Toyo HT-25 Installation, Operation & Maintenance Manual

Heavy duty submersible pumps

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HT-25, HT-50, HT-100
Heavy Duty Submersible Pumps
Installation, Operation & Maintenance Manual
TOYO PUMPS NORTH AMERICA CORPORATION
1550 Brigantine Drive
Coquitlam, British Columbia
Canada V3K 7C1
Fax:
(604) 298-7773
Telephone: (604) 298-1213
Email:
info@toyopumps.com

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  • Page 1 HT-25, HT-50, HT-100 Heavy Duty Submersible Pumps Installation, Operation & Maintenance Manual TOYO PUMPS NORTH AMERICA CORPORATION 1550 Brigantine Drive Coquitlam, British Columbia Canada V3K 7C1 Fax: (604) 298-7773 Telephone: (604) 298-1213 Email: info@toyopumps.com...
  • Page 2: Table Of Contents

    TOYO PUMPS NORTH AMERICA CORPORATION Table of Contents Introduction ......................1     1.1 General ............................1   Terms and Conditions .................... 2     2.1 Materials and Compatibility with Buyer’s System or Process: ............2   2.2 Warranties: ............................2  ...
  • Page 3 TOYO PUMPS NORTH AMERICA CORPORATION 8.5 Suction Cover and Shim Assembly ....................24   8.6 Final Assembly ..........................26   8.7 Adding Oil to Oil Chamber ......................27   Appendix ....................... 28     9.1 Bolt Torque Table .......................... 28  ...
  • Page 4: Introduction

    The instructions in this manual are intended for personnel with a general training in operation and maintenance of centrifugal pumps. Toyo Pumps reserves the right to change the design, construction material of any part without incurring the obligation of installing such changes on pumps already delivered.
  • Page 5: Terms And Conditions

    TOYO PUMPS NORTH AMERICA CORPORATION 2 Terms and Conditions By placing this piece of equipment into service you agree to the Terms and Conditions below. TPNA’s acceptance to supply equipment is conditional upon the Buyer’s and subsequent Owner’s agreement that the Terms and Conditions set out below govern the relationship between the Manufacturer and Owner.
  • Page 6: Exclusivity Of Warranties

    TOYO PUMPS NORTH AMERICA CORPORATION d) On equipment and materials furnished by TPNA, but manufactured by others, the Buyer shall accept in lieu of any liability or guarantees on the part of TPNA, the benefits of any guarantees (if any) that are obtained by TPNA from such manufacturers or vendors.
  • Page 7: Arbitration

    TOYO PUMPS NORTH AMERICA CORPORATION 2.6 Arbitration: If there is any disagreement, dispute or controversy (a "Dispute") between the parties with respect to any matter arising under this Agreement or the construction of this Agreement, then the Dispute shall be referred to and finally resolved by arbitration under the rules of the Commercial Arbitration Act, R.S.B.C.
  • Page 8: Installation

    The unit should be inspected upon arrival. If there are any product irregularities, contact HEVVY-TOYO immediately. Damage due to shipment should be reported to the carrier. Care should be taken when unpacking and moving pumps. Rough handling of the pump can cause breakage.
  • Page 9: Installing The Pump

    TOYO PUMPS NORTH AMERICA CORPORATION WARNING! Using the pump outside its temperature range could lead to electrical hazards or pump failure. 3.3 Installing the Pump 1. Lifting the pump can be done by securing a rope/chain to the eye bolts, ensuring not to drop or heavily impact the unit on contact.
  • Page 10: Electrical

    5. If the cabtyre cable requires extending, use a conductor size equal to or greater than the previous cable to maintain performance and prevent overheating. For length longer than a total cable length of 100 feet consult your cable supplier or Toyo to confirm line voltage drop is less than 5% total.
  • Page 11 TOYO PUMPS NORTH AMERICA CORPORATION 6. Keep the power supply and cabtyre cable away from water. If the cabtyre cable needs to be submerged in water, make certain there is no damage to the insulation and any splices are completely sealed and protected from water damage.
  • Page 12: Operation

    TOYO PUMPS NORTH AMERICA CORPORATION 4 Operation 4.1 Pre-start Checks 1. Double check that the frequency and voltage ratings are correct for the pump model. Caution Using incorrect power ratings may lead to damage of the pump as well as lower performance and efficiency.
  • Page 13: Operation

     Refer to nameplate data. If current exceeds the rated value overloading the motor is the likely reason, check pump specifications. 4. Stop the test operation of the pump if abnormal sounds, vibration or odor result and contact Toyo immediately. If no problems arise, allow the pump to continue under operation. Caution Allowing the pump to operate under such non-desirable conditions may result in electrical hazard or damage.
  • Page 14: Shut Down

    TOYO PUMPS NORTH AMERICA CORPORATION 4.4 Shut down 1. Prior to pump shutdown lift the pump into clear fluid for several minutes to completely flush the system of any slurry. Caution Never stop the pump while pumping slurry through the lines as there is a risk the lines will plug and the pump will be buried.
  • Page 15: Storage

    TOYO PUMPS NORTH AMERICA CORPORATION 5 Storage 5.1 General Instructions The pump is protected against corrosion for the period of shipment and installation only. If the pump is not to be installed right away, find a clean, dry location for storage indoors.
  • Page 16: Maintenance

     Recommended OEM authorized inspection. Every 1-2 Years depending on severity of service  Consult Toyo for seal refurbishment/replacement if necessary. Out of Use  Clean and dry the pump for indoor storage.  Rotate once a month by hand.
  • Page 17: Lubrication And Additional Maintenance

    TOYO PUMPS NORTH AMERICA CORPORATION 6.2 Lubrication and Additional Maintenance 1. For details on approved oil and grease for pump lubrication, see Appendix. 2. Always tailor lubrication intervals to your application specific requirements. If pump is run intermittently, the oil reservoir should be examined more often.
  • Page 18: Electrical Check (Megger Test)

    TOYO PUMPS NORTH AMERICA CORPORATION 6.4 Electrical Check (Megger Test) Whenever the pump is serviced the following test should be performed to check the insulation resistance of the motor and cable. 1. Disconnect the cabtyre cable from the power source.
  • Page 19 TOYO PUMPS NORTH AMERICA CORPORATION 7. Any motor reading less than ten (10) meg-ohms (M) indicates damage in the motor in which case the motor must be checked by a qualified repair facility. Caution: It is very important that appropriate corrective action/repair be performed before the pump is returned to service if it does not pass the Megger Test.
  • Page 20: Troubleshooting

    TOYO PUMPS NORTH AMERICA CORPORATION 7 Troubleshooting Problem Possible Causes and Solutions Pump will not start. The power has not been turned on. Fuse or circuit breaker blown. The power supply is inadequate. The motor is burned out or is burning out.
  • Page 21 TOYO PUMPS NORTH AMERICA CORPORATION Problem Possible Causes and Solutions Lift or discharging capacity is The suction strainer is clogged and requires cleaning of debris. low. The pump may be placed on a mounting block to reduce clogging. The motor direction is reversed. See sections on Electrical and Test Operation for interchanging leads.
  • Page 22: Pump Assembly

    TOYO PUMPS NORTH AMERICA CORPORATION 8 Pump Assembly Inspect and inventory all parts before you begin assembly. Clean the parts and remove any burrs as required. Assembly should be performed in a clean, dust free area. Read instructions and drawings before you begin.
  • Page 23: Motor Assembly

    TOYO PUMPS NORTH AMERICA CORPORATION 8.1 Motor Assembly 1. Ensure the Stator Housing is secured to proper work bench. 2. Attach the studs to the Stator Housing. TED-236 Section 8 - Pump Assembly PAGE 20...
  • Page 24: Rotor Bearing Assembly

    TOYO PUMPS NORTH AMERICA CORPORATION 8.2 Rotor Bearing Assembly 1. Slide the Bearing Cover onto the Rotor assembly. 2. Preheat both Inboard and Outboard Bearings to 110–115 °C (230–240 °F) in an induction heater, oven, or oil bath. Note: An induction heater will have the best results for even heating.
  • Page 25 TOYO PUMPS NORTH AMERICA CORPORATION 3. Attach O-ring to the Stator Housing. 4. Apply a thin coat of grease to the Inboard Bearing. Insert the Rotor Assembly into the Stator Housing. Note: Ensure bearing is seated properly. 5. Attach the Bearing Housing to the Stator Housing with socket head cap screws.
  • Page 26: Housing And Impeller Assembly

    TOYO PUMPS NORTH AMERICA CORPORATION 7. Attach the Lower Stationery Seat onto the Pump Casing. 8. Attach the Mechanical Seal Washer to Pump Casing using hex bolts and lock washers. This will hold the Lower Stationery Seat in place. 9. Attach the Distance Sleeve. Make sure it fits tight between the shaft and the Lip Seal.
  • Page 27: Suction Cover And Shim Assembly

    TOYO PUMPS NORTH AMERICA CORPORATION 3. Attach the two Oil Sight Glass Covers – one on each side of the pump. 4. Attach the Key into the Keyway. 5. Attach the Impeller. 8.5 Suction Cover and Shim Assembly 1. Attach the Suction Cover to the Pump Casing with lock washers and socket head cap screws.
  • Page 28 TOYO PUMPS NORTH AMERICA CORPORATION 2. Tighten the Suction Cover firmly against the Pump Casing until it makes contact with the impeller vanes. Measure the remaining gap between the Suction Cover and the Pump Casing. 3. Make up a Shim Pack to get as close as possible to the measured gap.
  • Page 29: Final Assembly

    TOYO PUMPS NORTH AMERICA CORPORATION 8.6 Final Assembly Attach the Agitator. Attach the Washer, Lock Washer, and Hex Nut. 3. Attach the Strainer. 4. Attach the Discharge Elbow with lock washers and hex bolts. TED-236 Section 8 - Pump Assembly...
  • Page 30: Adding Oil To Oil Chamber

    TOYO PUMPS NORTH AMERICA CORPORATION 8.7 Adding Oil to Oil Chamber Use the table below to determine the correct quantity of oil to use for your pump. Toyo Pumps come assembled with MOBIL SHC 624 Synthetic Bearing and Gear Oil. Use this oil or similar ISO VG 32 oil to refill chambers.
  • Page 31: Appendix

    TOYO PUMPS NORTH AMERICA CORPORATION 9 Appendix 9.1 Bolt Torque Table Nominal Diameter Grade 8.8 Grade A4-70 Coarse Thread Nm [lb-ft] Nm [lb-ft] 3.10 [2.29] 6.15 [4.54] 10.5 [7.7] 17.5 [12.9] 26 [19] 51 [37] 89 [65] 215 [158] 420 [309]...
  • Page 32: Technical Data Sheet - 60Hz

    TOYO PUMPS NORTH AMERICA CORPORATION 9.2 Technical Data Sheet – 60Hz Pump Data Pump Model HT-3 HT-5 HT-7.5 Discharge Diameter (in.) Flow at rated point (USgpm) Head at rated point (ft) Impeller Diameter (in.) 4.33 5.12 8.07 Impeller No. of Vanes Max.
  • Page 33: Technical Data Sheet - 50Hz

    TOYO PUMPS NORTH AMERICA CORPORATION 9.3 Technical Data Sheet – 50Hz Pump Data Pump Model HT-3 HT-5 HT-7.5 Discharge Diameter (mm) Flow at rated point (m /hr) Head at rated point (m) Impeller Diameter (mm) Impeller No. of Vanes Max. Solid Size (mm) Rated Output (HP) No.
  • Page 34: Customer Fill-In Data Sheet

    TOYO PUMPS NORTH AMERICA CORPORATION 9.4 Customer Fill-in Data Sheet Start-up Operating Customer Data Conditions Metric Imperial Flow (USPGM) Normal Maximum Minimum Discharge Pressure (PSI) Slurry S.G. Solids % by volume Maximum particle size (In.) Temperature (°F) Start-up Pump Data...
  • Page 43 2. ISO VG 32 OIL USED IN THE SEAL BOX 3. 275ml OIL QUANITY PUMP DISCHARGE 3" FLANGE 150# FF ASME / ANSI B16.5 OIL SIGHT GLASS PRODUCT LINE TYPE / FRAME HT-25 SCALE 0.250 DRAWN DATE 20-JUN-14 CHKD. DATE TITLE DRAWING NO.
  • Page 44 HT-25, 460V 60Hz 26413 26363 28939 28937 28931 HT-25, 460V 60Hz, HCr 26403 HT-25, 575V 60Hz SEE TABLE 'A' STATOR, ROTOR, SHAFT UNIT, HT-25 12.8 26416 26364 28932 HT-25, 575V 60Hz, HCr 28939 28937 SEE TABLE 'A' THERMAL PROTECTION, MOTOR...
  • Page 45 2. ISO VG 32 OIL USED IN THE SEAL BOX 3. 275ml OIL QUANITY PUMP DISCHARGE 3" FLANGE 150# FF ASME / ANSI B16.5 OIL SIGHT GLASS PRODUCT LINE TYPE / FRAME HT-25-MS SCALE 0.250 DRAWN DATE 01-MAY-17 CHKD. DATE TITLE DRAWING NO.
  • Page 46 2. ** = CRITICAL SPARE (0-2) YEARS) 29086 HT-25-575-60-MS 26416 26364 29112 HT-25-575-60-MS-HC 28939 28937 SEE TABLE 'A' STATOR, ROTOR, SHAFT UNIT, HT-25 SEE TABLE 'A' THERMAL PROTECTION, MOTOR 30305 ASSEMBLY, CABLE, HT-25,50, SHD-GC 26496 SCREW, CROSS RECESSED PAN HEAD 412000_STEEL_GRADE_A2_CLASS_70 26492 NUT, HEXAGON...
  • Page 47 ZONE CHANGE DESCRIPTION APPROVED DATE 393 (REF) NOTES: REVISED P/N 23965 MATERIAL AND 23999 DWG NO. A.P. 15 DEC 15 1. CONTINUOUS RUNNING WATER LEVEL (C.W.L.) REVISED TITLE, DRAWING NO. & TYPE/FRAME FROM HNS-5 TO HT-5, 172.9 2. ISO VG 32 OIL USED IN THE SEAL BOX CHANGED ITEMS 27 &...
  • Page 48 STATOR, ROTOR, SHAFT UNIT, HT-50 17.4 29616 HT-50-460-60-HC 28655 28654 SEE TABLE 'A' THERMAL PROTECTION, MOTOR 24656 HT-50-575-60 30306 ASSEMBLY, CABLE HT-25, 50 SOOW 26417 26367 29617 HT-50-575-60-HC 28655 28654 26496 SCREW, CROSS RECESSED PAN HEAD 412000_STEEL_GRADE_A2_CLASS_70 26494 SCREW, HEX HEAD, PT, CAP 412000_STEEL_GRADE_A2_CLASS_70 12.9...
  • Page 49 ZONE CHANGE DESCRIPTION APPROVED DATE 393 (REF) MODEL NAME WAS HT-5. ADDED 460V P/N AND CABLE ASSEMBLY P/N. 11-JUN-18 172.9 PUMP DISCHARGE 3" FLANGE 150# FF ASME / ANSI B16.5 OIL SIGHT GLASS SCALE 0.250 PRODUCT LINE TYPE / FRAME HT-50-MS SCALE 0.250...
  • Page 50 WASHER, LOCK 416000_STEEL_GRADE_A2 26470 WASHER, LOCK 416000_STEEL_GRADE_A2 26387 WASHER, LOCK 416000_STEEL_GRADE_A2 26360 ASSEMBLY, MECHANICAL SEAL EW-00904-01-00 29103 HOUSING, RADIAL BEARING, HT-25, 50 001000_ASTM_A48_CL_30B DN12593 26348 HOUSING, MECHANICAL SEAL, HT-25,50 003000_ASTM_A536_GR_60-40-18 012TK1151155 26346 COVER, BEARING 074000_JIS_G_3101_SS34 021050000765 26344 HANDLE, HT-25, 50...
  • Page 51 ZONE CHANGE DESCRIPTION APPROVED DATE 501 (REF) NOTES: REVISED DRAWING TO AS BUILT 20 JUL 15 1. CONTINUOUS RUNNING WATER LEVEL (C.W.L.) REVISED TITLE, DRAWING NO. & TYPE/FRAME FROM HNS-7.5 TO HT-7.5 4 JAN 16 AND ADDED CRITICAL/RECOMMENDED SPARES DESIGNATIONS 2.
  • Page 52 TABLE A ESTIMATED PUMP WEIGHT = 150 KG NOTES: PUMP ITEM 50 ITEM 51 ITEM 17 ITEM 16 1. * = RECOMMENDED SPARE (3-5 YEARS) DESCRIPTION MT PROTECTOR STATOR/ROTOR SUCTION COVER PUMP CASING 2. ** = CRITICAL SPARE (0-2 YEARS) 24660 HT-100-380-60 26419...
  • Page 53 ZONE CHANGE DESCRIPTION APPROVED DATE 501 (REF) NOTES: REVISED MODEL NUMBER, WAS HT-7.5. ADDED CABLE ASSY P/N. 19 JUN 18 1. CONTINUOUS RUNNING WATER LEVEL (C.W.L.) 2. ISO VG 32 OIL USED IN THE SEAL BOX 3. 650ml OIL QUANTITY LIFTING EYE BOLTS DIN 580 C15 M12 30mm...
  • Page 54 TABLE A ESTIMATED PUMP WEIGHT = 150 KG NOTES: 1. * = RECOMMENDED SPARE (3-5 YEARS) PUMP ITEM 50 ITEM 51 ITEM 17 ITEM 16 DESCRIPTION MT PROTECTOR STATOR/ROTOR SUCTION COVER PUMP CASING 2. ** = CRITICAL SPARE (0-2 YEARS) 29088 HT-100-575-60-MS 26419...

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Ht-50Ht-100

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