met-e-2 - iwaki america · 5)pour cement mortar between the gap below the base and foundation bolt...

Introduction for safety

● Instructions for Safe Usage - - - - - - - - - - - - - - 8

Equipment Failure / Accident Prevention and

Safe Operation Checks - - - - - - - - - - - - - - - - - - - - - 8

Precautions When Pumping Special Liquids - - - - - - - - 9

● Transport and unpacking - - - - - - - - - - - - - - - - - 10

1. Transport - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

2. Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

● Preliminary Check - - - - - - - - - - - - - - - - - - - - - 11

● Pump Installation - - - - - - - - - - - - - - - - - - - - - - 12

1. Foundation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

2. Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12

3. Centerring - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14

4. Piping - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

5. Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

● Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - 15

1. Checking before Startup - - - - - - - - - - - - - - - - - - 15

2. Startup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

operation and handnng - - - - - - - - - - - - - - - - - - - - 19

3. Stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21

6

Contents

● Maintenance and Inspection - - - - - - - - - - - - - - 21

1. Dairy lnspection - - - - - - - - - - - - - - - - - - - - - - 21

2. Replacement of Bearing - - - - - - - - - - - 22

3. Periodical Inspection - - - - - - - - - - - 22

4. Stopping of Pump for a Long Period of Time- - - - - - - 22

5. Configuration and Location of Part - - - - - - - - - - - 23

Configuration - - - - - - - - - - - - - - - - - - - - - - - - 23

Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

● Check record table - - - - - - - - - - - - - - - - - - - - - 28

● Trouble shooting - - - - - - - - - - - - - - - - - - - - - 29

● Repairs and Guarantee - - - - - - - - - - - - - - - - - 31

7

● Pump Installation

1. Foundation

Provide a foundation that has sufficient area and capacity to absorb vibrationand withstand the weight of the pump and the motor.

Do not bury the foundation bolts in the foundation bolt holes before

installing the pump. Otherwise, installation of the pump, leveling and

adjustment of the shaft center will become difficult.

2. Installation

ATTENTION● When lifting the pump, check the weight of the pump (including the motor),

and prepare ropes and lifting equipment suited to this weight in order to

prevent it from dropping.

● Before centering, always turn the main electric switch

(electromagnetic switch) to OFF.

Install the pump where maintenance and inspection can be done easily in consideration of the suction head.

1) Lift the pump.

2) Mount foundation bolts on the pump base.

・ Insert the foundation bolts into designated positions of the base,

and mount a nut on the head of each foundation bolt fully.

3) Install the pump at a designated position.

・ Insert a several sets of liners between the common base and the foundation,

and put down foundation bolts into the foundation bolt holes.

・ Always insert liners on both sides of the foundation bolts.

12

Foundation boltLiner

4) Check if the pump and the motor are level and centered properly, and

adjust if required.① Remove paint completely, using thinner or other solvent,

from the coupling outer surface.

② Place a scale at 4 positions around the coupling, and check that

the couplings of the pump and the motor are not different in level.

③ Measure a gap correctly at 4 positions around the couplings of the

pump and the motor.

④ Drive in the liner to adjust the difference in level and gap.

5) Pour cement mortar between the gap below the base and foundation bolt holes.

6) When the cement mortar is hardened, tighten the nuts of the foundation bolts

to fix the pump.

Tighten the nuts while centering the pump and the motor.

Adjust leveling of the pump and the motor by regulating the

thickness of liners below the base.

(Level: Below 0.3mm/1m)

13

Square Below 0.1mm

Good Not good

Liner

3. Centering

Check centering after finishing piping. After centering is finished, manually turnthe bearing to check that it does not come into contact with the pump inside and turns easily and smoothly.

1) Connect the pump and the motor directly.

2) Turn the coupling by 90°each time to check the value on the dial

gauge to see if there is misalignment. Check the change of the gap

as well, using a clearance gauge.

Angle of deviation a (min) Deviation 2Y (mm)

14

0.08 Angle of deviation Z (mm)

Displacement in axial direction, deviation and angle of deviation

JIS flange type flexiblecoupling

±0.50.05

--

Displacement in axial direction X (mm)

Change of gap

Dial gauge with

Z＝Z1－Z2

4. Piping

Connect piping while paying attention to the following points.・ Adjust the level section of the suction pipe to become higher little by little

toward the pump suction port (at 1/50 or more).・ Mount a foot valve or strainer on the end of the suction pipe to prevent

foreign objects from entering.・ Make the suction pipe as short as possible and reduce the number of bends.・ Never use a suction pipe that is narrower than the pump aperture.・ Do not provide any projecting section that may cause an air pocket halfway

of the suction pipe when it is laid horizontally.・ Pay careful attention to the piping work to prevent thread chips and foreign

objects from entering the piping.・ It may be convenient to provide a gate valve in the suction pipe to facilitate

overhauling only when the suction side is of a casting type or pushing type. Open the valve fully during operation.

1) For suction type

2) For pushing type

15

Gate valve

Pressure gaugeAchievement gauge

Piping support

Screen Suction pipe steady rest(required for long suction pipe)

2D or more than 500

Foot valve

Over 1 – 1.5D(Over 50D if mud or sand accumulates)

Over 1.5D

Gate valve

The pump is not designed to support expansion/contraction of the pipe due to

temperature change of piping (suction pipe, discharge pipe and auxiliary pipe)

or weight of the piping and liquid. If such loads are applied to the pump, it may

cause misalignment or failures.

Support the piping sufficiently, referring to the table below.

Allowable load to piping MET TYPE □FOOT

PUMP NOZZLE (mm)

Mx N-m

My N-m

Mz N-m

Fx N

Fy N

Fz N

Fx N

Fy (comp)N

Fy (tens)N

Fz N

4. Wiring

ATTENTION● Improper wiring or grounding work by unqualified personnel not only violates

regulations but also causes hazards.Never conduct such works if you are

not qualified.

Wiring or grounding (earthing) of the motor power supply facilities should be done correctly according to the electric facility technical provisions and in-house regulations. Ground fault interrupters and overload protectors are required by laws to prevent electric shock and fire.

1373 1765 2746 3628

1030 1422 1961 2844

2059 2844 3923 5688

1765 2256 3138 4413 Forcea[Discharge]

588 981 1275

785 1177 1569

392 588 785

1765 2256 3138 4413

1373 1765 2746 3628

2059 2844 3923 5688 Forcea[End Suction]

785 1177 1569

588 883 1079

588 981 1275

490 686 1177 1765

686 981 1765 2550

981 1275 2256 3530 Bendinga[Suction]a[Discharge]

392 490 588

294 392 490

196 245 294

80 100 150 200

16

25 40 50

588 883 1079

● Operation

1. Checking before Startup

1) Tighten the flange bolts and base bolts.

2) Supply water after cleaning the piping and the tank thoroughly.

Soils and foreign objects inside the suction tank and suction pipe

may cause failures. Clean them in advance before supplying water.

3) Dismount the coupling guard and manually rotate the pump to check

for smooth rotation.

If it does not rotate smoothly or evenly, check if the inside is

rusty or the gland packing is tightened excessively.

4) Mount the coupling guard.

5) Check the amount of lubricant in the bearing housing.

For the oil bath type, the center (marked by ●) of the oil gauge

on the side of the bearing housing is the proper position.

Supply oil to this position.

・ Lubricant type ……Turbine oil ISO VG46

・ Oil amount ……… The amount of oil varies depending on the bearing type.

・ Oiling method ……Supply an appropriate amount of oil from the air bent

on the upper part of the pump into the bearing housing.

For the procedure of replacing bearing, refer to “Replacement of Bearing”.

6) Discharge air completely.

・ When pushing is required as suction conditionsFully open the valves in the suction pipe and discharge pipe of the pump, and discharge air completely from the casing while manually rotating the pump to check for smooth rotation.

・ When suction is required as suction conditionsUse a vacuum pump. The pump can be filled with liquid from inside the discharge pipe. Open the bypass valve of the check valve, and discharge air completely by opening the air vent valve while checking that excessively high discharge pressure is not applied to the suction pipe or foot valve.

17

Oil gauge

Proper position

Good NotNot Good

2. Valve Operation before Startup

1) Close the gate valve of the pump discharge pipe completely.

・ When the suction pipe also has a gate valve, fully open that valve.・ If pushing is required as suction conditions, check the pressure

in the pushing pipe.

2) Manually rotate the pump again while priming the pump and check if

it rotates smoothly. Discharge air completely from the casing.

・ For priming, use a priming funnel or vacuum pump.・ Priming can be done from inside the discharge pipe by opening

the bypass valve of the check valve. In this case, however, open the air discharge cock to discharge air fully in order to prevent the suction pipe and the foot valve from being applied by high discharge pressure.

3. Startup

DANGER● Take special disaster prevention measures for the following liquid when

checking a test run.

- Explosive liquid - Flammable liquid

- Chemically reactive liquid - Physically hazardous liquid

- Liquid that is contaminant to food

- Other liquids that involve the risk themselves

WARNING● Never bring your fingers to the shaft, coupling or motor fan during operation.

Otherwise, it may touch the rotating object and become injured.

ATTENTION● Never bring your hands to the casing or hanger when handling

high-temperature liquid. Otherwise, they may be burnt.

18

1) Turn on and off the switch once or twice to check that the rotating direction

(clockwise when viewed from the motor) and operating status are normal.

2) Start the pump.

After the pump starts rotating at a designated speed and the discharge

pressure reaches the shutoff pressure, open the gate valve of the discharge

pipe little by little to adjust to the designated discharge pressure.

3) Check after starting operation.

Check for abnormal noises, vibration, or rising discharge pressure.

NOTE

■

period of time. (Max. 1 minute under ordinary circumstances)

■ Excessively opening the discharge valve will overload the motor. You should keep an eye on the ammeter while opening the valve to avoid excessive current.

Operation and handling

■ Never perform cavitation or no-load operation. Doing so could damage the bushings. Shut the pump off immediately if you discover the pump to be operating in such conditions.

■ If the magnet coupling slips, stop the pump immediately within one minute. Continuing to operate with the magnet coupling slipping may demagnetize the magnet coupling, resulting in engine failure. Protection;

To check the demagnetize problem, cavitation operation and no-load operation, we recommend installing our “SHAFT POWER MONITOR”.

■ The number of starts should be as shown below. If this number increases, the life of the pump and the motor is shortened.

Do not operate the pump with the discharge valve shut for an extended

19

Within 3 times/hour

Motor output

Below 7.5kW

11 ～ 22kW

Over 30kW

Number of starts

Within 6 times/hour

Within 4 times/hour

ATTENTION● No-Load Operation Prohibited

The bearings of META Series pumps are lubricated by liquid pumped. Running

the pump without liquid to be pumped should be avoided. If for some reason

no-load operation is happened for several seconds, do not introduce liquid right away, but rather let the pump cool for at least an hour before restarting

operation with liquid. (Suddenly introducing cool liquid can crack ceramic

parts, etc.)

● Shut-Off Operation Prohibited

Performing shut-off operation for an extended period of time can heat the

pump resulting in an accident.

≪Affects of High Temperature≫■ Although the performance of the pump itself is not affected by temperature,

the specific gravity, viscosity, vapor pressure and corrosiveness of the liquid are affected. You must therefore be aware of changes in the properties of the liquids handled. The temperature range for liquids for Model “MET” is -10 to +150 deg C .

(Option；-30～+150 deg C)The temperature range for liquids for Model “MTF” is -30 to +150 deg C .

(Option；-80～+150 deg C)

≪Variation of Performance by Specific Gravity ≫■ Pump performance is not affected by specific gravity of the liquids, but a

suitable power unit (motor, inner-magnet coupling and outer magnet coupling) must be applied by considering the specific gravity of the liquid.

≪Variation in Performance According to Viscosity ≫■ Discharge flow rate and the total head of Model META pumps are lower

for high viscosity liquids than when using fresh water, and more power is required to pump viscous liquids. Use a power unit which meet the power required.

≪Slurry ≫■ The pump is designed to handle some slurry and sludge. Before attempting

to pump liquids containing slurry or sludge, find out the slurry content and size of the particles, and consult with us.

20

4. Stop

1) Shut the discharge valve.

2) Stop the motor. When turned off, the motor should gradually slow down to a

smooth stop. (If it doesn't stop smoothly, check the inside of the pump to see

if evefything is as it should be.)

3) In case of power failure during operation, turn off the switch and shut the

discharge gate valve.

● Maintenance and Inspection

1. Daily Inspection

Smooth pump rotation The standard vibration is below 28 (for both amplitudes) at without vibration the bearing for the 2P motor and below 47 for the 4P motor.

(JIS-B8301)If abnormal noise occurs to the bearing, etc., immediately stop operation and check each section. If the cause cannot be located, immediately contact Sanwa.

Water level of the suction Indication of the pressure gauge is proportional to the specific pump and pressure of the gravity of the liquid. Open the gauge cock of the pressure suction port gauge and the vacuum gauge only when measuring, and close

them after measurement is finished. Load to the pump during Compare the discharge pressure and current during operation operation with those described on the motor nameplate. Temperature of bearing Check that the temperature of the bearing is below “room

temperature + 40℃”, and below 75℃. Amount of lubricant For the oil lubricated type, check the oil gauge for the amount

of oil during operation. If the amount is lowered, supply designated lubricant (Turbine Oil ISO VG46)

･ Replace lubricant after 200 hours of operation for the first

time and every 3000 hours (4 months) of operation

afterwards.

･ For the grease sealed type, grease is sealed in the

bearing. Therefore, daily inspection or grease

replenishment is not required.

Inspection of spare pump When a spare pump is provided, operate it for 10 ～ 15 minutes once a month.

21

Inspection Item Standard and Remarks

2. Replacement of Bearing

Manually rotate the bearing during periodical inspection and check if it rotates heavily or produces abnormal noise. If so, replace it with a new one. For ordinary application, the standard replacement cycles are as shown below:

1) Types and Replacement Cycles of Bearing and Lubricant

2) Types of Lubricant

ＪＩＳＫ２２１３ Append Turbine Oil No.2 (ISO VG46)

Shell TURBO Oil T-46

Esso/General Teresso #46

Mobil DTE Oil Medium

Cosmo Turbine super #46

Idemitsu Daphne Turbo Oil #46

Nippon Oil Corporation FBK Turbine #46

3. Periodical Inspection

Conduct periodical inspection at least once a year. Make sure to keep the record of it.■ Inspection of Bearing

Check if the bearing is loose or generates abnormal noise. The life of the bearing is

more than 30,000 hours from the standpoint of design. Replace the bearing, however,

with a new one every 2 ～ 3 years for the oil lubricated type.

■ Inspection of Impeller

When handling any liquid that may cause abrasion or corrosion, the impeller may

become off-balanced after operation for a long period of time. Roll the impeller on

two rails to check the balance. Correction is possible if the eccentric amount is

within about 30μ. If correction is not possible, replace with a spare impeller.

4. Stopping of Pump for a Long Period of Time

Always discharge liquid from inside by opening the drain valve or the plug. When using in the cold district, liquid may freeze and destroy the pump.Make sure that the finished surface of the bearing, coupling, etc. do not become rusty.

SUJ

Type Q'ty

22

TYPE-G 6208

6207

Replacement cycle

2～3years

Bearingtype BRG. No. Material

TYPE-U

Ball bearing Lubricant

Replacement cycle

4 monthsTurbine Oil 0.09

ISO VG46 0.17

L

L

5. Configuration and Location of Part

The list of parts and a configuration diagram are given to rovide a general description of the pump. You may refer to these as you read the instruction manual.

※Configuration

※PartsNo. Parts Material Qty. Remarks1 Impeller SCS13/14 1

2 Casing SCS13/14 1

3 Casing cover SCS13/14 1

4 Rear casing SUS316 1

6 Sleeve bolt SUS316 1

6A Set screw SUS316 1

7 Impeller nut SCS16 1

7A Set screw SUS316 1

23

※ Sequel (Parts)

8 Shaft SUS316 1

8A Impeller key SUS316 1

8B Coupring key SUS316 1

8C Sleeve key SUS316 1

9A Sleeve(F) SiC 1

9B Sleeve(R) SiC 1

10 Frame adapter FC200 1

10A Eye bolt SF440 1

11A Bearing cover(F) CAC403 1

11B Bearing cover(R) CAC403 1

13 Deflector C3604 1

13A Set screw SCM435 1

16 Support SS400 1

17 Oil gauge RESIN 1

18 ball bearing SUJ 2

19 Oil seal NBR 1

20A Magnet coupling(P) SUS316 1

20B Magnet coupling(M) FCD400 1

29A Thrust ring(F) SiC 1

29B Thrust ring(R) SiC 1

30 Screw SUS316 2

31 Pin SUS316 1

33 Sheet gasket PTFE 1

33A O ring PTFE 1

33B Gasket (Three sheet packing) ～ 2

35 Air vent RESIN 1

37 Plug FCMB 1

38 Hexagon socket head plug SCM435 1

45A Bushing（F） SiC 1

45B Bushing（R） SiC 1

50 Plug SUS316 1

51 Outer magnet shaft S45C 1

51A Magnet coupling key S45C 1

51B Coupring key S45C 1

60 Set screw SCM435 2

61 Hexagon socket head bolt SUS304 8 / 12

62 Hexagon socket head bolt SUS304 8

63 Hexagon head bolt SS400 6

64 Hexagon socket head bolt SUS304 8

65 Hexagon head bolt SS400 2

69 Name plate SUS304 1

24

（photo 1）（photo 2）




25





26





27

● SANWA MAGNET DRIVE PUMP

Check record tableITEM No. ； Check day (this time) ；

Pump name ； Check day (Last time) ；

Pump type ； Work No. ； Operation time ； Hr

t R ； Measures by the impeller movement.

P ； D - d

IMPELLER SIDE (FRONT) MOTOR SIDE (REAR)

BUSHING SLEEVE THRUST RING THRUST RING SLEEVE BUSHING

DIMENSIONS mm

+0.10 0 0 +0.117 0 0±0.1 +0.05 -0.02 ±0.1 ±0.1 +0.065 -0.021 ±0.1

+0.142 0 0 +0.142 0 0±0.1 +0.08 -0.025 ±0.1 ±0.1 +0.08 -0.025 ±0.1

CLEARANCE mm

DF

0.1

0.1

TYPE

U

G

LF

40

40

28

0 1.5 0.2 0.2

+0.2 -0.2 -0.3-0.3 +0.2 -0.2 -0.3 -0.3

0.1

0.1

0

0

0.5

0.5

U

G

ALLOWANCEmeasurement

value

IMPELLER SIDE (FRONT) MOTOR SIDE (REAR)

TYPE P RP Ft Ft F

Max. WEARmeasurement

value

32

SLEEEVE TRUST RINGBUSHINGBUSHING TRUST RINGSLEEEVE

TRDR dR

46

29

38

LRTFdF

8.5

10

32

46

29

3840

10

10

20

　

t F t R

P F

P F

D F

L F

d F

T FL R

D R

d R

T R

取説No.MET01A(E)/0312-00

met-e-2 - iwaki america · 5)pour cement mortar between the gap below the base and foundation bolt...

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