DEALER:
Magnatex Pumps, Inc.
3375 West 12th Street, Houston, TX, 77008
Toll Free: 866.MAG.PUMP
Phone:
713.972.8666
Fax: 713.972.8665
for Maintenance
date of commissioning:
.......................................................................................
position / system reference:
.......................................................................................
service:
.......................................................................................
USER MANUAL
MFRP
2
ADDENDA: User manual standard elastic coupling
3—IDENTIFICATION CODE
4—SECTION VIEW - size G3
5—LEGEND - size G3
6—SECTION VIEW - size G4
7—LEGEND - size G4
8—MECHANICAL SEAL: BF
8—MECHANICAL SEAL: TR
8—MECHANICAL SEAL: MTR
9—LEGEND INTERNAL MECHANICAL SEAL TYPE BF..
9—LEGEND EXTERNAL MECHANICAL SEAL TYPE TR..
9—LEGEND DOUBLE MECHANICAL SEAL MTR..
10—GENERAL NOTES
11—OPERATING PRINCIPLES OF THE PUMP
11— HYDRAULICALLY
11— MECHANICALLY
11— THE MECHANICAL SEAL
11—MOTOR
11— ELECTRICAL CONNECTIONS
11— PROTECTION LEVEL
12— DIRECTIONS FOR USE
12—TRANSPORT
12—STORAGE INSTRUCTIONS
12—INSTALLATION INSTRUCTIONS
13—PRESSURE SWITCH TO PREVENT DRY RUNNING
14—START-UP
14—USE
14—SHUTDOWN
14—MAINTENANCE
15—INSPECTION
15—SAFETY RISKS
15—INSTALLATION AND START-UP PERSONNEL
15—MAINTENANCE AND OPERATIONAL PERSONNEL
16—PERSONNEL RESPONSIBLE FOR REPAIRS
16—WASTE DISPOSAL
16—RECOMMENDATIONS
16—DISASSEMBLING
17—IMPROPER USE
17— OPERATING FAULTS AND POSSIBLE CAUSES
17— LUBRICATION
18— INSTRUCTIONS FOR FILLING LUBRICATING OIL
19— TECHNICAL DATA
INDEX:
3
clockwise rotation looking at the motor-fan
CENTRIFUGAL PUMP No
range
seal
type
item
n| giri/lí.PERFORMANCE DATA
H| m.
Q|m /h
3
capacity |l/lí|SEAL FLUSHING DATA
pressure min./max. |bar|
year of manufacture XXXX MADE IN ITALY
Via Labirinto 159
BRESCIA
ITALY
IDENTIFICATION CODE
PART NUMBER
MODEL
RANGE
Each pump is supplied with the serial and model abbreviation and the serial number on the rating plate, which is riveted
onto the support side. Check these data upon receiving the goods. Any discrepancy between the order and the delivery
must be communicated immediately.
In order to be able to trace data and information, the abbreviation, model and serial number of the pump must be quoted
in all correspondence.
PUMP DATA MOTOR DATA
size
model version
O-ring
material
Ø impeller mechanical seal baseplate rpm standard power
G3
□ 3x2x8
□ V1G
resina vinilestere standard
□ V
FPM
______________
mm
□ TR5
singola
esterna
□ 245 □ 1450
□ E
IEC
_______kW
□ 3x2x10
□ V1A
miscela resina vinilestere
□ E
EPDM
□ TR8
□ 252 □ 2900
□ U
NEMA
□ 4x3x8
□ V1C
miscela resina vinilestere
□ F
FEP
□ TC8
□ 258 □ 1750
□ 4x3x10
□ V1F
miscela resina vinilestere
□ K
FFKM
□ BF8
singola
interna
□ 264 □ 3500
□ 6x4x10
□ E1S
resina epossidica
□ MTR5
doppia
flussata
□ 268
□ 6x4x13 □ MTR6 □ 280
G4
□ 8x6x13
□ MTC8
□ 368
□ 10x8x15 □ 380
□ 398
Year of manufacture part number
_____________________ ___________________
4
3
36
4
19
17
77
74
10
12
14
38
9
6
5
11
18
12
16
15
35
44
71
24
41
42
66
26
68
65
VEDI TENUTE MECCANICHE
SEE MECHANICAL SEAL
22
33
27
20
37
21
13
31
72
73
35
29
51
52
128
80
79
123
127
126
78
69
70
32
75
76
30
34
43
28
2
A
A
B
B
B
45
B
140
SECTION VIEW - size G3
5
LEGEND - size G3
pos. ref Part name Q.ty
Disassembling steps sequence
(A1,...,A10,B1,...,B10,C1....)
Spare parts stock
1 2 3 4 5 6 7 8 9 10 start up 2 years 5 years
2 939 Plug 1
A
3 807.1 Bearing flange 1
B
4 320.1 Bearing (motor side) 1
B
1 1
5 940.1 Feather key (impeller) 1
6 940.2 Feather key (motor) 1
9 210 Shaft 1
B
10 360.1 Bearing cover (motor side) 1
B
11 320.2 Bearing (pump side) 1
B
1 1
12 412.5 O-ring bearing cover 2
B
1 1
13 910.11 FASTENERS Base support / support 1
A
14 643 Constant level oiler 1
A
1
15 360.2 Bearing cover (pump side) 1
B
16 421.1 MIM 1
B
1 1
17 421.2 MIM 1
B
1 1
18 932.1 Seeger ring 1
B
19 932.2 Seeger ring 1
B
20 331 Bracket 1
21 183 Base support 1
A
22 155 Rear flange 1
A
24 102 Volute casing 1
A
26 230 Impeller 1
A
1 1
27 910.6 Removing plate screws 2
28 910.1 FASTENERS volute casing / baseplate 1
A
29 910.2 FASTENERS motor / motor thickness 1
A
30 910.12 FASTENERS coupling cover 1
A
31 910.4 FASTENERS Base support / baseplate 1
A
1
32 910.14
FASTENERS Coupling cover flange /Coupling
cover
1
A
33 910.9 FASTENERS rear flange / support 1
34 910.10 FASTENERS support / bearing cover 1
B
35 910.7 FASTENERS bearing flange / bearing cover 1
B
36 638.1 Oil hole cup 1
A
1
37 918 Eyebolt 1
A
38 638.2 Oil drain plug 1
A
1
41 260 Ogive 1
A
1 1
42 920 Nut impeller 1
A
1
43 925 Washer 1
A
1
44 910.5 FASTENERS volute casing / rear flange 1
A
45 840 Coupling (complete) 1
51 800 Motor 1
A
52 891 Baseplate 1
65 412.1 O-ring volute casing / intermediate disc 1
A
1 1 1
66 412.2 O-ring impeller (pump side) 1
A
1 1 1
68 412.3 O-ring impeller (motor side) 1
A
1 1 1
69 850 Ring (elastic insert) 1
A
1 1 1
70 848 Elastic insert 1
A
1 1 1
71 905 Tie rods
A
1
72 638.3 Drain plug 1
A
1
73 412.4 O-ring drain plug 1
A
1 1
74 875.1 Coupling cover flange 2
A
75 875.2 Coupling cover (fixed) 1
A
76 875.3 Coupling cover 1
A
77 910.15
FASTENERS coupling cover flange/coupling
cover
1
A
78 842 Semi coupling(pump side) 1
A
1
79 862 Spacer 1
A
1
80 841 Semi coupling (motor side) 1
A
1
123 901 FASTENERS coupling
A
126 904.1 Grub screw semi coupling(pump side) 1
A
127 904.2 Grub screw ring (elastic insert) 2
A
128 904.3
Grub screw coupling (motor side)
1
A
140 910.30
Oiler kit connection
1
A
1
3
36
4
19
17
77
74
10
12
14
38
9
6
5
11
18
12
16
15
35
44
71
24
41
42
66
26
68
65
27
37
21
13
31
72
73
35
29
51
52
128
80
79
123
127
126
78
69
70
32
75
76
30
34
43
28
A
A
B
B
B
45
B
20
B
130
129
VEDI TENUTE MECCANICHE
SEE MECHANICAL SEAL
140
6
SECTION VIEW - size G4
7
pos. ref Part name Q.ty
Disassembling steps sequence
(A1,...,A10,B1,...,B10,C1....)
Spare parts stock
1 2 3 4 5 6 7 8 9 10 start up 2 years 5 years
3 807.1 Bearing flange 1
B
4 320.1 Bearing (motor side) 1
B
1 1
5 940.1 Feather key (impeller) 1
6 940.2 Feather key (motor) 1
9 210 Shaft 1
B
10 360.1 Bearing cover (motor side) 1
B
11 320.2 Bearing (pump side) 1
B
1 1
12 412.5 O-ring bearing cover 2
B
1 1
13 910.11 FASTENERS Base bracket / braket 1
A
14 643 Constant level oiler 1
A
1
15 360.2 Bearing cover (pump side) 1
B
16 421.1 MIM 1
B
1 1
17 421.2 MIM 1
B
1 1
18 932.1 Seeger ring 1
B
19 932.2 bearing flangeSeeger ring 1
B
20 331 Bracket 1
21 183 Base support 1
A
24 102 Volute casing 1
A
26 230 Impeller 1
A
1 1
27 910.6 Removing plate screws 2
28 910.1 FASTENERS volute casing / baseplate 1
A
29 910.2 FASTENERS motor / motor thickness 1
A
30 910.12 FASTENERS coupling cover 1
A
31 910.4 FASTENERS Base support / baseplate 1
A
1
32 910.14
FASTENERS Coupling cover flange /Coupling
cover
1
A
34 910.10 FASTENERS support / bearing cover 1
B
35 910.7 FASTENERS bearing flange / bearing cover 1
B
36 638.1 Oil hole cup 1
A
1
37 918 Eyebolt 1
A
38 638.2 Oil drain plug 1
A
1
41 260 Ogive 1
A
1 1
42 920 Nut impeller 1
A
1
43 925 Washer 1
A
1
44 910.5 FASTENERS volute casing / rear flange 1
A
45 840 Coupling (complete) 1
51 800 Motor 1
A
52 891 Baseplate 1
65 412.1 O-ring volute casing / intermediate disc 1
A
1 1 1
66 412.2 O-ring impeller (pump side) 1
A
1 1 1
68 412.3 O-ring impeller (motor side) 1
A
1 1 1
69 850 Ring (elastic insert) 1
A
1 1 1
70 848 Elastic insert 1
A
1 1 1
71 905 Tie rods
A
1
72 638.3 Drain plug 1
A
1
73 412.4 O-ring drain plug 1
A
1 1
74 875.1 Coupling cover flange 2
A
75 875.2 Coupling cover (fixed) 1
A
76 875.3 Coupling cover 1
A
77 910.15
FASTENERS coupling cover flange/coupling
cover
1
A
78 842 Semi coupling(pump side) 1
A
1
79 862 Spacer 1
A
1
80 841 Semi coupling (motor side) 1
A
1
123 901 FASTENERS coupling
A
126 904.1 Grub screw semi coupling(pump side) 1
A
127 904.2 Grub screw ring (elastic insert) 2
A
128 904.3
Grub screw coupling (motor side)
1
A
129 135
Protection
2
A
130 910.20
FASTENERS Protection / bracket
2
A
140 910.30
Oiler kit connection
1
A
1
LEGEND - size G4
8
89
61
84
81
82
85
88
83
62
54
87
86
63
B
B
120
121
23.B
94
90
92
91
55
97
B
B
122
23.T
94
90
93
124
91
56
102
103
104
101
105
106
100
B
B
122
135
23.T
MECHANICAL SEAL: BF
MECHANICAL SEAL: TR
MECHANICAL SEAL: MTR
9
LEGEND INTERNAL MECHANICAL SEAL TYPE BF..
LEGEND EXTERNAL MECHANICAL SEAL TYPE TR..
LEGEND DOUBLE MECHANICAL SEAL MTR..
pos. ref Part name Q.ty
Disassembling steps sequence
(A1,...,A10,B1,...,B10,C1....)
Spare parts stock
1 2 3 4 5 6 7 8 9 10 start up 2 anni 5 anni
23.B 134.1
Intermediate disc
1
54 524.1
Shaft sleeve (BF)
1 1 1 1
61 135.1
Diaphragm
1 C 1
62 488
Lock ring
1 C 1
63 360
Locking counter-plate
1 C 1
81 472.1
Rotating seal
1 1 1 1
82 475.1
Fixed seal
1 C 1 1 1
83 477
Spring
1 C 1
84 412.6
O-ring rotating seal
1 1 1 1
85 412.7
O-ring fixed seal
1 C
1 1 1
86 910.16
FASTENERS counter-plate / spring spacer
1 C
87 478
Spring spacer
1 C 1
88 476
Stationary seal locking ring
1 C 1
89 412.8
O-ring diaphragm / intermediate disc
1 C 1 1 1
120
ROTATING SEAL COMPLETE
121
FIXED SEAL COMPLETE
pos. ref Part name Q.ty
Disassembling steps sequence
(A1,...,A10,B1,...,B10,C1....)
Spare parts stock
1 2 3 4 5 6 7 8 9 10 start up 2 anni 5 anni
23.T 134.2
Intermediate disc
1
55 524.2
Shaft sleeve (TR)
1
1 1 1
90 475.2
Fixed seal
1
C
1 1 1
91 472.2
Rotating seal
1
C
1 1 1
92 135.2
Diaphragm TR
1 C
1
93 412.7
O-ring
1
94 412.8
O-ring fixed seal
1
C
1
1 1
97 910.17
FASTENERS Diaphragm
1
C
122
FIXED SEAL COMPLETE
pos. ref Part name Q.ty
Disassembling steps sequence
(A1,...,A10,B1,...,B10,C1....)
Spare parts stock
1 2 3 4 5 6 7 8 9 10 start up 2 anni 5 anni
23.T 134.2
Intermediate disc
1
56 524.3
Shaft sleeve( MTR)
1
1 1 1
90 475.2
Fixed seal (pump side)
1
C
1 1 1
91 472.2
Rotating seal (pump side)
1
C
1 1 1
93 412.7
O-ring fixed seal / diaphragm
1
C
94 412.8
O-ring fixed seal
1
C
1
1 1
100 910.19
FASTENERS flushing chamber
1
101 412.9
O-ring flushing chamber
1
C
1
1 1
102 472.3
Rotating seal (motor side)
1
C
1
1 1
103 475.3
Fixed seal (motor side)
1
C
1
1 1
104 412.10
O-ring fixed seal
1
C
1
1 1
105 471
Flushing chamber
1
C
1
106 910.18
Flushing piping
2
C
1
122
FIXED SEAL COMPLETE (pump side)
135
FIXED SEAL COMPLETE (motor side)
124 605.3
Diaphragm MTR
1
C
1
10
GENERAL NOTES
“ZGS” pumps are designed and built for the transfer of liquid chemical products having a specific weight, viscosity, temperature and stability of state appropriate for use with centrifugal pumps in a fixed installation, from a tank at a lower
level to a tank or a pipe to a higher level. The characteristics of the liquid (pressure, temperature, chemical reactivity,
specific weight, viscosity, vapour tension) and the enviromental conditions must be compatible with the characteristics
of the pump and are defined upon ordering. Impeller and static casings, in contact with the liquid, are constructed from
thermosetting resins; other parts in high chemical-resistant materials.
The pump’s performance (capacity, head, rpm) is defined upon ordering and specified on the identification plate.
“ZGS” series pumps are manufactured in compliance with ANSI/ASME B73.1 standards. They are of the centrifugal,
horizontal, single-stage type, with self-supporting shaft. ZGS pumps are coupled to a non-synchronous electric motor
by means of flexible coupling and spacer; with axial inlet and radial outlet for connection to the hydraulic system. These
pumps are of the foot-mounted type for fixing onto base-plate in compliance with ASME B73.1.
“ZGS” pumps are not self priming.
“ZGS” pumps cannot run dry.
The liquid being pumped may contain a maximum 5% of solid non-abrasive particles not greater than 0,1 mm in size.
The presence of fibrous, adhesive or abrasive bodies is not allowed. The maximum allowed size for bodies occasionally
present is 0,5 mm.
Clockwise rotation seen from the motor side.
Make sure that the chemical and physical characteristics of the liquid have been carefully evaluated for pump suitability.
The specific weight which can be pumped at a temperature of 25°C (both of the liquid and the ambient) depends upon the
diameter of the impeller (shown on the identification plate) and the installed motor power (shown on the motor identifica-
tion plate) ans has to be defined upon ordering.
The level of kinematic viscosity must not exceed 40 cSt so as not to significantly modify the pump’s performance. Higher
values up to a maximum of 120 cSt are possible provided that the pump is equipped with suitable impeller and motor to
be defined upon ordering.
The maximum continuous working temperature referred to water depends on the choice of materials (specified on the
identification plate):
80 °C execution V1G
80 °C execution V1A
80 °C execution V1C
80 °C execution V1F
110°C execution E1S
modifications may occour depending upon the operating pressure value.
The ambient temperature interval is related to the choice of materials (specified on the identification plate):
The maximum pressure the pump may be subjected to is 1.5 times the head value developed with the outlet closed.
The vapour pressure value of the liquid to be pumped must exceed (by at least 1m w.c) to the difference between the
absolute total head (suction side pressure added to the positive suction head, or subtracted by the suction lift) and the
pressure drops in the suction side piping (including the inlet NPSHr drops shown on the specific tables).
In case of double mechanical seal, the value of the pressure in the seal chamber must be equal to half value of the operating pressure of the pump.
In case of double mechanical seal, the flushing liquid must be clean and must not lead to violent chemical reactions on
contact with the liquid being pumped.
The pump shaft is supported by rolling bearings packed with grease (to be periodically recharged).
The pump does not include any non return valve nor any liquid flow control or motor stop device.
The coupling guard must be fitted before starting up the pump.
11
R T
U
V
W
S
X
Z
Y
R T
U
V
W
S
X
Z
Y
OPERATING PRINCIPLES OF THE PUMP
HYDRAULICALLY alike to all centrifugal pumps, it is equipped with a blade-type impeller rotating within a fixed housing.
It has a radial outlet (facing the upper part of the pump, with an internal deflector) and, by creating a depression in the
center, it allows the liquid to flow from the central suction side. Then, flowing through the impeller’s blades the fluid acquires energy and is conveyed towards the outlet.
MECHANICALLY, the static stress caused by the piping is borne by the pump body. Directly the pump shaft causes the
impeller to rotate and is driven by rolling bearings that transfer all the mechanical impeller loads onto the support. The
pump is connected to the electric motor (IEC, B3 frame, to be fixed onto a common base) by means of a flexible coupling and spacer. A guard (non-hermetically sealed) prevents unauthorised access. The spacer allows worn components
(pump rotor) to be removed without having to disconnet the piping and remove the motor.
THE MECHANICAL SEAL, placed at the point where the shaft enters the pump body to drive the impeller, is made up
of two main sections: a fixed section inserted in the pump body and a rotating section integral with the shaft. The tight
contact between these two parts guarantees a seal against leakage whether the pump is rotating or not. The rubbing
action that occurs between these two parts when the pump is operating generates heat by friction; this heat is absorbed
by the liquid being pumped in the case of single mechanical seal and by the cooling liquid (generally water) in the case
of double seal. The presence of the thin layer of liquid between the sealing surfaces, as well as its cooling action, is
indispensable for the life of the seal.
MOTOR
ELECTRICAL CONNECTIONS
The electrical connection to the motor terminal determines the direction of rotation of the motor and can be verified by
looking at the cooling fan at the rear of the motor ( for the Argal pump this has to rotate clockwise looking at the front
end).
With single phase motors the direction of rotation may be reversed by changing the position of the connection plates.
With three-phase motors the direction of rotation may be changed by swapping any two of the three conductors independently of the type of connection to the windings:
Star/Delta starting is used when the motor power is above 7.5 kW (10 HP ) only in case of frequent starts and short
running times, but always when the motor power is above 15 kW (20 HP ). All this is also to safeguard the structure of
the pump.
PROTECTION LEVEL
The initials IP are followed by two numbers :
The first number indicates the level of protection against penetration of solid objects, The second number indicates the
protection against the penetration of liquids.
According to the IP protection indicated on the identification plate of the motor and to the environmental conditions, arrange for opportune extra protections allowing in any case correct ventilation and rapid drainage of rainwater.
12
DIRECTIONS FOR USE
TRANSPORT
cover the hydraulic connections•
when lifting the unit do not exert force on the plastic fittings•
lay the pump on its base or fixing plate during transport•
if the road is particularly rough, protect the pump by means of adequate shock absorbing supports•
bumps and shocks may damage important working parts vital for safety and functionality of the machine•
STORAGE INSTRUCTIONS
When is necessari to store the pump bifore installation don’t remove it from the original packaged. The packaged •
pump must be stored lifted from ground level, the ambient must be close, clean and dry.
If at the receipt of the pump package seems damaged is necessary to free the pump in order to check its integry •
and to store a new package
The place where the pump is stored must be closed with an ambient temperature not lower than –5°C and not •
higher than 40°C, the air humidity rate not higher than 80%, the package pump mustn’t received shock, vibrations
and loads rising above.
If the storing period is higher than 6 months, bifore installation check the condition of the grease in the support, •
eventually provide to restore it.
INSTALLATION INSTRUCTIONS
clean the plant before connecting the pump•
make sure that no foreign bodies are left in the pump. Remove safety caps on the hydraulic connections.•
follow the instructions indicated in the following diagram:
1) Suction head adapts to delivery rate in order to prevent winage
2) YES: expansion joint (indispensable with long piping or hot liquids) and/or vibration damping system at inlet and outlet; anchor system near the pump
03) YES: connection point for pressure gauge or safety pressure switch
04) YES: non-return valve (particularly with long vertical or horizontal pipe runs; mandatory with pumps in parallel)
05) YES: flow control valve on the discharge side
06) Maximum fluid speed on the discharge side: 3.5 m/sec
07) NO: bends (or other fittings) close to the pump (both at inlet and outlet)
08) Auxiliary piping for double mechanical seal (only for M type seals):
09) pressure reducer
10) inlet filter
11) inlet shut-off valve
12) delivery hand control valve
13) pressure gauge for checking seal chamber pressure
14) YES: drain channel around the base plate
15) The pump must be installed using all of the fixing holes provided; the fixing points must be kept at the same level
16) YES: pipe drain (perfectly airtight); drain valve must be closed when the system is working
17) YES: firmly fix all piping by suitable brackets, close to the pump
18) YES: drain collecting sump (leak proof)
19) Maximum fluid speed on suction side: 2.5 m/sec
20) NO: air pockets. The circuit must be linear and short
21) Incline the piping towards the pump
22) YES: shut off gate valve ( one is also fitted near the pump in case of long piping)
23) YES: filtering sector (5÷10 mm mesh screen)
anchor the pump to an adequate base plate having a mass at least 5 times that of the pump•
do not use anti-vibration mounts to fix the pump•
anti-vibration joints are recommended on the pipe connections•
manually verify that all rotating parts are free to turn without abnormal friction by turning the motor cooling fan•
make sure that the power supply is compatible with the data shown on the pump motor identification plate•
connect the motor to the power supply via a magnetic/thermal control switch•
ensure that star-delta starting is implemented for motors whose power is more than 15kW•
install emergency stop devices to switch off the pump in case of low liquid level (floating, magnetic, electronic, pres-•
suresensitive)
ambient temperature as a function of the physical-chemical characteristics of the liquid to be pumped and in any •
13
0.00
7 8
9
10
11
12
13
1
2
3
4
5
6
14
15
16
17
18
19
20
15
22
23
case not greater or lower than the interval indicated in the GENERAL HINTS
other environmental conditions in accordance with the IP protection of the motor•
install a drainage pit to collect any liquid overflow from the base drainage channel due to normal maintenance •
work
leave enough free space around the pump for a person to move•
leave free space above the pump for lifting operations•
highlight the presence of aggressive liquids with coloured tags following the local safety regulations•
do not install the pump (made in thermosetting material) in close proximity to heating apparatus•
do not install the pump in areas subject to solid or liquid matter falling•
do not install the pump in an explosive atmosphere unless the motor and its coupling have been adequately pre-•
arranged
do not install the pump in close proximity to workplaces or crowded areas•
install extra protection guards for the pump or persons as the need arises•
install a spare equivalent pump in parallel•
CAUTION: final alignment of the pump and driver through the flexible coupling must be done after the pump installation
and before the pump start. During transit and subsequent handling any factory alignment may be disturbed. The pump
must be fixed to the base of support and to the foundation. To access the elastic coupling remove the protections ref.
75 and 76. For the assembly and alignment instructions you refer to the instructions of the manufacturer of the coupling
(attached the manual of standard elastic coupling).
MAX TORQUE FROM EQUATION SETS AT 20°C [Nm]
25 2” / 3”
25 4”
33 6”
64 8”
PRESSURE SWITCH TO PREVENT DRY RUNNING
The principal cause of pump malfunctions is dry-running (being it caused by improper use or cavitation ). It is therefore
advisable to install a simple device that will stop the pump motor when the pressure falls below a preset level. This is ju-
stified by the fact that such a condition is normally caused to an inadequate flooding of the impeller due to various causes:
absence of liquid, suction valves closed at start-up, cavitation, clogged channels, dirty filters, etc.....
The pressure switch (pressure gauge with electrical contacts) must be fitted on the discharge side of the pump at approximately 20cm from the outlet. This device needs furthermore:
1) ) A fluid separator to transmit pressure to the instrument via a secondary fluid separated from the main one by a chemically resistant diaphragm.
2) Remote-control switch to energize the motor (controlled by a pushbutton or auxiliary relay) having the normally closed
contact of the pressure switch in series with the latch circuit of said remote-control switch.
In order to obviate any pulsations of the pressure switch, it is necessary to set its setpoint to a pressure value equal to 65%
of the working pressure. It is obvious that this device cannot be used to control working pressure.
On start-up the pressure switch contact must be by-passed for a sufficient time to allow pressure to build up in the system.
In case of automatic start-up it is necessary to short circuit the latch with a timer for the pressure build-up time.
The system is not suitable for full capacity applications in which case it is advisable to install some control devices for the
motor power absorbtion.
All of the above must be adapted to the local safety rules and in particular when the classification of the environment
requires explosion-proof equipment.
14
START-UP
verify that the instructions outlined in the INSTALLATION have been followed•
verify the correct direction of rotation (clockwise from the motor side) supplying the motor with short impulses•
ensure that the NPSH available is greater than that required by the pump (in particular for hot liquids, liquids with •
high vapour pressure, very long suction pipes or negative suction lift)
close the discharge valve; completely cover the suction pipe and the pump. •
close the outlet valve. Start up the motor two or three times with short supplies of current in order to expel the air •
from the pump and the lubrication circuit between the guide shaft and bush.
start the pump with the suction valve completely open and the outlet valve semi-closed. •
slowly adjust the flow by adjusting the outlet valve (never adjust the suction valve) and making sure that the motor •
absorption is does not exceed the nominal power rating shown on the plate
do not operate at the extremes of the operating curve: maximum head (discharge valve shut too tight) or maximum •
flow (total absence of loss and lift in discharge circuit).
set the operating point for which the pump has been requested•
check that there are no unusual vibrations or noises due to inadequate fixing or cavitation •
avoid excessively short and/or frequent start-ups by adjusting the consent appliances•
check that temperature, pressure and characteristics of liquid match order specifications •
Motor power kW 0,75÷5,5 7,5÷30 37÷110 132÷200 250÷315
Max. no. starts/hour 2-47 poli 20-40 10-20 6-12 2-4 1-2
USE
switch automatic control on•
do not activate valves whilst the pump is in operation•
risks of dangerous water hammer effects in case of sudden or improper valve actuation (only trained personnel •
should operate valves)
completely empty and wash the pump before using a different liquid•
isolate or empty the pump if the crystallization temperature of the liquid is the same or lower than the ambient tem-•
perature
stop the pump if the liquid temperature exceeds the maximum allowed temperature indicated in the general notes; •
if the increase is of approximately 20%, check internal parts
close the valves in case of leaks•
wash with water only if compatible from the chemical point of view. As alternative use an appropriate solvent that will •
not generate dangerous exothermal reactions
contact the liquid supplier for information on the appropriate fire precautions•
empty the pump in case of long periods of inactivity (in particular with liquids which would easily crystallize)•
SHUTDOWN
disconnect the motor•
before starting maintenance, turn off the suction and discharge valves•
MAINTENANCE
all these maintenance operations must be performed under the supervision of qualified personnel•
make periodic inspections (2 to 30 days depending on the type of liquid and the operating conditions) clening filte-•
ring sections
make periodic inspections (1 to 6 months depending on the type of liquid and the operating conditions) on the rota-•
ting parts of the pump (pump rotor); clean or replace or lubricate as necessary (see RECOMMENDATIONS)
make periodic inspections (3 to 5 months depending on the type of liquid and the operating conditions) on the fun-•
ctionality of the motor control system; efficiency must be guaranteed
excessive current consumption could be an indication of impeller problems•
unusual vibrations could be due to unbalanced impeller (due to damage or presence of foreign material obstructing •
its blades)
reduced pump performance could be due to an obstruction of the impeller or damages to the motor•
motor damages could be due to abnormal friction within the pump•
damaged parts must be replaced with new original parts•
the replacement of damaged parts must be carried out in a clean dry area •
15
SAFETY RISKS
WARNING! CHEMICAL HAZARD. The pumps are designed to pump different types of liquid and chemical. Follow the
specific instructions to decontaminate during inspection or maintenance. §
WARNING! Safety risks for personnel mainly arise from improper use or accidental damages.
These risks may be of an electrical nature as far as the non-synchronous motor is concerned and may cause injury to
hands if working on an open pump. Risks may also arise due to the nature of the liquids pumped. It is therefore of utmost
importance to closely follow all the instructions contained in this manual so as to eliminate the causes that may lead to
pump failure and the consequent leakage of liquid dangerous for both personnel and the environment.
Risks may also arise from improper maintenance or dismantling practices.
In any case five general rules are important:
A - all services must be carried out by specialised personnel or supervised by qualified personnel depending on the type
of maintenance required
B - install protection guards against eventual liquid sprays (when the pump is not installed in remote areas) due to an
accidental pipe rupture. Arrange for safety basins to collect possible leakage
C - when working on the pump always wear acid-proof protective clothing
D - arrange for proper conditions for suction and discharge valve closing during disassembly
E - make sure that the motor is completely disconnected during disassembly.
Proper design and building of the plants, with well positioned and well marked piping fitted with shut-off valves, adequa-
te passages and work areas for maintenance and inspections are extremely important (since the pressure developed
by the pump could give some kind of damage to the plant in case this one should be faulty made or wear and teardamaged).
It must be stressed that the major
cause of pump failures leading to a consequent need to intervene is due to the pump
running dry in manually operated plants. This is generally due to:
- the suction valve being open at start-up or
- the suction tank being emptied without stopping
INSTALLATION AND START-UP PERSONNEL
Interventions allowed only to specialised personnel who may eventually delegate to others some operations depending
on specific evaluations (technical capability required: specialisation in industrial plumbing or electric systems as needed).
MAINTENANCE AND OPERATIONAL PERSONNEL
Interventions allowed to general operators (after training on the correct use of the plant):
pump starting and stopping•
opening and closing of valves with the pump at rest•
emptying and washing of the pump body via special valves and piping•
cleaning of filtering elements•
Interventions allowed to qualified personnel (technical capacities required: general knowledge of the mechanical, electrical and chemical features of the plant being fed by the pump and of the pump itself):
verification of environmental conditions•
verification of the condition of the liquid being pumped•
inspections of the control/stop devices of the pump•
INSPECTION
Check:
the pump shaft for cracks and excessive wear•
excessive wear of seal rings•
counterthrust bushing for cracks or excessive wear•
the impeller, volute and intermediate disk for abrasion and corrosion •
that the pressure balancig holes on the impeller blades are not blocked•
for lumps and clusters created by the pumped liquid (especially at the bottom of the rear chamber)•
Replace broken, cracked or deformed parts.
Reopen all the blocked pipes and eliminate any chemical agglomeration.
Clean all surfaces before reassembly; in particular seal rings (risk of leakage or premature wear) and O-ring seats (risk
of leakage).
16
inspections of the rotating parts of the pump•
trouble shooting•
PERSONNEL RESPONSIBLE FOR REPAIRS
Interventions allowed to general operators under the supervision of qualified personnel:
stopping of the pump•
closing of the valve•
emptying of pump body•
disconnection of piping from fittings•
removal of anchoring bolts•
washing with water or suitable solvent as needed•
transport (after removal of electrical connections by qualified personnel)•
Interventions by qualified personnel (technical capacities required: general knowledge of machining operations, awareness of possible damage to parts due to abrasion or shocks during handling, know-how of required bolt and screw
tightening required on different materials such as plastics and metals, use of precision measuring instruments):
opening and closing of the pump body•
removal and replacement of rotating parts•
WASTE DISPOSAL
Materials: separate plastic from metal parts. Dispose of by authorized companies.
RECOMMENDATIONS
DISASSEMBLING
all these maintenance operations must be performed under supervision of qualified personnel
cut off the power supply from the motor and disconnect the electrical wiring; pull the wires out from the terminal box and
isolate their extremities accordingly
close discharge valves
use gloves, safety glasses and acid-proof overalls when disconnecting and washing the pump
disconnect the piping and leave enough time for the residual liquid to exit the pump body and atmospheric air to fill the
empty volume
wash the pump before carrying out any maintenance work
do not scatter the liquid in the environment
lift the pump vertically avoiding to exert traction on the liner
before attempting to dismantle the pump ensure that its motor is disconnected and that it may not be started accidentallly
now open the pump following the sequence indicated in the respective table of the LEGEND and following the suggestions outlined in the RECOMMENDATIONS section
ll threads are right handed
The impeller, once the pump rotor is disconnected, must be removed by blocking the opposite end of the shaft (removing
the half coupling if necessary); unscrew the protection cap (ogive) and locking nut (right hand thread), then remove the
impeller axially.
Follow the specific attached instructions when working on the mechanical seal.
Remove the shaft from its support (with the bearing on the motor side) by sliding it in direction of the coupling side; the
bearing on the pump side must be in position before refitting the shaft (see Table 5: bearings and oil seal rings).
Replace the parts that was: broken, cracky, smelt.
Clean all surfaces before reassembly; in particular seal rings (risk of leakage or premature wear), O-RING seats (risk
of leakage). bearings rings and seats of the support.
Shaft run-out on the impeller side must not exceed 30μm.
Check alignment and end play among the flexible components of the coupling after reassembling:
Max. radial deviation <0,5 mm; max. angular displacement <1°; end play: 2÷4 mm
Screw fastening torque M4 M6 M8 M10 M12 M16 M20 M24
to be reduced by 25 % clamping plastic components Nm 4 14 24 48 60 75 120 175
17
LUBRICATION
The pump is supplied without oil (bearing housing is empty); before starting pump fill with lubricating oil as per ISO 6743:
Kinematics viscosity ref. to 50 °C (125°F): 2,8÷3,3 °E (≈ 20 cSt) - Operating conditions: temperature increment 40°C;
max. temperature 100 °C; max. rpm 4000.
Business names: ESSO Teresso 68; SHELL Tellus T68; MOBIL DTE 68; BP Energol HLC 68; AGIP Blasia 68 (remark:
68 mm2/s at 40°C with gradation SAE 20).
Add oil in the bulb lubricator (100 cc) approximately every 300 hours of working.
Feed rate: 100cc/300hrs.
Completely drain and replace oil after 2000 operating hours.
Quantity required for the first filling: 2000 cc for G3 size / 7500 cc for G4 size.
IMPROPER USE
The pump must not be used for purposes other than the transfer of liquids.
The pump cannot be used to generate isostatic or counter pressures.
The pump cannot be used to mix liquids generating an exothermal reaction
The pump must be installed vertically on a firm structure.
The pump must be installed on a suitable hydraulic plant with outlet connection to proper discharge pipe.
The plant must be able to shut off the liquid flow independently from the pump.
Handling of aggressive liquids requires specific technical knowledge
OPERATING FAULTS AND POSSIBLE CAUSES
The pump does not deliver:
01- wrong sense of rotation
02- suction piping is too long or has too many bends
03- not enough suction head on the pump
04- air intake from suction and secondary piping
05- pump or suction piping not completely flooded
06- impeller blades obstructed by impurities
07- non-return valve on the discharge pipe blocked
08- the geodetic head of the plant is greater than the maximum head developed by the pump
09- impeller blocked by a considerable layer of crystals or by melting due to dry running
The pump has reduced capacity or insufficient pressure: see 01, 02, 03, 04, 05, 06
10- the head required by the plant is greater than that expected
11- insufficient nominal diameter of suction piping, shut-off valve or other suction parts
12- insufficient geodetic suction head on the pump
13- damaged or worn impeller
14- viscosity of liquid greater than that expected
15- excessive quantities of air or gases in the liquid
16- bends, non-return valve or other parts close to the outlet
17- liquid (especially if hot) liable to change to gaseous state
The pump is overloaded: see 14
18- capacity is higher delivery than expected
19- the specific weight of the liquid is greater than expected
20- impurities inside the pump generate abnormal friction
21- the power supply voltage is not the one on the motor identification plate
The pump vibrates and is noisy: see 20
22- the pump is working at free capacity (zero head)
23- the pump or piping are not firmly fixed
24- damaged or dry central support bearings
25- wrong alignment of the flexible coupling
The pump shows signs of premature wear of internal parts: see 20
26- liquid is excessively abrasive
27- frequent recurrence of cavitation (see 02, 11, 15, 17)
28- high tendency of the liquid to crystallize or polymerize in stand-by
29- pump execution with materials not suitable for the liquid being pumped
30- operation at much reduced capacity
1. Purpose:
Indicate the filling method of the bearing lubrication oil.
2. Applicability:
This statement refers to SATURN ZGS pumps.
3. Areas / corporations concerned:
REPAIRS - Customer.
4. Operating method:
Filling phases.
INST RUC TIONS FO R FILLING L UBRICAT ING OI L
PHASE 3.
PHASE 2.
oil through the upper spout.
Finally screw it on the ampoule.
- Working conditions: the ampoule must be closed.
- Ordinary maintenance: repeat the step 2 only once the
ampoule is being emptied completely of oil.
Fill with lubricant the appropriate oil hole at the top of
the carrier.
During the filling phase keep open the ampoule.
The phase 1 is considered ended when the oil begins
to overflow into the ampoule elbow.
This step is to be performed only during the starting of
the pump.
PHASE 1.
18
19
LT=CP+HT+LM
HD=HG+D
TECHNICAL DATA
TAB. 1 PUMP ANSI/ASME B73.1
TAB. 2 CONNECTIONS - ANSI/ASME B16.5 class 150
MODEL CP Y D X F E1 E2 H U LA DA weight (kg)
3 x 2 x 8 597 102 210 242 318 124 92 16 41.3 n.a. n.a. 95
3 x 2 x 10 597 102 210 242 318 124 92 16 41.3 n.a. n.a. 95
4 x 3 x 8 597 102 210 280 318 124 92 16 41,3 n.a. n.a. 100
4 x 3 x 10 597 102 210 280 318 124 92 16 41,3 n.a. n.a. 100
6 x 4 x 10 597 102 254 343 318 124 92 16 41,3 60 20 120
6 x 4 x 13 597 102 254 343 318 124 92 16 41,3 60 20 120
8 x 6 x 13 860 152 368 406 476 203 114,5 22 60,3 60 20 240
10 x 8 x 15
860 152 368
483 476 203
114,5 22 60,3 60 20 280
Dimension in mm
MODEL
INLET OUTLET
DNa Ca ea n° tipo DNm Cm em n° tipo
3 x 2 x 8 80 152 19 4 hole 50 121 19 4 hole
3 x 2 x 10 80 152 19 4 hole 50 121 19 4 hole
4 x 3 x 8 100 191 19 8 hole 80 152 19 4 hole
4 x 3 x 10 100 191 19 8 hole 80 152 19 4 hole
6 x 4 x 10 150 241 20 8 tie rod 100 191 19 8 hole
6 x 4 x 13 150 241 20 8 tie rod 100 191 19 8 hole
8 x 6 x 13 200 298 20 8 tie rod 150 241 22 8 hole
10 x 8 x 15 250 362 20 12 tie rod 200 298 22 8 hole
Dimension in mm
20
TAB. 3 BASEPLATE
TAB. 4 MOTOR IP 55 - COUPLING
TAB. 5 SUPPORT:bearing and seal
TAB. 6 CONNECTION LOADS
F1 (kg): 250
F2 (kg): 250
F3 (kg): 250
torque (kgm): 28,5
TAB. 7 PUMP PERFORMANCE
MODEL
2 poles 4 poles 6 poles
Capacity
max (m
3
/h)
Head
Max ( m )
Noise
( dB )
Capacity
max (m3/h)
Head
Max ( m )
Noise
( dB )
Capacity
max (m3/h)
Head
Max ( m )
Noise
( dB )
Frequency
50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz
3 x 2 x 8 120 120 50 73 78 80 60 80 12,5 18 74 75
3 x 2 x 10 140 140 90 130 79 80 80 80 22 32 74 75
4 x 3 x 8 160 200 52 76 78 79 100 100 13 19 75 77
4 x 3 x 10 200 240 93 135 78 80 100 120 23 34 74 76
6 x 4 x 10 250 300 21 31 74 76
6 x 4 x 13 300 350 36 53 75 76 200 250 17 23 74 75
8 x 6 x 13 700 800 32 47 76 77 500 500 15 20 74 75
10 x 8 x 15 1000 1000 45 66 76 77 700 800 22 29 75 76
temperature support (max): 70 °C
size
MODEL
Pump side motor side
bearing seal ring bearing seal ring
G3
3 x 2 x 8
NUP310ECJ 50x72x8 5311 E 55x72x8
3 x 2 x 10
4 x 3 x 8
4 x 3 x 10
6 x 4 x 10
6 x 4 x 13
G4
8 x 6 x 13
6314Z 70x90x10 3314A 70x90x10
10 x 8 x 15
kW 1,5 2,2 3 4 5,5 7,5 11 15 18,5 22 30 37 45 55 75 90 110 132 160
Poles 2 4 2 4 2 4 2 4 2 4 2 4 6 2 4 6 2 4 6 2 4 6 2 4 6 2 4 6 2 4 6 2 4 6 2 4 6 2 4 6 4 6 4 6 4 6 4 6
frame
90S
90L
90L
100L
112
132S
132S
132M
160M
160M
160L
160M
160L
180L
160L
180M
200LA
180M
180L
200LB
200L
225M
200L
225S
250M
225M
280S
250M
280M
280S
315S
280M
315M
315S
315LA
315M
315LM
315LA
355MA
LM (1)
310
337
337
368
395
437
437
475
655
655
675
655
675
768
675
720
760
720
768
760
760
850
760
825
925
820
850
975
925
1015
960
975
1190
1015
1300
1190
1300
1300
1270
1570
Weight kg(1)
1315162223272732424346
53
103
122
134
121
133
169
173
163
196
221
190
242
236
252
275
301
275
328
370
315
355
478
417
451
615
572
591
790
615
880
870
997
990
1103
1053
1400
HT
size
G3
112
112
112
112
112
112
117
117
117
122
117
122
147
122
147
147
147
147
150
147
150
150
172
150
172
172
172
172
216
size
G4
137
137
142
1137
142
167
142
167
167
167
167
170
167
172
170
212
170
212
212
212
212
236
L
coupling
size
G3
100
100
100
100
100
100
100
100
100
120
100
120
120
120
120
120
120
140
120
140
140
140
140
180
size
G4
120
120
120
140
120
140
140
140
140
140
140
180
140
180
180
180
180
200
size coupling
A1
A1
A1
A1
A1
A1
A2
A2
A2A3A2A3A4
A3
A4
A4
A4
A4
A45A4A45
A45A5A45
A5
A5
A5A5A6
Dimensioni in mm / (1) can change for different brands
N° HA HB HE HF HG HH HL HP
weight (kg)
245 381 1143 114 1080 95 19 114 32 50
252 457 1321 152 1257 105 19 114 32 65
258 533 1473 191 1410 121 25 114 32 85
264 533 1626 191 1562 121 25 114 32 95
268 660 1727 241 1664 121 25 114 32 110
280 660 2032 241 1664 121 25 165 32 125
368 660 1727 241 1664 121 25 165 32 140
380 660 2032 241 1969 121 25 165 32 150
398 660 2489 241 2426 121 25 165 32 190
Dimension in mm
°C
m
%
m
3
/h
w.o.
The INSTRUCTION MANUAL must be delivered to the pump-user , who
takes diligent note of it, fills in data for Maintenance Department (page
1), keeps the file for subsequent reference.Possible modifications do not
imply updating of the existing manuals
© Copyright 2008 - ARGAL srl
Draw and text total or partial duplication is
prohibited
MANUFACTURER DATA
CONTRACTUAL DATA
medium
conc.
capacity
temperature
head
REV.8 - 02/16
Magnatex Pumps, Inc.
3375 West 12th Street, Houston, TX, 77008
Toll Free: 866.MAG.PUMP
Phone: 713.972.8666
Fax: 713.972.8665
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