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masosine Certa 100, User Manual

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masosine Certa 100 User Manual Download Page 23

17

Troubleshooting

Fault

Cause

Fix

Pump does not draw in

Direction of rotation not correct

Check direction of rotation

No wetting liquid in pump

Fill pump with liquid

Screw fastening not tight

Check screw fastening

Suction pipe too long

Adapt suction pipe

Suction pipe too narrow

Adapt suction pipe

Shaft seal leaking

Check all seals for damage

Wearing parts worn

Replace wearing parts

Motor speed not correct

Measure and regulate speed

Pump does not deliver

Direction of rotation not correct

Check direction of rotation

Suction and pressure pipe
interchanged

Check pipe system

Motor speed not correct

Check pump speed against performance curves - see your
purchase order

Wearing parts worn

Replace wearing parts

Inserted gate valve closed

Check pipe system

Pump is noisy

Noises from the drive

Consult manufacturer

Noises from the pump

Consult manufacturer

Suction pipe too small (cavitation)

Shorten suction pipe or increase diameter, reduce speed

Knocking noises from the
pumphead

Check if gate is worn and replace if necessary

Cavitation. Refer to See Cavitation on page 15

Noises from the power frame

Fill oil, change tapered roller bearings

Coupling not aligned

Align coupling correctly. See section See Good pump installation
practice on page 13

Pump leaks

Sealing system is leaking

Change static/dynamic seal faces

O-ring seal leaking

Replace O-ring

Lip seal ring on the power frame
leaking, oil escapes

Dismantle power frame, replace lip seals

Seal faces are worn / show burning
marks

Use a seal flush to prevent mechanical seal from dry run

Pump leaks at front
housing or back
housing

Housing seal not installed or
wrongly installed

Install housing O-ring correctly or replace

Housing seal defective

Install housing O-ring correctly or replace

Pump is blocked

Foreign body in the pump

Remove foreign body, examine pump for damage

Power supply interrupted

Check electrical installation and fuses, check drive

Defect in the drive

Separate the coupling and turn the pump by hand to confirm

Severe wear after
short operating time

Solids in the pumped fluid

Change the wearing parts frequently; check material
compatibility

Pumped fluid is abrasive

Choose larger pump, reduce speed

Rotor has wear on
one side

Rotor not tightened correctly on
installation

Tighten shaft nut firmly on block

Adjusting dimensions changed
after working on the bearing
housing

Check and correct dimension X: see section See Assembling the
support / Centering the rotor with the shim ring on page 30

Pump not clean after
CIP cleaning

Cleaning regulation not complied
with.

See section See Cleaning and sterilisation on page 20

Pump assembly
subject to vibrations

Speed of the drive motor is too high

Reduce the speed of the drive motor

Smells and smoke
coming from the pump

Pump is running dry

Stop the pump immediately. Check inner parts for damage and
replace if necessary

17.1 Technical support

For full contact details, please go to our website:

http://www.watson-marlow.com/gb-en/range/masosine/

m-certa800-en-01

23

Summary of Contents for Certa 100

Page 1: ...devices 7 9 9 Dangers due to hazardous pumped material 7 9 10 Dangers due to electrical energy 7 9 11 Dangers due to hydraulic energy 7 9 12 Special danger points 7 9 13 Constructional changes to the machine 8 9 14 Noise 8 9 15 Limit values for the pump 9 9 16 Maintenance and repair 9 9 17 Cleaning the pump 10 9 18 Faults 10 10 Pump specifications 11 10 1 Standards 11 10 2 Dimensions 11 Dimensions...

Page 2: ...hanging the nozzle orientation 29 18 5 Assembling the support Centering the rotor with the shim ring 30 18 6 Checking the X Dimension 30 18 7 Assembling the front mechanical seal 31 18 8 Assembling the pump head 33 18 9 Assembling the flush ring of a single mechanical seal system 36 18 10 Assembling the back seal in a double mechanical seal system 36 19 Tightening torques 40 20 Parts lists 40 20 1...

Page 3: ...nisation of the laws of the Member States relating to electromagnetic compatibility recast Official Journal of the EU L 96 79 of 29 03 2014 Directive 2014 35 EU was complied with in accordance with Annex I No 1 5 1 MRL 2006 42 EC with regard to its protection objectives According to Directive 2014 68 EU Artikel 4 3 the above mentioned manufacturer certifies in accordance with the applicable good e...

Page 4: ...ts or subcontractors MasoSine grants no implicit warranties on the suitability of the products described for a certain application MasoSine accepts no liability for errors contained in this documentation or consequential damage occurring due to the design performance and the use of this documentation MasoSine s General sales and delivery conditions contain full details These are available to the p...

Page 5: ...ts distributors Failure to do so will cause delays Please ensure that you email us this information and receive a RGA Returned Goods Authorisation before you despatch the product s A copy of the RGA form must be attached to the outside of the packaging containing the product s Please complete a separate decontamination certificate for each product and attach it to the outside of the packaging cont...

Page 6: ...nd trouble free operation of this machine These operating instructions contain the most important instructions to operate the machine safely These operating instructions especially the safety instructions must be observed by all persons who work on the machine In addition the rules and regulations for accident prevention applicable at the place of use must be obeyed The following safety instructio...

Page 7: ...ces may be removed only after the machine has stopped and protection measures against restarting the machine have been taken After spare parts have been fitted protective devices must be attached according to the operating organisation s regulations If contact with hot or cold machine parts could be dangerous protection must be provided for the pump user 9 9 Dangers due to hazardous pumped materia...

Page 8: ...parts Parts that are not obtained from MasoSine are not guaranteed to be designed and manufactured in compliance with load and safety requirements The warranty is invalid if genuine spare parts from MasoSine are not used 9 14 Noise The continuous sound pressure level proceeding from the machine should not exceed 70 dB A Higher sound pressure levels that can cause deafness can arise depending upon ...

Page 9: ... screw connections for firm seating Use only original spare parts After maintenance work is finished check the safety devices are functioning Bearings maintenance Note Remove the bearing housing only to replace or adjust the shim ring Do not attempt to dismantle the power end of the pump or replace the bearings Pumps needing repair servicing new bearings or other work on the power end must be retu...

Page 10: ...fore installing the lock nut again to prevent the build up of microorganisms in the area of the thread for example use a small brush and or compressed air or pressurised water cleaning fluid for the blind hole l Check elastomer parts for elasticity and changes in characteristics e g stickiness roughness discolouring substantial deformation l To assemble elastomer parts in food and beverage applica...

Page 11: ...ected to a drive See See Declaration of conformity on page 3 10 2 Dimensions Dimensions in millimetres Model Nozzles Foot N1 N2 N3 F1 F2 F3 F4 F5 L1 L2 H1 H2 C1 C2 C3 C800 535 367 38 480 500 Ø32 372 72 807 145 405 497 Ø110 28 116 Dimensions in inches Model Nozzles Foot N1 N2 N3 F1 F2 F3 F4 F5 L1 L2 H1 H2 C1 C2 C3 C800 21 06 14 45 1 50 18 90 19 69 Ø1 26 14 65 2 83 31 77 5 71 15 94 19 57 Ø4 33 1 10 ...

Page 12: ... The pump must be suspended correctly for transport If using a crane or fork lift truck the ropes or belts must be sufficiently dimensioned If the pump is transported with a lift truck or fork lift truck note that the unit s centre point is not necessarily the centre of gravity 12 m certa800 en 01 ...

Page 13: ...direct as possible though ideally not shorter than one metre and follow the straightest route Use bends of large radius at least four times the pipe diameter Ensure that connecting pipework and fittings are suitably rated to handle the predicted pipeline pressure Avoid pipe reducers and lengths of smaller bore pipe than the pumphead section particularly in pipelines on the suction side Any valves ...

Page 14: ...agreed in the purchase order and listed in the technical data sheet is not possible MasoSine pumps normally run with such a low resonant frequency that no damage results However particularly when running with inverters certain frequencies can cause interference vibrations which must be avoided It is important during commissioning to ascertain whether such vibrations exist and to define them so tha...

Page 15: ...e peaks up to several thousand bar These pressure peaks can cause material erosion and are noisy To identify cavitation If the pump is very noisy and vibrates vigorously along with the pipe system attached to the pump cavitation is likely to be the cause To avoid or remove cavitation Increasing the inlet pressure on the suction side installing a larger diameter or shorter inlet pipe or slowing the...

Page 16: ...te According to EHEDG regulations the pump head should always be completely self draining In a standard installation this can only be assured in the 02 04 or 08 10 nozzle position Changing the pump orientation See See Disassembling the support Changing the nozzle orientation on page 29 for details about changing the pump orientation 12 5 Connecting to a power supply The motor must be connected acc...

Page 17: ...d with the fluid level above the rotor see diagram This can be done manually through a side channel of your system s pipework or by using a vacuum device where very viscous fluids are to be pumped contact MasoSine for further information The need to prime can be avoided by leaving product in the pump after it is stopped by leaving CIP or SIP fluid in the pump after cleaning Before start up make su...

Page 18: ...to the atmosphere l The single mechanical seal should be flushed without pressure the flushing fluid should be allowed to drain from the system without pressure The double mechanical seal can be used pressureless or alternatively with an overpressure l Fill the pump with liquid to prevent it from running dry possibly via a separate intake valve connected to the suction or pressure pipe l If your p...

Page 19: ...ted 45 off the vertical axis l For all other nozzle orientations this is the flush port on top of the pump The connection with the sight glass must be fitted to the flush port which is offset by 45 from the vertical axis Remove the threaded plug of the required flush port by using a 10mm Socket with extension Apply an appropriate sealing material e g Teflon tape to both threads of the double nippl...

Page 20: ... Suitable cleaning fluids for the CIP process may include concentrations below 1 of additives They may be o Sodium hydroxide in distilled water o Nitric acid in distilled water o Phosphoric acid in distilled water l CIP cleaning can be carried out between 60C 140F and 100C 212F depending on customer needs l Cleaning should be done at maximum pump speed to achieve a good cleaning result l It is rec...

Page 21: ... ensure that a suitable acclimatisation period is maintained before the pump is put back into operation Class II SIP and CIP procedure Recommended temperature Recommended pressure differential CIP 80 90C 176 194F 2 bar 29 psi SIP 120C 248F Key CIP and SIP safety information l A distance of one metre around the pump should be kept clear during SIP to minimise danger in case of leakage l CIP and SIP...

Page 22: ...w until it is nearly full l Close oil vent valve A l Check the oil level in viewing glass at B Do not allow the level to fall below the viewing glass centre line Note When a new pump is supplied it is filled as standard with Klüberoil 4 UH 1 220 N lubrication oil for the food and pharmaceutical industries which is suitable for process temperatures between 30C 22F and 120C 248F Filling volumes Volu...

Page 23: ...ng oil escapes Dismantle power frame replace lip seals Seal faces are worn show burning marks Use a seal flush to prevent mechanical seal from dry run Pump leaks at front housing or back housing Housing seal not installed or wrongly installed Install housing O ring correctly or replace Housing seal defective Install housing O ring correctly or replace Pump is blocked Foreign body in the pump Remov...

Page 24: ...ing procedures may show a Certa pump of medium size for illustration purposes In this case the component and procedure is the same for the Certa 800 Removing the static flushing device If the flushing device has been fitted it must be emptied and removed before disassembling the pump For details see See Static flushing device on page 19 18 1 Disassembling the pump Removing the front housing l Make...

Page 25: ...before opening the locking screw on the rotor l Use one of the cap nuts from the front housing to fasten the blocking tool l Open the locking screw using the socket adapter turning it counter clockwise for part code see See Tools on page 46 High torque required Use appropriate tool An O ring seal keeps the disc spring of the locking screw in place The component parts of the locking screw m certa80...

Page 26: ...e screws are opened Removing the rotor and gate l Screw in the 4 shaft extensions The fixation plate can be used as a stopper l Pull the rotor together with the gate out of the housing as shown Note The gate can be changed in this position Open the screws and remove the fixation plate Use the fixture to lift the rotor 26 m certa800 en 01 ...

Page 27: ...ving the rotor to ensure the seal faces are not damaged The seal faces are brittle To re assemble the pump refer to the assembly instructions below starting with section See Assembling the support Centering the rotor with the shim ring on page 30 m certa800 en 01 27 ...

Page 28: ...ssary for regular maintenance Removing the seal system l Carefully remove the back seal face and the o ring from the mechanical seal system and store it safely The seal face with O ring at the outer diameter which is installed in the pump housing Removing the spring assembly l Remove the spring assembly from the back housing 28 m certa800 en 01 ...

Page 29: ... l Pull the middle housing off the pump The assembly procedure of the middle housing is shown in section See Assembling the pump head on page 33 18 4 Disassembling the support Changing the nozzle orientation Disassembling the support unit l Undo the screws on the support at the back of the housing by turning them counter clockwise with a wrench l Carefully pull out the support unit Changing the no...

Page 30: ... Checking the X Dimension The rotor and locking screw need to be fully tightened using the appropriate torque value see See Tightening torques on page 40 l Check the X Dimension by measuring the distance from the rotor to the back housing from the flat part at the peak of the rotor curve X Dimension tolerances If the X Dimension is not within the tolerances shown in the table below take out the ro...

Page 31: ...e two notches in the housing The pins need to match the according notches to prevent the part from rotating l Make sure the spring assembly fits into the two notches Use a screwdriver or similar tool and move the spring assembly axially If it is locked it is in position If you can turn the ring turn it carefully until it is possible to push it into the notches l Fit the O Ring to the inner diamete...

Page 32: ...t the part from rotating l The seal face is in place once a catching can be noticed and the seal face stays in place l A higher force might be required Check for compression of the spring assembly Fitting the rotor seal system The seal face for fitting in the rotor together with the rubber cup l Install the rubber cup on the seal face 32 m certa800 en 01 ...

Page 33: ...e rear of the middle housing You do not need to disassemble the middle housing to change for example the Gate or the mechanical seal system This is only explained for the sake of completeness l Locate the middle housing over the studs l Make sure you align the slot where the gate is placed with the same slot in the back housing l Tighten the nuts clockwise to hold the middle housing in place Make ...

Page 34: ...s on page 40 Ensure Disc Springs are oriented properly when placed onto the Locking Screw with cup side pointing away from Locking Screw head Failure to do so will result in the Locking Screw vibrating loose Cup side of disc spring 1x Disc Spring Use the appropriate torque value see See Tightening torques on page 40 l Fasten the locking screw with the socket adapter You may need to lock the shaft ...

Page 35: ...he middle ring Remove the blocking tool Assembling the front housing l Fit the seal in the front of the middle housing l Attach the front housing Make sure you align the channel correctly over the gate l Tighten the cap nuts by turning them clockwise with a wrench m certa800 en 01 35 ...

Page 36: ... support Changing the nozzle orientation on page 29 The component parts of the flush ring for the single mechanical seal system Flush ring completely assembled with lip seal and O Ring The flush ring in the back of the housing This is used with the single mechanical seal system 18 10 Assembling the back seal in a double mechanical seal system The component parts of the back seal assembly 36 m cert...

Page 37: ...he pins need to match the according notches to prevent the part from rotating l Press the seal face in place into the seal holder l Fit the O Ring in the notch on the inner diameter of the seal holder The red arrow shows the O Ring in place l Put the assembled seal system on the shaft of the disassembled support unit The pins need to match the according notches to prevent the part from rotating m ...

Page 38: ...ll the atmospheric side of the double mechanical seal l Install the spring assembly in the rear of the back housing Make sure that the pins fit into the notches The pins need to match the according notches to prevent the part from rotating For instructions on assembling the parts in the spring assembly See Assembling the front mechanical seal on page 31 The spring assembly correctly assembled in t...

Page 39: ...using with the assembled seal system on the end shield Make sure you install it in the required orientation See See Possible pump orientations on page 16 l Tighten the screws by turning them clockwise The first part of the back seal system installed in the pump back housing l Carefully assemble the support unit with the installed seal face l Tighten the screws on the support at the back of the hou...

Page 40: ...05 lb ft Fixation plate Locking screw M16x1 5 135Nm 99 5 lb ft Front housing Cap nut SW46 750Nm 555 lb ft 20 Parts lists With the exception of the codes for springs part codes are composed of three sections in the form xxxx yyyy zz Where xxxx is the pump type yyyy is the part zz is the material Where appears instead of an alphanumeric code in positions zz select from the table below Plastics e g f...

Page 41: ...20 1 Pumps m certa800 en 01 41 ...

Page 42: ...2600 25 Tapered roller bearing 26 1 C800 2000 12 Drain plug 27 1 C800 3800 51 Oil sight glass 28 1 C800 5000 25 Snap ring 29 8 C800 1900 12 Hexagon socket head cap screw 30 1 C800 1300 12 End shield 31 1 C800 1301 12 Foot plate 32 Not required 33 Not required 34 Not required 35 3 C800 1850 12 Stud 36 2 C800 1750 Seal pump housing 37 4 C800 1800 12 Stud 38 1 C800 5010 12 Pin Number Quantity Part co...

Page 43: ...61 1 C800 5245 41 Static face 63 1 C800 5246 O Ring 69 1 C800 5220 10 Spring assembly Flush ring Number Quantity Part code Item 80 1 C800 1308 10 Distance ring 81 1 C800 1755 80 O Ring 82 1 C800 2340 80 Lip seal X 1 See Single mechanical seal above Sealing system m certa800 en 01 43 20 2 Options ...

Page 44: ...c ring holder 71 1 C800 5340 41 Dynamic face 72 1 C800 5345 41 Static face 74 1 C800 5311 O Ring 75 1 C800 5341 O Ring 76 1 C800 5346 O Ring 79 1 C800 5320 10 Spring assembly X 1 Sealing system 44 m certa800 en 01 Atmospheric side of double mechanical seal ...

Page 45: ... 0171 10 Flush pipe 92 1 C800 0173 10 Vent pipe 93 2 80 6009 10 Double nipple 94 2 80 6020 10 Connecting piece 95 1 80 6021 10 Connecting piece Dynamic flush system Number Quantity Part code Item 99 2 C800 0504 34 Flush connection m certa800 en 01 45 Static flush system ...

Page 46: ...ing device Pump Size Quantity Part code Item C800 1 TL C800 170 12 Lifting device Socket adapter Pump Size Quantity Part code Item C800 1 TL C800 003 10 Socket adapter Shaft extension Pump Size Quantity Part code Item C800 1 TL C800 165 12 Shaft extension 4x 46 m certa800 en 01 20 3 Tools ...

Page 47: ...son Marlow Limited Fluid Technology Group accepts no liability for any errors it contains and reserves the right to alter specifications without notice WARNING This product is not designed for use in and should not be used for patient connected applications 23 Publication history m certa800 en 01 Certa 800 Pump User Manual First published 11 19 m certa800 en 01 47 ...

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