Watson-Marlow EC 25 User Manual
Manual - Technical Documentation
ATEX
Watson-Marlow MasoSine - Pumps
EC 25 / EC 40 / EC 60
Revision 4.4 / November 2010 1
Content
Technical datasheet ........................................................................................................................................4
1 GENERAL ............................................................................................................ 5
2 PURPOSE ............................................................................................................ 5
3 FUNCTIONING PRINCIPLE................................................................................. 5
4 SAFETY INSTRUCTIONS.................................................................................... 5
4.1 Basic safety instructions......................................................................................................................5
4.2 Safety symbols ...................................................................................................................................5
4.3 Obligation of the operator....................................................................................................................5
4.4 Organizational measures ....................................................................................................................5
4.5 Obligation of the personnel .................................................................................................................6
4.6 Training of the personnel ....................................................................................................................6
4.7 Informal safety measures....................................................................................................................6
4.8 Dangers when handling the machine..................................................................................................6
4.9 Safety measures in normal operation .................................................................................................6
4.10 Protective devices ...............................................................................................................................6
4.11 Dangers due to hazardous pumped material......................................................................................6
4.12 Dangers due to electrical energy ........................................................................................................6
4.13 Dangers due to hydraulic energy ........................................................................................................6
4.14 Special danger points..........................................................................................................................6
4.15 Constructional changes to the machine..............................................................................................7
4.16 Noise of the machine ..........................................................................................................................7
4.17 Maintenance and repair, troubleshooting............................................................................................7
4.18 Maintenance of the bearings...............................................................................................................7
4.19 Cleaning the machine .........................................................................................................................7
4.20 Faults...................................................................................................................................................7
4.21 Use as intended ..................................................................................................................................7
5 SAFETY INSTRUCTIONS (ATEX)....................................................................... 7
5.1 Safety signs.........................................................................................................................................7
5.2 Pump classification .............................................................................................................................7
5.3 Zone classification...............................................................................................................................8
5.4 Classification of the ex-atmospheres ..................................................................................................8
5.5 Ignition protection ................................................................................................................................8
5.6 Temperature classes...........................................................................................................................8
5.7 Limit values for the pump ....................................................................................................................8
5.8 Grounding the pump ...........................................................................................................................8
5.9 Material properties ..............................................................................................................................8
5.10 Pressure Conditions............................................................................................................................8
5.11 Maintenance / Repair ..........................................................................................................................9
5.12 Cleaning ..............................................................................................................................................9
5.13 Medium to be pumped ........................................................................................................................9
5.14 Coupling ..............................................................................................................................................9
5.15 Drive ....................................................................................................................................................9
6 WARRANTY AND LIABILITY.............................................................................. 9
7 TRANSPORT INSTRUCTIONS ........................................................................... 9
8 INSTALLATION ................................................................................................. 10
9 CONNECTION TO THE PIPING ........................................................................ 10
10 POSSIBLE CONNECTION POSITIONS ......................................................... 10
Revision 4.4 / November 2010 2
11 CHANGING THE CONNECTION POSITION.................................................. 11
12 CHANGING THE DIRECTION OF ROTATION............................................... 11
13 IMPORTANT: OBSERVE BEFORE START-UP!............................................ 11
14 CLEANING ...................................................................................................... 12
14.1 Cleaning in own circuit with water, alkali, acid ..................................................................................12
14.2 Cleaning in the CIP circuit.................................................................................................................12
14.3 Manual cleaning ................................................................................................................................12
14.4 Sterilization........................................................................................................................................12
15 OIL CHANGE .................................................................................................. 13
15.1 Filling volumes ..................................................................................................................................13
16 DISPOSAL ...................................................................................................... 13
17 SPARE PARTS ............................................................................................... 13
18 TAKING OUT OF SERVICE............................................................................ 13
18.1 Provisional taking out of service .......................................................................................................13
18.2 Final putting out of service ................................................................................................................13
19 TROUBLESHOOTING .................................................................................... 14
20 ADJUSTING DIMENSION............................................................................... 15
21 TIGHTENING TORQUES ................................................................................ 16
22 DISMANTLING ............................................................................................... 17
23 DISMANTLING „LIP SEAL SYSTEM“ ........................................................... 19
24 DISMANTLING „MECHANICAL SEAL SYSTEM“ ......................................... 20
25 ASSEMBLY..................................................................................................... 21
25.1 Assembly „Rotor-Assembly“..............................................................................................................21
26 PUMP SIZES ................................................................................................... 22
26.1 Cross section drawing EC 25 with Lip Seal System.........................................................................22
26.2 Cross section drawing EC 25 Mechanical Seal System ...................................................................22
26.3 Cross section drawing EC 40 with Lip Seal System.........................................................................23
26.4 Cross section drawing EC 40 with Mechanical Seal System............................................................23
26.5 Cross section drawing EC 60 with Lip Seal System.........................................................................24
26.6 Cross section drawing EC 60 with Mechanical Seal System............................................................24
26.7 Parts list for an EC 25 / EC 40 / EC 60 Pump...................................................................................25
26.8 Parts list for the Lip Seal System EC 25 / EC 40 / EC 60.................................................................25
26.9 Parts list for the Mechanical Seal System EC 25 / EC 40 / EC 60 ...................................................25
27 CODE-STRUCTURE FOR SPARE PART ORDERS ...................................... 26
28 DIMENSIONAL DRAWINGS........................................................................... 27
28.1 Dimension table for pump with German Milk Fittings .......................................................................27
28.2 Dimension table for pump with TRI-CLAMP (TC).............................................................................28
28.3 Dimension table for pump with RJT ..................................................................................................28
28.4 Dimension table for pump with SMS (Swedish norm) ......................................................................28
28.5 Dimension table for pump with SMS (French norm).........................................................................28
Revision 4.4 / November 2010 3
Technical datasheet
Please remove all technical information from the technical Data Sheet.
For spare parts ordering refer to software component list.
If you have problems to identify parts, please refer the drawing and parts list. In case of any questions
please contact the Technical Support
Revision 4.4 / November 2010 4
1 General
The operating instructions apply for the Watson-Marlow MasoSine:
EC 25 / EC 40 / EC 60
The operating instructions must be read before installing the pumps. Please observe the safety instructions and the safety
regulations.
2 Purpose
The purpose of your pump is defined exactly in the delivery note. The warranty becomes null and void following any changes to
the purpose, including changes to components and materials.
Always consult the manufacturer before any changes are to be made to the pump, its components or application.
3 Functioning principle
The functioning principle of the Watson-Marlow MasoSine Pump is ingeniously simple. The pump consists of modular
components to allow for easy assembly, disassembly and in-line maintenance, preventing the need to return the pump for
factory repair. The MASO-Sine pump’s exclusive sinusoidal rotor creates four symmetrical pumping chambers that draw product
through the pump. As product is drawn through in a continuous flow, it encounters the scrapergate and is discharged by product
flowing behind it creating a continuos pulse-free laminar flow. The MASO-Sine pump’s large pumping chambers maintain
constant volumetric displacement throughout the entire pumping cycle that eliminates product compression and minimizes
damage to large particles.
4 Safety instructions
4.1 Basic safety instructions
Failure to follow these safety instructions may result in damage to property, personal injury or death.
A basic requirement for safe handling and troublefree operation of this machine is knowledge of the basic safety instructions and
practice of the safety regulations.
These operating instructions contain the most important instructions to operate the machine safely.
These operating instructions, especially the safety instructions, must be observed by all persons who work on the machine.
Moreover the rules and regulations for accident prevention applicable at the place of use must be complied with.
The following safety instructions must be observed absolutely.
They are an essential and indispensable part of the user documentation. Non-compliance can result in loss of warranty claims.
It is recommended in the interest of all involved to enter all installation measures, maintenance, fault and repair cases, training
courses, instructions and special occurrences in a logbook assigned to the machine.
4.2 Safety symbols
Safety instructions that must be followed. Failure to comply with these instructions may result in damage
to property, personal injury or death.
Safety instruction for electrical voltage. Failure to comply with these instructions may result in damage to
property, personal injury or death.
CCAAUUTTIIOONN
Safety instruction to prevent damage to the pump or system.
4.3 Obligation of the operator
Only persons who are familiar with the basic regulations concerning working safety and accident prevention, have read and
understand this manual, and are instructed in handling the MASO-Sine pump are to be allowed to on or with the machine.
The safety-conscious working of the personnel should be checked at regular intervals.
4.4 Organizational measures
Any required personal protective equipment shall be provided by the operator.
All existing safety devices shall be checked regularly.
Revision 4.4 / November 2010 5
4.5 Obligation of the personnel
All persons who are authorized to work with or on the machine obligate themselves to observe the basic regulations concerning
working safety and accident prevention before starting work. All persons to read and understand the safety chapter and warning
notes in the operating instructions and to confirm by their signature that they have understood these. If there are any questions
regarding this manual or the proper use and maintaining of the MASO-Sine pump, contact the factory before use..
4.6 Training of the personnel
Only trained and instructed personnel may work with or on the machine. The responsibilities of the personnel shall be defined
clearly for assembly, disassembly, start-up, operation, maintenance and repair.
Personnel under training may work on the machine only under supervision of an experienced person.
4.7 Informal safety measures
The operating instructions must be kept on file and be made readily available to all persons who work with or on the MASO-Sine
pump. The generally valid as well as the local regulations for accident prevention and environmental protection shall be provided
and observed in addition to the operating instructions. All safety and danger warnings on the machine shall be kept in legible
condition. Contact the factory if additional manuals are required.
4.8 Dangers when handling the machine
The Watson-Marlow MasoSine Pump is built according to the state of the art and the recognized safety engineering rules at
the time of manufacture. Danger to life and limb of the user or other persons or impairments to the machine or to other assets
can arise if safety instructions are not followed.
The machine must be used only:
• for the intended use delivery note
• in perfect safety engineering condition.
Faults which can impair safety must be rectified immediately.
4.9 Safety measures in normal operation
Operate the machine only if all safety devices are fully functioning. Before switching the machine on make sure that the starting
machine can endanger no one. At least once per shift inspect the machine for “externally detectable damage” and for
functioning of the safety devices.
4.10 Protective devices
All protective devices must be attached correctly and functioning before every start-up.
Protective devices may be removed only
- After standstill and simultaneous protection against restarting the machine. Always follow proper LOCKOUT – TAGOUT
procedures.
- The pump is not under pressure.
- All components are allowed to reach a comfortable temperature.
4.11 Dangers due to hazardous pumped material
In the case of hazardous pumped material as defined by MSDS, the corresponding regulations must be followed.
4.12 Dangers due to electrical energy
Follow proper LOCKOUT – TAGOUT procedures before handling electrical components.
Have work on the electrical supply performed only by a qualified electrician.
Check the electrical equipment of the machine regularly. Rectify loose connections and scorched cables
immediately.
Keep the control cabinet closed always. Access is allowed only to authorized personnel
Only qualified personnel should handle electrical components.
4.13 Dangers due to hydraulic energy
Only personnel with special knowledge and experience in hydraulics may work on hydraulic devices.
Relieve the pressure in system sections and pressure lines to be opened before starting repair work. Replace hydraulic hose
lines at appropriate intervals, even if no safety-relevant defects are detectable.
4.14 Special danger points
This pump and equipment utilize rotating components that may pose
potential injury. The user must protect the pump so that there is no
exposure to rotating components. In the case of work on the stationary
rotor, the drive must be secured against unintentional switching on.
Follow proper LOCKOUT – TAGOUT procedures. Increased danger
exists with dismantled pipes and opened pump.
Revision 4.4 / November 2010 6
4.15 Constructional changes to the machine
Make no changes, attachments or conversions to the machine without prior written approval of the manufacturer. All conversion
measures require the written approval of the Watson-Marlow MasoSine Company. Damaged or improperly functioning parts
should be immediately replaced. Use only original MASO-Sine parts. Use of parts not supplied by MASO-Sine or other
aftermarket parts will void all warranties. Aftermarket parts are not authorized by Watson-Marlow MasoSine and void all
certifications such as 3-A, USDA and FDA.
4.16 Noise of the machine
The continuous sound level proceeding from the pump is less than 70 dB(A). A higher sound pressure level that causes noise
deafness can arise depending upon the local conditions. In this case protect the operating personnel with corresponding
protective equipment / protective measures.
4.17 Maintenance and repair, troubleshooting
Perform specified adjustment, maintenance and inspection work in a timely manor to prevent possible damage. Inform operating
personnel before starting the maintenance and repair work. Protect all plant parts and operating media connected before and
after the machine such as compressed air and hydraulics and similar against unintentional start-up. Follow proper LOCKOUT –
TAGOUT procedures before performing any maintenance. In all maintenance, inspection and repair work switch
the machine free of voltage and secure the main switch against unexpected starting. Fasten and secure larger
assemblies on replacement carefully to lifting gear. Be sure all fasteners are tightened to proper specifications. Use
only original spare parts.
After ending the maintenance work check the safety devices for function.
4.18 Maintenance of the bearings
• For pumps in series, EC 25 and EC 40 both bearings must be replaced by new ones after running for 10,000 hours!
• For pumps in series EC 60, please refer to the enclosed table:
200 rpm 400 rpm 600 rpm
3 bar
6 bar
4.19 Cleaning the machine
Handle substances and materials used correctly, especially
- when working on lubricating systems
- when cleaning with solvents.
10000 hours
9199 hours 6133 hours
4.20 Faults
In the case of operating faults switch off the machine and secure it against unauthorized or inadvertent starting up again.
4.21 Use as intended
The accurate intention is listed in the order confirmation. Another use or use going beyond this is not as intended.
If you want to change the product, the pressure, the speed or the temperature, you must firstly consult us or one of our
representatives.
5 Safety instructions (ATEX)
Watson-Marlow MasoSine - Pump used in production machinery with explosive mixtures will be equipped accordingly in the
factory.
5.1 Safety signs
Grounding symbol
5.2 Pump classification
The pumps are only designed for jobs lasting several days and are therefore assigned to the Device Group II – Application field
“dust – or gas – explosive areas”!
Revision 4.4 / November 2010 7
5.3 Zone classification
The Watson-Marlow MasoSine - Pumps can be used in explosive areas of the zone 1 / 21.
This corresponds to the category 2 G / D.
It is expressly forbidden to use the pump(s) in the zone 0!
5.4 Classification of the ex-atmospheres
A distinction is made between dust and gas explosive atmospheres. In the model code, the atmosphere is abbreviated with G
(Gas) and D (Dust). Watson-Marlow MasoSine - Pumps are only designed for the explosive atmospheres G (Gas) and D
(Dust)!
5.5 Ignition protection
Our pumps are subject to ignition protection "c" constructive safety according to the standard for "non-electric appliances for use
in explosion-risk areas" EN 13463-5
5.6 Temperature classes
For product temperature up to max. 95°C: EX II 2 G c T4
EX II 2 D c T=120°C
5.7 Limit values for the pump
The limit values for the pump (max. speed, max. pressure, max. temperature) are stated in the data sheet (see page 4). These
limit values must never be exceeded under any circumstances! This applies in particular when using a frequency converter.
If the pumps are supplied without a drive, the following values apply!
EC25 EC40 EC60
max. Pressure * 6 bar 6 bar 6 bar
max. Speed * 600 rpm 600 rpm 600 rpm
max. Temperature *
95°C* 95°C* 95°C*
Ambient temperature -12°C bis +40°C -12°C bis +40°C -12°C bis +40°C
* depending on the rating of the pump (pls. see order confirmation)
5.8 Grounding the pump
All supplied pumps are equipped with a grounding option.
In particular in ex-areas, the pump must be grounded by fixing a grounding cable to the corresponding position (see diagram).
In addition to the grounding of the pump, the motor also needs to be grounded! If the drive is not grounded, the pump aggregate
may not be operated.
Grounding
5.9 Material properties
Plastic parts that are fitted inside the pump react more to temperature changes that stainless steel parts. For this reason, the
specified maximum medium temperature (Tm=95°C), for which the pump is designed, may not be exceeded. If the specified
temperature is exceeded, this may cause a linear expansion and may block single components; this in turn could cause the
pump to fail or could result in damage to parts of the pump. Also, excessive temperatures can accelerate the wear of dynamic
parts and therefore reduce the lifespan of the plastic parts.
Corrosion may occur to the Power Frame of the pump if the paintwork is damaged. Corrosion represents a hazard for the use of
pumps in explosive areas (for measures, see Troubleshooting Chap. 21).
5.10 Pressure Conditions
To avoid any over-pressure in the pump as a result of a closed pressure line, a pressure controller must be installed.
Revision 4.4 / November 2010 8
5.11 Maintenance / Repair
• The Filling of the pump is only permitted outside the explosion aria. Tools that are used should in compliance with
ATEX.
• The pump aggregate always needs to be kept clean of dust with a damp cloth to prevent the dust from smouldering.
• The rinsing channels in the power frame must always be checked for blockages and if necessary cleaned.
5.12 Cleaning
Caution! No solvent cleaning agents may be used to clean the pump as this could create an uncontrollable explosive
atmosphere.
5.13 Medium to be pumped
Chemicals that are combustible below the temperature 120 degrees Celsius (T4/T=120°C) and Carbon disulphide must not be
pumped.
5.14 Coupling
If the pump is used in an explosion-risk area, the pump must only be coupled to the drive by means of an elastic, positive
coupling with ATEX certification, at least corresponding to the supplied pump. Chains, toothed belts, v-belts or similar equipment
which may transmit radial forces on the bearings should not be used.
5.15 Drive
Any preceding reduction gears and/or control units must have the corresponding ATEX certification, at least corresponding to
the supplied pump. Combustion engines must never be used!
For operation with a frequency converter, this must either be installed outside the ex-zone, or have the same ATEX certification
corresponding to the delivered pump. In any case the converter must have the properties required for operation in ex-zones, for
example, temperature monitoring, speed limitation, etc.
6 Warranty and liability
Basically our “General sales and delivery conditions” apply.
These are available to the operator at the latest since conclusion of the contract.
Warranty and liability claims for personal and material damage are excluded if they are attributable to one or several of the
following causes:
- Use of the machine not as intended
- Incorrect installation, operation and maintenance of the machine
- Operating the machine with defective safety devices or not correctly attached or not functioning safety and protective
- Non-compliance with the instructions in the operating instructions regarding
transport,
storage,
installation,
start-up,
operation, maintenance and setting of the machine.
- Unauthorized constructional changes to the machine
- Insufficient monitoring of machine parts subject to wear
- Incorrectly performed repairs
- Cases of catastrophe due to effect of foreign bodies and acts of God.
Watson-Marlow MasoSine grants no warranty on this documentation as well as no implicit warranties on commercially
customary quality and suitability for a certain application.
Watson-Marlow MasoSine undertakes no liability for errors contained in it or consequential damage occurring by chance
arising due to the design, performance and the use of this documentation.
This publication contains own information protected by copyright. All rights are reserved.
This publication may be neither photocopied, nor duplicated nor translated without previous agreement of Watson-Marlow
MasoSine. Rights reserved to make changes in these operating instructions.
devices
7 Transport instructions
The choice of the means of transport is according to the size of the pump and of the drive. The pump must be suspended
correctly for transport. The crane/forklift truck and the ropes/belts must be sufficiently dimensioned. If the pump is transported
with a lift truck or a forklift truck, it must be noted that the console centre point is not automatically the centre of gravity.
Wrong! Rright!
Revision 4.4 / November 2010 9
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