MXM_Series_Manual
IWAKI AMERICA
MXM SERIES
MAGNETIC DRIVE PUMP
INSTRUCTION MANUAL
MXM SERIES INSTRUCTION MANUAL
Table of Contents
1
SAFETY INSTRUCTION ..................................................................................................................................1
2
CAUTION ............................................................................................................................................................2
3
UNPACKING AND INSPECTION ...................................................................................................................3
4
MODEL IDENTIFICATION .............................................................................................................................4
5
SPECIFICATIONS .............................................................................................................................................5
6
MATERIALS OF CONSTRUCTION ...............................................................................................................6
7
HANDLING INSTRUCTIONS ..........................................................................................................................7
8
INSTALLATION, PIPING, AND WIRING ...................................................................................................10
INSTALLATION POSITION ....................................................................................................................................10
INSTALLATION ....................................................................................................................................................10
PIPING ..............................................................................................................................................................11
SUCTION PIPING ................................................................................................................................................11
DISCHARGE PIPING ...........................................................................................................................................13
WIRING .............................................................................................................................................................14
9
OPERATION .....................................................................................................................................................15
NOTES ON OPERATION .......................................................................................................................................15
START-UP PREPARATION ...................................................................................................................................15
STARTING OPERATION STEPS..............................................................................................................................16
STOPPING OPERATION STEPS .............................................................................................................................17
10
MAINTENANCE AND INSPECTION .......................................................................................................17
DAILY INSPECTION.............................................................................................................................................17
PERIODIC INSPECTION .......................................................................................................................................18
REPLACEMENT TOLERANCE CHART ....................................................................................................................20
11
TROUBLESHOOTING ................................................................................................................................21
12
PARTS DESCRIPTION AND EXPLODED VIEW...................................................................................23
13
DISASSEMBLY AND ASSEMBLY OF PUMP .........................................................................................24
DISASSEMBLY ....................................................................................................................................................24
REASSEMBLY......................................................................................................................................................28
14
SPARE PARTS ..............................................................................................................................................30
15
DIMENSIONS AND WEIGHTS..................................................................................................................31
This product is protected by patents.
P/N 180334 Rev. C1 Jul 2008
Thank you for selecting an Iwaki America MXM Series magnetic drive pump. This instruction manual
explains the correct handling, operating, maintenance, inspection and troubleshooting procedures for your
pump. Please read through it carefully to ensure the optimum performance, safety and long service of
your pump.
1
Safety Instruction
WARNING:
1.
Pay attention to the magnet field
The magnet drive pump has a pair of strong magnets. The strong magnet field could adversely affect
any persons who are assisted by electronic devices such as the pacemaker, etc.
2.
Be sure to turn off power prior to any inspection/maintenance and installation works. Be careful
power is not turned on unintentionally while working on the pump. In a noisy or dark place, display
a sign of "Men Working" near the power supply switch.
3.
Wear protective clothing
When arranging piping or dismantling the pump, wear protective clothing such as safety goggles,
protective gloves etc.
4.
Lifting pump
When lifting the pump, apply a chain or belts to the eye bolts to keep the pump horizontal.
5.
Do not remodel pump
Do not remodel the pump. Iwaki America is not responsible for any personal injury or damage to the
pump due to modifications.
6.
Handling of dangerous liquids
For the transfer of the dangerous liquids mentioned below, be sure to conduct daily inspection and
maintenance for the prevention of liquid leakage or other failure. Liquid leakage may result in a
personal injury, explosion or fire.
• Explosive or flammable liquids
• Corrosive or stimulus toxic liquids
• Harmful liquids to human health
7.
Preventative measure against harmful gas
When handling harmful chemical gas, provide a preventative measure such as installation of an air
fan.
1
2
Caution
1.
Attention to magnetic force
Strong magnets are used in this pump. Personal injury may be caused from the strong magnetic
force. Follow the procedure on "Disassembly and Assembly of Pump" when conducting maintenance
work.
2.
Do not run pump dry
Do not run pump dry. Frictional heat generated under dry run conditions can cause damage to the
pump. NEVER operate the pump with a suction side valve closed.
3.
Restriction on pump operator
The pump must be handled or operated by a qualified person with a full understanding of the pump.
4.
For specified application only
The use of the pump in any application other than those clearly specified may result in the failure or
damage to the pump.
5.
Countermeasure against static electricity
When low electric conductivity liquid such as the ultra-pure water and the fluor inactive liquid (e.g.
Fluorinert™) are handled, static electricity may generate in the pump, which may cause a static
discharge resulting in damage to the pump. Countermeasure must be taken to remove static
electricity.
6.
Air elimination prior to pumping operation
Eliminate air in the pump chamber before operating the pump. Care must be taken to eliminate air
when handling fluids which easily generate bubbles (hydrogen peroxide, sodium hypochlorite, etc.).
Any operation with air remaining in the pump chamber may cause frictional heat and result in
damage to the pump.
7.
Countermeasure against efflux
Take protective measures against the accidental efflux caused by damage to the pump or piping.
Also, take an appropriate measure for preventing any spilled liquid from directly soaking into the
ground.
8.
Pump disposal
A used or damaged pump must be disposed of in accordance with local laws and regulations.
2
3
Unpacking and Inspection
Open the package and check that the product conforms to your order. Also, check each of the following
points. For any problem or inconsistency, contact your distributor at once.
1.
Check that the model number and the HP indicated on the nameplate conform to the specifications of
your order.
2.
Check that all the accessories you ordered are included.
3.
Check that the pump body and parts have not been accidentally damaged or that any bolts or nuts
have not been loosened in transit.
IWAKI
MODEL MXM
HEAD (FT.)
CAPACITY
(GPM) HP
SERIAL NO.
60 Hz.
RPM
HOLLISTON, MA
3
4
Model Identification
MXM-
1
54
2
1
CF
V
H
-XX
1
2
3
4
5
6
7
Connection Size
Model
54
2
Horsepower
Model
2
3
5
3
Suction
2” Flange
HP
2
3
5
Impeller Range
Code Number
1
2
3
4
4
Maximum Capacity
Maximum Head
110 GPM
95 GPM
150 GPM
165 GPM
128 Ft
88 Ft
98 Ft
146 Ft
Materials of Construction
Material Code
CF
Front casing liner/Rear casing
Impeller/Magnet Capsule
Bearing
Spindle
Liner Ring
Mouth Ring
Rear Thrust Ring
5
Discharge
1.5” Flange
FF
KK
CFRETFE
High Density
High Purity
Carbon
Alumina Ceramic
High Purity Alumina Ceramic
High Purity Alumina Ceramic
PTFE
CFRPFA
SiC
O-ring/Gasket Material:
V: FKM (Fluoroelastomer
E: EPDM
A: AFLAS®
P: Dal-el-Perfluoro®
6
H: Rear Casing with Cover
7
Special Configuration: 2 digit numeric code denoting special configuration
4
5
Specifications
Model
Connections
Suction x Discharge
MXM-542
MXM-543
2" x 1.5" Flange
MXM-545
Max.
Impeller Capacity
Code
@ 60 Hz
(GPM)
Max.
Head
(Ft.)
2
95
88
3
45
98
1
44
128
2
95
88
3
60
98
4
75
125
1
110
128
2
95
88
3
150
98
4
165
146
Min.
Flow
Rate
(GPM)
Motor
(RPM)
Motor
(HP)
2
5.5
3
3450
13.2
5
Notes:
1. Rated performance (head/capacity) represents the maximum discharge head/capacity measured with
water at 68°F (20°C).
2.
Liquid temperature range: 14 to 221°F (-10 to 105° C)
3.
Maximum Allowable Working Pressure: 101.5 PSI
3.
Slurry: In general, slurries should not be handled. However, a pump with a SiC bearing system, KK,
can handle slurries if the hardness is 80Hs or below, with a maximum grain size of 2 MIL (50
microns) and maximum density 5% wt. Contact Iwaki America or your distributor for details.
5
6
Materials of Construction
N0.
Item
1
2
3
4
5
Front Casing
Rear Casing
Impeller
Magnet Capsule
Spindle
6
Bearing
7
8
9
10
Liner Ring
Mouth Ring
Rear Thrust Ring
O-ring
11
12
Impeller Locking Pin
Rear Casing Support
Materials of Construction
FF
CF
KK
CFRETFE
High Purity Alumina Ceramic
High Purity
High Density
Alumina
SiC
Carbon
Ceramic
High Purity Alumina Ceramic
PTFE with Filler
CFRPFA
®
®
FKM/EPDM/AFLAS /Dal-el Perfluoro
CFRETFE
FRP
6
7
1.
Handling Instructions
Do not operate the pump dry
The sliding parts used in the MXM Series pumps are lubricated and cooled by the fluid being
pumped. Never operate the pump dry or with the valves on the suction side closed. Otherwise, the
inside of the pump will be damaged. If the pump is unavoidably or accidentally operated dry, with
no obvious damage, allow the pump to cool down for a minimum of one hour before attempting to
restart. Do not allow fluid to enter the pump cavity until the pump has cooled down. Sudden or rapid
cooling of the pump may cause damage to the ceramic components. A dry run monitoring device
(current or power sensor) is recommended for the prevention of damage when dry run operation is
likely.
"CF" Models
Some MXM models are designed to tolerate brief or intermittent dry run operation. They are
identified by the "CF" material code. These models can tolerate dry run conditions for up to one
hour. Longer dry run periods, or frequent dry running may result in premature wear of the bushing
and shaft. This can rapidly affect the standard clearances of the rotating elements inside the pump.
These pumps are designed to reduce the likelihood of cracking resulting from sudden cooling with
liquid immediately after dry run operation. However, to ensure that this does not occur, Iwaki
America recommends that the pump be allowed to cool for at least 20 minutes after dry running
before introducing fluid again.
2.
Starting and Stopping
Pay close attention to the following points to avoid water hammer upon starting and stopping of
pump operation. Extra attention is required when the discharge piping is very long.
Starting
Prior to starting the pump, make sure that the power is turned off. Then carry out priming to fill the pump
cavity with liquid.
Next, close the valves on the discharge side. Now you can turn the power on and start up the pump. When
the pump has reached full speed and line pressure is stable, the discharge valve can be opened to the
desired pressure setting.
Caution! If the pump is operated with air remaining within the pump cavity, pitting, cracking,
or breakage of the bushing and/or thrust collar may occur, causing damage to the pump.
Stopping
When stopping the pump, first close the discharge valve gradually. When it is completely closed, turn off
the power switch so that the pump stops. Never stop the pump suddenly by quickly closing a valve (i.e.,
solenoid or hydraulic valves).
Caution! Quick valve closure may cause water hammer that can cause severe damage to the
pump.
7
Max. Allowable Pressure
MPa
PSI
0.7 101.5
Figure 1
14
-10
221
105
(Deg. F)
(Deg. C)
Temperature Limit
3.
Maximum system pressure rating
The chart above shows the maximum system pressure rating of each model. Take care that the
system pressure does not exceed the maximum pressure rating.
NOTE: Allowable liquid temperature range is 50 - 221° F (10 - 105° C) with Aflas® O-ring.
Ambient Temperature: 32 - 104° F (0 - 40° C)
Ambient Humidity:
35- 85% RH
4.
Handling of slurry liquid
In general, slurries should not be handled. However, a pump with silicon carbide bearing system
(KK material code) can handle slurries if the hardness is 80 Hs or below, with a maximum grain size
of 2 MIL (50 microns) and the maximum density 5% wt. Contact Iwaki America or your distributor
for details.
5.
Influence of specific gravity on pump performance
The performance of the MXM pump does not change when pumping fluids of high specific gravity.
However, the effect of specific gravity on shaft power and magnet coupling torque requirements
must be considered in the selection of the appropriate model for your application.
6.
Influence of liquid viscosity on pump performance
When pumping a high viscosity liquid, the discharge head and capacity of the pump may be lower
than in the case of pure water. The required driving power may also vary and should be verified.
7.
Allowable liquid viscosity with FF material code
Liquid viscosity should be 1 mPa•S (cP) or more.
8.
Intermittent operation
Frequent start/stop switching shortens the service life of the pump. Limit the frequency of switching
on or off to six times or less per hour.
9.
Effects of temperature
The pump itself may not suffer a change in performance due to temperature fluctuation. However,
the liquid may change in terms of viscosity, vapor pressure, and corrosive properties. Pay special
attention to changes in liquid characteristics as a result of temperature fluctuation.
8
Liquid temperature range:
Ambient temperature range:
14 - 221° F (-10 - 105°C)
32 - 104° F (0 - 40°C)
Refer to corrosion resistance tables for the recommended temperature range for various types of liquids.
In case of any questions, contact Iwaki America or your distributor to determine if operation is feasible.
NOTE: Allowable liquid temperature range is 50 - 221° F (10 - 105° C) with Aflas® O-ring.
10. Separation of magnet coupling (decoupling)
If the magnet coupling should disconnect, stop the pump immediately. If operation is continued, the
torque rating of the coupling will be permanently reduced.
11. Operation within range of bell-shaped head/capacity curve
In the case of a pump which generates a bell-shaped capacity curve in a low-flow range, do not
operate the pump in the section where the line ascends. (Refer to the standard performance curve to
verify the head/capacity). If the rightward ascending section of the head/capacity curve is part of the
pump operation specifications, design the piping by observing the following points:
1. The discharge piping should have no water tank or air trap,
2. The discharge quantity must be adjusted by a valve that is installed close to the
discharge port of the pump.
9
8
Installation, Piping, and Wiring
Installation Position
1.
Install the pump as close to the suction tank as possible (flooded suction). If the suction port of the
pump is positioned higher than the suction tank (suction lift), be sure to arrange a foot valve in the
suction pipe. The lifting capability depends upon the liquid properties, temperature, and length of
suction piping. For details, consult Iwaki America or your distributor.
2.
The pump can be installed indoors or outdoors. However, there should be sufficient space around
the pump to enable efficient and easy maintenance.
Installation
1.
The pump anchoring area must be greater than the area of the pump baseplate. If the anchoring area
is not large enough, the baseplate may be damaged due to the concentration of loads placed on it.
2.
Set the pump baseplate on a concrete foundation and fasten the anchor bolts tightly to prevent the
pump from vibrating during operation. A sturdy metal (or reinforced) skid or platform is also an
acceptable mounting surface.
3.
Insert a spacer between the concrete suface and the bottom of the base to level the pump
horizontally. Next put a level on the discharge flange surface to adjust the pump horizontally in the
direction of the pump shaft. Also adjust the direction vertical to the pump shaft at the same time by
placing a level on the suction flange surface. Pour cement mortar into the anchor bolt holes after
leveling has been completed. When the cement mortar is hardened, fasten the anchor bolt nuts
firmly. [Fig. 2]
4.
In case there is influence of motor vibration during operation (e.g. sympathetic vibration with
piping), an expansion joint should be provided between the pump and the piping before installation.
Otherwise, pipes and gauges may be damaged.
Anchor bolt
Base
Spacer
Figure
Figure 32
10
Piping
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
*
1
Discharge pipe (use a support
To keep the pump free from the
load of the pipe)
Gate valve
Check valve
Pressure gauge
Motor
18
Pump
Priming pump
Gate valve
Drain valve
Compound gauge
Suction pipe (shortest horizontal
section with an ascending gradient
toward the pump)
Pipe support
Pump drain
Suction pipe
Suction pipe stabilizer brace
(used if suction pipe is particularly
long)
Foot valve
1.5D* or more
18 inches or more
1-1.5D* or more (if sediment
accumulates easily)
Suction tank
Screen
Short pipe
Pipe diameter
2
7
12
8
3
4
12
8 12 11
22
6
10
5
9
15
22
21
18
13
14
20
16
19
17
Figure 3
Suction Piping
1.
The suction pipe should employ the flooded suction method if possible. The shortest pipe possible,
with the minimum number of bends, should be designed. Arrange a proper support on the suction
pipe so that the load and the thermal stress of the pipe itself are not applied to the pump.
2.
Attach the coupling on the suction pipe carefully, so that no air enters the line. The presence of air in
the suction pipe may prevent priming of the pump.
3.
Avoid installations with poor suction conditions (e.g. vacuum in suction tank, large suction head or
long suction piping). NPSHa should always be at least 2 feet greater than NPSHr. For NPSHr
values, refer to the standard performance curve for your pump model or contact Iwaki America or
your distributor.
11
4.
When using a bend on the suction side, install a straight pipe which is more than 20 inches long or 10
times as long as the suction port diameter before the suction port of the pump. Use the largest
possible radius of curvature for the bend.
5.
Do not allow any projection where air may be trapped along the suction pipe. The suction pipe
should have an ascending gradient toward the pump.
6.
If the diameters of the pump suction port and the suction pipe are different, use an eccentric reducer
pipe. Connect the eccentric reducer pipe such that the upper part of it is level. Never use a suction
pipe with a diameter smaller than that of the pump's suction port.
7.
When using the flooded suction method, the suction pipe should be given a slight ascending gradient
toward the pump so that no air pocket is created on the suction side.
8.
The end of the suction pipe should be located 18 inches or more below the surface of the liquid.
9.
A screen should be provided at the inlet of the suction tank to prevent the entrance of foreign matter
into the suction pipe. Foreign matter may cause malfunctioning of and/or damage to the pump. The
end of the suction pipe should be a least 1- 1.5D from the bottom of the suction tank. (D=Diameter
of suction pipe).
10. When employing the suction lift method, install a foot valve on the suction pipe.
11. When using the flooded suction method, it is recommended that a gate valve be installed on the
suction pipe for easier overhaul inspection of the pump. Since this valve is used only in the overhaul
inspection of the pump, keep it fully opened during normal pump operation.
12. Pay close attention to the lowest level of the liquid in the suction tank to avoid vortexing, air
entrapment and associated suction piping concerns.
The inflow pipe into the suction tank should be distanced from the suction pipe and positioned below
the liquid surface as a means of preventing air entrainment to the suction pipe. If air bubbles are
generated in the suction tank, install a baffle.
13. It is recommended that a vacuum/pressure gauge be installed on the suction piping approximately 6
pipe diameters from the pump suction port.
12
Figure 4
Discharge Piping
1.
Use proper pipe supports so that the weight of the piping does not load the pump nozzle.
2.
If a method other than flooded suction is used, install a special pipe for priming.
3.
If the piping is very long, its diameter should be determined by calculating the piping resistance.
Otherwise, the specified performance may not be obtained due to increased piping resistance.
4.
A check valve should be installed if any of the following conditions exists in the piping:
• The discharge piping is very long.
• The discharge head is 50 feet or more.
• The end of the discharge pipe is located 30 feet higher than the surface of the suction tank.
• Several pumps are connected in parallel with the same piping.
5.
The installation of a gate valve on the discharge pipe is recommended for the adjustment of
discharge quantity and for the prevention of motor overload. When installing both a check valve and
a gate valve, the check valve should be positioned between the pump and the gate valve.
6.
A pressure gauge must be installed on the discharge piping, prior to the gate valve.
13
7.
An air bleeding valve should be installed if the discharge pipe is very long in the horizontal
direction.
8.
A drain valve should be installed for the drainage of liquid if there is a chance that the liquid in the
discharge pipe will freeze.
Wiring
POWER
R
S T
For ½ - 7½ HP motor:
OLR
OFF
MC
MC
PUSHBUTTON
M
M
MC
ON
OFF
OLR
ON
MOTOR
ELECTROMAGNETIC SWITCH
PUSH BUTTON
OVERLOAD RELAY
Figure 5
Use appropriate wiring materials, follow the instruction manual for the motor and abide by the local
and national electrical codes. In addition, follow the instructions given below:
1.
Use a motor contactor that conforms to the specifications (voltage, current, etc.) of the pump motor.
2.
If the pump is installed outdoors, use waterproof wiring to protect the switches from rainwater and
moisture.
3.
The motor contactor and push button should be installed a reasonable distance from the pump.
Refer to the wiring examples shown above. (These examples do not include the installation of a dry
run prevention device. Follow the instruction manual of the dry run prevention device when
installing it.)
14
9
Operation
Notes on Operation
1.
Never operate the pump with the suction valve (gate valve) closed. Otherwise, the internal bushing
of the pump will be damaged.
2.
In the event of cavitation, stop the pump immediately.
3.
If the magnet coupling disconnects, stop the pump immediately. The torque rating of the magnet
coupling will be reduced if operation is continued with the coupling disconnected.
4.
Liquid temperature fluctuation should not exceed 144o F (62°C) when starting, stopping, and
operating the pump.
5.
Be sure to close the discharge valve completely prior to start-up in order to prevent water hammer.
6.
The pump should never be operated with the discharge valve closed for longer than one minute. A
resulting rise in temperature of liquid within the pump may cause damage.
In the event of a service power failure, turn off the power switch immediately and close the
discharge valve.
Start-Up Preparation
When operating the pump for the first time after installation, and when restarting operation after a
long interval, prepare for operation as described below.
1.
Thoroughly clean the inside of the piping and pump.
2.
Tighten the union fittings or flange connecting bolts and base plate installation bolts. Check the
torque of the bolts that couple the front casing and the bracket together. Proper torque is 18 Ft-lbs
(24.5 N·m).
3.
Close the cocks of any pressure or vacuum gauges to prevent damage from sudden pressure changes.
Open only when taking measurements.
4.
Fully open the suction gate valve and partly open the discharge valve. Discharge valve may be
adjusted after completion of priming and start-up process.
5.
Use a screwdriver to rotate the motor fan and check that the fan rotates smoothly. This also purges
any residual air from in and around the impeller.
6.
If using flooded suction, measure the pressure in the suction pipe to verify that the pump is filled
with liquid.
7.
Run the motor momentarily to check the direction of motor rotation. The motor should run in the
direction indicated by the arrow cast on the pump casing. If the direction is reversed, exchange two
wires of the three-phase power wires.
15
Note: All Iwaki America MXM Series pumps rotate counter-clockwise when looking at the suction
port of the pump. Naturally, from the motor fan side, this would be viewed as clockwise.
Starting Operation Steps
Pump operation is detailed below.
Operation Step
1. Verify valve position
2. Check that the pump is filled with liquid.
3. Turn motor switch ON momentarily to check
for correct direction of pump rotation
Flow rate adjustment:
Once total discharge pressure is
increased to shut off pressure, open discharge
valve gradually to set discharge pressure to
desired specification.
Notes
Suction valve should be fully open, discharge valve
fully closed.
If the pump is not full of liquid, fill it according to
steps 5 & 6 of “Startup Preparation.”
Note the arrow direction on the casing to confirm the
direction of rotation (clockwise when viewed from the
motor fan side).
Open valve slowly, paying attention to the motor
current draw to prevent it from being overloaded
through excessive opening of the valve.
Pump should be operated at a minimum flow rate of:
Model: MXM-542
5.3 GPM (20 LPM)
Model: MXM-543
5.3 GPM (20 LPM)
Model: MXM-545
13.5 GPM (50 LPM)
In case of automatic control, close discharge valve when starting pump and gradually open the discharge
valve thereafter.
Do not operate the pump with the discharge valve closed for more than one minute.
Points to be observed during operation:
If the pump enters continuous operation condition, check flow meter and confirm that pump
operation meets specifications.
If flow meter is unavailable, check values of discharge pressure, suction pressure and current in
relation to piping resistance.
16
Stopping Operation Steps
Operation Step
1. Close discharge valve gradually.
Notes
Caution! Do not cause sudden closure by
using solenoid valve, etc. Pump may be
damaged by water hammer.
Observe that the motor stops rotating slowly and
smoothly. If not, check inside of pump.
2. Stop motor.
Points to be observed when stopping:
If pump operation is stopped in cold weather, liquid inside the pump cavity may freeze and
damage the pump. Be sure to drain liquid completely. In case of short term shut down, that does
not allow removal of liquid, use band heater to prevent liquid from freezing.
In case of service power failure, turn power switch OFF and close discharge valve.
10
Maintenance and Inspection
Daily Inspection
1.
Check that the pump operates smoothly, without generating abnormal sounds or vibration.
2.
Check the level of the liquid in the suction tank, and the suction pressure.
3.
Compare the discharge pressure and current measured during operation with the specifications
indicated on the motor and pump nameplates to verify normal pump load.
Note that the indicated value of the pressure gauge varies in proportion to the specific gravity of the
liquid.
Note: The valve of the pressure gauge or vacuum gauge should be opened only when measurements
are recorded. It must be closed after completion of each measurement. If the valve remains open
during operation, the gauge mechanism may be affected by abnormal pressure caused by water
hammer.
4.
If a spare pump is included in the installation, keep it ready for use by operating it from time to time.
17
Periodic Inspection
1.
To ensure efficient, smooth operation of the pump, carry out periodic inspection by following the
procedure described below. Inspection records should be maintained.
2.
When carrying out an overhaul inspection, handle the internal bushings and plastic components most
carefully. Since the outer drive magnet and inner magnet capsule are very powerful, handle these
components with caution. Take care not to trap hands and fingers between the magnets and metal
objects. Also avoid positioning the magnets near any electronic device that could be affected by a
strong magnetic field (i.e.. ATM cards or computer disks).
Inspection
Interval
Every 6
months
Every 3
months
Part
Outer magnet
assembly
Containment
shell
Inspection Points
Operator Action
Check for scoring
Contact distributor if any
abnormality is found.
Is magnet mounted normally?
Is hexagonal
socket set
screw loose?
Reinstall magnet on motor
shaft and fasten hexagonal
socket set screws.
Is inner perimeter of magnet
& motor shaft concentric?
Check for scoring on inner
diameter.
Re-tighten or replace
hexagonal socket set screws.
Contact distributor is
abnormality is observed.
Are there any cracks in liquidcontaining section?
Replace if abnormality is
observed.
Wear of thrust collar?
Replace if abnormality is
observed
Stain in containment shell?
Clean.
18
Inspection
Interval
Every 3
months
Impeller
Inner magnet assy
Part
Inspection Points
Operator Action
Is there scoring on rear face or
cylindrical body?
Contact distributor if any
abnormality is observed.
Are there any cracks in the
plastic of the rear section or
cylindrical body?
Contact distributor if any
abnormality is observed
Bushing wear.
Are there any cracks?
Replace if abnormality is
observed. (See Tolerance
chart)
Replace if abnormality is
observed.
Are there any cavitation marks?
Impeller
Eliminate cause.
Stain or clogging inside
impeller?
Clean.
Dimensional change of impeller?
Replace if abnormality is
observed.
Stain in liquid-contacting
section?
Front casing
liner
Every 3
months
Clean
Are there any cracks?
Replace if abnormality is
observed.
Wear or crack on inboard thrust
collar?
Contact distributor if
abnormality is observed.
Expansion or wear of O-ring?
Replace if part is damaged.
Scoring on inner surface?
Contact distributor if
abnormality is observed.
Replace if abnormality is
observed.
Are there any cracks?
Shaft
Wear on surface?
19
Replace if wear limit is
exceeded.
Replacement Tolerance Chart
Dimensions in inches (mm)
Model
(N)= New
(W) = Worn
(A) Bushing ID *
(B) Shaft OD*
(C) Thickness of mouth ring **
*
MXM-542, 543, 545
N
W
0.944 in.
0.984 in.
24 mm
25 mm
0.944 in.
0.905 in.
24 mm
23 mm
0.295 in.
0.216 in.
7.5 mm
5.5 mm
If the difference between Bushing ID and shaft OD exceeds 0.039 in. (1mm), either the bushing or
the shaft, whichever has greater wear, should be replaced regardless of the values in the above table.
In case of a ceramic bushing type pump (FF material code), the shaft and the bushing should be
replaced simultaneously.
Initial wear may appear in the sliding part in the first stages of operation. This should not be
mistaken for an abnormal condition.
** The step between the surfaces of the mouth ring and the impeller upon shipment is 0.079 in.
(2mm).Replacing the mouth ring is recommended when this step is reduced to 0 in. [Fig. 6]
UPON SHIPMENT
STEP 0.078in (2 mm)
IMPELLER
MOUTH
RING
Figure 6
20
11
Troubleshooting
Problem
Symptom on Pump
Discharge valve
Discharge valve
closed
open
Pressure gauge & vacuum
gauge indicate zero
Liquid level drops
immediately when priming
Cause
Insufficient priming
Dry run operation
Foot valve clogged
with foreign matter
Air enters thru suction
pipe or gasket section
Inspection &
Countermeasures
Stop pump, feed priming liquid
& restart
Replace strainer
Check whether seat is clogged
Check that connection flange in
suction piping is sealed airtight
Check whether suction liquid
level is abnormally low
Stop pump & use a screwdriver
to check for easy & smooth
rotation of motor fan.
Measure current level to check
for low reading
Liquid is not
pumped
Liquid level drops if
discharge valve is opened
after starting operation
Pressure & vacuum gauge
needles swing but return to
zero immediately
Magnet coupling is
disconnected
(de-coupled)
Check for foreign matter inside
pump cavity
Check whether voltage level is
normal
Replace outer magnet and/or
inner magnet assembly
RPM of pump is
insufficient
Vacuum gauge indicates
high value.
Vacuum gauge indicates
abnormally high value.
Discharge
quantity is small.
Needles of pressure &
vacuum gauges indicate
normal values.
Pressure & vacuum gauges
fluctuate.
Vacuum gauge reads high
while pressure gauge
indicates normal value.
Pressure gauge reads high
while vacuum gauge
indicates normal value.
21
Pump rotation is
reversed
Strainer is clogged
with foreign matter &
liquid passage is
blocked.
Air is trapped in
suction pipe.
Confirm fluid specific gravity &
magnet rating, determine if S.G.
exceeds magnet rating
Check wiring & motor and fix as
necessary
Correct motor wiring
Remove foreign matter in
strainer.
Inspect installation of suction
pipe & modify as necessary.
Inlet section of
impeller unit is
clogged with foreign
matter.
Partially disassemble unit &
remove foreign matter.
Air enters via suction
pipe or gasket section.
Check flange gaskets of suction
pipe & tighten.
Discharge side of
pump is clogged with
foreign matter.
Remove foreign matter or scale
inside of piping.
Air pocket or
resistance in suction
pipe.
Discharge piping
section causing high
resistance or actual
head & loss of head is
too high.
Inspect suction piping
installation & make corrective
adjustments.
Check actual head & piping loss
of discharge pipe & take
necessary measures.
Problem
Discharge
quantity is small
Symptom on Pump
Discharge valve
Discharge valve
closed
open
Pressure gauge reads low
& vacuum gauge reads
very low
Pressure & vacuum gauges
indicate low values
Motor overheats
Discharge
quantity is
suddenly
lowered.
Vacuum gauge reads high
22
Cause
Inspection &
Countermeasures
Rotating direction of
pump/motor is
reversed.
Insufficient voltage
Correct motor wiring to reverse
rotation (clockwise when viewed
from motor side)
Check whether voltage &
frequency levels are adequate.
Overload
Check whether specific gravity
& viscosity of liquid are above
spec.
Stop pump & use screwdriver to
check whether motor fan rotates
easily & smoothly.
Ambient temperature
is high.
Improve air ventialtion.
Strainer is clogged
with foreign matter
Remove foreign matter.
12
Parts Description and Exploded View
MXM-542 Only
No.
Description
Qty
1 + 1.1
Cover A/B1
1
314.1
Rear Thrust Collar
1.2
1.3
2
6
19
Cover C2
Front Casing Liner
Impeller
Spindle
Frame
1
554.1
900
903.1
903.2
903.3
Spring Washer
Eye Bolt
Hex Socket Bolt
Hex Socket Bolt
Hex Socket Bolt3
72
73.1
73.2
122.1
230
231
231.1
232
237
Mouth Ring
O-ring
Gasket
Drain Cap
Magnet Capsule Assy.
Rear Casing
Rear Casing Cover
Drive Magnet
Bearing
1
903.4
903.5
908.1
942
330
904
1
1
1
1
1
2
2
1
1
1
1
1
No.
554.2
Description
Qty
1
M10
6
M10
M10 x 40
M10 x 80
M6 x 18
1
5
1
3
M8 x 20
Hex Socket Bolt3
M8 x 15
Hex Socket Bolt
4
M8 x 10
Hex Socket Set Screw
Locking Pins
Motor Adaptor, MXM-542 Only
M12 x 40
Hex Head Bolt
MXM-542 Only
M12
Spring Washer
MXM-542 Only
2
1. The two pieces make a single set.
2. Cover C is divided into right & left parts. The two make a single set.
3. Hex socket bolts included with cover sets.
4. Hex socket bolts Included with Item# 232, drive magnet.
23
4
2
2
1
4
4
13
Disassembly and Assembly of Pump
Caution!
Since the magnets used in the pump are powerful, be careful not to catch your fingers or hand between
them during disassembly or assembly. Also, keep the magnet unit away from any electronic device that
could be affected by a strong magnetic field.
Prior to servicing, the suction and discharge valves must be closed. The piping and the pump often retain
some liquid. It is recommended the piping and pump cavity be drained prior to servicing.
If dangerous liquid is used, wear protection and flush pump with clean water or decontaminant prior to
service.
Make sure power to motor is OFF.
Disassembly
Vent Cap
1.
Remove the drain and vent caps (122.1) to discharge the
liquid from the pump. Flush the inside of the pump with a
neutralizing fluid. [Fig. 7]
2.
Remove the hex head or socket bolts (903.1 & 903.2) and
pull the front casing straight forward to detach from the
frame (19). [Fig. 8 & 9] Be careful not to damage the spindle
when removing the front casing. The spindle may come off
with the front casing. If this happens, take care to no lose the
rear thrust collar (314.1).
Figure 7
Caution!
Strong impacts may crack the shaft or liner. Do not hit them with a tool.
Figure 9
Figure 8
24
3.
Remove impeller (2) and inner magnet assembly (230) from
the containment shell (231) by drawing it forward. Be
careful not to scratch the surface of each part. Since the
inner magnet assembly is strongly magnetized, store it in a
place free of metal pieces. Handle the front casing liner
(1.3), inner magnet assembly and impeller with extra care so
as not to scratch the bushing and sealing surfaces. [Fig. 10]
4.
To remove rear casing, insert a flat head screw driver into
the periphery of the rear casing and slightly twist the screw
driver. If the spindle remains in the front casing liner,
remove if from the front casing. [Fig. 11]
Figure 10
5.
Remove spindle from rear casing, while firmly grabbing spindle, simultaneously pull and wiggle the
spindle. If necessary, submerge spindle where fixed to casing in hot water (194º F / 90º C) for
approx. 5 minutes.
6.
To disassemble impeller and magnet capsule assembly, turn the locking
pins counter clockwise 90 degrees using a slotted screw driver and then
push it towards the inside of the impeller. [Fig. 12] If it is hard to push
it out, slightly tap the end of the screwdriver handle. If the screw- driver
cannot be used because the groove of the pin was crushed, turn the pin
from inside of magnet capsule using hex wrench. [Fig. 13] When doing
so, turn the wrench clockwise. After turning the pin, push it in from the
outside using a screwdriver or drive pin.
After the two locking pins are removed, remove the impeller from the
magnet capsule by slightly tapping the periphery of the impeller with a
plastic hammer. If it is hard to remove, warm it with hot water (approx.
194º F / 90º C) for five minutes and remove it by slightly tapping
the impeller as described above. Pay attention to not burn yourself.
If impeller is forced from magnet capsule before the locking pins
are removed, the impeller and magnet capsule may be damaged.
7.
Remove the drive magnet assembly (232). Stand the motor up and
remove two M8 hex head socket set screws (908.1) from the access
hole in the frame (19). Insert a screwdriver and apply it to the boss
(lower portion) of the outer magnet assembly and pull or lever the
unit upwards. [Fig. 14] Store the magnet assembly in a proper place
so that metal pieces, etc.are attracted to it.
Figure 12
Figure 13
Caution! Do not strike the outer magnet assembly. Direct
impact may loosen the magnet strips or damage the motor
bearings.
Figure 14
25
8.
Replacement of Bushing, Mouth Ring
Bushing
1. Warm the inner magnet assembly (230) in hot water at 194° F (90° C) for
approximately 5 minutes. Then using a hand (arbor) press, remove the bushing (237)
by pressing the replacement jig from the front end of the inner magnet assembly. [
Fig. 15] (Consult Iwaki America for jig specifications).
Figure 15
* Bearing is pressed in from far end of
magnet capsule.
2. Align the new bushing to the back end of the inner magnet assembly.* Use the
replacement jig to press the bushing into the inner magnet with the hand
(arbor) press. (If the inner magnet is cold, warm it as in step 1 above prior to
pressing in the bushing).
3. After pressing in the new bushing, ensure that it is seated at the top and protrudes
from the bottom of the inner magnet assembly.
Mouth Ring:
1. Heat weld tabs that are folded over mouth ring on impeller (2).
2. Remove the outboard thrust collar by applying a screwdriver to the bottom of it and
lift upwards.
3. Place a new outboard thrust collar into the impeller by aligning the recessed areas of
the outboard thrust collar with the mating surfaces of the impeller and press using the
hand (arbor) press. Ensure that the outboard thrust collar is completely seated against
the recess in the impeller.
COVER C
Front Casing Liner:
1. Remove the drain and vent caps (121.1).
2. Remove the four hex socket bolts (903.5).
3. Remove the two hex socket bolts (90.4) and
separate Cover C (1.2) [ Fig. 16].
* Note: Cover C is divided into two halves. The
two make a single set.
4. Remove the three hex socket bolts (903.3) and
separate Cover A (1+1.1).
*Note: Cover A is divided into two halves. The
two pieces make a single set.
26
FRONT CASING
LINER
COVER A
Figure
20
Figure 16
Detach the front casing liner from Cover A. If this is difficult due to corrosion or rust on
the cover, use a resin hammer and gently tap the suction port of the front casing. (This
step completes disassembly of the front casing liner).
*Note: Cover A should always be stored as a single unit.
Cover B
Cover A
Front Casing
Cover A
Cover C
Figure 17
5. Align and install a new front casing liner into cover A, paying attention to the drain
port and locating tabs. [Fig. 17] If the front casing liner is difficult to attach, tap it
gently with a resin hammer. *Note: Tapping the back portion of the front casing
liner may cause sealing difficulty during reassembly.
6. Attach and temporarily secure both halves of Cover A with the hex socket bolts
(903.3).
7. Attach and temporarily secure the two halves of Cover C (1.2) to Cover A (1 + 1.1)
with the hex socket bolts (17). Tap the two parts gently in a slanted direction from
the front casing liner suction port. [Fig. 16]
8. Align Covers A and C and secure all hex socket bolts tightly.
9. Insert gasket (73.2) into the vent and drain caps (122.1) prior to installing them.
27
Reassembly
Reassemble the pump by reversing the order of disassembly. Refer to the exploded view diagram
on page 23 for parts and locations. Pay attention to the following points:
1.
Replacement of o-ring and gasket
When reassembling pump, always replace the o-ring and gaskets. In addition, confirm that the oring and gaskets are not twisted or pinched by another part.
The sealing section should be cleaned free of dust or scratches before installation.
2.
Fastening of bolts
Fasten the front casing bolts in a diagonal order, applying an equal torque to each.
Fastening Torque
Model
Type
542, 543, 545
Hex socket head bolt
Nm
Kgf/cm
Lbf/in
24.5
250
216
Size of Bolt
M10 x 80, M10 x 40
3.
Ceramic type
For pumps containing a ceramic bushing (FF), apply a small film of fluorocarbon grease on the
inside diameter of the bearing and spindle. This will prevent premature wear during initial start-up.
4.
Use the following table [Fig. 18] for correct placement of the drive magnet.
Figure 18
ID Mark
H
Motor
or motor
adapter
Model
Height - H
in (mm)
MXM-542
5.98” (152)
MXM-543 & 545
6.17” (157)
5.
Mount and bolt the frame (19) to the motor.
6.
Mount and secure the drive magnet (232) to the motor shaft. [Fig. 18] *Note: Use Loctite 242
(thread locker) and torque the set screws to 8.9 ft-lbs (12 Nm).
7.
Mount the impeller to the magnet capsule.
The mating part of the magnet capsule has two holes. The larger
hole is for the lock pin (stepped hole on the outside is 6 mm dia and
the inside is 12mm dia) and a smaller hole (3mm dia.) is for cooling
purposes. The U-shaped hole of the impeller and smaller hole (3
mm dia) of magnet capsule are also for cooling purposes. Insert the
impeller into the magnet capsule slowly by positioning the two holes
together. If it is hard to insert them, warm the magnet capsule only
with hot water (176º F 90 deg. C) for five minutes. [Fig. 19]
Figure 19
After the impeller is inserted (press-fit), insert the lock pins from the
inside and then tighten the pin by turning it clockwise 90 degrees from outside with a slotted
screwdriver. You will feel a snap when it is fixed securely.
28
If the groove for a slotted screwdriver is deformed, the pin can be
locked from the inside with a 4mm hex wrench. Turn the wrench
counter clockwise. [Fig. 20]
8.
Place rear thrust collar (314.1) on shaft (6) and press shaft into rear
casing. Make sure the anti-rotational flat on the spindle aligns with
the flat edge in rear casing. Place rear casing (231) with spindle (6)
and rear thrust collar (231) on pump frame (19).
9.
Place assembled impeller (2) and magnet capsule assembly (230) in
rear casing (231).
Caution
Magnet force is very strong. Apply plastic or wooden spacers
between the rear casing and frame to absorb any slack. [Fig. 21]
Be careful not to pinch your fingers.
Figure 21
Figure 20
10 Verify that there are no scratches or foreign material on the sealing
surface of the front casing liner (1.3). Install the o-ring (73.1) into the recess in the front casing liner.
Place front casing with liner (1.1 & 1.3) on rear casing (231). Make sure the spindle fits in front
casing liner spindle support.
11. Fasten the hex socket bolts (903.1 & 903.2 & 23) in a diagonal order applying equal torque to each.
Required torque is 18.0 ft-lbs. Use a screwdriver to verify that the motor fan rotates smoothly.
29
14
Spare Parts
Appropriate spare parts are necessary to ensure continued pump operation. Expendable parts
should always be kept on hand.
MXM-542/543
No.
Description
6
Spindle
72
Mouth Ring
Rear Thrust
Collar
314.1
230 +
237
Magnet Cap.
Assy.
73.1
O-ring
73.21
Gasket
MXM-545
Model
Number:
Material
Code
Model Number:
CF/FF
MXM0001
MXM0001
KK
CF/FF
MXM0002
MXM0063
MXM0002
MXM0063
CFRPFA
CF/FF/KK
MXM0064
MXM0064
CFRETFE + HD Carbon
CFRETFE + High purity
Al. Cer.
CFRETFE + SiC
FKM
EPDM
Aflas®
Dai-El Perfluor®
FKM
EPDM
Aflas®
Dai-El Perfluor®
CF
FF
MXM0004
MXM0119
MXM0012
MXM0120
KK
V
E
A
P
V
E
A
P
MXM0005
MXM0006
MXM0007
MXM0008
MXM0014
MXM0009
MXM0010
MXM0011
MXM0015
MXM0013
MXM0006
MXM0007
MXM0008
MXM0014
MXM0009
MXM0010
MXM0011
MXM0015
Material
High Purity Alumina
Ceramic
SiC
PTFE with filler
1. Two gaskets are required per pump.
30
15
Dimensions and Weights
Dimensions in inches (mm)
Model
a
b
c
d
D
e
f
F
g
MXM-542
MXM-543
9.9
2.6
(251.4) (66.0)
7.1
5.5
6.1
0.55
(180.3) (139.7) (154.9) (14.0)
4.2
10.8
0.55
(106.6) (274.3) (14.0)
MXM-545
Model
MXM-542
MXM-543
MXM-545
i
J
O
X
Y
11.5
(292.1)
10.9
18.5
11.6
5.5
3.4
(276.9) (469.9) (294.6) (139.7) (86.4)
10.9
(276.9)
X
Y
CP*
5.51
(140)
3.43
(87)
21.93
(557)
24.68
(627)
* Varies according to motor manufacturer.
31
CP*
21.9
(556.2)
24.7
(627.3)
24.7
(627.3)
Weight
(LESS MOTOR, LBS)
55
66
Iwaki America Corporation
5 Boynton Road Hopping Brook Park Holliston MA 01746-1446 USA
TEL: 508-429-1440 FAX: 508-429-1386 Website: www.iwakamerica.com
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