Johnson Pump MDR Series User manual

Instruction Manual
MDR-series
Magnetic Drive Centrifugal Pumps
Read and understand this manual prior to
operating or servicing this product.
MDR/EN (0909)

Declaration of conformity
(Directive 98/37/EG, Annex IIA)
Manufacturer
SPX Process Equipment NL B.V.
Dr.A.F. Philipsweg 51, 9403 AD Assen
P.O. Box 9, 9400 AA Assen
The Netherlands
We declare under our sole responsibility that the product:
MDR-series
Magnetic Drive Centrifugal Pump
is in conformity with
COUNCIL DIRECTIVE on the approximation of the laws of the
Member States relating to Machinery 98/37/EG.
Declaration of incorporation
(Directive 98/37/EG, Annex IIB)
The pump must not be put into service until the machinery into which it is to
be incorporated has been declared in conformity with the provisions of the
Directive.
Assen, May 1 st 2008
Gerwin Schaafsma
Managing Director

Index
1.0 Introduction ______________________________________________5
1.1 General____________________________________________________5
1.2 Reception, handling and storage_______________________________5
1.2.1 Reception __________________________________________________ 5
1.2.2 Handling___________________________________________________ 5
1.2.3 Storage ____________________________________________________ 6
1.3 Safety _____________________________________________________6
1.4 Type designation ____________________________________________7
1.5 Function and operating principle ______________________________7
1.6 General precautions _________________________________________8
1.7 Standard parts ______________________________________________8
2.0 Technical information ______________________________________9
2.1 Material specification ________________________________________9
2.2 Suction lift and liquid level ___________________________________9
2.2.1 Max suction lift (Hs) _________________________________________ 9
2.2.2 Min required liquid level _____________________________________ 9
2.3 Min back pressure__________________________________________10
2.4 Min flow required __________________________________________10
2.5 Temperature range _________________________________________10
2.6 Max temperature versus system pressure ______________________10
2.7 Viscosity and specific gravity limits____________________________11
2.8 Sound level _______________________________________________11
3.0 Capacity_________________________________________________12
3.1 MDR - 1V (full impeller diameter) ___________________________12
3.2 MDR - 1VD (reduced impeller diameter)______________________13
4.0 Installation and maintenance _______________________________14
4.1 General___________________________________________________14
4.2 Installation and piping ______________________________________14
4.3 Start up___________________________________________________15
4.4 Routine control ____________________________________________15
4.5 Disassembly and assembly___________________________________16
4.5.1 Disassembly _______________________________________________ 16
4.5.2 Assembly _________________________________________________ 16
4.6 Waste handling/material recycling ____________________________17

5.0 Spare parts list ___________________________________________18
6.0 Trouble shooting chart_____________________________________19
7.0 Dimensions and weights ___________________________________21

5
MDR/EN (0909) 1.0
1.0 Introduction
1.1 General
Johnson magnetic drive centrifugal pumps type MDR are manufactured by SPX Process
Equipment, Assen, The Netherlands.
This instruction manual contains necessary information on the magnetic drive
centrifugal pumps and must be read carefully before installation, service and maintenance.
The manual must be kept easily accessible to the operator.
Important!
The pump must not be used for other purposes than recommended and quoted for
without consulting SPX Process Equipment’s distributor.
Liquids not suitable for the pump can cause damages to the pump unit and imply
risk of personal injury.
1.2 Reception, handling and storage
1.2.1 Reception
Remove all packing materials immediately after reception. Check the consignment for
damage immediately on arrival and make sure that the name plate/type designation is in
accordance with the packing slip and your order.
In case of damage and/or missing parts, a report should be drawn up and presented to the
carrier at once. Notify your local distributor.
On the pump there is a plate with
article number and fabrication num-
ber.Always state these numbers and
the pump type when contacting your
local distributor.
1.2.2 Handling
Check the weight of the pump unit (see section 7.0). All parts weighing more than 20
kg must be lifted using lifting slings or suitable lifting devices, e.g. overhead crane or an
industrial truck.
Always use two lifting slings. Make sure that they
are secured in such a way as to prevent them from
slipping and that the pump unit is hanging straight.
Never lift the pump unit with only one fastening
point. Incorrect lifts can cause personal injury
and/or damage to the product.
Ø
No.
SPX Process Equipment NL B.V., P.O. Box 9,
NL-9400 AA Assen - www.johnson-pump.com

6MDR/EN (0909) 1.0
1.2.3 Storage
If the pump is not installed immediately, it must be stored in a dry and cool place.
1.3 Safety
Personnel who have a pacemaker should not be allowed to work with the magnetic
coupling! The magnetic field is sufficiently strong to affect the operation of a pacemaker.
A safe distance is 1 metre!
Important!
The pump must not be used for other purposes than recommended and quoted for
without consulting SPX Process Equipment’s distributor.
A pump must always be installed and used in accordance with existing national and
local sanitary and safety regulations and laws.
• Alwayswearsuitablesafetyclothingwhenhandlingthepump.
• Anchorthepumpproperlybeforestartuptoavoidpersonalinjuryand/ordamageto
the pump unit.
• Installshut-offvalvesonbothsidesofthepumptobeabletoshutoffthein-andoutlet
before service and maintenance. Check to see that the pump can be drained without
injuring anyone and without damaging the environment or nearby equipment.
• Makesurethatallmovablepartsareproperlycoveredtoavoidpersonalinjury.
• Donotrunthepumpdry.Ifthepumpisrundrythereisariskofpumpbreakdown
caused by generated friction heat. If there is a risk of dry running, install a suitable dry
running protection to avoid serious damages.
• Allelectricalinstallationworkmustbecarriedoutbyauthorizedpersonnelin
accordance with EN60204-1. Install a lockable circuit breaker to avoid inadvertent
starting. Protect the motor and other electrical equipment from overloads with suitable
equipment. The electric motors must be supplied with ample cooling air.
If the pump is used for easily flammable liquids it is absolutely necessary that the pump
and the pipe system is filled up before start up and during operation. Make sure that no
air occurs in the system. Follow the instructions for start up (see section 4.3).
In environments where there is risk of explosion, motors classified as explosion safe
must be used, along with special safety devices. Check with the governmental agency
responsible for such precautions.
Improper installation can cause fatal injuries.
• Dust,liquidsandgasesthatcancauseoverheating,shortcircuits,corrosiondamage
and fire must be kept away from motors and other exposed equipment. If the pump
handlesliquidshazardousforpersonorenvironment,somesortofcontainermustbe
installed into which leakage can be led.
• Ifthesurfacetemperatureofthesystemorpartsofthesystemexceeds60°C,these
areas must be marked with warning text reading ”Hot surface” to avoid burns.

7
MDR/EN (0909) 1.0
• Thepumpunitmustnotbeexposedtorapidtemperaturechangesoftheliquid
without prior pre-heating/pre-cooling.Absolutely forbidden to flush a hot pump with
cold water. Big temperature changes can cause crack formation or explosion, which in
turn can entail severe personal injuries.
• Thepumpmustnotoperateabovestatedperformance.
• Beforeinterveninginthepump/system,thepowermustbeshutoffandthestarting
device be locked. When intervening in the pump unit, follow the instructions for
disassembly/assembly. If the instructions are not followed, the pump or parts of the
pump can be damaged. It will also invalidate the warranty.
• Ifthepumpdoesnotfunctionsatisfactorily,contactyourdistributor.
1.4 Type designation
Example
1 Family name
Magnetic Drive Centrifugal Pump
2 Pump size
45, 75, 85, 105, 116
3 Pump material
P2 = polyvinylidenfluoride (PVDF)
P3 = polypropylene (PP)
4 Impeller diameter
1V = full diameter for specific gravity up to 1.2 kg/dm3 and viscosity 10 cP
1VD = reduced diameter for specific gravity up to 1.8 kg/dm3 and viscosity 30 cP
1.5 Function and operating principle
The drive magnet, attached to the drive shaft transfers its torque to the impeller magnet.
The impeller can thereby rotate around the ceramic shaft in the pump body without any
physical contact between the drive shaft and the pump body. This makes the pump
completely leak-proof.
Ceramic shaft
Impeller magnet
Impeller
Magnet housing
Drive shaft
Drive magnet
MDR 45 P2 - 1V
1 2 3 4

8MDR/EN (0909) 1.0
1.6 General precautions
• Donotrundry.Ifthepumpisrunwithoutliquid,frictionheatwillbegeneratedinside
the pump which will melt the impeller onto the ceramic shaft and also possibly cause
damage to other parts.
• Donotusethepumpforotherliquidsthanquotedforwithoutconsultingyour
SPX Process Equipment distributor.
• Donotrunagainstclosedvalve.Thepumpwillbedamagedifitisrunmorethan3
minutes against closed valve.
• Donotrunreverse.Theimpellermustrotateinclockwisedirectionwhenviewedfrom
the motor end (see rotation arrrow on the pump body).
• Donotrunwithcavitationorairentrainment.
• Donotrunwithuidcontainingsolidorabrasiveparticleswithoutconsultingyour
local distributor.
• Donotexposethepumptothermalchocks.
• Checktheimpellerbearing,shaftandwearplatesregularlyforwear(seesection4.4).
• Donotcausechockpressure.
1.7 Standard parts
1. Pump body 4. Impeller 7. Magnet housing 10. Flange
2. Wear plate 5. Ceramic
shaft
8. Reinforcement
(not available for MDR45)
11. Motor
3. Bearing 6. O-ring 9. Drive magnet
65423321
79810
11

9
MDR/EN (0909) 1.0
2.0 Technical information
2.1 Material specification
Flange (not exposed to the liquid) Polypropylene filled with glass fibre
Magnet housing, impeller, body Polypropylene filled with glass fibre alt
Polyvinylidenfluoride with carbon fibre
Shaft, wear plates Ceramic/Al2O3
Impeller bearings PTFE-Rulon LD
O-ring FPM
Impeller magnet
(not exposed to the liquid)
Ferrite
2.2 Suction lift and liquid level
2.2.1 Max suction lift (Hs)
Hs [m] =
To be used only as a guidance.
Please contact your local
distributor for NPSH curves.
2.2.2 Min required liquid level
Minimum required liquid level at the
suctionnozzlemustbemorethan3x
the diameter of the suction pipe.
1øx3>H
1øx3>H
1ø
ø1
Foot-valve
Hs
4
Specific gravity [kg/dm3]
Pump
Foot-valve
Filling liquid

10 MDR/EN (0909) 1.0
2.3 Min back pressure
The MDR-series demands a
certain head for good function.
Min head = 0.5 m wc or 0.05 bar
manometric pressure. If less,
install a valve in the discharge
pipe to adjust head.
2.4 Min flow required
To cool and lubricate the impeller bearing and shaft a certain flow
is required through the pump.
Min. flow
l/min
Max. system pressure
bar (20°C)
MDR45 3 3
MDR75 5 3
MDR85 7 3
MDR105 10 3
MDR116 10 3
2.5 Temperature range
P2(PVDF) =-10°C-+100°C
P3(PP) =-10°C-+85°C
2.6 Max temperature versus system pressure
Valid for P3 (polypropylene) pumps tested in water
H
Pump
1
2
4
3
10 20 30 40 50 60 70 80 90
p (bar)
MDR45 / 85 / 105 / 116
°C
MDR75

11
MDR/EN (0909) 1.0
2.7 Viscosity and specific gravity limits
Impeller
diameter
Max. viscosity cP Specific gravity kg/dm3
-1V 10 1.2
1VD 30 1.8
2.8 Sound level
Highest measured sound level for the MDR-pump is 70 dB(A) for pump fitted to standard
electric motor.

12 MDR/EN (0909) 1.0
82
62
42
22
02
81
61
41
21
01
8
6
4
2
0
050 006055005054004053003052002051001
V1-58RDM
V1-57RDM
V1-54RDM
V1-611RDM
V1-501RDM
3.0 Capacity
3.1 MDR - 1V (full impeller diameter)
Basedonwaterat20°C(68°F)
Flow (l/min)
Head [m]

13
MDR/EN (0909) 1.0
3.2 MDR - 1VD (reduced impeller diameter)
Basedonwaterat20°C(68°F)
Flow (l/min)
Head [m]
82
62
42
22
02
81
61
41
21
01
8
6
4
2
0
050 006055005054004053003052002051001
DV1-611RDM
DV1-54RDM
DV1-58RDM
DV1-57RDM
DV1-501RDM

14 MDR/EN (0909) 1.0
4.0 Installation and maintenance
4.1 General
• Anchorthepumpproperly.
• Thepumpmustbeprovidedwithlockablecircuitbreakertoavoidinadvertant
starting.
• Beforeanyserviceormaintenanceinthepumporsystem,shutoffthepowerandlock
the starting device to prevent inadvertent start. Close the valves on the in- and outlet
line and drain the pump and system before it is separated from the system. Follow the
instructions for disassembly/assembly (see section 4.5).
4.2 Installation and piping
• Use at least the same diameter on pipes from and to the pump as for the diameter of
the in- and outlet ports.
• Flushallpipesbeforeinstallingthepump.
• Installthepumpclosestpossibletothetanktobepumpedfrom.
• Boltthepumpinplacehorizontally.
• Onlyuseplasticpipeconnections.
• Usecaretopreventscrapsortrashesfromenteringthepipingduringpipingwork.
• Onlyusepipesealantsformulatedspecicallyforplastics,i.e.Teontape,Permatex
no. 2, etc.
• Usethegriponthepumpoutletwhenassemb-
ling/disassembling the pipe connections to avoid
damaging the pump body (see fig).
• Installavalveonthesuctionandpressuresideto
be able to disconnect the pump from the system.
Make sure that the pump can be drained without
damaging persons, environment or equipment.
• Whenthepumpdoesnothaveaoodedsuction,installafootvalveonthesuction
line. Fill up the pump and evacuate all air. Make sure that it will never run dry.
• Ifthereisanyriskofairpocketsinthesystemorinthepumpbody,aventilatingvalve
must be installed on the pressure side.
• Ifthereisanyriskthatthedischargeheadwillnotreachtheminimumheadneeded
(see section 2.3), install a valve to adjust the head.
• Ifthereisanyriskofdryrunning,installasuitabledryrunningprotectiontoavoid
pump breakdown. This is absolutely necessary and required when pumping liquids that
are easily flammable.
Grip

15
MDR/EN (0909) 1.0
4.3 Start up
• Prime pump
When operating with lift, prime and work out all air.
Note! Pump must not be run without liquid – not even for a short time. When
pumping liquids that are easily flammable, no air is allowed in the system. This
is absolutely necessary in order to avoid that static electricity is generated in
the pump which may cause sevre personal and material damage.
• Check rotation
Open the suction valve and close discharge valve.
Check the rotation of the pump by turning the pump on briefly once. Make sure that
the motor rotates in the correct direction (see rotation arrow on the pump body).
• Starting
When the pump has been started, open the discharge valve slowly and check the
pressure, temperature and flow. Make sure that the piping is properly sealed and that
the pump functions satisfactorily. If not, follow the trouble shooting chart (see section
6.0) or contact yourlocal distributor.
Do not run against closed valve for more than 3 minutes.
When returning a pump for repair, investigation or other reason, it must be cleaned and
wrapped up in a proper way. Documentation stating pumped liquid, operating conditions,
your own opinion of fault/failure reason and your contact person must be included in the
pump package. Also contact the consignee before returning the pump.
4.4 Routine control
• Toavoidproblems,regularlycheckpumpnoise,vibration,capacity,pressuregauge,
motor amperage draw, etc.
• Checkimpellerbearingsforwearafter1to2monthsofoperation.
• Decidethecontrolintervalsaccordingtowearandbearingdiameter.
Diameter of impeller bearing
Replace the impeller at the following inner diameters:
MDR45 7.25 mm
MDR75 10.35 mm
MDR85 10.35 mm
MDR105 15.50 mm
MDR116 15.50 mm
• Iftheimpellerbearingsonlyarereplaced,theyhavetobereamedjointlytothe
following diameters after assembly:
MDR45 7.10 ± 0.05 mm
MDR75/85 10.16 ± 0.04 mm
MDR105/116 15.21 ± 0.04 mm
• Checkwearontheceramicshaftandtheceramicwearplates.
Replace when necessary.
• Ifthepumpwillbestoppedforalongtime,drainandcleantheinteriorofthepump.

16 MDR/EN (0909) 1.0
4.5 Disassembly and assembly
See drawing, section 5.0.
Always wear suitable safety clothing. Clean the pump carefully before disassembling.
4.5.1 Disassembly
1. Place the pump vertically with the motor facing downwards and the pump body
upwards.
2. Remove the screws (pos 10) and the pump body (pos 8).
3. Remove the front wear plate (pos 4), the impeller (pos 6), O-ring (pos 7), shaft (pos 5)
and rear wear plate (pos 4). MDR105 and MDR116 have only the rear wear plate. The
front wear plate is integrated in the impeller.
4. Remove the magnet housing (pos 3) including the reinforcement (pos 19 – not
available for MDR45).
5. If the motor, drive magnet or flange is to be replaced, loosen the two locking screws
(pos 2) locking the drive magnet onto the motor shaft. The screws can be reached
through the assembly hole in the flange (see section 5.0). Remove the drive magnet
(pos 13).
6. Remove the screws (pos 12) and the flange (pos 1).
7. Check and clean all the parts which will be reused.
4.5.2 Assembly
1. Place the motor with the shaft facing upwards. Check that the drive magnet (pos 13)
easily can be slided onto the motor shaft. If necessary the motor shaft should be
polished.
2. Assemble the flange (pos 1) to the motor with the assembling hole facing in the same
direction as the motor feet. Bolt the flange to the motor with the 4 screws (pos 12) and
the washers (pos 11). Secure with Loctice.
3. Assemble the drive magnet (pos 13) to the motor shaft and lock the drive magnet with
the two locking screws (pos 2). The screws can be reached through the assembling hole
in the flange (see section 5.0).
4. Assemble the magnet housing (pos 3) with the reinforcement (pos 19 – not available
for MDR45) on the flange and check that the drive magnet can be turned without
touching the magnet housing or reinforcement.
5. Assemble the rear wear plate (pos 4) onto the ceramic shaft (pos 5). Note that the
smooth side (without the ”dot”) of the wear plate must face the impeller bearing.
Assemble the shaft and wear plate in the magnet housing. Slide the impeller (pos 6)
onto the shaft followed by the front wear plate (pos 4) with the smooth side facing the
impeller bearing (not available for MDR105 and MDR116 where the front wear plate
is integrated in the impeller).
6. If reusing an old impeller, check that the impeller bearings are not worn beyond the
diameter specified in section 4.4. If the bearings need to be replaced, the new bearings
must be reamed jointly after assembly in the impeller.Turn the impeller by hand and
check that it is running easily on the shaft.
7. Assemble the O-ring (pos 7)
for MDR45 and MDR85 in the groove of the magnet housing
for MDR75 in the groove of the pump body
for MDR105 and MDR116 at the dia 135 mm in the magnet housing.
8. Assemble the pump body (pos 8) and tighten the screws (pos 10) together with the
washers (pos 9) and nuts (pos 15).
Note! For the MDR116 the spacer (pos 16) must be mounted before assembly in the
pump body.

17
MDR/EN (0909) 1.0
4.6 Waste handling/material recycling
At the products end of life, please dispose of the product according to applicable law.
Where applicable, please disassemble the product and recycle the parts material.

18 MDR/EN (0909) 1.0
37 13 411 122
19
5
14
4
6,1
6,1
16
4,1
MDR105/116
8
6
9
10
15 1
16
9
5.0 Spare parts list
Pos Nos Description Material MDR45 MDR75 MDR85 MDR105 MDR116
1 1 Flange P2/P3 PP 01-24373-1 58-08299 01-13097-1 58-018376 58-018376
2 2 Screw 0.0300.544 0.0300.524 0.0300.523 0.0300.565 0.0300.565
3 1 Magnet housing PP 01-24374-1 58-08301 01-13098-2 58-08334 58-08334
1 Magnet housing PVDF 01-24405-1 58-08302 01-13113-2 58-08335 58-08335
4 2* Wear plate Ceramic 01-45897-1 58-08298 58-08298 58-08330 58-08330
4,1) 1 Wear ring Rulon - - - 58-08343 58-08343
5 1 Shaft Ceramic 01-45896-1 58-08297 01-35340-1 58-08329 58-08329
6 1 Impeller -1V PP/Rulon 04-35345-01 58-08630 04-35334-01 58-08636 58-18695
Impeller -1VD PP/Rulon 04-35345-02 04-46243-02 04-35334-02 04-46245-02 04-46612-02
1 Impeller -1V PVDF/Rulon 04-35671-01 58-08631 04-35361-01 58-08637 58-18696
Impeller -1VD PVDF/Rulon 04-35671-02 04-46244-02 04-35361-02 04-46246-02 04-46613-02
6,1) 2 Bearing Rulon 01-35348-1 58-08311 58-08311 58-08342 58-08342
7 1 O-ring FPM 0.2172.021 0.2172.029 0.2172.020 0.2172.022 0.2172.022
8 1 Body PP 01-24375-1 58-08307 01-13100-1 04-35766 58-08368
1 Body PVDF 01-24406-1 58-08308 01-13115-1 58-08659 58-08369
9 Washer SS 0.0350.605 (6) - 0.0350.207 (6) 0.0350.208 (12) 0.0350.208 (12)
10 6 Screw SS 0.0138.050 0.0251.690 0.0142.738 0.0142.730 0.0142.730
11 4 Washer SS 0.0350.206 0.0350.206 0.0350.207 0.0350.208 0.0350.208
12 4 Screw SS 0.0251.688 0.0251.688 0.0251.704 0.0251.714 0.0251.714
13 1 Drive magnet 04-35360-01 58-08624 04-35342-01 58-08634 58-08677
14 1 Motor 1-ph 220 V 4.9309.008 4.9309.317 - - -
1 Motor 3-ph 220/380 V 4.9309.009 4.9309.006 4.9309.005 4.9309.012 4.9309.004
15 6 Nut SS 0.0185.350 0.0185.350 0.0185.069 0.0163.014 0.0163.014
16 1 Spacer PP - - - - 58-08370
1 Spacer PTFE - - - - 58-08372
19 1 Reinforcement SS - 58-08295 01-35344-1 58-08324 58-08324
* The number of wear plates for MDR105 and MDR116 is 1 pce.
Assembling hole
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19
MDR/EN (0909) 1.0
6.0 Trouble shooting chart
Problem Possible cause Remedy
No flow Air pockets in suction lines Check piping of suction
lines and work out all air
Lack of prime (when suc-
tion head is negative)
Prime again
Air pockets inside the
pump
Work out all air
Insufficient suction head See section 2.2.1
Slipping magnet coupling Excessive specific gravity
and/or viscosity - check
against original specifica-
tion (see point 2.7)
Wear or damage of parts Replace parts
No liquid in the pump Check liqud level in the
tank. If a foot valve is
installed on the suction line
make sure that it is properly
sealed. Fill the pump again.
Underfeed Air entrainment or air
pockets
Check joint sections of suc-
tion lines. Work out all air
Run reverse Check direction of rotation
Excessive piping loss Reduce suction line length
or increase diameter
Impeller is clogged with
foreign materials
Remove foreign materials
Excessive power Excessive specific gravity
and/or viscosity
Check viscosity and specific
gravity against pump per-
formance (see section 2.7).
Excessive wear of pump
parts
Replace parts
Excessive wear of motor
bearings
Replace bearings/motor
Excessive vibration or
noise
Wear or damage of parts Replace parts
Short of head Increase discharge head
(see section 2.3)
Impeller is clogged with
foreign materials
Remove foreign materials

20 MDR/EN (0909) 1.0
Problem Possible cause Remedy
Leakage from pump
body
Loose pump body screws Tighten screws
Wrongly installed O-ring Replace O-ring
Damaged O-ring Replace O-ring
Make sure that the material
is resistant to the media
Shaft break Dry running, thermal-shock,
running against closed
valve, shock at
handling, corrosion
Replace shaft
Make sure that the material
is resistant to the media
Short of head Increase discharge head
(see section 2.3)
Magnet housing
damage
Dry running, excessive
wear, running against closed
valve, corrosion
Replace magnet housing
Make sure that the material
is resistant to the media
and that no dry running will
occur
Short of head Increase discharge head
(see section 2.3)
Impeller damage Excessive wear, corrosion Replace impeller
Make sure that the material
is resistant to the media
Impeller deformation Excessive temperature Replace impeller (see
section 2.5)
Excessive temperature vs
system pressure
Replace impeller (see
section 2.6)