Sondermann MAGSON MA Series User manual

MAGSON
magnetically coupled centrifugal pumps
MA types 4 to 7
Operating Manual

2
Table of contents
1. Declaration of conformity.........................................................4
2. Basic information......................................................................6
2.1 Notes on the operating manual .................................................................6
2.2 Validity of data.........................................................................................6
2.3 Purpose ................................................................................................... 6
2.4 Use to the intended purpose ..................................................................... 6
2.5 Anticipated misuse....................................................................................7
2.6 Limits of use ............................................................................................7
2.7 Warranty and liability................................................................................7
2.8 Contact details ......................................................................................... 7
3. Safety ........................................................................................8
3.1 Standards and directives...........................................................................8
3.2 Depiction of safety instructions..................................................................9
3.3 Symbols used........................................................................................... 9
4. Technical Information.............................................................10
4.1 General description................................................................................. 10
4.2 Nameplate ............................................................................................. 10
4.3 Type codes and materials........................................................................ 10
4.4 Structure of MAGSON MA pumps............................................................. 12
5. Transport and temporary storage ..........................................13
5.1 Safety instruction.................................................................................... 13
5.2 Transport............................................................................................... 13
5.3 Temporary storage................................................................................. 13
6. Installation..............................................................................14
6.1 Safety precautions.................................................................................. 14
6.2 Installation requirements ........................................................................ 14
6.3 Installation............................................................................................. 14
6.3.1 Hose and pipe lines...................................................................... 14
6.3.2 Suction line.................................................................................. 15
6.3.3 Discharge line .............................................................................. 15
6.3.4 Flange or threaded connections..................................................... 16

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Declaration of conformity
6.3.5 Electrical connection..................................................................... 17
6.3.6 Controlling the direction of rotation ............................................... 18
7. Putting into operation.............................................................19
7.1 Safety precautions.................................................................................. 19
7.2 Preparatory work.................................................................................... 19
7.3 Putting into operation............................................................................. 19
7.4 Possible malfunction when putting the pump into operation...................... 20
8. Shut-down procedure .............................................................21
9. Service and maintenance........................................................22
9.1 Safety precautions.................................................................................. 22
9.2 General information................................................................................ 22
9.3 Preventive maintenance.......................................................................... 23
9.3.1 Overall pump ............................................................................... 23
9.3.2 Wearing parts .............................................................................. 23
9.3.3 Motor .......................................................................................... 24
9.3.4 Static O-ring seals........................................................................ 24
9.4 Dismantling and replacing the motor ....................................................... 25
9.5 Dismantling the pump head .................................................................... 25
9.6 Disassembling the pump head................................................................. 26
9.7 Assembling the pump ............................................................................. 26
10. Troubleshooting......................................................................28
Appendix ...........................................................................................30

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1. Declarationofconformity

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Declaration of conformity

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2. Basicinformation
2.1 Notes on the operating manual
This operating manual has been prepared to meet all product-specific and user-related
requirements of the law and of all relevant regulations and rules, technical standards,
directives and agreements.
The manual includes important information on the functioning of MAGSON magnetically
coupled centrifugal pumps and how to use, install, service and dispose of them.
In the following, the magnetically coupled centrifugal pumps are referred to as “pump”.
Before putting the pump into operation, carefully read the operating manual and make
sure that it is always ready at hand to all users of the pump.
Complying with all instructions of this operating manual is an essential prerequisite to
guarantee the safe operation and maintenance of the pump.
Make sure that all operators and service technicians have fully read and understood the
manual before they start working at or with the pump.
2.2 Validity of data
All technical data, dimensions and indications of weight etc. were valid at the day when
this manual went to press. Specifications listed here may differ from the actual design of
the pump but will not modify any relevant information in principle.
2.3 Purpose
MAGSON pumps are designed to function as centrifugal pumps delivering fluids.
2.4 Use to the intended purpose
MAGSON pumps must only be used to deliver fluids of watery viscosity without coarse
solids. So the fluids meant to be delivered are
#water and aqueous solutions,
#acids,
#bases,
#similar fluids free of magnetizable metal particles.
Do not use the pump to deliver
#inflammable or explosive fluids,
#solids-bearing or abrasive fluids,
#fluids being used to process food because the pump has not been certified according
to FDA or EC 1935/2004 standards.
If you want to deliver solids-bearing or abrasive fluids, please contact the pump’s
manufacturer.

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2.5 Anticipated misuse
The pump is misused if
#it is used other than to the intended purpose;
#it is operated beyond its defined limits;
#it is used to deliver inadmissible fluids like fluids containing magnetizable metal
particles or coarse contaminants, for example.
2.6 Limits of use
Dimensional limits
For dimensions of the pump see æDimensioned drawings in the Appendix page 30 foll.
For technical data of the pump see æAppendix page 30 foll.
Other limits
Ambient temperature 0 to 40°C for PP;
-20 to ±40°C for ETFE
Pumps made of PP must not be operated in frost because PP will embrittle at
temperatures below 0°C.
2.7 Warranty and liability
The pump must only be used to the intended purpose specified by this operating manual.
Inappropriate operation or insufficient service and maintenance will cancel the right to all
warranty claims.
2.8 Contact details
SONDERMANN
Pumpen + Filter GmbH & Co. KG
August-Horch-Strasse 2
51149 Cologne (Porz), Germany
Phone: [phone]
Fax: [phone]
[e-mail]
www.sondermann-pumpen.de

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3. Safety
3.1 Standards and directives
Name
Contents
2006/42/EG
Directive 2006/42/EC of the European Parliament and
of the Council of 17 May 2006 on machinery, and
amending Directive 95/16/ECG (recast) (1)
2014/30/EU
Directive 2014/30/EU of the European Parliament and
of the Council of 26 February 2014 on the harmonisation of
the laws of the Member States relating to
electromagnetic compatibility (recast)
Table 1: European Directives
Name
Contents
EN ISO 13732
-
1:2008
Ergonomics of the thermal environment
—
Methods for the
assessment of human responses to contact with surfaces –
Part 1: Hot surfaces (ISO 13732-1:2008)
EN 1032:2003+A1:2008
Mechanical vibration
-
Testing of mobile machinery
in order to determine the vibration emission value
EN 61000
-
6
-
4:2007+
A1:2011
Electromagnetic compatibility (EMC)
-
Part 6
-
4:
Generic standards - Emission standard for industrial
environments
EN 61000
-
6
-
2:2005/
AC:2005
Electromagnetic compatibility (EMC)
-
Part 6
-
2:
Generic standards - Immunity for industrial environments
EN 809:1
998+A1:2009 +
AC:2010
Pumps and pump unit
s
for liquids
-
Common safety requirements
EN ISO 12100:2010
-
11
Safety of machinery
–
General
principles for design
-
Risk
assessment and risk reduction (ISO 12100:2010)
EN 60204
-
1:2006/
AC:2010
Safety of
machinery
-
Electrical equipment of machines
-
Part 1: General requirements
EN 60034
-
1:2010/
AC:2010
Rotating electrical machines
-
Part 1: Rating and
performance
EN 60034
-
5/A1:2007
-
01
Rotating electrical machines
-
Part 5: Degrees of protection
provided by integral design of rotating electrical machines
(IP code) – Classification
EN 60034
-
6:1993
-
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Rotating electrical machines
-
Part 6: Methods of
cooling (IC code)
EN 60034
-
9/A1:2007
-
04
Rotating electrical machines
-
Part 9: Noise limits
Table 2: EN Standards

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Safety
3.2 Depiction of safety instructions
All safety instructions of this document are marked with symbols designed on the basis of
the SAFE principle. Each of them describes the kind and source of danger, possible
consequences and information on how to avert them.
DANGER
The symbol warns you of a potential accident resulting from ignoring safety or other instructions. The
accident will cause serious and maybe even mortal injuries or death when touching a high-voltage electrical
equipment, for example.
WARNING
The symbol warns you of a potential accident resulting from ignoring safety or other instructions. The
accident may cause serious and maybe even mortal injuries or death when touching a high-voltage electrical
equipment, for example.
CAUTION
The symbol warns you of a potential accident resulting from ignoring safety or other instructions. The
accident may cause slight injuries like burns, injuries of the skin and bruises, for example.
ATTENTION
The symbol warns you of a potential material damage.
NOTE
The symbol indicates an important information.
3.3 Symbols used
Symbol
Meaning
æ
Cross
-
reference
such as
“see chapter xx“, “see page yy“
Table 3: Symbols used

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4. TechnicalInformation
4.1 General description
MAGSON magnetically coupled centrifugal pumps are non-self priming centrifugal pumps
made of plastic and built in horizontal single-stage monoblock design. A magnetic
coupling connects the pump to the motor and transmits the power of the motor to the
impeller.
Pump housings, impellers, inner magnet sheaths and rear casings are made of plastic.
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 mechanically or gland sealed pumps, any leakage at the shaft is completely
impossible.
4.2 Nameplate
The nameplate of the pump not only specifies its operating data but also its type and
serial number. Please indicate all these data when making an inquiry, reordering parts
and, in particular, when ordering spare parts.
Data of the electric motor are given on a separate rating plate.
For further information, contact your pump's supplier or the manufacturer.
4.3 Type codes and materials
The type code on the nameplate informs you about the pump materials in contact with
fluid.

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Technical Information
Overview of available materials being in contact with fluid:
Component Symbol Material Temperature
All components in contact
with fluid
PP Polypropylene 0 to 70°C
ETFE Ethylene tetrafluoride ethylene -20 to +100°C
PTFE Polytetrafluoroethylene -20 to +100°C
CFR-PTFE Carbon fiber reinforced
polytetrafluoroethylene -20 to +100°C
PPS
P
olyphenylene
sulphide
-
20 to +100°C
SIC Silicon carbide -20 to +100°C
Alumina Aluminium oxide ceramic (99.7%) -20 to +100°C
Seals
EPDM Ethylene-propylene-diene rubber -20 to +100°C
FKM Fluorinated rubber -20 to +100°C
FEP FEP-coated FKM -20 to +100°C
NOTE
Pump housings made of PP are of dark blue colour.
Pump housings made of ETFE are of black colour and marked with a yellow
sticker.
WARNING
Danger of chemical non-resistance of components
#Make sure that the materials used for making the pump are resistant to the fluid(s) delivered.
#Chemical non-resistance may result in leakage of fluid.
#Potential danger to the environment and health.
#In case of doubt, please contact the pump’s manufacturer.
NOTE
For the chemical resistance of materials, please request the material resistance list of the pump’s
manufacturer.
ETFE

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4.4 Structure of MAGSON MA pumps
Fig. 1: Structure of an MA pump of type 4
1 Slip-on flange 2 Pump housing
3 Impeller magnet 4 O-ring of housing
5 Rear casing 6 Starting ring of rear casing
7 Mounting flange 8 Lantern
9 Driving magnet 10 Adapter plate (types 4 and 6
only)
11 Motor 12 Base plate
13 Centering axis 14 Impeller starting ring
15 Shaft mounting 16 O-ring of flange
The figure shows an MA pump of type 4. The structure of other types may differ,
see the spare-parts drawing of the Appendix.

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Transport and temporary storage
Overview of MAGSON MA pump types
MA
non self priming Size Suction
port Discharge
port
Type 2 7/70
G 1 ½“ G 1 ½“
8/80
Type 3 15/40 10/100
13/120
Type 4
8/160
DN40
DN40
10/180
12/190
14/220
Type 5
10/240
13/260
15/280
18/320
Type 6
22/400
DN50
26/450
29/470
30/510
Type 7 29/950 DN65 DN5036/750
42/500
5. Transportandtemporarystorage
5.1 Safety instruction
WARNING
Danger of getting jammed or bruised during transport of the pump
#Make sure to use lifting devices suitable to the weight of the pump.
#Do not remove the lifting device before you have put down the pump safely.
5.2 Transport
1. Unpack the pump or unit upon receipt and check it for damage in transit.
2. In case of damage in transit, make sure to have the carrier draw up and sign the
damage report document.
3. Make sure that the information of the nameplate corresponds with the specifications
and dimensions of the purchase order.
4. The packaging material has to be disposed of according to local regulations.
5.3 Temporary storage
The pump must only be stored at a dry place free of frost. When storing the pump,
protect it against any contaminants getting in.

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6. Installation
6.1 Safety precautions
WARNING
Danger of getting jammed or bruised during installation of the pump
#If necessary, use lifting and holding devices suitable to the size and weight of the pump.
#Make sure that all installation work is done by competent and qualified personnel only.
WARNING
Danger of being hit by falling components
#If necessary, use lifting and holding devices suitable to the size and weight of the pump.
#Make sure that all installation work is done by competent and qualified personnel only.
6.2 Installation requirements
Install the pump at a place that allows you easy access at any time. The limit values of
the ambient temperature are as follows: 0 to +40°C for pumps of PP;
-20 to +40°C for pumps of ETFE.
6.3 Installation
1.
Install the pump in a horizontal
position. For any other installation
position, please contact the
manufacturer.
2. Note: As the pump is non-self
priming, it has to be supplied.
3. Make sure that the pump does not
draw in impurities when priming.
Remove all covers and caps from the flanges before installing the pump.
6.3.1 Hose and pipe lines
1. All pipe line diameters should be sufficiently large. The flow rate of the suction line
should be between 1 and 2m/s, that of the discharge line should not exceed 3m/s.
Pipe line diameters have to be at least the size of the suction and discharge ports.
2. All suction and discharge lines to the pump housing should be free of tensile stress.
3. If necessary, install expansion joints at the pipe lines to compensate excessive tension
due to the pipe’s thermal expansion.
4. Avoid bending radii of less than 1.5 times the nominal pipe size.
5. Also avoid sharp changes in diameters within the piping.

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Installation
6.3.2 Suction line
ATTENTION
Risk of damaging the pump by cavitation
When installing the suction line, make sure to meet the NSPH value given in the æAppendix page 30 foll.. If
the NPSH falls below this value, there will be cavitation resulting in running noise, drumming and vibration of
the pump.
We do not provide warranty for any damage to the pump caused by cavitation!
1. The suction pipe or hose should be made of a material that will not deform or distort
by vacuum or higher temperatures.
The suction line also should be as short as possible, its installation preventing any gas
accumulation.
2. When dimensioning pipelines, fittings etc., make sure to keep the flow resistances as
low as possible.
3. Provide for a straight steadying section of at least 5 times the nominal diameter
before the suction port.
4. Suction lines have to be vacuum-sealed because penetrating air causes malfunction
and may result in damage to the pump.
5. Make sure that the flow rate in the suction line installed does not exceed 1m/s.
6. Protect the pump against dry-running by installing adequate equipment (optionally
available).
7. For easy installation and removal of the pump, a shut-off valve (but no diaphragm
valve) should be built into the suction line.
NOTE
Do not use the shut-off valve of the suction line to adjust the delivery rate!
6.3.3 Discharge line
Standard flow rate of the discharge line is 3m/s.
We recommend installing a control element to adjust the flow rate of the discharge line.
ATTENTION
Damaging of the pump housing by pressure jerks
Do not install any quick-acting stop valves to the pipelines!
To measure working conditions, you better install a manometer between the discharge
port of the pump and the throttle valve as well as a volume flow meter, if necessary.

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6.3.4 Flange or threaded connections
MAGSON MA pumps of types 4 to 6 are equipped with
slip-on flanges as standard features. The rotating
flange allows you to easily connect the pump without
considering the angular position of the mating flange.
Do not use hard material to seal the flange but
appropriate elastomer seals.
MAGSON MA types 7 are equipped with loose flange
but cannot be disassembled.
Replacing a flange by a threaded
adapter
Alternatively you can use an insert fitting
and spigot nut to connect the pump.
To do so, you have to replace the screwed
flange by the attached threaded adapter as
follows:
1. Take the slip-on flange off the flange
fixture using a rubber mallet.
2. Use a strap wrench to unscrew the
flange fixture. Take the O-ring off the
fixture and put it into the (inner thread)
of the threaded adapter.

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3.
Screw the threaded adapter to the
pump housing using the strap wrench.
Make sure that the O-ring fits exactly
into the groove of the inner thread.
6.3.5 Electrical connection
NOTE
Qualified personnel only are allowed to connect the pump to the electrical mains.
All electrical connections and the installation of additional protection devices has to be done in accordance
with the regulations of your local power supplier and the VDE Association of German Electrical Engineers.
Before working on the terminal box of the pump, the power supply must have been cut
off for at least 5 minutes.
1. Make sure that the power supply available corresponds to the data of the nameplate.
2. Connect the motor according to the following schematic attached to the terminal box:
3. As standard features, all three-phase AC motors have PTC resistors to monitor the
winding temperature. To operate the pump with frequency converter, also connect
the PTC resistors.
4. All AC motors have a thermal sensor as standard feature which also has to be
connected.
5. Do not operate any AC motor without circuit-breaker!
NOTE
Please ask the manufacturer for additional motor protection devices.

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6.3.6 Controlling the direction of rotation
ATTENTION
Dry-running will damage the pump
Do not check the direction of rotation when there is no fluid in the pump!
1. Mind the direction of rotation indicated by an arrow on the pump. Before verifying it
after the installation, fill the pump housing and suction line with water or fluid.
2. Then switch on and immediately off the motor to check the direction of rotation.
To check whether the direction of rotation corresponds to the direction indicated by
the arrow, push a piece of soft material like paper or cable tie into the slots of the fan
cowl.
3. If necessary, exchange 2 phases at the terminal box to reverse the direction of
rotation.

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Putting into operation
7. Puttingintooperation
7.1 Safety precautions
WARNING
Danger of breaking during operation
Regularly check the pump for damages.
#If there is a damage, the pump must not be operated!
#Replace wearing parts at regular intervals.
#Do not operate the pump to other than the intended purpose.
WARNING
Risk of electrical hazards when touching parts carrying voltage by fault
#Fasten all loose connections. Immediately replace defective cables.
#Always disconnect the power supply before doing any electrical work.
#Cables must neither be jammed nor squeezed. When laying cables and connections make sure you
cannot trip over them and they won’t be damaged.
#Check all electrical equipment at regular intervals according to the locally valid regulations (like the
German DGUV accident prevention regulation 3, for example).
#Only qualified and authorized personnel are allowed to do any work at the electrical equipment.
7.2 Preparatory work
WARNING
Danger of injuries and intoxication by fluid squirting out
#Always wear personal protective equipment when working at the pump.
NOTE
We recommend installing dry-running protection devices such as flow monitors, contact manometers,
differential pressure switches or level controllers.
1. Fill the pump housing and the suction line with water or fluid.
It is absolutely necessary to avoid any dry-running of the pump!
2. Make sure that all flange screws are tight. Fasten all screwed connections.
3. Open the suction and discharge valves to fill the pump with fluid. Fully open all shut-
off valves of the suction line. Fill up the pump with fluid and deaerate it.
7.3 Putting into operation
1. Switch on the motor.
2. Slowly open the shut-off valve of the discharge side to adjust the operating point. 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.
ATTENTION
Overheating will damage the pump!
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.

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WARNING
Hazard of pressure
#Use a manometer at the discharge line to check the system pressure and prevent it from going beyond
its limit specified in the technical data sheet (see Appendix).
#If the system pressure is too high, the rear casing may burst releasing fluid.
#When pressure testing the piping, take into account the maximum system pressure, but do not test the
pump as well, if possible.
3. Check all screw joints and union pieces of the piping system for leakage.
4. Check the pump for vibration. Excessive vibration suggests cavitation or foreign
particles in the impeller (see æchapter 10: Troubleshooting).
5. Make sure that the power input of the motor is less than or equal to the rated current
given on the motor’s nameplate.
If the power input is too high, reduce the delivery rate of the pump at the discharge
side or decrease the density of the fluid, if possible.
7.4 Possible malfunction when putting the pump into operation
If the motor circuit-breaker switches off the motor, proceed as follows:
1. Before switching on the motor again, check whether the impeller turns readily.
2. Make sure that the suction line and the pump housing are filled with fluid.
3. Switch on the motor.
If the pump delivers for a short period of time only and then stops pumping, the magnetic
coupling has been overloaded and disengaged. In this case, follow the instructions of æ
chapter 10: Troubleshooting (see page 28).