GRUNDFOS INDUSTRY

Principle ofprecision.

Competence in machine tool industry

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GRUNDFOS Management A/SPoul Due Jensens vej 7DK-8850 Bjerringbrophone +4587501400

www.grundfos.com

Being responsible is our foundationThinking ahead makes it possible

Innovation is the essence

Principle ofcompetence.

Varied program > Grundfos immersible, normand block pumps are suitable for almost every appli-cation in the area of mechanical engineering. Thespectrum ranges from cooling and lubrication oftools and component cool-down, water treatmentduring production process, all the way to filtration,drilling, washing or wire eroding. Thus, it is possibleto cover every requirement within the scope of indus-trial production, from single-part productionto complete production line.

Profound experience > The expertise and applica-tion skills gathered by us over decades are unparalleledon the market. In combination with the new machinetool business structure, they are the assurance thattoday - more than ever before - we are in a position toaddress the needs of your industry. With an extremelydiversified, innovative product program – specificallytailored to the mechanical engineering sector – we

provide you with customer-oriented systems solutions

that meet highestexpectations at all

times.

Excellently organised > Surviving intoday's competitive world and providingcustomers not only with outstandingproducts, but also with comprehensiveservice, require fully integrated con-cepts. For this reason we have setup a completely new machine toolbusiness structure with customerservice units as well as a dedicatedmachine tool sales force. For our dis-cerning customers from the mechanicalengineering sector, this organisation posi-tions us as leading provider of systems andcomplete solutions, which are complemented byour optimal distribution and logistics structure. Wealso want you to benefit from the competence of astrong brand that offers everything from one source.

Competence area of machine tool industry:New structures for increased customer focus >

Production cell

Competence area of machine tool industry:All processes individually coordinated >

Maximum reliability > Basic conditions in modern metal processingbecome increasingly more difficult, as demands on product quality, and thusthe entire production process, grow continuously. This requires absolute reli-ability of cooling lubricant pumps, which is warranted by Grundfos in everyrespect. Regardless whether they are used for disposal or the actual produc-tion process, Grundfos pumps cover the complete application spectrum inproduction. In doing so, all components are optimally coordi-nated and can be precisely adapted to your individualrequirements.

Perfect service > Grundfos stands for competence in allmatters. In addition to pumps of exemplary quality andreliability, we also offer our customers a worldwide servicenetwork, should the need arise. In case of a malfunction,we are always in a position to provide quick and profes-sional solutions, thus ensuring a smooth uninterruptedproduction flow.

Flexible dynamics > For a majority of our pumps wealso offer electronic motors with integrated frequencyconverters, with a power range up to 22 kW. They can beindividually controlled and dynamically adjusted at alltimes to the prevailing operating conditions. Thus, in addi-tion to permanent optimal cooling of tools or workpiece,they also save an enormous share of operating power.They are particularly efficient to operate and contributegreatly to the reduction of total cost of ownership (TCO).

Supply >Cooling lubricant clean

MTS(E)

MTR(E)/SPK(E)

MTH/MTC

CRN(E)

NK(E)

NB(E)

Recirculation >Cooling lubricant polluted

MTB

MTPO

MTA

Principle ofperformance.

Competence area of machine tool industry:Customised production >

MTR(E), SPK(E) > The MTR and SPK series offer deliveries up to 1500l/min and pressures up to 25 bar, and are all equipped with EFF1 motor,in doing so they achieve up to 81% efficiency. Due to variable totallengths and capacity, both pump series – in addition to circulation ofcooling lubricants - are also used as condensate or filter pumps, as wellas in numerous industrial cleaning processes. Their cartridge-type shaftsealing can be replaced in a simple and quick manner, if necessary.Process optimisation is ensured by the design with integratedfrequency converter, which provides the correct supply pressure duringeach processing step.

MTS(E) > The newly developed MTS series for high pressuresupply of machine tools proves its strengths especiallyduring the production of filigree parts. Here, the three-spindle self-priming screw pump convinces with a deliverypressure up to 130 bar. Its high efficiency ensures a very lowheat input into the cooling lubricant. In addition, the verywear-resistant system guarantees maximum reliability andminimum vibrations. This series can also be optionallysupplied with integrated frequency converter.

MTH/MTC > The immersible pumps of the MTH series are characterisedby a very compact design, which is especially suitable for installation in flatcontainers. As multistage pump in segment design, it covers a very widerange of performances with delivery rates up to 130 l/min.

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NB> the single stage centrifugal pumps in close-coupled design of the NB series fulfill their task in anefficient and reliable manner. This requirement isensured by the high hydraulic efficiency, in connec-tion with the standard EFF 1 motors. The compactdesign of this series allows for use in a number ofindustrial applications, e.g. in parts cleaningmachines, as filter pumps, or in cooling and air condi-tioning systems.

MTPO> Single stage, self-priming recircula-tion pump in closed-coupled design, withmechanical seal. Its special constructionmakes the MTPO suitable for delivery ofhighly aerated emulsions and oils. Maximumdelivery is 350 l/min.

Competence area of machine tool industry:Optimal solution for each application >

CR/CRN/CRNE HS> The normal-priming multistage centrifugal pumps ininline-design are series equipped with EFF 1 motors, and convince by highest effi-ciency and unsurpassed reliability. Thanks to numerous raw material variants, likeair-cooled top and MAG-drive, they have a particularly diverse application spec-trum. Cooling water circuits, washing plants, industrial circulation systems, as well as general pressure increase applications belong to their application area.Furthermore this series is applicable as a filter pump for reconditioning of coolinglubricant.

MTA> The lower performance range up to 100 l/min and delivery heightsup to 10 m are attended to by immersible pumps of the MTA series. Theirrobust construction with open stainless steel impeller makes them suitablefor media with increased viscosity and corrosiveness, as well as for highsolids content. This is why the MTA series is preferred for cooling lubricantsupply during lathing and parts cleaning.

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MTB> The single stage, normal-primingrecirculation pump in closed-coupled designis equipped with a mechanical seal and ispreferably applied in parts cleaning andwashing systems, cooling lubricant disposal,and waste water treatment. Particle sizes upto 20 mm ball diameter can be safely deliv-ered with the SuperVortex impeller. Themaximum delivery is 1500 l/min.Su

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NK > The NK cast iron pumps performtheir task in an efficient and reliablemanner, especially for delivery of largequantities of water. Thus, they achieveup to 2000 m3/h at an operating pres-sure of max. 16 bar, making the normpumps suitable for a number of indus-trial applications, like central installa-tions for cooling lubricant recondi-tioning. Their specific process designpermits easy removal of motor andimpeller, without requiring additionalwork on the pump housing.

Principle ofquality.

Competence area of machine tool industry:Absolute minimal heat input >

During processing, many production processes inmechanical engineering require a variety of delivery data(flow/pressure), depending on tools. To optimally meetthese requirements, Grundfos supplies electronicallycontrolled E-pumps with integrated frequency converter.

Principle ofefficiency.

Efficient and powerful > Pumps with integratedfrequency converter offer additional benefits:• Individual adjustment to required operating point• Multi voltage range of 3 x 380-480 Volt; 50/60 Hz mains

side• cURus and CE certification – as a standard• Motor connection via unique plug and play system• Controllable through sensors for pressure, flow, temper-

ature and the like (0-10V or 4-20 mA)• Adjustable via remote control R100

This means specifically for the machine tool industry:• Lower heat input into cooling lubricant

• Reduced cooling efficiency• Increased process safety

• Lower operating costsIntelligent application > The E-pumps can be inte-grated into innovative production processes without anyproblem. The analogue and digital inputs permit indi-vidual control, e.g. depending on tool magazine assign-ment.

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Cooling lubricant tank

1 Spindle and tool with IKZ2 Flow monitor Qmin (optional)3 Pressure sensor4 Frequency control5 High pressure pump6 Pressure relieve valve

Comparison of actual pressure value 4-20 mA

Target pressure value 0-10V

On/off control via M-code

400VAC/24VDC

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42Die neue Grundfos Industriedivision> Industrielle Anwendungen.Synergie aus Know-how und Erfahrung.

Special characteristics ofthis series:• The cartridge mechanical seal canbe replaced without disassembly of the pump • Flexible immersion depth: Pump length can be adjusted

to installation conditions• A suction cycle protects the pump against dry running.• Pump parts made of stainless steel, optimised suction

chamber and impellers• Leak channel to tank• Energy-efficient high performance motor (EFF1).

The reason for selecting a speed-controlled variant isexplained by Dipl.-Ing. Klaus Bock, who is in charge ofsales support at Mayfran: “The maximum required by alleight machine tools together lies between 400 and 500l/min cooling lubricant. The duty pump must be designedfor this. However, when for instance only two machinetools are running, the requirement decreases accordingly –and the pump automatically reduces its speed. Important:The pump still delivers the same pressure!” This is neces-sary to ensure proper function, since the cooling-lubricantmust be fed to each machine tool at 3 bar.

Advantage of this operation: Significant energy savings(reduced operating costs), as well as a technologicallyadvantageous aspect: If the pump operates at reducedspeed, the heat output to the cooling lubricant is alsoless, thus no separate cooler must be switched on.

Why the cooling lubricant must not heat up? Klaus Bock:“Especially the grinding machines are very sensitive totemperatures and require a preferably constant coolinglubricant temperature for processing a workpiece withinthe specified narrow tolerances.

Knapheide is a renowned manufacturer of top-quality and extremely robust hydraulic systems.With its parent company, Knapheide GmbHHydrauliksysteme in Beckum, and diverse specialisedcompanies for precision lathing, hydraulic hoses, hosetechnology, materials handling, and electrohydrauliccontrol and process engineering, the group with itsroughly 850 employees is in a position to offer everythingfrom one source, “made in Germany”.

For reasons of safe process control and tool life,Knapheide uses mainly carbide drills with interior coolingfor processing of work pieces. For this purpose, a coolinglubricant with particularly high pressure might be needed.Because the smaller the tool, the tighter the cooling chan-nels – and the greater the required pressure. ProductionManager Bernhard Nauber: “When performing deep holedrilling, an additional complication is that the chips mustsafely be disposed from up to 600 mm deep bore holes.Only very powerful high pressure pumps can accomplishthis.”

For special applications, like deep hole drilling for high-precision turning processes, Knapheide has installedGrundfos MTS screw pumps in its Beckum plant. Thispump ensures high pressures up to 130 bar, in connectionwith uniform delivery characteristics, long tool life, andlow heat input into the cooling lubricant. MTS pumps are available in two executions:One in form of immersible pumps withshaft seal-ring (type DQ), the other asdry installed variant with mechan-ical seal (type D8.6). Due to theircompact design, the pumps aresuitable for vertical installationin or on top of tanks, or for dryinstallation. With seven sizesand 15 types, there is a rightpump for every task.

Important performance data:Production flow up to 900 l/min;

Constant pressure for machine tools >

Deep hole drilling: Powerfulchip disposal >

Delivery of abrasive, gas-containing cooling lubricants >

Customer: FETTE GmbH, GermanyApplications: SUPPLY AND RECIRCULATION OF COOLINGLUBRICANTS

Products of Grundfos Industry:MTPO: Self-priming centrifugal pumps MTR: Immersible pumps

Customer: Mayfran GmbH, NetherlandsApplications: DELIVERY OF COOLANTS AND LUBRICANTS

Products of Grundfos Industry:MTRE: Immersible pumps with frequency converter

FETTE GmbH, Schwarzenbek, is known for highly efficientprecision tools and powerful compacting presses for thepharmaceutical and chemical industry. The company ispart of the Leitz association - ten industrial enterpriseswith subsidiaries around the globe, internationallyleading in the manufacturing of precision tools andsystems for processing of wood, plastic and metal.

For the production of tools, the company operates morethan 600 machine tools, mainly in wet processing. Theclean flow of the cooling lubricant cycle is equipped withconventional immersion pumps; they consist of severalhundred units, mainly from the large Grundfos productrange. In the polluted recirculation from machine tool tofilter system, however, other qualities are in demand: It isnot just a matter of maintaining a delivery rate; thepumps must also deliver abrasive and gas-containingparts. This concerns the abrasion of the tools to bemachined, and the applied grinding discs. A particularcritical point: “The grinding oils absorb a lot of air due tothe high pressure of the cooling lubricant during impactonto the grinding disc”, says Martin Peters, master inindustrial engineering. Conventional immersion

centrifugal pumps have problems with this combinationof liquid, solid and gaseous parts. Furthermore, duringstart-up of a machine tool it takes several seconds untilthe polluted cooling lubricant reaches the pump - andafter the machine tool comes to a stop, the pump mustcompletely discharge the cooling lubricant to filtration.Thus, the pump should survive at least a short dryrunning period.

For the “dirty” part of the cooling lubricant cycle, and forthe particular challenge of gas-containing medium,Grundfos offers the Pomona MTPO 23 series. This is awear-resistant and self-priming (!) centrifugal pump, withdry installation to save space. Designed as ‚wastewaterpump’, the Pomona bearing shells are accordinglymoulded. Due to special construction measures (specialbearing shell contour, arrangement of guide fingers in thehousing cap, scavenging port in the wear plate), thesuctioned air is mixed with the pumping media. The unitis suitable for delivery of gas-containing, solid media –abrasive parts up to a particle diameter of 10 mm are noproblem. The components are engineered in such a way tofacilitate easy pump assembly. The replacement ofwearing parts is also simple.

Martin Peters: “The Pomona is more cost efficient thanconventional specialty pumps, and significantly easier tohandle than the alternatively applied lifting units. More-over, the pump requires hardly any space, and functionsreliable – it does a good job.” Consequently, the old pumpsare replaced one by one with Pomona pumps, so faralready 30 pumps.

1Extrude Hone VMB GmbH specialises in the constructionof machines and devices for electrolytic deburring andfinishing of metallic precision parts (ECM technology). Inthe past, this form of 'electrolytic machining' has beenused rather seldom The high precision during deburringand edge contouring of metallic components is character-istic for this process; in doing so, the material struc-ture is neither subject to thermal nor mechanicalstress. The extremely precise ECM metalmachining offers maximum component accu-racy and efficiency. For instance, builders ofsuperfine nozzles for modern common railDiesel engines will value this precision.

The pump requirements in an ECM installa-tion are very high: The media can be alkalineas well as acidic; stability against salts andpollutants must be ensured, and naturally,service-friendliness is in demand. On one hand, theunits move the electrolytic solution; on the other handthey deliver cleaning agents in the washing stations. Theyreturn used media to the central treatment plant, load thefilter systems and finally empty the tanks. In short: Every-thing that flows in an ECM installation is moved bypumps.

After Extrude Hone VMBhas been relying on twopump suppliers in thepast, meanwhile onlyGRUNDFOS is listed: “In

addition to the entireproduct range, we value the

flexibility and commitment ofGRUNDFOS”, states Managing

Director Markus Günther. On thecurrent ECM installations, Extrude Hone

VMB is now changing the entire pump technology toimmersion pumps of the MTRI series, which also feature astainless steel head. Günther: “On the MTRI pumps weparticularly like the easy way of exchanging the cartridgeseal - this feature is also well accepted by our customers.”Though all pumps are designed with speed control, thecorresponding frequency converters are externally posi-tioned, separate from the process, in a control cabinet.Reason: The effect of the not always preventable saltvapours on the integrated or attached frequencyconverter would be extreme.

Markus Günther is more than satisfied with theGRUNDFOS-Service: “The reaction times to inquiriesand/or problems are very good!” Added to this is the greatcommitment, for instance in the event of a technicaldefect. “If such is the case, we receive a comprehensiveanalysis, together with a recommendation how such afailure can be best avoided in the future.” Of particularimportance is the globally available GRUNDFOS serviceand spare parts supply - thus Extrude Hone VMB canensure the support for its international customer base.

MTRI pumps are resistantagainst aggressive electrolytes >

Customer: Extrude Hone VMB GmbH, GermanyApplications: DELIVERY OF ELECTROLYTE SOLUTIONS ANDCLEANING AGENTS, RECIRCULATION, LOADING OF FILTERSYSTEMS

Products of Grundfos Industry: MTRI: Immersible pumps made of stainless steel

Extrude Hone VMB developed thecomplete systems engineering itself,including automation and washingprocess.

FETTE is theleading manufacturerof precision tools, like hobs.

On the current ECM installations, Extrude HoneVMB is now changing all pumps to immersionpumps of the MTRI series, which also feature astainless steel head.

For the mechanicaldepartment (milling,lathing, drilling andgrinding of turbine parts),Mayfran supplied a central coolinglubricant filter installation for the newplant in Arnstadt. Part of the delivery scope wasalso the piping to the eight machine tools. Grundfos pumps can beseen at bottom right and left of installation.

On the screw pump of the MTSseries, the operator can choosebetween different pressure stages, inorder to achieve the optimal settingfor cooling or chip flushing for eachtool.

media temperature up to 80°C; final pump-pressure up to130 bar; viscosity up to 2.000 mm2/s; pollution level up to250 mg/l; filtration level up to 100 mym.

Knapheide has clearly defined the requirements for thesepumps. They must deliver a ‚fatter’ cooling lubricant (up to12 % emulsion level – 6 to 7 % are normal). And, most ofall, they must provide such a high pressure that the chipsare safely flushed out even from 600 mm deep bore holes.

Because the very expensive deep hole drills - due totheir length - are less solid than conventional

drills, a chip congestion would result in abroken drill within seconds – and the

tight cost calculation for a hydraulicvalve or a turning process would be

ruined.

The newly applied MTS pumpperforms a good job, asconfirmed by Nauber. “We have a3-shift operation, thus the pump

is actually continuously running. In our opinion, the pump stability

is excellent.”

With the Pomona MTPO 23,Grundfos offers a pump for

the 'dirty' part of the coolinglubricant cycle; compared

to the lifting units,Pomona requires signifi-cantly less space and ismore cost efficient.

Customer: Knapheide GmbH, GermanyApplications: Delivery of cooling lubricant in the high-pressure area

Products of Grundfos Industry: MTS: Screw pumps

3The Mayfran Company, with more than 1000 employeesworldwide and production sites in the United States,Europe and Asia, is one of the leading global manufac-turers of conveyor and filtration systems for the metal-working industry.

Mayfran’s reputation throughout the world is evident inthis current project: N3 Engine Overhaul Services ( jointventure of Lufthansa Technik AG and Rolls-Royce plc) hasestablished a plant in Arnstadt, near Erfurt, for the recon-ditioning of Rolls-Royce power units.

N3 assigned Mayfran with the planning and installationof a central cooling lubricant filtration system for thesupply of eight machine tools with water soluble coolinglubricants. The central system (band filter installation) islocated in the basement and supplies the machine toolswith up to 500 l/min cooling lubricants in 3-shift opera-tion, six days per week. Regardless how many machinetools are simultaneously running, each machine tool mustbe continuously supplied with cooling lubricants at a pres-sure of 3 bar.

To meet this requirement, the filter installation isequipped with two immersible Grundfos pumps (changein 24-hour rhythm). The units of the MTRE series selectedby Mayfran feature frequency controlled motors.

Competence area of machine tool industry:Tried, tested and proven >

Customer-specific solutions > Due to theircompact design, Grundfos MT products can be integrated

in the cooling lubricant tank and chip conveyor in asimple and space-saving manner, at various

immersion depths. The modular design makesmore than 100.000 individually configurablevariants possible.

Technical top performances >Each detail of our pumps contains theinnovative Grundfos expertise. Our impellers,for instance, are laser welded and thus createextremely good flow behaviour and minimum frictionloss. The floatingly mounted seal ring reduces the leakageloss inside the pump to an absolute minimum. The uniquecartridge seal is extremely wear-resistant, and also veryeasy to replace.

Count on groundbreaking top technology and benefitfrom an unparalleled product quality. For the manufac-ture of Grundfos pumps, high-quality materials and latestprocedures are used, so that they fully comply with yourrequirements in all application areas.

Grundfos Industry:A strong industry partner >

Principle ofpartnership.

Tradition and greatness > Grundfos was founded in1945 by the visionary and inventor Poul Due Jensen. Hispersonal values have accompanied the Grundfos successstory. Today, the company is worldwide presented as fullrange supplier of pumps and pump systems by more than70 companies. The corporate group, with its headquartersin Denmark, has more than 14.500 employees around theglobe, which produce annually over 10 million pumps,thus generating a sales volume exceeding 2 milliard Euro.

Philosophy>“Be – Think – Innovate” are ourcompany principles in short. Ourphilosophy has proven itself. As world market leader inthe field of cooling lubricant pumps, Grundfos offers acomprehensive range of specialised pumps. In addition tomaximum product quality, our exceptional vertical inte-gration is an important assurance of unparalleledGrundfos quality. In-house research and developmentcentres are specifically set up to continuously expand ourinnovation potential. In the process, excellently trained,competent employees are our best calling card in themarket.

Logistics and distribution> The Grundfos logistics concept isdesigned for top performance. Our standard pumps are generally onhand due to high stock availability, for instance via E-Trading (EDI) orour web shop. The in-house distribution network is supported world-wide by ten logistics centres. A central, efficient spare parts supply in

all European countries is ensured by the Grundfos spare partscentre in the Netherlands.

The worldwide presence of Grundfos guarantees anextensive distribution and service organization. Our

customers in the machine tool sector are attendedby a globally positioned network of specialists.

High efficiency, low costs > Due to optimalhydraulics, Grundfos pumps offer a significantly higherdegree of efficiency, reducing energy consumption andheat input in the cooling lubricant by 15 to 20%. Thisresults in a significant reduction of operating costs overthe entire service life of the installation, especially whenconsidering that 85 % of the overall costs stem fromenergy consumption. During actual operation, this canalso cause smaller cooling requirements. Maintenanceperiods are reduced due to theeasily replaceable cartridgeseals and the application of standard tools.