MDF-M_Series_Manual

MDF-M_Series_Manual
IWAKI WALCHEM
MAGNETIC DRIVE PUMP
MDF-M SERIES
INSTRUCTION MANUAL
Thank you for having selected an Iwaki Walchem MDF-M Series magnetic drive
pump. This instruction manual deals with the correct handling, maintenance, inspection, and troubleshooting procedures for the MDF-M magnetic drive pump. Please
read through it carefully to ensure the optimum performance, safety and long service
of your pump.
Contents
Item
Page
1
Unpacking and Inspection ............................................................................................. 3
2
Identification ................................................................................................................. 3
3
Specifications ................................................................................................................ 4
4
Handling Instructions .................................................................................................... 5
5
Installation, Piping and Wiring ....................................................................................... 7
6
Pump Operation ...........................................................................................................11
7
Maintenance and Inspection ....................................................................................... 14
8
Troubleshooting ........................................................................................................... 17
9
Parts Description and Exploded View ........................................................................ 21
10
Disassembly and Assembly of Pump ......................................................................... 23
11
Spare Parts ................................................................................................................. 29
12
External Dimensions and Weight ................................................................................ 30
P/N II20068.A
! 2
1
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.
IWAKI WALCHEM
MODEL MDF-M
HEAD (FT.)
CAPACITY (GPM)
HP
60 Hz.
RPM
1. Check that the model number and the voltage
indicated on the nameplate conform to the
specifications of your order.
SERIAL NO.
HOLLISTON, MA 01746
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.
2
Identification
1
2
3
4
MDF-M 40 07 P
1. Series name
2. Pump bore symbol
Suction × discharge
25: 1½ × 1
40: 2 × 1½
3. Magnet Coupling Rating (@ 3600 rpm)
02: 2 HP
03: 3 HP
05: 5 HP
07: 7.5 HP
5
CF
4. Material of Wetted Parts (portions made of resin)
P: PFA
E: ETFE
5. Material of Bearing Surfaces
Shaft
CF
Thrust Collar High purity Ceramic
Bushing
High density Carbon
KK
SiC
SiC
3 !
3
SPECIFICATIONS
Model
MDF-M2502
Connections
Inlet × Outlet
1½ × 1
Head
(ft)
Rated Capacity
(gpm)
60 Hz
116
53
MDF-M2503
MDF-M4005
2 × 1½
116
132
MDF-M4007
Motor
RPM
Motor Output
(HP)
3440
2
3440
3
3450
5
3470
7.5
Notes:
1. Rated performance (head/capacity) represents the maximum discharge/head/capacity measured with
pure water at 68°F.
2. Liquid temperature range:
PFA type: 32 - 248° F
ETFE type: 32 - 212° F
3. Slurry: Hardness 80Hs or below, grain size maximum 2 mil, density maximum 5% wt. Contact Iwaki
Walchem or your distributor for details.
4. Specific gravity limit: contact Iwaki Walchem or your distributor for details.
! Materials of Main Components
Parts
CF
1
2
3
4
5
! 4
KK
1
Casing Liner
ETFE or PFA
2
Containment Shell
ETFE or PFA
3
Bushing, Bearing
4
Shaft
5
Thrust Collar
6
Impeller Asm.
7
Gasket
6
7
Type
High density
SiC
Carbon
High purity
SiC
Alumina
Ceramic
High purity
SiC
Alumina
Ceramic
ETFE or PFA
PTFE
4
HANDLING INSTRUCTIONS
1. Do not operate the pump dry.
The sliding parts used in the MDF-M series pump 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 bearing system. A dry run operation device is recommended
for the prevention of dry pump operation.
2. Points to be observed in starting and stopping pump operation.
Pay close attention to the following points to avoid water hammer upon starting and stopping 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 valving can be opened
to the desired settings.
! Caution
If the pump is operated with air remaining in the pump cavity, biting, 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 which can cause severe damage to the pump.
3. Maximum system pressure rating
The table on the right shows the maximum
pressure rating of each model. Take care
that the system pressure does not exceed the
maximum pressure rating.
Model
Max. Pressure Rating
PSI
MDF-M2502
MDF-M2503
71
MDF-M4005
MDF-M4007
85
5 !
4. Handling of slurry liquid.
In general, slurries should not be handled. However, a pump with SiC bearings (KK type) can handle
slurries if the density is 5% or less and the grain size is 2 mil or less. Prior to pumping such slurry liquid,
you should call Iwaki Walchem or your distributor to verify if the operation is feasible.
5. Influence of specific gravity pump performance.
The performance of the pump does not change even for liquids of higher specific gravity. However, a
magnet assembly and motor selected for the specific gravity should be used.
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 checked.
7. Intermittent operation.
Frequent start/stop switching shortens the service life of the pump. Limit the frequency of switching to
six times or less per hour.
8. Influence 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 resistance. Pay special attention
to changes in liquid characteristics as a result of temperature fluctuation.
Liquid temperature range:
Ambient temperature range:
PFA type: 32 - 248° F
ETFE type: 32 - 212° F
32 - 104°F
* Refer to the corrosion resistance table for the recommended temperature ranges for various
types of liquids. In case of any questions, contact Iwaki Walchem or your distributor to determine if
operation is feasible.
9. Separation of magnet coupling.
If the magnet coupling should disconnect, stop the pump within 1 minute. If operation is continued, the
torque rating of the coupling will be permanently reduced.
10. Operation within range of bell-shaped head capacity curve.
In the case of a pump which generates a bell-shaped head capacity curve in a low-quantity range, do
not operate the pump in the section where the line ascends rightward. (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 which is installed close to the discharge port
of the pump.
! 6
5
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
priming pipe and the suction pipe. The lifting capability depends upon the liquid properties, temperature,
and length of suction piping. For details, consult Iwaki Walchem 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 base. If the anchoring area is not large
enough, the base may be damaged due to the concentration of loads placed on it.
2. Set the pump base on a concrete foundation and fasten the anchor bolts tightly to prevent the pump
from vibrating during operation.
3. Insert a spacer between the concrete surface 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. (See figure
below.)
4. Prior to the installation of the MDF-M KK
series pump (with SiC type shaft and bushing),
remove the cardboard pad inserted in the
suction port.
A n cho r b o lt
5. 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 the installation. Otherwise, pipes and
guages may be damaged.
!
Piping
B a se
S p a ce r
Fig. 1
7 !
1
2
7
12
8
3
4
12
18
22
8 12
11
6
10
5
9
15
22
21
13
14
20
18
16
19
17
1. Discharge pipe (Use a support to keep the pump
free from the load of the pipe.)
2. Gate valve
3. Check valve
4. Pressure gauge
5. Motor
6. Pump
7. Priming pipe
8. Gate valve
9. Drain ditch
10. Compound gauge
11. Suction pipe (D=Diameter of pipe) (Shortest
horizontal section with an ascending gradient
toward the pump)
12. Pipe support
13. Pump drain
14. Suction pipe (D=Diameter of pipe)
15. Suction pipe stabilizer brace (Used if the
suction pipe is particularly long.)
16. Foot valve
17. 1.5D or more
18. 18 inches or more
19. 1- 1.5D or more (if sediment accumulates
easily)
20. Suction tank
21. Screen
22. Short pipe
1. The suction pipe should employ the flooded suction method if possible. The shortest pipe possible, with
! Suction Piping
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. If the suction process condition is not good (e.g., the suction tank is a vacuum, the suction head is large,
or the suction pipe is long), NPSHa should always be at least 2 feet greater than NPSHr. For the
NPSHr , refer to the standard performance curve.
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.
! 8
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 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 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.
G O O D C O N D IT IO N S
U N A C C E P TA B LE C O N D IT IO N S
A IR TR A P
A IR TR A P
A IR TR A P
A IR TR A P
9 !
12. Pay close attention to the lowest level of the liquid in the suction tank so that air entrainment to the
suction piping will not occur.
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 D
from the pump suction flange.
! 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.
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.
! 10
!
PO W ER
R
S
T
O LR
O FF
Wiring
Use appropriate wiring materials, follow the
instruction manual for the motor and abide by the
local and national standards for electrical codes. In
addition, follow the instructions given below:
MC
MC
PUS HBUTTO N
M
M
MC
ON
OFF
OLR
ON
1. Use an electromagnetic switch that conforms
to the specifications (voltage, capacity, etc.) of
the pump motor.
M O TO R
E LE C TRO M AG N E TIC S W IT C H
P U S H B UT TO N
O V E R LO A D R E LAY
2. If the pump is installed outdoors, use waterproof
wiring to protect the switches from rainwater
and moisture.
3. The electromagnetic switch and push button
should be installed a reasonable distance from
the pump.
4. Refer to the wiring example shown on the left.
(This example does not include the installation of
a dry-operation prevention device. Follow the
instruction manual of the dry-operation prevention device when installing it.)
6
Operation
! Notes on Operation
1. Never operate the pump dry or with the suction-side valve (gate valve) closed. Otherwise, the inside
of the pump will be damaged.
2. In the event of cavitation, stop the pump within a minute.
3. If the magnet coupling disconnects, stop the pump within a minute. The torque rating of the magnet
coupling will be reduced if operation is continued with the coupling disconnected.
4. Temperature fluctuation should not exceed 176o F when starting, stopping, and operating the pump.
5. Be sure to close the discharge valve completely before starting operation in order to prevent water
hammer upon start-up.
6. The pump should never be operated for a lengthy period with the discharge valve closed. A resulting
rise in temperature of liquid in the pump may cause damage to the pump.
7. In the event of a service power failure, turn off the power switch immediately and close the discharge
valve.
11 !
! 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. Supply water.
2. Tighten the flange connecting bolts and base installation bolts. Check the torque of the bolts which
couple the front casing and the frame together. Proper torque is 32.5 ft-lbs.
3. Use a screwdriver to rotate the motor fan and check that the fan rotates smoothly.
4. After priming the pump, fully close the discharge valve.
5. If using flooded suction, measure the pressure in the suction pipe to check that the pump is filled with
liquid.
6. Run the motor momentarily to check the direction of motor rotation. The motor should run in the
direction indicated by the arrow sealed on the pump. If the direction is reversed, exchange two wires
of the three-phase power wires.
!
Operation
Pump operation is detailed below.
Check/Operation Step
Remarks
1.
Verify valve position.
Suction valve fully open.
Discharge valve fully closed.
2.
Check that the pump is filled with liquid.
If pump is not filled with liquid, fill it in accordance with step 5 of ‘Start-up Preparation'.
3.
Turn ON motor switch momentarily and
check for correct direction of pump
operation.
See the arrow on the casing to confirm the
direction of rotation (clockwise when viewed
from the motor fan side).
! 12
4.
Check/Operation Step
Remarks
Flow rate adjustment.
If total discharge pressure is increased to
shut off pressure after achieving normal pump
operation, open discharge valve gradually to
set discharge pressure as specified.
Open valve carefully, paying attention to
ammeter to prevent motor from being
overloaded through excessive opening of
the valve.
Pump should be operated at a minimum discharge quantity of: 5.3 gpm (20 L/m) or more.
In case of automatic control, close discharge valve when starting pump and gradually open
the discharge valve thereafter.
Don’t operate the pump with the discharge valve closed for more than one minute.
5.
Points to be observed during operation.
If flowmeter is unavailable, check values of
If pump enters continuous operation
discharge pressure, suction pressure and current
condition, check flow meter and confirm in relation to piping resistance.
that pump operation meets specifications.
! Stopping Operation
Check/Operation Step
1.
Close discharge valve gradually.
2.
Stop motor.
3.
Points to be observed when stopping pump.
Remarks
Caution
!
Do not cause sudden closure by using solenoid
valve, etc. Otherwise, pump may be damaged
by water hammer.
Observe that the motor stops rotating slowly
and smoothly. If not, check inside of pump.
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, which
does not allow removal of liquid, use band heater, etc., to prevent liquid from freezing.
In case of service power failure turn OFF power switch and close discharge valve.
13 !
7
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.
! Periodic Inspection
To ensure efficient, smooth operation of the pump, carry out periodic inspection by following the procedure
described below. When carrying out an overhaul inspection, handle the sliding and resin parts most
carefully. Since the outer magnet and impeller unit magnet are very powerful, be careful not to position
them near any electronic device that could be affected by a strong magnetic field.
! 14
Inspection
Interval
Every 6 months
Part
Outer magnet
assembly
* Inspection
record should be
maintained.
Containment
shell & cover
Every 3 months
* Inspection
record should be
maintained.
Inner
magnet
Impeller
unit
Impeller
Inspection Points
Operator Action
" Is there scoring?
# Contact your distributor if
any abnormality is observed.
" Is housing mounted normally?
Is hexagonal socket setscrew
loose?
# Reinstall housing on motor
shaft and fasten hexagonal
socket setscrews.
" Are inner perimeter of magnet
and motor shaft concentric?
# Retighten or replace hexagonal socket setscrews.
" Is there scoring on inner
diameter?
# Contact your distributor if
abnormality is observed.
" Are there any cracks in
liquid-containing section?
# Replace if abnormality is
observed.
" Wear of rear thrust collar?
" Stain in rear casing?
# Replace if abnormality is
observed.
# Clean.
" Is there scoring in rear face or
cylindrical body?
# Contact your distributor if
any abnormality is observed.
" Are there any cracks in resin of
rear section or cylindrical body?
# Contact your distributor if
abnormality is observed.
" Bearing wear.
# Replace if abnormality is
observed.
# See tolerance chart.
" Are there any cracks?
# Replace if abnormality is
observed.
# Eliminate cause.
" Are there any cavitation
marks?
" Stain or clogging inside
impeller.
" Dimensional change of
impeller.
# Clean.
# Replace if abnormality is
observed.
15 !
Inspection
Interval
Part
Inspection Points
Front casing
Every 3 months
* Inspection
record should be
maintained.
Shaft
Operator Action
" Stain in liquid-contacting
section.
# Clean.
" Are there any cracks?
" Is drain clogged?
# Replace if abnormality is
observed.
# Clean.
" Wear or crack of front thrust
collar.
# Contact your distributor if
abnormality is observed.
" Expansion or wear of gasket.
# Replace if part is damaged.
" Scoring in abnormal location.
# Contact your distributor if
abnormality is observed.
" Are there any cracks?
# Replace if abnormality is
observed.
" Wear of abrasive section.
# Replace if wear limit is
exceeded.
! Wear Limit of Bushing, Shaft, Front Thrust Collar
Model
MDF-M25
Part
Bushing
New
MDF-M40
Replacement
New
Replacement
Flange thickness (in.)
.236
.196
.236
.196
Inner diameter (in.)
.787
.826
.945
.984
Outer diameter of shaft (in.)
.787
.748
.945
.905
Front thrust collar thickness (in.)
.275
.236
.275
.236
* When the difference between the inner diameter of the bushing and the outer diameter of the shaft
exceeds .040 inches, replace the worn bushing or shaft with a new one regardless of the above table.
* The sliding parts often suffer initial wear in a short period of time after the start of operation. This is
not an abnormal phenomenon.
0.275 in.
WHEN
S H IP P E D
I.D.
O .D.
0.236 in.
WHEN
S H IP P E D
S H A FT
B U S H IN G
! 16
FR O N T
TH R U S T
C O LLA R
8
Troubleshooting Guide
Symptom on Pump
Trouble
With Discharge
Valve Closed
With Discharge
Valve Open
Pressure gauge
and vacuum
gauge indicate
'zero'
Liquid Level
drops immediately when
priming is
carried out
Liquid is
not
pumped
Liquid level
drops if discharge valve is
opened after
starting operation.
Needles of
pressure and
vacuum gauges
swing but return
to zero immediately.
Cause
Inspection and
Countermeasures
" Insufficient
priming.
" Dry Operation
# Stop pump, feed priming
liquid and restart pump.
" Foot valve is
clogged with
foreign matter.
# Replace strainer.
# Check whether seat is
clogged with foreign
matter.
" Air enters through
suction pipe or
gasket section.
# Check that the connection flange in suction
piping is sealed airtight.
# Check whether suction
liquid level is abnormally low.
" Magnet coupling
is disconnected.
# Stop pump and use a
screwdriver to check for
easy and smooth rotation of motor fan.
# Measure current level to
check for low reading.
# Check for foreign matter
inside pump cavity.
# Check whether voltage
level is normal.
" RPM of pump is
insufficient.
" Pump rotation is
reversed.
# Check wiring and motor,
and fix as necessary.
# Correct motor wiring.
17 !
Trouble
Symptom on Pump
With Discharge
With Discharge
Valve Closed
Valve Open
Needles of
Discharge
pressure and
quantity
vacuum gauges
is small.
indicate normal
values.
! 18
Cause
Inspection and
Countermeasures
Needle of
vacuum gauge
indicates high
value.
" Strainer is clogged
with foreign matter
and liquid passage
is blocked.
# Remove foreign matter
in strainer.
Needle of
vacuum gauge
indicates abnormally high value.
" Air is trapped in
suction pipe.
# Inspect installation of
suction pipe and modify
it as necessary.
" Inlet section of
impeller unit is
clogged with
foreign matter.
# Partially disassemble
unit and remove foreign
matter.
" Air enters via
suction pipe or
gasket section.
# Check flange gaskets of
suction pipe and tighten
it as necessary.
" Discharge side of
pump is clogged
with foreign
matter.
# Remove foreign matter
in pump.
# Remove foreign matter
or scale inside of piping.
Vacuum gauge
needle indicates
high value while
pressure needle
indicates normal
value.
" Air pocket or
resistance in
suction pipe.
# Inspect suction piping
installation and make
corrective adjustments.
Pressure gauge
needle indicates
high value while
vacuum gauge
needle indicates
normal value.
" There is a section in
discharge pipe that
causes high resistance or actual
head and loss of
head are too high.
# Check actual head and
piping loss of discharge
pipe and take necessary
measures.
Needles of
pressure gauge
and vacuum
gauge fluctuate.
Symptom on Pump
Trouble
Discharge
quantity is
low.
With Discharge
Valve Closed
Needle of
pressure gauge
indicates low
value and
vacuum gauge
indicates
extraordinarily
low value.
With Discharge
Valve Open
Needle of
pressure gauge
and vacuum
gauge indicate
low value.
Cause
" Rotating direction
of pump/motor is
reversed.
# Correct motor wiring to
reverse roation. (Clockwise when viewed from
motor side.)
" Voltage is insufficient.
# Check whether voltage
and frequency levels are
adequate.
" Overload.
# Check whether specific
gravity and viscosity of
liquid are above specification.
# Stop pump and use
screwdriver, etc., to
check whether motor fan
rotates easily and
smoothly.
" Ambient temperature is high.
# Improve air ventilation.
" Strainer is clogged
with foreign matter.
# Remove foreign matter.
Motor
overheats
Discharge
quantity is
suddenly
lowered.
Needle of
vacuum gauge
indicates high
value.
Inspection and
Countermeasures
19 !
Trouble
Pump
vibrates.
! 20
Symptom on Pump
With Discharge
With Discharge
Valve Closed
Valve Open
Cause
Inspection and
Countermeasures
" Foundation is inadequate.
" Anchor bolt is loose.
" Suction pipe is
closed. Cavitation is
caused.
" Wear or melting of
pump bushing.
" Damaged inner
magnet assembly or
pump shaft.
" Fluctuating dynamic
balance of outer
magnet assembly
" Impeller is in contact
with inner magnet
assembly anchoring
section.
" Wear of motor
bearing.
# Carry out installation
process again.
# Retighten bolt.
# Clean, eliminate cause
of cavitation.
# Replace.
# Replace.
# Remove or replace.
# Replace bearing or
motor.
9
Parts Description and Exploded View
! MDF-M25
Quantity
No.
Description
Front Casing Liner
1
18
Front Thrust Collar
1
2
Containment Shell
1
19
Rear Thrust Collar
1
3
20
Shaft
1
1
1
21
Bushing
1
5
Impeller Unit & Inner
Magnet Assembly
Outer Magnet Assy
23
Gasket
1
7
Bolt
6
24
Drain Gasket
1
9
Frame
1
25
Eye Bolt
1
10
Setscrew
2
26
Containment Shell Cover
1
11
Casing, Front
1
70
Setscrew
2
14
Bolt
2
71
Bolt
4
16
Motor
1
17
Drain Plate
1
No.
Description
1
Quantity
21 !
!
MDF-M40
Quantity
No.
Description
Front Casing Liner
1
20
Shaft
1
2
Containment Shell
1
21
Bushing
1
3
23
Gasket
1
1
1
24
Drain Gasket
1
5
Impeller & Inner
Magnet Assembly
Outer Magnet Assy
25
Eye Bolt
1
7
Bolt
6
26
Containment Shell Cover
1
9
Frame
1
50
Base Plate (optional)
1
10
Setscrew
2
70
Setscrew
2
11
Casing, Front
1
71
Bolt
4
14
Bolt
2
72
Bolt
2
16
Motor
1
73
Bolt
4
17
Drain Plate
1
74
Front Spacer
2
18
Front Thrust Collar
1
19
Rear Thrust Collar
1
No.
Description
1
! 22
Quantity
10
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 disassembly or assembly, 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.
!
Caution
If dangerous liquid is used, wear protection.
! Disassembly
1. Loosen the hexagonal head bolts (14) and
remove the drain plate (17) so that the liquid in
the pump is drained out. Flush the inside of the
pump.
* The drain plate of the MDF-M40 is located
under the front casing.
MDF-M25
2. Remove the hex head bolts (7) and pull the
casing (11) straight forward to detach it. DO
NOT force or use impact, since the shaft (20 is
press-fit into the front casing liner (1) attached
to the cover. (The shaft may break or the
casing may be cracked if too much force is
applied.)
23 !
MDF-M40
2. Remove the anchoring bolts (72) on the frame
(9) and remove the casing bolts (7). Then, draw
the frame backward on the base. Be careful
not to strike the shaft, which is pressed into the
casing liner, or subject it to other impact. (The
shaft might break or the casing might crack if
the shaft is struck.)
3. Draw the impeller unit (3) forward. Handle the
impeller very carefully to avoid scratching it.
Since the impeller unit is strongly magnetized,
store it such that no metal pieces are attracted
to it. In addition, pay close attention to the
handling of the front casing (1) and the impeller
unit to prevent scratching or cracking the
bushing or sealing surfaces.
! Caution
Be careful not to let your fingers
or hand get caught between the impeller and
frame.
4. To remove the containment shell (2), insert a
screwdriver into the recess on the perimeter and
pull the containment shell forward while lifting it
slightly upward. Do this with utmost care so as
not to damage the seal surface of the gasket
(23).
! 24
5. To remove the outer magnet (5), first remove
the motor (16) from the frame (9). Then, stand
the motor upright and remove the two M8
hexagonal socket setscrews (10). Apply a pry
bar to the boss on the outer magnet assembly
and pull or lever the unit upward. Store the unit
such that no metal particles are attracted to it.
* Clamping torque of drive magnet unit: 8.7
ft-lbs.
6. The bushing (21), front thrust collar (18), and
shaft (20) should be replaced as described
below.
Disassembly and replacement of bearing.
(a) Warm the impeller unit (3) with hot water
(approximately 195o F) for about 5 minutes.
Then, use a hand press and a replacement jig
to remove the bearing. (Consult Iwaki
Walchem for special jig specification.)
(b) Press a new bushing into the unit by
means of an arbor press. (If the impeller unit
is cold, warm it up as in step (a) before
pressing the bushing into it.)
(c) After pressing in the bushing, check that
it is correctly positioned inside the impeller
unit. (See the figure on the left.)
Replacement of shaft.
A shaft (20) equipped with front thrust collar
(18) is pressed into the front casing liner (1).
Pay attention to the following points when
replacing the shaft.
* The shaft section should not be disassembled unless replacement is unavoidable,
such as when the shaft is worn.
(a) Holding the worn shaft in one hand, tap
25 !
the perimeter section of the front casing
lightly and evenly with a plastic hammer to
remove the shaft from the casing liner.
Never strike the seal surface of the front
casing liner or the shaft.
* If the shaft does not come out easily, warm
the front casing with warm water of about
195o F.
(b) Wipe off the stains on the front casing
liner. Then, insert a new shaft into a new
front thrust collar and press the shaft into the
front casing with your hand, trapping the
thrust collar between the shaft and liner.
Next, tap the shaft lightly with a plastic
hammer to drive it into position.
! Disassembly and Replacement of Front
Casing Liner
Disassembly
1. Remove the hexagonal head bolts (7) and front
casing cover assembly.
2. Remove the hexagonal socket bolts (70) and
split the casing (11) in two directions to remove
the casing liner. If the casing does not come off
easily due to stains or rust on it, tap it lightly with
a plastic hammer. (This step concludes the
disassembly process.)
* The casing is divided into a pair of right and left
sections. A single set consists of a right and a
left section.
Replacement
! 26
1. Attach the casing (11) to a new front casing
liner (1), paying attention to the drain port.
Then, loosely fasten the hexagonal socket bolts
(70). If the casing is difficult to attach in place,
tap it lightly so that the seal section of the front
casing liner is not damaged.
2. When attaching the casing onto the front casing
liner, be careful not to misalign it in the vertical
or horizontal directions. Fix the casing by firmly
tightening the hexagonal socket bolt (70).
* Be sure not to damage the casing liner in this
step.
* The casing is not to be disassembled unless
casing liner replacement is required.
3. Install the drain plate (17).
* The PFA front casing liner used in the MDFM40 type is integrated into a single assembly
with the casing. The front casing and liner must
be replaced as an assembly.
! Assembly
The pump should be assembled in the reverse order of disassembly, as described below. Refer to the
exploded view diagrams on pages 21-22 for parts and locations.
Clean the gasket seating section thoroughly so that no dust or scratches are observed. Fasten the bolts
evenly.
1. Install the containment shell cover (26) and containment shell (2) onto the frame (9).
2. Check that there are no metal pieces, etc.,
attracted to the impeller/inner magnet assembly
(3). Then, slowly insert the unit into the contain-
27 !
ment shell. Since its magnetic power is
strong, the unit must be inserted carefully.
! Caution Be careful not to let your fingers
or hand get caught between the impeller and
frame.
3. Check that there is no dust or scratches on the
seal surface of the front casing liner (1). Then,
attach the gasket (23) to the front casing liner.
4. For the MDF-M25, insert the shaft (20) installed
in the front casing liner (1) into the guide holes
of the impeller/inner magnet assembly (3) and
the containment shell (2), thus assembling the
front casing to the frame and containment shell
assembly.
* In assembling, take care not to apply too much
force to the shaft.
For the MDF-M40, slide the frame (9) on the
base (50) forward to position it into the front
casing.
5. Fasten the hexagonal head bolts (7) one after
another diagonally, to apply even torque. Then,
use a screwdriver to rotate the motor fan and
check its ease and smoothness of rotation.
* Clamping torque: 32.5 ft-lbs.
6. For the MDF-M40, after the above step, fasten
the base anchoring bolt (72) on the frame (9).
! 28
11
Spare Parts
Appropriate spare parts must be used to ensure continued pump operation. Expendable parts, in particular,
should always be kept on hand. When placing orders, supply the following information.
1. Description and part number (according to this instruction manual).
2. Pump model number and serial number (as shown on the nameplate of the pump).
3. Drawing number if you have received a certified drawing.
! MDF-M Series Spare Parts List
No.
2*
Description
Material
Containment
ETFE, ceramic
MFM1467
MFM1543
shell (with
ETFE, SiC
MFM1488
MFM1566
PFA, ceramic
MFM1421
MFM1516
collar)
PFA, SiC
MFM1478
MFM1556
Containment
ETFE
MFM1458
MFM1563
shell
PFA
MFM1400
MFM1500
Front thrust
Ceramic
MFM1377
MFM1491
collar
SiC
MFM1471
MFM1548
Rear thrust
Ceramic
MFM1398
MFM1498
collar
SiC
MFM1476
MFM1551
Shaft
Ceramic
MFM1378
MFM1520
SiC
MFM1472
MFM1549
High-density
carbon
SiC
MFM1391
MFM1494
MFM1475
MFM1550
MFM1399
MFM1499
(19) rear thrust
2
18*
19*
20*
21*
Bushing
23*
Gasket
PTFE
24*
Drain gasket
PTFE
26*
Containment
shell cover
Impeller/
Inner Magnet
Assembly
FRP
3
MDF-M2502
MDF-M2503
MDF-M40005 MDF-M4007
MFM1381
MFM1401
MFM1501
PFA
MFM1395
MFM1413
MFM1517
ETFE
MFM1455
MFM1464
MFM1544
Items with asterisks are expendable parts.
Note: For replacement of item 3, Impeller/Inner Magnet Assembly, specify existing impeller trim or pump
serial number at the time of order placement.
29 !
!
Dimensions and Weights
Pump Dimensions inches (mm)
Model
MDF-M2502
MDF-M2503
Size
1.5 x 1.0 x 5.4
X
6.31
(160)
MDF-M4005 2.0 X 1.5 X 5.4
MDF-M4007
!
D
5.91
(150.0)
E1
5.13
(130)
CP
9.80
(249)
F
7.22
(184)
6.31
(160)
7.48
(190)
10.48
(266)
9.84
(250)
H
0.63
(16)
HL
3.94
(100)
Weight
lbs (kg)
86 (39.1)
Y
3.16
(80)
4.52
(115)
130 (59.1)
145 (65.9)
MDF-M25
CP
Y
X
D
!
E1
HL
F
H
MDF-M40
CP
Y
X
D
F
H
! 30
HL
E1
5 BOYNTON ROAD HOPPING BROOK PARK HOLLISTON, MA 01746 USA
TEL: 508-429-1440
FAX: 508-429-1386
E-MAIL: [email protected]
ON THE INTERNET: WWW.IWAKIWALCHEM.COM
P/N II20068.A
31 6/94
!
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