Pratissoli MW Series User manual

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MW Series
Use and maintenance
manual
MW45 – MW50 – MW55
MW32 – MW36 – MW40
Menu

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INDEX
1. INTRODUCTION 3
2. DESCRIPTION OF SYMBOLS 3
3. SAFETY 4
3.1 General safety warnings.......................................................................................................4
3.2 Essential safety in the high pressure system........................................................................4
3.3 Safety during work...............................................................................................................4
3.4 Rules of conduct for the use of lances .................................................................................4
3.5 Safety during system maintenance.......................................................................................5
4. PUMP IDENTIFICATION 5
5. TECHNICAL CHARACTERISTICS 6
6. DIMENSIONS AND WEIGHT 7
7. OPERATING INSTRUCTIONS 8
7.1 Water temperature................................................................................................................8
7.2 Maximum pressure and flow rate.........................................................................................8
7.3 Minimum rotating speed......................................................................................................8
7.4 Brands and types of oils recommended ...............................................................................9
8. PORTS AND CONNECTIONS 11
9. PUMP INSTALLATION 12
9.1 Installation .........................................................................................................................12
9.2 Rotation direction ..............................................................................................................13
9.3 Version change and reduction gear positioning.................................................................13
9.4 Hydraulic connections .......................................................................................................14
9.5 Pump power supply ...........................................................................................................14
9.6 Suction line........................................................................................................................15
9.7 Filtration ............................................................................................................................15
9.8 Outlet line ..........................................................................................................................16
9.9 Calculation of the internal diameter of the duct pipes. ......................................................17
9.10 V-belt transmission..........................................................................................................18
10. START-UP AND OPERATION 18
10.1 Preliminary checks..........................................................................................................18
10.2 Start-up ............................................................................................................................19
11. PREVENTIVE MAINTENANCE 19
12. PUMP STORAGE 20
12.1 Method for filling pump with anti-corrosion emulsion or anti-freeze solution................20
12.2 Tubes................................................................................................................................20
13. PRECAUTIONS AGAINST FROST 20
14. GUARANTEE CONDITIONS 20
15. OPERATING FAULTS AND THEIR POSSIBLE CAUSES 21
16. EXPLODED DRAWING AND PARTS LIST 22

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1. INTRODUCTION
This manual describes the instructions for use and maintenance of the MW pump and should be carefully
read and understood before using the pump.
Proper pump operation and duration depend on the correct use and maintenance.
Interpump Group disclaims any responsibility for damage caused by negligence or failure to observe with the
standards described in this manual.
Upon receipt, verify that the pump is intact and complete.
Report any faults before installing and starting the pump.
2. DESCRIPTION OF SYMBOLS
Read the contents of this manual
carefully before each operation.
Warning Sign
Danger sign
Danger of electrocution.
Danger sign
Wear a protective mask.
Danger sign
Wear protective goggles.
Danger sign
Put on protective gloves before each
operation.
Danger sign
Wear appropriate footwear

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3. SAFETY
3.1 General safety warnings
Improper use of pumps and high pressure systems as well as non-compliance with installation and
maintenance standards can cause serious damage to people and/or property. Anyone assembling or using
high pressure systems must possess the necessary competence to do so, knowing the characteristics of the
components that will assemble/use and take all precautions necessary to ensure maximum safety in all
operating conditions. In the interest of safety, both for the Installer and the Operator, no reasonably
applicable precaution should be omitted.
3.2 Essential safety in the high pressure system
1. The pressure line must always be provided with a safety valve.
2. High pressure system components, particularly for systems that operate primarily
outside, must be adequately protected from rain, frost and heat.
3. The electrical control system must be adequately protected against sprays of water and must meet
specific regulations in force.
4. The high pressure pipes must be properly sized for maximum operating pressure of the system and
always and only used within the operating pressure range specified by the Manufacturer of the pipe itself.
The same rules should be observed for all other auxiliary systems affected by high pressure.
5. The ends of high pressure pipes must be sheathed and secured in a solid structure, to prevent dangerous
whiplash in case of bursting or broken connections.
6. Appropriate protective casing must be provided in pump transmission systems (couplings, pulleys and
belts, auxiliary power outlets).
3.3 Safety during work
The room or area within which the high pressure system operates must be clearly marked and prohibited to
unauthorised personnel and, wherever possible, restricted or fenced.
Personnel authorised to access this area should first be instructed how to operate within this area and
informed of the risks arising from high pressure system defects or malfunctions.
Before starting the system, the Operator is required to verify that:
1. The high pressure system is properly powered (see point 9.5).
2. The pump suction filters are perfectly clean; it is appropriate to include a device indicating the clogging
level on all devices.
3. Electrical parts are adequately protected and in perfect condition.
4. The high pressure pipes do not show signs of abrasion and the fittings are in perfect order.
Any fault or reasonable doubt that may arise before or during operation should be promptly reported and
verified by qualified personnel. In these cases, pressure should be immediately cleared and the high
pressure system stopped.
3.4 Rules of conduct for the use of lances
1. The Operator must always place his safety and security first, as well as that of others that may be directly
affected by his/her actions, or any other assessments or interests. The Operator's work must be dictated
by common sense and responsibility.
2. The Operator must always wear a helmet with a protective visor, waterproof gear and wear boots that are
appropriate for use and can ensure a good grip on wet floors.

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Note: appropriate clothing will protect against sprays of water but not from direct impact with jets of water or
very close sprays. Additional protections may therefore be necessary in certain circumstances.
3. It is generally best to organise personnel into teams of at least two people capable of giving mutual and
immediate assistance in case of necessity and of taking turns during long and demanding operations.
4. The work area jet range must be absolutely prohibited to and free from objects that, inadvertently under a
pressure jet, can be damaged and/or create dangerous situations.
5. the water jet must always and only be pointed in the direction of the work area, including during
preliminary tests or checks.
6. The Operator must always pay attention to the trajectory of debris removed by the water jet.
Where necessary, suitable guards must be provided by the Operator to protect anything that could
become accidentally exposed.
7. The operator should not be distracted for any reason during work. Workers needing to access the
operating area must wait for the Operator to stop work on his/her own initiative, after which they should
immediately make their presence known.
8. It is important for safety that all team members are always fully aware of each other's intentions in order to
avoid dangerous misunderstandings.
9. The high pressure system must not be started up and run under pressure without all team members in
position and without the Operator having already directed his/her lance toward the work area.
3.5 Safety during system maintenance
1. High pressure system maintenance must be carried out in the time intervals set by the manufacture who
is responsible for the whole group according to law.
2. Maintenance should always be performed by trained and authorised personnel.
3. Assembly and disassembly of the pump and the various components must only be carried out by
authorised personnel, using appropriate equipment in order to prevent damage to components, in
particular to connections.
4. Always only use original spare parts to ensure total reliability and safety.
4. PUMP IDENTIFICATION
Each pump has a specification label which contains:
Pump model and version
Serial number
Maxrevs.
Absorbed power Hp – kW
Pressure bar – P.S.I.
Flow rate l/min – Gpm
Model, version and serial number must always be
indicated when ordering spare parts.
fig. 1

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5. TECHNICAL CHARACTERISTICS
Flow rate Pressure Power
Model Rpm/1’ l/min Gpm bar psi kW Hp
1500 135 35.7 300 4350 77 105
1800 136 35.9 300 4350 78 106
MW 32
2200 136.5 36.1 300 4350 78 106
1500 171 45.2 240 3480 78 107
1800 172 45.4 240 3480 79 107
MW 36
2200 173 45.7 240 3480 79 108
1500 211 55.7 190 2755 77 104
1800 212 56.0 190 2755 77 105
MW 40
2200 213 56.3 190 2755 77 105
1500 267 70.5 155 2248 79 107
1800 269 71.1 155 2248 80 108
MW 45
2200 270 71.3 155 2248 80 109
1500 330 87.2 125 1813 79 107
1800 332 87.7 125 1813 79 108
MW 50
2200 333 88.0 125 1813 79 108
1500 399 105.4 100 1450 76 104
1800 401 105.9 100 1450 77 104
MW 55
2200 403 106.5 100 1450 77 105

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6. DIMENSIONS AND WEIGHT
For dimensions and weights of MW32, MW36 and MW40 pumps, refer to fig. 2.
For dimensions and weights of MW45, MW50 and MW55 pumps, refer to fig. 2/a.
Dry weight – 245 Kg
Dry weight - 244 Kg
fig. 2/a
fig. 2

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7. OPERATING INSTRUCTIONS
The MW pump was designed to work with clean water (see point 9.7) and at maximum
temperature of 40°C.
Other liquids can be used only after approval by the Technical or Customer Service
Departments.
7.1 Water temperature
The maximum permissible water temperature is 40°C. However, the pump can be used with
water up to a temperature of 60, but only for short periods. In this case, it is best to contact our
Technical or Customer Service Departments.
7.2 Maximum pressure and flow rate
The rated specifications stated in our catalogue are the maximum that can be obtained from the pump.
Independently of the power used, the maximum pressure and rpm indicated in the specification label can
never be exceeded unless expressly authorised by our Technical or Customer Service Departments.
7.3 Minimum rotating speed
Any rotating speed other than that indicated in the performance table (see chapter 5) must be expressly
authorised by our Technical or Customer Service Departments.

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7.4 Brands and types of oils recommended
The pump is supplied with oil suitable for room temperatures from 0°C to 30°C.
Some types of recommended oil are indicated in the table below. These oils have additives to increase
corrosion resistance and fatigue resistance (DIN 51517 part 2).
Alternatively you can also use Automotive SAE 85W-90 oil for gearing lubrication.
Check the oil level by means of the cap with dipstick,
equipped with minimum and maximum reference notches
c, fig.3. Refill if necessary to top up level.
The correct checking of the oil level is made with the pump
at room temperature.
Oil changes are to be made with the pump at working
temperature, removing the plug pos.d, fig.3.
The oil check and change must be carried out as indicated
in chapter 11.
The quantity required is ~ 9 litres.
fig. 3

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In any case the oil must be changed at least once a year, as it is degraded by oxidation.
For a room temperature other than between 0°C - 30°C, follow the instructions in the following diagram,
considering that oil must have a minimum viscosity of 180 cSt.
Viscosity / Room temperature Diagram
The oil must be placed in a suitable container and disposed of in special centres.
It absolutely should not be discarded into the environment.
Viscosity
Room Temp.

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8. PORTS AND CONNECTIONS
The MW series pumps are equipped with (see fig.4 and fig.4/a):
2 “IN“ inlet ports: G2” (in versions MW32, MW36, MW40)
Ø66 mm (in versions MW45, MW50, MW55)
Line connection to any of the two ports is indifferent for proper pump functioning.
The unused ports must be hermetically closed.
2 “OUT“ outlet ports: G1” (in versions MW32, MW36, MW40)
G1 ¼” (in versions MW45, MW50, MW55)
1 “DRAIN“ port: with a G1/2” hole positioned in the lower cover to monitor any water leaks due to pressure
seal wear. Refer to the repair manual for any leaks.
The above-mentioned holes must always be kept open.
fig. 4
fig. 4/a

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9. PUMP INSTALLATION
9.1 Installation
The pump must be fixed horizontally using the M16 threaded support feet.
Tighten the screws with a torque of 200 Nm.
The base must be perfectly flat and rigid enough as not to allow bending or misalignment on the pump
coupling axis/transmission due to torque transmitted during operation.
Two lifting brackets are mounted on the pump for easy installation, as per the figure below.
The brackets are sized solely for pump lifting and therefore are absolutely not permitted for use of
additional loads.
Replace the oil filling hole closing service plug positioned on the rear casing cover
with the plug with oil dipstick. Check the correct quantity.
The oil dipstick must always be reachable, even when the unit is assembled.
The pump shaft (PTO) should not be rigidly connected to the propulsor unit
The following types of transmission are recommended:
- Flexible joint.
- Cardan-shaft ( comply with manufacturer's Max. recommended working angles).
- Belts. For proper application consult with our Technical or Customer Service Departments.

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9.2 Rotation direction
The PTO rotation direction is indicated by an arrow located on the reduction gear cover.
From a position facing the pump head, the rotation direction will be as in fig. 5
9.3 Version change and reduction gear positioning
The pump version is defined as right when:
Observing the pump facing the head side, the pump shaft must have a PTO shank on the right side.
The pump version is defined as left when:
Observing the pump facing the head side, the pump shaft must have a PTO shank on the left side (see
fig.5).
The version can only be modified by trained and authorised personnel and carefully
following the instructions below:
1. Separate the hydraulic part from the mechanical part as indicated in chapter 2 in points 2.2.1 and
2.2.3 of the repair manual.
2. Turn the mechanical part 180° and reposition the rear casing cover in such a way that the oil
dipstick is turned upward. Reposition the lifting bracket and relative hole closing plugs in the
upper part of the casing. Invert the two inspection covers, ensuring that the open one is
positioned lower. Finally, properly reposition the specification label in its housing on the casing.
Make sure that the lower inspection cover draining holes are open
3. Unite the hydraulic part with the mechanical part as indicated in chapter 2 in points 2.2.1 and
2.2.4 of the repair manual.
It is also possible to place the reduction gear in 5 different positions as per fig.6.
fig. 5

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The reduction gear position can only be modified by trained and authorised personnel
carefully following directions contained in the repair manual.
9.4 Hydraulic connections
In order to isolate the system from vibrations produced by the pump, it is advisable to make the first section
of the duct adjacent to the pump (both suction and outlet) with flexible piping. The consistency of the suction
section must be such as to prevent deformations caused by vacuums produced by the pump.
9.5 Pump power supply
The MW pumps must always be installed under the positive head, or rather they must receive water as it falls
or by means of forced power and never suctioned from a lower level.
The pumps are able to tolerate minimum heads of 1 metre though, to obtain best volumetric performance
and above all to prevent cavitation, the available positive head (NPSH avail) measured on the suction flange
of the head should be equal or exceed the following values:
MW32 MW36 MW40 MW45 MW50 MW55
NPSHr(m) 4.5 5.5 6.5 7.5 8 9
For higher cylinder capacity, pumps MW 45 - 50 - 55, forced power by means of a booster pump is strongly
recommended to prevent cavitation, considering the geometry of the hydraulic part and the considerable flow
rate.
The booster pump must have a flow rate that is at least double the nominal flow rate of the plunger pump
with minimum pressure between 2 and 3 bars.
These supply conditions must be respected at any operating rpm.
Booster pump start-up must always come before start-up of the plunger pump.
Installing a pressure regulator downstream from the pump protection filters on the power
supply line is recommended.
fi
g
. 6
RIGHT SIDE LEFT SIDE

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9.6 Suction line
For a smooth operation of the pump, the suction line should have the following characteristics:
1. Minimum internal diameter as indicated in the graph at point 9.9 and equal to or exceeding that of the
pump head.
Localised restrictions should be avoided along the run of the duct, as these can cause load
losses resulting in cavitation. Avoid 90° elbow bends, connections with other piping, constrictions,
counterslopes, inverted U-curves and T-connections.
2. With a layout that is set in such a way to prevent cavitation.
3. Completely airtight and constructed to ensure sealing over time.
4. Prevents that pump stopping causes emptying, even partial.
5. Do not use hydraulic fittings, 3 or 4-way fittings, adapters, swivel joints, etc. as they could jeopardise pump
performance.
6. Do not install Venturi tubes or injectors for detergent suction.
7. Avoid use of base valves or other types of unidirectional valves.
8. Do not recirculate by-pass valve discharge directly into suction.
9. Provide for proper guards inside the tank to prevent that water flow from the bypass and the tank supply
line can create vortexes or turbulence near the pump supply pipe port.
10.Make sure the suction line is thoroughly clean inside before connecting it to the pump.
11.Install the pressure gauge to control booster pressure near the plunger pump suction port and always
downstream from the filters.
9.7 Filtration
Two filters must be installed on the pump suction line, positioned as indicated in fig. 7 and fig. 7/a.
With a manually activated control valve
fig. 7
10
1 Filter n.1
2 Booster Pump
3 Filter n.2
7 Pressure gauge
8 Safety valve
Inlet Prefilter
Bypass
Supply
Tank
6 Plunger pump
1 2 3 4 5 6 7 8 9
4 Pressure gauge 9 Accumulator
10 Supply control valve
5 Pressure regulator

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With a pneumatically activated control valve
The filter must be installed as close as possible to the pump, it must be easily inspected and must have the
following characteristics:
1. Minimum flow rate at least 3 times the nominal flow rate of the pump.
2. Inlet/outlet port diameters no smaller than the inlet port diameter of the pump.
3. Filtration grade between 200 and 360 μm.
For smooth pump operation, regular filter cleaning is necessary, planned according to the
actual use of the pump in relation to the quality of water used and actual clogging conditions.
9.8 Outlet line
For the correct laying of the outlet line, the following installation rules must be followed:
1. The internal diameter of the pipe must be sufficient to ensure correct fluid velocity, see graph at
point 9.9.
2. The first section of the line connected to the pump outlet must be a flexible hose, in order to
isolate the vibrations produced by the pump of the rest of the system.
3. Use high pressure pipes and fittings to ensure high safety margins in all operating conditions.
4. The outlet line must always be installed with a safety gauge.
5. Use pressure gauges suitable to withstand pulsating loads typical of the plunger pumps.
6. During the design stage, keep in mind the line load losses which result in a drop in pressure
during use with respect to the pressure measured on the pump.
7. For those applications where pulses produced by the pump on the outlet line may prove harmful
or unwanted, install a pulsation dampener of sufficient size.
Inlet Prefilter
Supply
Tank 1 2 3 4 5 6 7 8 9 10
Bypass
fig. 7/a
1 Filter n.1
2 Booster Pump
3 Filter n.2
6 Plunger pump
7 Pressure gauge
8 Safety valve
9 Accumulator
4 Pressure gauge
5 Pressure regulator 10 Pneumatic control valve

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9.9 Calculation of the internal diameter of the duct pipes.
To determine the internal diameter of the duct, refer to the following diagram:
Suction duct
With a flow rate of ~ 400 L/min and a water velocity of 1 m/sec. The graph line joining the two scales meets
the central scale showing the diameters, corresponding to a value of ~ 90 mm.
Outlet duct
With a flow rate of ~ 400 L/min and a water velocity of 5.5 m/sec. The graph line joining the two scales meets
the central scale showing the diameters, corresponding to a value of ~ 40 mm.
Optimal speed to be obtained with the Booster pump:
- Suction: ≤1 m/sec.
- Outlet: ≤5.5 m/sec.
The graph does not take into account pipe resistance, valves, load loss produced by the length of
the ducts, the viscosity of the liquid pumped or the temperature itself.
If necessary, contact our Technical or Customer Service Departments.
suction line
outlet line

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9.10 V-belt transmission
As indicated in point 9.1, the pump can be controlled by a v-belt system only in exceptional cases.
For proper layout sizing, consult our Technical or Customer Service Departments.
10. START-UP AND OPERATION
10.1 Preliminary checks
Before start-up, ensure that:
The suction line is connected and pressurised (see chapter 9): the pump must never run dry.
1. The suction line ensures a hermetic seal over time.
2. Any shut-off valves between the supply source and the pump are fully open. The outlet line is
free discharge, to permit air present in the pump head to come out quickly and therefore
favour fast priming.
3. All suction and outlet fittings and connections are properly tightened.
4. The coupling tolerances on the pump/transmission axis (half-joint misalignment,
Cardan joint tilt, belt pulling, etc.) remain within limits required by the transmission
manufacturer.
5. Oil in the pump casing is at level, verified with a dipstick (position 1 fig.8)
In case of prolonged storage or long-term inactivity, reset proper
functioning of the suction valves opening the three valve lifter devices (see position 2 fig.9).
Make sure to have closed the valves back up before starting up the pump.
See fig. 10 for "work" and "rest" positions.
fig. 8
CLOSED VALVE UNLOCKING OPEN VALVE
- WORK SAFETY DEVICE -REST
POSITION- POSITION-
fig. 10
fig. 9

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10.2 Start-up
1. At first start-up, verify that the rotation direction is correct.
2. Check proper pump supply.
3. Start-up the pump without any load.
4. Check that the rotation rpm during operation does not exceed the nominal rpm of the pump.
5. Let the pump run for a period of no less than 3 minutes, before putting it under pressure.
6. Before each pump stop, reset pressure by means of the control valve or with any relieving devices.
Whenever priming problems arise due to an insufficient supply,
intervene by removing the front three plugs on the head as shown in position 3 fig.11 and
11a.
11. PREVENTIVE MAINTENANCE
For pump reliability and efficiency, comply with maintenance intervals as shown in the table below.
PREVENTIVE MAINTENANCE
Every 500 hours Every 1500 hours
Check oil level Change oil
Check / Replace * : Valves
Valve housings
Valve springs
Valve guides
Check / Replace * : H.P. seals
L.P. seals
* for replacement follow instructions contained in the repair manual
fig. 11
fig. 11a

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12. PUMP STORAGE
12.1 Method for filling pump with anti-corrosion emulsion or anti-freeze solution using an external
diaphragm pump based on the layout shown in point 9.7
a) Close the filter drainage, if open.
b) Make sure the connecting pipe is clean, spread with grease and connect them to the high
pressure discharge.
c) Fix the suction pipe to the diaphragm pump, open the pump suction connection and attach the
pipe between it and the diaphragm pump.
d) Fill the container with solution / emulsion.
e) Put the free ends of the suction pipe and the high pressure exhaust pipe inside the container.
f) Switch on the diaphragm pump.
g) Pump the emulsion until it exits from the high pressure exhaust pipe.
h) Continue pumping for at least another minute. The emulsion can be reinforced if necessary by
adding Shell Donax for example to the solution.
i) Stop the pump, remove the pipe from the suction connection and close with a plug.
j) Remove the hose from the high pressure exhaust. Clean and grease and plug both
connections and pipes.
12.2 Tubes
a) Before greasing and protecting pipes according to previously described procedure, dry
connections with compressed air.
b) Cover with polyethylene.
c) Do not wind too tight, ensure that there are no folds.
13. PRECAUTIONS AGAINST FROST
Follow the instructions in Chapter 12 in areas and times of the year at risk of frost (see point 12.2 ).
In the presence of ice, do not run the pump for any reason until the circuit has not been fully
defrosted, in order to avoid serious damage to the pump.
14. GUARANTEE CONDITIONS
Pumps are guaranteed for a period of 12 months from the date of supply or else for 1,000 hours of work with
the exception of worn parts.
Refer to the terms of the contract for other guarantee conditions.
The guarantee will be invalidated if:
a) The pump is used for purposes other than for those agreed upon.
b) The pump is fitted with an electric or combustion motor with performance exceeding those indicated
in the table.
c) Safety devices are decalibrated or disconnected.
d) The pump is used with accessories or parts not supplied by Interpump Group.
e) Damage has been caused by:
1) improper use
2) failure to follow maintenance instructions
3) any use different from that described in the operating instructions
4) insufficient flow rate
5) defective installation
6) improper positioning or sizing of pipes
7) unauthorised plan modifications
8) cavitation