Sondermann MAGSON MAS Type 4, MAGSON MAS Type 5, MAGSON MAS Series, MAGSON MAS Type 6 Operating Manual

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MAGSON magnetically coupled self-priming

centrifugal pumps

MAS types 4-6

Operating Manual

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Table of Contents

1. Declaration of conformity ......................................................... 5

2. Basic information ...................................................................... 7

2.1 Notes on the operating manual ................................................................. 7

2.2 Validity of data ......................................................................................... 7

2.3 Purpose ................................................................................................... 7

2.4 Use to the intended purpose ..................................................................... 7

2.5 Anticipated misuse .................................................................................... 8

2.6 Limits of use ............................................................................................ 8

2.7 Warranty and liability ................................................................................ 8

2.8 Contact details ......................................................................................... 8

3. Safety ........................................................................................ 9

3.1 Standards and directives ........................................................................... 9

3.2 Depiction of safety instructions ................................................................ 10

3.3 Symbols used ......................................................................................... 10

4. Technical Information............................................................. 11

4.1 General description ................................................................................. 11

4.2 Nameplate ............................................................................................. 11

4.3 Types MAGSON MAS ............................................................................... 11

4.4 Type codes and materials........................................................................ 12

4.5 Structure of MAGSON MAS ...................................................................... 14

5. Transport and temporary storage .......................................... 15

5.1 Safety instruction.................................................................................... 15

5.2 Transport ............................................................................................... 15

5.3 Temporary storage ................................................................................. 15

6. Installation .............................................................................. 15

6.1 Safety precautions .................................................................................. 15

6.2 Installation requirements ........................................................................ 15

6.3 Installation ............................................................................................. 16

6.3.1 Hose and pipe lines ...................................................................... 16

6.3.2 Suction line .................................................................................. 17

6.3.3 Discharge line .............................................................................. 17

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6.3.4 Flange or threaded connections..................................................... 18

6.3.5 Electrical connection ..................................................................... 19

6.3.6 Controlli ng the direction of rotation ............................. .................. 20

7. Putting into operation ............................................................. 21

7.1 Safety precautions .................................................................................. 21

7.2 Preparatory work .................................................................................... 21

7.3 Putting into operation ........................................................................... .. 22

7.4 Possible malfunction when putting the pump into operation .......... ............ 22

8. Shut-down procedure ............................................................. 23

9. Service and maintenance ........................................................ 24

9.1 Safety precautions .................................................................................. 24

9.2 General information ................................................................................ 24

9.3 Preventive maintenance .......................................................................... 25

9.3.1 Overall pump ............................................................................... 25

9.3.2 Wearing parts .............................................................................. 25

9.3.3 Motor .......................................................................................... 26

9.3.4 Static O-ring seals ........................................................................ 26

9.4 Dismantling and replacing the motor ....................................................... 27

9.5 Dismantling the pump head .................................................................... 27

9.6 Disassembling the pump head ................................................................. 28

9.7 Assembling the pump ............................................................................. 29

10. Troubleshooting ...................................................................... 30

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Appendix ........................................................................................... 32

A) Technical data of MAS BG 4 - 6 ............................................................... 32

B) Exploded view MAS BG 4......................................................................... 35

C) Exploded view MAS BG 5......................................................................... 37

D) Exploded view MAS BG 6; 2.2 kW ............................................................ 39

E) Exploded view MAS BG 6; 3.0 – 4.0 kW .................................................. 41

F) Sicherheitshinweis Elektromotor .............................................................. 43

G) Declaration of decontamination ............................................................... 44

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1. Declaration of conformity

Hausanschrift/Office: Postanschrift/Post address: Telefon/Phone: (02203) 9394-0 Bankverbindung/Bank Account: IBAN August-Horch-Str. 2 Postfach/P.O.Box 92 01 01 Telefax/Fax: (02203) 9394-48 Stadtsparkasse Köln Kto. 30 02 425 (BLZ 370 501 98) DE94 3705 0198 0003 0024 25 D-51149 Köln D-51151 Köln Dresdner Bank AG, Köln Kto. 3 739 958 (BLZ 370 800 40) DE52 3708 0040 0373 9958 00

e-mail: [email protected] - Internet: http:// www.sondermann.com Geschäftsführer/Managing Dir.: Klaus Hahn, HRA Köln 1739 - Sitz der Ges.: Köln - Registered Office: Köln - Ust-IdNr./V.A.T.-id.-No.: DE122907251

EC Declaration of Conformity

pursuant to the EC Machinery Directive 2006/42/EC, Annex II 1. A

Manufacturer:

S O N D E R M A N N Pumpen + Filter GmbH & Co. KG August-Horch-Str. 2 D - 51149 Köln

Description and identification of the machine:

Product: Centrifugal pump Type: MAGSON, series MA(S), MM, MPL, MPLN, MPT Trade name: Magnetically coupled (self-priming) centrifugal pump,in horizontal alignment Function: Pumps of the MAGSON series are designed to operate as centrifugal pumps

and are used to pump liquids.

It is explicitly stated that the machine corresponds to all relevant provisions of the following EC Directives:

2006/42/EC Directive 2006/42/EC of the European Parliament and the European Council

from 17 May 2006 concerning machinery and the amendment to the 95/16/EC Directive (new version) (1)

2014/30/EU Directive 2014/30/EU of the European Parliament and of the Council of 26

February 2014 on the harmonisation of the laws of the Member States relating to electromagnetic compatibility (recast)

Source of applied harmonised standards according to Article 7 Paragraph 2: Type A standard

EN ISO 12100:2010-11 Safety of machinery - General principles for design - Risk assessment and risk

reduction (ISO 12100:2010)

Type B standard EN ISO 13732-1:2008 Ergonomic of the thermal environment – Methods for the

assessment of human responses to contact with surfaces – Part 1: Hot surfaces (ISO 13732-1:2008)

EN 1032:2003+A1:2008 Mechanical vibration – Testing of mobile machinery in order to determine the

vibration emission value

EN 60204-1:2006/AC:2010 Safety of machinery – Electrical equipment of machines – Part 1: General

requirements

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Type C standard 809:1998+A1:2009/AC:2010 Pumps and pump units for liquids – Common safety requirements

Standard

EN 61000-6-4:2007/A1:2011 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards; Emission

standards for industrial environments

EN 61000-6-2:2005/AC:2005 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity

for industrial environments EN 60034-1:2010/AC:2010 Rotating electrical machines – Part 1: Rating and performance EN 60034-5/A1:2007-01 Rotating electrical machines – Part 5: Degrees of protection provided by the

integral design of rotating electrical machines (IP Code) – Classification EN 60034-6:1993-11 Rotating electrical machines – Part 6: Methods of cooling (IC Code) EN 60034-9/A1:2007-04 Rotating electrical machines – Part 9: Noise limits

Cologne, 08.01.2018

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2. Basic information

2.1 Notes on the operating manual

This operating manual has been prepared to meet all product-specific and user-related requirements of the law and of all relevant re gulat ions and rules, technical standards, directives and agreements.

The manual includes important information on the funct ioning of M AGSON magnetically coupled centrif ugal pumps and how to use, install, service and dispose of them.

In the following, the ma gnetica lly coupled centrifugal pumps are refe rred to a s “pump”. Before putting the pump into operation, carefully rea d the operating manual and make

sure that it is always ready at hand to all users of the pump. Complying with a ll i nstructions of this operati ng manual is an e ssentia l prerequ isite to

guarantee the safe opera tion and maint enance of t he pump. Make sure that all operators and service technicians have fully read and understood the

manual before they sta rt working a t or with the p ump.

2.2 Validity of data

All technical data, dimensions and indications of weight etc. were valid at the day when this manual went to pre ss. Specif ication s listed here may differ from the actual desig n of the pump but will not modify any relevant informa tion in principle.

2.3 Purpose

MAGSON p umps are d esigned to function as centrifugal pumps delive ring fluids.

2.4 Use to the intended purpose

MAGSON pumps must only be used to deliver fluids of w atery viscosity without coarse solids. So the fluids meant to be delivered are

# wat er and aqueous solutions, # acid, # base (brine), # si milar fluids free of magnetizable me t al particles.

Do not use the pump to deliver

# inflammable or explosive fl uids, # solid cont aining or a brasive fluids, # fluids being used to process food because the pump has not been certified according

to FDA or EC 1935/2004 standards.

If you want to deliver solid containing or abrasive fluids, please contact the pump’s manufacturer.

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2.5 Anticipated misuse

The pump is misu sed if

# it is used other than to the intended purpose; # it is operated beyond its def ined limits; # it is used to deliver inadmissible fluids like f luids cont aining magnetiz able metal

particles or coarse contaminants, for example.

2.6 Limits of use

Dimensional limits

For dimensions of the pump see æ Dimensioned drawings in the Appendix page 32 ff. For technical data of the pump see æ Appendix page 30 ff.

Other limits

Ambient temperature 0 to 40°C for PP;

Pumps made of PP must not be operated in frost because PP will embrittle at temperatures below 0°C.

-20 to ±40°C for ETFE

2.7 Warranty and liability

The pump must only be used to the intended purpose specified by this operating ma nual. Inapp ropriate operation or insufficient service and maintenance will cancel the rig ht to all warrant y claim s.

2.8 Contact details

SONDERMANN Pumpen + Filter GmbH & Co. KG

August -Horch-Strasse 2 51149 Cologne (Porz), Germany

Phone: +49(0)2203 93940 Fax: +49(0)2203 939 448

[email protected] www.sondermann-pumpen.de

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3. Safety

Name

Contents

2006/42/EG

Directive 2006/42/EC of the European Parliamen

t and

2014/30/EU

Directive 2 014/30/EU o f the European Parliament and

Name

Contents

EN ISO 13732

1:2008

Ergonomics of the thermal environment

—

Method s for the

EN 1032:2003+A1:2008

Mecha nical vib ration

Testing of mobile machi nery

EN 61000

-6-

4:2007+

Electromagnetic comp atibility (EMC)

Part 6

EN 61000

-6-

2:2005/

Electromagnetic comp atibility (EMC)

Part 6

EN 809:1998+A1:2009 +

Pumps and pump unit s for liquid s

EN ISO 12100:2010

-11Safety of ma chinery

–

Genera l prin ciples for design

Risk

EN 60204

1:2006/

Safety of ma chinery

Electr ical equipment of machines

60034

1:2010/

Rotating electrical machines

Part 1: Rating and

EN 60034

5/A1:2007

-01Rotating electrical machines

Part 5: Degrees of protection

EN 60034

6:1993

-11Rotating electrical machines

Part 6: Methods of

EN 60034

9/A1:2007

-04Rotating electrical machines

Part 9: Noise limits

3.1 Standards and directives

of the Council of 17 May 2006 on machi nery, and amending Directive 95/16/ECG (recast) (1)

of the Council of 26 February 2014 on the harmonisation of the laws of the Member States relating to electromagnetic compatibility (recast)

Table 1: European Directives

assessment of human responses to contact with surfaces – Part 1: Hot surfaces (ISO 13732-1:2008)

in order to d etermine t he vibration emission value

A1:2011

AC:2005

AC:2010

Generic standards - Emission standard for indust rial environ ments

Generic standard s - Immunity for indu strial env ironment s

Common sa fety requi rements

assessment and risk reduction (ISO 12100:2010)

Part 1: General requi rements

performance

provided by int egral design of rotating electric al machines (IP code) – Classificat ion

cooling (IC code)

Table 2: EN Standards

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3.2 Depiction of safety instructions

Symbol

Meaning

Cross

reference such as “see chapter xx“, “see page yy“

All safety instructions of this document are marked with symbols designed on the basis of the SAFE principle. Each of them describes the kind and source of danger, possible consequenc es and information on how to avert t hem.

DANGER

The symbol warns you of a potential accident resulting from ignoring safety or other instructions. The accident will cause serious and maybe even mortal injuries or death when touching a high-voltage electrical equipment, for example.

WARNING

The symbol warns you of a potential accident resulting from ignoring safety or other instructions. The accident may cause seri ous and maybe even morta l injuries or death when touching a high-voltage electrical equipment, for example.

CAUTION

The symbol warns you of a potential accident resulting from ignoring safety or other instructions. The accident may cause slight injuries like burns, injuries of the skin and bruises, for example.

ATTENTION

The symbol warns you of a p otential material damage.

NOTE

The symbol indicates an important information.

3.3 Symbols used

Table 3: Symbols used

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4. Technical Information

4.1 General description

MAGSON type MAS magnetically co upled cent rifugal p umps are self-priming centrifugal pumps made of plast ic and bui lt in horizo ntal singl e-stage mo noblock design. A magnetic coupling connects the pump to the motor and transmits the power of the motor to the impeller. Pump housings, i mpellers, inner mag net sheaths and rea r casings are made of plastic. The rear casing hermetically seals the fluid from the ambient atmosphere. Because of magnetic power transmission, there is no need to mechanically seal the shaft. So, in contrast to mechanically or gland sealed pumps, any leakage at the shaft is completely impossible.

Pump type MAS has an integrated priming tan k whic h must b e filled with liquid b ef ore initial startup.

4.2 Nameplate

The nameplate of the pump not only specifies its operating data but also its type and serial number. Please indicate all these data when making an inquiry, reordering parts and, in particular, when ordering spare parts. Data of the electric motor are given on a separate rating plate. For further information, con tact your p ump's supplier or the manufacturer.

4.3 Types MAGSON MAS

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4.4 Type codes and materials

PPS

polyphenylene sulphide

-20to +100°C

The type code on the nameplate informs you about the p ump material s in contact with fluid.

Overview of available materials being in contact with fluid:

Component Symbol Material Temperature

PP polypropylene 0 to 70°C

All components in contact with fluid

Seals

ETFE ethylene tetrafluoride ethylene -20 to +100°C PTFE polytetrafluoroethylene -20 to +100°C

CFR-PTFE

SIC silicon carbide -20 to +100°C

Alumina aluminum oxide ceramic (99.7%) -20 to +100 °C

EPDM ethylene-propylene-diene rubber -20 to +100°C

FKM fluorinated rubber -20 to +100°C

FEP FEP-coated FKM -20 to +100°C

carbon fibre reinforced

polytetrafluoroethylene

-20 to +100°C

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NOTE

Pump housings made of PP are of dark blue colour. Pump housings made of ETFE are of black colour and marked with a yellow

sticker.

WARNING Danger of chemical non-resistance of components

# Make sure that the materials u sed for making the pump are resistant to the fluid( s) delivered. # Chemical non-resistance may result in leakage of fluid. # Potential danger to the environment and health. # In case of doubt, please con tact the pump’s manufacturer.

NOTE

For the chemical resistance of materials, please request the material resistance list of the pump’s manufacturer.

ETFE

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4.5 Structure of MAGSON MAS

Abb. 1: Structure of MAS BG 5

1 Pump casing 2 Shaft mounting 3 Impeller magnet 4 Casing-O-Ring 5 Rear casing with shaft 6 Mounting flange 7 Bracket with base 8 Outer magnet 9 Motor 10 Lose flange 11 Filling plug 12 Drain plug

Picture shows a MAS BG 5. Other sizes may differ, please refer spare part drawing within appendix

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5. Transport and temporary storage

5.1 Safety instruction

WARNING Danger of getting jammed or bruised during transport of the pump

# Make sure to use lifting devices sui table to the wei ght of the pump. # Do not remove the lifting device before you have put down the pump safel y.

5.2 Transport

1. Unpack the pump or unit upon receipt and che ck it for damage in trans it.

2. In case of damage in transit, make sure to have the carrier draw up and sign the damage report document.

3. Make sure that the information of the namep late corre sponds with the specifications and dimensions of the purchase order.

4. The packag ing material has to be disp osed of acco rding to lo cal regu lations.

5.3 Temporary storage

The pump must only be stored at a dry place free of frost. When storing the pump, protect it against any contaminants getting in.

6. Installation

6.1 Safety precautions

WARNING Danger of getting jammed or brui sed d uring installation of the pump

# If necessary, use lifting and holding d evices suitable to the size and weight of the pump. # Make sure that all installation w o rk is done by competent and qualifi ed personnel only.

WARNING Danger of being hit by falling components

# If necessary, use lifting and holding d evices suitable to the size and weight of the pump. # Make sure that all installation w o rk is done by competent and qualifi ed personnel only.

6.2 Installation requirements

Install the pump at a place that allows you easy access at any time. The limit values of Ambie nt temperature is as follow s: 0 to +40°C for pumps of PP;

-20 to +40°C for pumps of ETFE.

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6.3 Installation

Install

the pump in a horizontal

position. For any other installation position, plea se contact the manufacturer.

2. Remove all covers and caps from the flang es before i nstalling the pump.

3. The Pump is self-p ri mi ng. There fore it can b e placed above liquid level.

4. Max. suction height is 5 mWc (Water @ 20°C)!

Maximum s uction height depends on the fluid to be handled. It may change due to:

# Fric tion lo sses in suc tion pipe # Higher temperature of the fluid # Higher density and/or visco sity # Low er boiling t emperature

WARNING Make sure all bolting’s at suction pipe are vacuum tight! In case of leaky suction pipe the suction capacity of the pump can be reduced or pump

fails!

Make sure t hat the pump does not d raw in impurit ies when prim ing.

6.3.1 Hose and pipe lines

5. All pipe line d iameter s should be sufficiently la rge. The speed within the suction pipe should be between 1 and 2m/s; speed within the discharge pipe should not exceed 3m/s. Pipe diameters have to be at least the size of the suction and discharge ports.

6. All suction and discharge p ipes to t he pump housing shou ld be free of tensi le stress.

7. If necessary, instal l expansion joint s at the p ipes to c ompensat e excess ive tension due to the pipe’s thermal expansion.

8. Avoid bending radii of less tha n 1.5 times the nominal pipe size.

9. Also avoid sharp changes in diamet ers withi n the piping .

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6.3.2 Suction line

ATTENTION Risk of damaging the pump by cavitation

When installing the suction line, make sure to meet the NSPH value given in the æ Appendix page 32 foll.. If the NPSH fal ls below this value, there will be cavitation result ing in running noise, drumming and vibration of the pump.

We do not prov ide warranty for any damage to the pump caused by cavitation!

10. The suction pipe or hose should be made of a material that will not deform or distort by vacuum or higher temperatures. The suct ion line also should be as short as possibl e, its installati on preventing an y gas accumu lation.

11. When d imensioning pip elines, fittings etc., ma ke sure t o keep t he flow resi stances as low as possible.

12. Provide for a straight st eadying sectio n of at least 5 times t he nominal diameter before the suction port.

13. Suction lines have to be vacuum-sealed because penetrating air causes malfunction and may result in damag e to the p ump.

14. Make sure that the flow rate in the suction line installed does not exceed 1m/s.

15. Protect the pump against dry-r unning by installing adequate equipment (optionally available).

16. For easy installation and removal of the pump, a shut-off valve (but no diaphragm valve) should be built into t he suction line.

NOTE

Do not us e the shut- off valve of the sucti on line to adjust the de livery ra te!

6.3.3 Discharge line

Standard flow rat e of the discharge line is 3m /s. Discha rge pipe should go straig ht upwards (approx. 500 mm) to avoid liqu id losses d uring

suction procedure. We recommend installing a control element to adjust the flow rate of the discharge line.

ATTENTION Damaging of the pump housing by pr essure jerks

Do not install any quick-acting stop valves to the pipelin es!

To measure working conditions , you bett er install a manome ter between the discharge port of the pump and the throttle valve as well as a volume flow meter, if necessary.

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6.3.4 Flange or threaded connections

MAGSON MAS pumps of types BG4 to BG6 are

Replacin

g a flange by a threaded

equipped wit h slip-on flanges a s standard features. The rotating flange allows you to easily connect the pump wit hout considering the a ngular position of t he mating flange. Do not use hard material to seal the flange but appropriate elastomer se als.

adapter

Alternatively yo u can use an in sert fitting and spigot nut to connect the pump. To do so, you have to replace the screwed flange by the attached threaded adapter as follows:

1. Take the slip-on flange off the flange fixture using a rubber mallet.

2. Use a strap wrench to unscrew the flange fixture. Take the O-ring off the fixture and put it into the (inner thread) of the threaded adapter.

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3. Screw the threaded adapter to the pump hou sing using t he strap wrench. Make sure that the O-ring fits exactly into the groove of the inner thread.

6.3.5 Electrical con nection

NOTE

Qualified personnel only are allowed to conne ct the pump to the electrical mains. All electrical connections and the installation of additional protection devices has to be done in accordance

with the regulations of your local power supplier and the VDE Association of German Electrical Engineers.

Before working on the terminal box of the pump, the power supply must have been cut off for at least 5 minutes.

17. Make sure that the power supply available corresponds to the data of the nameplate.

18. Connect t he motor according to the following schematic attached to the termina l box:

19. As standard features, all three-phase AC motors have PTC resistors to monitor the winding temperature. To operate the pump with frequency converter, also connect the PTC resistors.

20. All AC motors have a thermal sensor as standard feature which also has to be connected.

21. Do not operate any AC motor without circuit-breaker!

NOTE

Please ask the manufacturer for additional motor protection devices.

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6.3.6 Controlling the direction of rotation

Detach filling

plug at pump casing a

ndfill

Filling amount

MAS BG

4 13/115

2,7

Liter

MAS BG

5 17/230

2,7

Liter

MAS BG

6 27/470

3,6

Liter

ATTENTION Dry-running w ill damage the pum p

Do not check the direction of rotation when there is no fluid in the pump!

1. Mind the direction of rotation indicated by an arrow on the pump. Before verifying it after the installation, fill the pump housing and suction line with water or fluid (refer item 2).

fluid into the integrated priming tank. Attach filling plug properly afterwards. Dry run of pump without fluid within integrated priming tank has to be avoided!

Filling plug

3. Then switch on and immediately off the motor to check the direction of rotation. To check whether the direction of rotation corresponds to the direction indicated by the arrow, push a piece of soft material like paper or cable tie into the slots of the fan cowl.

4. If necessary, exchange 2 phases at the terminal box to reverse the direction of rotation.

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7. Putting into operation

Detach filling

plug at pump casing and fill

7.1 Safety precautions

WARNING Danger of break ing during opera tion

Regularly check the pump for damages.

# If there is damage, the pump must not be operated! # Replace wea ring parts at regular intervals. # Do not operate the pump to other than the intende d purpose.

WARNING Risk of electrical hazards when touching parts carrying voltage by fault

# Fasten all loose connections. Immediately replace defective cables. # Always disconnect the power supply before doing any electrical work. # Cables must ne ith er be jammed nor squeezed. When lay ing cables and conn ections make sure you

cannot trip over them and they won’t be damaged.

# Check all el ectrical equipment at regular intervals according to the locally valid regulations (like the

German DGUV accident pre vention regulation 3, for example).

# Only qualified and authorized personnel are allowed to do any work at the elec trical equipment.

7.2 Preparatory work

WARNING

Danger of injuries and intoxicat ion by fluid squirting out

# Always wea r personal protective equipment when workin g at the pump.

NOTE

We recommend installing dry-running protection dev ices such as flow monitors, c ontact manome ters, differential p ressure switches or level contr ollers.

Filling plug

fluid into the integrated priming tank. Attach filling plug properly afterwards. Dry run of pump without fluid within integrated priming tank has to be avoided!

2. Check necessary torques at all screws of the flanges. Take care of vacuum tight suction pipe installation.

3. Open all valves at suct ion and discharge side completely.

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7.3 Putting into operation

1. Switch on the motor .

2. Pump starts to suck the air from suction pipe. This may take between 5 – 10 minutes depending size and length of suction pipe As soon as the suction pipe is filled completely with fluid the norma l pump operatio n starts.

3. Slowly open discharge valve to reach operation point. If no valve is installed at discharge side the op eration conditio ns will be creat ed according t o plant installation and pump performance curve.

ATTENTIO N Overheating will damage the pump!

Do not run the pump with the discharge lin e closed for a longer period of t ime. This may result in heating up the fluid inside the pump housing and damaging interior com ponents of the pump.

WARNING Hazard of pressure

# Use a manometer at the disch arge line to check the system pressure and prevent it from going beyond

its limit specified in the technical data shee t (se e Appendix).

# If the syste m pressure is t oo high, the rear casing may burst releasi ng fluid. # When press ure testing the piping, take into account the max imum system pressure, but do not test the

pump as well, if possible.

4. Check all screw joints and union pieces of the piping system for leakage.

5. Check the pump for vib ration. Ex cessive vibrat ion sugg ests cavit ation or f oreign particles in the impeller (see æ chapter 10: Troubleshooting).

6. Make sure that the power input of the motor is less than or equal to the rated current given on the motor’s nameplate. If the power input is too high, reduce the delivery rate of the pump at the discharge side or decrease the density of the fluid, if possible.

7.4 Possible malfunction when putting the pump into operation

If the motor circuit-breaker switches off the motor, proceed as follows:

7. Before switching on the motor again, check whether the impeller turns readily.

8. Make sure that the suction line a nd the pump housing are fil led with fluid.

9. Switch on the motor .

If the pump delivers for a short period of time only and then stops pumping, the magnetic coupling has been overloa ded and disengaged. In this case , follow the instructions of æ chapter 10: Troubleshooting (see page 30).

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8. Shut-down procedure

1. Switch off the motor.

2. Close the shut-off valve s.

3. When some fluid remains within the pump , secure the shut-off valves to prevent an accidental opening.

4. In case of crystallizing fluids, heat both the pump and the p iping. Protect freezing fluids against frost.

5. If the pump will be out of operation for a longer period of time, thoroughly rinse it off with a clean and neut ral liquid t o prevent remaining fluid from depositing within the pump and at the sleeve bearings.

6. Open the drain plug an the integrated priming tank and rinse the fluid. Now open filling p lug and clean the pump wit h fresh water.

7. In case the pump is shut down for repair or maintenance work, lock the driving unit so that it cannot be sw itched on. Before dismant ling the p ump, shut off the s uction and discha rge lines and empty the pump housi ng under monitored conditions.

NOTE

Secure all valves to prevent an accidental opening! Always wear personal protective equipment!

Filling plug

Drain plug

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9. Service and maintenance

9.1 Safety precautions

WARNING Risk of electrical hazards when touching parts carrying voltage by fault

# Only qualified an d authorized p ersonnel are allowed to work on motors at a stand still. The motors h ave

to be disconnected and secured against any accidental start.

# Strictly f o llow the instructions of the motor manufactur er. # Comply with the safety rules for working on ele ctrical equipment.

WARNING Hazardous magnetic fields

The magnetic fields resulting from the pump’s permanent-magnetic components will endanger persons with cardiac p acema kers.

WARNING Danger of break ing during opera tion

Regularly check the pump for damages.

# If there is damage, the pump must not be operated! # Immediately replace the corrosi on p rotection if it’s damaged. Replace wea ring parts at regular int erv als. # Do not operate the pump to other than the intende d purpose.

WARNING Risk of electrical hazards when touching parts carrying voltage by fault

cannot trip over them and they won’t be damaged.

# Check all el ectrical equipment at regular intervals according to the locally valid regulations (like the

German DGUV accident pre vention regulation 3, for example).

# Only qualified and authorized personnel are allowed to do any work at the elec trical equipment.

WARNING Risk of getting into contact wit h da ngerous substances

Before doing se rvice and maintenance work th at requires opening the pump, carefully clean the pump and rinse it off with a neutral fluid.

WARNING Danger of faulty installation and use of wrong or inadmissible spare parts

Components should be only replaced with genuine parts or spare parts authori zed by the manufactu rer.

WARNING Risk of getting into contact with hot surfaces

Before working on drive units cool down the motors and actuators or wear heat-resistant protection gloves.

9.2 General information

This pump is designed for c ontinuous operation and does not require sp ecific maintena nce. Nevertheless, we recommend doing the following p reventive ma intenance work.

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9.3 Preventive maint enance

The sleeve bearing and centering shaft

The start ing ring inside the impeller

9.3.1 Overall pump

Check the pump at reg ular interval s for

1. vibrations or unu sual noise,

2. a minimum volume flow of at least 5% of the maximum volume flow,

3. changes in normal op era ting cond itions, over heating or dry-running ,

4. leakage at the pump or piping,

5. cavitation in running,

6. open valves of the suction line and a clogged filter, if any.

9.3.2 Wearing parts

Though slee ve bearing , centering s haft and starting rings are d esigned for continuou s operation, they are subject to wear and tear as well. So check the bearings for wear and deposits at regular intervals, and replace them, if necessary.

should be replaced when they slack.

should be replaced once the grooves are no longer vis ible.

Page 26

Impeller

All spare parts are available at Sonder mann Pumpen + Filter GmbH & Co. KG. See the Appendix for the spare

Replace the impeller magnet as soon as you see signs of wear or corrosion.

Starting rings

Check them for fissures, cracks and wear.

Rear casing

Check it inside and outside for signs of wear.

O-ring

Replac e the O-ring as soo n as the ela stomer s hows signs of chemical attack, fissures or loss of elasticity.

NOTE

parts lists.

When delivering dirty, muddy or c rystallizing fluids, you should check and clean the pump at shorter intervals.

9.3.3 Motor

8. Clean the fan cowl and cooling fins once a mont h.

9. Check the power input of the motor and compare it to the rated current given on the nameplate.

9.3.4 Static O-ring seals

7. Visually in sp ect the seals for signs of wear at regula r i nterval s.

8. Replace the seal, if necessary.

NOTE

If not only wear parts are replaced, but also repair work has to be done, this should be performed by an expert only. Im proper mainten ance wor k often re sults in superfluous ex tra costs.

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9.4 Dismantling and replacing the motor

The back pull

out design

Loosen

of5nuts

atfront of pu mp

Loosen

of 3 screws on top of backside

allows you to replace the entire d rive unit wit hout dismounting the p ump. So neither the pump nor the piping has to be drained. Just loosen the 4 motor screws and pull the motor off the pump .

WARNING Danger of stro ng magnetic forces and bruises

There are strong magnetic forces inside the pump between t he inn er magnet and the driving magnet. So pu ll out the drive unit with a jerk being careful not to be bruised. Perhaps you will want to w ork in pairs.

9.5 Dismantling the pump head

1. Before dismantl ing the pump head, drain a nd careful ly rinse it.

casing.

of pump casing.

Page 28

Dismantling the pump head

Pull off the

complete

casing

(1)

Take rear casing

(4)

off the bracket

Dismantling pump head – explosion drawing

5. Pull off the impeller magnet (2)

6. Remove casing O-Ring (3)

9.6 Disassembling the pump head

Press out the sleeve bearing B of the impeller magnet C and replace it.

Press out the shaft mou nting D of the front housing E and replace it.

Use appropriate tools to press out the component s. If in doubt, ask the manufacturer to replace them.

(5)

Caution: Strong magnetic forces and risk of bruises!

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9.7 Assembling the pump

Place t he driving magnet on the motor

Screw mounting flange to bracket. Check if

Place rear casing with impeller magnet into

To reassemble t he dismantled pump, proc eed as follo ws:

shaft and align it.

Valid for motor with following power:

0,37; 0,55; 0,75; 1,1; 3,0; 4,0; 5,5 kW

Valid for motor with following power:

1,5; 2,2 kW

outer magnet can be moved easily.

Mark „V“ hast o be

placed at the bottom

bracket.

O-Ring

Caution: Strong magnetic forces and risk of bruises.

Place O-Ring at rear casing

Page 30

10. Troubleshooting

Malfunction

Cause

Elimination

The pump does not start

The impeller jams.

Check bot h the impelle r and

The magnetic coupling

The impeller jams.

Open the pump head t o

There is a loud flow noise.

Wrong direction of

Correct the motor’s direction

There is air in the

Deaerate the piping and the

Since the p ump is non

Fill the suc tion line and

The delivery rate is too

Wrong direction of

Correct the direction of

The suctio n and/or

Clear the line, open the valves.

Cavitation.

Increase the NPSH of the

There is air in the pump.

Check the suc tion line and seal

No voltage. Check the voltage.

when being switched on.

the fan blade of the motor for easy movement.

disengages.

There is a loud drumming flow noise.

The starting delivery rate is insufficient.

The relative density and/or viscosity of the fluid are too high.

The pump was switched off, then swit ched on again before the rotor stopped completely.

Cavitation. Reduce the delivery rate of the

rotation.

suction li ne or pump housing .

Reduce the delivery rate; use a stronger magnetic coupling and a more powerful motor. Reduce the impeller diameter.

Make sure that the rotor has stopped completely before you switch o n the pump again.

eliminat e the obst ruction.

discharge line. Increase the suction line diameter. Cool down the fluid. Incr ease the NPSH of the system.

of rotation.

housing .

low.

self-pri ming, both the suction li ne and the pump hou sing must be filled with fluid .

rotation.

discharge line is clogged.

housing with fluid

rotation.

system, see Ca vitatio n above.

it.

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Malfunction

Cause

Elimination

The deliv

ery rate is too

high.

Pump losses are less

Reduce the flow rate of the

Unusual mecha n ical

Damaged bearing of the

Take the mo tor off the pump

Foreign p article in the

Open the pump head to check

The pump head bearing

Open the pump head to check

Leakage between pump

The pump housing is

Make an expert dismantle the

signif icant tha n presumed.

discharge line. Reduce the impeller diameter. Use a frequency converter to adjust the motor speed.

running noise.

and motor.

motor.

pump head.

overheat s when running dry or hot.

damaged.

and check the motor b earings.

it.

it. Replace the sleeve bearing, if necessary.

pump and eliminate the fault. The pump is damaged becau se of solid s, dryrunning or overheating*.

Table 4: Troubleshooting

*) Detailed information on overheating and dry-running „Overheating“ means the excessive warming of the fluid resulting from a closed

discharge and/or suc t ion line. As the fluid cannot leave the pump, there is no exchange of fluid. The fluid remains in the pump where it p ermanently circulates and heats up. This excessive warming may cause considerable damage to the pump and its components.

To avoid an increase in temperature, the minimum flow rate must not fall below 5% of the maximum delivery rate!

If a pump is „running dry“, there is either air in the pump cha mber or the pump is not filled up with fluid. Being neither cooled nor lubricated, the sleeve bearings will overheat.

As a consequence, the p lastic mat erial of the pump will also o verheat result ing in a lea ky rear casing out of which fluid will pass.

Page 32

Appendix

A)Technical data of MAS BG 4 - 6

Tab. 5: Te chnical data of MAS BG 4

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9-01Appendix

Abb. 2: Technical drawing of MAS BG 4

Page 34

Fig. 3: performance curves MAS, measured with water @ 20°C

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9-01Appendix

B)Exploded view MAS BG 4

Page 36

Spare parts list MAS BG 4

Part no.

Quantity

Article no.

Name

Material

1011Pump casing

see technical data sheet

1451Mounting flange

Cast iro n

1611Rear casing

see technica

l data sheet

2111Shaft

aluminum

oxide

230.847

Impeller magnet

see technical data sheet

3101Sleeve bearing

SiC / PTFE

314.1

Impeller starting ring

Graphit

314.2

Starting ring of rear casing

aluminum

oxide

3451

Bracket

412.1

1O-

Ring of flange

see technical data sheet

412.2

1O-

Ring of flange

see technical data sheet

412.3

1O-

Ring Fil ling plug

see technical data sheet

412.4

1O-

Ring Draing plug

see technical data sheet

412.5

1O-

Ring of casing

see technical data sheet

5061Shaft mounting

see technical data sheet

722.1

Flange insert suction port

see technical data sheet

722.2

Flange insert discharge port

see technical data sheet

723.1

Slip-on flange suction port

see technical data

sheet

723.2

Slip-on flange discharge port

see technical data sheet

8001Elektr

motor

Aluminum

8471Outer

magnet

Cast iro n

/ferrite8921Base plate

PP (

glass

fiber

901.1

Hexagon screw

M10 x 25

901.2

Hexagon screw

M8 x

9023Stud bolt

M5A2

9042Set screw

M8 x 10

9111Filling plug

see technical data sheet

9121Drain plug

see technical data sheet

914.1

Allen screw

M6 x 12

914.2

Allen screw

M8 x 25

9205NutM6A2

ceramic 99.7%

reinforced)

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9-01Appendix

C)Exploded view MAS BG 5

Page 38

Spare parts list MAS BG 5

Part no.

Quantity

Article no.

Name

Material

1011Pump casing

see technical data sheet

1451Mounting flange

Cast iro n

1611Rear casing

see technical data sheet

2111Shaft

aluminum

oxide c eramic

230.8

471Impeller magnet

see technical data sheet

3101Sleeve bearing

SiC / PTFE

314.1

Impeller starting ring

Graphite

314.2

Starting ring of rear casing

aluminum

oxide c eramic

3451Bracket

412.1

1O-

Ring of flange

see technical data

sheet

412.2

1O-

Ring of flange

see technical data sheet

412.3

1O-

Ring Fil ling plug

see technical data sheet

412.4

1O-

Ring Dra in

g plug

see technical data sheet

412.5

1O-

Ring of casing

see technical data sheet

5061Shaft mounting

see technica

l data sheet

722.1

Flange insert suction port

see technical data sheet

722.2

Flange insert discharge port

see technical data sheet

723.1

Slip-on flange suction port

see technical data sheet

723.2

Slip-on flange discharge port

see technical

data sheet

8001Electric

motor

Aluminum

8471Outer magnet

Cast iron / ferrite

8921Base plate

PP (glass

fiber

reinforced)

901.1

Hexagon screw M10 x 25

901.2

Hexagon screw M8 x 25

9023Stud bolt M5

9042Set screw M8 x 10

9111Filling plug

see technical data sheet

9121Drain plug

see technical data sheet

914.1

Allen screw M6 x 12

914.2

Allen screw M8 x 25

9205Nut M6

99.7%

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9-01Appendix

D)Exploded view MAS BG 6; 2.2 kW

Page 40

Spare parts list MAS B G 6; 2.2 kW

Part no.

Quantity

Article no.

Name

Material

1011Pump casing

see technical data sheet

1451Mounting flange

Cast iro n

1611Rear casing

see technical data sheet

2111Shaft

aluminum

oxide c eramic

230.847

Impeller magnet

see technical data sheet

3101Sleeve bearing

SiC / PTFE

314.1

Impeller starting ring

Graphite

314.2

Starting ring of rear casing

aluminum

oxide c eramic

3451Bracket

412.1

1O-

Ring of flange

see technical data sheet

412.2

1O-

Ring of flange

see technical

data sheet

412.3

1O-

Ring Fil ling plug

see technical data sheet

412.4

1O-

Ring Dra in

g plug

see technical data sheet

412.5

1O-

Ring of casing

see technical data sheet

5061Shaft mounting

see technical data sheet

722.1

Flange insert suction p

ort

see technical data sheet

722.2

Flange insert discharge port

see technical data sheet

723.1

Slip-on flange suction port

see technical data sheet

723.2

Slip-on flange discharge port

see technical data sheet

8001Electric

motor

Aluminum

8471

Outer magnet

Cast iron / ferrite

8921Base plate

PP (glass

fiber

reinforced)

901.1

Hexagon screw M10 x 25

901.2

Hexagon screw M8 x 25

9023Stud bolt M5

9042Set screw M8 x 10

9111Filling plug

see technical data sheet

9121Drain plug

see technical data sheet

914.1

Allen screw M6 x 12

914.2

Allen screw M8 x 25

9205Nut M6

99.7%

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9-01Appendix

E) Exploded view MAS BG 6; 3.0 – 4.0 kW

Page 42

Spare parts list MAS B G 6; 3.0 – 4.0 kW

Part no.

Quantity

Article no.

Name

Materia

1011Pump casing

see technical data sheet

1451Mounting flange

Cast iro n

1611Rear casing

see technical data sheet

2111Shaft

aluminum

oxide c eramic

230.847

Impeller magnet

see technical data sheet

3101Sleeve bearing

SiC / PTFE

314.1

Impeller starting ring

Graphite

314.2

Starting ring of rear casing

aluminum

oxide c eramic

3451Bracket

412.1

1O-

Ring of flange

see technical data sheet

412.2

1O-

Ring of flange

see technical data sheet

412.3

1O-

Ring Fil li

ng plug

see technical data sheet

412.4

1O-

Ring Dra in

g plug

see technical data sheet

412.5

1O-

Ring of casing

see technical data sheet

5061Shaft mounting

see technical data sheet

722.1

Flange insert suction port

see technical data sheet

722.21

Flange insert discharge port

see technical data sheet

723.1

Slip-on flange suction port

see technical data sheet

723.2

Slip-on flange discharge port

see technical data sheet

8001Electric

motor

Aluminum

8471Outer magnet

Cast iron / ferr

ite

8921Base plate

PP (glass

fiber

reinforced)

901.1

Hexagon screw M12 x 30

901.2

Hexagon screw M8 x 25

9023Stud bolt M8

9042Set screw M8 x 10

9111Filling plug

see technical data sheet

9121Drain plug

see technical da

ta sheet

914.1

Allen screw M6 x 12

914.2

Allen screw M8 x 30

914.3

Allen screw M8 x 20

9205Nut M8

99.7%

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9-01Appendix

F) Safety infor mations electric motor

Page 44

G)Declaration of decontamination

According to various legal regula tion s on labor protection, incl uding the German Workplace Reg ulations (ArbSt ättV), Hazard ous Subst ances Reg ulations (GefSt offV) and regulations fo r the prevention of accid ents, as we ll as environme ntal regulations such as the German Waste Act (AbfG) and the Water Resources Law (WHG), all industrial and commercial enterprises are obliged to protect their employees and other persons as well as the environment from harmful i nfluences and effects when handling hazard ous substanc es.

We therefore ask you to attach a declaration of decontamination to any pump or component you send us for repair, stating that you carefully cleaned and, if necessary, thorough ly rinsed wit h neutral fluid the pump or component before you shipped it t o us. Notwithstanding the receipt of this declaration, we reserve the right to reject its repair for other reasons.

No SONDERMANN product or component of them will be accepted for service or repair unless the declaration of decontaminatio n is enclosed!

Apart from that, we do NOT accept any pump that has been operated with radioactive substances.

When sending in the pump or a component, please inform us if, despite ca refully emptying and cleaning the pump, there are still some safety precautions required.

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9-01Appendix

Declaration of Decontamination

The undersigned herewith declare that the follow ing pump and its accessories are h armless and ask you to service and/or repair it for them.

Type:

......................................................................................... ..........................

Serial num b er :

............. ... .... .... ... .... .... .... ... .... .... .... ... .... .... .... ... .... .... ..... .... .... ... .... .... ... .... ....

Date of delivery:

............. .............. ........................... ............... ................ .......................... ....

Kind of problem:

...................................................................................................................

Declaration: The pump was not used to deliver harmful or noxious substances □ but with the following fluids:

...................................................................................................................

□ Before being shipped, the pump was carefully emptied and cleaned inside and outside. □ There are no special safety precautions required. □ It is necessary to take the following safety precautions with regard to residual fluids and waste

disposal:

...................................................................................................................

Date: Signature:

Page 46

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9-01Index

Page 48

SONDERMANN Pumpen + Filter GmbH & Co. KG August-Horch-Straße 2 51149 Köln (Porz)

Phone: +49(0)2203 93940 Fax: +49(0)2203 939 448

[email protected] www.sondermann-pumpen.de

modifications BA-MAS4-6; E

This operating manual is protected by copyright and must not be copied no r transmitted or used in any form or by any means in full or in parts, unless explicitly authorized in writ ing by SONDERMANN Pumpen + Filter GmbH & Co. KG.