Watson-Marlow SPS User Manual

MASOSINE PROCESS PUMPS MANUALS

m-maso-sps-gb-04

MasoSine Process Pumps

SPS sinusoidal pumps

Contents

1	Declaration of conformity		2		13	Possible pump orientations		25
2	Declaration of incorporation		2			13.1	Changing pump orientation	25
3	Warranty and liability		3			13.2	Changing rotation direction	26
4	When you unpack your pump		4		14	Connecting this product
5	Information for returning pumps		5			to a power supply		27
6	Sinusoidal pumps—an overview		5		15	Start-up and operation		27
7	Safety notes		6		16	Flushing the seal system		28
	7.1	Obligation of the operating				16.1	Static flushing device	28
		organisation	6		17	Cleaning and sterilisation		29
	7.2	Organisational measures	6		18	Heating and cooling option		31
	7.3	Obligation of the operators	7		19	Oil change		32
	7.4	Personnel training	7		20	Troubleshooting		33
	7.5	Safety measures	7		21	SPS 200, SPS 300 and SPS 400:
	7.6	Dangers when handling the				Adjusting the shaft		35
		machine	7			21.1	Adjusting dimension X in
	7.7	Safety measures in normal					models with cast power
		operation	8				frame	35
	7.8	Protective devices	8			21.2	Adjusting dimension X
	7.9	Dangers due to hazardous					in models with stainless
		pumped material	8				steel power frame	37
	7.10	Dangers due to electrical			22	Dismantling and assembly		39
		energy	8			22.1	Dismantling all models	39
	7.11	Dangers due to hydraulic				22.2	Dismantling and
		energy	9				assembling the SPS 100	39
	7.12	Special danger points	9			22.2.1 Dismantling the SPS 100		39
	7.13	Constructional changes to				22.2.2 Assembling the SPS 100		47
		the machine	9			22.3	Dismantling and assembling
	7.14	Noise	9				the SPS 200	53
	7.15	Limit values for the pump	10			22.3.1 Dismantling the SPS 200		53
	7.16	Maintenance and repair	10			22.3.2 Assembling the SPS 200		66
	7.17	Cleaning the pump	12			22.4	Dismantling and assembling
	7.18	Faults	12				the SPS 250, SPS 300,
	7.19	Use as intended	13				SPS 400 and SPS 500	79
8	Safety notes (ATEX)		13			22.4.1 Dismantling the SPS 300
	8.1	Safety signs	13				and SPS 400	79
	8.2	Earthing the pump	14			22.4.2 Assembling the SPS 250,
	8.3	Material properties	14			SPS 300, SPS 400 and SPS 500		88
	8.4	Pressure conditions	14		23	The static flushing device		96
	8.5	Maintenance and repair	14		24	Tightening torques		102
	8.6	Cleaning the pump	15		25	Parts lists		104
	8.7	Medium to be pumped	15			25.1	Pumps	105
	8.8	Coupling	15			25.2	Seals	123
	8.9	Drive	15			25.3	Front support versions	133
9	Pump specifications		15			25.4	The flushing ring for tubing138
	9.1	Dimensions (in millimetres) 16				25.5 The static flushing device		139
10	Transport		22		26	Decontamination certificate		142
11	Installation		22		27	Trademarks		143
12	Connection to the piping		23		28	Publication history		143
	12.1	Cavitation	24
MasoSine SPS sinusoidal pumps User Manual								1

1 Declaration of conformity

This pump complies with: Machinery Directive 2006/42/EC.

2 Declaration of incorporation

When this pump unit is to be installed into a machine or is to be assembled with other machines for installations, it must not be put into service until the relevant machinery has been declared in conformity with the Machinery Directive 2006/42/ EC. See 9 Pump specifications.

Responsible person: Ulrich Fromm, General Manager, MasoSine, Postfach 100, 74358 Ilsfeld, Germany.

Telephone: [phone]. Fax: [phone].

The information in this user guide is believed to be correct at the time of publication. However, MasoSine Process Pumps accepts no liability for errors or omissions. MasoSine Process Pumps has a policy of continuous product improvement, and reserves the right to alter specifications without notice. This manual is intended for use only with the pump it was issued with. Earlier or later models may differ. The most up-to-date manuals appear on the MasoSine website: http://www.masosine.de

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3 Warranty and liability

MasoSine warrants, subject to the conditions and exceptions below, through either MasoSine, its subsidiaries, or its authorised distributors, to repair or replace free of charge the pump housing or the pump front cover if it fails within 20 years of the day of manufacture of the product. MasoSine warrants, subject to the conditions and exceptions below, through either MasoSine, its subsidiaries, or its authorised distributors, to repair or replace free of charge any other part of the product which fails within three years of the day of manufacture of the product. Such failure must have occurred because of defect in material or workmanship and not as a result of operation of the product other than in normal operation as defined in this manual.

MasoSine will not be liable for any loss, damage, or expense directly or indirectly related to or arising out of the use of its products, including damage or injury caused to other products, machinery, buildings, or property, and MasoSine will not be liable for consequential damages, including, without limitation, lost profits, loss of time, inconvenience, loss of product being pumped, and loss of production. This warranty does not obligate MasoSine to bear any costs of removal, installation, transportation, or other charges which may arise in connection with a warranty claim.

Specific exceptions to the above warranty are:

Exceptions

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 or maintenance of the machine

•Operating the machine with defective safety devices or safety and protective devices not correctly attached or not functioning

•Non-compliance with the operating instructions regarding transport, storage, installation, start-up, operation, maintenance and setting of the machine.

•Unauthorised constructional changes to the machine

•Insufficient monitoring of machine parts subject to wear

•Incorrectly performed repairs

•Catastrophe due to the effect of foreign bodies and acts of God

MasoSine grants no implicit warranties on the suitability of the products described for a certain application. Watson-Marlow MasoSine accepts no liability for errors contained in this documentation or consequential damage occurring due to the design, performance and the use of this documentation.

MasoSine’s “General sales and delivery conditions” contain full details. These are available to the purchaser at the latest when the purchase contract­ is finalised.

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4 When you unpack your pump

Unpack all parts carefully, retaining the packaging until you are sure all components are present and in good order. Check against the components supplied lists, below.

Packaging disposal

Dispose of packaging materials safely, and in accordance with regulations in your region.

Inspection

Check that all components are present. Inspect components for damage in transit. If anything is missing or damaged, contact your distributor immediately.

Components supplied (SPS 100, SPS 200, SPS 250, SPS 300, SPS 400 and SPS 500)

•SPS 100, SPS 200, SPS 300 or SPS 400 sinusoidal pump, bare-shaft, with stainless steel or cast iron power frame

•The technical datasheet identifying, describing and defining the pump

•Operating instructions

Optional items

•Coupling

•Coupling guard

•Drive

•Baseplate

Optional special design

•Flush systems

•Guard Master

•Jacketing for heating and cooling

	stainless		cast iron
	power frame		power frame
SPS 100			n/a

SPS 200

SPS 250	n/a

SPS 300

SPS 400

SPS 500			n/a

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Storage

This product has an extended shelf life. However, plastic parts and elastomeric parts should be stored in a cool, dry environment. The blue polyamide gate should be stored in cool, clean water if it will be out of use for more than four weeks. Care should be taken after storage to ensure that all parts function correctly.

5 Information for returning pumps

Equipment which has been contaminated with, or exposed to, body fluids, toxic chemicals or any other substance hazardous to health must be decontaminated before it is returned to MasoSine or its distributor.

A certificate included at the rear of these operating instructions, or signed statement, must be attached to the outside of the shipping carton. This certificate is required even if the pump is unused. See 28 Decontamination certificate.

If the pump has been used, the fluids that have been in contact with the pump and the cleaning procedure must be specified along with a statement that the equipment has been decontaminated.

If a returned pump requires cleaning, a charge will be made. Internal parts that have not been decontaminated will be replaced and a charge will be made.

6 Sinusoidal pumps—an overview

The functioning principle of MasoSine pumps is ingeniously simple.

The pump consists of modular components.

The sinusoidal rotor creates a chamber within the pump body four times per revolution, in which the pumped fluid is displaced. As a filled chamber rotates, it contracts, closes and discharges its contents. At the same time, the opposite chamber opens by the same fraction of a millimetre to draw in more fluid. The result is a pump free of pulsation.

The gate works as a seal between the pressure side and the suction side of the pump. It prevents an equalization of the pressure created by the rotor, stopping it escaping to the suction side.

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7 Safety notes

Knowledge of these safety instructions and of the safety regulations in your area is a requirement for safe handling and trouble-free operation of this machine.

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. In addition, the rules and regulations for accident prevention applicable at the place of use must be obeyed.

The following safety instructions must be observed absolutely. They are an essential and indispensable part of the user documentation. Non-compliance can result in failure of warranty claims.

It is recommended in the interests 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.

This symbol highlights a safety instruction which must be followed to avoid danger to people or to the pump.

This symbol means: Beware of high voltage.

7.1 Obligation of the operating organisation

The operating organisation must ensure that people who work on the machine are familiar with and comply with the regulations concerning working safety and accident prevention.

7.2 Organisational measures

The personal protective equipment required must be provided by the operating organisation. Safety devices must be checked regularly.

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7.3 Obligation of the operators

People who work on the machine must observe the relevant safety regulations concerning working safety and accident prevention before starting work; must read the safety chapter and the warning notes in these operating instructions.

7.4 Personnel training

Only trained people may work on the machine. Their responsibilities must be defined clearly for assembly, start-up, operation, setting, maintenance and repairing.

7.5 Safety measures

The operating instructions must be kept with the machine. General and local regulations for accident prevention and environmental protection, and the operating instructions, must be observed. Safety and danger warnings on the machine must be legible.

7.6 Dangers when handling the machine

The MasoSine pump is built according to state-of-the-art principles and the recognised safety engineering rules. Nevertheless, danger to life and limb of the user or third persons, or impairments to the machine or to other assets, can arise in its use.

The machine must be used only:

•for its intended use

•if it is in a safe engineering condition.

Faults which can impede safety must be rectified immediately.

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7.7 Safety measures in normal operation

Operate the machine only if all protective devices are functioning. Before switching the machine on make sure that no one can be endangered when the machine starts. At least once per shift inspect the machine for damage and for proper functioning of the safety devices.

7.8 Protective devices

All protective devices must be attached correctly and functioning before every startup. Protective devices may be removed only after the machine has stopped and protection measures against restarting the machine have been taken.

After spare parts have been fitted, protective devices must be attached according to the operating organisation’s regulations.

If contact with hot or cold machine parts could be dangerous, protection must be provided for the pump user.

7.9 Dangers due to hazardous pumped material

If hazardous material is to be pumped, the appropriate regulations must be observed.

7.10 Dangers due to electrical energy

Work on the electrical supply must be performed only by an electrician.

Check the electrical equipment of the machine regularly. Rectify loose connections and scorched cables immediately.

Keep the control cabinet locked closed or secured with a tool. Access is allowed only to authorised personnel.

If work on parts conducting voltage must be done, call in a second person to switch off the mains power if necessary.

Electrical connection of the pump must be made according to local regulations, by skilled personnel only.

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7.11 Dangers due to hydraulic energy

Only personnel with special knowledge and experience in hydraulics may work on hydraulic devices.

Relieve the pressure in the 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.

7.12 Special danger points

The pump contains a rotating rotor,	7
which can crush or sever fingers and
hands. The pump must be guarded so
that it is not possible for people to hold the
pump by its inlet or delivery ports with the
rotor running. When the rotor is stationary,

the drive must be secured against unintentional start-up. Increased danger exists if pipes are dismantled or the pump is open.

7.13 Constructional changes to the machine

Make no changes, attachments or conversions to the machine without the manufacturer’s approval. All conversion measures require the written confirmation of Watson-Marlow MasoSine.

Replace machine parts which are not in perfect condition immediately. Use only original spare and wearing parts. Parts not obtained from MasoSine are not guaranteed to be designed and manufactured in compliance with load and safety requirements.

The warranty is invalid if genuine spare parts from MasoSine are not used.

7.14 Noise

The continuous sound pressure level proceeding from the machine should not exceed 70 dB(A). Higher sound pressure levels that can cause deafness can arise, depending upon local conditions. If this occurs, protect the operating personnel with appropriate protective equipment / protective measures.

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7.15 Limit values for the pump

The pump’s maximum speed, maximum pressure and maximum temperature are included in the technical data sheet supplied with each pump. These limit values must not be exceeded in any circumstances. This applies in particular when using a frequency converter.

If pump is supplied without a drive, the following values apply:

		SPS 100	SPS 200	SPS 250	SPS 300	SPS 400	SPS 500
	Maximum	10 bar	10 bar	15 bar	15 bar	15 bar	15 bar
	pressure *
	Maximum	1,000 rpm 1,000 rpm 800 rpm			600 rpm	600 rpm	600 rpm
	speed *
	Maximum	100°C	100°C	100°C	100°C	100°C	100°C
	temperature *
	Ambient	-12°C to	-12°C to	-12°C to	-12°C to	-12°C to	-12°C to
	temperature	+40°C	+40°C	+40°C	+40°C	+40°C	+40°C

* These limits may be lower, depending on the drive, the application and the rating of the pump. (See your purchase order confirmation, or contact MasoSine and give your pump’s serial number.) On customer request, higher pressures are possible.

7.16 Maintenance and repair

Inform operating personnel before starting maintenance and repair work. Protect all plant parts and operating media connected before and after the machine, such as compressed air and hydraulics, against unintentional start-up. In all maintenance, inspection and repair work, switch the machine off and secure the main switch against unintentional start-up.

Secure larger assemblies carefully to lifting gear. Check loosened screw connections for firm seating. Use only original spare parts.

After maintenance work is finished, check the safety devices for function.

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Bearings maintenance

•The bearings of SPS 100 pumps must be renewed after running for the periods shown in the table below.

	200 rpm	400 rpm	600 rpm	800 rpm	1,000 rpm
5 bar	10,000 hours	10,000 hours	6,986 hours	5,239 hours	4,191 hours
10 bar	2,079 hours	1,040 hours	693 hours	520 hours	416 hours

•We recommend renewing the bearings of SPS 200 pumps with cast iron power frames after running for 10,000 hours at any pressure.

•We recommend renewing the bearings of SPS 200 pumps with stainless steel power frames after running for the periods shown in the table below.

	200 rpm	400 rpm	600 rpm	1,000 rpm
5 bar	10,000 hours	10,000 hours	10,000 hours	10,000 hours
10 bar	10,000 hours	10,000 hours	10,000 hours	6,260 hours

•We recommend renewing the bearings of SPS 250 pumps with stainless steel power frames after running for the periods shown in the table below.

	200 rpm	400 rpm	600 rpm	800 rpm
5 bar	10,000 hours	10,000 hours	10,000 hours	10,000 hours
10 bar	10,000 hours	10,000 hours	10,000 hours	10,000 hours
15 bar	10,000 hours	10,000 hours	10,000 hours	10,000 hours

•We recommend renewing the bearings of SPS 300 pumps with cast iron or stainless steel power frames after running for 10,000 hours at any pressure.

•We recommend renewing the bearings of SPS 400 pumps’ with cast iron power frames after running for the periods shown in the table below.

	200 rpm	400 rpm	600 rpm
5 bar	10,000 hours	10,000 hours	10,000 hours
10 bar	10,000 hours	10,000 hours	10,000 hours
15 bar	10,000 hours	7 ,689 hours	5,126 hours

•We recommend renewing the bearings of SPS 400 pumps with stainless steel power frames after running for the periods shown in the table below.

	200 rpm	400 rpm	600 rpm
5 bar	10,000 hours	10,000 hours	10,000 hours
10 bar	10,000 hours	10,000 hours	10,000 hours
15 bar	10,000 hours	7,210 hours	4,800 hours

•We recommend renewing the bearings of SPS 500 pumps with stainless steel power frames after running for the periods shown in the table below.

	200 rpm	400 rpm	600 rpm
5 bar	10,000 hours	10,000 hours	10,000 hours
10 bar	10,000 hours	10,000 hours	10,000 hours
15 bar	10,000 hours	10,000 hours	7,500 hours

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Note: Remove the bearing housing of SPS 200, SPS 300 and SPS 400 ­models only to replace or adjust the shim ring (see 21 Adjusting the shaft). Do not attempt to dismantle the power end of the pump or replace the bearings. Pumps needing repair, servicing, new bearings or other work on the power end must be returned to MasoSine for attention. Special training is available for users of SPS 200, SPS 300 and SPS 400 ­models. Please contact MasoSine for further information.

7.17 Cleaning the pump

Handle substances and materials used correctly, especially when working on lubricating systems and when cleaning with solvents. For information on cleaning the parts in contact with the pumped fluid, see 17 Cleaning.

7.18 Faults

If an operating fault occurs, switch off the machine and secure it against unintentional start-up.

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7.19 Use as intended

The intended use of this product is listed in the order confirmation. The product should not be put to a different use or a use going beyond the use described.

Consult MasoSine if you wish to change the product, its pressure, speed or operating temperature.

8 Safety notes (ATEX)

If your MasoSine pump is to be used in production machinery in potentially explosive atmospheres, it will be equipped accordingly from the factory.

8.1 Safety signs

						II 2 G c T4		II 2 D c T = 120C
							Grounding symbol

Pump classification

MasoSine pumps are designed for continuous duty and are therefore assigned to the Device Group II – Application field “dust – or gas – explosive areas”.

Zone classification

MasoSine pumps can be used in explosive areas of zone 1 / 21. This corresponds to the category 2 G / D.

It is expressly forbidden to use the pumps in zone 0.

Classification of explosive 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). MasoSine pumps are designed to be used in explosive atmospheres G (Gas) and D (Dust).

Ignition protection

MasoSine pumps 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.

Temperature classes

•EX II 2 G c T4 ≥ 135C

•EX II 2 D c T = 120C

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8.2 Earthing the pump

SPS pumps are equipped with an earthing point.

The pump must be earthed by an earthing cable secured to the correct position. SPS 100 must be earthed at the base of the rear foot. Other models must be earthed as shown: with cast iron power frame, right; with stainless steel power frame, below right. This is particularly important in potentially explosive atmospheres.

In addition to earthing the pump, the drive motor must also be earthed. If the drive is not earthed,

the pump unit may not be operated.

8.3 Material properties

The plastic parts fitted inside the pump react more to temperature changes than stainless steel parts. For this reason, the specified maximum fluid temperature for which the pump is designed must not be exceeded. This temperature is included in your purchase documents. If the specified temperature­ is exceeded, linear expansion may block the pump; this in turn could cause the pump to fail or could result in damage to parts of the pump. In addition, excessive temperatures can accelerate the wear of dynamic parts and reduce the life of plastic parts.

Corrosion may occur to a pump’s cast iron power frame if the paintwork is damaged. Corrosion represents a hazard for the use of pumps in potentially explosive atmospheres (for measures, see 20 Troubleshooting).

Pumps with a stainless steel power frame are not subject to power frame corrosion.

8.4 Pressure conditions

A pressure controller must be installed to avoid over-pressure in the pump as a result of a closed pressure line.

8.5 Maintenance and repair

•Fill the pump with product before starting only outside the explosive atmosphere area. All tools used should comply with ATEX regulations.

•The pump unit must be kept free of dust with a damp cloth: accumulated dust can smoulder.

•The flushing channels in the power frame must be free of blockages and, if necessary, cleaned.

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8.6 Cleaning the pump

No solvent cleaning agents may be used to clean the pump as they could create an uncontrollable explosive atmosphere.

8.7 Medium to be pumped

Carbon disulphide and chemicals that are combustible below 120C must not be pumped.

8.8 Coupling

If the pump is used in potentially explosive atmospheres, it must be coupled to the drive by means of an elastic, positive coupling with ATEX certification for use with the pump. Chains, toothed belts, V-belts or similar equipment which may transmit radial forces to the bearings should not be used.

8.9 Drive

Any reduction gears in the drive chain and control units must be ATEX-certified for use with the pump. Combustion engines must never be used.

An inverter must be installed away from potentially explosive atmospheres, or have the same ATEX certification as the pump. In any case the inverter must have the properties required for operation in potentially explosive atmospheres: temperature monitoring, speed limitation, etc.

9 Pump specifications

Your pump carries a type plate on the bearing housing. It includes a serial number, which identifies the features of the product. The serial number also appears on the technical data sheet.

MasoSine Process Pumps, 74360 Ilsfeld, Germany

s/n.

133777 0807

Typ

SPS 200

model

month / year of manufacture (eg August 2007)

serial number

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Standards

	2006/42/EC: EC Machinery Directive
Relevant EC	73/23/EEC: EC Low Voltage Directive
directives	2004/108/EC: EMC Directives
	97/23/EG: Pressure Equipment Directive
	Safety of machinery—electrical equipment of machines:
	EN 60204-1
	EN ISO 12100, 1-2 : Safety of machinery
EC	For ATEX: EN 1127-1: Explosive atmospheres—
harmonised	Explosion prevention and protection Part 1
standards	For ATEX: EN 13463-1: Non-electrical equipment
	for use in potentially explosive atmospheres Part 1
	For ATEX: EN 13463-5: Non-electrical equipment
	for use in potentially explosive atmospheres Part 5
	EN 809: Pumps and pump units for liquids—
	Common safety requirements
National techni-	DIN 31000/A1: General principles for the safe design of
	technical products (Amendment 1)
cal standards,	DIN 11850: Pipes made of stainless steel for food and
guidelines and
specifications	chemical industries
	DIN 11851: Stainless steel fittings for the food and chemical
	industry - Screw pipe connections for expanding and welding

9.1 Dimensions (in millimetres)

SPS 100

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SPS 200 pumps, dimensions

Cast iron power frame

Stainless steel power frame

All critical dimensions of old and new power frame designs are the same, including mounting bolt holes. Both designs are interchangeable

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SPS 250 pumps, dimensions

Stainless steel power frame

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SPS 300 pumps, dimensions

Cast iron power frame

Stainless steel power frame

All critical dimensions of old and new power frame designs are the same, including mounting bolt holes. Both designs are interchangeable

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SPS 400 pumps, dimensions

Cast iron power frame

Stainless steel power frame

All critical dimensions of old and new power frame designs are the same, including mounting bolt holes. Both designs are interchangeable

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SPS 500 pumps, dimensions

Stainless steel power frame

Unit weights

	Pump weight,		Pump weight,
			stainless steel		Weight of standard baseplate
	cast power frame
			power frame
SPS 100			17.00kg	37lb 8oz	Part no: KK-... 13.00kg	28lb 11oz
SPS 200	23.00kg	50lb 11oz	20.00kg	44lb 1oz	Part no: KK-... 13.00kg	28lb 11oz
SPS 250			39.00kg 86lb		Part no: KK-... 13.00kg	28lb 11oz
SPS 300	80.00kg	176lb 6oz	68.00kg	149lb 15oz	Part no: KM-... 19.00kg	41lb 14oz
SPS 400	160.00kg	352lb 12oz 125.00kg		275lb 9oz	Part no: KG-... 31.00kg	68lb 5oz
SPS 500			171.00kg 377lb		Part no: KG-... 31.00kg	68lb 5oz

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10 Transport

Choose the means of transport according to the size of the pump and the drive. The pump must be suspended correctly for transport. If using a crane or a fork-lift truck, the ropes or belts must be sufficiently dimensioned. If the pump is transported with a lift truck or a fork-lift truck, note that the unit’s centre point is not necessarily the centre of gravity.

7 73 3

11 Installation

The motor shaft and pump shaft connection must be guarded to protect the user from contact.

7 73

•Place the pump on a level surface.

•Do not start the pump without a guard to protect the user from contact.

•The mounting surface should be strong enough to support the pump.

•There should be sufficient space for maintenance work around the pump.

•The motor must receive an adequate air supply.

•If the pump is used in potentially explosive atmospheres, an Ex-protected motor must be used. Contact the manufacturers for assistance.

•The unit must be protected against static charge.

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180°

73

• Align the pump shaft with the drive shaft.

12 Connection to the piping

Before connection, clean the piping and remove foreign bodies such as welding residues.

Fit elastic intermediate members (compensators) between pump and fixed piping on the suction and pressure sides, to stop pump vibrations being transmitted to the piping system.

Avoid forces and torques acting from the piping on the pump connections (e.g. distortion, expansion due to temperatures etc.).

The piping on the pressure side of the pump should run upwards from the pump, so that residual liquid can flow back into the pump when pumping stops, and total dry running is avoided. Fluid left in the pump facilitates suction when pumping re-starts.

The user must ensure that a pressure rise above the pressure agreed in the purchase order and listed in the technical data sheet is not possible.

MasoSine pumps normally run with such a low ­resonant frequency that no damage results. However, particularly when running with inverters, certain frequencies can cause interference­ vibrations which must be avoided. It is important during ­commissioning to ascertain whether such vibrations exist

and to define them, so that the inverter can be programmed to avoid these frequencies. Similarly, interference from cavitation or rigid lines must be avoided. See 12.1

Cavitation.

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12.1 Cavitation

Cavitation is a problem in certain devices where fluid interacts with a moving surface. It can occasionally occur in sinusoidal pumps.

Where a surface moves through a fluid, low pressure areas are formed on the surface. The faster the surface moves, the lower the pressure around it can become. If the static pressure of the liquid falls below its vapour pressure, vapour bubbles form on the pressure side. These implode, causing very high, short-term pressure peaks up to several thousand bar. These pressure peaks can cause material erosion and are noisy.

To identify cavitation

If the pump is very noisy and vibrates vigorously, along with the pipe system attached to the pump, cavitation is likely to be the cause.

To avoid or remove cavitation

Increasing the inlet pressure on the suction side, installing a larger diameter or shorter inlet pipe or slowing the pump may solve the problem. Make sure that the pump is not starved of duty fluid at all times.

Cavitation can destroy the pump. The operator must ensure that the pump can work free of cavitation.

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13 Possible pump orientations

The pump can be positioned in three orientations, and rotate clockwise or counterclockwise.

9-12			10-2	12-3						12-9			2-10	3-12
Counter-clockwise rotation												Clockwise rotation
	of the rotor and motor										of the rotor and motor

Unless ordered otherwise, the pump is delivered in position 2-10. Special customised nozzle orientations are possible.

13.1 Changing the pump orientation

Disconnect the pump from the mains power, and secure it against unintentional start-up.

SPS 100

• Turn the pump on to its side to allow access to the baseplate securing bolts.

• Remove the three bolts and washers using a 13mm spanner. As each bolt is withdrawn, a spacer between the baseplate and the pump will fall out.

• Three sets of threaded fixing points are provided on the pump; the central set (pictured in use above) allows the inlet and outlet ports to be positioned

at 10-2 or 2-10; the other sets (one fixing point arrowed) allow the pump to be

positioned with the inlet or outlet horizontal and the other port vertical.

•Pass the bolts with washers through the baseplate and the spacers (Note: the longer bolt and the longer spacer secure the baseplate to the bearing

housing at the rear of the pump). Screw the bolts into the set of fixing points ­appropriate for the desired pump orientation. Tighten to 25Nm using a 13mm spanner.

SPS 200, SPS 250 SPS 300, SPS 400, SPS 500

•Follow the dismantling and assembly steps for your pump model. See 22

Dismantling and assembly

•Remove the screws on the power frame. Turn the housing by an angle of 45° to the left or right.

•Refit the screws in their new position and tighten them to the correct torque:

SPS 200: 16 Nm SPS 250: 16 Nm SPS 300: 33 Nm SPS 400: 56 Nm SPS 500: 56 Nm

Note: If the direction of flow is also changed, the gate and gate guide must be reversed. See 13.2 Changing rotation direction.

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Take care that fluid in the pressure line leaves the pump in an upward direction, so that when pumping stops, some fluid remains in the pump. This will make it easier for the pump to draw in viscous products when pumping restarts. This applies particularly­ when the pressure connection is horizontal: positions 12-3 and 12-9. Take care that the pressure line is run so that the pump rotor is always covered with fluid, and dry running is avoided.

13.2 Changing rotation direction

When the direction of rotor rotation is reversed, the suction side and the pressure side of the pump are exchanged. The orientation of the gate and the gate guide must be changed, too, or the pump cannot pump efficiently. The pump can run for only a short time with the gate and the gate guide wrongly oriented, and it will not achieve more than 2 bar pressure. See 22 Dismantling and assembly.

SPS 100 is shown here. All models are similar.

The gate and gate­ guide shown inverted to make clear the gate’s position within the guide for counter-­clockwise rotor rotation

The gate and gate guide oriented for clockwise­ rotor rotation

The gate and gate­ guide oriented for counter-­clockwise rotor rotation

If the direction of rotation is reversed, change the rotation direction indicator arrows and mark the suction and pressure ports correspondingly.

Disconnect the pump from the mains power, and secure it against unintentional­ start-up. Ensure that the direction change is carried out by a trained engineer.

•Follow the dismantling and assembly steps for your pump model. See 22

Dismantling and assembly

•Take special note of the instructions for fitting the rotor, the gate and the gate guide

Take care that fluid in the pressure line leaves the pump in an upward direction, so that when pumping stops, some fluid remains in the pump. This will make it easier for the pump to draw in viscous products when pumping restarts. This applies particularly­ when the pressure connection is horizontal: positions 12-3 and 12-9. Take care that the pressure line is run so that the pump rotor is always covered with fluid, and dry running is avoided.

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14 Connecting this product to a power supply

The motor must be connected according to local regulations by a qualified person. See the instruction manual supplied with your drive motor.

15 Start-up and operation

•If you are starting the pump for the first time, or have performed cleaning or repair work, check first that all screws are correctly and completely tightened.

•The pump may have been contaminated during transport. Remove the pump front cover and clean if necessary before start-up.

•Before you start the pump, check that the gate and the gate guide are in the correct orientation in relation to the suction side and the pressure side of the pump. (See 13.2 Changing rotation direction).

Observe the appropriate regulations if hazardous fluid is to be pumped.

Ensure that the pump is installed in an appropriate position with all necessary safety guards and precautions­ (sensors, switches, pressure gauges, etc).

MasoSine pumps must be primed before use. Fluid Before commissioning and during operation, the level

pump must be filled with fluid, with the fluid level above the rotor (see diagram). This can be done

manually through a side channel of your system’s pipework, or by using a vacuum device where very

viscous fluids are to be pumped; contact MasoSine for further information. The need to prime can

be avoided by leaving product in the pump after it is stopped; by leaving CIP or SIP fluid in the pump after cleaning. For ATEX use, fill the pump

away from potentially explosive atmosphere, and be aware that if the pump runs dry, the temperature limit for the explosive area may be

exceeded.

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Make sure before start-up that all valves on the pressure­ and suction sides are open. The pump must not pump against a closed valve without an over­ pressure valve.

If the pump leaks, stop pumping as quickly as ­possible and replace the damaged sealing elements. See 22

Dismantling and assembly and 25.2 Seals.

The operator must ensure that the pump can work free of cavitation. Cavitation can destroy the pump. See 12.1 Cavitation.

16 Flushing the seal system

Flushing fluid at atmospheric pressure—usually water—flushes the area behind the seal system and prevents the product from hardening and damaging the seal system. If a static flushing device is fitted, the flushing fluid fills the area behind the seal.

•Cast iron power frame: If no static flushing device is fitted, adapt a fitting and a tube to the threads of the intake and outlet in the power frame (see diagram below; models differ) and circulate flushing fluid through the system.

•Stainless steel power frame: Make sure that the correct flush ring is installed with tube connections and circulate flushing fluid through the system.

•The flushing medium must be at least suitable to the product being pumped. It should not contain abrasive particles, which would damage the seals. We recommend that transparent plastic tubes are used as flushing tubes.

•The pump should be flushed without pressure: the flushing fluid should be allowed to drain from the system without pressure.

•Fill the pump with liquid to prevent it from running dry, possibly via a separate intake valve connected to the suction or pressure pipe.

•If your pump is set up for permanent flushing, always check the intake and outlet (see diagram below).

16.1 Static flushing device

			Intake
Before	commissioning,	fill	the
flushing device (if supplied) with a suit-
able flushing fluid, depending on the
product­	being pumped. Fill the sight glass

with flushing fluid until the fluid level is

just below the bend in the outlet pipe.

Outlet

Note: The diagram shows a flushing

device fitted to a pump with a cast iron frame. Pumps with stainless steel frames are similar.

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17 Cleaning and sterilisation

MasoSine SPS pumps may be cleaned in place. Please follow our CIP cleaning instructions—see below.

Maintaining a clean process line is vital to maintain a high level of hygiene and no contamination of an end-product. Contamination costs time and money.

The heat or chemical reaction from clean-in-place (CIP) and steam-in-place (SIP) cleaning processes damages a living cell’s essential structures, including­ the cytoplasmic membrane, rendering the cell no longer viable.

The process automatically re-circulates cleaning detergent and rinse solutions­ .

The benefits of clean-in-place (CIP) and steam-in-place (SIP)

•Cleaning is faster

•Cleaning is less labour-intensive

•Cleaning is repeatable

•There is a reduced chance of operators being exposed to hazardous chemicals

Clean-in-place (CIP) for MasoSine products

Clean-in-place (CIP) is a method of cleaning the interior surfaces of pipes, vessels, process equipment and associated fittings without disassembling­ .

The CIP procedure

•Before the CIP process begins, a preliminary clean should be performed at maximum speed with no back pressure. This will remove most of the residual product.

•Suitable cleaning fluids for the CIP process may include concentrations below 1% of additives. They may be:

• Sodium hydroxide in distilled water • Nitric acid in distilled water

• Phosphoric acid in distilled water

•CIP cleaning can be carried out between 80°C and 90°C as standard.

•Cleaning should be done at maximum pump speed to achieve a good cleaning result.

•It is very important that the differential pressure on the discharge side of the pump is at least 3.0 bar / 43.5 psi higher than the pressure on the suction side of the pump during the CIP process.

Attention: Keep a minimum distance of 50cm from the pump while performing high-pressure cleaning.

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•A choke valve should be installed in the discharge pipeline immediately after the pump. Close the choke valve slowly until the pressure­ difference is correct­ .

•The CIP time for the pump is in accordance with the time required for system cleaning: usually 20-40 minutes.

flow of
cleaning		X		Y
fluid
		bar/psi		bar/psi		choke
	suction			discharge		valve
	side			side

Y-X ≥

3 bar / 43.5 psi

Steam-in-place (SIP) for MasoSine products

Steam sterilisation kills micro-organisms through the application of moist heat (saturated steam) under pressure without disassembly.

•Sterilising the pump with standard equipment is possible up to 120°C only at standstill.

•The pressure should be high enough to ensure that the steam reaches all parts of the static pump through the existing clearances.

Class II SIP and CIP	Maximum	Recommended
procedure	temperature	pressure differential
CIP	80-90°C / 176-194°F	3 bar
SIP	120°C / 248°F	-

Key CIP and SIP safety information

•A distance of one metre around the pump ­should be kept clear during SIP to minimise danger in case of leakage.

•CIP and SIP processes should be monitored continuously.

•If a leak occurs during CIP or SIP, the pumphead should not be touched until system pressure has been relieved and the pumphead has been allowed to cool down.

•Ensure that an acclimatisation period is observed after SIP before the pump process is started. The temperature inside a standard pump should not exceed 85C (176F) during operation.

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