Watson-Marlow SPS 600 User Manual

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Manual - Technical Documentation

ATEX

Watson-Marlow MasoSine – Pump

SPS 600

Revision 4.1 / March 2014

1

Inhalt

 

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

Cleaning the machine.........................................................................................................................

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

8

 

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

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10

POSSIBLE CONNECTION POSITIONS ..................................................................

10

11

CHANGING THE CONNECTION POSITION ...........................................................

11

12

CHANGING THE DIRECTION OF ROTATION ........................................................

11

13

IMPORTANT: OBSERVE BEFORE START-UP!.....................................................

11

14

PURGING .................................................................................................................

12

14.1

Static purging device ........................................................................................................................

12

15

CLEANING ...............................................................................................................

12

15.1

Cleaning in own circuit with water, alkali, acid .................................................................................

12

15.2

Cleaning in the CIP circuit ................................................................................................................

12

15.3

Manual cleaning ...............................................................................................................................

13

15.4

Sterilisation .......................................................................................................................................

13

16

HEATING / COOLING ..............................................................................................

13

17

LUBRICATION .........................................................................................................

13

18

DISPOSAL ...............................................................................................................

13

19

SPARE PARTS ........................................................................................................

13

20

TAKING OUT OF SERVICE .....................................................................................

14

20.1

Provisional taking out of service.......................................................................................................

14

20.2

Final taking out of service ................................................................................................................

14

21

TROUBLESHOOTING .............................................................................................

15

22

SETTING DIMENSION .............................................................................................

17

23

DISMANTLING .........................................................................................................

18

24

ASSEMBLY ..............................................................................................................

19

25

DRAWINGS AND PART LIST..................................................................................

23

25.1

Pump ................................................................................................................................................

23

25.2

Part list of the pump .........................................................................................................................

24

25.3

Sealing system „Mechanical Seal Assembly“ ..................................................................................

25

25.4

Parts list „Mechanical Seal Assembly“ .............................................................................................

26

25.5

Sealing system „Mechanical Seal Assembly“ ..................................................................................

27

25.6

Parts list „Mechanical Seal Assembly“ .............................................................................................

28

25.7

Sealing system „Lip Seal Assembly“................................................................................................

29

25.8

Parts list „Lip Seal Assembly“ ..........................................................................................................

30

25.9

Dimensional drawing ........................................................................................................................

31

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3

TECHNICAL DATASHEET

Please remove all technical information from the delivery note.

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 4.1 / March 2014

4

1General

The operating instructions apply for the Watson-Marlow MasoSine Pump :

SPS 600

The operating instructions must be read before installing the pump. Please observe the safety instructions and the safety regulations.

2Purpose

The purpose of your pump is defined exactly in the delivery note. The ATEX certification becomes null and void following any changes to the purpose, including changes to components and materials. This is why you should always consult the manufacturer first!

3Functioning principle

The functioning principle of the Watson-Marlow MasoSine is ingeniously simple. The pump consists of modular components. Because of the sinusoidal form of the rotor, a chamber through which the product to be pumped is „pushed through“ or displaced is created four times per revolution when running through the stator space.

As soon as a chamber closes, the opposite chamber opens by the same fraction of a millimeter as the closing chamber is contracted.

A suction and pressure characteristic of the pump free of pulsation results. The scraper prevents the pressure compensation of the pressure to the suction side. At the same time the scraper undertakes the important function of forced lubrication of the pump bearings, or when the pump is cleaned the intensive purging of the bearing or of the seal.

4Safety instructions

4.1Basic safety instructions

A basic requirement for safe handling and troublefree operation of this machine is knowledge of the basic safety instructions and 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.

4.2Safety symbols

Safety instruction which can cause danger for persons if not complied with

Safety instruction for electrical voltage

CAUTION

Safety instruction which can cause danger for the pump and is function if not complied with.

4.3Obligation of the operator

The operator obligates itself to let only persons who are familiar with the basic regulations concerning working safety and accident prevention and are instructed in handling the machine, as well as have read, understood and confirmed by their signature the warning notes in these operating instructions to work on the machine.

The safety-conscious working of the personnel will be checked at regular intervals.

4.4Organizational measures

The required personal protective equipment shall be provided by the operator.

All existing safety devices shall be checked regularly.

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4.5Obligation of the personnel

All persons who are authorized to work on the machine obligate themselves to observe the basic regulations concerning working safety and accident prevention before starting work, to read the safety chapter and the warning notes in these operating instructions and to confirm by their signature that they have understood these.

4.6Training of the personnel

Only trained and instructed personnel may work on the machine. The responsibilities of the personnel shall be defined clearly for assembly, start-up, operation, setting, maintaining and repairing.

Personnel under training may work on the machine only under supervision of an experienced person.

4.7Informal safety measures

The operating instructions must be kept constantly at the place of use of the machine. 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.

4.8Dangers when handling the machine

The Watson-Marlow MasoSine Pump is built according to the state of the art and the recognized 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 the intended use delivery note

in perfect safety engineering condition.

Faults which can impair safety must be rectified immediately.

4.9Safety measures in normal operation

Operate the machine only if all protective devices are fully functioning.

Before switching the machine on make sure that no one can be endangered by the starting machine.

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.

On delivery of part components the protective devices must be attached according to regulations by the operator. If hot or cold machine parts can lead to danger, these must be protected by the operator on site against contact.

4.11 Dangers due to hazardous pumped material

In the case of hazardous pumped material (according to ArbStoffV) the corresponding regulations must be complied with.

4.12 Dangers due to electrical energy

Have work on the electrical supply performed only by an 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 with key or tool.

If work on parts conducting voltage is necessary, call in a second person who switches off the main switch if necessary.

If you make the electrical connection of the pump, act according to DIN EN 60204 Connect only by skilled personnel

4.13Dangers 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

Rotating rotor in the pump. Danger of crushing or cutting off fingers and hands.

The pump must be protected by the customer so that it is not possible for persons to grasp in the opening with the rotor running. In the case of work on the stationary rotor, the drive must be secured against unintentional switching on.

Increased danger exists with dismantled pipes and opened pump.

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4.15 Constructional changes to the machine

Make no changes, attachments or conversions to the machine without approval of the manufacturer. All conversion measures require a written confirmation of the Watson-Marlow MasoSine company. Immediately replace machine parts in not perfect condition. Use only original spare and wearing parts. In the case of parts not obtained from MasoSine it is not guaranteed that they are designed and manufactured in compliance with load and safety requirements.

4.16 Noise of the machine

The continuous sound pressure level proceeding from the machine is max. 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 on time. 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. In all maintenance, inspection and repair work switch the machine free of voltage

and secure the main switch against unexpected switching back on. Switch off the main switch and withdraw the key. Attach a warning sign indicating that the switch must not be turned on again. Fasten and secure larger assemblies on replacement carefully to lifting gear. Check loosened screw connections for firm seating. Use only original spare parts.

After ending the maintenance work check the safety devices for function.

4.18Cleaning the machine

The bearings that are placed in the bearing housing of the pump wear off continuously which influences the run time. That is why both bearings should be replaced after a certain amount of working hours. (see table below)

 

200 rpm

400 rpm

600 rpm

5 bar

10000

Std.

10000

Std.

10000

Std.

10 bar

10000

Std.

7238

Std.

4825

Std.

15 bar

3747

Std.

1873

Std.

1249

Std.

4.19 Cleaning the machine

Handle substances and materials used correctly, especially:

-when working on lubricating systems

-when cleaning with solvents.

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 the Watson-Marlow MasoSine company or one of our representatives.

5Safety instructions (ATEX)

Watson-Marlow MasoSine - Pump used in production machinery with explosive mixtures will be equipped accordingly in the factory.

5.1Safety signs

Grounding symbol

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5.2Pump 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”!

5.3Zone 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!

5.4Classification 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)!

5.5Ignition 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

5.6Temperature classes

-EX II 2 G c T4

-EX II 2 D c T=120°C

5.7Limit values for the pump

The limit values for the pump (max. speed, max. pressure, max. temperature) are stated in the delivery note. 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!

 

 

SPS 600

 

 

 

max. Druck

*

15 bar

 

 

 

max. Drehzahl

*

600 UpM

 

 

max. Temperatur (T4) *

60°C

 

 

max. Temperatur (T3) *

120°C

 

 

Umgebungstemperatur

-12°C bis +40°C

 

 

 

5.8Grounding 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

5.9Material 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=100°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.

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5.11Maintenance / 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.

5.12Cleaning

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 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.

6Warranty 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 devices

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 customary quality and suitability for a certain application.

The 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 The Watson-Marlow MasoSine. Rights reserved to make changes in these operating instructions.

7Transport 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

right

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9

Watson-Marlow SPS 600 User Manual

8Installation

wrong

The motor shaft and pump shaft connection must be protected against contact!

DO NOT START WITHOUT PROTECTION AGAINST CONTACT!!

Place the pump on a level ground.

Do not start without the protection against contact!!

The foundation should be dimensioned sufficiently for the weight of the pump.

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

It must be guaranteed that the motor receives an adequate air supply.

If the pump is used in explosion endangered rooms, an Ex protected motor must be used.

The total unit must be protected against static charge.

Align the shaft of the pump with the shaft of the drive.

9Connection to the piping

CAUTION

CAUTION

CAUTION

CAUTION

CAUTION

CAUTION

Before connection clean the piping and remove foreign bodies. (e.g. there can still be residues in the pipes due to welding work).

Fit elastic intermediate members (compensators) between pump and fixed piping on the suction

and pressure side. This should prevent vibrations of the pump being transmitted to the piping system.

Forces and torques acting from the piping on the pump connections (e.g. due to distortion, expansion due to temperatures etc.) must be avoided.

The pressure line should point upwards, so that later residual liquid can always flow back into the pump. Thus total dry running is avoided. Further it facilitates the later suction process.

The operator has to ensure that an inadmissible pressure rise (above the pressure agreed in the order and listed in the technical data) is not possible.

The Watson-Marlow MasoSine pumps normally run with such a low resonant frequency that no corresponding damage is caused. However, particularly when running with converters, certain frequencies can cause interfering vibrations which must be avoided. It is important during initial commissioning to ascertain whether such vibrations exist and to define them accordingly, so that the frequency converter can then be programmed to avoid these frequencies. Similarly, interference from cavitation or rigid lines must be ruled out.

CAUTION

The operator has to ensure that the pump can work free of cavitation.

Cavitation destroys the pump

10 Possible connection positions

Counterclockwise rotation of the rotor and motor

Clockwise rotation of the rotor and motor

Unless otherwise ordered, the pump is delivered in position 10 - 2

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