Standard Chemical Pump Operating instructions MPC-B series Version BA-2006.03 Print-No. 01 VM-No. EN Munsch Chemie-Pumpen GmbH Im Staudchen 56235 Ransbach-Baumbach Germany Phone: +49 (0) 26 23-8 98-90 Fax: +49 (0) 26 23-8 98-95 E-mail: munsch@munsch.de Internet: http://www.munsch.de We reserve the right to make technical changes.
Table of contents Table of contents 1 About this document... 4 1.1 Target groups... 4 1.2 Other applicable documents... 4 1.3 Warnings and symbols... 5 1.4 Technical terms... 5 2 Security... 6 2.1 Intended use... 6 2.2 General safety instructions... 6 2.2.1 Product safety... 6 2.2.2 Operator's obligations... 7 2.2.3 Duties of the operating staff... 7 2.3 Special hazards... 7 2.3.1 Potentially explosive areas... 7 2.3.2 Hazardous pumped liquids... 7 2.3.3 Magnetic field... 7 3 Layout and function... 8 3.1 Labels... 8 3.1.1 Type plate... 8 3.1.2 ATEX plate... 8 3.1.3 Pump type code... 8 3.2 Layout... 9 4 Transport, storage and disposal... 10 4.1 Transport... 10 4.1.1 Unpacking and inspection on delivery... 10 4.1.2 Lifting... 10 4.2 Preservation... 11 4.3 Storage... 11 4.4 Disposal... 11 5 Setup and connection... 12 5.1 Preparing the installation... 12 5.1.1 Checking the ambient conditions... 12 5.1.2 Preparing the installation site... 12 5.1.3 Preparing the foundation and setup surface... 12 5.1.4 Preparing the pump... 12 5.1.5 Installing the heat insulation... 12 5.2 Setup with foundation... 13 5.2.1 Setting the pump group down on the foundation... 13 5.2.2 Fastening the pump group... 13 5.3 Setup without foundation... 14 5.4 Planning the pipes... 14 5.4.1 Avoid impurities in the pipes... 14 5.4.2 Laying out supports andflange connections... 14 5.4.3 Specifying nominal diameters... 14 5.4.4 Determining pipe lengths... 15 5.4.5 Optimising cross-section and direction changes... 15 5.4.6 Providing safety and monitoring devices (recommended)... 15 5.5 Connecting the pipes... 15 5.5.1 Installing auxiliary pipes... 15 5.5.2 Installing the suction pipe... 16 5.5.3 Installing the pressure pipe... 16 5.5.4 Checking that the pipe connections are stress-free... 16 5.6 Connecting the electrical system... 16 5.6.1 Connecting the motor... 16 5.6.2 Checking the direction of rotation... 16 6 Operation... 17 6.1 Preparations for the initial start-up... 17 6.1.1 Identifying the pump version... 17 6.1.2 Checking downtimes... 17 6.1.3 Preparing auxiliary operating systems... 17 6.1.4 Filling and bleeding... 17 6.1.5 Checking the direction of rotation... 17 6.2 Putting the pump into service... 18 6.2.1 Switching on the pump... 18 6.2.2 Switching off the pump... 19 6.3 Shut-down... 19 6.4 Restoring the pump to service... 20 6.5 Operating the stand-by pump... 20 7 Maintenance... 21 7.1 Inspections... 21 7.2 Maintenance... 22 7.3 Dismounting... 23 7.3.1 Returning the pump to the manufacturer... 23 7.3.2 Preparing the dismounting... 24 7.3.3 Undoing connections (if available)... 24 7.3.4 Pulling off the volute casing... 24 7.3.5 Dismounting the impeller, plain bearing bracket and pump rotor... 24 7.3.6 Dismounting the drive rotor... 26 7.4 Installing... 26 7.4.1 Preparing the installation... 26 7.4.2 Installing the drive rotor... 26 7.4.3 Installing the plain bearing bracket... 27 7.4.4 Fitting the pump in the installation... 27 7.5 Ordering spare parts... 27 8 Disturbance recovery... 28 9 Appendix... 31 9.1 Sectional drawing... 31 9.1.1 Part numbers and designations... 31 9.1.2 Overview sectional drawing... 32 9.1.3 Variants... 33 9.2 Technical specifications... 33 9.2.1 Ambient conditions... 33 9.2.2 Noise pressure level... 33 9.2.3 Tightening torques... 34 2 MPC-B series BA-2006.03 EN 01
Table of contents 9.2.4 Cleaning agents... 34 9.2.5 Socket loads according to ISO 5199... 34 9.3 Spare parts for two years of continuous operation according to DIN 24296... 35 List of figures Fig. 1 Type plate (example)... 8 Fig. 2 ATEX plate (example)... 8 Fig. 3 Pump type code (example)... 8 Fig. 4 MPC-B layout... 9 Fig. 5 Fastening the lifting gear to the pump group... 10 Fig. 6 Fastening the lifting gear to the pump... 10 Fig. 8 Setup without foundation... 14 Fig. 9 Straight pipe lengths in front of and behind the pump (recommended)... 15 Fig. 10 Undoing the flushing connector... 24 Fig. 11 Pulling off the volute casing... 24 Fig. 12 Undoing the impeller screw... 24 Fig. 15 Dismounting the drive rotor... 26 Fig. 16 Installing the plain bearing bracket... 27 Fig. 17 MPC-B overview sectional drawing... 32 Fig. 18 MPC-B housing foot... 32 Fig. 19 Emptying (optional)... 33 Fig. 20 Fluid connection (optional)... 33 Fig. 21 Socket loads at the pump... 34 List of tables Tab. 1 Target groups and their duties... 4 Tab. 2 Other applicable documents and their purpose... 4 Tab. 3 Warnings and consequences of non-observance... 5 Tab. 4 Symbols and their meaning... 5 Tab. 5 Technical terms and their meaning... 5 Tab. 6 Measures after long storage times/ downtimes... 12 Tab. 7 Measures to be taken if operation is interrupted... 19 Tab. 8 Measures to be taken, depending on the pumped liquid behaviour... 19 Tab. 9 Measures for return... 23 Tab. 10 Fault/number assignment... 28 Tab. 11 Troubleshooting table... 30 Tab. 12 Designation of components according to part numbers... 31 Tab. 13 Ambient conditions... 33 Tab. 14 Noise pressure level... 33 Tab. 15 Steel/cast pairings... 34 Tab. 16 Socket head cap screw 914.1 -steel/steel pairing... 34 Tab. 17 Cleaning agents... 34 Tab. 18 Socket loads... 34 Tab. 19 Socket loads torques... 34 Tab. 20 Spare parts for two years of continuous operation... 35 EN 01 BA-2006.03 MPC-B series 3
About this document 1 About this document This manual Ispartofthepump Applies to all of the afore-mentioned series Describes safe and appropriate operation during all operating phases 1.1 Target groups Target group Operating company Qualified staff, fitter Duty Keep this manual available where the installation is used, including for later use. Make sure the staff read and follow these instructions and the other applicable documents, especially all safety instructions and warnings. Observe any additional rules and regulations referring to the installation. Read, observe and follow these instructions and the other applicable documents, especially all safety instructions and warnings. Tab. 1 Target groups and their duties 1.2 Other applicable documents Document ATEX additional instructions Order data sheet Setup drawing Technical description Sectional drawing Supplier documentation Spare parts list Document of compliance Purpose Operation in potentially explosive areas Technical specifications, operating conditions Setup dimensions, connection dimensions etc. Technical specifications, operating limits Sectional drawing, part numbers, component designations Technical documentation for supplier parts Ordering spare parts Returning the pump to the manufacturer Declaration of conformity Tab. 2 Other applicable documents and their purpose Legal confirmation that the pump meets all requirements of the applicable EG guideline(s) 4 MPC-B series BA-2006.03 EN 01
About this document 1.3 Warnings and symbols Warning Risk level Consequences of non-observance WARNING CAUTION CAUTION Immediate acute risk Potential acute risk Potentially hazardous situation Potentially hazardous situation Fatal or serious injury Fatal or serious injury Minor bodily harm Material damage Tab. 3 Symbol Warnings and consequences of non-observance Meaning Safety warning sign Observe all information indicated by the safety warning sign to avoid injury or death. Instruction 1., 2.,... Multiple step instructions Requirement Cross reference Information, note Tab. 4 Symbols and their meaning 1.4 Technical terms Term Flushing medium Auxiliary operating systems Tab. 5 Technical terms and their meaning Meaning Medium for flushing the pump plain bearing surfaces Systems for operating the pump EN 01 BA-2006.03 MPC-B series 5
Security 2 Security The manufacturer does not accept any liability for damage resulting from non-observance of the entire documentation. 2.1 Intended use Only use the pump to pump the agreed pumped liquid ( order data sheet). Adhere to the operating limits and size-dependent minimum flow rate. Avoid dry running: Initial damage, such as destruction of plain bearings and plastic parts, within a few seconds. Make sure the pump is never put into operation or operated without pumped liquid. Avoid cavitation: Fully open the suction-side fitting; do not use the fitting to adjust the flow rate. Do not open the pressure-side fitting beyond the agreed operating point. Avoid overheating: Do not operate the pump while the pressure-side fitting is closed. Observe the minimum flow rate ( order data sheet). To avoid damage to the motor: Do not open the pressure-side fitting beyond the agreed operating point. Observe the number of permitted motor start-ups per hour ( manufacturer's specifications). Consult the manufacturer about any other use of the pump. 2.2 General safety instructions Take note of the following instructions before carrying out any work. 2.2.1 Product safety The pump has been constructed according to the latest technology and established technical safety rules. Nevertheless, a potential risk to life and limb of the operator or to other persons or damage to the pump and other property cannot be entirely excluded. Only operate the pump if it is in perfect technical condition; only use it as intended, staying aware of safety and risks, and adhering to the instructions in this manual. Keep this manual and all other applicable documents complete, legible and accessible to staff at all times. Refrain from any procedures that would endanger staff or third parties. If a safety-relevant fault occurs, shut down the pump immediately and have the fault corrected by appropriate staff. In addition to the entire documentation for the product, always comply with statutory or other safety and accidentprevention regulations as well as with the applicable standards and guidelines in the country where the pump is operated. Avoiding common types of misuse (examples) Observe the operating limits of the pump regarding operating temperature, pressure, flow rate and speed ( order data sheet). The power uptake of the pump increases with increasing density of the pumped liquid. To avoid any overload for the pump and motor, do not exceed the permissible density ( order data sheet). A lower density is allowed. Adapt the auxiliary systems accordingly. Adhere to the limits for solids content and grit size when pumping solids-carrying fluids ( order data sheet, technical description). When using auxiliary operating systems: Ensure the flushing medium is compatible with the product medium. Ensure there is a permanent supply of the respective flushing medium. 6 MPC-B series BA-2006.03 EN 01
Security 2.2.2 Operator's obligations Safety-conscious operation Only operate the pump if it is in perfect technical condition; only use it as intended, staying aware of safety and risks, and adhering to the instructions in this manual. Ensure the following are observed and monitored: Adherence to intended use, Statutory or other safety and accident-prevention regulations Safety regulations governing the handling of hazardous substances Applicable standards and guidelines in the country where the pump is operated Make protective equipment available. Staff qualifications Make sure all staff assigned with work on the pump have read and understood this manual and all other applicable documents, especially the safety, maintenance and repair instructions, before beginning with work. Organise responsibilities, who is in charge of any specific duty and how staff is supervised. Makesureallworkiscarriedout by specialist technicians only: Fitting, repair and maintenance work Work on the electrical system Make sure trainee staff only work on the pump under supervision of specialist technicians. Persons with implanted heart pacemakers Should stay away from the pump with magnetic coupling and parts of the magnetic coupling Should not be allowed to perform any work with or on magnetic parts Safety devices Provide the following safety devices and verify their integrity: For hot, cold and moving parts: contact protection of the pump provided by the customer If electrostatic charging is possible: fit appropriate earthing. Warranty Obtain the manufacturer's approval prior to carrying out any modifications, repairs or alterations during the warranty period. Only use original parts or parts that have been approved by the manufacturer. 2.2.3 Duties of the operating staff Observe and keep legible all directions on the pump, e.g. the arrow indicating the direction of rotation and the indication of fluid connections. Do not remove the protection against accidental contact for hot, cold and moving parts during operation. Use protective equipment if necessary. Carry out work on the pump only while the pump is not running. Isolate the motor from its supply voltage and keep it locked in that state while carrying out any fitting or maintenance work. Reinstall the safety devices on the pump according to regulations after completing any work on the pump. Persons with implanted heart pacemaker: Should keep a minimum distance of 1 m away from the pump with magnetic coupling or parts of the magnetic coupling. Should not be allowed to perform any work with or on magnetic parts 2.3 Special hazards 2.3.1 Potentially explosive areas ( ATEX additional instructions). 2.3.2 Hazardous pumped liquids Observe the safety regulations for handling hazardous substances when working with hazardous pumped liquids (e.g. hot, flammable, explosive, poisonous or potentially harmful). Use protective equipment when carrying out any work on the pump. 2.3.3 Magnetic field The magnetic field of the magnetic coupling can destroy magnetically sensitive products, including: Heart pacemakers ID cards with magnetic strips Credit cards and cheque cards Electrical, electronic or fine mechanical equipment (e. g. mechanical and digital watches, pocket calculators, hard drives) EN 01 BA-2006.03 MPC-B series 7
Layout and function 3 Layout and function 3.1 Labels 3.1.3 Pump type code 3.1.1 Type plate MPC 50-32 - 200 10 9 8 7 Typ type W.-Nr. serial-no. Lfrd. impeller Q P n MUNSCH Chemie-Pumpen GmbH D-56235 Ransbach-Baumbach 3 m /h kw min -1 Baujahr year Fig. 1 Type plate (example) 1 Pump type 2 Serial number 3 Year of construction 4 Pump head 5 Density 6 Torque 7 Speed 8 Power consumption 9 Flow rate 10 Impeller diameter 3.1.2 ATEX plate H M m kg/dm Nm 3 1 2 3 4 5 6 1 2 3 4 Fig. 3 Pump type code (example) 1 Series 2 Suction branch DN [mm] 3 Pressure joint DN [mm] 4 Nominal impeller diameter [mm] 1 2 Fig. 2 ATEX plate (example) 1 Explosion protection mark 2 Reference to ATEX additional instructions 8 MPC-B series BA-2006.03 EN 01
Layout and function 3.2 Layout 1 2 3 4 8 7 6 5 Fig. 4 MPC-B layout 1 Impeller 2 Housing armour 3 Volute casing 4 Motor 5 Drive shaft 6 Drive rotor 7 Pump rotor 8 Plain bearing bracket EN 01 BA-2006.03 MPC-B series 9
Transport, storage and disposal 4 Transport, storage and disposal 4.1 Transport 4.1.2 Lifting Weight specifications ( individual order documentation) Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Makesurenopartsofthemagneticcouplingareable to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. Death or crushed limbs caused by falling loads! Use lifting gear appropriate for the total weight to be lifted. Fasten the lifting gear as shown in the illustrations below. Do not stand under suspended loads. 4.1.1 Unpacking and inspection on delivery 1. Unpack the pump/group on delivery and check it for transport damage. 2. Report any transport damage to the manufacturer without delay. 3. Dispose of packaging material according to local regulations. Fig. 5 Fastening the lifting gear to the pump group Fig. 6 Fastening the lifting gear to the pump Lift the pump/group properly. 10 MPC-B series BA-2006.03 EN 01
Transport, storage and disposal 4.2 Preservation No preservation required. Do not preserve the pump. 4.3 Storage Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Make sure no parts of the magnetic coupling are able to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. CAUTION Material damage due to inappropriate storage! Store the pump properly. 1. Seal all openings with blank flanges, blind plugs or plastic covers. 2. Make certain that the storage room meets the following conditions: Dry Frost-free Vibration-free 3. Turn the motor shaft once a month. 4. Make sure the shaft and the bearing change their rotational position in the process. 4.4 Disposal Plastic parts can be contaminated by poisonous or radioactive pumped liquids to such an extent that cleaning is insufficient. Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Make sure no parts of the magnetic coupling are able to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. WARNING Risk of poisoning and environmental damage caused by pumped liquid or oil! Use protective equipment when carrying out any work on the pump. Prior to the disposal of the pump: Collect any pumped liquid and oil or grease running out and dispose of them separately according to local regulations. Neutralise residues of pumped liquid in the pump. Dismount plastic parts and dispose of them according to local regulations. Dispose of the pump according to local regulations. EN 01 BA-2006.03 MPC-B series 11
Setup and connection 5 Setup and connection For pumps in potentially explosive areas ( ATEX additional instructions) CAUTION Material damage caused by dirt! Do not remove the transport protection until immediately before installing the pump. Do not remove covers and transport and sealing covers until just before connecting the pipes to the pump. 5.1 Preparing the installation Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Makesurenopartsofthemagneticcouplingareable to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. 5.1.1 Checking the ambient conditions 1. Make sure the required ambient conditions are met ( 9.2.1 Ambient conditions, Page 33). 2. For installation sites > 1000 m above sea level, consult the manufacturer. 5.1.2 Preparing the installation site Make sure the installation site meets the following conditions: Pump freely accessible from all sides Sufficient space for installation/removal of the pipes and for maintenance and repair work, especially for the removal and installation of the pump and motor Pump not exposed to external vibrations (damage to bearings) Frost protection 5.1.3 Preparing the foundation and setup surface Setup options: With concrete foundation With steel foundation frame Without foundation Make sure the foundation and setup surface meet the following conditions: Level Clean (no oil, dust or other impurities) Capable of bearing the weight of the pump group and all operating forces Stability of the pump group ensured With concrete foundation: standard concrete of strength class B 25 5.1.4 Preparing the pump Take the following measures after long storage times / downtimes. Storage time/ Downtime Measure > 2 years Replace the motor bearing if necessary ( operating instructions of the motor manufacturer). Replace the elastomer seals (O-rings, shaft seal rings). Tab. 6 Measures after long storage times/downtimes 5.1.5 Installing the heat insulation Only necessary to maintain the temperature of the pumped liquid CAUTION Damage caused by overheating! Install the heat insulation only on the volute casing. Install the heat insulation properly. 12 MPC-B series BA-2006.03 EN 01
Setup and connection 5.2 Setup with foundation Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Make sure no parts of the magnetic coupling are able to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. 5.2.1 Setting the pump group down on the foundation Implements, tools and materials: Foundation bolts ( setup drawing) Steel washers Mortar grout, non-shrinking Spirit level 1. Lift the pump group ( 4.1 Transport, Page 10). 2. Hang the foundation bolts in the fixation holes of the base plate from below. Observe the specifications of the manufacturer when using chemical anchors. 3. Set the pump group down on the foundation, sinking the foundation bolts into the prepared anchoring holes. CAUTION Material damage due to base plate distortion! Place the base plate on the foundation and fasten it as described in the following. 2 1 2 3 Fig. 7 Setup with foundation 4. Use steel washers to align the pump group to the height and system dimensions as described in the following: Position one steel washer (2) to the left and right of each foundation bolt (1). If the distance between the anchoring holes is greater than 750 mm, position additional steel washer (3) at the centre of each side of the base plate. 5. Make sure the base plate and steel washers are in full surface contact. 6. Use a machine spirit level to check the permissible height deviation (1 mm/m) lengthwise and crosswise. 7. Repeat the procedure until the base plate is aligned correctly. 5.2.2 Fastening the pump group The damping behaviour is improved by filling out the base plate with mortar grout. 1. Fill the anchoring holes with mortar grout. 2. Once the mortar grout has set, screw the base plate tight at three points with the specified tightening torque ( 9.2.3 Tightening torques, Page 34). 3. Before tightening the remaining screws, compensate any unevenness of the fixation surface with metal shims next to each screw. 4. Make sure the base plate is not distorted. EN 01 BA-2006.03 MPC-B series 13
Setup and connection 5.3 Setup without foundation Implements, tools and materials: Wrench Spirit level Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Makesurenopartsofthemagneticcouplingareable to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. 5.4 Planning the pipes Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Makesurenopartsofthemagneticcouplingareable to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. 5.4.1 Avoid impurities in the pipes CAUTION Damage due to impurities in the pump! Ensure no impurities enter the pump. 1 1. Clean all pipe sections and fittings prior to assembly. 2. Ensure no flange gaskets are protruding inwards. 3. Remove any blank flanges, plugs, protective films and/or protective paint from the flanges. 1 1 1 2 3 4 5.4.2 Laying out supports and flange connections CAUTION Material damage due to excessive forces and torques of the pipes on the pump! Do not exceed the permissible limits ( 9.2.5 Socket loads according to ISO 5199, Page 34). Fig. 8 Setup without foundation 1. Lift the pump group ( 4.1.2 Lifting, Page 10). 2. Mount the four levelling feet (1) as illustrated. 3. Set down the pump group on the setup surface. 4. Adjust the height of the base plate with the levelling feet (1) as illustrated above: Use the wrench to hold the hexagon head on the levelling foot (4). Undo the hexagon nut (2). Adjust the height by turning the hexagon nut (3). Tighten the hexagon nut (2) ( 9.2.3 Tightening torques, Page 34). Use a machine spirit level to check the permissible height deviation (1 mm/m) lengthwise and crosswise. Repeat the procedure until the base plate is aligned correctly. 1. Calculate the pipe forces and take into account all operating conditions: Cold/warm Empty/full Unpressurised/pressurised Position shifts of flanges 2. Ensure the pipe can slide freely in the supports and does not seize up due to corrosion. 5.4.3 Specifying nominal diameters Keep the flow resistance in the pipes as low as possible. 1. Specify suction pipe nominal width suction flange nominal width. 2. Specify pressure pipe nominal width pressure joint nominal width. 14 MPC-B series BA-2006.03 EN 01
Setup and connection 5.4.4 Determining pipe lengths 5.4.6 Providing safety and monitoring devices (recommended) Avoid impurities 1. Install a filter in the suction pipe. 2. To monitor the level of dirt, install a differential manometer with a contact manometer. D Avoiding reverse operation C 1. Install a non return valve between the pressure joint and stop valve to ensure the medium does not flow back after thepumpisswitchedoff. 2. To allow bleeding, provide a bleeding connection between the pressure joint and non return valve. A B Make provisions for isolating and shutting off the pipes For maintenance and repair work Fig. 9 Straight pipe lengths in front of and behind the pump (recommended) Fit stop valves in the suction pipe and pressure pipe. A B C D > 5x DNs DNs DNd > 5x DNd Observe the recommended minimum values when installing the pump. Enable measurements of the operating conditions 1. For pressure measurements, fit manometers in the suction pipe and pressure pipe. 2. Provide for motor torque measurements. 3. Provide for pump temperature measurements. Suction side: shorter pipes are allowed but can restrict the hydraulic performance data. Pressure side: shorter pipes are allowed but can result in increased operating noises. 5.4.5 Optimising cross-section and direction changes 1. Avoid bends with radii smaller than 1.5 times the pipe diameter. 2. Avoid abrupt changes of cross-sections in the pipes. 5.5 Connecting the pipes Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Make sure no parts of the magnetic coupling are able to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. 5.5.1 Installing auxiliary pipes Follow the manufacturers' specifications if any auxiliary operating systems are available. 1. Install auxiliary pipes on auxiliary unions, ensuring stressfree and sealed connections ( setup drawing). 2. To avoid air enclosures, install the pipes so that they ascend to the pump. EN 01 BA-2006.03 MPC-B series 15
Setup and connection 5.5.2 Installing the suction pipe 1. Remove the transport and sealing covers from the pump. 2. To avoid air enclosures, install the pipes so that they ascend to the pump. 3. Ensure no gaskets protrude inwards. 4. For suction operation: install a foot valve in the suction pipe to prevent the pump and suction pipe from running empty during downtimes. 5.5.3 Installing the pressure pipe 1. Remove the transport and sealing covers from the pump. 2. Fit the pressure pipe. 3. Ensure no gaskets protrude inwards. 5.5.4 Checking that the pipe connections are stress-free Pipe installed and cooled down 1. Separate the connecting flange of the pipes from the pump. 2. Check whether the pipes are freely moveable in all directions within the range of expected expansions: Nominal width < 150 mm: by hand Nominal width > 150 mm: with a small lever 3. Make sure the flange surfaces are parallel. 4. Reconnect the connection flange of the pipes to the pump. 5.6 Connecting the electrical system Risk of fatal injury due to electric shock! Have all electrical work carried out by qualified electricians only. Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Makesurenopartsofthemagneticcouplingareable to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. Risk of fatal injury due to rotating parts! When carrying out any fitting or maintenance work, isolate the motor from its supply voltage and keep it locked in that state. 5.6.1 Connecting the motor Observe the specifications of the motor manufacturer. 1. Connect the motor according to the circuit diagram. 2. Ensure the electrical power does not pose any risks. 3. Install an EMERGENCY STOP switch. 5.6.2 Checking the direction of rotation Only possible when putting the pump into service ( 6.2 Putting the pump into service, Page 18). 16 MPC-B series BA-2006.03 EN 01
Operation 6 Operation For pumps in potentially explosive areas ( ATEX additional instructions) 6.1.4 Filling and bleeding Auxiliary operating systems ready for operation, if available 6.1 Preparations for the initial start-up Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Make sure no parts of the magnetic coupling are able to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. 6.1.1 Identifying the pump version Identify the pump version ( order data sheet). Pump versions are for example the type of shaft seal or auxiliary operating systems. 6.1.2 Checking downtimes After a downtime of more than one year: ( Table 6 Measures after long storage times/downtimes, Page 12). 6.1.3 Preparing auxiliary operating systems The manufacturer does not accept any liability for any damage resulting from the installation or use of a third-party or unapproved auxiliary operating system. Prepare the auxiliary operating systems, if available. WARNING Risk of injury and poisoning due to hazardous pumped liquids! Safely collect any leaking pumped liquid and dispose of it in accordance with environmental rules and requirements. CAUTION Damage caused by dry running! Make sure the pump is filled properly. 1. Fillthepumpandsuctionpipewithpumpedliquid. 2. Open the suction-side fitting. 3. Open the pressure-side fitting. 4. If any auxiliary operating systems are available, open them and check the flow rate. 5. Verify that all pipe connections are tight. 6.1.5 Checking the direction of rotation Risk of fatal injury due to rotating parts! Use protective equipment when carrying out any work on the pump. Keep a sufficient distance to rotating parts. CAUTION Material damage due to incorrect direction of rotation! Make sure the motor's direction of rotation corresponds to thearrowindicatingthedirectionofrotationofthepump. 1. Switch the motor on and immediately off again. 2. Check whether the motor's direction of rotation corresponds to the arrow indicating the direction of rotation of the pump. Risk of fatal injury due to electric shock! Have all electrical work carried out by qualified electricians only. 3. If the direction of rotation is different, replace two phases. 4. Reconnect the pump to the electrical power supply EN 01 BA-2006.03 MPC-B series 17
Operation 6.2 Putting the pump into service Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Makesurenopartsofthemagneticcouplingareable to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. 6.2.1 Switching on the pump Pump installed properly and connected All connections stress-free and leak-free Auxiliary operating systems ready for operation, if available All safety devices fitted and tested for integrity The pump prepared, filled and bled properly Risk of injury due to running pump! Do not touch the running pump. Do not carry out any work on the running pump. Allow the pump to cool down completely before starting any work. Risk of injury and poisoning due to pumped liquid spraying out! Use protective equipment when carrying out any work on the pump. CAUTION Damage caused by dry running! Make sure the pump is filled properly. CAUTION Risk of cavitation when throttling the suction flow rate! Fully open the suction-side fitting; do not use the fitting to adjust the flow rate. Do not open the pressure-side fitting beyond the operating point. CAUTION Damage caused by overheating! Do not operate the pump while the pressure-side fitting is closed. Observe the minimum flow rate ( order data sheet). 1. Open the suction-side fitting. 2. Close the pressure-side fitting. 3. Switch on the motor and check that it is running smoothly. 4. As soon as the motor is running at nominal speed, open the pressure-side fitting slowly until the operating point is reached. 5. After the initial stress caused by pressure and operating temperature, check whether the pump is not leaking. 18 MPC-B series BA-2006.03 EN 01
Operation 6.2.2 Switching off the pump Take the following measures if operation is interrupted: Pressure-side fitting closed (recommended) Pump is Measure WARNING Risk of injury due to hot pump components! Use protective equipment when carrying out any work on the pump. 1. Switch off the motor. 2. Check all connecting screws and tighten them if necessary. 6.3 Shut-down Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Make sure no parts of the magnetic coupling are able to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. WARNING Risk of injury and poisoning due to hazardous pumped liquids! Safely collect any leaking pumped liquid and dispose of it in accordance with environmental rules and requirements. shut down for a prolonged period emptied dismounted put into storage Tab. 7 Behaviour of pumped liquid Solids sedimenting Solidifying/ freezing, non-corrosive Solidifying/ freezing, corrosive Remains liquid, non-corrosive Remains liquid, corrosive Tab. 8 Take measures according to the pumped liquid ( Table 8 Measures to be taken, depending on the pumped liquid behaviour, Page 19). Close the suction-side and pressure-side fittings. Isolate the motor and secure it against being switched on by unauthorised persons. Follow the storage instructions ( 4.3 Storage, Page 11). Measures to be taken if operation is interrupted Duration of the interruption to service (depending on process) Short Long Flush the pump. Heat up or empty the pump and containers. Heat up or empty the pump and containers. Flush the pump. Empty the pump and containers. Empty the pump and containers. Preserve the pump and containers. Empty the pump and containers. Preserve the pump and containers. Measures to be taken, depending on the pumped liquid behaviour EN 01 BA-2006.03 MPC-B series 19
Operation 6.4 Restoring the pump to service Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Makesurenopartsofthemagneticcouplingareable to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. 1. Intheeventofadowntimeofmorethanayear: ( Table 6 Measures after long storage times/downtimes, Page 12). 2. Carry out all steps as for the initial start-up ( 6.2 Putting the pump into service, Page 18). 6.5 Operating the stand-by pump Stand-by pump filled and bled Operate the stand-by pump at least once a week. 1. Open the suction-side fitting completely. 2. Open the pressure-side fittingtosuchanextentthatthe stand-by pump reaches its operating temperature and the heat is evenly distributed ( 6.2.1 Switching on the pump, Page 18). 20 MPC-B series BA-2006.03 EN 01
Maintenance 7 Maintenance For pumps in potentially explosive areas ( ATEX additional instructions) Trained service technicians are available for fitting and repair work. Present a pumped material certificate (DIN safety data sheet or document of compliance) upon request. 7.1 Inspections 2. For trouble-free operation, ensure the following: No dry running No leaks No cavitation Suction-side gate valves open Unobstructed and clean filters Sufficient supply pressure No unusual running noises and vibrations No impermissible leaks at the shaft seal Proper functioning of the auxiliary operating systems The inspection intervals depend on the load placed on the pump. Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Make sure no parts of the magnetic coupling are able to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. Risk of injury due to running pump! Do not touch the running pump. Do not carry out any work on the running pump. WARNING Risk of injury and poisoning due to hazardous pumped liquids! Use protective equipment when carrying out any work on the pump. 1. Check at appropriate intervals: Compliance with minimum flow rate Roller bearing temperature < 70 C Normal operating conditions unchanged EN 01 BA-2006.03 MPC-B series 21
Maintenance 7.2 Maintenance Service life of the antifriction bearings for operation within the permissible operating range: > 2 years Intermittent operation, high temperatures, low viscosity and aggressive ambient and process conditions reduce the service life of antifriction bearings ( operating instructions of the motor manufacturer). Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Makesurenopartsofthemagneticcouplingareable to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. Risk of injury due to running pump! Do not touch the running pump. Do not carry out any work on the running pump. When carrying out any fitting or maintenance work, isolate the motor from its supply voltage and keep it locked in that state. Risk of fatal injury due to electric shock! Have all electrical work carried out by qualified electricians only. WARNING Risk of injury and poisoning due to hazardous or hot pumped liquids! Use protective equipment when carrying out any work on the pump. Allow the pump to cool down completely before performing any work. Make sure the pump is unpressurised. Empty the pump, safely collect the pumped liquid and dispose of it in accordance with environmental rules and requirements. For maintenance work ( operating instructions of the motor manufacturer) 22 MPC-B series BA-2006.03 EN 01
Maintenance 7.3 Dismounting Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Make sure no parts of the magnetic coupling are able to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. Risk of injury due to running pump! Do not touch the running pump. Do not carry out any work on the running pump. When carrying out any fitting or maintenance work, isolate the motor from its supply voltage and keep it locked in that state. Risk of fatal injury due to electric shock! Have all electrical work carried out by qualified electricians only. WARNING Risk of injury and poisoning due to hazardous or hot pumped liquids! Use protective equipment when carrying out any work on the pump. Allow the pump to cool down completely before performing any work. Make sure the pump is unpressurised. Empty the pump, safely collect the pumped liquid and dispose of it in accordance with environmental rules and requirements. 7.3.1 Returning the pump to the manufacturer Pump unpressurised Pump completely empty Electrical connections disconnected and motor secured against being switched on again Pump cooled down Auxiliary operating systems shut down, unpressurised and emptied Manometer lines, manometer and fixtures removed 1. Enclose a truthfully completed declaration of compliance when returning pumps or components to the manufacturer. Order a document of compliance from the manufacturer if necessary. 2. Take necessary measures, depending on the required repair work as specified in the table below, when returning thepumptothemanufacturer. Repairs At the customer's premises At the manufacturer's premises At the manufacturer's premises for warranty repairs Tab. 9 Measures for return Measure for return Return the defective component to the manufacturer. Flush the pump and decontaminate it if has been used for hazardous pumped liquids. Return the complete pump group (not disassembled) to the manufacturer. Only with hazardous pumped liquids: flush and decontaminate the pump. Return the complete pump group (not disassembled) to the manufacturer. EN 01 BA-2006.03 MPC-B series 23
Maintenance 7.3.2 Preparing the dismounting 7.3.4 Pulling off the volute casing Pump unpressurised Pump completely empty, flushed and decontaminated Electrical connections disconnected and motor secured against being switched on again Pump cooled down Auxiliary operating systems shut down, unpressurised and emptied Manometer lines, manometer and fixtures removed The pumps are constructed in process design as standard. The plug-in unit can be removed without removing the volute casing and pipes. 155+ 102 1. Observe the following for dismounting: Precisely mark the installation orientation and position of all components prior to dismounting. Dismount the components concentrically without canting. Dismount the pump ( sectional drawing). 2. Undo the fixation bolts on the housing feet 187. 3. Lift the pump out of the installation ( 4.1.2 Lifting, Page 10). 7.3.3 Undoing connections (if available) Flushing connector Fig. 11 Pulling off the volute casing 708.20 925 1. Undo the housing nuts. 2. Undo and pull off the housing armour 155 and volute casing 102 by screwing in the two jackscrews. 412.70 7.3.5 Dismounting the impeller, plain bearing bracket and pump rotor Fig. 10 Undoing the flushing connector 1. Undo the lock nut 925. 2. Undo and unscrew the fluid connection 708.20. 3. Remove the O-rings 412.70 from the fluid connection 708.20. Fig. 12 Undoing the impeller screw 412.4 906 1. Undo the impeller screw 906 and O-ring 412.4 with the circlip pliers and unscrew it. 24 MPC-B series BA-2006.03 EN 01
Maintenance 510 412.81 529.1 400.11/412.16 859 339 230 314 230 339 859 146 412.69 314 400.10/412.1 938 914.1 Fig. 13 Lifting the plain bearing out of the intermediate lantern 2. Screw the eye bolt in the tap hole for the impeller screw 906 andthreadinthecranecable. 3. Plain bearing bracket 339 Lift it with the impeller 230 and pump rotor 859 out of the intermediate lantern 146 with a crane. Set it down with the pump rotor downwards. 4. Unscrew the eye bolt again. Fig. 14 Dismounting the impeller, plain bearing bracket and pump rotor 5. Unscrew the socket head cap screw 914.1 with Schnorr spring washer 938. 6. Pull off the impeller 230 with thrust bearing 314. Use an M12 jackscrew if necessary. 7. Remove and replace the O-ring 412.69. 8. Raise the plain bearing bracket 339. Take out and replace the gaskets 400.10, 400.11 or O-rings 412.1, 412.16. 9. Press the bearing bush 545 with bearing seats 380 out of the plain bearing bracket 339. 10. Pull the bearing sleeve 529.1 and thrust bearing 314 off the pump rotor 859. 11. Replace the O-ring 412.81. 12. Remove the can 820 and can insert 830. EN 01 BA-2006.03 MPC-B series 25
Maintenance 7.3.6 Dismounting the drive rotor 7.4 Installing Fig. 15 Dismounting the drive rotor 216 901.16 858 939.8 1. Unscrew the hexagon screw 901.16. 2. Take out the spring ring 939.8. 3. Pull the hollow top shaft 216 with drive rotor 858 off the motor shaft. The drive rotor 858 and hollow top shaft 216 must be balanced as a unit. CAUTION Material damage due to unbalance in the pump rotor! Onlyundo thesockethead capscrew 914.11 to replace the drive rotor 858 or hollow top shaft 216. 4. If the drive rotor 858 or hollow top shaft 216 is to be replaced: Undo the socket head cap screws 914.11. Remove the drive rotor 858. Risk of fatal injury and material damage due to magnetic field! Make sure no-one with a heart pacemaker performs any work on the pump. Secure the workplace and cordon it off if necessary: Ensure staff with heart pacemakers keep a minimum distance of 1 m. Make sure no magnetisable metal parts are able to be attracted by the magnetic coupling of the pump. Makesurenopartsofthemagneticcouplingareable to be attracted by magnetisable metal parts. Keep magnetically sensitive objects at least 150 mm away from the magnetic coupling. 7.4.1 Preparing the installation 1. Observe the following for the installation: Replace worn out parts with original spare parts. Replace gaskets, inserting them in such a way that they cannot rotate. Observe the specified tightening torques ( 9.2.3 Tightening torques, Page 34). Refit components concentrically without canting according to the applied marks. 2. Clean all components ( 9.2.4 Cleaning agents, Page 34). but do not remove the applied marks. 3. Install the pump ( sectional drawing). Thepumpisinstalledinthereverseorderofthedismounting. The following sections show particular aspects to be observed when installing the product. 7.4.2 Installing the drive rotor Drive shaft 213 installed 1. Place the spring ring 939.8 on the hollow top shaft 216. The drive rotor 858 and hollow top shaft 216 must be balanced as a unit. CAUTION Material damage due to unbalance in the pump rotor! Only install the drive rotor 858 and hollow top shaft 216 if they have been balanced as a unit. Do not change the initial position of the components during the installation. 2. If the drive rotor 858 or hollow top shaft 216 have been replaced: Place the drive rotor 858 on the hollow top shaft. Screw the socket head cap screws 914.11 tight. 3. Place the hollow top shaft 216 with drive rotor 858 on the motor shaft. 4. Screw the hexagon screw 901.16 tight. 26 MPC-B series BA-2006.03 EN 01
Maintenance 7.4.3 Installing the plain bearing bracket Drive rotor installed Impeller installed 560 146 161 7.5 Ordering spare parts For trouble-free replacement in case of a fault, we recommend keeping complete plug-in units or spare pumps available on site. The application guidelines according to DIN 24296 recommend keeping a supply for two years of continuous use ( 9.3 Spare parts for two years of continuous operation according to DIN 24296, Page 35). Have the following information ready to hand when ordering spare parts ( type plate): Short designation of the pump Serial number Year of construction Part number Designation Quantity Fig. 16 Installing the plain bearing bracket 1. Insert the bearing bush 545 in the bearing seat 380. 2. Press the bearing seat 380 with bearing bush 545 in the plain bearing bracket 339. Make sure one of the grooves of the bearing bush points towards the location hole for the pin 560. 3. Insert the gaskets 400.10, 400.11 or O-rings 412.1, 412.16. 4. Insert the pin 560.7 and O-ring 412.81 inthepumprotor 859. 5. Push the bearing sleeve 529.1 onto the pump rotor 859. Make sure the pin 560.7 snapsintoplaceinthegrooveof the bearing sleeve. 6. Push the plain bearing bracket 339 slowly onto the pump rotor 859. 7. Push the impeller 230 onto the pump rotor 859. 8. Apply one drop of LOCTITE 243 onto the socket head cap screw 914.1. 9. Screw the impeller 230 tight onto the pump rotor 859 with the socket head cap screw 914.1 and Schnorr spring washer 938. 10. Insert the can 820 and can insert 830 in the intermediate lantern146. 11. Screw the eye bolt in the tap hole for the impeller screw 906 andthreadinthecranecable. 12. Insert the plain bearing bracket 339 with impeller and pump rotor 859 in the intermediate lantern 146 with the crane. Make sure the plain bearing bracket 339 snaps into place on the pin 560. 13. Unscrew the eye bolt again. 14. Screw the impeller screw 906 and O-ring 412.4 tight with the circlip pliers. 7.4.4 Fitting the pump in the installation ( 5 Setup and connection, Page 12). EN 01 BA-2006.03 MPC-B series 27