Viking Pump Technical Service Manual 685.1 forViking
Contents
1. CAUTION M10X120 CAPSCREW DO NOT PLACE FINGERS HERE 3 aL Do not place your fingers between the pump mounting flange and the face of the bracket Using extreme caution pull the inner magnet away from the outer magnet see figure 9 page 7 If you do not completely pull the pump out it will snap back and could pinch a finger or hand Once the inner magnet is removed from the bracket be careful setting it down as it will attract any iron or steel object 2 The canister will contain some liquid therefore use care while removing from the pump and pull it straight off 3 Remove the two 6mm buttonhead machine screws and the set collar Insert a brass bar through a port between two rotor teeth and remove the locknut See Figure 13 Slide the inner magnet off the shaft Do not forget this is a very strong magnet If further pump disassembly is required refer to Step 7 of PUMP DISASSEMBLY page 4 4 Do not remove the O ring unless it is bad especially if PTFE derivative encapsulated If a new O ring is required follow instructions in t2. Pipe Plug 2 Req d Head and Idler Pin Assembly SECTION TSM 685 1 ISSUE E PAGE 5 OF 16 MAGNETIC COUPLING OPTIONS TORQUE RATINGS AND DRIVER CONNECTION OPTIONS Long Magnetic Magnetic Close Coupled baci Pump Size i GS Coupling Coupling IEC B 5 Flange Mounting NEMA Motor Bearing Motor Mounts capscews Mounts Carrier e 143 145TC Yes e 213 215TC Yes e 254 256TC TABLE 3 COUPLING TORQUE AND SIZE OPTIONS FIGURE 7 M DRIVE CONFIGURATION MD2 A amp B SERIES COUPLING AND BEARING CARRIER COMPONENTS TEM DESCRIPTION ITEM DESCRIPTION ITEM Bolt on Hub with Hardware Capscrews for Pump 4 Required 613 60 soa eaae e00 inner Magnet Assembty ons 04 10 6 Capscrews for Motor or Bearing l Capscrew for Disassembly Carrier 4 Required Ball Bearing 2 Required Lifting Eye Bearing Carrier Housing 617 1 l eos Pipe Plug for Sensor Hole External Retaining Ring 2 Required Internal Retaining Ring TABLE 4 SECTION TSM 685 1 ISSUE E PAGE 6 OF 16 PUMP DISASSEMBLY Cont 7 With the inner magnet removed now remove the pump shaft key Remove the outer thrust washer The rotor and shaft may now be removed by tapping on the end of the shaft with a soft face hammer If a soft face hammer is not available a regular hammer may be used with a piece of hardwood 8 Remove the inner thrust washer from behind the rotor The casing should be examined for wear particularly in the area betwee
3. Then press the shaft out of the housing Remove the external retaining rings from shaft place unit into press and push out shaft out of the bearings ASSEMBLY 1 Place some Loctite on the O D of the first bearing and press into the housing bore Position the bearing spacer in the bore and insert the second bearing Center the bearing spacer then press in shaft with one external retaining ring on shaft Press down until ring contacts bearing race then install second ring Install internal retaining ring into bearing housing Slide outer magnet assembly onto pump shaft Locate the outer magnet per dimension A then tighten the two setscrews Coupling Series A Dim A Series 165 mm B Series 198 mm Bearing Housing Internal Retaining Ring Set Screw Outer Magnet 1 E Ai Sil AN my ISE N YY Yj ae N S is External AN Retaining Rings FIGURE 15 OUTER MAGNET BOLT ON HUB AND BEARING HOUSING INSTALLATION OF BUSHINGS CARBON GRAPHITE The canister bushing requires a special fixture for proper assembly It is only sold as an assembly with the canister If attempting to install the carbon graphite idler or casing bushing extreme care must be taken to prevent breaking Carbon graphite is a brittle material and easily cracked If cracked the bushing will quickly disintegrate Using a lubricant on the bushing and mating part will help facilitate ins
4. Service Bulletin ESB 31 RELIEF VALVE ADJUSTING SCREW CAP SUCTION DISCHARGE FIGURE 3 RELIEF VALVE POSITION CAUTION Rare earth magnets used in couplings have extremely strong magnetic fields capable of changing performance or damaging items such as the following Pacemakers Metal Implants Watches Computers amp disks Credit Cards Completely assembled magnetic couplings will not affect items listed above only disas sembled components There are no known harmful effects of these magnetic fields on the human body MAINTENANCE Series 855 pumps are designed for long trouble free service life under a wide variety of application conditions with a minimum of maintenance The points listed below will help provide long service life CLEANING PUMP Keep the pump as clean as possible This will facilitate inspection adjustment and repair work SECTION TSM 685 1 ISSUE E PAGE 3 OF 16 BEARING CANISTER CARRIER CANISTER O RING ASSEMBLY Optional RELIEF VALVE TEMPERATURE shown with optional PROBE HOLE RV coverplate CASING BUSHING ROTOR tha a SHAFT DS HEAD GASKET SEAL HEAD OUTER MAGNET GAUGE ASSEMBLY PORT BOSS IDLER PIN BRACKET IDLER INNER MAGNET CASING ASSEMBLY CUTAWAY VIEW MAG DRIVE PUMP MODEL HL855M MD2 B B ILLUSTRATED TYPICAL OF GG HL SIZES FIGURE 4 MAINTENANCE Cont PUMP DISASSEMBLY STORAGE WARNING If the pump an
5. make sure there is no interference If rubbing occurs motor to bracket FINGERS HERE check the dimension in Figure 19 or contact the factory 3 Check to make sure the pump rotates freely by turning the inner magnet assembly Inspect the magnet to make sure it has not picked up any foreign particles which could damage the pump Make sure the canister O ring is in good condition and in place Place the canister onto the pump and press on until the canister is in contact with the pump mounting flange CAUTION Do not place fingers onto front of pump mount ing flange Align canister into bore of bracket and gently slide in When magnets start to en gage the unit will finish engagement on its own very rapidly Make sure fingers are not on the front of the pump see Figure 20 DANGER FIGURE 20 PUMP AND BRACKET ASSEMBLY SEQUENCE Be certain that the driving means motor tur bine engine etc Has been locked out or made non operational so that it cannot be started while work is being done on pump Canister Bushing Canister Canister O ring 4 Finish the assembly by securing the pump to the bracket aa See Figure 20 Check that the pump rotates freely by bon a spinning the motor fan blades or bearing carrier shaft yo An if Button Head Screws Canister and Casing Drain Holes FIGURE 21 SECTION TSM 685 1 ISSUE E PAGE 11 OF 16 Series MD2 B14 Through B50 Coupling DANGER Follow
6. these directions exactly to avoid injury to self or damage to the pumping unit Be care ful to keep inner and outer magnets at least 1 foot apart until step 4 Do not engage magnets in any other fashion MD2 B Magnets 1 Inspect the magnets for any steel objects which may mA Dimension A Dimension be attached Remove any foreign material Locate the Motor ines Metric outer magnet assembly per dimension See Figure 22 Apply Loctite and tighten the setscrews onto the motor I E C 100 112 113 196 4 MM or bearing carrier key and shaft I E C 132 216 5 MM 2 If the bracket is not fastened to a base clamp it down 182TC 184TC 206 MM Mount the motor or bearing carrier to the bracket Reach 213TC 215TC 215 7 MM in and rotate the magnets by hand to make sure there is no interference If rubbing occurs check the dimension 254TC 256TC 231 5 MM in Figure 22 or contact the factory FIGURE 22 3 Check to make sure pump rotates freely by turning inner magnet assembly Inspect magnet to make sure it has not picked up any foreign particles which could damage the pump Make sure the canister O ring is in good condition and in place Place canister onto pump and press on until canister is in contact with pump mounting flange 4 Use a fully threaded M10X120mm capscrew to control assembling the pump Thread completely into bracket as shown in Figure 23 Support pump with overhead hoist if possible whi
7. CTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES ae Warning In addition to possible serious Symbol Danger E FAETO ONON Ne naea eg injury or death failure to follow the instruction may result in serious injury DORNING indicated instruction may cause damage Legend g or death to pump and or other equipment BEFORE opening any liquid chamber pumping WARNING INSTALL pressure gauges sensors next to the chamber reservoir relief valve adjusting cap fitting pump suction and discharge connections to monitor etc be sure that pressures e Any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections USE extreme caution when lifting the pump Suitable lifting devices should be used when appropriate Lifting e The pump drive system means motor turbine eyes installed on the pump must be used only to lift engine etc has been locked out or otherwise WARNING the pump not the pump with drive and or base plate been made non operational so that it cannot be If the pump is mounted on a base plate the base plate started while work is being done on the pump must be used for all lifting purposes If slings are used for lifting they must be safely and securely attached For weight of the pump alone which does not include the drive and or base plate refer to the Viking Pump product catalog i gt e You know what material the pump has been ha
8. F RAN FIGURE 26 VALVE GS GG HJ AND HL SIZES VALVE LIST OF PARTS 1 Valve Cap 6 Valve Body 2 Adjusting Screw 7 Valve Spring 3 Lock Nut 8 Poppet 4 Spring Guide 9 Cap Gasket B Bonet TABLE 7 SECTION TSM 685 1 ISSUE E PAGE 14 OF 16 DANGER Before starting pump be sure all drive equip ment guards are in place Failure to properly mount guards may result in serious injury or death PRESSURE ADJUSTMENT lf a new spring is installed or if the pressure setting of the pressure relief valve is to be changed from that which the factory has set the following instructions must be carefully followed 1 Carefully remove the valve cap which covers the adjusting screw 2 Loosen the locknut which locks the adjusting screw so pressure setting will not change during operation of pump 3 Install a pressure gauge in the discharge line for the actual adjustment operation 4 Turn the adjusting screw in to increase pressure and out to decrease pressure 5 With discharge line closed at a point beyond the pressure gauge gauge will show the maximum pressure valve will allow while the pump is in operation IMPORTANT When ordering parts for the pressure relief valve always give the model number and serial number of the pump as it appears on nameplate and name of the part wanted When ordering springs be sure to give pressure setting desired TROUBLESHOOTING Some of the following may help pin
9. SECTION TSM 685 1 TECHNICAL SERVICE MANUAL VIKING IIIMAG DRIVE SERIES 855 Sizes GS GG HJ HL PAGE 1 OF 16 ISSUE E Introduction 0 0 ee ee 1 UNMOUNTED PUMPS UNITS Safety Information 2 Special Information 08 3 Units are designated by the un S GS 855U GS 855M mounted pump model numbers Maintenance a eae 3 followed by the magnetic coupling Disassembly of Pump 4 size and a letter indicating drive o aCi gt GG 855U GG 855M siye isassembly of Couplings Example GG 855MA MD2 AQ M Disassembly Assembly Bearing Housing 9 D Direct Drive Installation of Bushings 9 HJ 855U HJ 855M M Motor Mount B Bearing Carrier Assembly of Pump aoaaa a a a a 9 R Viking Reducer Drive Pump Rotation oaoa a a 10 P Commercial Reducer Drive HL 855U HL 855M Assembly of Couplings eR a p koa wo oa a a A a am a a 11 See Page 4 for complete description of Adjusting End Clearance 13 the model number Pressure Relief Valve Instructions 13 TABLE 1 Troubleshooting 2 05050 15 WARNING Persons with surgical implants of a metallic or electronic nature should avoid working on pump especially the inner magnet assem bly INTRODUCTION FIGURE 1 GS GG SERIES 855MA MD2 A9 B The illustrations used in this manual are for identification Pump with Bearing Carrier purposes
10. a locknut socket External snap ring pliers 2 810 029 375 l l l 6 Remove the idler and bushing assembly If the idler bushing needs to be replaced see INSTALLATION OF BUSHINGS page 9 If further disassembly is required the pump must be separated from coupling Refer to DISASSEMBLY OF COUPLING page 7 before proceeding with Step 7 Internal snap ring pliers 2 810 047 999 Arbor press Brass bar Sa SS ee Hook style spanner wrench SECTION TSM 685 1 ISSUE E PAGE 4 OF 16 ee Drive Configurations Size D Direct drive Nominal displacement R Reducer drive GS HJ AS KE B Bearing carrier GG HL AK KKE P Purchased reducer AL Magnetic Coupling Size and Torque Specification Drive Related A 4and 9 Ft Lbs B 14 32 and 50 Ft Lbs Material C 40 90 135 and 180 Ft Lbs 5 Cast Iron Port Design and Fasteners Magnetic Coupling Design M DIN and metric fasteners a aa U ANSI and inch fasteners Coupling Size Pump Related A size Used on GS GG HJ or HL B size Used on HJ HL AS AK or AL C size Used on AS AK AL KE or KKE FIGURE 5 MODEL NUMBER SYSTEM FIGURE 6 EXPLODED VIEW SIZES GS GG HJ amp HL MAG DRIVE PUMPS NAME OF PART Locating Pin 21 Set Collar 38 Idler Bushing 80 _ Thrust Washer 2 Req d 33 Casing Stem O ring 45 Relief Valve Gasket_ Head O ring 46 _ Capscrews for Relief Valve 36 Rotor and Shaft Assembly 47 ReliefValve TABLE 2
11. and the purchaser by acceptance of delivery assumes all liability for the consequences of the use or misuse of Viking products by the purchaser his employees or others Viking will assume no field expense for service or parts unless authorized by it in advance Equipment and accessories purchased by Viking from outside sources which are incorporated into any Viking product are warranted only to the extent of and by the original manufacturer s warranty or guarantee if any THIS IS VIKING S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED WHICH ARE HEREBY EXCLUDED INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE No officer or employee of IDEX Corporation or Viking Pump Inc is authorized to alter this warranty 5 2007 Viking Pump Inc All rights reserved IDEX CORPORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA
12. crew caps must always point towards suction side of the pump If pump rotation is reversed position of the relief valve must be changed Pressure relief valves cannot be used to control pump P PP BEFORE operating the pump be sure that e tis clean and free from debris Pip PPP WARNING all valves in the suction and discharge pipelines flow or regulate discharge pressure For additional are fully opened information refer to Viking Pump s Technical Service e All piping connected to the pump is fully supported donne TSM 000 and Engineering Service Bulletin and correctly aligned with the pump e Pump rotation is correct for the desired direction of flow THE PUMP must be installed in a matter that allows safe access for routine maintenance and for inspection during operation to check for leakage and monitor WARNING pump operation SECTION TSM 685 1 ISSUE E PAGE 2 OF 16 SPECIAL INFORMATION DANGER Before opening any Viking pump liquid cham ber pumping chamber reservoir relief valve adjusting cap fitting etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections 2 That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on pump 3 That you know what liquid the pump has been handling and the p
13. d coupling are to be stored drain the pump and pour non detergent SAE 30 weight oil into the pump port Apply grease to the pump or the coupling shaft extension if present or accessible Refer to DANGER amp CAUTION listed on page 2 before proceeding Viking suggests rotating the pump shaft every 30 days to circulate the oil in the pump The coupling should be stored 1 To drain the liquid being pumped remove the two 2 in a dry area drain plugs located in the bottom of the casing Once the liquid has drained replace the plugs NOTE If the liquid to be pumped reacts with oil use an acceptable alternate SUGGESTED REPAIR TOOLS 2 Refer to Figures 4 6 amp 7 for names of parts 3 Mark the head and casing before disassembly to insure The following tools are required to properly repair Series 855 proper reassembly pumps These tools are in addition to standard mechanics tools such as open end wrenches pliers screwdrivers etc Most of the items can be obtained from an industrial supply house 4 To inspect the head and pin assembly and idler and bushing assembly remove the head capscrews 5 Remove the head from the pump Do not allow the idler to fall from the idler pin Tilt the top of the pump head back when removing to prevent this Avoid damaging the head shim set since all shims are required to maintain end clearance 1 Soft face hammer Metric Allen wrenches for set screws Torque Wrench with
14. dge of x Locknut FIGURE 17 Hot water makes the PTFE more pliable and allows the inner elastomer to pull the PTFE back to the orginal size SECTION TSM 685 1 ISSUE E PAGE 10 OF 16 NORMAL END CLEARANCE SET OF HEAD Shims INCLUDES GS GG 855 0 003 oa 1 005 2 002 2 001 End Clearances are adequate for viscosities up to 2500 SSU 540 cSt SAE 40 lube oil at room temperature Higher viscosities require additional clearances As a general rule the end clearance is doubled for higher viscosities For specific recommendations for end clearance for viscosity or for operating temperatures above 225 F check with your Viking representative or consult the factory TABLE 6 7 Coat the idler pin with a suitable lubricant and place the idler on the idler pin in head Make sure the O ring for the head is installed 8 The head can now be assembled onto the pump Tilt the top of the pump head away from the pump slightly until the crescent enters the inside diameter of the rotor and rotate the idler until its teeth mesh with the rotor teeth The pump head and casing should have been marked before disassembly to insure proper reassembly If not be sure the idler pin which is offset in the pump head is positioned toward and an equal distance from the port connections to allow for proper flow of liquid through the pump Install the head capscrews Rotate the shaft to make sure it turns freely 9 Follow
15. g it over a sharp edge Run hot water over the O ring until it shrinks down tight onto the pilot of the pump Dry with compressed air 2 Clean the rotor and shaft so it is free of dirt grit and other debris and apply lubricant Place one thrust washer onto shaft so that the blind hole in thrust washer will line up with the drive pin on back of rotor Push it into the casing as far as it will go 3 Slide the second thrust washer onto the shaft drive hole facing out and then install key into the shaft 4 Slide the inner magnet onto the shaft and engage the pin of magnet into hole of thrust washer Install the locknut beveled edge out set torque to measurements given in Table 5 Place a mark on the trailing edge of the locknut slot Refer to Figure 17 Back off the locknut until the leading edge of that same slot lines up with the mark This will establish the proper clearance for the thrust washers Locknut Torque Requirement TABLE 5 5 Place the set collar on the locknut and install the two machine screws 6 Ifthe old metal shims are not reusable or if any parts have been replaced operating clearances will need to be re established Refer to ADJUSTING END CLEARANCE page 13 Otherwise place the head shims on the head The proper amount of shims should be used to provide the correct end clearance Table 6 gives the quantity of shims available in a gasket set along with standard end clearance a Leading E
16. he ASSEMBLY section page 9 M10x120 CAPSCREW FIGURE 12 5 You should be able to visually inspect the outer magnets PUMP AND BRACKET SEPARATION SEQUENCE from the end of the bracket If removal is necessary start by removing the 4 capscrews See Figure 14 and separate the bracket from the motor or bearing carrier Loosen the 2 setscrews on the outer shell hub and slide the outer magnet assembly off the shaft If the unit features a bearing carrier the bearings should not require maintenance since they are sealed If Set Collar necessary disassemble by removing the single internal ate retaining ring then press the shaft and bearings out of FIGURE 13 the housing Remove the external retaining rings from INNER MAGNET AND LOCKNUT ASSEMBLY the shaft to remove the bearings Refer to Figure 7 page 6 and Figure 15 page 9 Capscrews Buttonhead Locknut Inner Magnet Screws Canister O ring Bracket Canister Bushing EKA KKM EAA EEE EMEA ELLA Button Head Screws Canister and Casing Drain Holes FIGURE 11 PUMP INNER MAGNET AND CANISTER ASSEMBLY SECTION TSM 685 1 ISSUE E PAGE 8 OF 16 FIGURE 14 MOTOR OR BEARING CARRIER AND BRACKET DISASSEMBLY ASSEMBLY OF BEARING CARRIER HOUSING DISASSEMBLY The bearing carrier housing features two sealed ball bearings along with an outer magnet assembly If further disassembly of this unit is required proceed as follows 1 Remove the internal retaining ring
17. lacing shims PROCEDURE A After rotor has been installed and locknut has been positioned and retained insert a feeler gage of the proper end clearance into the port and between two rotor teeth See Figure 24 For convenience remove head O ring and install one 0 007 shim onto the head With idler on idler pin place the head into the pump casing With the capscrews tight the feeler gage should fit snugly otherwise shims should be added or reduced in thickness until the proper clearance is attained PROCEDURE B If the pump is in line and ports are not accessible remove the head and shims Put the head back on without shims and measure the gap as shown See Figure 25 After determining the gap between the head and casing select a combination of shims equal to the measured gap plus the desired end clearance See Figure 25 Remove head install shims then install head Tighten the head capscrews and check the pump clearance by making sure the pump turns freely by hand Since the pump shaft is concealed it is best to work up the proper end clearance because it is difficult to determine when there is too much end clearance with this approach FIGURE 25 PRESSURE RELIEF VALVE INSTRUCTIONS DANGER Before opening any Viking pump liquid cham ber pumping chamber reservoir relief valve adjusting cap fitting etc Be sure 1 That any pressure in chamber has been completely vented through suction or discharge lines or o
18. le guiding canister into bracket opening Back capscrew off while guiding the pump being careful M10X120 CAPSCREW that end of capscrew is positioned in counterbore hole of casing flange Mount pump with 4 12mm capscrews FINGERS HERE 7 CAUTION Do not place fingers onto front of pump mount ing flange Align canister into bore of bracket and gently slide in When magnets start to en gage the unit will finish engagement on its own ni H very rapidly unless the M10x120mm capscrew is properly used Make sure fingers are not on i A the front of the pump See Figure 23 _ DO NOT PLACE 4 12mm Capscrew AS FINGERS HERE DANGER Be certain that the driving means motor tur bine engine etc has been locked out or made non operational so that it cannot be started while work is being done on pump 5 Be certain that the power supply to the pump is Locked out Finish assembly by securing the pump to the bracket See Figure 23 Check that pump rotates freely FIGURE 23 by spinning the motor fan blades or the bearing carrier PUMP AND BRACKET ASSEMBLY SEQUENCE shaft SECTION TSM 685 1 ISSUE E PAGE 12 OF 16 ADJUSTING END CLEARANCE Use either of the following procedure to properly adjust the end clearance when rep
19. line The pump may be running too slow Is motor the correct speed and wired up correctly The pressure relief valve is set too low stuck open or has a damaged poppet or seat The bypass line around the pump is partially open The pump is worn out or there is too much end clearance Pump takes too much power stalls motor The liquid is more viscous than the unit is sized to handle The system pressure relief valve is set too high The bushings have frozen up or the liquid has set up in the pump SECTION TSM 685 1 ISSUE E PAGE 15 OF 16 TECHNICAL SERVICE MANUAL res e PAGE 16 OF 16 VIKING IIMAG DRIVE SERIES 855 Sizes GS GG HJ HL ISSUE E VIKING PUMP ABER WARRANTY Viking warrants all products manufactured by it to be free from defects in workmanship or material for a period of one 1 year from date of startup provided that in no event shall this warranty extend more than eighteen 18 months from the date of shipment from Viking If during said warranty period any products sold by Viking prove to be defective in workmanship or material under normal use and service and if such products are returned to Viking s factory at Cedar Falls lowa transportation charges prepaid and if the products are found by Viking to be defective in workmanship or material they will be replaced or repaired free of charge FOB Cedar Falls lowa Viking assumes no liability for consequential damages of any kind
20. n ports Clean all other parts thoroughly and examine for wear or damage Check bushings idler pin and thrust washers replace if necessary When making major repairs such as replacing a rotor and shaft it is advisable to also install a new head and idler pin idler and bushing and casing bushings See INSTALLATION OF BUSHINGS page 9 DISASSEMBLY OF COUPLING Series MD2 A4 A9 Coupling 1 Remove piping to the ports and remove the 4 12mm capscrews securing the pump to the bracket See Figure 8 Support the pump with an overhead hoist if possible CAUTION Do not place fingers onto front of pump mount ing flange or face of bracket Using extreme caution pull inner magnet away from outer magnet See Figure 8 If you do not completely pull the pump out it will snap back and could pinch a finger or hand Once the inner magnet is removed from the bracket be careful setting it down as it will attract any steel object 2 The canister will contain some liquid therefore use care while removing from the pump and pull straight off 3 Remove the 2 4mm buttonhead machine screws and the set collar Insert brass bar into rotor teeth through port and remove locknut Slide off inner magnet assembly See Figures 9 amp 10 Do not forget this is a very strong magnet If further pump disassembly is required refer to step 6 of PUMP DISASSEMBLY page 6 4 Do not remove the O ring unless it is bad especially PTFE derivative enca
21. ndling have obtained a material safety data sheet MSDS for the material and understand and follow all precautions appropriate for the safe handling of the material DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is BEFORE operating the pump be sure all drive guards mounted on a pump that is operating are in place AVOID contact with hot areas of the pump and or drive Certain operating conditions temperature control devices jackets heat tracing etc improper installation improper operation and improper maintenance can all cause high temperatures on the pump and or drive DO NOT operate pump if the suction or discharge piping is not connected DO NOT place fingers into the pumping chamber or its connection ports or into any part of the drive train if there is any possibility of the pump shafts being rotated THE PUMP must be provided with pressure protection This may be provided through a relief valve mounted DO NOT exceed the pumps rated pressure speed and directly on the pump an in line pressure relief valve temperature or change the system duty parameters WARNING a torque limiting device or a rupture disk If pump from those the pump was originally supplied without rotation may be reversed during operation pressure WARNING confirming its suitability for the new service protection must be provided on both sides of pump Relief valve adjusting s
22. only and cannot be used for ordering parts Obtain a parts list from the factory or a Viking representative Always give the complete name of the part part number and material with the model number and serial number of the pump when ordering repair parts The unmounted pump or pump unit model number and serial number can be found on the nameplate secured to the pump This manual deals only with Series 855 magnetic drive pumps Refer to Figures 1 through 34 for general configuration and nomenclature used in this manual Pump specifications and recommendations are listed in Catalog Section 685 In the Viking model number system the basic size letters are combined with the series number 855 indicating basic pump construction material FIGURE 2 HJ HL SERIES 855MB MD2 B M Pump with Motor Directly Mounted to the Bracket IDEX CORPORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA SAFETY INFORMATION AND INSTRUCTIONS IMPROPER INSTALLATION OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY OR DEATH AND OR RESULT IN DAMAGE TO PUMP AND OR OTHER EQUIPMENT VIKING S WARRANTY DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION OPERATION OR MAINTENANCE THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION OPERATION OR MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP PUMP MUST BE INSTALLED OPERATED AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS THE FOLLOWING SAFETY INSTRU
23. point the problem Pump does not pump Pump has lost its prime from air leak or low level in tank Suction lift is too high Pump is rotating in the wrong direction The strainer may be clogged The bypass valve is open the pressure relief valve is set too low or the pressure relief valve poppet is stuck open Improper end clearance The pump is worn out Are there any changes in liquid system or operation that would influence pump or coupling performance e g new liquid additional lines or process changes Temperature changes either in the liquid or the environment The magnetic coupling is decoupling Changes in application temperature pressure viscosity etc may require torque beyond coupling capabilities Pump starts then loses its prime The supply tank is empty Liquid is vaporizing in the suction line An air leak or air pocket in the suction line Pump is noisy The pump is being starved heavy liquid cannot get to pump fast enough Increase the suction pipe size reduce its length or slow down the pump The pump is cavitating liquid vaporizing in suction line Increase suction pipe size or reduce its length Check alignment The magnetic coupling has decoupled Shut off and restart Pump is not delivering up to capacity The pump is starving or cavitating increase suction pipe size or reduce length or reduce pump speed The strainer is partially clogged An air leak somewhere in suction
24. psulated If a new O ring is required follow instructions in the ASSEMBLY section on page 9 5 You should be able to visually inspect the outer magnets from the end of the bracket If removal is necessary start by removing the 4 capscrews See Figure 8 Separate the bracket from the motor or bearing carrier Loosen the setscrew on the outer shell hub Pull the outer magnet assembly off the shaft If the unit features a bearing carrier the bearings should not require maintenance since they are sealed For additional information on bearing carrier repair Refer to ASSEMBLY DISASSEMBLY OF BEARING 4 12mm capscrews secure the pump 4 Capscrews secure motor to bracket DO NOT PLACE FINGERS HERE FIGURE 8 PUMP AND BRACKET SEPARATION SEQUENCE Canister O ring Canister Bushing e Button Head Screws Canister and Casing Drain Holes FIGURE 9 PUMP INNER MAGNET AND CANISTER ASSEMBLY Buttonhead Inner Magnet Screws Locknut Rotor Shaft FIGURE 10 INNER MAGNET AND LOCKNUT ASSEMBLY SECTION TSM 685 1 ISSUE E PAGE 7 OF 16 Series MD2 B14 MD2 B50 Coupling DO NOT PLACE 4 12mm Screw Sy FINGERS HERE 1 Remove the piping to the ports and remove the capscrews securing the pump to the bracket Support the pump with an overhead hoist if possible Use the M10 x 120 capscrew in the bracket to separate the inner magnet from the outer See Figure 12
25. recautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precaution ary measures may result in serious injury or death ROTATION Viking Mag Drive pumps are designed to run either direction See PUMP ROTATION page 10 PRESSURE RELIEF VALVES 1 Viking pumps are positive displacement pumps and must be provided with some sort of pressure protection This may be a relief valve mounted directly on the pump an inline pressure relief valve a torque limiting device or a rupture disk Do not rely on decoupling of magnets for protection from over pressure this may result in damage to the magnets pump or other equipment Relief valves are mounted as standard on the casing of GS GG HJ and HL size pumps If the pump rotation is to be reversed during operation pressure protection must be provided on both sides of the pump The relief valve adjusting screw cap must always point towards the suction side of the pump See Figure 3 If the pump rotation is reversed remove the pressure relief valve and turn end for end see PUMP ROTATION page 10 first for additional steps required for proper operation Pressure relief valves cannot be used to control pump flow or regulate discharge pressure For additional information on pressure relief valves refer to Technical Service Manual TSMO00 and Engineering
26. tallation Figure 16 shows the proper position of the casing bushing after installation This will require a special fixture for proper position Improper location may result in a pump with excessive slip or requiring a large number of shims The additional precautions listed below must be followed for installation 1 An arbor press must be used for installation 2 Be certain the bushing is started straight 3 Donotstop the pressing operation until the bushing is in the proper position starting and stopping will result in a cracked bushing 4 After installation check the bushing for cracks FIGURE 16 CASING BUSHING POSITIONING ASSEMBLY OF PUMP Use a suitable lubricant compatible with the fluid being handled when reassembling the pump Inspect all parts especially drilled holes in the casing for draining to make sure they are not plugged Replace any worn parts remove any burrs and clean all parts before assembling the pump 1 If the canister O ring needs to be replaced apply a lubricant to the O ring and place it into the O ring groove If the O ring is PTFE derivative encapsulated follow these special instructions SECTION TSM 685 1 ISSUE E PAGE 9 OF 16 Do not attempt to reuse a PTFE derivative encapsulated O ring if it has been removed Immerse a new O ring in boiling water for a few minutes Remove it from the water and stretch out the O ring so it will fit onto the casing hub without forcin
27. the instructions listed for assembling the appropriate size coupling on pages 11 and 12 CHANGING PUMP ROTATION The pump is designed to operate in either direction Process fluid is generally fed to the inner thrust washer and bushing interface and then through a groove in the bushing to the outer thrust washer Then the fluid is pulled into the canister bushing and back through the hollow shaft and idler pin to the suction side of the pump When the pump is operated in the opposite direction the fluid flow is reversed FIGURE 18 ASSEMBLY OF COUPLING Series MD2 A4 A9 Coupling DANGER Follow these directions exactly to avoid injury to self or damage to the pumping unit Be care ful to keep inner and outer magnets at least 1 foot apart until step 5 Do not engage the mag nets in any other fashion MD2 A Magnets A Dimension A Dimension Inch Metric I E C 90 100 112 6 32 160 5 MM 1 Inspect the magnets for any steel objects which may 56C 143TC 45TC 1651 MM be attached Remove any foreign material Locate the outer magnet assembly per dimension See Figure 19 182TC 184TC 170 2 MM Apply Loctite and tighten the 2 setscrews onto the motor or bearing carrier key amp shaft FIGURE 19 Motor 2 Mount the coupling bracket to the motor or bearing carrier and secure with 4 capscrews Figure 20 Carefully reach in and rotate the magnets by hand to 4 Capscrews secure DO NOT PLACE
28. ther appropriate openings or connections 2 That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on pump 3 That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precaution ary measures may result in serious injury or death SECTION TSM 685 1 ISSUE E PAGE 13 OF 16 DISASSEMBLY RELIEF VALVE Mark the valve and head before disassembly to insure proper reassembly 1 Remove the valve cap 2 Measure and record the length of extension of the adjusting screw Refer to A on Figure 26 3 Loosen the locknut and back out the adjusting screw until spring pressure is released 4 Remove the bonnet spring guide spring and poppet from the valve body Clean and inspect all parts for wear or damage and replace as necessary ASSEMBLY RELIEF VALVE Reverse the procedures outlined under DISASSEMBLY RELIEF VALVE If the valve is removed for repairs be sure to replace in the original position The relief valve adjusting screw cap must always point towards the suction side of the pump If the pump rotation is reversed remove the relief valve and turn end for end Refer to Figure 4 page 4 phr ence j i ia Li ULTA W
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