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Related Manuals for Masdaf UKMS Series
Summary of Contents for Masdaf UKMS Series
- Page 1 Self Priming Wastewater Pumps UKMS & MiniUKM SERIES Operating Manual MDKBK022023...
- Page 2 masdaf.com...
- Page 3 EC DECLARATION OF CONFORMITY AT UYGUNLUK BEYANI Manufacturer / İmalatçı : MAS DAF MAKİNA SANAYİ A.Ş. Address / Adres : Orta Mah. Atayolu Cad. No: 16 Tuzla - İSTANBUL / TÜRKİYE Organize Sanayi Bölgesi, Beyköy Beldesi, İstiklal OSB 1 Mah. 5. Cad. Dış Kapı No:7 Merkez/ DÜZCE Vahdettin YIRTMAÇ...
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Page 4: Table Of Contents
TABLE OF CONTENTS Page No INTRODUCTION 1. IMPORTANT SAFETY PRECAUTIONS 2. GENERAL 2.1. Definition of Pump and Usage Areas 2.2. Performance Information 2.3. Warranty Conditions 2.4. Test 2.5. Pressure Limit 3. SAFE OPERATING CONDITIONS 3.1. Training of Personnel 3.2. Hazardous Conditions That May Occur When One does not Comply with the Safety Instructions 3.3. Safety Measures for Operator 3.4. Safety Measures for Maintenance and Installation 3.5. Spare Parts Replacement 4. TECHNICAL INFORMATION 4.1. Design 4.2. Construction of Pump Group 5. -
Page 5: Introduction
INTRODUCTION • This manual contains instructions for the installation, operation and maintenance of the UKMS type self-priming wastewater pumps of MAS DAF MAKİNA SANAYİ A.Ş. • Please read carefully this manual and apply all the instructions to operate pumps without problems. Pumps shall be used for their intended duties. In this manual, there are information on operating condi- tions, installation, starting-up, settings and main controls of pumps. • These operating and maintenance instructions contain MAS DAF MAKİNA SANAYİ A.Ş.`s suggestions. The special operating and maintenance information of the plumbing that a pump is fitted to is not considered in these instructions. This information must be given by the plumbing constructors only. -
Page 6: Important Safety Precautions
IMPORTANT SAFETY PRECAUTIONS 16. If flammable and explosive liquids are pumped, ground connection of electricity should be carried out properly. In order to minimize the accidents during the mounting and putting into service of the pump, 17. Do not expose the pump unit to sudden tem- the following rules have to be applied: perature variations Do not work without taking safety measures 18. All personnel who work with the wastewater relevant to equipment. Cable, mask and system need to be vaccinated in case of con- safety band must be used when necessary. -
Page 7: Performance Information
2.5. Pressure Limit Technical specifications of UKMS type pumps Suction Flange : 2” - 10” Discharge Flange : 2” - 10” Capacity : 15-730 m : 4-40 m Pressure at the discharge flange must not Speed : 750-2900 rpm exceed 10 Bar. A special order is necessary for applications with higher pressures. 2.2. Performance Information 3. -
Page 8: Hazardous Conditions That May Occur When One Does Not Comply With The Safety Instructions
3.2. Hazardous Conditions That May Occur Notice: MAS DAF MAKINA SANAYI A.Ş. is not re- sponsible from the usage of improper spare parts. When One does not Comply with the Safety Instructions 4. TECHNICAL INFORMATION Incompliance with safety regulations may put the personnel, the environment and the machine in 4.1. Design danger and thus may cause damages. Incompli- ance with safety regulations may give rise to situ- Since they are self-priming, the UKMS type pumps ations listed below. -
Page 9: Construction Of Pump Group
4.2. Construction of Pump Group Pump Type Bearings at the Bearings at the impeller side motor side 4.2.1. Drive UKMS 2”x2” 6208 (SRBB) 6208 (SRBB) TEFC (Totally Enclosed Fan Cooled) 3 phase, UKMS 3”x3” 6208 (SRBB) 6208 (SRBB) squirrel caged, IM 1001B3 type electrical or diesel UKMS 4”x4” 6308 (SRBB) 3308 (DRBB) motor (along with belting if needed) which com- plies with DIN EN 60034 IEC is used to drive the UKMS 6”x6”... -
Page 10: Transport
5.1. Transport Pump and pump group must be carried safely to the installation location by lifting equipments. Incorrect lifting may damage the pump unit and cause injuries. CAUTION Damages caused in transport Current general lifting safety instructions must be Check the pump when it is delivered to you. Please applied. Please use a suspension system shown in let us know of there is any damage. figure while you are carrying and lifting the pump unit. The suspension rings may be broken because 5.2. Storage of the excessive load and may result in a damage of the pump. Prefer fabric cable for suspension. Please keep the unit clean, dry and closed area during storage. If the pump is out of use for a long time, please consider the instructions below. -
Page 11: Assembly / Installation
6. ASSEMBLY / INSTALLATION signed in such a way that the base plate is bolted or welded contacting to all area. 6.1. Installation In our standard production, the pump and the mo- CAUTION tor have been installed in a common base plate. If base plate is supported from only four points, 6.1.1. Location of Installation pump group will stay in the middle, causing Pump will be installed in a location where the con- misalignment of the coupling and increasing the trol and the maintenance of the pump are easily noise level. - Page 12 wearing of the rolling bearings, alignment of the coupling has to be made properly and checked often. Do not use a different coupling other than the original type installed on pumping group.. 6.4.2. Method of Coupling Alignment Wrong Right When the motor moves towards the pump, a gap must be maintained in order that the two faces of the coupling do not touch each other. The recom- mended distance is 3 mm. To check the coupling...
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Page 13: Piping
Screw the two bolts in coupling hub. Make sure that a suitable spacing is left be- tween the coupling halves while mounting pump and the rotor. Horizontal pump groups mounted on the base plate or directly mounted on the base, alignment of the coupling shall be as de- scribed in 6.4.2 Put into place the coupling guard. According to the accident prevention regulations, all preventions and protective devices should be in their intended place and in operational form. Coupling Axial Axial... -
Page 14: Suction Lines
6.5.2.1. Fittings actly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or Suction lines should be the same size as the couplings. pump inlet. If reducers are used in suction lines, Lines near the pump must be independently sup- they should be the eccentric type and should be ported to avoid strain on the pump which could installed with the flat part of the reducers upper-... -
Page 15: Automatic Air Release Valve
the suction lines; it must be the rigid-wall, rein- QUANx(GPM)x0.321 VELOCITY (ft⁄s)= forced type to prevent collapse under suction. AREA Using piping couplings in the suction lines is not FLOW(m³⁄s) recommended. VELOCITY (ft⁄s)= AREA (m³) Suction inlet at a distance 1.5 times the diameter of the suction pipe. The baffle will allow entrained 6.5.3. Automatic Air Release Valve air to escape from the liquid before it is drawn into The air release valve is going to permit air to es- the suction inlet. cape through the bypass line and then close au- If two suction lines are installed in a single sump, tomatically when the pump is fully primed and the flow path may interact, reducing the efficien-... -
Page 16: Discharge Lines
CAUTION CAUTION Some leakage from 3.8 to 19 l/min will occur when It is recommended that each air release valve the valve is fully closed. Be sure the bypass line is should be fitted with an independent bleeder directed back to the wet well or tank to prevent line directed back to the wet well. However, if hazardous spills. multiple air release valves are installed in a When the pump shuts down, the spring returns system, the bleeder lines may be directed to a the diaphragm to its original position. Any solids... -
Page 17: Motor Connection For Applications With Electric Motor
hold the discharge check valve closed. dangerous overheating and possible explosive rupture of the pump casing. Personnel could be Note: The by-pass line should be sized so that it severely injured. Allow an over-heated pump does not affect pump discharge capacity; however to cool before servicing. Do not remove plates, the by-pass line should be at least 1” in diameter to covers, gauges, or fittings from an overheated minimize the chance of plugging. -
Page 18: Commissioning, Start Up And Operating
COMMISSIONING, START UP AND OPERATING 7.1. Preparations Before Start Up Oil Check: For bearings, non-abrasive, high quali- ty oil such as SAE#30 should be used. UKMS type pumps are transported filled up with fluid oil. Nevertheless one should check before start-up if there is oil in the reservoir. In normal conditions, every year, the ball bearing must be cleansed from oil and refilled. UKMS 2”x2” ≈ 0,7 liter Figure 6: Electric Connection Diagram UKMS 3”x3” ≈ 0,7 liter UKMS 4”x4” ≈ 0,8 liter Electrical circuit Motor UKMS 6”x6”... -
Page 19: Checking The Direction Of Rotation
CAUTION CAUTION After filling the pump casing, reinstall and Do not start your pump dry (WITHOUT WATER). tighten the fill plug. Do not attempt to operate the pump unless all connecting piping is 7.2. Checking The Direction of Rotation securely installed. Otherwise, liquid in the pump forced out under pressure could cause injury to CAUTION the personnel. -
Page 20: The Checks During The Operation
• Continuous monitoring and maintenance will the pump and removing the back cover assem- increase the engine’s and pump’ s lives. bly. If major repair is required, the piping and/or power source must be disconnected. The follow- The instructions below should be applied. ing instructions assume complete disassembly is required. 8.1. The Checks During the Operation Before attempting to service the pump, disconnect •... -
Page 21: Shaft And Bearing Removal And Disassembly
Inspected the wear plate, and replace it if badly there is evidence of wear or damage. scored or worn. To remove the wear plate, disen- gage the hardware (301 and 361). Inspect the back CAUTION cover O-ring (401) and replace it if damaged or worn. Shaft and bearing disassembly in the field is 8.2.2. Flap Valve (Suction Check Valve) not recommended. These operations should be Removal performed only in a properly equipped shop by qualified personnel. - Page 22 CAUTION CAUTION Clean the bearings thoroughly in fresh To prevent damage during removal from the cleaning solvent. Dry the bearings with filtered shaft, it is recommended that bearings be compressed air and coat with light oil. cleaned and inspected in place. It is strongly recommended that the bearings be replaced any Bearings must be kept free of all dirt and foreign time the shaft and the bearings are removed.
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Page 23: Seal And Installation
Slide the shaft and assembled bearings into bear- CAUTION ing housing until the retaining ring on the out- board bearing seats against the bearing housing. A new seal assembly should be installed any time the old seal is removed from the pump. CAUTION Wear patterns on the finished faces cannot be realigned during reassembly. Reusing an old seal could result in premature failure. -
Page 24: Impeller Installation
Handle the seal parts with extreme care to pre- CAUTION vent damage. Be careful not to contaminate precision finished Shaft and impeller key must be completely clean faces with a non-oil based solvent and a clean, lint- during reassembly. Even the slightest amount of free tissue. dirt on the threads can cause the impeller to seize to the shaft, making future removal difficult or im- Wipe lightly in a concentric pattern to avoid possible without damage to the impeller or shaft. scratching the faces. Note: At the slightest sign of binding, immediately Carefully wash all metallic parts in fresh cleaning back the impeller off and check the threads fro solvent and allow drying thoroughly. -
Page 25: Suction Check Valve Installation
8.2.9. Suction Check Valve Installation can catch clothing, fingers or tools or causing se- vere injury to personnel. Inspect the check valve assembly and replace it if Install the suction and discharge lines and open badly worn. all valves. Note: The check valve assembly must be replaced Make certain that all piping connections are tight, as a complete unit. Individual parts are not sold properly supported and secure. separately. Reach through the back cover opening Be sure the pump and the power source have with the check valve and position the check valve been properly lubricated. -
Page 26: Drive
The Number of Equivalent Pumps in the Installation Component Name 1-2 3 6-7 8-9 Shaft (key included) kit Worn out elastic bands must be replaced. Impeller (kit) 8.4. Drive Wearing Plate Apply to the operating instructions of the motor Bearings (kit) manufacturer. O-Ring for Casing (kit + 1) 8.5. Auxiliary Components O-Ring for Shaft (kit) Sealing Bushes (kit) Check regularly the fittings and the gaskets, re-... -
Page 27: Noise Level And Vibration
9. NOISE LEVEL AND VIBRATION Sound Pressure Level (dB) * Power of Motor PN 2 Poles 4 Poles The reasons which increase the noise level are in- [kW] 2900 rpm/min 50 Hz 1450 rpm/min 50 Hz dicated below: 0,37 <70 <70 • Touch of coupling halves due to worn rubber 0,55 <70 <70... -
Page 28: Possible Failures, Causes, Solutions
10. POSSIBLE FAILURES, CAUSES, SOLUTIONS Possible failures and solution strategies are listed in the table below. Please apply to the Customers’ Service Department of our company when a generic solution is not found to your problem. While the failures are repaired the pump must always be dry and un-pressurized. POSSIBLE FAILURE CAUSES SOLUTIONS Pump fails to prime. • Not enough liquid in casing. • Add liquid to casing. • Flap valve contaminated or damaged. • Clean or replace check valve. • Air leak in suction hose collapsed. • Correct leak. • Leaking or worn seal or pump gasket. • Replace suction hose. •... -
Page 29: Tightening Torques
11. TIGHTENING TORQUES TIGHTENING TORQUE MAX (Nm) THREAD Property Classes DIAMETER 10.9 1050 1100 1550 1450 2100 1970 2770 2530 3560 Table 8: Tightening Torques Table... -
Page 30: Ukms Sectional Drawing And Part List (2"X2" - 3"X3" - 4"X4" - 6"X6" - 8"X8")
12. UKMS SECTIONAL DRAWING AND PART LIST (2”x2” - 3”x3” - 4”x4” - 6”x6” - 8”x8”) Figure 9: UKMS Sectional Drawing (2”x2” - 3”x3” - 4”x4” - 6”x6” - 8”x8”) Part No Part Name Part No Part Name Part No Part Name Part No Part Name Pump Casing Shaft (with Key) Oil Drain Plug Suction Plate Seal Sleeve Stud Fibered Nut Flap Valve Rubber Roller Pin... - Page 31 UKMS SECTIONAL DRAWING AND PART LIST (10”x10”) Figure 10: UKMS Sectional Drawing (10”x10”) Part No Part Name Part No Part Name Part No Part Name Part No Part Name Pump Casing Key for Pump Shaft Hex Bolt (Bearing) Washer Cover Plate Oil Gasket Hex Bolt Washer, Impeller Washer, Suction Flap Suction Flange Oil Gasket Hex Bolt Valve Connect part Fill Cover Mechanical Seal Hex Bolt Washer (Corner Cover ) Wearing plate...
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Page 32: Miniukm Sectional Drawing And Part List
13. MiniUKM SECTIONAL DRAWING AND PART LIST Figure 11: MiniUKM Kesit Resmi Part No Part Name Part No Part Name Pump Casing Hex Bolt Volute Casing Hex Bolt Flap Valve Casing Hex Bolt Adaptor İmbus Bolt Impeller Casing Nut Shaft Washer for Impeller Cap Screw Suction Flap Setscrew Key for Impeller O-Ring Mechanical Seal O-Ring Plug Electrical Motor Casing Stud Table 11: MiniUKM Sectional Part List... -
Page 33: Ukms Drawing For Dismantling
14. UKMS DRAWING FOR DISMANTLING Figure 12: UKMS 2x2, 3x3, 4x4, 6x6, 8x8 Drawing for Dismantling Part No Part Name Part No Part Name Part No Part Name Part No Part Name Pump Casing Shaft (with Key) Oil Drain Plug Suction Plate Seal Sleeve Stud Fibered Nut Flap Valve Rubber Roller Pin Bolt Lock Washer Flap Valve Upper Part Roller Pin Sleeve Bolt Lock Washer Wearing Plate Deep Groove Ball Bearing 322 Bolt Lock Washer Flap Valve Casing... - Page 34 Figure 12: UKMS 10”x10” Drawing for Dismantling Part No Part Name Part No Part Name Part No Part Name Part No Part Name Pump Casing Key for Pump Shaft Hex Bolt (Bearing) Washer Cover Plate Oil Gasket Hex Bolt Washer, Impeller Washer, Suction Flap Suction Flange Oil Gasket Hex Bolt Valve Connect part Fill Cover Mechanical Seal Hex Bolt Washer (Corner Cover ) Wearing plate Pipe Plug Hex Bolt Suction Flap Valve Part Impeller Back Plate Pipe Plug Hex Bolt Washer...
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