VARISCO V Series, V 6, V 12, V 25-2, V 30-2 Operating Manual

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

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Operating Manual

V-Series

Internal Gear Pumps with Magnetic Coupling

Page2

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.

Page3

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

Page4

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

Page5

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:

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perating

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anual is in

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ccording to

ided may

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rding to IE

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eir function

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ardous co

n

at persons

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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

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cardiac p

a

symbol:

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ollowing s

y

e and its f

u

cemaker a

mbol:

nctions.

re at risk, for

It is

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a

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imperative

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onscious

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the owner

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hen the p

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nstructio

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ontact.

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ersons wh

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ironmental

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uded in thi

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hall be ob

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mp unit is

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tection on

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have a p

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nformation

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uid conne

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personn

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d, they are
facturer/su

p

onnel has

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liance wit

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afety infor

m

achine. F

u

ll claims f

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ty informa

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rtant machi

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b

hazards ca

Operatin

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sed in are

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ner/oper

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parts may

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cemaker

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ody becau

Page7

signs dire

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gible.

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ntenance,

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sibility, co

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safety in

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rthermore,

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ion may re

ne/equipm

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for maint

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a

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a

t preventi

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ing Manua

l

tor

ause pote

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ust not sta

se of the e

f

tly attache

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nspection

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petences

d and inst

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rovide su

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lly underst

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structions

result in ri

s

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v

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sult in the

f

nt functio

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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

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and chemi

dous subs

t

ll applicabl

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house lab

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osive atmo

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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.

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f necessar

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ntents of th

to person

s

ety instruc

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zards/risk

s

cal effects

a

ances.

national

a

ur, indust

pheres, it

i

mbol.

ust be pro

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oved whe

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h

netic field

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as

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b

personnel

n request
. Furtherm

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ions may r

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s well as

nd internat

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a

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ected agai

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xposure o

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F

omponent

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ake meas

u

ountry-spe

c

ublic utiliti

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f the units

perated a

s

on-compli

nstructio

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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

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res to prev

e

ific regula

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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

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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

Page8

, 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

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by electrici

t

n issued b

y

explosion

eed the op

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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

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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

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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

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e unit is

pecified.

formed on

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uct.

s imperati

v

l safety an

d

n of work.

f service“

(

consultati

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re parts a

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rantee saf

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pliance w

i

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6.).

n of

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n.

Page9

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

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riant 2:

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here is a ri

umstance

s

ase of con

t

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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

Page10

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

Page11

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

3 3



Dcb

TinpTlif

a

Transp

o

.1 Transp

o

T

o

rtra

It
l

oin

sl

M

w

uring star

t

omponent

s

e used.
ransport a

n

order to p
ersonnel.
he lifting lu

f

ting comp

o

re indicate

Always

u

that the

p

p

ump u

n

!

rt, inter

m

rt

he pump u

n

pump unit

nsport su

s

is not per

m

ops of the

m

jury and d

a

inging poin

ake sure t

o

ith the pu

m

-up and m

a

. To this

e

d handling

revent any

gs of the v

a

nents. The

d in bold i

n

M

se two rope

ump canno

t

it is suspen

d

ediate sto

it must be

remains in

pension p

o

itted to att

a

otor. Any

mage to p

r

t for the pu

m

use suita

b

p can be r

e

intenanc

e

nd, suitabl

must be p

e

damage to

rious com

p

suspensio

the figure

ax. lifting

s

s to be secu

r

slip. Make

s

ed in a horiz

o

rage

transporte

d

a horizont

a

ints.

ch the slin

g

slippage o

f

operty. Ple

a

p.

le lifting d

e

moved aft

e

, ensure s

a

e suspens

i

rformed b

y

the pump

a

onents ma

y

n points of
on the rig

h

peed: V/

m

ed in such

a

ure that the

ntal positio

n

Page12

properly

b

l position

d

ing ropes

t

the transp

o

se note th

vices for tr

a

r transport

fe transp

o

on facilitie

s

competen

t

nd injuries

only be u

s

some sup

p

t.

ax < 0.5 m

/

way

p

i

y compete

n

uring tran

s

o the free

s

rt suspen

s

at the ring

b

nsport. Th

.

rt of all

should

personnel

to

ed for
ort frame

s

s

Never lift th

e

oint only. I

n

njury and/or

t personn

e

port so tha

t

haft end o

f

ion points

m

olt on the

b

e transport

pump at o

n

correct liftin

g

damage to

p

l. Make su

r

it will not

s

the pump

ay cause

earing lan

t

locking de

v

e suspensi

o

may result i

n

roperty.

e that the

p

lip out of t

h

or to the ri

n

risk of per

s

t

ern is the

o

ices suppli

n

personal

ump

e

g

onal

nly

ed

3.2

AfonC

N

3

Interme

d

s required,

r a period
eutral dete

r

lean the p

u

ever start

.3 Return

Pumps

before t

A decla

r

be encl

o

precaut

i

iate stora

pumps sh

o

of six mo

n

gent.

mp prior t

o

up the pu

m

that have

d

hey are ret

u

ation of co

n

sed with t

h

ons and d

e

ge/preser

v

uld be tes

t

ths from t

h

installatio

n

p with w

a

elivered c

o

rned to th

e

formity co

n

e returned
contamina

t

ation

ed and set

e time of

d

if the fille

d

ter and d

o

rrosive or

p

manufact

u

firming th

a

pump (see
ion measu

r

Page13

using a liq

elivery. T

h

-in liquid

m

not leave

oisonous

m

rer.

t it is safe t
Anne

x

”Ce

es taken.

id that als

o

is liquid is

ight conta

m

any traces

edia must

use and

a

rtificate of

C

serves to

a mixture

o

inate the

p

of water i

n

be thoroug

h

safety dat

a

onformity“

)

protect th

e

f lube oil

roduct to

b

the pum

p

ly flushed

sheet for

. Please st

a

pump’s in

t

nd passiv

a

e pumped.

.

and cleane

d

the mediu

m

te safety

erior

ting

must

Page14

4 Description of the product and accessories

4.1 General description

4.1.1 General description of the pump

V-Series internal gear pumps are volumetric rotary displacement pumps with internal gears designed to
deliver fluids of any viscosity. The flow of the fluid to be delivered is produced by two gears: The directly
driven rotor designed as a gear and the pinion which, also designed as a gear, engages the rotor in an
off-centre configuration.

Rotor and pinion are isolated from one another by a stationary steady (crescent-shaped partition). For the
pumped fluid to be drawn in (inlet), the teeth of the rotor and the pinion in engagement will come out of
mesh, whereas the teeth moving into mesh will result in discharge of the fluid (outlet).

The pump shaft is supported in the bearing housing in a plain bearing; similarly, the pin of the pinion
(single-ended shaft) is also supported in a plain bearing. The plain bearings are lubricated by the pumped
fluid. The pumps are self-priming. Optionally, the pumps are equipped with a safety relief valve (a pressure
relief valve designed as a bypass). When the valve operates, as a rule fluid will flow from the discharge side
to the suction side of the pump, which - in an extreme case - can entail recirculation (internal circulation)
with overheating.

It is the key property of pumps with magnetic couplings (VTRM Series) that they are driven through a
magnetic coupling. The external magnet core is connected to the motor shaft; it serves to transmit the
torque to the internal magnet core that is mounted to the pump shaft. The magnetic field generated by the
motor-driven magnet hub with the externally placed set of (permanent) magnets causes the internal
magnet core and, thus, the rotor to rotate.

Arranged between the two magnet cores is a containment shell which hermetically seals the pumped fluid
from the atmosphere without any shaft seal fitted. Suitably designed coolant and lubricant grooves are
provided to continuously dissipate heat to which the magnetic coupling is exposed because of eddy current
losses. The coolant flow is returned to the pump's suction side through the gap between the containment
shell and the internal rotor, via the internal rotor's rear side and a centre port in the pump shaft.

Pumps with a drive-end magnetic coupling and a pressure relief valve at the opposite end do not have any
dynamic shaft seals fitted. These pumps are hermetically sealed.

The drive shaft which mounts the magnet hub at its drive end is supported in the bearing flange in two ball
bearings with a shaft seal made of Perbunan fitted to cover the bearings towards the outside. Where it is
desirable to monitor the temperature on the magnetic coupling the pumps can be equipped with a PT 100
temperature sensor that is inserted into the flange of the containment shell from above. Moreover,
provision for PT 100 temperature monitoring is made directly on the pump casingr.

The maximum operating pressure for all pump types is in the range from 8 to 16 bar, depending on pump
type, design and operating conditions.

The ambient temperature range T

A

is: - 40°C… to TA + 60°C.

The maximum allowable operating temperature range (at the same time the
pumped-fluid temperature range) is: - 40°C to + 220°C.

Page15

4.1.2 Operating principle

Arranged in a pump casing a gear pump has two gears that mesh to provide its pumping action through
rotation in opposite senses. The gears are mounted on two shafts which, in turn, are supported in the pump
casing and the pump cover. One of the two gears is driven through a shaft, with the former also driving
the second gear in mesh. As the space between any two teeth opens a pressure below atmospheric is
generated, drawing the fluid into the pump and advancing it between the tooth spaces and the casing wall.
In the area where the teeth re-mesh the fluid is forced from the tooth gaps and into the outlet. Thus, the fluid
can also be delivered against a higher pressure.

The figure above shows the liquid as it advances through the pump; the point where the teeth come out of
mesh governs the phase of the liquid entering between the rotors and is, therefore, physically located
close to the suction zone. The liquid is carried between the teeth and the steady and the discharge opening
developing as the teeth come into mesh eject the liquid.
The permanent-magnet coupling guarantees operation that requires no maintenance, it is without leakage,
and prevents air entrainment, e.g., when product is drawn in from a vacuum.

4.2 Designation

4.2.1 Marking of the pump

SAXMAG V 80-2 G - K +Y

Magnetic coupling

V6,V12,V20,V25-2,
V30-2, V60-2, V80-2
second shaft
extension

G all grey cast iron,
with carbide plain
bearing
K stainless steel with
carbide plain bearing

+R: Pump casing with heating jacket (or cooling jacket). From V50-3 with flange or flange

with groove to DIN 2512 (+RN).
+R 2: Heati ng jac ket on ca sin g c ove r. Specifically used on pumps made of S.S.
+Y: Pressure relief valve (bypass).
+Y

Y

: Double block and bleed valve (bypass).

Page16

4.2.2 Nameplate

The data on the nameplate relates to a final acceptance with oil at 20°C and a vis cosity of 100 cSt.

4.2.3

II 2 G C X

See below
Protection by constructional safety to EN 13463-5
Use in atmospheres with gas/vapour/mist
Category 2
Group II

As the actual maximum surface temperature varies with the temperature of the pumped fluid rather than
the ignition sources, no marking is made to show a temperature class or temperature. The marking
includes the symbol "X" and reference to surface temperatures occurring is made in Section 2.9.6 of this
Operating Manual.

4.3 Main components

4.3.1 Magnetic coupling

The external rotor is driven by an electric motor through antifriction
bearings. It is due to the magnetic forces of the permanent magnets
that the internal rotor is driven in synchronism with the motor
speed. The rotating magnetic field induces in the containment shell
eddy currents attributable to the conductivity of the latter. Hence,
there is a heat build-up in the containment shell. In the hydraulic
section, part of the pumped fluid is branched off through ports in the
rear casing cover, to pass through the inside of the containment
shell and return through a shaft bore, thereby dissipating heat. The
hydrodynamic plain journal bearings are lubricated by the pumped
fluid present in the containment shell.

Page17

4.3.1.1 Internal rotor

The internal rotor is mounted on the pump drive shaft. The magnets are pasted on the rotor outside and
hermetically sealed in to protect them from chemical attack.

4.3.1.2 External rotor

The external rotor with the coupling hub is mounted on the motor shaft. The magnets sit on its inside. The
magnets actually fitted are provided as a function of the torque to be transmitted by the coupling.

4.3.1.3 Magnets

The magnets consist of high-grade samarium cobalt (SmCo). Outstanding features are high magnetic
energy density and low unit volume as well as a high field service temperature limit. Given the magnets'
limited chemical resistance the internal rotor is encapsulated (i.e., hermetically sealed).

4.3.2 Bearings

The drive-end shaft is supported in deep groove ball bearings which, featuring C3 bearing clearance and
high-temperature grease packing, have sealing washers on either side.
The pump-end shaft is supported in hydrodynamic carbide plain bearings which are lubricated by the
pumped fluid.

4.3.3

Pump component

Materials

Pump casing S.S. Grey iron

Shaft Ceramics-coated S.S.

Plain bearings Carbide / Bronze

External magnet Samarium cobalt (Sm2Co17)

Internal magnet Samarium cobalt (Sm2Co17)

Containment shell 1.4571 S.S.

Radial shaft seal Perbunan (temperature-resistant up to 100°C)

Gaskets between containment
shell and bearing housing

Centellen / PTFE

4.3.4 Monitoring

Depending on the unit's operational reliability and availability requirements, it is recommended that
appropriate monitoring equipment be fitted.

On request we can supply equipment for the following functions:

Level monitoring to prevent running dry;
Temperature monitoring on the containment shell to detect overtemperature inside the
containment shell (must be fitted as called for in the ATEX certification);
Pressure monitoring;

Motor monitoring (current consumption).

4.

3

4.

3

Th

e

dis

4.

4

Sh
To

uBas

4.

5

Di

m

5

5.1

Eq
re

g

Pe
ge

n

.5 Permi

s

P

u

V6, V
V20,

V

V60-

2

V80-

2

V100

-

.6 Expe

c

sound pr

e

tance from

Acce

s

aft couplin

g

ch guard:

eplate:

Dime

n

ensions a

n

Moun

t

Safet

y

uipment o

p

ulations. T

h

sons who

h

erated by

t

sible for

c

mp Type

12

25-2, V30

-

2

ted noise

ssure leve

l

the pump,

sories

: Flexi

b

Coupl
Weld

e

desig

n

Wher

e

by th

e

sions and

d weights

ing/Install

regulatio

n

erated in p

o

is require

m

ave a pac

e

he magnet

es, torque

s

Flan

g(DN

1

5

2

4

05080

10

of V-Serie

s

is less tha

n

le coupling
ing guard

d fabricati

o

.
complete

supplier.

weights

can be see

n

ation

s

tentially e

x

ent is clea
maker sh

o

ic coupling.

Tempe

r

s

and mo

m

e

)

0

Varisco p

u

75 dB for

with / with

o

n, for co

m

units are d

e

from the

p

plosive at

m

r from the r

a

uld not be

Persons

w

Page18

ature mo

n

ents on t

h

Fx, Fy, F

z

N

196
520

650
1,040
1,300

mps with

d

all models.

ut adapter

plete (to IS

livered th

e

ump's inst

a

ospheres
ting plate

s

allowed in

t

ithin 2 m o

f

itoring

e pump b

r

Mx,

MNm

9

926335266

rive, as m

e

sleeve

O 3661) u

n

coupling

a

llation dra

w

must comp

l

of the pu

m

he vicinity

o

the pump

w

anches

y

, M

z

0
0
0
0

asured at

t

it (pump a

n

nd the cou

p

ing.

y with rele

v

p and the

m

f the stron

ould be ri

s

he pump h

e

d motor) o

f

ling guard

ant explosi

otor.

g magneti

c

king their li

ight at 1 m

torsionall

y

will be fur

n

on protecti

o

field
ves!

rigid

ished

n

5.

2

5.

2

5.

2

A

ll

co

vasssup

5.

3

M

oaro

fro

n

Instal

l

.1 Chec

k

• Pri

o

• Ch

edocreq

• Da

m

is

rdou

• Ca
ad

vexc

.2 ATEX

additional

c

ered by th

e

embled pu

plied by th

Chec

k

unt the pu

m

und to faci

t of the p

u

• Th

eope

• M

a• A

n

• Th

epos

we

• Th

egua

co

o

lu

bguamo

• M

a

si

mcon

ation

s

r to startin

g

ck to mak

e

umentatio

n

uirements.

age as m

a

equired to

h

bt or if da

m

re must be

ersely affe
eed 40°C.

Certificati

o

omponent

s

ATEX 95

mp unit is r

e

e manufac

t

s prior to

i

p as close

litate main

t

mp to per

m

pump an

d

ration.

ke sure th

a

electric m

o

pump sh

o

ition other

ll as on the

bearing b

r

rantee pr

o

ling may e

rication an

d

ranteed a

t

nitored.

ke provisio

n

ilar to are

a

form to IE

C

installatio
sure that

t

, etc.) is i

n

y have oc

c

ave been

s

age is fo

u

taken to m

a

ct the envir

n

such as c

o

certificatio

n

quired to

h

urer of the

nstallatio

n

as possibl

e

enance w

o

it the guar

d

the syste

m

t there is u

n

tor should

h

uld be mo

u

than speci

f

magnetic

c

acket nee

d

per functio

ntail unacc

e

, thus, pre

all times t

h

for equip

o

s in potent

i

60079-14

n, inspect

a

he data of

t

conformit

y

urred: The

tored prop

nd, please

ke sure th

a

ons of the

p

uplings, g

u

or certifie

d

ave a sep

a

pump unit.

to the tan

k

rk, inspect

i

to be att

a

must be

a

obstructe

d

ave a cle

a

nted horiz

o

ied will hav

e

oupling's p

r

s to be fre

e

ning and lu

ptable sur

f

mature ball

ere will be

tential bon

d

ally explos

i

.

Page19

nd check t

h

t

he unit (s

p

with the h

pump unit t
erly (for thr

e

contact yo

u

t hot air fr

o

ump syste

m

ards, driv

e

separatel

y

rate certifi

c

of the liqu

on and ch

e

ched.

ccessible f

o

air supply

rance of n

o

ntally and

p

an impac

t

oper functi

-standing i

n

brication of

ace tempe

r

bearing fa

i

a need for

ing betwe

e

ve atmosp

h

e entire u

n

ecified on

azardous

z

o be install

e

e years m

a

r supplier

m other in

s

; the amb

, motor, p

e

for the a

p

ation and

a

id to be pu

m

cks. K e e

p

r mainten

a

to the pum

p

t less than

laced dire

c

on drainin

g

on.

the atmo

s

the greas

e

atures of t

h

lure. Wher

e

the bearin

g

n the pum

p

eres, the

c

it and syst

e

the rating

p

one, the c

a

d must be
x.) prior to

of Varisco

p

tallations o

ient air tem

ripheral eq

propriate t

e

separate

r

ped and

a

enough f

r

nce and in

s

, the drive

25% of th

e

tly on the

p

, filling an

d

phere to p

e

-lubricated
e bearing

b

adequate

bracket's

s

and the f

o

onnection

t

m.
late, in the
tegory and

in a sound

installation

umps.

r systems

d

perature m

uipment, e

t

mperature

ating plate

llow suffici
ee space

s

pection du

and the m

o

motor dia

m

ump feet.

A

venting of

rmit coolin

ball bearin

g

racket, in

s

cooling ca

n

urface te

m

undation. I
o electric

p

the syste

m

condition

a

. In case o

f

oes not

ust not

c. must be

category.

T

which is

ent space

pecifically

ring

tor.

eter.

ny mounti

the pump

a

g and

s. Inadeq

u

ufficient

not be

perature to

n locations

ower must

nd

he

in

ng

s

ate

be

5.

4

Th

edraThefunThehor

Su
tra

nSmdampip

5.

5

Ci

r

Foun

d

structure

wing/instal

concrete

f

ctional mo

u

concrete

f

izontal an

d

pport the p

u

smission

o

aller pump

s

pers bet

w

ing system

.

Pipin

g

Piping

neces

s

Piping
pump

n

comp

a

The fo

l

cumferen

t

A

s set f

o

to occu

r

ation

must be pr

e

lation draw

i

oundation

s

nting acco

r

oundation

m

level. The

mp syste

m

f vibration

s

may be i

n

een the pu

m

connected

ary to sup

p

must be a

d

ozzles. It i

s

red with th

a

lowing are

Pipin

g

Suction lin

e

Discharge l

Recirculati

o

ial speed:

Pump t

y

V 6
V 12
V 20
V 25-2
V 30-2
V 50-3
V 60-2
V 70
V 80-2
V 100-2

rth in prE

N

on the sh

a

pared suc

h

ng.
shall have

ding to DI

N

ust have

c

anchor bol

t

or parts t

h

and noise

stalled in t

h

p and the

to the pum

ort conne

c

equately di

recomme

n

t of the pu

m

guide valu

e

ine

n line

pe

Driv

e

dia

m

[

m

111223344

5

13463-5:

2

ft seals at

c

that the d

a sufficien

t

1045 or a

n

ompletely

s must be

s

ereof on vi
to the envi
e piping wi
piping so

a

p must not

t

ted pipes u

mensioned

ded for th

e

p's suction

s for the m

-shaft
eter

m]

4
4
4
2
2
0
5
0
0
5

002 Secti

o

ircumfere

n

Page20

imensions

c

concrete s

equivalen

cured prior

uspended

bration da

m

ronment.

thout any f

o

s to preve

n

t

ransmit fo

r

pstream of
. The size t

suction si

d

nozzle.

ax. flow ve

l

Recom

m

the

Max. spe

e

[rpm

]

1,450
1,450
1,450

1,450 ( 1,0

0

1,450 ( 1,0

0

700
640
500
500
350

n 5.1, no f

r

tial speed

s

onform to

t

trength (at
t standard.

to putting

t

in the bas

e

pers (whe

r

undation.

I

t transmiss

ces, torqu

e

the pump.

o be chose

e that the n

ocities in t

h

ended fl

o

piping sy

s

0.5 ... 1.0

3.0 ... 5.0

1.0 ... 2.0

d

cir

c

0 )
0 )

iction-indu

c

of 1 m/s.

hose sho

w

least Class

he unit in p
plate.

e necessa

r

n such an

a

ion of vibra

t

s or mome

n

n should n

o

ext larger n

e piping:

w velocit

y

tem [m/s]

Maxim

u

umferenti

[m/s]

1.06

1.06

1.06

1.67 ( 1.

0

1.67 ( 1.

0

1.09

1.14

1.04

1.04

1.00

ed temper

a

n in the di

m

X0) to per

m

lace. Its su

y) so as to

pplication,

ions from t

ts to the l

a

t be less t

h

ominal size

in

m

al speed

9 )
9 )

ture rise i

s

ensional

it safe an

d

rface must

reduce

install vibr

a

he pump to

tter; it may

an that of t

h

be chosen

anticipate

d

be

tion

the

be

e

6

To p

r

a filt

e

ratin

g

Ben

d

sho

u

Start-

u

A

t the

p

avoid

c

recom

m

Prior t

o

Check
Check
requir

e

Piping
techni

c

j

oints

a

electri

c

Check
correc

t

in parti
fluid to

A

ll pu

m

with th

e

pressu

Check
Do not
Consu

l

been s
Check
Follow

i

pump

a

event entr

y

r rating n

e

must be

s

s in the pi

p

ld be avoid

V6, 12,

V

p and pla

ump start-

uost

ly incide

ended for

starting

t

the alignm

e

that the filt

e

d to have

u

must not e

x

al section.
re installe

d

motor's p

o

that the pu

m

ly mounted

.

cular on a

s

be pumpe

d

ps are pro

t

pumped

f

re gauge a

n

that the oil

use the ge

t customer

old.

that all val

v

ng pump s

t

nd inspec

t

of foreign

eds to be

ufficiently l
ing laid sh

o

ed.

P

u

20, V25-2,

cing out o

f

p phase, p
nts - See in
star

t

-up.

he pump,

nt of the p

u

and the

p

ndergone

a

ert an exc

e

Where the

in the pipi

n

wer and t

h

p's directi

Move the

elf-primin

g

or a fluid

t

ected duri

n

luid the pu

m

d a vacuu

m

reservoir i

n

ar pump fo

r

service if fl

es are op

e

arting, che

both the p

u

matter, whi

installed o
arge since

uld have

a

mp type

V30-2, V6

0

service

articular ca

r

the manua

it is cruci

a

mp with th

e

iping are f

r

leakage t

e

ssive load

liquid can r

e

g. Check

t

e sense o

f

on of rotati

o

pump shaft

pump, mu

s

hat is com

p

g installati

o

p must b

e

gauge.

the vicinit

y

tests or fi

n

uids need

t

n.

ck that flui

d

mp and th

Page21

ch may res
n the inlet

s

it affects t

h

radius as

-2, V80.-2

e must be

t

ls of the va

r

l that the

f

supportin

g

ee from re

m

st.

on the pu

m

ach high t

e

he motor’

s

rotation.

n is correc

and check

t not be d

r

atible with

n by a pa

s

removed

a

of the sea
al accepta

n

o be pump

e

has enter

e

e system if

ult in destr

u

ide. Give

n

e pump's

s

large as pr

a

, V100-2

aken to me
ious pump

v

ollowing

c

structure

ainders,

s

p casing.

S

mperatur

e

electrical

c

t. The safe

t

to be sure

y. Fill or lu

b

the latter.

sivating oil

y

nd cleane

d

l/gasket is

f

ce tests

w

d which di

f

d and the

p

the pump i

s

ction of th

e

its inner fl

o

uction cap

a

ctical. Sm

Filter r

a

et the requi

ersions w

h

hecks be

c

as may be

mall welde

ee the ma

x

s it must b

e

onnection

s

y relief val

v

that it rotat

e

ricate the i

liquid. If t

h

. Prepare t

illed.

ith water.

fer from th

o

ump funct

i

still runni

n

pump, a s

u

w resistan
city.

all-angle pi

p

ting [mm]

0.5

rements lis

t

ich spare p

onducte

d

provided, a

d pieces, e

t

. permissi

b

ensured t

h

, the bala

n

e (if to be i

n

s freely. T

nternal co

m

e latter is

n

he taps for

se for whi

c

ons prope

r

g dry after

ction filter

ce, the filt

e

e elbows

ed below s

o

arts are

:

nd the mot

o

t

c. Flanges

le loads in

at expans

i

cing of the

stalled) m

u

he pump in

ponents w

ot compat

i

connecting

h the pum

p

ly. Stop th

e

one minut

e

with
r

as to

r.
are

the

on

st be

terior,

ith the

ble
a

has

.

Page22

7 Removing the pump

If the pump is under warranty you will need to contact Varisco prior to removing the pump. Otherwise,
warranty claims will be null and void.

Prior to opening the pump, make sure that:

it is completely depressurised;

all its content was drained and the pump flushed;

it was vented and allowed to cool down.

8 Risk analysis according to EN 13463-1

Predictable malfunction denotes equipment trouble which, usually occurring in the field, entails a situation
such that the pumps do not function any longer as intended or fail to meet the design parameters.

When operating the pumps the following aspects need to be given particular consideration:

Faulty design: Failure of a pump component (e.g., bearing damage);

Trouble caused by external effects: Obstruction attributable to foreign matter in the pumped medium,
or discharge-side clogging;

Overtemperature resulting from recirculation when the pressure relief valve has operated;

Operator's failure to conduct checks as necessary.

Referring to the appraisal of malfunctions, it can be anticipated that predictable malfunction because of
faulty design or installation faults is ruled out by implementing the 'Internal Production Control' quality
assurance system established at the manufacturer's in conformity with Annex VIII of the Directive 94/9/EC.
This quality system, while guaranteeing design in line with good engineering practice, also serves to
ensure that agreements with the customers as well as the design solutions chosen are in conformity with
Directive 94/9/EC and the underlying standards.

Consistent compliance with the operating manual and maintenance instructions implies that loss of control of
the pumps by the operators is ruled out.

An assessment of concrete design solutions with respect to ignition hazards (acc. to EN 13463-1) is
made in the table below (see next page).

Page23

Potential ignition source

Measures

Reference to
standards
considered

Normal
service

Trouble to be

expected

Hot surface

- Make sure that the max. permitted temperature is not

exceeded!

EN 13463-1

-

Hot surface

Make sure that the rotor, the pinion and the plain bearings are
properly lubricated.

Every precaution must be taken to prevent the pump running
dry!

EN 13463-1

5.2.; 6.1.2.

Mechanical
sparking

The materials employed are stainless steel or ductile cast iron.
These materials are permitted as set out in EN 13463-1. All
bearings are made of stainless steel.

Mechanical
sparking

Mechanical sparking which could ignite a potentially explosive
atmosphere is not considered as a trouble to be expected.

Faster-than-

normal heating
of the gland
packing

Lubrication of the packing rings must be ensured.
Temperature monitoring is essential – see Section 5.1

Faster-than-

normal heating
of shaft seals
and
mechanical
seals

Quenching and flushing liquid must be checked. Pump must
not be allowed to run dry!



Operating
Manual



Electrostatic charges

During normal service, while complying with the design
criteria, dangerous electrostatic charges which can result in
discharge sparks that could ignite a potentially explosive
atmosphere are ruled out as trouble to be expected since

Æthe thickness of a paint coat that may not be

electroconductive is less than 0.2 mm;

Æthere are no exposed components of non-conductive

plastics in pumps;

Æall conductive components of the pump are in metal-to-

metal contact to one another and the pump is included in
the equipotential bonding system of the equipment;

Æit needs to be remembered that a flexible coupling with non-

conductive elastoms functions as insulation.

Potential differentials between the individual assemblies
(pump and motor) are prevented in that all the assemblies
of the pump are bonded through metal-to-metal screwed joints
and, in the end, the pump is included in the equipotential
bonding system of the equipment (earthed). The oil film
between the rotating and the stationary components is not
considered a mutual insulation. However, it should be
remembered that a flexible coupling with non-conductive
elastomers between the motor and the drive shaft functions as
insulation.

EN 1127-1

6.4.7
EN 13463-1

7.4.1, 7.4.2,

7.4.4, 11

Ignition sources other than those described above are not likely to occur.

Therefore, no further evaluation of ignition hazards is required.

Page24

Trouble Potential causes Trouble shooting

No fluid delivered

1. Pump not filled with fluid.

2. Discharge suction valve closed

3. Incorrect sense of rotation

4. Suction line clogged

5. Filter clogged

6. Leaky suction line

7. NPSH too low (excessive

manometric suction head)

9. Relief valve opens too early or

fails to close

10. Magnetic coupling slips

1. Fill the pump

2. Open the valve

3. Reverse sense of rotation, taking note of the
arrow on the pump.

4. Eliminate clogging

5. Clean the filter

6. Find and eliminate leakage

7. Increase diameter of suction line and/or
piping. Reduce manometric suction head.
Consider vapour pressure of pumped fluid;
alter arrangement, if appropriate.

9. Set opening pressure. Check valve mechanism

10. Stop motor immediately and eliminate cause of
pump obstruction trouble.

Insufficient
delivery rate

1. Back pressure higher than
designed

2. Leaky suction line

3. Speed too low

4. Suction line clogged

5. Filter clogged

6. Viscosity higher than designed

7. Relief valve incorrectly set or
leaking

8. Insufficient suction pressure

9. Worn pump components
(gear s, sliding

plate)

1. Reduce pressure drop

2. Inspect suction line for leaks

3. Check speed (contact manufacturer).

4. Eliminate line clogging

5. Clean the filter

6. Reduce viscosity or re-design pump.
(contact manufacturer

)

7. Re-set relief valve or renew gasket

8. Increase suction pressure

9. Renew components

Pump's suction
capacity diminishes

1. Piping improperly designed

2. Discharge line shut off

3. Suction line shut off

4. Pump worn

5. Suction line leaky

1. Check sizing of piping

2. Open shutoff valve

3. Open suction valve

5. Inspect suction line for leaks

Pump causes noise

1. Cavitation - excessive
manometric suction head

2. Rotor/Teeth deformed

3. Pump/Motor misalignment

4. Vibration noise from relief valve

1. See above "NPSH too low". Check to see if
head is set too high, suction line or valves
and filter are clogged.

2. Check and, if necessary, renew

3. Check alignment

4. Increase spring pressure. Repair or renew
relief valve.

Pump experiences
faster-than-normal
wear

1. Foreign matter in pumped fluid

2. Operating range exceeded
(excessive noise development),
Misalignment

1. Install filter; Check materials selected.
Contact Varisco

2. Correct pump alignment.

Page25

Trouble Potential Causes

Trouble shooting

Drive gets hot or
is overloaded

Incorrectly designed delivery,
delivery pressure

Check the piping
Contact the manufacturer

High containment
shell temperature

Excessive viscosity
Product flow for cooling

interrupted

Contact the manufacturer
Check filter and design

High casing
temperature



Foreign matter in pumped fluid
Pump running dry
Relief valve spring broken
Fluid temperature too high
Insufficient delivery rate
Magnetic drive desynchronised

Reduce delivery head or delivery.

Page26

Disassembly of the V-Series Internal Gear Pump

with Magnetic Coupling

9. Disassembly

9.1 General

Improper or incorrect assembly and disassembly may cause pump malfunctions and result in high
repair costs and long downtimes. If you have questions or require further information, please do not
hesitate to contact VARISCO S.p.A.

! Failure to observe these instructions and/or the warning notes may result in risks to the operator

and/or serious damage to the pump or pump unit. VARISCO S.p.A.shall not be held liable for any
accidents or damage caused as a result of non-observance of this manual.

The specific safety requirements in relation to strong magnetic fields must be strictly observed.

Persons who have a pacemaker should not be allowed to work on a pump with magnetic
coupling! The magnetic field is sufficiently strong to affect a pacemaker’s proper operation. For
this reason, a safe distance of at least three (3) metres should be kept.

Always keep equipment with magnetic data carriers (memory) such as cheque cards, computer
disks, watches, etc. at a distance from the magnetic coupling (at least 1 m) because they might
be damaged and/or data loss might occur.

Prior to opening the pump, make sure that

- it is completely depressurized

- all its content was drained and the pump flushed

- it was vented and allowed to cool down.

Page27

9.2 Disassembly of the pump cover (04)

Remove the screws (43). Where present, use the two threaded bores to facilitate removal. When

removing the cover (04) make sure that the seal (31) will not be damaged. If damaged, replace it.

! This also applies to all other pump seals.

Pull off the pinion (03) with pressed-in plain bearing (37) from the cover (04) via the pin (06).

Heat the pinion (03) to approx. 80°C. When the temperature is high enough, the pinion’s plain

bearing (37) can be removed from the pinion (03).

Heat the pump cover to approx. 80°C. Press the pin out of its seat. Make sure that the pin is

pressed out in the direction of the crescent.

Page28

9.3 Disassembly of the pump casing (01)

Unscrew the screws (44) and pull-off the casing (01).

Page29

9.4 Disassembly of the plug-in unit

Unscrew the bolts (M3.02) and (M3.03) and pull-off the complete plug-in unit from the bearing
bracket (M1.01).

! On principle, the plug-in unit should only be separated from the external magnet (M2.02) by radial

guidance (restricted guidance). Make sure that the external magnet (M2.02) and the containment
shell (M2.03) do not get in contact. If they get in contact, the external magnet (M2.02) could be
damaged. In such a case pump malfunction cannot be excluded.

Page30

Remove the bolts (M2.05) and pull-off the containment shell (M2.03) from the intermediate flange
(M3.01).

! As regards the containment shell (M2.03), please remember that some remainders of the pumped

fluid may still be in the pump. For safety instructions, please see the relevant media data sheet.

Remove nut M18 (M3.13) and washer (M3.12) from the pump shaft (M3.08).

Separate the internal magnet (M2.04) from the pump shaft (M3.08) with the help of a suitable pull-off
device.

Remove the thrust washer (M3.11) from the pump shaft (M3.08).

Pull-off the intermediate flange (M3.01) via the pump shaft (M3.08).

Heat the intermediate flange (M3.01) to approx. 80°C. Press-out the shaft slide bearing (M3.09) from
the bearing seat.

Press out the pump shaft (M3.08) from the rotor (02).

! Make sure that the thrust washer (M3.10) will not be damaged because it loosens when pump shaft

(M3.08) and rotor (02) are pressed out.

Page31

9.5 Disassembly of the bearing bracket



Remove the feather key (M1.12) from the drive shaft (M1.03).

Remove the shaft sealing ring (M1.05), the slotted nut (M1.09) and the safety plate (M1.10) from the
drive shaft (M1.03).

Press out the external magnet (M2.02) and the drive shaft (M1.03) with magnet hub (M2.01) from the
bearing bracket (M1.01) in the direction of the external magnet (M2.02).

Unscrew the bolts (M1.08) and dismantle the ball bearing cover (M1.02) from the bearing bracket
(M1.01).

Remove the ball bearing (M1.04) from the ball bearing cover (M1.02).

Unscrew the screws (M2.06) and separate the external magnet (M2.02) from the magnet hub
(M2.01).

Press out the drive shaft (M1.03) from the magnet hub (M2.01) in the direction of the feather key
(M1.12).

Remove the ball bearing (M1.04) from the drive shaft (M1.03).

Page32

9.6 Adjusting the axial play

! The axial play is dependent on the viscosity and can be adjusted through various thicknesses of

the cover or the casing seal. Please see the table below for further information.

Class

Pump type

V25-2
V30-2

V50-3
V60-2
V70-2
V80-2

V85-2

V100-2

1

0.2 mm

0.2 mm 0.3 mm 0.5 mm

2

0.3 mm 0.5 mm 0.7 mm 0.7 mm

3

0.5 mm 0.7 mm - 1.0 mm

Pump type

Viscosity

Stainless steel

Grey cast iron

Class 2 Class 1 up to 600 cSt and up to 180°C
Class 3 Class 2 from 600 to 6000 cSt and up to 180°C
Class 3 Class 3 over 6000 cSt and over 180°C

Page33

Annex

Certificate of No Objection

We, the undersigned, submit the following pump and pump accessories for repair I inspection:

Type:

................................. Please note:

Specification: ......... ...... ...,. ........ This certificate must be filled out

and enclosed with any shipment
for repair purposes to ensure
proper handling of the pump.

Series no..:.. ... ......

Cause of inspection/repair order:

The pump and/or pump accessories:

has/have not been used to pump any liquids that are harmful to health;

was/were used for

(type of use)..............

was/were in contact with liquids subject to labelling requirements under the law on

hazardous substances and/or dangerous goods. If known, please state the last medium

pumped: ....................................................................

Prior to shipment / provision the pump has been carefully drained and cleaned both inside and outside with a
suitable cleaning agent.
No special safety precautions are required for further handling.
The following safety precautions are required in relation to flushing fluids, residual fluids and
disposal:

We, the undersigned, confirm that the information provided above is correct and complete and
shipment is in compliance with legal regulations.

Company:

Department:
Contact:
Phone:
Fax:
Address:
Street:
Postal code / town

………………………………………………

Place I date / company stamp / signature

Page34

Page35







______________________________________________________________________________________________

VARISCO SpA

Terza Strada, 9 - Z.I. Nord - 35129 PADOVA - Italy

Tel. [phone] - Fax [phone]

www.variscospa.com

Vendite Italia: Tel. [phone] - Fax [phone]

[e-mail]

International sales: Ph. [phone] - Fax [phone]

[e-mail]

______________________________________________________________________________________________