TECHNICAL SERVICE MANUAL
Contents
1. ry ees aCe ZAN LIP SEALS END CAP SNAP RING OR KEEPER RING FIGURE 22 THRUST BEARING ADJUSTMENT 1 Loosen two axial set screws in the outer face of the bearing housing and turn the thrust bearing assembly clockwise until it can no longer be turned by hand Back off counterclockwise until the rotor and shaft can be turned by hand with a slight noticeable drag For standard end clearance back off the thrust bearing assembly the required number of notches or an equivalent length measured on the outside of the bearing housing See the following table Turn Outer End Cap C C W No of Notches or Length on O D Inches 1 Tighten the two axial set screws in the outboard face of the bearing housing with equal force against the bracket Your pump is now set with standard end clearance and locked NOTE Be sure the shaft can rotate freely If not back off additional notches and check again Each additional notch or each on the outside diameter of the bearing housing is equivalent to an extra end clearance of 002 on HL size pumps and 0015 on K KK LQ and LL size pumps Insert the pipe plug drain into the bracket Close the hand valve and fill oil reservoir within 1 of the top with light Refrigeration Oil It is recommended that the oil be drained and the reservoir be refilled after the first 100 hours of operation and then after every 1000 hours NOTE Re open the hand valve b2. YNAMOMOO OH 10 P Vania ay anes Ma A 47 4 sail li HIUUIIUY 1 Apress must be used for installation 2 Be certain bushing is started straight 3 Do not stop pressing operation until bushing is in proper position Starting and stopping will result in a cracked bushing 4 Check bushing for cracks after installation Valve Cap Valve Spring Adjusting Screw Poppet PRESSURE RELIEF VALVE 3 INSTRUCTIONS a Bonnet Bonnet Gasket Valve Body YI OMSOOOEe DANGER 10 Before opening any Viking pump liquid chamber pumping chamber reservoir 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 See detailed procedure for venting the pumps pages 5 and 6 That the driving means motor turbine engine etc has been locked out or made otherwise non operational so that it cannot be inadvertently started while work is being done on the pump Valve Cap Valve Body 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 Adjusting Screw Valve Spring Lock Nut Poppet Spring Guide Pressure Relief Plug Bonnet Cap Gasket Failure to follow above listed precautionary measures may result in
3. serious injury or death SECTION TSM 420 ISSUE F PAGE 12 OF 18 DISASSEMBLY NOTE Mark the valve and head or casing to be sure they are reassembled in the same relative position 1 Remove end cap Make sure the bonnet is not loosened as valve cap is removed 2 Measure and record the length of extension of the adjusting screw Refer to A on Figure 17 and 18 3 Loosen the lock nut and back out adjusting screw until spring pressure is released 4 Remove the bonnet spring guide spring and poppet from valve body Clean and inspect all parts for wear or damage and replace as necessary ASSEMBLY Reverse the procedure outlined under disassembly If valve is removed for repairs be sure to replace in same position CASING OUT RETURN TO TANK OUT FIGURE 19 iN RETURN TO TANK n CASING ie VALVE PORT COVER PLATE FIGURE 20 Figure 19 shows the standard pump rotation clockwise When viewing the shaft end the inlet port is on the right and the outlet on the top If the pump rotation is reversed as shown on figure 20 to give counterclockwise rotation when viewing the shaft end the inlet port is on the top and the outlet port on the right On HL size pumps equipped with Return To Tank pressure valves see figure 17 the cap should point towards the suction side of pump On K LL size pumps equipped with return to tank pressure relief valves see figure 18 the valve must always be
4. EXCLUSIVE WARRANTY AND SHALL BE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ALL WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE AND NON INFRINGEMENT ALL OF WHICH OTHER WARRANTIES ARE EXPRESSLY EXCLUDED See complete warranty at www vikingopump com All rights reserved 3 2014 Viking Pump Inc
5. LP Gas and other vapor high pressure liquids has to be kept in a closed container to keep it from boiling away For a given temperature the pressure built up within the container is equal to the vapor pressure or saturation pressure Conversely for any given pressure there is a temperature at which the liquid and vapor are in equilibrium saturation temperature see table 2 If the pressure in the container is held constant and the vapor is withdrawn the ammonia will vaporize boil As it boils it picks up heat from the area around the container since over 500 Btu s are necessary to change one pound of ammonia from liquid to vapor If the pressure over the ammonia is reduced the boiling temperature will be reduced and the boiling temperature will be lowered SECTION TSM 420 ISSUE F PAGE 16 OF 18 Thus the temperature around the container can be controlled by the pressure maintained in the container Table 2 shows the ammonia vapor pressure for various temperatures The same phenomena takes place to lower the boiling point of water when the pressure is lowered This explains the low boiling point of water on a mountain top The saturation properties of ammonia make it desirable for use as a refrigerant The temperatures necessary for freezing and keeping food products can be quite easily achieved with pressures or vacuums readily developed by available equipment SATURATED VAPOR PRESSURE PSI Absolute Hg Temp B Vac
6. START TO ROTATE A Motor not hooked up or hooked up correctly check wiring B Something has gotten into pump and has jammed remove head and take out rotating parts obstruction C End clearance has been set too close adjust end clearance D Drive equipment jammed remove obstruction 2 PUMP FAILS TO PUMP A Suction line valve not open open valve B Suction strainer is plugged clean strainer C Pump vapor bound vent discharge lines Relief valve bypassing remove obstruction or open valve Weld bead or other foreign material under poppet disassemble valve and remove foreign material Valve setting too low for differential pressure required increase setting or get heavier spring Pump rotating wrong way change direction of motor rotation or change piping No liquid in accumulator check controls Drive equipment broken repair or replace 3 PUMP IS NOISY A Cavitation liquid vaporizing on suction side of pump increase head of liquid on pump reduce line loss in suction piping insulate suction line reduce pump speed Pump is starved due to no liquid in the accumulator adjust floats or time cycle Relief valve chattering increase pressure setting of relief valve Binding check alignment of unit check for pipe Strain Drive equipment worn or damaged replace repair or 4 LOW CAPACITY Motor running at wrong speed check wiring Speed too slow c
7. 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 see 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 420 ISSUE F PAGE 2 OF 18 4 PUMP SPEED The slower the operating speed the longer the service life This is particularly true on refrigeration ammonia pumps where 4 1 the liquid has virtually no lubrication value or film strength to prevent surface to surface contact 4 2 the heat generated by friction can cause the ammonia to vaporize which in turn causes cavitation 5 TESTING All Viking Ammonia pumps are tested prior to shipment but it is good practice to pressure test the pump along with the rest of the system before adding the ammonia Shipping storage and installation all have strange ways of producing detrimental effects on sound equipment 6 SYSTEM CLEANLINESS Ammonia is a good detergent as such it has a t
8. carefully loosen the pipe plug drain 3 in figure 6 towards the bottom of he bracket This pipe plug is found only on the K KK LQ and LL 4925 pumps The small HL 4925 does not have one When working on an HL 4925 that has no line between the bracket and double seal oil reservoir carefully loosen the pipe plug 4 in figure 6 in the suction port of the pump Carefully loosen any unions or tubing fittings in any other lines to the pump that have been blocked off by closing the shutoff valves so that venting from these segments of the system can be accomplished Typical of such lines would be that from the pump mounted return to tank relief valve to the accumulator E in figure 4 or a line from the high pressure side of the system to the double seal oil reservoir line 2 in figure 5 ALWAYS LISTEN FOR THE PSST AT ANY POINT LOOSENED TO PROVIDE VENTING Carefully loosen the fill plug 5 in Figure 5 in the top of the double seal oil reservoir After the ammonia has stopped venting turn the pump shaft 6 in figure 5 over for at least 10 complete revolutions This will make sure that there is no pocket of accumulated ammonia that has not been exposed to a venting point Carefully loosen the plugs 4 in figure 6 and 7 in figure 5 in the suction and discharge ports of the pump If ammonia continues to vent wait until the venting stops When venting from all the loosened connections stops then
9. end cap in the bracket until tight against the bearing see figure 15 For Viking Old Series 924 Heavy Duty Refrigeration Pumps see page 14 for bearing housing disassembly assembly and adjusting instructions Put lockwasher and locknut on shaft Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Tighten locknut to 50 70 ft lbs torque HL or 100 130 ft Ibs torque K LL 21 22 Bend one tang of lockwasher into a slot of the locknut If tang does not line up with a slot tighten locknut until it does Failure to tighten locknut or engage lockwasher tang could result in early bearing failure and cause damage to rest of pump Remove length of hardwood or brass from port opening Adjust the pump end clearance as indicated in THRUST BEARING ADJUSTMENT below Insert the pipe plug drain into the bracket Close the hand valve and fill the reservoir to within 1 inches of the top with light Refrigeration Oil It is recommended that the oil be drained and the reservoir be refilled after the first 200 hours of operation and then after every 1000 hours NOTE Re open the hand valve before the pump is put into operation The double mechanical seal will not function properly if it is exposed to ammonia pressure with this valve closed THRUST BEARING ADJUSTMENT 1 Loosen the square head setscrews over the outer and inner end caps two for the HL size four for t
10. the pump some maintenance people close the inlet shutoff valve before stopping the pump but this is not recommended practice 2 Close the inlet suction side shutoff valve A in figure 4 3 Close the discharge side shutoff valve B in figure 4 A ON PAGE 6 a fe XY PUMP 0 HX li VW T K 2X T FIGURE 4 Schematic of Piping and Valves For a Liquid Ammonia Recirculating Pump in a Refrigeration System SECTION TSM 420 ISSUE F PAGE 5 OF 18 SECTION TSM 420 Close all other shut off valves in lines connected to the pump Typical shut off valves include valve C in line E in figure 4 from the pump mounted return to tank type relief valve to the accumulator or the valve from an in line mounted safety relief valve to the accumulator or the valve in a pressurizing line from the high pressure side of the system to the pump double seal oil reservoir line 2 in figure 5 The segment of line E in figure 4 between the return to tank pressure relief valve and the shutoff valve C should include a pressure relief valve vented to a safe area Allow ice on pump to melt This process can be speeded up by running cold water over the pump Start the venting process as soon as convenient after the ice has been removed from the pump This will allow venting the ammonia at the lower pressures of a cold pump rather than at the high vapor pressures in a room temperature pump For systems with vent purge or bleed valves
11. 0 ISSUE F PAGE 3 OF 18 DANGER Include provision for a pressure relief device in any part of a pump and piping system that can be valved off and thus completely isolated Cold liquid ammonia when isolated will as it warms up to room temperature expand and exert tremendous pressures which may rupture the pump or piping unless relieved See Viking Technical Service Manual TSMOOO for additional general installation information PREVENTATIVE MAINTENANCE Series 4925 pumps are designed for long trouble free life under a wide variety of application conditions with a minimum of maintenance However the following should be considered 1 LUBRICATION 1 1 Periodic external lubrication should be applied slowly with a hand gun at all lubrication fittings A good quality multi purpose polyurea NLGI 2 grease is satisfactory in the majority of cases however applications involving very low temperatures may require other types of lubricants Suggested frequency of lubrication is once every 500 hours of operation Refer to Engineering Service Bulletin ESB 515 Consult the factory if you have specific lubrication questions 1 2 Double Mechanical Seal Reservoir The Series 4925 ammonia pumps are shipped without oil in the reservoir Before letting ammonia into a new or rebuilt pump fill the reservoir with one pint of light Refrigeration Oil that is compatible with the Neoprene seal and has a maximum viscosity of 15 000 SSU at op
12. BEFORE ASSEMBLY FIGURE 14 SPRING Z After replacing the casing on the bracket place the rotor and shaft into the casing NOTE If the casing is removed from the bracket be sure the bracket O ring is in place before placing casing on bracket Place the O ring or head gasket on the head Coat idler pin with light Refrigeration Oil and place idler and bushing on idler pin in head If replacing carbon graphite bushing refer to Installation of Carbon Graphite Bushings page 12 Install head and idler assembly onto the pump Make sure the idler pin which is offset in the pump head is positioned toward and equal distance between port connections to allow for proper flow of liquid through the pump Tighten the head capscrews evenly Place the tapered installation sleeve furnished with replacement seals K LL size on the shaft as shown in figure 14 Clean and oil the D of the inner rotary member place on shaft and slide over the tapered installation sleeve into position against the inner seal seat Push against the rubber tail section of the bellows with a sleeve or smooth piece of pipe having an inside diameter no more than 22 inch larger than the shaft diameter and a wall thickness of at least inch Be sure to install correct end against seal seat see figure 11 page 9 Be sure carbon face does not fall out of the rotary member Slide the spring along the shaft and make sure it seats properly over the inner
13. Electronic copies of the most current TSM issue can be found on the Viking Pump website at www vikingpump com TECHNICAL SERVICE MANUAL HEAVY DUTY REFRIGERATION AMMONIA PUMPS CONTENTS Installation General Comments 1 Pump Installation o 4 66a 2 ee R Gee wee 3 Preventative Maintenance 4 Safe Practices 0 0 0 00000 ae 5 Venting the Pump 55058004 5 Disassembly ou sme Pw REE KER a 7 Assembly eve bps 6 Oe eR ee 10 Thrust Bearing Adjustment 11 Installation of Carbon Graphite Bushings 12 Pressure Relief Valve Instructions 12 Troubleshooting 4 ow amp eo ob de we ew 2 15 Ammonia 0 ee ee a 16 INTRODUCTION The illustrations in this manual are for identification purposes only and cannot be used for ordering parts Obtain a parts list from the factory or a Viking representative Due to the nature of the pump and the close manufacturing tolerances certain replacement parts are only available in assemblies Always give complete name of part part number and mate rial with the model number and serial number of pump when ordering repair parts The pump or pump unit model number and serial number are on the nameplate In the Viking model number system the basic size letters are combined with the series 4925 indicating either an un mounted pump or mounted pump unit UNMOUNTED PUMP amp UNIT MODEL NUMBERS UNMOUNTED
14. PSIG FIGURE 23 Schematic of a Simple Vapor Compression Ammonia Refrigeration System VALVE 2 DX SECTION TSM 420 ISSUE F PAGE 17 OF 18 TECHNICAL SERVICE MANUAL HEAVY DUTY REFRIGERATION AMMONIA PUMPS Figure 24 shows a typical schematic of a Continuously Recirculating System with vertical accumulator Space or other physical requirements may make a_ horizontal accumulator more practical As long as the minimum submergence requirement of 4 of liquid is maintained the arrangement of the accumulator is of little consequence to good pump operation The schematic is intended only to show in a general way piping and connections directly related to the pump No attempt has been made to show all the necessary controls valves regulators gauges etc that are necessary for successful operation of this portion of an ammonia refrigeration system UP LINE FROM HIGH PRESSURE RECEIVER RETURN LINE FROM PUMP MOUNTED RELIEF VALVE VIKING REFRIGERATION THROTTLE VALVE AMMONIA PUMP FIGURE 24 Schematic of Liquid Ammonia Recirculating System Pumps on this system run continuously as long as there is a load on the evaporators The evaporators are flooded with several times the amount of ammonia needed this helps maintain an even temperature in the evaporators The pressure or head differential across the pump is generally very low the only head the pump must develop is that required to over come any elevation head and a
15. UNITS MECH SEAL Units are designated by the HL4925 unmounted pump model numbers followed by a letter s indicating drive style V V Belt R Viking Speed Reducer P Commercial Speed Reducer K4925 KK4925 LQ4925 LL4925 This manual deals exclusively with Series 4925 Heavy Duty Refrigeration Ammonia Pumps Refer to Figures 1 thru 24 for general configuration and nomenclature used in this manual NOTE DO NOT OPERATE SERIES 4925 PUMPS AT SPEEDS HIGHER THAN THOSE STATED IN CATALOG SECTION 420 Series 4925 Heavy Duty Refrigeration Ammonia Pumps NOTE Single reservoir sight glass is standard Images are shown with optional reservoir fittings FLUID amp METERING SECTION TSM 420 PAGE 1 OF 18 SERIES 4925 ISSUE SIZES HL LL Ea ar id f JER S cae Var l FIGURE 1 Series 4925 Unmounted Pump INSTALLATION GENERAL COMMENTS Consideration of the following points during design and installation of the system will help ensure successful operation of the Viking Refrigeration Ammonia Pump 1 SUBMERGENCE Submergence is the head of liquid ammonia above the centerline of the pump suction port A liquid head is necessary to keep the ammonia from flashing as it goes into the pump The minimum liquid head or submergence for good pump operation is 4 feet this is assuming a large short suction line 2 SUCTION LINE A large short suction line is necessary for good operation A good suctio
16. aterial 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 screw 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
17. before the liquid is introduced into the pump This will allow the seat to seal itself properly before the pressure is applied NOTE If your pump has an automatic snap on filler valve arranged similar to that shown in figure 3 it is not necessary to stop the pump to add oil to the reservoir Merely connect lubrication pump to automatic filler valve Open manual valve and fill reservoir with light Refrigeration Oil to approximately 1 2 inch from the top Close manual valve and remove lubrication pump from filler valve To change oil proceed as indicated in steps A thru G except vent pumping chamber to atmosphere before changing oil 2 END CLEARANCE ADJUSTMENT After long term operation it is sometimes possible to improve the performance of a pump without major repair through adjustment of the end clearance of the pump Refer to instruction under Thrust Bearing Adjustment page 11 for information regarding this procedure MANUAL VALVE FIGURE 3 3 CLEANING THE PUMP It is good practice to keep the pump as clean as possible This will facilitate inspection adjustment and repair work and help prevent overlooking a dirt covered grease fitting 4 STORAGE If pump is to be stored or not used for six months or more pump must be drained and a light coat of light oil must be applied to all internal pump parts Lubricate fittings and apply grease to pump shaft extension Viking suggests rotating pump shaft by hand one comple
18. complete the loosening of the fittings and complete the removal of the plugs FIGURE 6 Viking K4925 Refrigeration Ammonia Pump with Internal Pressure Relief Valve 12 When all venting has stopped continue with removing the pump from the system or disassembly of the pump in place DISASSEMBLY DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings orconnections See detailed procedure for venting the pumps pages 5 and 6 That the driving means motor turbine engine etc has been locked out or made otherwise non operational so that it cannot be inadvertently started while work is being done on the pump 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 precautionary measures may result in serious injury or death NOTE BE SURE TO READ PAGES 4 THRU 7 PRIOR TO PUMP DISASSEMBLY 1 Mark head and casing before disassembly to ensure proper reassembly The idler pin which is offset in pump head must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Remove head from p
19. e g D figure 4 go to step 6 for systems without a vent valve go to step 7 A hose should be connected to any vent valve e g D in figure 4 in the blocked off portion of the system The open end of the hose should be placed under water in a tank containing at least 10 times as much water as there is ammonia in the blocked off portion of the system or the end of the hose should be lead to a safe well ventilated area After the hose has been attached and the open end properly located under water then open the vent valve Check the open end of the hose to make sure the ammonia is venting After ammonia has stopped venting continue with step 8 bell fees Melber ja a 9 FIGURE 5 Viking K4925 Refrigeration Ammonia Pump with Return To Tank Pressure Relief Valve If there are no vent valves in the blocked off piping the Viking Model 4925 ammonia pump should be vented by carefully loosening the fitting 1 in figure 5 on the lower end of the tubing that runs from the pump bracket to the double seal oil reservoir THERE SHOULD BE A DISTINCT PSST SOUND WHEN THE AMMONIA VAPOR LIQUID STARTS TO VENT LEAVE THE AREA UNTIL THE VENTING IS COMPLETE ISSUE F PAGE 6 OF 18 10 11 If there is rigid pipe instead of tubing running from the pump bracket to the double seal oil reservoir the pipe union should be loosened carefully until the psst is heard If there is no line from the bracket to the reservoir
20. e to follow the instruction may result in serious injury WARNING 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 handling have obtained a material safety data sheet MSDS for the material and understand and follow all precautions appropriate for the safe handling of the m
21. e will result if care is taken during installation NOTE Never touch mechanical seal faces with anything except clean hands cardboard or clean cloth Minute particles can scratch the seal faces and cause leakage COAT WITH LIGHT OIL BEFORE ASSEMBLY A SEAL HOUSING BORE INNER SEAL SEAT LUAN AND GASKET G4 LIL eee yyy Clean the bracket seal housing bore making sure it is free of dirt and grit FIGURE 12 Coat the outside of the inner seal seat and O ring gasket and also the inside diameter of the seal housing bore with light Refrigeration Oil not grease see figure 12 Press the inner seal seat with O ring gasket into place in the seal housing bore with your fingers or by putting a piece of cardboard over the face of the seal seat and pressing with a block of wood or squared off piece of pipe Remove the cardboard Figure 13 shows how the inner seal seat pin fits into either of the slots in the end of the bracket bushing Be sure the pin engages one of these slots in the bushing when you have finished pushing the seal seat into the seal housing bore Check by looking through the bracket bushing from the casing end FIGURE 13 ISSUE F PAGE 10 OF 18 4 10 11 12 13 Clean and coat the pump shaft with light Refrigeration Oil Check to be sure no scratches have been cut into the shaft in the seal area MECHANICAL SEAL OUTER ROTARY MEMBER tf id TAPERED SLEEVE COAT WITH LIGHT OIL
22. efore the pump is put into operation The double mechanical seal will not function properly if it is exposed to ammonia pressure with the valve closed Return to Installation of Carbon Graphite Bushings page 12 and continue on TROUBLESHOOTING A Viking pump that is properly installed and maintained will give long satisfactory performance If trouble does develop one of the first steps toward finding the difficulty is to install a vacuum gauge in the suction line and a pressure gauge in the discharge line Readings on these gauges often give a clue on where to start looking for trouble DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir etc Be sure 1 Failure to That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings orconnections See detailed procedure for venting the pumps pages 5 and 6 That the driving means motor turbine engine etc has been locked out or made otherwise non operational so that it cannot be inadvertently started while work is being done on the pump 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 follow above listed precautionary measures may result in serious injury or death 1 PUMP WILL NOT
23. endency to remove all the dirt pipe scale weld beads and loose or foreign material in the system Unfortunately not all of this material settles out in traps or can be caught in strainers and as a result a considerable amount goes through the pump The abrasive solids going through the pump will cause excessive wear during the start up of a new system Thus the cleaner a new system is before start up the less wear and trouble with the pump 7 STAND BY EQUIPMENT Stand by equipment is always good insurance when possible breakdown of any single piece of equipment could jeopardize the Operation of the entire system Often on circulating systems two pumps are used with operation of the pumps alternated by day or week Alternating operation of the pumps is not always considered the best practice since both pumps may both wear out at the same time If operation of the pumps is not alternated the stand by pump should be run for several hours at least once a month to make sure it is in good operating condition Sometimes on large systems three pumps are used two running continuously with the third for use as a standby and for peak loads PUMP INSTALLATION One of the most important considerations on any circulation Refrigeration Ammonia pump installation is proper design of the pump inlet line Refrigeration Ammonia when stored in a closed container will exert a pressure within the container equal to its saturated vapor pressure The sat
24. erating temperature Before opening valves and allowing ammonia to fill the pump be sure the hand valve on the reservoir shown in figure 9 is open Change the oil in your double seal pump reservoir after the first 200 hours of operation and then every 1000 hours of operation by the method mentioned below A Stop pump and close hand valve on oil reservoir see figure 9 DANGER Be sure ammonia pressure in pump is not above 5 PSIG when filling reservoir If pressure is higher pumping chamber should be bled down to reduce pressure to 5 PSIG or below Before bleeding pump read SAFE PRACTICES on page 5 and VENTING THE PUMP on pages 5 and 6 Pressure above 5 PSIG in the pump may cause inner seal seat to be unseated or may force the faces of the inner seal apart allowing any dirt accumulated around the inner seat to be forced between the faces which may cause the seal to leak when the pump is started SECTION TSM 420 ISSUE F PAGE 4 OF 18 B Remove 2 inch NPT oil filler plug in top of reservoir carefully and allow the small amount of ammonia trapped in the reservoir to vent C Open oil drain plug and allow old oil to drain D Replace oil drain plug and fill reservoir with light Refrigeration Oil to within 1 inch of the top approximately 1 pint Replace 1 2 inch NPT oil filler plug in top of reservoir T Open hand valve Wait one minute then start the pump and allow it to run from two to three minutes
25. gasket by bending the ends of two lengths of wire and then by inserting the bent end in the slots in the bushing and pulling the seal seat through the housing from the shaft end If removal is difficult an arbor press may be used to push the bracket bushing seal seat and gasket out of the bore from the rotor end Another coating of light oil may be helpful to ease the seal seat out of the housing Another way of removing the inner seal seat is to drive it out while inserting a screwdriver through the bracket bushing from the casing end so it hits the seal seat at the 11 The pump has now been disabled to the point where the notches in the bracket bushing Be careful and do not double mechanical seal may be removed from the seal damage the bracket bushing when removing the inner housing bore of the bracket seal seat in this manner HAND VALVE r OIL FILLER PLUG ERR EY i ADJUSTING SIGHT SCREW CAP GLASS OIL RESERVOIR ADJUSTING CASING Di THRUST OUTER BEARING LOCKNUT LOCK IDLER PIN POPPET WASHER LOCKNUT n pen ee ee SHAFT i ig ISi eaa aa Mm _ ce END CAP SETSCREWS a m 4 DOUBLE MECHANICAL SEAL RETURN TO TANK RELIEF VALVE IDLER BUSHING VALVE COVER PLATE IDLER OIL DRAIN ROTOR PLUGS BRACKET BRACKET BUSHING FIGURE 9 SECTION TSM 420 ISSUE F PAGE 8 OF 18 L B Ml Be E a i 300 VUVIrrery l B 6 FIGURE 10 Exploded View Series 4925 Es EJ E EJ E
26. hange drive or get motor with faster rated speed Too much end clearance adjust end clearance Internal wear replace worn parts Pump too small use a larger pump or two small ones Suction line too small reduce length or increase size Relief valve opening increase pressure setting Bypass line valve open adjust valve 5 RAPID WEAR A B Dirt in the system install suction line strainer temporarily until system is clean Cavitation liquid vaporizing on suction side of pump increase head of liquid on pump reduce line loss in suction piping insulate suction line reduce pump speed Pump misaligned or distorted check alignment of unit check for pipe strain Running too fast change drive or use larger pump that could run slower Pump runs dry part of time check level controls to be sure there is always liquid in the pump 6 RELIEF VALVE DOES NOT FUNCTION A Installed incorrectly return to tank type relief valve should be mounted on the head opening toward the discharge side of pump Internal type relief valve should be mounted so the cap points toward suction port of pump SECTION TSM 420 ISSUE F PAGE 15 OF 18 B Setting too high reduce setting or get lighter spring C Valve poppet binding remove poppet check for burrs or foreign material D Shut off valve in relief valve return line closed open valve would apply only to pumps with return to tank type relief va
27. he K thru LL size pumps Turn the inner end cap clockwise viewed from shaft end until it projects slightly from the bracket exposing approximately three threads Turn the outer end cap clockwise until the rotor is tight against the head and the rotor shaft cannot be turned Make a reference mark on the bracket end opposite a notch on the outer end cap Back off the outer end cap the required number of notches shown in the table see figure 16 Tighten the inner end cap with a spanner wrench Tap the Spanner wrench lightly but DO NOT OVER TIGHTEN as it will only damage the threads Tighten all the square head setscrews that hold the inner and outer end caps to prevent their turning in the bracket The rotor and shaft should turn smoothly for one complete revolution If the rotor and shaft doesn t turn smoothly go back and repeat the Thrust Bearing Adjustment steps 1 thru 7 Turn Outer End Cap C C W ka No of Notches or Length on O D Inches E FIGURE 16 SECTION TSM 420 ISSUE F PAGE 11 OF 18 INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing carbon graphite bushings 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 and adding a chamfer on the bushing and the mating part will help in installation The additional precautions listed below must be followed for proper installation
28. he compressor The ammonia enters as a liquid at the temperature in the receiver it leaves as a vapor gas at the saturation temperature For the system being considered the pressure in the evaporator would have to be maintained at 19 PSIG This is the pressure corresponding to a saturation temperature of 5 F WATER COOLING PIPES CONDENSER 5 86 F 154 PSIG 6 5 F 19 PSIG VIKING REFRIGERATION AMMONIA PUMPS USED IN THIS PORTION a OF SYSTEM TO WITHDRAW LIQUID i AMMONIA FROM THE ACCUMULATOR SEE FIGURES 2 amp 4 RECEIVER 1 7 7 4 e e mer A a 4 ACCUMULATOR 7 COMPRESSOR The compressor pulls the ammonia vapors from the evaporator The pressure or vacuum pulled in the evaporator by the compressor will determine the pressure at which the evaporator works The compressor compresses the ammonia gas to the pressure corresponding to the saturation pressure of the ammonia at the temperature maintained in the condenser The compressed ammonia gas as it leaves the compressor is hot and is in a super heated vapor state The vapor pulled into the compressor is at 5 F the vapor as it leaves is at a temperature of approximately 210 F and a pressure of 154 PSIG The pressure of 154 PSIG is the saturation pressure of the ammonia at the 86 F condenser temperature CONDENSER The condenser cages the super heated ammonia vapors back to liquid ammonia It does this by transferring the hea
29. he rotor and do not allow either end of the shaft to tilt downward NOTE Considerable force may be required to remove the rotor and shaft from the pump Be careful as not to damage seal parts as the rotor and shaft is removed Some of the seal parts may fall off when the rotor and shaft are removed Place them to the side to be put with other mechanical seal parts when they are removed 7 Loosen the four setscrews over the outer and inner end caps Remove both end caps ball bearing and bearing spacer collars See figure 8 GREASE FITTING LOCATION NYLON INSERT SETSCREWS INNER END HAAN FOS HALF ROUND RINGS OUTER END CAP a LOCKWASHER LOCKNUT Ss z ath ty UU we DASS Io WA rl Lar y aK i zP YAAD DNN AAE DUT ated ex Mors G 7 ey pee EA pS n SHAFT l INNER SPACER COLLAR OUTER SPACER COLLAR OUTER LIP SEAL BEARING FIGURE 8 NOTE The inner end cap can be removed through the side opening in the bracket For Viking old series 924 Heavy Duty Refrigeration Ammonia Pumps go to page 14 for bearing housing disassembly instructions SECTION TSM 420 ISSUE F PAGE 7 OF 18 10 The seal seats and rotary members of the seal may be removed from the side opening of the bracket see step 11 for removal of the double mechanical seal Clean all parts thoroughly and examine for wear or damage Check lip seals ball bearing bushi
30. ield to keep dirt and other abrasive particles from entering the bearing When installing new lip seals be sure they are assembled with the lips facing toward the shaft end See figure 22 Return to page 8 step 8 for further disassembly ASSEMBLY 1 SECTION TSM 420 Place the inner bearing spacer collar on the shaft as far as it will go NOTE First replace the snap ring or keeper rings if furnished in your pump See figure 22 Install the bearing housing with inner lip seal into the bracket NOTE If bearing housing has not been disassembled or has been pre assembled skip items 3 and 4 Pack the ball bearing with grease place on the shaft and push or gently drive into place in the housing Turn the bearing housing end cap with lip seal and bearing collar inside into the bearing housing until it is tight against the bearing Lock in place by tightening the radial set screws in the outside diameter of the bearing housing Turn the bearing housing assembly clockwise until pump shaft can no longer be turned by hand The rotor is now forced against the head Install the lockwasher and locknut on the shaft tighten lock nut and bend down tang of the lockwasher into slot of locknut NOTE A piece of brass or wood inserted through the port opening between the rotor teeth will keep the shaft from turning ISSUE F PAGE 14 OF 18 BALL BEARING SPACER BEARING HOUSING SETSCREW SPACER COLLAR OUTER i ee ee ai
31. ing operation of pump 3 Install a pressure gauge in discharge line for actual adjusting operation 4 Turn adjusting screw in to increase pressure and out to decrease pressure 5 With discharge line closed at point beyond pressure gauge gauge will show maximum pressure valve will allow while pump is in operation SECTION TSM 420 ISSUE F PAGE 13 OF 18 The Viking Over Pressure Relief Valve is strictly an over pressure relief valve it is not a pressure regulating valve When ordering parts for relief valve always be sure to give Model and Serial Number of the pump as it appears on the nameplate secured to the pump and the name of the part wanted When ordering springs be sure to give the pressure setting desired VIKING OLD SERIES 924 HEAVY DUTY REFRIGERATION AMMONIA PUMPS THRUST BEARING DISASSEMBLY ASSEMBLY amp ADJUSTMENT DISASSEMBLY 1 Loosen radial set screws in the outer ring of the bearing housing and remove the bearing housing end cap lip seal and bearing spacer collar Use a spanner wrench to remove the end cap Remove the double row ball bearing The bearing should be washed thoroughly and examined If there is any evidence of wear or damage a new bearing should be used Examine the lip seal in the bearing housing and end cap These lip seals are important to the assembly and should be replaced if not in first class condition They are a grease seal for the ball bearing and also act as a sh
32. lves 7 MECHANICAL SEAL LEAK A Normal wear replace seal B Improper installation review installation procedure outlined on pages 10 and 11 C Abrasive material in liquid if abrasive material on ammonia side use traps or strainer to clean system if on oil side change oil more frequently and use clean oil D Pump operating at very low temperature causing oil to become heavy use lighter oil or use immersion heater to heat oil AMMONIA Ammonia Anhydrous Ammonia NH3 Ammonia is a colorless gas or liquid has a pungent odor as a gas is lighter than air is easily liquefied by pressure alone and is very soluble in water or alcohol Ammonia is one of the best known and widely used refrigerants in use today in ice plants food lockers cold storage warehouses and other industrial cooling processes Ammonia has a higher refrigeration effect per unit of liquid volume than any other type of commonly used refrigerant other advantages are low initial cost and low pipe friction losses PHYSICAL PROPERTIES Boiling point atmospheric pressure 28 F Freezing point atmospheric pressure 107 9 F Viscosity at 28 F 0 27 centipose 0 68 42 6 lbs ft 5 7 lbs gal 589 BTU Ib Specific Gravity at 28 F Liquid Density at 28 F Liquid Density at 28 F Latent heat of vaporization at 28 F TABLE 1 Number of Btu s to change one pound liquid ammonia from liquid to gas Ammonia like
33. mounted on the valve port nearest the pump discharge port see figure 21 Valve port nearest the pump inlet port must be covered with the valve cover plate PRESSURE ADJUSTMENT lf the pressure setting of the valve is to be changed from that which the factory has set the following instructions should be carefully followed DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings orconnections See detailed procedure for venting the pumps pages 5 and 6 That the driving means motor turbine engine etc has been locked out or made otherwise non operational so that it cannot be inadvertently started while work is being done on the pump 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 precautionary measures may result in serious injury or death RETURN LINE TO TANK CONNECTS HERE VALVE PORT COVER PLATE FIGURE 21 Carefully remove valve cap which covers the adjusting screw Make sure the bonnet is not loosened as valve cap is removed 2 Loosen the locknut which locks the adjusting screw so pressure setting will not change dur
34. n Ea Pipe Plug Check Valve 2 Req d Reservoir with Sight Glass amp Plug Head Idler Pin Capscrew for Head 6 Req d Braciet Bushing as Capscrew for Bracket 8 Req d 39 Capscrew for Valve amp Cover Plate 8 Req d 42 Nutfor Seal Holder Plate 2 Req d Pipe Plug 4 Reqd 40 Return To Tank Relief Valve amp Cover Plate S Bracket and Bushing 37 Pipe Plug O Ring Valve Gasket 2 Req d 18 19 20 2n Ring Half Round 2 Req d 22 Nipple 23 2A 25 26 EJ Capscrew for Seal Holder Plate 2 Req d O Ring Gasket Bracket Cover Plate Relief Valve SEAL HOUSING BORE SPRING INNER ROTARY MEMBER OUTER ROTARY MEMBER SEAL SEAT PIN OUTER SEAL SEAT amp GASKET NNN SEAL SEAT PIN SEAL CAP e Uia St WX ROTOR amp SHAFT BRACKET BUSHING INNER SEAL SEAT amp GASKET FIGURE 11 SECTION TSM 420 ISSUE F PAGE 9 OF 18 ASSEMBLY 1 SECTION TSM 420 Installing a new seal The seal is simple to install and good performance will result if care is taken in installation see figure 11 page 9 for parts identification Seals made by different manufacturers are used in these pumps and are used interchangeably though they may look different and have a different spring After all parts have been examined and cleaned or replaced as necessary the first step in reassembling the pump is installation of the inner seal seat Good performanc
35. n line 2 1 is a suction line that is at least one size larger than the pump suction port connection 2 2 is connected to the pump by an eccentric reducer with the offset or eccentric portion down when suction to the pump is horizontal 2 3 is as short as practical for the installation 2 4 has no strainer sometimes a temporary strainer is used during start up to keep weld beads etc from going through the pump 2 5 uses a long sweep elbow if any elbow is unnecessary 2 6 has a full flow shut off valve 2 7 and is fully insulated to prevent heat pickup 3 INSULATION Insulation on the suction line and on the pump helps reduce the amount of heat pickup by the liquid ammonia 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 INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES a Warning In addition to possible serious Symbol Deen EEE OO E ea injury or death failur
36. ngs and mechanical seal and replace as necessary Check all other parts for nicks burrs excessive wear and replace if necessary NOTE Be sure that the shaft is free from burrs and foreign particles that might damage the bracket bushing Scratches on the shaft in the seal area will provide leakage paths under the mechanical seal Check casing for wear or damage while mounted to the bracket DOUBLE MECHANICAL SEAL See figure 11 The mechanical seal consists of five basic parts They are inner and outer seal seats with O ring gaskets inner and outer rotary members and spring When pump is running the seal cap and inner and outer seal seats with O ring gaskets remain stationary in the bracket seal housing bore the inner and outer rotary members turn with the shaft 12 13 14 15 NOTE Pay particular attention to the location arrangement and construction of the seal parts as it will help considerably when the pump is reassembled Remove the seal cap if it was not removed in step 6 A light tap may be necessary to loosen it The O ring gaskets of the seal seats may have become slightly sealed against the side of the housing and require extra effort If this happens apply light oil in the seal housing bore in front of the seats so they will slide freely After removing the outer seal seat the outer rotary member the spring and the inner rotary member can be removed Remove the inner seal seat and
37. ntense irritation to the surface tissue of the eyes nose throat and lungs Exposure to high concentrations of ammonia may blind burn strangle or kill SAFE PRACTICES Basic safety practices and equipment should always be used when working with ammonia Only personnel familiar with ammonia systems should work on these pumps A listing of safe practices and equipment are available from many sources including those listed below A copy of such a listing and safe practices and equipment should be made available to everyone working where ammonia is used Safety Department The Safety Department of any company using ammonia should have information about the basic safety practices and equipment to use when working with ammonia The supplier of the ammonia should always have the same information ANSI American National Standard Institute Inc 1430 Broadway New York New York 10018 Bulletin ANSI K61 1 CGA The Compressed Gas Association Inc 500 Fifth Avenue New York New York 10036 Pamphlet G 2 on Anhydrous Ammonia IIAR International Institute of Ammonia Refrigeration 1 Illinois Centre 111 East Wacker Drive Chicago Illinois 60601 The above references give specifics on safety practices and equipment In addition to those some general precautions include WORK CAREFULLY DO NOT HURRY LOOK AT ANY PRESSURE GAUGES TO DETERMINE CONDITIONS IN THE SYSTEM HAVE PLENTY OF WATER AVAILABLE VENTING THE PUMP 1 Stop
38. ny line losses FLUID amp METERING VIKING PUMP INC A Unit of IDEX Corporation Cedar Falls IA 50613 USA SECTION TSM 420 PAGE 18 OF 18 SERIES 4925 ISSUE F SIZES HL LL VIKING PUMP FLUID amp METERING 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 The warranty period for Universal Seal series pumps ONLY Universal Seal models listed below is three 3 years from date of startup provided that in no event shall this warranty extend more than forty two 42 months from the date of shipment from Viking UNDER NO CIRCUMSTANCES SHALL VIKING BE LIABLE UNDER THIS WARRANTY OR OTHERWISE FOR SPECIAL INCIDENTAL INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST OR UNREALIZED SALES REVENUES PROFITS INCOME COST SAVINGS OR BUSINESS LOST OR UNREALIZED CONTRACTS LOSS OF GOODWILL DAMAGE TO REPUTATION LOSS OF PROPERTY LOSS OF INFORMATION OR DATA LOSS OF PRODUCTION DOWNTIME OR INCREASED COSTS IN CONNECTION WITH ANY PRODUCT EVEN IF VIKING HAS BEEN ADVISED OR PLACED ON NOTICE OF THE POSSIBILITY OF SUCH DAMAGES AND NOTWITHSTANDING THE FAILURE OF ANY ESSENTIAL PURPOSE OF ANY PRODUCT THIS WARRANTY IS AND SHALL BE VIKING S SOLE AND
39. onia will start to boil or vaporize and the pump will be required to take in a mixture of liquid and vapor Since a given weight of vapor takes up a much greater volume than the same weight of liquid handling both liquid and vapor will reduce the liquid output from the pump The vapor is compressed back to a liquid on the discharge side of the pump causing it to be noisy and to wear rapidly Values for pipe friction losses for calculating suction line pressure drop can be found in refrigeration hand books Since Viking pumps are of the positive displacement type be sure that there is no obstruction in the discharge line and that all valves are in operating position before starting the pump Factory assembled port orientation will have right hand port suction and top port discharge unless otherwise specified Port location is determined by looking at shaft end of pump The pressure relief valve on the pump provides over pressure protection Return to Tank pressure relief valves should be mounted on the discharge side of the pump Internal type pressure relief valves should be mounted with the cap pointing towards the suction side of pump Also see information under Relief Valve Instructions page 12 The Viking pump mounted return to tank pressure relief valve see Figure 18 page 12 amp Figures 19 20 and 21 page 13 is fitted with a pressure relief plug to keep a valid off return line from building up excessive pressures SECTION TSM 42
40. operating with a condenser temperature of 86 F and an evaporator temperature of 5 F 1 RECEIVER A storage tank for ammonia at ambient temperatures The receiver receives the liquid ammonia as it comes from the condenser The pressure in the receiver will correspond to the vapor pressure of the ammonia at the temperature of the cooling medium used in the condenser In this case with an 86 F condenser temperature the ammonia pressure would be 154 PSI the saturation pressure corresponding to a temperature of 86 F EXPANSION VALVE A throttling valve that controls the amount of liquid that flows into the evaporator It can be controlled manually or by thermostats located in the evaporator The temperature and pressure of the liquid on the inlet side of the expansion valve is the same as that in the receiver 86 F and 154 PSIG the pressure on the outlet side of the expansion valve is that maintained in the evaporator by the compressor the compressor would have to pull down and hold the pressure in the evaporator at 19 PSIG to maintain the evaporator temperature at 5 F this is the saturation temperature corresponding to 19 PSIG EVAPORATOR The evaporator is the main purpose for the existence of the refrigeration system It is through the evaporator that heat is picked up by the ammonia The temperature in the evaporator area will be pulled down to the saturation temperature of ammonia at the pressure maintained by t
41. rotary member It may be helpful to stand pump on end to facilitate centering the spring Coat the outer seal seat and O ring gasket with light Refrigeration Oil Spread a thin film of grease on the seal cap Place the outer seal seat in position on the seal cap Make sure the pin in the seal seat engages the hole in the seal cap The film of grease will hold these two parts together set them aside temporarily Coat the inside diameter of the outer rotary member with light Refrigeration Oil Place it on the shaft and slide over the tapered installation sleeve until it engages the spring Be sure to install the correct end towards the spring see figure 11 page 9 Quickly install the outer seal seat and cap prepared in step 11 over the shaft and press down against the outer rotary member until the seal cap hits the end of the bracket This compresses the spring and positions the outer rotary member Do not release the seal cap 14 Still holding the seal cap against the end of the bracket 15 16 INNER SPACER INNER LIP SEAL 17 18 19 20 HALF ROUND place half moon shaped seal holder plate in position and tighten the two locknuts uniformly This holds the seal cap in position and ensures proper positioning of seal NOTE Do not permit either the inner or outer rotary member to remain on the shaft in any position other than their final position for more than 30 seconds since the rubber bellows of the rotary membe
42. rs have a tendency to stick to the shaft If the bellows are not in correct position the rotary member will be improperly seated Remove tapered sleeve Place the inner bearing spacer collar on the shaft as far as it will go NOTE First replace the snap ring HL size or half round rings K LL size see figure 15 GREASE FITTING LOCATION NYLON INSERT SETSCREWS INNER O E END CAP 7 SR rite NENT ANN C D Bi TR AN Ko OUTER END CAP D LOCKWASHER RINGS LOCKNUT AS D SSS OUTER SPACER COLLAR OUTER LIP SEAL COLLAR BEARING FIGURE 15 Press the lip seal lip toward end of shaft into the inner end cap and insert the end cap through the shaft end of bracket With two fingers turn it clockwise looking at end of shaft until it engages the threads The spanner holes in the inner end cap must be toward the rotor Turn the end cap with a spanner wrench until it projects slightly into the opening on the side of the bracket NOTE The end cap must not be turned so far that the lio of the seal drops off the end of the spacer collar on the shaft or the end cap becomes disengaged with the threads see figure 15 Pack the ball bearing with multi purpose polyurea NLGI 2 grease and place on the shaft and push or gently drive into place in the bracket Install the lip seal lip toward end of shaft and bearing spacer in the outer end cap and turn the
43. t from the ammonia to a cooling liquid such as water flowing through the condenser tubes The pressure that the compressor must develop is determined by the saturation pressure of the ammonia at the temperature maintained in the condenser The temperature maintained in the condenser by the cooling medium is 86 F the saturation pressure at the condenser temperature is 154 PSIG which is the pressure that must be maintained in the condenser to change the ammonia vapor back to liquid The liquid ammonia coming from the condenser is stored in the receiver From here it is ready to start the cycle over again ACCUMULATOR The accumulator or low pressure receiver is not one of the essential pieces of equipment in the simple system but in practice it serves a very important function For the proper operation of the compressor it is important that no liquid ammonia can be carried over from the evaporator The accumulator serves as a trap to keep liquid ammonia from being entered with the ammonia vapors that are pulled from the evaporator by the compressor The temperature and pressures are the same as they are in the evaporator As the liquid is collected or accumulated in the accumulator it must be removed THE REMOVAL OF THE LIQUID AMMONIA FROM THE ACCUMULATOR IS WHERE THE VIKING REFRIGERATION AMMONIA PUMP IS USED 210 F 154 PSIG lt i COMPRESSOR 4 EVAPORATOR 3 5 F 19 PSIG REFRIGERATOR EXPANSION 86 F 154
44. te revolution every 30 days to circulate the oil Tighten all pump assembly bolts before putting pump in service after being stored MAINTENANCE IMPORTANT READ THE FOLLOWING BEFORE REMOVING A PUMP FROM AN AMMONIA SYSTEM OR BEFORE STARTING REPAIR WORK ON A PUMP DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir 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 See detailed procedure for venting the pumps pages 5 and 6 That the driving turbine engine means motor etc has been locked out or otherwise made non operational so that it cannot be inadvertently started while work is being done on the pump 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 listed result in above may Failure to follow precautionary measures serious injury or death AMMONIA Anhydrous Ammonia NH3 Ammonia is a colorless gas or liquid has a pungent odor as a gas is lighter than air is easily liquefied by pressure alone and is very soluble in water It boils at 28 F vapor pressure is 16 PSIG at 0 F 45 PSIG at 30 F 93 PSIG at 60 F and 138 PSIG at 80 F DANGER Exposure to ammonia causes i
45. ump Do not allow idler to fall from idler pin Tilt top of head back when removing to prevent this Avoid damaging head gasket If pump is furnished with pressure relief valve it need not be removed from head or disassembled at this point Refer to Pressure Relief Valve Instructions page 12 Remove idler and bushing assembly from the idler pin Bend up the tang on the lockwasher and use a spanner wrench to remove the lockwasher and locknult NOTE A piece of brass or wood inserted through the port opening and between the rotor teeth will keep the shaft from turning SEAL CAP _S lt SEAL HOLDER PLATE SHAFT LOCKNUT amp CAPSCREW m FIGURE 7 4 Loosen the two locknuts and remove the seal holder plate For parts identification see figure 7 5 Drive the shaft forward approximately 2 and remove the pair of half round rings K LL size under the inner bearing spacer collar or a snap ring HL size at the end of the inner bearing spacer collar see figure 8 NOTE The snap ring HL size or half round rings K LL size must be removed before the rotor and shaft can be removed from the pump These rings will not pass through the mechanical seal and bracket bushing 6 Carefully remove the rotor and shaft As the shaft is being removed decreasing shaft diameters tend to allow the shaft to drop onto the bracket bushing To avoid damaging the bracket bushing support t
46. urated vapor pressure of a liquid may be defined as the pressure at which both liquid and vapor exist in equilibrium in the same container The vapor pressure has a different value for each temperature The saturated vapor pressure of water at 212 F waters boiling point is 14 7 PSIA In other words when handling Refrigeration Ammonia we are handling a liquid which is at its boiling point A slight reduction in the pressure being exerted on the liquid will cause boiling and thus vapor formation With this information in mind let us examine figure 2 which illustrates one of the most important considerations when installing a pump to handle Refrigeration Ammonia The pressure P1 in the accumulator is equal to the saturated vapor pressure of the ammonia When the pump is not running the pressure P2 at the pump inlet is equal to the tank pressure P1 plus the static head H P2 P1 H X P3 L PUMP L X FIGURE 2 As soon as the pump is started and the liquid begins to flow the pressure at the pump P2 will drop by an amount equal to the pressure loss in the piping between the accumulator and the pump When liquid is flowing P2 P1 H pressure loss in the piping In order to have an installation in which the pump handles all liquid and no vapor the pressure drop in the piping must be equal to or less than the static head H on the pump inlet If the piping loss is greater than the static head the liquid amm
47. uum 100 27 4 180 24 3 PSI Gage AMMONIA VAPOR PRESSURE TABLE 2 Grades of Ammonia Available commercial grade 99 5 refrigeration grade 99 95 Explosive Limit in Air by Volume 15 to 28 Corrosion Ammonia will not attack iron or steel even in the presence of moisture it will attack copper brass bronze and zinc in the presence of moisture Toxicity Concentrations of ammonia in air as low as 53 parts per million can be detected by the sharp penetrating odor Exposure to ammonia causes intense irritation to the surface tissues of the eyes nose throat and lungs Exposure to high concentration of ammonia may blind burn strangle or kill The effect of ammonia on the skin is that of a caustic burn varying in severity with the concentration of ammonia and the length of time exposed Changes in respiratory and heart action produced are reflex actions resulting from the irritation of the respiratory tract For information on the safe handling of ammonia see SAFE PRACTICES page 5 Figure 23 is a schematic of a simple Vapor Ammonia Refrigeration System with the major pieces of equipment named and numbered Each piece of equipment is described briefly and its function in the system discussed in the following paragraphs To illustrate temperatures and pressures that would exist in a actual illustration there is given with the discussion of each piece of equipment the actual temperature and pressure for a system
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