Operating Instructions - SONDERMANN Pumpen + Filter GmbH
Contents
1. Ne e Caen E eeu ie RR 7 E C o b EUM ee ee d up ed 7 4 Product features and accessories nes 7 41 General description ione e ee ees 7 2 0 7 4 3 JACCOSSOIIBS neh 8 5 Mounting andl installation 8 5 1 assassin ii 8 3 2 Hoses and pipelines css br tee er beni 8 3 3 Electical nl e Mec m 9 5 4 Check sense se p 10 6 Starting and shutdown procedures 11 6 1 Preparations for Starting sss utter Bee 11 6 2 Starihiqg the UIT isa er bee 11 e E ee EE 11 64 Shutdown procedure ain meme ple eek 12 6 5 Waste disposal cet ed hal 12 7 Service and Maintenance ss 13 7 1 General Teen e eos de scs tut Mt er um A Edd 13 7 2 Prevenuvermamntenanee sce sea 13 8 4 f bleshoolihg nn euer 14 9 Spare Parts 16 10 Tor RARE 20 10 1 Dimensioned drawing RMB 3 1 20 oA Eaa o IRo Eee EE E 21 10 3 Performance charts ucc ee aa AA ett tea olde bon see 22 10 4 Labour protection and accident prevention nenn 23 10 5 Declaration of 55 66565 24 nnn nnne 24 Operating Instructions 1 General Information2. significant than presumed the delivery line motor by solid parts or dry run expert and repair the damage NOTE At dry running of the pump the impeller magnet will heat sealed with the magnet housing The remaining liquid heats up inside the casing in fact of the rotation of the impeller on the shaft and will vaporize The heat cannot evacuate any more the plastic material will lose it s consistency and this results into a frictional welding The pump may not run for longer time against the closed pressure line or with closed suction line If the dry run is happened liquid gets out of the hole in the intermediate housing between pump and motor because by the welding of the inner parts the magnet housing can get leaky Operating Instructions 9 Spare parts 9 1 Sectional view RMB 3 1 made of PP 7 417 2 6 6217 Lei LOL 2 7 ogl en SVT CA EYLE 206 66 7 Eh ALZA MI gt A yee LT IM iS a eme fe OR 270 OEZ SSR Al LE 22 20285 Sle ZA Hamm ai RE ER IS t qe ur died ar ap E E aw END fi ie N CICR Ss Si Es ak el 4 B TWEEN 2478 E ARM e L7SS L7L6 e e LOL 706 008 178 2746 06 16 Operat
3. The pump may only be used in the range of applications authorized by the manufacturer In case of modified operating conditions please consult your supplier and or the manufacturer 1 1 Fields of application e Pumping of liquids which are in viscosity like water without abrasive particles Pumping of acids and alcanlines e Pumping of gaseous fluids e Any use other that the authorized one as well as any conversion of the pump is not permitted CAUTION Make sure that the materials of which the pump is made are resistant to the fluids delivered Ask your pump s supplier or the manufacturer for the respective chemical resistance chart e f you pump crystallizing fluids make sure that the fluid does not crystallize within the pump Should this happen carefully clean all parts being in contact with the fluid immediately after shut off the pump NOTE Disassembly of the pump will cancel the right to all warranty claims 1 2 Capacity ratings Besides the operational data of the pump the type plate also gives its type and serial number Please cite these data when asking for additional information placing reorders and in particular ordering spare parts For additional information please consult your supplier or the manufacturer Technical data 12 175 175 l min 15 225 225 l min 18 250 250 l min 12 175 12 WC 15 225 15m WC 18 250 18 m WC PP or PVDF Ceramic Teflon Graphite FKM
4. 1 920 1 Sechskantmutter DIN 934 Hexagon nut DiN 934 i2 Me Sechskantmutter DIN 934 Jbenwurfmutter PVD N PVD 4 1 Eiting spring o HNE 1 Laufradmagneteinheit i bestehend aus den Pos 230 310 314 2 230 310 314 2 847 1 847 1 1 pan N LA 4 E A in on en E on en A N on in gt Ww e I N 75 kw 2 1 4 Oo 5 9 9 c D 5 07 fe 8 en S il w Qty Ew 412 4 Em RS 10 EX EX 10 In Js o Parts of wear and tear NOTE I n case of ordering spare parts please indicate the item of the needed part the pump type the serial no motor power and drawing no 19 Operating Instructions 10 Appendix 10 1 Dimensioned drawing RMB 3 1 62 PNWO ON3Z motor with PN 0 DN32 Pg MER i terminal box il rotating by 90 9140 450 PVDF M8 mounting slot maximum distance of mounting screws 47 mm Position of the terminal box standard position is on top if you need it mounted the right or the left please indicate when placing your order 20 Operating Instructions 10 2 Technical Data 12 175 Un suction side 1 m s discharge side 3 m s Other voltages available upon request With maximum volume rate of flow To deliver liquids with a higher relative density the pum
5. EPDM FEP see type plate 0 55 0 75 kW see type plate clockwise seen from the pump towards the motor 2800 min 1 Protection class IP 55 Materials Motor power Rated current A Sense of rotation EIE 5 2 e 2 2 Q Q 3 x jo approx 11 13 kg Max temperature of the pumped liquid 65 PVDF 85 C Max system pressure at 20 2 5 bar PVDF 3 5 bar NOTE In order to determine the maximally allowed temperature of the fluid please refer to the delivery note and or the type plate for information on the materials used for the pump Operating Instructions The materials on the type plate are built on following key PP Polypropylene glass fiber reinforced P Polyvinylidenfluoride K Oxide ceramic G Teflon Graphite V Seal material K K K VDF Bearing ceramic Casing thrust ring ceramic Centering shaft ceramic possible V FKM EPDM FEP coated 2 Safety This operating manual gives basic instruc tions which are to be observed during in stallation operation and maintenance of the pump Therefore it is imperativ that this manual has to be read by the responsible personnel operator prior to assembly and commissioning It is always to be kept available at the installation site It is not only the general safety instructions contained under this main heading safety that are to be observed but also the specific information provi
6. all parts being in contact with the fluid once the pump has been shut off e Please check the condition of the static seals at regular intervals and replace them if necessary Before longer shutdown periods we recommend to flush the pump cleanly Please take care that no residual dirt can cure in the pump and will block out the impeller at the re start e f not only wear parts are replaced but also repair work is to be done this should be performed by an expert only Inappropriate service and maintenance work often results in a waste of money 13 CAUTION When assembling or disassembling the pump make sure that there are no magnetisable metal particles in the working area When the complete head of the pump is assembled or disassembled magnetic forces can cause serious injury CAUTION After completion the pump head the impeller item 230 and the impeller magnet item 847 1 should be sliding along the axis of the centering shaft item 211 Operating Instructions 8 Troubleshooting Pump does not run when switched on Pumpe does not suck Up Magnet clutch is disengaged Motor is overheating Pump is working delivering Too much flow noises but not No voltage Impurities in the pump housing Wrong sense of rotation Pump housing is not filled up Suction line is not vacuum tight Discharge line is closed by valve or liquid so that the suction line can not be e
7. connection 400 V purple S 5 4 Check sense of rotation CAUTION Do not check the sense of rotation before the pump is filled with fluid Check the sense of rotation of the motor by switching it on and off in immediate succession The sense of rotation must be in accordance with the arrow figuring on the pump Slip a soft material such as a paper strip into the slits of the motor skirt to determine the sense of rotation Mind the sense of rotation indicated by an arrow on the pump and verify if after installation If necessary please change the sense of rotation by interchanging of 2 phases at the terminal board 10 Operating Instructions 6 Starting and shut down procedures 6 1 Preparations for starting Always wear protective clothing The suction housing has to be filled up with water respectively pump medium Pump of PP Open both toggle screws at the cover on the pump housing and fill up the liquid Set in the cover currently and tighten the toggle screws equally Pump of PVDF Open the screwed cover on the pump housing and fill up the liquid Screw the cover and tighten it closely Please take care the the cover at the pump housing is air proof otherwise the pump is not able to suck up CAUTION Avoid any dry running of the pump NOTE We recommend installing dry running protection devices such as flow monitors contact manometers different
8. SONDERMANN PUMPEN FILTER GMBH amp Co KG Operating Instructions Magnetically coupled Centrifugal Pumps Type RMB 3 1 self priming Made of PVDF Operating Instructions EG KONFORMIT TSERKL RUNG EC Declaration of Conformity Declaration de Conformite CE Hiermit erkl ren wir dass die SONDERMANN magnetisch gekuppelten Kreiselpumpen in den gelieferten Werkstoffen und Ausf hrungen folgenden einschl gigen Bestimmungen entsprechen We herewith confirm that the SONDERMANN magnetically coupled centrifugal pumps in the supplied materials and versions corresponds to the following EC rules Nous confirmons que les pompes centrifuges accouplement magn tique SONDERMANN livr es en mat riaux et versions diff rents sont conformes aux dispositions r glementaires suivantes 1 EG Richtlinie Maschinen EC Machinery Directive Directive CE Machines 98 37 CE 98 37 CE 98 37 CE 2 EG Niederspannungsrichtlinie EC Low Voltage Directive Directive CE Bas Voltages 2006 95 EG 2006 95 EG 2006 95 EG SONDERMANN 01 09 2007 PUMPEN FILTER GMBH amp Co KG bk Klaus Gesch ftsf hrer Operating Instructions TABLE OF CONTENTS 1 General Informalion na 4 11 Applications ee le A 1 2 Gapacity 4 5 3 Transportation and 2 2 nana nans nnn ac aa ana saxa 7
9. ded under the other main headings 2 1 Identification of safety instructions in the operating manual Safety instructions given in this manual non compliance with which would affect safety are identified by the following Safety sign according to DIN 4844 W9 Warning of electricity are identified by the specific Safety sign according to DIN 4844 W Instructions non compliance with which would give rise to malfunctioning of the machinery are identified by the word Signs and labels affixed to the equipment such as Arrows indicating the sense of rotation Symbols indicating fluid connections e Warnings to protect the pump from dry running Must be strictly observed and always kept legible 2 2 Qualification and training of operating personnel The personnel responsible for operation maintenance inspection and assembly must be adequately qualified Scope of responsibility and supervision of the personnel must be exactly defined by the plant operator If the staff does not have the necessary knowledge they must be trained and instructed which may be performed by the machine manufacturer or supplier on behalf of the plant operator Moreover the plant operator has to make sure that the contents of the operating manual are fully understood by the personnel Operating Instructions 2 3 Hazards in the event of non compliance with the safety instructions Non compliance with the safety instructions may
10. ial pressure switches or level controllers Tighten all screwed connections Entirely open all valves of the suction line 6 2 Starting the pump Switch on the motor 11 Await the procedure of sucking up until the pump has evacuated the suction line This can last until 15 minutes 02 4 6 8 10 12 14 16 18 2C Ansaugzeit in Minuten Adjust the operating point by slowly opening the shut off valve of the discharge line If there is no shut off valve installed to the discharge line the operating point is automatically adjusted in accordance with the characteristic curve of the pump CAUTION Do not run the pump with the discharge line closed for a longer period of time This may result in heating up the fluid inside the pump housing and damaging interior components of the pump CAUTION Always protect the pump from coarse impurities and magnetisable metal particles within the fluid delivered 6 3 Operation If the motor circuit breaker switched off the pump motor proceed as follows Operating Instructions Before switching on the motor again check whether the impeller turns readily Make sure that the suction line and the pump housing are filled with fluid Switch on the motor If the pump delivers for a short period of time only and then stops pumping the magnetic coupling has been disengaged Proceed as described in chapter 8 Troubleshooting below 6 4 Shut down pr
11. ing Instructions 9 2 Spare parts list RMB 3 1 made of PP ER B FE Dimension Pump casingwitnr2 Jee sca Zwischengeh use 0 75kW intermediate Casing Jee sc31 143 1 saugsieb opionan Suction screen fee 160 1 Deckel mit kneben Jee Joes Anlaufscheibe Item 314 1 1742 1 Leitschaufelemsatz Guide biade insert pp Joes 230 1 115mm jee 3141 1 Antautingspattopt Thrust disc casing 1314 2 1 Laufrad Aniautring impeller thrustring bas 3143 1 1 Gen use aniautring Casing thrust disc kerami ara 1 Viton Joss anzar 1 Jo Ring Jong fns 25 1 forn Joan fwon 50 4127 1 foring Ju j406x53 541 U Scheive DIN 125 Jane Jaz 64 1 _ motorzwischentiansen 800 1 motor 0 75 kw 230 400 v Motoroz5kw 4o0v 847 1 Antriebsmagnet 30 305 _ magnet Jee 17 8472 1 mnenmagnet __ Jee Zylinderkopfschraube eo 1 Istitscnrauve I Pinscrew 912 1 Jentieerungsstopfen Drain plug PP D D 115 mm M 5 x 12 6 x 10 OHNE 1 Laufradmagneteinheit bestehend aus den Pos Parts of wear and tear GX100DIN NOTE In case of ordering spare parts please indicate the item of the needed part the pump type the serial no motor power and drawing no 9 3 Sectional view RMB 3 1 made of PVDF Operating Instruct
12. ions LOL 72 7 Lae 47 ZIE 2 DIE 1 ELL LIL 2 78 zg AE UI E ee TSE g YL 2106 2 FIRER SCH KU XX HAIE YU Coen CL 2 4 im e NUS i PM NWY Se S AI LL KZ A H ES wa 6217 721 00 7 1046 076 Z 758 ELDOG 706 14106 1755 EZZ 008 18 Operating Instructions 9 4 Spare parts list RMB 3 1 made of PVDF Geh use mit Gewinde 2 Pump casing with G2 G 3 1 Zwischengeh use 0 75KW Intermediate Casing PP G 3 1 re cover cpl with PVDF Anlaufscheibe Item 314 3 VDE 63 1 Zentrierwelle Oxidkeramik eramik 50 mm VDF 115 Gleitlager i G3 Laufrad Anlaufring eflon G Anlaufscheibe Topf eramik O Ring Geh use O ring casing iton u o o o 3 14 2 D 10 b WIN IN J lt j gt Io I I Io D ES i 7 4 d 7 D N n BE 1 A Elsie leis Is z zz aj 1 e N 4 N N 40 x 5 47 x 5 3 0 x 3 0 40 x 5 D c O ring iton fiton Gm Viton ton U Scheibe DIN 125 U Scheibe DIN 125 Motorzwischenflansch a lindscheibe PVDF 2 000 min 1 VDF 115mm Antriebsmagnet 30 30 S Drive magnet 30 305 ps1 mm Skt Schraube DIN 933 9012 10 901 3 94
13. l be the plant operator s responsibility to ensure that all maintenance inspection and assembly work is performed by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail Any work on the machine shall only be performed when it is at a standstill it being imperative the procedure for shutting down the machine described in this manual be followed Pumps and pump units which convey hazardous media must be decontaminated On completion of work all safety and protective facilities must be re installed and made operative again Prior to re starting the machine the instructions listed under Initial com missioning have to be observed 2 7 Unauthorized alterations and production of spares Any modifications may be made to the machine only after consultation with the manufacturer Using spare parts and accessories authorised by the manu facturer is in the interest of safety Use of other parts may exempt the manufacturer from any liability Operating Instructions 2 8 Unauthorized modes of operation The reliability of the machine delivered will be only guaranteed if it is used in the manner intended in accordance with clause 1 of this manual The limit values specified in the data sheet must under no circumstances be exceeded 3 Transportation and storage 3 1 Transportation The pump is delivered by the manufacturer in a ready to wo
14. mp was carefully emptied and cleaned we have to take any safety precautions you have to give us the necessary information when sending the pump or its component 23 Operating Instructions 10 5 Declaration of harmlessness The undersigned herewith declares that the following pump and its accessories are harmless and asks you to service and or repair it or them Type of the pump We herewith declare that the pump was not used to deliver harmful or noxious substances it was used with the following fluids before being shipped the pump was carefully emptied and cleaned inside and out it is not necessary to take any special safety precautions you have to take the following safety precautions with regard to residual fluids and waste disposal Date signature 24 Operating Instructions 25 Operating Instructions 26 Operating Instructions 27 SONDERMANN PUMPEN FILTER GMBH amp Co KG August Horch Str 4 D 51149 K ln Cologne Germany Tel 49 0 2203 9394 0 Fax 49 0 2203 9394 48 info sondermann pumpen de www sondermann pumpen de Subject to alterations Copyright by SONDERMANN PUMPEN FILTER GMBH amp Co KG e Technische Anderungen vorbehalten e SB BG3 1 08 08 D
15. ocedure e Switch off the motor e Close all valves Incase some fluid remains within the pump secure the shut off valves to prevent an accidental opening e f the pump is not to be used for some time carefully rinse it off with a clean and neutral liquid This is to prevent remaining fluid from depositing within the pump and the sleeve bearings e If the pump is shut down for repair or maintenance work lock the driving unit so that it cannot be switched on Before dismantling the pump close the suction and the discharge lines and empty the pump under controlled conditions e Secure all valves to prevent an accidental opening Wear protective clothing 6 4 Waste disposal This product as a whole as well as parts of it should be disposed of in an environmentally safe way 12 CAUTION Please comply with the respective regulations that are currently in force at your place especially with regard to electronic scrap Operating Instructions 7 Service and maintenance 7T 1 General information This pump is designed for continuous operation and does not require specific maintenance 7 2 Preventive maintenance Although bearings centering shaft and starting rings are designed for continuous operation they should be periodically inspected for deposits e deliver crystallising fluids make sure that the fluid does not crystallise within the pump Should this happen carefully rinse off
16. p has to be throttled see the following performance chart 21 Operating Instructions 10 3 Performance Charts Him WS 60 porto at 20 C Q l min Q m7h motor capacity Iw 9 22 Operating Instructions 10 4 Labour protection and accident prevention NOTE In order to protect their employees and other people as well as the environment from harmful influences and effects when handling hazardous substances industrial and commercial companies are obliged to comply with legal provisions referring to labour protection such as the German Workplace Regulations ArbSt ttV Hazardous Substances Regulations GefStoffV and regulations for the prevention of accidents as well as environmental regulations such as the German Waste Act and the Water Resources Law WHG We therefore ask you to enclose a declaration of harmlessness with any pump or component you send us for repair With this form duly filled in and signed you declare that the pump or the component was cleaned and thoroughly rinsed with neutral fluid before being shipped to us Notwithstanding this we reserve the right to refuse acceptance of repair orders for any other reason So SONDERMANN products and their components are neither serviced nor repaired unless this declaration of harmlessness is enclosed see page 25 below Pumps that have been operated with radioactive substances are not accepted at all In case that although the pu
17. produce a risk to the personnel as well as to the environment and the machine and results in a loss of any right to claim damages For example non compliance may involve the following hazards Failure of important functions of the machine plant Failure of specified procedures of maintenance and repair Exposure of people to electrical mechanical and chemical hazards Endangering the environment owing to hazardous substances being released 2 4 Compliance with regulations pertaining to safety at work When operating the pump the safety instructions contained in this manual the relevant national accident prevention regulations and any other service and safety instructions issued by the plant operator are to be observed 2 5 Safety instructions relevant for operation f hotor cold machine components involve hazards they must be protected against accidental contact Guards for moving parts must not be removed from the machine during operation Any leakage of hazardous e g explosive toxic hot fluids e g from the shaft seal must be drained away so as to prevent any risk occuring to persons or the environment Statuory regulations are to be complied with Hazards resulting from electricity are to be precluded see for example the VDE specifications and the bye laws of the local power supply utilities 2 6 Safety instructions relevant for maintenance inspection and assembly work It shal
18. rk state In the event of damages occuring during and due to transportation the forwarding agent must make a factual statement The pump should always be transported appropriately and according to the state of the art 3 2 Storage An eventual storage place must be absolutely dry Make sure that the interior of the pump is protected from pollutants 4 Product features and accessories 4 1 General descritption The magnetically coupled pumps of group 3 1 are self priming pumps of plastics single staged horizontal in block system Pump and electrical motor are connected by a magnet coupling which transmits the motor power to the impeller The pumps are constructed with an integrated suction tank which has to be filled up prior to the first start up 4 2 Design Housing impeller impeller magnet and rear casing are made of plastics Standard pumps are equipped with centering shafts and bearings made of oxide ceramics The rear casing hermetically seals the fluid from the ambient atmosphere Because of magnetic power transmission there is no need to mechanically seal the shaft So in contrast to mechanical or gland sealed pumps leakages through worn shaft sealing are definitely ruled out The pump is magnetically coupled Attention Coming in contact with permanent magnetic parts during repair or maintenance work dangerously exposes to magnetic forces which for example may influence pace makers Keep your di
19. stance The pump housing parts are sealed by static o rings The impeller of the pump is a radial flow wheel Depending on the fluid to be delivered each component of the pump is available in various materials NOTE The materials used are listed on the name plate or the delivery note Choice of material Pump housing rear PP PVDF casing impeller impeller magnet coating and suction tank Centering shaft Teflon Graphite FKM FEP coated 4 3 Accessories Hose connections thermo switches switch on and off with cable and plug Operating Instructions protective motor switches sieves foot valves and more components are available upon inquiry 5 Mounting and installation The place of installation should be dry and make easy to handle the pump At moist area a good ventilation has to be guaranteed Ambient temperature 10 C bis 40 C 95 relative humidity non condensing Humidity max NOTE In case of higher ambient temperatures please consult your supplier manufacturer 5 1 Mounting The pump is set up to be mounted horizontally and please attend to leave enough space for maintenance In fact of the pump is conditionally self priming it s also possible to install it above the liquid level Following geodetic suction heights have to be kept Type Max suction height water 20 12 175 3 0 mWC 15 225 3 5 mWC 18 250 1 0 mWC The max suc
20. t exceed the limit of 1m s For easy installation and removal of the pump a shut off valve but no diaphragm valve should be built into the suction line ACHTUNG Do not use the shut off valve built into the suction line to adjust the delivery rate 5 2 2 Discharge line Standard flow velocity within the discharge line is 3m s To adjust the flow rate we recommend installing a control element to the discharge line 5 3 Electrical connection All electrical connections to the pump should be performed by experts only All electrical connections and installations of additional protection devices should be performed by experts only and in accordance with the instructions of your local power supplier and or the Association of German Electrotechnical Engineers VDE The motor must be equipped with a motor circuit breaker or a pilotherm to protect it from overloading NOTE Motor protection devices are available with the pump s manufacturer Make sure that the power supply has been cut off for at least 5 minutes before you start working on the terminal box of the pump e Check out whether the power supply available corresponds to the data given on the name plate The electrical connections had to be done according to the following schematic Three phase motor delta connection d 230V i yellow green purple Operating Instructions star
21. tion height depending on the kind of liquid can be reduced in reason of Friction loss in the suction line Higher temperature of liquid Higher density or and viscosity lower boiling point CAUTION Please take care for vacuum restistant connections at the suction line If the suction line is leaky the pump will suck up very bad or not at all 5 2 Hoses and pipe lines Make sure that the cross sections of the pipe lines fit the suction and discharge ports All suction and discharge line to the pump housing should be free of tension The weight of the hoses and pipes must not burden the housing CAUTION Do not install any quick acting stop valves into the tubes Pressure jerks may damage the pump and magnet housing 5 2 1 Suction line The suction line should be a tube or hose which will not deform by the Operating Instructions resulting partial vacuum or by high temperatures The suction line should be as short as possible Make sure to mount it so that there will be no gas accumulation Especially at long suction lines and suction heights of more than 1 5 m we recommend the installation of a foot valve for shortening the suction time The foot valve will prevent total drainage of the suction line when the pump stands still When dimensioning pipelines fittings etc make sure to keep the flow resistances as low as possible Flow velocity within the fitted suction line should no
22. vacuated Resistance in the suction line is too high Specific weight and or viscosity of the fluid is too high Pump was switched off then switched on again before the rotor stopped Impeller blocks out Clogged ventilator cowl Motor is overloaded Motor cooling is not sufficient Gas accumulation in the lines Valve in suction delivery line is closed Cavitation 14 Test the voltage Remove the impurities Reverse the polarity of the motor Fill up the housing with liquid Tighten the connections Open the valve and evacuate the discharge line Reduce the suction height and or clean the suction line Reduce the delivery rate use a stronger magnet clutch and a more powerful motor The rotor should have stopped before the pump can be switched on again Clean the inner parts Clean the ventilator and the cowl Reduce the delivery rate Use a stronger motor Care for a better motor cooling Evacuate the lines Open the valves Increase the suction line cross section Reduce the delivery rate Cool down the fluid Operating Instructions Delivery rate is too low Air in the system Evacuate the system Suction and delivery line Increase the suction and cross sections are too small delivery line cross sections significant losses Cavitation Increase the suction line corss section Wrong sense of rotation Reverse the polarity of the motor Valve is not entirely open Open the valves
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