Typ : MAPE 50 V3 MAPE 100 V3 MAPE 150

Installation and operation instructions for MAPE 50, 100 and 150

MAPE CZ s.r.o., Bulharská 740/5, 360 01 Karlovy Vary IČ: 453 494 10, DIČ: CZ 453 494 10, zapsaná v OR vedeném u Krajského soudu v Plzni, oddíl C, vložka 2189

Bankovní spojení : Raiffeisen Bank K. Vary, číslo účtu : 102 301 5680/5500

verze 2.7 1

Centrifugal sludge pump

Typ : MAPE 50 – V3

MAPE 100 – V3

MAPE 150 – V3

Important warnings – see articles

5.2.4 and 5.3

(Read through efore starting up!)




verze 2.7 2

Content:

1. General information ...................................................................................................... 3

2. Use, technical specifications .......................................................................................... 4 2.1 Specifications ..................................................................................................................................... 4 2.2 Name plate ........................................................................................................................................... 4 2.3 Dimensions ......................................................................................................................................... 5

3. Description of pump parts ............................................................................................. 6 3.1 pump ...................................................................................................................................................... 6 3.2 drive ...................................................................................................................................................... 7

4. Safety ............................................................................................................................ 8 4.1 Warning signs used in operating instructions ......................................................................................... 8 4.2 Safety instructions .................................................................................................................................. 8

5. Instruction for installation ........................................................................................... 10 5.1 Transport, packaging, acceptance and storage ..................................................................................... 10 5.2 Installation ........................................................................................................................................... 10

5.2.1 Personnel and material requirements regarding the installation and commissioning of the pump 10 5.2.2 Attaching the pump to the base .................................................................................................... 11 5.2.3 Connecting the pump to the pipeline ............................................................................................ 12 5.2.4 Pump connection to the Mains ..................................................................................................... 12 5.2.5 Tightening of V-belts ..................................................................................................................... 13 5.2.6 Water connection for seal flushing ............................................................................................... 14 5.2.7 Putting seal into operation ........................................................................................................... 15

5.3 Putting the pump into operation .......................................................................................................... 16 5.4 Inspection after putting the pump into operation ................................................................................ 16

6. Pump maintenance and service ................................................................................... 17 6.1 Extent of competencies ........................................................................................................................ 17

6.1.1 Pump operators ............................................................................................................................ 17 6.1.2 Trained person or manufacturer ................................................................................................... 17

6.2 Regular maintenance ........................................................................................................................... 17 6.3 Warranty inspections within the warranty period ................................................................................ 18 6.4 Cord packing maintenance ................................................................................................................... 19

6.4.1 Cord packing adjustment .............................................................................................................. 19 6.4.2 Addition of packing cord ............................................................................................................... 19 6.4.3 Replacement of packing cords ...................................................................................................... 20

6.5 Replacement of V-belts ........................................................................................................................ 21

7. Replacement of the damaged parts of the pump .......................................................... 22 7.1 Spare parts ........................................................................................................................................... 22

8. Waste management .................................................................................................... 23

9. EC Declaration of conformity ....................................................................................... 24

10. Warranty certificate .................................................................................................... 26

11. Contacts ...................................................................................................................... 27

12. Notes .......................................................................................................................... 28




verze 2.7 3

1. GENERAL INFORMATION

Dear Costumer, Congratulations on your purchase of the MAPE pump and thank you for your trust. Before installating and operating , you should read through this assembly and service manual. We hope you will be satisfied with our product after reading it. This manual is an integral part of the machine. These instructions match the type of pump and the safety and technical standards in force at the time of printing.

The installer and operating stuff must carefully read these service instructions before installing and starting the pump, because unskilled manipulation may couse a health hazard and damage the machine.

The manufacturer is not responsible for any damage caused by incorrect installation, misuse, unskilled maintenance, or for any damage caused by any modification of the pump or its parts without the manufacturer´s approval.




verze 2.7 4

2. USE, TECHNICAL SPECIFICATIONS

The MAPE horizontal centrifugal sludge pump is intended for the transport of solid, bulk and both fine and coarse grained material in the form of suspension in liquid. The most frequently used liquids are sludge waters or chemicals in various concentrations.

2.1 SPECIFICATIONS

density of medium 1.100 kg.m-3 – 1.800 kg.m-3*

delivery head (H) 0 – 75 m*

flow rate (Q) 0 – 115 l.s-1*

pH of medium from 0 to 14

temperature of liquid (T) up to 80ºC (120º C)

size of grain 0 – 55 mm*

ambient temperature 0º – 40ºC

operation of the pump continuous/intermittent operation – 24 h/d

voltage 380/400 V

environment humid, water splashed

shielding IP 55 – suitable for humid environment

total noise level 75,2 dB(A) *depends on the actual type of pump (see the pump passport)

2.2 NAME PLATE

Every pump is labelled with a metal plate containing all the basic data.

type of pump

serial number

RPM

manufacturer´s name

density of medium

pumped amount

weight (kg)

suction head




verze 2.7 5

2.3 DIMENSIONS

* Weight of the pump is without the weight of the elektromotor

Type Proportions of the pumps (mm) Weight*

(kg) A B C D E F G H J K L M N ø O P R

M 50 657 435 375 410 58 20 90 216 417 - 368 323 26 18 146 780 197

M 100 960 730 460 565 102 20 135 315 680 68 510 400 30 18 243 1100 470

M 150 1140 830 610 650 110 30 275 420 809 - 580 510 50 22 248 1340 615

Type Bore of pipe

Connecting flange DNs SL (mm) DNv VL (mm)

M 50 DN 60 PN 16 150 DN 50 PN 16 150 ČSN EN 1092 - 1

M 100 DN 125 PN 10 150 DN 100 PN 10 150 ČSN EN 1092 - 1

M 150 DN 150 PN 10 200 DN 150 PN 10 200 ČSN EN 1092 - 1




verze 2.7 6

3. DESCRIPTION OF PUMP PARTS

3.1 PUMP

consists of following main parts: Tailstock Bears all the pump parts and is used for mounting the pump to the base plate. It is made from material 42 2420. This type of pump does not need an extra frame. Rear/front casing After bolting together, the casings form the pump body with displacement and suction branches. Both casings have replaceable rubber pads inside. Casings are cast from material 42 2420. Rear/front pad Replaceable rubber parts with steel cords. Both pads together form spiral working place for the impeller. The type of rubber type is chosen according to the type of medium being transported. Impeller It is constructed for the axial inlet and radial outlet of liquid and it is bolted on the shaft. It has a cast-steel rubber cord. It can be replaced after it wears. The type of impeller is chosen according to the type of medium being transported.

suction

displacement

drive housing

V-belts

pulley

engine

base plate

panel protecting transport flow of displacement

panel protecting transport flow of suction

front casing (inside front rubber pad and impeller)

rear casing (inside rear rubber pad)

tightening bolt with safety nut

tailstock lid (under lid is shaft-

seating)

tailstock lids bolts

tailstock

type plate

seal




verze 2.7 7

Shaft It connects the impeller with the driven pulley. It´s stored in roller bearings and tightened by the seal from the side of impeller. It´s made from noble metal. Sleeve Sleeve is used for supporting the bearings of the shaft slide-fitted in the body. When sliding it, the clearance of the impeller between the inserts in the pump body can be adjusted. It is made of material no. 42 2420.

3.2 DRIVE

consists of:

Plate The electric motor is fixed ton this adjustabel steel plate. It is stored on three bolts above the tailstock. It is possible to strech the V-belts with by moving the bolts. Electric motor The size of electric motor is determined according to the amount of medium being transported. Most MAPE pumps use a Siemens electric motors. V-belt pulley The V-belt pulley is driving or driven. It transmits torque from the electric motor to the pump. V-belt set The belt size and amount are determined by motor power.V-belts are installed after proper determination of the motor direction. They are delivered in XPA quality.




verze 2.7 8

4. SAFETY

4.1 WARNING SIGNS USED IN OPERATING INSTRUCTIONS

During installation follow the safety instructions to avoid injury to yourself , those around you, or to property. These instructions carry a warning safety symbol. The safety instructions are dividid into different levels. Below is a table of safety symbols (pictograms) and key words for concrete dangerous and possible consequence.

Pictogram Key word Definition / Consequence

WARNING! Risk: Danger can cause serious injury or death.

CAUTION! Danger or dangerous process which can harm humans or which can cause property damage.

ATTENTION ! Process can cause damage to the machine or to other property. No danger of injury to people.

INFORMATION Important or useful information and instruction. No danger for humans or belongings.

4.2 SAFETY INSTRUCTIONS

Please follow all safety instructions and warnings included in this manual. When installing the pump, make sure that the electric connection is made according the current electrical engineering regulations. The connection may be made only by duly qualified personnel. The pump complies with the requirements of the Czech Ministry of Health Decree on the protection of health against noise and vibration nuisance - Ministry of Health Decree No. 13/1997 Coll. If the pump is not in operation, it must be prevented from being put into operation by an unauthorized person. Never operate the pump with wet hands - there is a risk of an electric shock.




verze 2.7 9

The rotating parts of the pump are covered to prevent accidental contact. Never remove the safety covers when the pump is in operation. The pump must never be operated without these covers installed. Special attention should be paid to the area around the shaft and the mechanical seal (if this pump is fitted with a seal). When the pump is in operation, the shaft rotates, creating the risk of a part of the body or clothing getting caught in the machine. It is therefore necessary to keep a sufficient distance from all rotating parts during operation. All inspection and maintenance work must only be performed by authorized personnel and only when the pump is switched off and disconnected from the power supply. In the event of a fire, water must never be used to extinguish the fire but rather only fire extinguishers (e.g., powder extinguishers) intended for this purpose. When dismantling the pump after pumping chemical substances, use appropriate personal protective equipment. Remember that ignoring safety instructions may result in danger to persons, the environment, and the pump itself. This may also make the warranty void.




verze 2.7 10

5. INSTRUCTION FOR INSTALLATION

Prior to the installation and putting into operation of the machine, please read the pump operating manual thoroughly.

5.1 TRANSPORT, PACKAGING, ACCEPTANCE AND STORAGE

MAPE pumps are delivered anchored to wooden beams on pallets. The intake and discharge openings are blinded to prevent the intrusion of foreign objects. The pumps are supplied assembled, including oil in the bushing and intake and discharge reducers. The V-belts of the pump drive are fitted. These instructions for installation and operation also make up part of the delivery. The pumps are shipped as free-loaded by means of railway or road delivery. When handling the pump, make sure to avoid any shocks which might cause damage to some of its parts. After the takeover of the product at the factory, appropriate transport is the responsibility of the customer. MAPE pumps must be stored in a covered, dry place and protected against mechanical damage. Appropriate storage is the responsibility of the customer. The transport, packaging, and storage of Siemens electric motors is governed by Regulation 5 610 70000 38 006 b from 10/2006 Article 3 of the motor manufacturer.

After unpacking the pump with the shaft, do not turn the pump – this could cause permanent damage to the mechanical seal!

5.2 INSTALLATION

During the installation and commissioning of the pump, proceed chronologically according to the following chapters!

5.2.1 Personnel and material requirements regarding the installation and commissioning of the pump

Staff - required professions: - fitter - electrician Lifting machinery up to 1000 kg Time required for installation: - pump anchoring 1 h - connecting the pump to the pipeline 2h - connecting the electric motor 1h - tightening belts ½ h - putting the seal into operation ¼ h - pre-commissioning inspection ¼ h




verze 2.7 11

5.2.2 Attaching the pump to the base

The on-site installation is performed by the customer or manufacturer upon request. The pump does not need a special frame and it can be installed directly on a flat surface. Mount the pump directly to the base by anchors inserted in the holes of the body. To make later handling of the pump possible, the manufacturer recommends the use of anchor bolts rather than concrete rods with nuts. (The anchoring material is not included the pump delivery.) Anchoring dimensions see Chapter 2.3

Recommended anchoring material of HILTI brand

Pump MAPE 50, 100 Anchor bolt: HSL-3 M 16/25 Product number: 00371784 Anchor length: 153 mm Basic materials: cracked concrete (tension zone), concrete (non-cracked) Environment conditions : Indoor, dry environment Min. thickness of base material : 200 mm Anchor type: Mechanical Operating principle : Torque application Mounting type: Sleeve mounting (through a fastening element) Material finish : Galvanized (min. 5 μm) Effective anchorage depth: 100 mm Thickness of mounted material: 25 mm Diameter of the hole in the anchor plate: 26 mm Drill diameter: 24 mm Min. hole depth: 125 mm Recommended torque: 120Nm Wrench size: 24 mm Pump MAPE 150 Anchor bolt: HSL-3 M 20/60 Product number: 00371788 Anchor length: 213 mm Basic materials: cracked concrete (tension zone), concrete (non-

cracked) Environment conditions: Indoor, dry environment Min. thickness of base material: 250 mm Anchor type: Mechanical Operating principle: Torque application Mounting type: Sleeve mounting (through a fastening element) Material finish: Galvanized (min. 5 μm) Effective anchorage depth: 125 mm

4 anchor bolts




verze 2.7 12

Thickness of mounted material: 31 mm Diameter of the hole in the anchor plate: 28 mm Drill diameter: 24 mm Min. hole depth: 155 mm Recommended torque: 200 Nm Wrench size: 30 mm

5.2.3 Connecting the pump to the pipeline

First, remove the cover plates on the pump inlet and outlet, which protect against the intrusion of foreign objects into the pump during transport and storage. As the pitch of the pump intake and discharge flanges does not conform to ČSN - EN, connect the intake and discharge pipeline using the supplied reducers with standardized flanges. The intake and discharge rubber necks protrude from the metal casing and therefore play the role of sealing. Additional sealing is thus unnecessary. We also recommend that a compensator be inserted to prevent the transmission of vibrations and simplify the matching of the pump with the piping that is already installed (the compensator is not included in the delivery - it can be ordered separately).

The flanges are mounted on the pump using only the screws delivered, or screws of prescribed lengths, respectively. If longer screws are used, permanent deformation of the hydraulic parts of the pump may occur.

5.2.4 Pump connection to the Mains

Remove the protective cover of the drive, take off the supplied V-belts. Then connect the pump to the mains. The connection of the pump is carried out by connecting the supply cable to the electric motor terminal box, either in wye or delta.

Caution! The connection may only be made by duly qualified personnel! Risk of electric shock!

Pump MAPE 50 8x screw M16x40 DIN 931 8x washer ø16 DIN 125 Pump MAPE 100 intake: 8x screw M20x45 DIN 931 8x washer ø20 DIN 125 discharge: 8x screw M16x45 DIN 931 8x washer ø16 DIN 125 Pump MAPE 100, 150 intake: 8x screw M20x45 DIN 931 discharge: 8x screw M20x70 DIN 931 16 x washer ø20 DIN 125

discharge reduction

intake reduction




verze 2.7 13

The utmost care should be taken when the connection of the electric motor to the mains is by made by the customer. The direction of the motor shaft rotations must correspond to the arrow, which is shown on the front pump housing. If this requirement is not met, the hydraulic parts of the pump will be damaged. (Such damage is not covered by the warranty!)

5.2.5 Tightening of V-belts

After checking and setting the correct direction of rotation (according to the arrow on the front pump housing), the V-belts may be fitted on the pulleys of the pump and electric motor. First, place the V-belt into the groove of the motor pulley closer to the front side of the motor; then place the V-belt into the groove of the pump pulley also closer to the pump front side. Proceed in the same way when fitting other belts. Once all the belts have been fitted, they should be tensioned. The tensioning of the belts is done by pulling a steel rod of 8 mm diameter through the tensioning screw hole (see Chapter 3 “Description of the Pump Components") and by turning the tensioning screw counter-clockwise the belts are tensioned. Secure the tensioning screw (or tensioning screws in the case of MAPE 150) in the desired position by tightening the securing nut and measure the prescribed tensioning torque of belts. Re-tighten the belts at the required torque in case of insufficient tension of the belts, or loosen them in case of excessive tension. Having reached the prescribed tensioning torque, secure the tensioning screw(s) again with the securing nut. Finally, reinstall the protection cover of the drive belt.

The belt tensioning torque values are specified in the “Pump Passport” sheet.

Use only the type, size and number of belts specified by the manufacturer. Using the wrong type of the belt, or an insufficient number of belts, will result in insufficient transmission of the driving torque, such that the pump will not operate at full capacity.

In the case of visible damage to the belt, shut down the pump immediately and replace the damaged belt.

Measure the tensioning torque of the belts with the belt pretensioning measuring device, which can be ordered from the pump manufacturer. (Not included in the pump supply)

arrow identifying the correct direction of rotation




verze 2.7 14

5.2.6 Water connection for seal flushing

The stuffing box forms a very important part of the pump that prevents leakage of pumped medium from the hydraulic area of the pump along the drive shaft. Stuffing box can be in MAPE pumps designed in several basic manners:

1. cord seal

“the simplest” variant in the terms of operation

shaft seal can be but does not have to be flushed

requires regular inspection

disadvantage of persistent dripping of pumped medium outside the pump

2. mechanical seal singular

simple cassette cartridge

maintenance-free system

the seal is dripping-free

dilution of pumped medium occurs

3. mechanical seal twofold

simple cassette cartridge

the seal is dripping-free

maintenance-free system

no dilution of pumped medium

the seal is connected to / flushed from its own source of seal water with the return of flushing water back to the seal circuit, which is controlled by an automatic system equipped with its own pressure vessel, manometric and thermometric systems, a valve system, and a hand pump.

safe operation - in case of seal failure, the seal medium circuit is secured against the leak of the delivered medium by two circuits of seal rings

When pumping substances with abrasive admixtures, seal water must always be supplied and all types of aforementioned seal must be flushed. The pressure water flushes the seal and prevents the penetration of mechanical impurities into the seal. Operation without flushing the mechanical seal may result in permanent damage thereto!

If seal with flushing is used, the seal body must be supplied with clean pressure water of the following pressure: pucp = (H x 0,7) + 10% pucp - water pressure at the seal [ kPa ]

H - discharge head [ m ]

Example calculation: H = 40 m

pucp = (40 x 0,7) + 10% = 308 kPa = 3,08 bar

The flushing water may be supplied to the seal by a hose of 3/8” section, which is fitted on to the seal body nozzle (included in the pump delivery) and secured against disconnecting with a clip (not included in the pump delivery).




verze 2.7 15

It is recommended to fit the seal water supply with a shut-off valve and/or a magnetic valve controlling the volume and pressure of water delivered to the seal or turning off the water supply completely.

5.2.7 Putting seal into operation

Before putting the pump into operation, check the type of your pump seal. The seal data is specified in the “Pump Passport”.

If the pump has a mechanical seal, the seal must be first released (unscrewing the locking clips, or turning the key of the locking clip by 90° in the direction of the rotation of the pump shaft, protecting the seal rings in the seal during delivery). Only then can the pump shaft be rotated for the first time. Keep the clips with screws for future use. You will need them when performing service work on the pump.

seal flushing water supply

locking clips of the seal

Mechanical seal Chesterton S10,S20




verze 2.7 16

5.3 PUTTING THE PUMP INTO OPERATION

Inspection of installation before the pump commissioning:

1. pump anchoring 2. connecting the pump inlet and outlet 3. connecting the electric motor and checking the correct direction of rotation 4. tensioning of V-belts 5. checking the flush water supply to the seal 6. checking the seal unlocking (only for mechanical seal) 7. opening of the seal flush water supply 8. opening of the delivered medium supply (if the piping is fitted with a shut-off valve) 9. opening of the delivered medium discharge (if the piping is fitted with a shut-off valve)

Now the pump can be put into operation.

Make sure that the pump never runs dry, i.e., without seal flush water and without the substance being pumped. Operation without flushing the mechanical seal may result in permanent damage thereto! In case of continuous seal flushing, the interruption of the pumped substance column (short suction failure, e.g., due to decreased level of the pumped medium) will not reduce the life of the seal.

5.4 INSPECTION AFTER PUTTING THE PUMP INTO OPERATION

Having put the pump into operation, check immediately:

1. the smooth running of the pump - the pump should not make any unusual noises such as bouncing, squealing, knocking, etc.

2. the smooth running of the motor - the motor should not make any unusual noises such as bouncing, squealing, knocking, etc.

3. the tightness of the seal - in case of mechanical seal, no leak out of the seal area is permissible, in case of cord packing check the leak - 12 to 20 drops per minute, or adjust; see Chapter 6.4.1

4. the tightness of the pump hydraulic parts - no leakage of the substance being pumped outside the pump

CAUTION ! Operating the pump with one of the above-mentioned defects can cause permanent damage to the pump or pump motor and risk to the environment or operator’s health! If a defect is discovered, shut down the pump immediately and contact the manufacturer.




verze 2.7 17

6. PUMP MAINTENANCE AND SERVICE

MAPE pump is generally designed as a maintenance-free and simple machine that will work in the toughest operating conditions. It is characterized by low operating costs, long life, and low consumption of spare parts.

6.1 EXTENT OF COMPETENCIES

Given the two-year warranty, the pump manufacturer specifies the scope of the pump maintenance work as follows:

6.1.1 Pump operators

are authorized to perform the following activities:

cord packing – adjustment

V-belts - inspection, tensioning and/or replacement For detailed description of activities see Chapter 6.2

6.1.2 Trained person or manufacturer

is authorized to perform the following activities:

mechanical seal - replacement

hydraulic part - adjustment and/or replacement of the impeller - replacement of pads

repairs to the pump drive parts

A trained person may only be a person with expert qualification in engineering or related field or a person with more than 5 years’ experience in the field of pumping equipment.

6.2 REGULAR MAINTENANCE

During the pump operation, the operators regularly inspect and carry out the following:

1. the condition of V-belts

Check their correct tension and if they are loose, tension them immediately using the tensioning screw, otherwise they might snap and cause the failure of the pump. If damaged, replace them immediately (see Chapter 5.2.5).

2. pressure water supply to the seal (if the seal is flushed) Failure of the seal water supply would result in the destruction of the sleeve and the surfaces of the mechanical seal, which would cause general leakage of the seal.

3. the condition of the seal – risk of the pumped medium leakage from the hydraulic parts of the pump.The mechanical seal must operate without leaks,




verze 2.7 18

while the cord packing must permanently weep the fluid (leak of 12-20 drops per minute). The packing/seal wear time depends on the pump operation. Adjustment of the cord packing; see Chapter 6.4.1.

4. lubrication of shaft bearings

The standard version MAPE XXX V3 1 comprises bearings with permanent lubricant filling requiring no maintenance. Under optimum conditions, the bearing life can reach 17,500 hours. The pump is not equipped with any inspection or test point, which would allow determining the actual condition of the bearing. 1

Actual designation of the pump, such as MAPE 100

6.3 WARRANTY INSPECTIONS WITHIN THE WARRANTY PERIOD

Throughout the duration of the warranty (see Warranty Certificate), the regular warranty inspections are carried out by the manufacturer or a person trained by the manufacturer. The warranty inspections are carried out every 6 months. The customer is obligated to order the warranty inspection at the manufacturer's customer service line or trained individual in advance.

CAUTION! If the regular warranty inspections are not carried out, the manufacturer’s warranty becomes void!




verze 2.7 19

6.4 CORD PACKING MAINTENANCE

6.4.1 Cord packing adjustment

The packing is tightened or loosened by turning the nuts on the bolts of the packing cover.

The cord packing should exhibit a leak of 12 to 20 drops per minute. If the packing leak exceeds 20 drops per minute, the packing has to be tightened - turning the nuts clockwise.

If the packing leak is lower than 12 drops per minute, the packing has to be loosened - turning the nuts counter-clockwise.

The operation of the pump with cord packing requires regular inspections.

CAUTION! If the cord packing does not drip, this could cause the packing cord could to burn or the creation of grooves in the packing sleeve. Such damage is not covered by the warranty!

6.4.2 Addition of packing cord

The cord ring is added after 100 operating hours. The cord ring is supplied by the

manufacturer as part of the delivery.

1. Loosen both nuts on the bolts of the packing cover

2. Remove the split packing cover, separate the lower and upper parts of the packing

cover




verze 2.7 20

3. Insert one packing ring into the packing chamber and push it in

4. First attach the lower part of the packing cover with a drain groove, then attach the

upper part of the packing cover and tighten both nuts evenly to reach the specified drip

of the packing; see Chapter 6.4.1.

6.4.3 Replacement of packing cords

1. Dismantle the split packing cover; see Chapter 6.4.2.

2. Remove all packing cords from the packing chamber

For removing all packing cords you can use a special tool

lower part of the packing cover with a drain groove




verze 2.7 21

3. Place two new packing rings back into the packing chamber (first the lattice and then

the graphite one) mutually turned 180°, install the third ring after 100 operating hours

acc.to chapter 6.4.2.

4. Replace the packing cover and tighten to reach the specified packing drip according to

Chapter 6.4.1.

6.5 REPLACEMENT OF V-BELTS

CAUTION! Before performing any work on the motor drive, the pump must be shut down and secured against accidental start! There is a direct hazard to health and life!

The V-belts are replaced in reverse order of the assembly according to Chapter 5.2.5.

1. Loosen the screws of the protective cover of the drive and remove the belt drive cover. 2. Loosen the securing nut of the tensioning screws

3. Pull a steel rod of 8 mm diameter through the tensioning screw hole (see Chapter 3

“Description of the Pump Components") and by turning the tensioning screw clockwise

the belts are loosened.

4. Remove the damaged V-belts.

5. Then install new V-belts according to Chapter 5.2.5

180º mutual turning of packing cords

Lattice ring

Graphite ring




verze 2.7 22

7. REPLACEMENT OF THE DAMAGED PARTS OF THE PUMP

Throughout the warranty period, the full servicing is provided by the manufacturer or a trained person. In the case of improper handling or interference in the pump, modification of any of the pump components, or the use of non-original parts, the warranty becomes void.

Before each pump adjustment or the replacement of any of its parts, the mechanical seal must always be locked with centring clips (this applies only if the pump is equipped with mechanical seal). Having locked the mechanical packing, do not turn the pump shaft. Warning - permanent damage to the seal may occur!!

7.1 SPARE PARTS

The manufacturer handles the distribution of original spare parts.




verze 2.7 23

8. WASTE MANAGEMENT

When disposing of the pump packaging and the pump itself, all related regulations and implementation decrees, must be complied with.




verze 2.7 24

9. EC DECLARATION OF CONFORMITY

EC Declaration of conformity According to Act 22/1997 Coll.

DECLARATION OF CONFORMITY ISSUED BY

Trade name: CINK – MAPE s.r.o. Registered office: Bulharská 740/5, 360 01 Karlovy Vary ID No.: 45349410 as the manufacturer of product

Name: Sludge pumps Type: MAPE 50 - NDO-227- 8-GC-00 MAPE 100 - NDO-352-40-GC-00 MAPE 150 - NDO-380-63-GC-00 Model: ČR Serial number: od 7/98 Product description and function identification: Pumping turbid, abrasive, aggressive or other substances according to the type of the pump (see operating manual). I DECLARE AND CONFIRM THAT

A. This product is safe under normal conditions and under the operating conditions specified in the manual, and that measures have been taken to ensure the compliance of all marketed products with the technical documentation, basic requirements of governmental regulations applying to it, and the requirements of the technical regulations specified in Part B.

B. The characteristics of this product meet the technical requirements applying to it

which are specified in: 1. Government Regulation No. 176/2008 Coll., laying down technical requirements for machinery 2. Government Regulation No. 17/2003 Coll., laying down technical requirements on low voltage electrical equipment. 3. Government Regulation No. 616/2006 Coll. laying down technical requirements on products from the perspective of their electromagnetic compatibility.

and the following technical regulations: 1. Government Regulation No. 148/2006 Coll., on the protection of health against noise and vibration nuisance. 2. Decree of the Czech Occupational Safety Authority No. 48/1982 Coll. laying down the basic requirements for occupational and technical equipment safety - see later amendments of the Czech government regulations.




verze 2.7 25

C. Conformity assessment was carried out by the procedure specified in:

a) Article 3 Para. 1 of Government Regulation No. 176/2008 Coll., laying down technical requirements for machinery, b) Article 4 Para. 1 of Government Regulation No. 616/2006 Coll. laying down technical requirements on products from the perspective of their electromagnetic compatibility, b) Article 3 Para. 1 of Government Regulation No. 17/2003 Coll., laying down technical requirements on low voltage electrical equipment.

D. Testing of this type of product according to section C Letter a) of this the

declaration of conformity was conducted by the company in the pump test station.

E. The aforementioned product meets the following harmonized Czech technical standards applied when assessing its compliance: ČSN EN ISO 12100-1, ČSN EN ISO 13857, ČSN EN 349+A1, ČSN EN 13850, ČSN EN 60 204-1 ED2., ČSN EN 60335-2-51 ED2., ČSN EN 61000-6-3 ED2., ČSN EN 61000-6-4 ED2., ČSN EN 61000-6-1 and ČSN EN 61000-6-2.

Date 13. March 2011 Karlovy Vary

Jan Studnička

General Manager

This statement does not relieve the manufacturer of the responsibility in view of the product liability, provided that the operating manual is adhered to. The safety instructions stated in the accompanying documentation must be observed.




verze 2.7 26

10. WARRANTY CERTIFICATE

The pump manufacturer provides a warranty according to the Civil or Commercial Code for 24 months from the time of removal of the product from the factory, unless stated otherwise in the purchase contract. The manufacturer guarantees perfect product quality, assuming the cost of repair by the replacement of damaged parts in case of hidden defects in the material or manufacturing defects that appear during the warranty period after the pump is commissioned by a qualified employee of the manufacturer. The warranty will be void in case of the following defects: • Non-observance of the operating manual. • Violent interference, improper handling or use of the pump with other type of substances

than those specified. • Use of inappropriate (non-original) pump spare parts and/or components. • Negligence of required maintenance. • Failure to carry out regular warranty inspections. • Wear resulting from standard use. Wear depends on the type of substance being pumped. • The warranty does not apply to the parts that come into contact with the substance being

pumped (front and rear inserts, impeller, packing piece or oil retainer, packing bushing, packing rings).

Date of sale : ...................................................

Description Stamp and signature

Putting the pump into operation

on :………………….. carried out by………………..…………

date of next warranty inspection: ………………………………

1. Warranty inspection

on :………………….. carried out by………………..…………



on :………………….. carried out by………………..…………



on :………………….. carried out by………………..…………



on :………………….. carried out by………………..…………




verze 2.7 27

11. CONTACTS

Firm name : MAPE CZ s.r.o. Adress : Premise Karlovy Vary Loketská 10 360 06 Karlovy Vary - Dvory Phone : +420 359 572 106 Fax : +420 359 572 107 E - mail : info@ mapecz.cz Web - site: www.mapeCZ.CZ VAT Reg No.: CZ 453 494 10 Record in business index by regional judgement in Plzeň ,section C, number 2189




verze 2.7 28

12. NOTES

Documents

Typ : MAPE 50 V3 MAPE 100 V3 MAPE 150