,040
36 B9
+0,232
+0,170 ---
+0,20
+0,25
9 - SPARE PARTS
When ordering the pump it is good practice to also order the necessary spare parts, especially when there are no stand-
by pum ps in the ins tallation. T his w ill m inimise unnec essary dow n tim es in the event of pum p f ailure or r outine
maintenance. Following spare parts are suggested for each pump size:
1 or more Impellers
1 or more Suction plates
1 or more Discharge plates
1 Shaf t assembly
1 Bear ing set
2 Sets gaskets
1 Set of bearing spacer rings
However for proper parts management, consult the VDMA 24296 standard that recommends the quantity of spare parts
to be stocked in relation to the number of pumps installed.
On the pum p nam eplate ar e pr inted the pum p m odel, the y ear of m anufacture and the pump serial number: always
provide this information when requesting spare parts.
Specify also the VDMA num ber of the r equired part, as seen on the pum p sectional drawing (chapter 11) and parts list
(chapter 10) for proper identification of spare parts.
We recommend the use of original spares: in case this is not respected, POMPETRAVAINI declines any responsability
for eventual damages caused by not original spare parts.

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps
8
10 – PARTS LIST
VDMA
No. DESCRIPTION VDMA
No. DESCRIPTION
106 Suction casing 554.6 Elastic washer
107 Dis charge casing 554.7 Washer
109 Suc tion plate 562… Pin
114 Dis charge plate 730 Elbow
132 F ly-wheel 731.8 Fitting
149 Centr ifugal diffuser 735 M.M. fitting
161 Casing cover 818 Rotor bearing housing
183 Support foot 818.1 Internal magnetic rotor
210 Primary shaft 818.2 External magnetic rotor
210.1 Sec ondary shaft 818.3 Sealing can
230 Stellar impeller 818.4 Internal cover
230.2 Centr ifugal impeller 818.5 Ex ternal cover
310 Bear ing 818.6 Rotor sleeve
310.1 Plate bearing 818G Magnetic coupling assembly
310.3 Hous ing bearing 900… Screw
310.5 Bearing holder sleeve 900.5 Eyebolt
320 Single row ball bearing 901… Screw
320.1 Single row ball bearing 902 Stud wit nut
330 Ball bearings housing 903… Plug
355 Bear ing housing 904 G rub screw
360.1 External ball bearing cover 905 Tie-bolt with nuts and washers
360.2 Internal ball bearing cover 914… Screw
400.1 Plate gasket 920 Nut
400.2 Bearing housing gasket 925 Cap nut
412 O -Ring 932… Circlip
502 Reduc tion ring 935 Elas tic ring
521 Cer amic sleeve 940… Key
550 Rotor bottom ring
550.1 Fly-wheel bottom ring
554 Shaft bottom ring STM Thermometric probe

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps 9
11 – TYPICAL SECTIONAL DRAWINGS
562.1310.5230
161
310
731.8735 STM
903.S
400.2 355 940.4
905
901
903
914.5 554.7 554 521 310.3
902
210.1 903.1 940.2 114 109310.1 562.2 818G
107 400.1 106 412914.1 914 554.6
360.2730 900.1550.1 940.3 320.1
901.1 183 330
914.4 320
940
914.3
900.5 914.2940.1
550
360.1 935
900920 132
210 932 932.1904
502
Fig. 6 - Pumps series TBK/2 Fig. 7 - Pumps series TBK/1
With sealing can (VDMA 818G) Ø75
Only for construction with Thermometric Probe

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps
10
902
210.1 400.2
903.1
355 940.4
940.2 114 109310.1 562.2 818G
905
901
107 903
400.1 106 412914.1 914 554.6
360.2730 900.1550.1 940.3 320.1
901.1 183 330
914.4 320
940
914.3
900.5 914.2940.1 550
360.1 935
900920 132
210 932 932.1310.5230
161
562.1 903.S
914.5 554.7 554 521 310.3 310
STM731.8 735
Fig. 8 - Pumps series TBK/2 Fig. 9 - Pumps series TBK/1
With sealing can (VDMA 818G) Ø110 o 135
Only for construction with Thermometric Probe

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps 11
932.1
932
360.2
183940.3550.1 900.1562.3562818G 730 132
161107 914.1 914400.1
412562.1
109230310.1
114
903.1 940.2 562.2
554.6
905903106 310149
210.1
940.4 925 521 230.2
502904902 900.5
935 940
360.1
210 320
320.1 901.1
900914.3 330920914.2 550940.1
Fig. 10 - Pumps series TBAK
With sealing can (VDMA 818G) Ø75
Only for construction with Thermometric Probe

Disassembly and assembly instructions for magnetic drive multistage self-priming centrifugal pumps
12
NOTES
PUMP model
.........................................................................
Serial Number
......................
Computer Number
........................................................
Year of manuf.
......................
LIQUID handled
.........................................................................
Capacity
...............m3/h
Suction Pressure
........................m
Discharge Press.
........................m
Temperature
..................°C
Lethal Toxic Nox ious Corrosive Ir ritant Malodor ous ...................
Clean Dirty With suspended parts Spec. Gravity........... Viscosity.............. PH..........
TOTAL WEIGHT
...................KGs.
MAX IMUM DIMENSIONS
X =................c m
Y =................c m
Z =................c m
NOISE (measured at 1 m)
Pressure =...................dB(A)
Power =...................dB(A)
INSTALLATION SERVICE
Ins ide O utside Continuous Inter mittent
Ex plosive area ............................. ......................................................................
MOTOR type / Frame
..................................
No Poles
................................
No Revolutions
........................RPM
Absorbed power
.........................Amp
Installed Power
...............kW / ..............HP
Frequency
.............................Hz
Supply
..........................Volt
Enclosure
IP............................
Insulation class
...............................
Absorbed Power
..............kW / ..............HP
COMMENTS
NA4.SM.TBAK.GB00 / PRINTED IN ITALY
Smontaggio TBK-TBAK Inglese
Continuing research of POMPETRAVAINI results in product improvements: therefore any specifications may be subject to change without notice.
S.p.A.
20022 CASTANO PRIMO (Milano) ITALY
Via per Turbigo, 44 – Zona Industriale
Tel. [phone] – Fax [phone]
www.pompetravaini.com