Viking KK825, K-825, KK823, K-827, KK827 User Manual

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Viking KK825, K-825, KK823, K-827, KK827 User Manual

Electronic copies of the most current TSM issue can be found on the Viking Pump website at www.vikingpump.com

TECHNICAL SERVICE MANUAL

magnetic drive pumps series 823 steel 825 cast iron 827 stainless steel sizes k & kk

SECTION

 

TSM 845

 

PAGE

 

1 of 14

ISSUE

 

F

 

 

 

CONTENTS

Introduction

1

Safety Information

2

Special Information

3

Maintenance

3

Disassembly: Pump

4

Disassembly: Coupling

6

Disassembly & Assembly

8

of MD-C Series Bearing Housing

Installation of Bushings

10

Assembly: Coupling

10

Adjusting Head Gasket End Clearance

11

Pump Rotation

11

Pressure Relief Valve

11

Troubleshooting

13

Warranty

14

WARNING !

Persons with surgical implants of a metallic or electronic nature should avoid working on pump – especially the inner magnet assembly.

INTRODUCTION

The illustrations used in this manual are for identification purposes only and should not be used for ordering parts. Secure a parts list from the factory or a Viking® representative. Always give complete name of part, part number or material with model number and serial number of pump when ordering repair parts. The unmounted pump or pump unit model number and serial number can be found on the nameplate.

In the Viking® model number system, the basic size letters are combined with the series (823, 825, 827), indicating basic pump construction material (steel, cast iron, or stainless steel respectively). See Model Number Chart.

Model Number Chart

UNMOUNTED

UNITS

Units are designated by the unmounted pump model numbers K-823 , 825 , 827 followed by a letter(s) indicating

drive style.

B = Bracket Mount

KK823 , 825 , 827 R = Viking Reducer Drive

P = Commercial Speed Reducer

(Example: KK-827-MD-C80R)

TABLE 1

This manual deals only with Series 823, 825 and 827 magnetic drive pumps and couplings. Refer to Figures 1 thru 23 for general configuration and nomenclature used in this manual. Pump specifications and recommendations are listed in Catalog Section 845.

figure 1

K & KK-827 (stainless steel) MD-C80 B Bearing Carrier, Footed Bracket and Mounted Pump with Flanged Ports.

figure 2

K & KK-825 (cast iron) MD-C80 R Unit complete with Motor, “B” Gear Reducer, Bearing Carrier mounted to base with Mounted Pump featuring Tapped Ports.

VIKING PUMP, INC. A Unit of IDEX Corporation Cedar Falls, IA 50613 USA

SAFETY INFORMATION

INCORRECT INSTALLATION, OPERATION OR MAINTENANCE OF EQUIPMENT MAY CAUSE SEVERE PERSONAL INJURY OR DEATH AND/OR EQUIPMENT DAMAGE AND MAY INVALIDATE THE WARRANTY.

This information must be read fully before beginning installation, operation or maintenance and must be kept with the pump. All installation and maintenance must be undertaken by suitably trained or qualified persons only.

 

 

Danger - Failure to follow the listed

 

Warning - Safety instructions which

Symbol

 

 

shall be considered for reasons of safe

 

precautionary measures identified by

WARNING

 

!

operation of the pump or pump unit and/

Legend :

this symbol may result in serious injury

 

or protection of the pump or pump unit

 

 

or death.

 

 

 

 

itself are marked by this symbol.

 

 

 

 

!

!

!

!

!

WARNING

!

!

DO NOT OPERATE PUMP IF:

The front cover is not installed correctly.

Any guards are missing or incorrectly installed.

The suction or discharge piping is not connected.

DO NOT place fingers, etc. 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. Severe injury will occur.

DO NOT exceed the pumps rated pressure, speed, and temperature, or change the system/duty parameters from those for which the pump was originally supplied, without confirming its suitability for the new duty.

INSTALLATION AND OPERATION OF THE PUMP MUST ALWAYS COMPLY WITH HEALTH AND SAFETY REGULATIONS.

Rare earth magnets used in couplings have extremely strong magnetic fields capable of changing performance or damaging items such as: Pacemakers, Metal Implants, Watches, Computers & Disks, and Credit Cards

Completely assembled magnetic couplings will not affect items listed above - only disassembled components.

There are no known harmful effects of these magnetic fields on the human body.

A device must be incorporated into the pump, system, or drive to prevent the pump exceeding its stated duty pressure. It must be suitable for both directions of pump rotation where applicable. Do not allow pump to operate with a closed/blocked discharge unless a pressure relief device is incorporated. If an integral relief valve is incorporated into the pump, do not allow re-circulation through the relief valve for extended periods.

The mounting of the pump or pump unit should be solid and stable. Pump orientation must be considered in relation to drainage requirements. Once mounted, shaft drive elements must be checked for correct alignment. Rotate pump shaft by at least one full revolution to ensure smoothness of operation. Incorrect alignment will produce excessive loadings and will create high temperatures and increased noise emissions. Do not use any drive arrangements which cause sideloading of the drive shaft.

The installation must allow safe routine maintenance and inspection (to check for leakage, monitor pressures, etc) and provide adequate ventilation necessary to prevent overheating.

WARNING

WARNING

WARNING

!

!

!

!

!

!

Before operating the pump, be sure that it and all parts of the system to which it is connected are clean and free from debris and that all valves in the suction and discharge pipelines are fully opened. Ensure that all piping connecting to the pump is fully supported and correctly aligned with its relevant connections. Misalignment and/or excess loads will cause severe pump damage.

Be sure that pump rotation is correct for the desired direction of flow.

DO NOT INSTALL THE PUMP INTO A SYSTEM WHERE IT WILL RUN DRY (I.E. WITHOUT A SUPPLY OF PUMPED MEDIA).

Pressure gauges/sensors are recommended, next to the pump suction and discharge connections to monitor pressures.

Caution must be taken when lifting the pump. Suitable lifting devices should be used as appropriate. Lifting eyes installed on the pump must only be used to lift the pump, not pump with drive and/or baseplate. If pump is baseplate mounted, the base plate must be used for all lifting purposes. If slings are used for lifting, they must be safely and securely attached. For weights of bare shaft pumps refer to catalog.

DO NOT attempt any maintenance or disassembly of the pump or pump unit without first ensuring that :

The pump is fully isolated from the power source (electric, hydraulic, pneumatic).

The pumping chamber, relief valve and any shaft seal support system are depressurized and purged.

Any temperature control devices (jackets, heattracing, etc) are fully isolated, that they are depressurized and purged, and components are allowed to reach a safe handling temperature.

DO NOT attempt to dismantle a pressure relief valve which has not had the spring pressure relieved or is mounted on a pump that is operating. Serious personal injury or death and/or pump damage may occur.

DO NOT loosen or undo the front cover, any connections to the pump, shaft seal housings, temperature control devices, or other components, until sure that such action will not allow the unsafe escape of any pressurized media.

Pumps and/or drives can produce sound power levels exceeding 85 dB(A) under certain operating conditions. When necessary, personal protection against noise must be taken.

Avoid any contact with hot parts of pumps and/or drives which may cause injury. Certain operating conditions, temperature control devices (jackets, heattracing, etc.), bad installation, or poor maintenance can all promote high temperatures on pumps and/or drives.

SECTION TSM 845

ISSUE F

PAGE 2 OF 14

 

 

 

SPECIAL INFORMATION

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 appropriateopeningsorconnections. (See detailed procedure for venting the pumps, pages 4, 5 and 6).

2.That the driving means (motor, turbine, engine, etc.) has been “locked out” or made otherwise nonoperational so that it cannot be inadvertently started while work is being done on the 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 precautionary measures may result in serious injury or death.

ROTATION: Viking Mag-Drive® pumps are designed to run in the direction indicated on the nameplate only. If rotation must be reversed, see “Pump Rotation” on page 10.

PRESSURE RELIEF VALVES:

1.Relief valves are mounted on the head of K and KK size pumps. Relief Valves are not available on jacketed heads.

2.If a Relief Valve is not furnished on the pump, some means of over protection such as an in-line relief valve should be provided. Do not rely on magnets decoupling for protection from over pressure. This may result in damage to magnets, pump or other equipment.

3.Relief valve adjusting screw cap must always point towards suction side of pump. If pump rotation is reversed, remove pressure relief valve and turn end for end (See “Pump Rotation” on page 10 for additional steps required for proper operation). See Figure 3.

4.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 TSM000 and Engineering Service Bulletin ESB-31.

DISCHARGE

SUCTION

RELIEF VALVE ADJUSTING SCREW CAP

Figure 3

MAINTENANCE

CAUTION !

Rare earth magnets used in these couplings have extremely strong magnetic fields capable of changing the performance or damaging items such as the following:

Pacemakers

Metal Implants Watches Computers & discs Credit Cards

Completely assembled magnetic couplings will not affect items listed above.

Altered performance or damage can occur only when the coupling halves are separated.

There are no known harmful effects of these magnetic fields on the human body.

Series 823, 825 and 827 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.

SECTION TSM 845

ISSUE F

PAGE 3 OF 14

 

 

 

CLEANING PUMP: Keep pump as clean as possible. This will facilitate inspection, adjustment and repair work.

STORAGE: If pump and coupling are to be stored, drain 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. Viking suggests rotating pump shaft by hand one complete revolution every 30 days to circulate the oil. The coupling should be stored in a dry area.

Note: if the liquid to be pumped reacts with oil, use an acceptable alternate.

SUGGESTED REPAIR TOOLS: The following tools are required to properly repair Series 823, 825, and 827 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.

1.Soft face hammer

2.Allen wrenches

3.External Snap ring pliers - 2-810-029-375

4.Internal Snap ring pliers - 2-810-047-999

5.Feeler gauge set

6.Arbor Press

7.Brass Bar

8.Hand Knobs - 2-790-046-999 (2 Required)

9.Standard 5/16” 12 point socket

DISASSEMBLY: PUMP

1.Refer to Figures 4, 5 & 6 for names of parts.

2.Mark head, casing, and bracket before disassembly to insure proper reassembly. The idler pin, which is offset in the pump head, must be positioned toward and an equal distance from port connections to allow for proper flow of liquid through the 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 appropriateopeningsorconnections. (See detailed procedure for venting the pumps, pages 4, 5 and 6).

2.That the driving means (motor, turbine, engine, etc.) has been “locked out” or otherwise made nonoperational so that it cannot be inadvertently started while work is being done on the 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 precautionary measures may result in serious injury or death.

3.Remove the head capscrews.

 

 

 

CANISTER

BALANCE

ROTOR

 

CANISTER

CASING

OUTER MAGNET

O-RINGS

PLATE

 

 

 

BRACKET

 

ASSEMBLY

 

 

 

IDLER PIN

 

 

 

 

BUSHINGS

 

 

 

 

PRESSURE

 

 

 

 

 

 

 

 

 

 

RELIEF

 

 

 

 

 

VALVE

BEARING

CARRIER

ASSEMBLY

 

BRACKET

 

BRACKET

IDLER

HEAD

 

 

 

INNER MAGNET

HEAD

ASSEMBLY

GASKET

figure 4

cutaway view mag-drive pump, model kk-825 md-80 b illustrated

SECTION TSM 845

ISSUE F

PAGE 4 OF 14

 

 

 

4.Remove head from pump. Do not allow idler to fall from 7. Mark the location and orientation of the Balance plate

idler pin. Tilt top of head back when removing to prevent this. Avoid damaging head gasket set, all gaskets are required to maintain end clearance.

5.Remove idler and bushing assembly. If idler bushing needs replacing, see “Installation of Bushings” page 9. If further disassembly is required pump must be separated from coupling. Refer to “Disassembly: Coupling,” on page 6, before proceeding with Step 6.

6.After inner magnet is removed then remove key and external retaining ring from the shaft. Rotor and shaft may now be extracted by tapping on end of the shaft with a soft face hammer (if a soft faced hammer is unavailable a regular hammer may be used with a piece of hardwood).

before removing by pulling out. (The balance plate may not be removable in the 825 series).

The casing should be examined for wear, particularly in the area between ports. All parts should be checked for wear before pump is assembled.

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” on page 9.

Clean all parts thoroughly and examine for wear or damage. Check bushings, idler pin and balance plate; replace if necessary.

ITEM

NAME OF PART

ITEM

NAME OF PART

ITEM

NAME OF PART

 

 

 

 

 

 

1

Bracket Gasket - Primary

10

Casing

19

Head Gasket

2

Bracket Gasket

11

Capscrew for Inner Magnet

20

Idler Pin

3

Orifice

12

Lockwasher

21

Head & Pin

4

Bracket

13

Washer

22

Pipe Plug

5

Capscrews for Casing

14

External Retaining Ring

23

Capscrews for Head

6

Casing Gasket

15

Key

24

Gaskets for Relief Valve

7

Bracket Bushings

16

Rotor & Shaft

25

Relief Valve

8

Balance Plate (Maybe Not in 825)

17

Idler Bushing

26

Capscrews for Relief Valve

9

Pipe Plugs

18

Idler & Bushing

 

 

FIGURE 5

K & KK Mag Drive Pump

SECTION TSM 845

ISSUE F

PAGE 5 OF 14

 

 

 

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