Munsch MPC-B series Bedienungsanleitung

Standard Chemical Pump

Operating instructions MPC-B series

Version BA-2006.03

Print-No. 01

VM-No. EN

Munsch Chemie-Pumpen GmbH

Im Staudchen

56235 Ransbach-Baumbach

Germany

Phone: +49 (0) 26 23-8 98-90

Fax: +49 (0) 26 23-8 98-95

E-mail: [email protected]

Internet: http://www.munsch.de

We reserve the right to make technical changes.

Table of contents

1 About this document ............................... 4

1.1 Target groups ................................. 4

1.2 Other applicable documents ................ 4

1.3 Warnings and symbols ....................... 5

1.4 Technical terms ............................... 5

2Security .............................................. 6

2.1 Intended use .................................. 6

2.2 General safety instructions .................. 6

2.2.1 Product safety ................................ 6

2.2.2 Operator's obligations ........................ 7

2.2.3 Duties of the operating staff ................. 7

2.3 Special hazards .............................. 7

2.3.1 Potentially explosive areas .................. 7

2.3.2 Hazardous pumped liquids .................. 7

2.3.3 Magnetic ﬁeld ................................. 7

3 Layout and function ................................ 8

3.1 Labels ......................................... 8

3.1.1 Type plate ..................................... 8

3.1.2 ATEX plate .................................... 8

3.1.3 Pump type code .............................. 8

3.2 Layout ......................................... 9

4 Transport, storage and disposal .................. 10

4.1 Transport ...................................... 10

4.1.1 Unpacking and inspection on delivery . ..... 10

4.1.2 Lifting .......................................... 10

4.2 Preservation .................................. 11

4.3 Storage ....................................... 11

4.4 Disposal ....................................... 11

5 Setup and connection .............................. 12

5.1 Preparing the installation .................... 12

5.1.1 Checking the ambient conditions ... . .. . . .. . 12

5.1.2 Preparing the installation site ............... 12

5.1.3 Preparing the foundation and setup

surface ........................................ 12

5.1.4 Preparing the pump .......................... 12

5.1.5 Installing the heat insulation .. .. . . .. . . .. . ... . 12

5.2 Setup with foundation ........................ 13

5.2.1 Setting the pump group down on the

foundation .................................... 13

5.2.2 Fastening the pump group .................. 13

5.3 Setup without foundation .................... 14

5.4 Planning the pipes ........................... 14

5.4.1 Avoid impurities in the pipes ................. 14

5.4.2 Laying out supportsandﬂange

connections ................................... 14

5.4.3 Specifying nominal diameters ............... 14

5.4.4 Determining pipe lengths .................... 15

5.4.5 Optimising cross-section and direction

changes ....................................... 15

5.4.6 Providing safety and monitoring devices

(recommended) .............................. 15

5.5 Connecting the pipes ........................ 15

5.5.1 Installing auxiliary pipes ..................... 15

5.5.2 Installing the suction pipe .................... 16

5.5.3 Installing the pressure pipe .................. 16

5.5.4 Checking that the pipe connections are

stress-free .................................... 16

5.6 Connecting the electrical system . ... ... ... . 16

5.6.1 Connecting the motor ........................ 16

5.6.2 Checking the direction of rotation .. . . .. . ... . 16

6Operation ............................................ 17

6.1 Preparations for the initial start-up ... . .. . . .. 17

6.1.1 Identifying the pump version ................ 17

6.1.2 Checking downtimes ......................... 17

6.1.3 Preparing auxiliary operating systems . . . .. . 17

6.1.4 Filling and bleeding .......................... 17

6.1.5 Checking the direction of rotation .. . . .. . ... . 17

6.2 Putting the pump into service ............... 18

6.2.1 Switching on the pump ...................... 18

6.2.2 Switching off the pump ....................... 19

6.3 Shut-down .................................... 19

6.4 Restoring the pump to service .............. 20

6.5 Operating the stand-by pump ............... 20

7 Maintenance ......................................... 21

7.1 Inspections ................................... 21

7.2 Maintenance .................................. 22

7.3 Dismounting .................................. 23

7.3.1 Returning the pump to the manufac-

turer ........................................... 23

7.3.2 Preparing the dismounting .................. 24

7.3.3 Undoing connections (if available) ... . .. . . .. 24

7.3.4 Pulling off the volute casing ................. 24

7.3.5 Dismounting the impeller, plain bearing

bracket and pump rotor ...................... 24

7.3.6 Dismounting the drive rotor .................. 26

7.4 Installing ...................................... 26

7.4.1 Preparing the installation .................... 26

7.4.2 Installing the drive rotor ...................... 26

7.4.3 Installing the plain bearing bracket .. . ... . .. 27

7.4.4 Fitting the pump in the installation .......... 27

7.5 Ordering spare parts ......................... 27

8 Disturbance recovery .............................. 28

9 Appendix ............................................. 31

9.1 Sectional drawing ............................ 31

9.1.1 Part numbers and designations ... . .. . ... . .. 31

9.1.2 Overview sectional drawing ................. 32

9.1.3 Variants ....................................... 33

9.2 Technical speciﬁcations ...................... 33

9.2.1 Ambient conditions ........................... 33

9.2.2 Noise pressure level ......................... 33

9.2.3 Tightening torques ........................... 34

2 MPC-B series BA-2006.03 EN – 01

Table of contents

9.2.4 Cleaning agents .............................. 34

9.2.5 Socket loads according to ISO 5199 .. . ... . 34

9.3 Spare parts for two years of continuous

operation according to DIN 24296 . . .. . ... . . 35

List of ﬁgures

Fig. 1 Type plate (example) ........................ 8

Fig. 2 ATEX plate (example) ........................ 8

Fig. 3 Pump type code (example) .................. 8

Fig. 4 MPC-B layout ................................. 9

Fig. 5 Fastening the lifting gear to the pump

group .......................................... 10

Fig. 6 Fastening the lifting gear to the pump ... . .. 10

Fig. 8 Setup without foundation .................... 14

Fig. 9 Straight pipe lengths in front of and behind

the pump (recommended) ................... 15

Fig. 10 Undoing the ﬂushing connector ............. 24

Fig. 11 Pulling off the volute casing ................. 24

Fig. 12 Undoing the impeller screw ................. 24

Fig. 15 Dismounting the drive rotor .................. 26

Fig. 16 Installing the plain bearing bracket .. . . .. . .. 27

Fig. 17 MPC-B – overview sectional drawing .. . . .. . 32

Fig. 18 MPC-B – housing foot ....................... 32

Fig. 19 Emptying (optional) .......................... 33

Fig. 20 Fluid connection (optional) .................. 33

Fig. 21 Socket loads at the pump ................... 34

List of tables

Tab. 1 Target groups and their duties .. . . .. . ... . . .. 4

Tab. 2 Other applicable documents and their

purpose ....................................... 4

Tab. 3 Warnings and consequences of

non-observance .............................. 5

Tab. 4 Symbols and their meaning ................. 5

Tab. 5 Technical terms and their meaning . .. . .. . . . 5

Tab. 6 Measures after long storage times/

downtimes .................................... 12

Tab. 7 Measures to be taken if operation is

interrupted .................................... 19

Tab. 8 Measures to be taken, depending on the

pumped liquid behaviour .................... 19

Tab. 9 Measures for return .......................... 23

Tab. 10 Fault/number assignment ................... 28

Tab. 11 Troubleshooting table ........................ 30

Tab. 12 Designation of components according to part

numbers ...................................... 31

Tab. 13 Ambient conditions ........................... 33

Tab. 14 Noise pressure level ......................... 33

Tab. 15 Steel/cast pairings ........................... 34

Tab. 16 Socket head cap screw 914.1 -steel/steel

pairing ......................................... 34

Tab. 17 Cleaning agents .............................. 34

Tab. 18 Socket loads .................................. 34

Tab. 19 Socket loads – torques ...................... 34

Tab. 20 Spare parts for two years of continuous

operation ...................................... 35

EN – 01 BA-2006.03 MPC-B series 3

About this document

1 About this document

This manual

• Ispartofthepump

• Applies to all of the afore-mentioned series

• Describes safe and appropriate operation during all oper-

ating phases

1.1 Target groups

Target group Duty

Operating company Keep this manual available where the installation is used, including

for later use.

Make sure the staff read and follow these instructions and the

other applicable documents, especially all safety instructions and

warnings.

Observe any additional rules and regulations referring to the

installation.

Qualiﬁed staff, ﬁtter Read, observe and follow these instructions and the other

applicable documents, especially all safety instructions and

warnings.

Tab. 1 Target groups and their duties

1.2 Other applicable documents

Document Purpose

ATEX additional instructions Operation in potentially explosive areas

Order data sheet Technical speciﬁcations, operating conditions

Setup drawing Setup dimensions, connection dimensions etc.

Technical description Technical speciﬁcations, operating limits

Sectional drawing Sectional drawing, part numbers, component designations

Supplier documentation Technical documentation for supplier parts

Spare parts list Ordering spare parts

Document of compliance Returning the pump to the manufacturer

Declaration of conformity Legal conﬁrmation that the pump meets all requirements of the

applicable EG guideline(s)

Tab. 2 Other applicable documents and their purpose

4 MPC-B series BA-2006.03 EN – 01

About this document

1.3 Warnings and symbols

Warning Risk level Consequences of non-obser-

vance

DANGER Immediate acute risk Fatal or serious injury

WARNING Potential acute risk Fatal or serious injury

CAUTION Potentially hazardous situation Minor bodily harm

CAUTION Potentially hazardous situation Material damage

Tab. 3 Warnings and consequences of non-observance

Symbol Meaning

Safety warning sign

Observe all information indicated by the safety warning sign to

avoid injury or death.

Instruction

1. , 2. , ... Multiple step instructions

9Requirement

→Cross reference

Information, note

Tab. 4 Symbols and their meaning

1.4 Technical terms

Term Meaning

Flushing medium Medium for ﬂushing the pump plain bearing surfaces

Auxiliary operating systems Systems for operating the pump

Tab. 5 Technical terms and their meaning

EN – 01 BA-2006.03 MPC-B series 5

Security

2Security

The manufacturer does not accept any liability for dam-

age resulting from non-observance of the entire documen-

tation.

2.1 Intended use

• Only use the pump to pump the agreed pumped liquid

(→order data sheet).

• Adhere to the operating limits and size-dependent mini-

mum ﬂow rate.

• Avoid dry running:

Initial damage, such as destruction of plain bearings and

plastic parts, within a few seconds.

– Make sure the pump is never put into operation or oper-

ated without pumped liquid.

• Avoid cavitation:

– Fully open the suction-side ﬁtting; do not use the ﬁtting

to adjust the ﬂow rate.

– Do not open the pressure-side ﬁtting beyond the

agreed operating point.

• Avoid overheating:

– Do not operate the pump while the pressure-side ﬁtting

is closed.

– Observe the minimum ﬂow rate (→order data sheet).

• To avoid damage to the motor:

– Do not open the pressure-side ﬁtting beyond the

agreed operating point.

– Observe the number of permitted motor start-ups per

hour (→manufacturer's speciﬁcations).

• Consult the manufacturer about any other use of the pump.

Avoiding common types of misuse (examples)

• Observe the operating limits of the pump regarding oper-

ating temperature, pressure, ﬂow rate and speed (→order

data sheet).

• The power uptake of the pump increases with increasing

density of the pumped liquid. To avoid any overload for the

pump and motor, do not exceed the permissible density

(→order data sheet).

A lower density is allowed. Adapt the auxiliary systems

accordingly.

• Adhere to the limits for solids content and grit size when

pumping solids-carrying ﬂuids (→order data sheet, techni-

cal description).

• When using auxiliary operating systems:

– Ensure the ﬂushing medium is compatible with the

product medium.

– Ensure there is a permanent supply of the respective

ﬂushing medium.

2.2 General safety instructions

Take note of the following instructions before carrying out

any work.

2.2.1 Product safety

The pump has been constructed according to the latest tech-

nology and established technical safety rules. Nevertheless, a

potential risk to life and limb of the operator or to other persons

or damage to the pump and other property cannot be entirely

excluded.

• Only operate the pump if it is in perfect technical condition;

only use it as intended, staying aware of safety and risks,

and adhering to the instructions in this manual.

• Keep this manual and all other applicable documents com-

plete, legible and accessible to staff at all times.

• Refrain from any procedures that would endanger staff or

third parties.

• If a safety-relevant fault occurs, shut down the pump imme-

diately and have the fault corrected by appropriate staff.

• In addition to the entire documentation for the product,

always comply with statutory or other safety and accident-

prevention regulations as well as with the applicable stan-

dards and guidelines in the country where the pump is

operated.

6 MPC-B series BA-2006.03 EN – 01

Security

2.2.2 Operator's obligations

Safety-conscious operation

• Only operate the pump if it is in perfect technical condition;

only use it as intended, staying aware of safety and risks,

and adhering to the instructions in this manual.

• Ensure the following are observed and monitored:

– Adherence to intended use,

– Statutory or other safety and accident-prevention reg-

ulations

– Safety regulations governing the handling of hazard-

ous substances

– Applicable standards and guidelines in the country

where the pump is operated

• Make protective equipment available.

Staff qualiﬁcations

• Make sure all staff assigned with work on the pump have

read and understood this manual and all other applicable

documents, especially the safety, maintenance and repair

instructions, before beginning with work.

• Organise responsibilities, who is in charge of any speciﬁc

duty and how staff is supervised.

• Makesureallworkiscarriedout by specialist technicians

only:

– Fitting, repair and maintenance work

– Work on the electrical system

• Make sure trainee staff only work on the pump under super-

vision of specialist technicians.

• Persons with implanted heart pacemakers

– Should stay away from the pump with magnetic cou-

pling and parts of the magnetic coupling

– Should not be allowed to perform any work with or on

magnetic parts

Safety devices

• Provide the following safety devices and verify their integ-

rity:

– For hot, cold and moving parts: contact protection of

the pump provided by the customer

– If electrostatic charging is possible: ﬁt appropriate

earthing.

Warranty

• Obtain the manufacturer's approval prior to carrying out

any modiﬁcations, repairs or alterations during the warranty

period.

• Only use original parts or parts that have been approved

by the manufacturer.

2.2.3 Duties of the operating staff

• Observe and keep legible all directions on the pump, e.g.

the arrow indicating the direction of rotation and the indica-

tion of ﬂuid connections.

• Do not remove the protection against accidental contact for

hot, cold and moving parts during operation.

• Use protective equipment if necessary.

• Carry out work on the pump only while the pump is not

running.

• Isolate the motor from its supply voltage and keep it locked

in that state while carrying out any ﬁtting or maintenance

work.

• Reinstall the safety devices on the pump according to reg-

ulations after completing any work on the pump.

• Persons with implanted heart pacemaker:

– Should keep a minimum distance of 1 m away from the

pump with magnetic coupling or parts of the magnetic

coupling.

– Should not be allowed to perform any work with or on

magnetic parts

2.3 Special hazards

2.3.1 Potentially explosive areas

•(→ATEX additional instructions).

2.3.2 Hazardous pumped liquids

• Observe the safety regulations for handling hazardous sub-

stances when working with hazardous pumped liquids (e.g.

hot, ﬂammable, explosive, poisonous or potentially harm-

ful).

• Use protective equipment when carrying out any work on

the pump.

2.3.3 Magnetic ﬁeld

The magnetic ﬁeld of the magnetic coupling can destroy mag-

netically sensitive products, including:

• Heart pacemakers

• ID cards with magnetic strips

• Credit cards and cheque cards

• Electrical, electronic or ﬁne mechanical equipment

(e. g. mechanical and digital watches, pocket calcula-

tors, hard drives)

EN – 01 BA-2006.03 MPC-B series 7

Layout and function

3 Layout and function

3.1 Labels

3.1.1 Type plate

MUNSCH Chemie-Pumpen GmbH

D-56235 Ransbach-Baumbach

W.-Nr.

Lfrd.

impeller

serial-no.

type

Typ

-1

kg/dm

Baujahr

m /h

year

min

Fig. 1 Type plate (example)

1Pumptype

2 Serial number

3 Year of construction

4 Pump head

5Density

6Torque

7 Speed

8 Power consumption

9Flowrate

10 Impeller diameter

3.1.2 ATEX plate

Fig. 2 ATEX plate (example)

1 Explosion protection mark

2 Reference to ATEX additional instructions

3.1.3 Pump type code

MPC 50 - -32 200

Fig. 3 Pump type code (example)

1Series

2 Suction branch DN [mm]

3 Pressure joint DN [mm]

4 Nominal impeller diameter [mm]

8 MPC-B series BA-2006.03 EN – 01

Layout and function

3.2 Layout

32 4

568 7

Fig. 4 MPC-B layout

1 Impeller

2 Housing armour

3 Volute casing

4 Motor

5 Drive shaft

6 Drive rotor

7 Pump rotor

8 Plain bearing bracket

EN – 01 BA-2006.03 MPC-B series 9

Transport, storage and disposal

4 Transport, storage and disposal

4.1 Transport

Weight speciﬁcations (→individual order documentation)

DANGER

Risk of fatal injury and material damage due to magnetic

ﬁeld!

Make sure no-one with a heart pacemaker performs any

work on the pump.

Secure the workplace and cordon it off if necessary:

– Ensure staff with heart pacemakers keep a minimum

distance of 1 m.

– Make sure no magnetisable metal parts are able to be

attracted by the magnetic coupling of the pump.

– Makesurenopartsofthemagneticcouplingareable

to be attracted by magnetisable metal parts.

Keep magnetically sensitive objects at least 150 mm away

from the magnetic coupling.

4.1.1 Unpacking and inspection on delivery

1. Unpack the pump/group on delivery and check it for trans-

port damage.

2. Report any transport damage to the manufacturer without

delay.

3. Dispose of packaging material according to local regula-

tions.

4.1.2 Lifting

DANGER

Death or crushed limbs caused by falling loads!

Use lifting gear appropriate for the total weight to be lifted.

Fasten the lifting gear as shown in the illustrations below.

Do not stand under suspended loads.

Fig. 5 Fastening the lifting gear to the pump group

Fig. 6 Fastening the lifting gear to the pump

Lift the pump/group properly.

10 MPC-B series BA-2006.03 EN – 01

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