Operating Manual
V-Series
Internal Gear Pumps with Magnetic Coupling
Page2
Declaration of Conformity
in accordance with Directive 94/9/EC (ATEX) on equipment and
protective systems intended for use in potentially explosive atmospheres
Certificate
Manufacturer:
declares that
when ordered as ATEX pump or ATEX pump unit, the following pumps
are in conformity with Directive 94/9/EC of 23 March 1994:
within the meaning of Machinery Directive 98/37/EC, Annex II A
and ATEX Equipment Directive 94/9/EC, Annex X B.
We hereby declare that the pump unit of the V Series described on page 1 under "Technical Data"
delivered by us is in conformity with the following directives and standards:
EC Machinery Directive 98/37/EC, Annex I No. 1
ATEX Equipment Directive 94/9/EC, Annex II.
Applied harmonized European standards, in particular:
EN1127-1:1997 Explosive atmospheres – Explosion Protection, Part 1: Basic concepts and
methodology
EN13463-1:2001 Non-electrical equipment for potentially explosive atmospheres –
Part 1: Basic method and requirements
prEN13463-5:2002 Non-electrical equipment for potentially explosive atmospheres –
Part 5: Protection by constructional safety (“C“)
prEN13463-6:2002 Non-electrical equipment for potentially explosive atmospheres –
Part 6: Protection by control of ignition source (“b“)
prEN13463-8 Non-electrical equipment for potentially explosive atmospheres –
Part 8: Protection by liquid immersion (”k“)
Applied national technical standards and specifications, in particular:
DIN EN ISO 9906 VDMA 24276
DIN 24250 VDMA 24279
DIN 31001
DIN EN 22858
DIN ISO 5199
DIN EN 12723
Marking: symbol and certificate number are part of the marking.
Special requirements for safe operation are described in the supplementary
operating instructions for pumps in potentially explosive atmospheres.
Page3
Table of Contents:
Page
Declaration of Conformity 2
1
General
5
2 Safety 5
2.1 Marking of instructions/notes in the Operating Manual 6
2.2 Qualification and training of personnel 7
2.3 Risks involved in non-compliance with safety instructions 7
2.4 Safety-conscious work 7
2.5 Safety instructions for the owner/operator 7
2.6 Safety instructions for maintenance, inspection and installation work 8
2.7 Conversion and production of spare parts by customer 8
2.8 Improper modes of operation 8
2.9 Explosion protection 8
2.9.1 Filling the unit 9
2.9.2 Special operating conditions 9
2.9.3 Markings 9
2.9.4 Checking the sense of rotation 10
2.9.5 Mode of operation of the pump 10
2.9.6 T
emperature limits
10
2.9.7 Maintenance 11
2.9.8 Safety and accident prevention standards 11
3 Transport, intermediate storage 12
3.1 T
ranspor
t 12
3.2 Intermediate storage/preservation 13
3.3 Return 13
4 Description of the product and accessories 14
4.1 General description 14
4.1.1 General description of the pump 14
4.1.2 Operating principle of the gear pump 15
4.2 Designation 15
4.2.1 Marking of the pump 15
Page4
4.2.2 Rating plate 16
4.2.3 Marking pursuant to EU Directive on equipment and protective systems
intended for use in potentially explosive atmospheres 16
4.3 Main components 16
4.3.1 Magnetic coupling 16
4.3.2 Bearings 17
4.3.3 Materials 17
4.3.4 Monitoring 17
4.3.5 Permissible forces, torques and moments on the pump branches 18
4.3.6 Expected noise levels 18
4.4 Accessories 18
4.5 Dimensions and weights 18
5 Mounting/Installation 18
5.1 Safety regulations 18
5.2 Installation 19
5.2.1 Checks 19
5.2.2 A
TEX Certification
19
5.3 Checks prior to installation 19
5.4 Foundation 20
5.5 Piping 20
6 In- und Außerbetriebnahme..........................................................................21
7
Ausbau
...........................................................................................................22
8 Risikoanalyse nach EN
13463-1
...................................................................22
9 Disassembly 26
9.1 General 26
9.2 Disassembly of the pump cover 27
9.3 Disassembly of the pump casing 28
9.4 Disassembly of the plug-in unit 29
9.5 Disassembly of the bearing bracket 31
9.6 Adjusting the axial play 32
Annex: Certificate of No Objection
Page5
1 General
This state-of-the-art Varisco pump has been manufactured with greatest care and is subject to
continuous quality control.
The present Operating Manual will familiarize you with the pump, its intended purpose and
fields of application.
This Operating Manual contains important information on the safe, proper and efficient operation of the
pump. Follow these instructions to ensure the pump’s reliable operation and long service life and to avoid
potential risks.
This Operating Manual does not include any site-specific regulations. The owner of the pump is responsible
for complying with such regulations. This also applies to the assembly/installation personnel concerned.
This pump unit must not be operated beyond the operating limits specified in the technical documentation in
terms of pumped medium, delivery rate, speed, density, pressure, temperature and motor power or other
instructions given in the Operating Manual or contract documentation. If you have any questions or
require further information, please do not hesitate to consult the manufacturer.
Pump series/size, major operating data and the series number are indicated on the rating plate. We kindly
request you to supply this information whenever you have questions, for supplementary orders and when
ordering spare parts.
2 Safety
This Operating Manual contains important information to be observed during installation, operation,
supervision and maintenance. Therefore, ensure that the fitter of the pump and the future operator/owner
carefully reads and understands this manual prior to installation and commissioning. Make sure that this
Operating Manual is always available at the place where the pump is used.
Apart from the general safety instructions provided in this Section, all other relevant safety information,
particularly as regards the use of the pump in potentially explosive atmospheres as described in Section
2.9 must also be observed.
Persons who have a pacemaker must not stay in the vicinity of the pump because of
the pump’s strong magnetic field!
Be aware of potential hazards (both during transport and handling) before returning
the unit.
2.1
Sa
f
No
W
a
an
d
Saf
e
Non
Th
eexa
W
Markin
g
f
ety inform
a
G
n-complian
c
rning of el
e
explosion
ty instructi
o
-complianc
following
w
mple, due
arning of a
of instru
c
tion contai
n
eneral haz
a
c
e with the
ctric powe
r
protection:
ns pertaini
e with thes
e
w
arning si
g
to the stro
n
magnetic fi
tions/not
e
ed in this
O
rd symbol
safety info
r
:
Safety
s
ng to mach
notes ma
y
n is used t
o
g magneti
c
eld:
s in the O
perating
M
for areas a
mation pro
v
ymbol acc
o
ines and th
y
cause ha
z
indicate t
h
field:
Page6
perating
M
anual is in
d
ccording to
ided may
c
rding to IE
C
eir function
s
ardous co
n
at persons
anual
icated by
t
ISO 7000
–
ause haza
r
417 - 50
3
are indic
a
ditions for
who have
a
he followin
g
0434
ds to pers
o
6
ted by the
f
the machi
n
cardiac p
a
symbol:
ns.
ollowing s
y
e and its f
u
cemaker a
mbol:
nctions.
re at risk, for
It is
M
a
2.2
Th
e
sui
Th
eopethetheMa
2.3
In
p
2.
4
A
ll
re
g
re
g
2.
5
imperative
ke sure th
e
Qualifi
c
personne
tably qualifi
owner m
u
rators are
owner of t
h
owner mu
s
nual.
Risks i
n
Nei
articular,
n
-
-
-
-
Safety-
c
safety info
r
ulations o
n
ulations of
W
o
Safety
i
I
c
C rPc
to observe
- S
e
- S
y
- R
a
y are kept
ation and
l entrusted
w
ed for the j
o
st clearly
d
not sufficie
e machin
e
t ensure t
h
volved in
on-compli
nvironme
n
n the loss
o
on-compli
a
Fail
u
Fail
u
Ris
k
expl
Env
onscious
mation inc
l
explosio
n
the owner
s
hen the p
u
bserve the
nstructio
n
f hot or col
d
ontact.
ontact pr
o
unning.
ersons wh
o
oupling clo
s
important
i
nse of rota
mbol for li
q
ting plate
clean and
a
training o
f
ith the op
e
b.
efine scop
e
ntly qualifi
e
, the manu
at the per
s
non-com
p
ance with
s
t and the
m
f any and
a
nce of saf
e
re of impo
re of spec
i
s to perso
n
osions,
ironmental
work
uded in thi
s
protecti
o
hall be ob
s
mp unit is
u
sections in
s for the o
w
machine
tection on
m
have a p
a
e to their
b
nformation
/
tion arrow
uid conne
c
re easily l
e
personn
e
ration, ma
i
s of respo
n
d, they are
facturer/su
p
onnel has
r
liance wit
h
afety infor
m
achine. F
u
ll claims f
o
ty informa
t
rtant machi
fic method
s
s caused
b
hazards ca
Operatin
g
n, accide
n
erved.
sed in are
a
this Opera
t
ner/oper
a
parts may
c
oving par
t
cemaker
m
ody becau
Page7
signs dire
c
tions
gible.
l
ntenance,
i
sibility, co
m
to be train
e
plier may
p
ead and fu
safety in
ation may
rthermore,
damages
ion may re
ne/equipm
e
for maint
e
y electric,
m
used by le
a
Manual,
a
t preventi
o
s with pot
e
ing Manua
l
tor
ause pote
n
s (e.g. cou
ust not sta
se of the e
f
tly attache
d
nspection
a
petences
d and inst
r
rovide su
c
lly underst
a
structions
result in ri
s
non-obser
v
.
sult in the
f
nt functio
n
nance and
echanical
ks of haza
r
s well as a
n and in-
ntially expl
marked wi
tial risks,
s
pling) must
y in the vic
i
fects of th
e
to the m
a
nd installa
t
and super
v
ucted appr
o
h training,
i
nds the co
n
ks/hazard
s
ance of sa
f
ollowing h
a
s
repai
r
and chemi
dous subs
t
ll applicabl
e
house lab
o
osive atmo
s
th the Ex s
y
uch parts
m
not be re
m
nity or brin
g
strong ma
g
chine such
ion of the
p
ision of th
e
priately.
O
f necessar
y
ntents of th
to person
s
ety instruc
t
zards/risk
s
cal effects
a
ances.
national
a
ur, indust
pheres, it
i
mbol.
ust be pro
t
oved whe
n
parts of t
h
netic field
.
as
ump must
b
personnel
n request
. Furtherm
is Operatin
g
, the
ions may r
e
:
s well as
nd internat
rial and s
a
s imperativ
ected agai
the syste
m
e magneti
c
e
. If
by
ore,
sult
ional
fety
e to
nst
is
2.
6
Th
eautTheWo
foll
Pu
pr
o
Pri
o
2.
7
2.
8
.
2.
9
I
f eoc TcpIo
N
Safety
i
owner h
a
horized an
d
pump mu
s
rk on the
m
ow the shu
mps or pu
m
tective cov
e
r to restar
t
Conve
r
Ata
T
Improp
O
f
d
Explos
i
I
t
hazardou
s
xposure o
f
bserved.
F
omponent
s
ake meas
u
ountry-spe
c
ublic utiliti
e
f the units
perated a
s
on-compli
nstructio
n
s to ensur
e
duly quali
f
t have am
b
achine sh
o
tdown pro
c
p units tha
t
rs should
b
ing the pu
m
sion and
p
ny modifi
c
he manufa
ccessorie
s
he use of
er modes
o
perationa
ollowing s
e
ata sheet
on protec
t
f the units
a
aken and i
n
media (e.
g
people or
urthermor
e
.
res to prev
e
ific regula
t
s).
are used i
n
intended.
ance may
c
s for main
t
that all
m
ied person
ient temp
e
uld typical
edure des
c
discharge
e reattach
e
p, follow t
h
roduction
ation of or
cturer or wi
authorize
d
other parts
f operati
o
l safety is
o
ctions of t
h
are not ex
c
ion
re used in
structions
. explosiv
e
the enviro
n
, the magn
nt any dan
ions and/o
locations
ause the
p
enance, i
n
aintenanc
e
nel who is
w
rature. It
m
ly be carri
e
ribed in thi
s
media haz
a
d or their
f
e notes lis
t
of spare
p
changes to
thin a scop
by the m
a
may annul
n
nly guaran
e Operati
n
eeded und
potentially
provided i
n
Page8
, toxic, hot
)
ment to an
y
etic field m
i
ger caused
r informati
o
subject to
ump to ex
c
spection
a
, inspectio
n
ell familia
r
ust be dep
r
d out only
w
Operatin
g
rdous to h
e
unction res
ed in the
S
arts by cu
s
the machi
n
e permitte
d
nufacturer
liability for
teed if the
e
g Manual.
M
er any circ
u
explosive
a
Sections
2
leak out, t
h
risk. Rele
ght damag
e
by electrici
t
n issued b
y
explosion
eed the op
e
nd install
a
and insta
l
with the c
o
essurized
a
hen the
m
Manual.
alth must
b
tored imm
e
ection “Sta
tomer
e are only
by the ma
n
should be
u
any resulti
n
quipment
i
ake sure
mstances.
reas, alwa
y
.9.1 to 2.9.
ey must b
e
vant legal
p
data carri
. (For det
a
local ene
r
hazards,
m
rating tem
tion work
lation wor
k
ntents of t
h
nd draine
d
achine sta
n
e deconta
m
diately upo
rt-up and p
allowed aft
e
ufacturer.
sed becau
g consequ
e
s used pro
the operati
n
s follow th
e
6 to guara
n
drained o
f
rovisions
m
ers and el
e
ils, please
gy supply
c
ake sure t
h
peratures
s
will be pe
r
is Operatin
of any pro
d
ds still. It i
inated. Al
n completi
o
lacing out
o
r previous
Original sp
a
se they gu
a
nces.
perly in co
m
g limits s
p
notes on
tee explos
i
f
f to preve
n
ust be
ctronic
consult
ompanies
/
e unit is
pecified.
formed on
g Manual.
uct.
s imperati
v
l safety an
d
n of work.
f service“
(
consultati
o
re parts a
n
rantee saf
e
pliance w
i
ecified in t
h
measures
t
on protecti
o
t
ly by
e to
6.).
n of
d
ty.
th the
e
o be
n.
Page9
2.9.1 Filling the unit
Normally the system of suction and discharge lines and consequently the pump’s interior that is in contact
with the fluid is permanently filled with the pumped medium during pump operation to prevent any potentially
explosive atmosphere and the risk of dry running.
If the operator cannot meet this requirement, we recommend providing appropriate monitoring facilities.
Moreover, ensure that auxiliary, heating and cooling systems are filled properly.
2.9.2 Special operating conditions
In the standard model of the pump, the inner (fluid-filled) space of the magnetic coupling is cooled by a
partial flow that branches off from the main fluid flow. If particular properties of the fluid (sticking, clogging)
lead to a disruption of the cooling flow, the temperature may rise inadmissibly. If such risk exists, make
sure to take suitable monitoring measures (see 4.3.4).
In case of overloading, overheating or non-observance of design data or improper selection of the
magnetic coupling, the internal and external magnet may become desynchronized. Furthermore, thermal
energy generated in the containment shell or on the external magnet may also cause an inadmissible rise
in temperature. If such risk exists, make sure to take suitable monitoring measures (see 4.3.4).
If an environmental hazard arises as a result of damage to the containment shell (rare incident) causing
liquid to leak, make sure to provide leakage detection facilities (see 4.3.4). If necessary, check if there is
any potential interaction between the liquid and the pumped medium.
2.9.3 Markings
Markings and signs on the pump refer only to a specific pump section, i.e., shaft coupling and motor should
be considered separately. A Manufacturer’s Declaration with the appropriate marking is required for the
shaft coupling. The drive is subject to a separate marking on the pump section. Example of marking on
the pump section: II 2 GT3 -T4.
The marking shows the range of theoretically available temperature classes. Admissible temperatures
depending on the relevant pump design are specified in 2.9.6.
Variant 1:
II 2 G Eex c T3 – T4
II 2 G: Surface unit intended for use in an area where an explosive atmosphere in the form of
gases or mists is likely to occur occasionally in normal operation (EN 1127-1 Sec. 6.3)
Eex c: Equipment with protection by constructional safety (prEN 13463-5)
T3 – T4: Temperature classes T3 – T4
Va
II
2
Ee
x
TX
2.
9
If t
cir
c
in
c
2.
9
O
pa c
2.
9
Un
ca
scastemmu
Te
m
th
e
Th
eopetem
riant 2:
G:
S
g
c:
E: Iss
p
.4 Checki
n
here is a ri
umstance
s
ase of con
t
.5 Mode
o
en all gat
e
losed sys
t
.6 Tempe
r
der normal
ing, the m
a
ing is equ
i
perature
c
st have fr
e
Atd
perature
c
oretical lim
maximu
m
rating con
d
perature o
II 2
G
urface uni
ases or m
i
quipment
f the pump
witch off t
h
ite of appli
umped m
e
g the sen
sk of expl
o
by briefly
s
act with ro
t
f operatio
n
valves a
n
em!
ature limi
t
operating
c
gnetic co
u
valent to t
h
lasses sp
e
e contact
w
t any rate
,
emperatur
e
epends o
n
lasses ac
c
it values fo
r
admissibl
e
itions of th
f
40°C.
Eex c Tx
t intended
f
sts is likel
y
with protec
is used in
a
e pump a
u
cation is re
dium shou
se of rotat
sion durin
g
witching o
ating or st
a
of the pu
d shut-off
s
onditions,
pling and
a
e tempera
cified in th
e
ith the en
v
the owner
) is obser
v
the releva
ording to E
N
the pump
e
temperatu
e pump. T
h
Tem
p
Tmax.
a
T
4T3T2
T1
or use in a
n
to occur in
tion by con
s
potentiall
y
tomatically
ached. On
ld be at lea
ion
the install
n the unfill
e
tionary par
t
mp
elements
i
expect the
ntifriction
b
ture of the
Annex a
r
ironment.
of the plan
t
ed. The m
a
nt tempera
t
13463-1
a
d medium.
re of the p
u
e temperat
erature cla
s
cc. to EN 1
3
– 135°C
– 200°C
– 300°C
– 450°C
Page10
area whe
normal op
e
tructional
s
explosive
10°C befo
r
the suction
st 10°C bel
ation phas
e
d pump in
s.
n the pipi
n
highest te
m
earings. T
h
pumped m
e observe
d
must ens
u
ximum ad
m
ure class.
re given i
n
mped med
ures given
i
ses
463-1
e an explo
ration occ
a
afety (prE
N
area, the
a
e the maxi
m
side of the
ow the tem
p
, do not c
order to pr
e
g. The p
u
peratures
e surface
edium. If t
h
. In the ar
e
re that the
issible te
m
the table
ium depen
d
n the table
Temp
e
Pumped
125°
C
190°
C
290°
C
290°
C
sive atmos
p
sionally (
E
13463-5)
ttached te
m
um admi
s
pump the
t
erature sp
e
heck the s
e
vent any
p
mp must
n
to occur at
temperatu
r
e pump is
a of the b
e
specified fl
perature
o
below toge
s on the te
below refe
r
rature
medium
here in th
e
N 1127-1
S
perature
m
sible temp
e
emperatur
e
cified for
s
nse of rot
a
ossible ris
e
ot discha
r
the surfac
e
e occurrin
g
heated, en
aring fram
uid temper
a
f the pump
e
ther with th
e
mperature
c
to a maxi
m
form of
ec. 6.3)
onitor will
rature for
t
of the
hutdown.
tion unde
r
in temper
a
ge agains
t
of the pu
m
on the pu
sure that t
h
e the pum
p
ture (oper
a
d medium
resulting
lass and t
h
um ambie
n
he
any
ture
p
mp
e
ting
e
t
S
2.9.
7
F
c
2
C
afety info
r
The rel
e
is oper
a
pump”,
A
ssumi
n
ensure
t
occur i
n
pumpe
d
(e.g., d
u
Mainten
a
or safe an
d
ondition. T
h
The act
u
conditi
o
caused
Regula
r
auxiliar
y
proper
f
.9.8 Saf
e
Wear a
p
A
void
l
get ca
u
meets
hearin
g
Do no
t
not co
m
coupli
n
parts.
D
AUTION!
S
t
mation:
vant admi
s
ted at a hi
g
contact the
g an ambi
e
hat tempe
r
the event
o
medium.
O
e to evap
o
nce
reliable
o
is also ap
p
al service
ns on site.
by overhe
a
ly monitor
v
systems
a
unctioning.
ty and ac
c
propriate
c
oose garm
e
ght in mo
v
safety reg
u
protector
s
perform a
n
e close w
i
gs, etc.) D
o not ste
p
witch the
he plant.
sible oper
a
her tempe
r
manufactu
nt temper
a
ature clas
s
f an insuff
i
perating t
h
ration in th
e
peration,
m
lies to the
f
life of the
a
Regular ch
e
ted bearin
g
ibration b
e
re installe
d
ident prev
e
lothing wh
e
nts with lo
o
ing compo
n
lations: glo
v
and helm
e
y mainten
a
th your ha
n
o not com
e
on the mo
t
motor off
ting tempe
ature and
n
rer for the
m
ture of 40
°
T4 is main
ciently fille
d
e pump o
u
interior).
ake sure
t
unction of
t
ntifriction
b
cks of the
s, start-up
haviour to
e
, check to
s
ntion sta
n
n working
se parts (t
ents. Wea
r
es, insula
t
t (see figu
r
nce work
w
ds to any
m
close with
or pump t
o
in case of
Page11
rature of th
e
o data sh
e
aximum
a
C, grease l
tained for t
h
interior, b
tside the a
d
he unit is
p
he antifricti
o
earings de
p
running no
of the exte
r
nsure the
ee whethe
dards
in the vicini
ies, scarve
s
protective
ing footwe
a
e on the ri
g
ith the mot
oving part
s
your hand
s
perform in
emergenc
y
pump is i
n
et is availa
dmissible
o
ubrication
a
e antifricti
o
ut also in t
h
missible r
a
roperly se
r
n bearing
s
ends on t
h
ise prevent
nal rotor o
n
proper fun
c
r monitorin
g
ty of the pu
, etc.) that
clothing th
a
, goggles,
ht).
r running.
(e.g. belt
s
to hot mo
t
terventions
. Inform t
h
dicated in
ble or the
p
perating te
nd proper
n bearing
s
e presenc
e
nge may
a
viced and
.
e mode of
the risk of
the lanter
tioning of t
h
facilities
s
mp.
could
t
Do
,
or
.
e person
n
the data s
h
ump is use
mperature
o
maintenan
c
. Dry-runni
of high ga
lso lead to
kept in pe
r
operation
a
excessive
t
n or defecti
e plain be
a
hould be i
n
el respon
s
eet. If the
p
d as a “po
o
f the pum
p
e and ope
r
ng may no
t
s contents
dry-runnin
g
fect techni
c
nd the spe
c
emperatur
e
ve bearing
rings. If
stalled to
e
ible for
ump
l
.
ation,
only
in the
al
ific
s
seals.
nsure
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