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Summary of Contents for IWAKI MDW Series
- Page 1 IWAKI Magnetic Drive Pump MDW Series Instruction Manual Read this manual before use of product...
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Page 2: Table Of Contents
Thank you for selecting an Iwaki MDW Magnetic Drive Pump. This instruction manual deals with "Safety instructions", "Outline", "Installation", "Operation" and "Maintenance" sec- tions. Please read through this manual carefully to ensure the optimum performance, safety and service of your pump. -
Page 3: Safety Instructions
Safety instructions For the Safe and Correct Handling of the Pump "Safety Instruction" section deals with important details about handling of the product. Before use, read this section carefully for the prevention of personal injury or property damage. Observe the instructions accompanied with "WARNING" or "CAUTION" in this manual. These instructions are very important for protecting users from dangerous situations. - Page 4 Safety instructions WARNING Access limitation The magnet drive pump has a pair of strong magnets (the magnet capsule unit and drive magnet). The strong magnet field could adversely affect the persons who are assisted by electronic devices such as the pacemaker. Prohibited Turn off power before work Be sure to turn off power to stop the pump and related devices before work.
- Page 5 Safety instructions CAUTION Magnetic force affects magnetic disks/cards and wrist watches A pair of strong magnets is mounted in the pump and its magnet force may affect Prohibited magnetic disks/cards or wrist watches. Do not bring them close to the pump. A qualified operator only The pump must be handled or operated by a qualified person with a full understanding of the pump.
- Page 6 Safety instructions CAUTION Do not stand on the pump Personal injury may result as the pump turns over. Prohibited Do not touch the pump or pipe with bare hands The surface temperature of the pump or pipe rises high along with liquid temperature in or right after operation.
- Page 7 Safety instructions CAUTION Do not touch a rotating part A pump shaft and a motor shaft may be coupled barely. Be sure to cover the coupling in order to reduce the risk of personal injury which may occur as coming in contact with the coupling in operation. Take countermeasures against static electricity When low electric conductivity liquids such as ultra-pure water and fluor inactive liquid (e.g.
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Page 8: Outline
Outline 1. Unpacking & Inspection ......7 2. Product outline ........7 3. Model code ........... 8 4. Overview ..........9 5. Dimensions ......... 10 6. Precautions for use ......11 - 6 -... -
Page 9: Product Outline
Hexagon bolts 2. Product outline An Iwaki magnetic drive pump, the MDW, is a long coupled pump. This large-scale process magnet pump has fluoroplastic and fine ceramic wet ends and is capable of sending most chemicals includ- ing strong acid and alkaline. -
Page 10: Model Code
Outline 3. Model code MDW 50 - 260 P K Z C 450 J - E 2 a. Series name MDW: A long coupled pump with a foot mounted motor b. Pump bore size & Motor output Motor output (kW) Pump bore size Model Weight (kg) -
Page 11: Overview
Outline 4. Overview The illustration below shows a long coupled pump on the base. Motor unit Transfers torque to the pump unit via a long coupling. Observe the power voltage specified on the motor label. Pump unit Outlet Air vent port (Air vent plate) Provided as requested. -
Page 12: Dimensions
Outline 5. Dimensions See an approved drawing for part names and structure. Pump unit See the approval drawing for detail dimension. MDW50 ø165 MDW80 ø200 MDW100 ø220 - 10 -... -
Page 13: Precautions For Use
Outline 6. Precautions for use Read through this section before operation. CAUTION Do not run pump dry Sliding parts always need liquid in the pump chamber for lubrication and cool- ing. Do not produce dry running or closed-discharge operation. The pump unit will be damaged. - Page 14 Outline 3. Maximum operating pressure (Discharge pressure limit) See the graph below for the maximum operating pressure. Always keep a pressure in the pump head within the limit, taking account of specific gravity and suction pressure. MDW50 MDW80/100 Allowable area Allowable area Liquid temperature (ºC) 4.
- Page 15 Outline 6. Slurry This pump is not designed for sending slurry but then is able to send slurry depending on concentration, particle size and hardness. Contact us for detail. 7. Performance change with specific gravity and viscosity Shaft power, a flow rate and a delivery head vary with the specific gravity and viscosity of liquid. The pump is designed according to a specified condition.
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Page 16: Installation
Installation 1. Before installation ....... 15 2. Pipework ..........16 3. Wiring ..........19 - 14 -... - Page 17 Installation 1. Before installation Read through instructions in this section to ensure the optimum performance, safety and service of your pump. 1. Discharge line 2. Gate valve (Shut off valve) 3. Check valve (Backflow prevention) 4. Pressure gauge 5. Motor 6.
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Page 18: Pipework
Installation Foundation work 1. Use a level to check if a foundation is flat. Securely fix the base by foundation bolts. 2. Insert a shim if there is a gap between the base bottom and foundation surface. 3. The foundation should be larger than a pump base footprint. 4. - Page 19 Installation Piping load and momentum Try not to apply a pipe weigh to the pump inlet and outlet flanges. Permissible piping weight and moment to the pump are as below. Permissible stress to inlet & outlet flanges Load kN Outlet flange Inlet flange Load direction MDW50...
- Page 20 Installation Suction line 1. Select an appropriate tank size Using a high flow pump and small supply tank, a liquid level in the tank changes greatly. 2. End of suction line Provide a screen in a supply tank for the prevention of foreign matter interfusion (Clean the screen periodically.). 3.
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Page 21: Wiring
Installation 3. Wiring Electrical works or wiring must be carried out by a qualified person according to local laws or regu- lations. Contact us or your nearest distributor. 1. Use the electromagnetic switch which conforms to the motor specifications such as voltage and capacity. 2. -
Page 22: Operation
Operation 1. Before operation ......... 21 2. Operation ..........22 3. Shutdown ..........23 - 20 -... - Page 23 Operation 1. Before operation CAUTION Never run the pump dry or shut off a gate valve on a suction line during operation. This may damage internal parts. Prohibited Stop the pump immediately when it is running under cavitation* Stop the pump immediately when the magnet coupling is disconnected. Magnetic force reduces if the pump keeps on running for more than one minute in this condition.
- Page 24 Operation 2. Operation 1. Fully close a discharge valve and fully open a suction valve. 2. Prime the pump. • In the flooded suction application, fully open both discharge and suction valves. • In the suction lift application, prime a suction line as well as the pump. 3.
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Page 25: Shutdown
Operation CAUTION 1. Check for loose bolts before operation. Retighten the split plate mounting bolts, the rear casing support mounting bolts and the air vent-/drain-plate mounting bolts by the specified torque. See page 46 and 47 for detail. 2. When the pump keeps running in negative rotation, the pump breaks. 3. - Page 26 Maintenance 1. Troubleshooting ........25 2. Maintenance & Inspection....26 3. Spare & Wear parts ......31 4. Assembly & Disassembly ....33 - 24 -...
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Page 27: Maintenance 1. Troubleshooting
Maintenance 1. Troubleshooting Turn off power to stop operation upon sensing abnormalities. And then look for a root cause or contact us as necessary. Symptom Point to be checked Troubles Cause & When a discharge When a discharge Countermeasures valve is closed. valve is opened. -
Page 28: Maintenance & Inspection
Maintenance Symptom Point to be checked Troubles Cause & When a discharge When a discharge Countermeasures valve is closed. valve is opened. The motor is • Voltage has dropped • Check voltage or fre- overheated. greatly. quency. • Overload • Check specific gravity and viscosity of liquid. - Page 29 Maintenance Mark each wire so that the wires can be connected correctly to the motor. Do not disassemble the pump beyond the extent shown on this manual. Make sure to close gate valves on the suction and discharge lines before dismantling/assembling the pump.
- Page 30 Maintenance Periodic inspection To ensure efficient and smooth operation, perform periodic inspection. Be careful not to damage internal sliding parts and plastic parts when dismantling the pump. Magnetic force of the pump is strong. Be careful not to catch the finger in parts in dismantlement/assembly work.
- Page 31 Maintenance Wear limit of the bearing and sleeve Check the wear depth of the sleeve on the magnet capsule assembly and the bearing on the split plate assembly. The bearing is a wear part. Note that a bearing life varies with operating conditions such as chemical char- acteristics and pressure.
- Page 32 Maintenance A ball bearing life The bearing housing on the pump accommodates sealed ball bearings. Grease filling is not necessary. The life limit and heat resistance of grease change with operating condi- tions. Conduct periodic inspection. Check and log the mechanical noise, vibration and surface temperature of the bearing housing every day to detect trouble on the ball bearings at an early stage.
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Page 33: Spare & Wear Parts
Maintenance 3. Spare & Wear parts Appropriate spare parts are necessary for a long period of continuous operation. We recommend that wear parts be always in stock. Place an order for spares with the following information. Part names and part number (See an approval drawing if you have.) Pump model identification code and Mfg number (See specification label.) Spare parts Part names... - Page 34 Maintenance Wear parts Place an order for spares with the pump model, a part name and a part number. The time for replacement shown below is based on an operating condition with ambient temperature clean water and changes with operating conditions such as a liquid characteristic and temperature. Take the time for replacement as a guide.
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Page 35: Assembly & Disassembly
Maintenance 4. Assembly & Disassembly WARNING Access limitation The magnet drive pump has a pair of strong magnets. The strong magnet field could adversely affect the persons who are assisted by electronic devices Prohibited such as the pacemaker. Turn off power during maintenance work Risk of electrical shock. - Page 36 Maintenance Be sure to close gate valves on both suction and discharge lines before dismantlement. See this exploded view when dismantling/assembling the pump. Do not dismantle the pump beyond the extent of instructions in this manual. Hex. head bolt Spring washer Rear casing support Rear casing cover Magnet capsule unit...
- Page 37 Maintenance Pump unit dismantlement Air vent plate 1. Remove the hex. head bolts (901.5) on the drain (901.6) plate to release chemical liquid out of the pump Front casing unit. Air vent port Air vent gasket CAUTION If the hex. head bolts are loosened at once, liquid may fly off, resulting in personal injury.
- Page 38 Maintenance 5. Screw the guide bolts into the rear casing sup- port via both bottom holes on the bracket edges. Split plate 6. Take the attached two hexagon bolts (M12×130) Attached hex. bolt and screw them into both upper holes on the (M12×130) bracket edges in order to pull the bracket out Guide bolt...
- Page 39 Maintenance 9. Remove the hex head bolts (901.2) and remove the rear casing support. Split plate CAUTION Be careful not to get wet with residual (901.2) chemical liquid in the pump unit. Rear casing cover Rear casing support 10. Remove the rear casing cover and the rear cas- ing.
- Page 40 Maintenance 13. Pull the split plate up straight from the mag- net capsule unit. Do not tilt the split plate. Otherwise, the bearing and sleeve may seize. Split plate Magnet capsule unit 14. When demounting the bearing... Split plate Carefully push the bearing out by the hand press Bearing via a plastic bar as necessary.
- Page 41 Maintenance Bearing housing dismantlement 1. Remove the hex. head bolts (901.4) on the bear- ing housing and detach the bracket. Note that (901.4) strong magnetic force is attracting the bracket. Bracket Be careful not to hit the bracket against the drive Bearing housing magnet unit.
- Page 42 Maintenance 4. Remove the hub and key from the drive shaft. Bearing housing 5. Pull out the drive shaft along with the ball bearing from the bearing housing. * In case the drive shaft can not be removed, tap the shaft end with a plastic hammer to push it out Drive shaft plus straight.
- Page 43 Maintenance Bearing housing assembly • Precautions for assembly Assembly can be made in reverse procedures to dismantlement. Pay attention to the following points. See manufacturer's instruction manual for detail information on the ball bearing and oil seal. Always apply even torque to each bolts diagonally, in turn. •...
- Page 44 Maintenance 3. Use a hand press to press-fit the oil seal into the groove on the bearing housing via a plastic bar. * Be sure to apply grease to the groove on the bearing housing and the sliding surface of the drive shaft.
- Page 45 Maintenance 7. Unscrew the hex soch set screws (908.1) once and apply the LOCKTITE to threads. And then Drive magnet unit screw them to fix the drive magnet unit by the tightening torque below. Tightening torque: 15N·m Recommended adhesive: LOCKTITE No.242 Hex soch set screws 8.
- Page 46 Maintenance Pump unit assembly • Precautions for assembly Wet a cloth with tap water and wring it out for cleaning the pump. Use a neutral detergent for greasy dirt and then rub with a dry cloth. Do not wipe labels or the pump body with any solvent. •...
- Page 47 Maintenance 6. Fit the O ring into the groove on the impeller unit Apply adhesive in place. slimly. O ring 7. Tighten the impeller lock nut while holding the Impeller lock nut magnet capsule unit. Apply adhesive slimly on the Impeller unit threads of the shaft not to allow the nut to loosen.
- Page 48 Maintenance 12. Place an air vent gasket and an air vent plate Air vent plate on the air vent port which is positioned on top of (901.6) Front casing the front casing. And fix them with the hex head Air vent port bolts (901.6) Place an drain gasket and drain Air vent gasket plate on the drain port which is positioned at the...
- Page 49 Maintenance 15. Tighten the rear casing support fixing bolts (901.2) and split plate assembly fixing bolts (901.1) at the tightening torque below. Front casing Split plate Tightening torque: 100N·m Rear casing support (901.1) (901.2) Remove the guide bolts. 16. Remove the guide bolts and install them on the rear casing support.
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- Page 52 IWAKI Norge AS TEL : (47)66 81 16 60 FAX : 66 81 16 61 China IWAKI Pumps (Guandong) Co., Ltd. TEL : (86)750 3866228 FAX : 750 3866278 Singapore IWAKI Singapore Pte. Ltd. TEL : (65)6316 2028 FAX : 6316 3221 China GFTZ IWAKI Engineering &...
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