Viking MAG DRIVE 855 User Manual

TECHNICAL SERVICE MANUAL

SERIES 855

Sizes AS, AK, AL, KE, KKE

SECTION TSM

PAGE

ISSUE

1 OF 16

685.2

CONTENTS

Introduction ................................................................... 1

Special Information ....................................................... 3

Maintenance ................................................................. 4

Parts Identification Drawings ........................................ 5-7

Disassembly of Pump ................................................... 7

Disassembly of Coupling .............................................. 8

Disassembly / Assembly Bearing Carrier ..................... 9-10

Installation of Bushings................................................. 10

Assembly of Pump........................................................ 10-11

Pump Rotation .............................................................. 11

Assembly of Couplings ................................................. 12

Adjusting End Clearance .............................................. 13

Pressure Relief Valve Instructions ................................ 13-14

Troubleshooting ............................................................ 15

Warranty ....................................................................... 16

WARNING!

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

MODEL NUMBER CHART

UNMOUNTED PUMPS UNITS

AS-855U, AS-855M,

AK-855U, AK-855M

AL-855U, AL-855M

KE-855U, KE-855M

KKE-855U, KKE855M

Units are designated by the unmounted pump model numbers followed by the magnetic coupling size and a letter indicating drive style.

(Example: AK-855MA MD2 B50 M )

D = Direct Drive, Base Mounted M = Motor, Face Mounted B = Bearing Carrier R = Viking Reducer Drive P = Commercial Reducer Drive

See Page 4 for complete description of the model number

TABLE 1

This information must be read fully before beginning any maintenance or repair of the pump. All maintenance or repair must be done by SUITABLY TRAINED or qualified persons only.

INTRODUCTION

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

This manual deals only with Series 855 magnetic drive pumps. Refer to Figures 1 through 22 for general configuration and nomenclature used in this manual. Pump specifications and recommendations are listed in Catalog Section 685.

In the Viking model number system, the basic size letters (AS, AK, AE etc.) are combined with the series number (855) indicating basic pump construction material.

FIGURE 1

SERIES AK855UB MD2-32 B

Pump with Bearing Carrier

FIGURE 2

AK SERIES 855UB MD2-14 M

Pump with Motor Directly Mounted to the Bracket

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

SAFETY INFORMATION AND INSTRUCTIONS

IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY OR DEATH AND/OR RESULT IN DAMAGE TO PUMP AND/OR OTHER EQUIPMENT. VIKING’S WARRANTY DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION, OPERATION OR MAINTENANCE.

THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION, OPERATION OR MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP. PUMP MUST BE INSTALLED, OPERATED AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS.

THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES.

Symbol Legend :

WARNING

Danger - Failure to follow the indicated

instruction may result in serious injury

or death.

BEFORE opening any liquid chamber (pumping chamber, reservoir, relief valve adjusting cap fitting, etc.) be sure that :

● Any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections.

● The pump drive system means (motor, turbine, engine, etc.) has been “locked out” or otherwise been made non-operational so that it cannot be started while work is being done on the pump.

● You know what material the pump has been handling, have obtained a material safety data sheet (MSDS) for the material, and understand and follow all precautions appropriate for the safe handling of the material.

BEFORE

are in place.

DO NOT operate pump if the suction or discharge piping is not connected.

DO NOT place fingers into the pumping chamber or its connection ports or into any part of the drive train if there is any possibility of the pump shafts being rotated.

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

BEFORE

● It is clean and free from debris

● all valves in the suction and discharge pipelines

are fully opened.

● All piping connected to the pump is fully supported

and correctly aligned with the pump.

● Pump rotation is correct for the desired direction

of flow.

operating the pump, be sure all drive guards

operating the pump, be sure that:

WARNING

Warning - In addition to possible serious

injury or death, failure to follow the indicated instruction may cause damage to pump and/or other equipment.

INSTALL pressure gauges/sensors next to the pump suction and discharge connections to monitor pressures.

USE extreme caution when lifting the pump. Suitable lifting devices should be used when appropriate. Lifting eyes installed on the pump must be used only to lift the pump, not the pump with drive and/or base plate. If the pump is mounted on a base plate, the base plate must be used for all lifting purposes. If slings are used for lifting, they must be safely and securely attached. For weight of the pump alone (which does not include the drive and/or base plate) refer to the Viking Pump product catalog.

DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is mounted on a pump that is operating.

AVOID contact with hot areas of the pump and/or drive. Certain operating conditions, temperature control devices (jackets, heat-tracing, etc.), improper installation, improper operation, and improper maintenance can all cause high temperatures on the pump and/or drive.

THE PUMP must be provided with pressure protection. This may be provided through a relief valve mounted directly on the pump, an in-line pressure relief valve, a torque limiting device, or a rupture disk. If pump rotation may be reversed during operation, pressure protection must be provided on both sides of pump. Relief valve adjusting screw caps must always point towards suction side of the pump. If pump rotation is reversed, position of the relief valve must be changed. Pressure relief valves cannot be used to control pump flow or regulate discharge pressure. For additional information, refer to Viking Pump’s Technical Service Manual TSM 000 and Engineering Service Bulletin ESB-31.

THE PUMP must be installed in a matter that allows safe access for routine maintenance and for inspection during operation to check for leakage and monitor pump operation.

SECTION TSM 685.2 ISSUE C PAGE 2 OF 16

SPECIAL INFORMATION

DANGER !

For additional information on pressure relief valves, refer to Technical Service Manual TSM000 and Engineering Service Bulletin ESB-31.

Before opening any Viking pump liquid chamber (pumping chamber, reservoir, relief valve adjusting cap fitting etc.) Be sure:

1. That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections.

2. That the driving means (motor, turbine, engine, etc.) has been “locked out” or made non- operational so that it cannot be started while work is being done on pump.

3. That you know what liquid the pump has been handling and the 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.

RELIEF VALVE ADJUSTING SCREW CAP

SUCTION

FIGURE 3

RELIEF VALVE POSITION

DISCHARGE

CAUTION !

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

ROTATION: Viking Mag Drive® pumps are designed to run in either direction. See PUMP ROTATION, page 11.

PRESSURE RELIEF VALVES:

1. Viking pumps are positive displacement pumps and must be provided with some sort of pressure protection. This may be a relief valve mounted directly on the pump, an inline pressure relief valve, a torque limiting device or a rupture disk. Do not rely on decoupling of magnets for protection from over pressure; this may result in damage to the magnets, pump, or other equipment.

2. Relief valves are mounted as standard on the casing of AS, AK,AL,KE and KKE size pumps.

3. If the pump rotation is to be reversed during operation, pressure protection must be provided on both sides of the pump.

4. The relief valve adjusting screw cap must always point towards the suction side of the pump. See

Figure 3. the pressure relief valve and turn end for end (see PUMP ROTATION, page 11 for additional information.

5. Pressure relief valves cannot be used to control pump

flow or regulate discharge pressure.

If the pump rotation is reversed, remove

Pacemakers Metal Implants Watches Computers & disks 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.

SECTION TSM 685.2 ISSUE C PAGE 3 OF 16

BEARING CARRIER ASSEMBLY (Optional)

SHAFT

CANISTER

CANISTER O-RING

TEMPERATURE

PROBE HOLE

CASING BUSHING

RELIEF VALVE

(shown with optional RV coverplate)

ROTOR

HEAD GASKET SEAL

HEAD

OUTER MAGNET ASSEMBLY

BRACKET

INNER MAGNET ASSEMBLY

FIGURE 4

CUTAWAY VIEW MAG DRIVE PUMP, MD2-B

WITH BEARING CARRIER ILLUSTRATED

MAINTENANCE

Series 855 pumps are designed for long, trouble-free service life under a wide variety of application conditions with a minimum of maintenance. The points listed below will help provide long service life.

CLEANING PUMP:

Keep the pump as clean as possible. This will facilitate inspection, adjustment and repair work.

LUBRICATION:

Some bearing carriers require external lubrication. This must be applied slowly with a handgun to lubrication fittings every 500 hours of operation with multi-purpose grease, NLGI # 2. Do not over-grease. Applications involving very high or low temperatures will require other types of lubrication. Refer to ESB-515. Consult factory with specific lubrication questions.

STORAGE:

If the pump and coupling are to be stored, drain the pump and pour non-detergent SAE 30-weight oil into the pump port. Apply grease to the pump or the coupling shaft extension, if present or accessible.

GAUGE PORT BOSS

IDLER PIN

IDLER

CASING

Viking suggests rotating the pump shaft every 30 days to circulate the oil in the pump. 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 855 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. Metric Allen wrenches (for set screws)

3. Torque Wrench with a locknut socket

4. External snap ring pliers - (Viking Part # 2-810-029-375)

5. Internal snap ring pliers - (Viking Part # 2- 810-047-999)

6. Arbor press

7. Brass bar

8. Hook style spanner wrench

SECTION TSM 685.2 ISSUE C PAGE 4 OF 16

Series

AS 8 5 5 M B-MD2 B14 B

Size

(Nominal displacement)

Material

5 = Cast Iron

Port Design M= DIN

U= ANSI

Coupling Size - Pump Related

A size = Used on GS, GG, HJ or HL B size = Used on HJ, HL, AS, AK or AL C Size = Used on AS, AK, AL, KE, or KKE

AS AK AL

KE KKE

FIGURE 5

MODEL NUMBER SYSTEM

Drive Congurations

M = Motor, Face Mount D = Direct Drive, Base Mounted B = Bearing Carrier R = Viking Reducer Drive P = Commercial Reducer Drive

Magnetic Coupling Size and

Torque Specication - Drive

A 4 and 9 Ft-Lbs B 14,32 and 50 Ft-Lbs C 40,90, 135 and 180 Ft-Lbs

Magnetic Coupling Design

Second generation and not interchangable with previous design.

FIGURE 6

EXPLODED VIEW – SIZES AS, AK, AL, KE & KKE MAG-DRIVE PUMPS

ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART

1 Locknut 37 Idler 53 Locating Pin

21 Set Collar 38 Idler Bushing 60 Thrust Washer - 2 Req’d

25 Casing Bushing 39 Idler Pin 61 Machine Screws (metric) - 2 Req’d

30 Pipe Plug - 2 Req’d 40 Head and Idler Pin Assembly 62 Drive Key

32 Casing and Bushing Assembly 43

33 Casing Stem O-ring 45 Relief Valve Gaskets - 2 Req’d

35 Head O-ring 46

36 Rotor and Shaft Assembly 47 Relief Valve

Capscrews (metric) for Head 6 Req’d

Capscrews (metric) for Relief Valve

- 6 Req’d

63 Shims for Head (metal)

TABLE 2

SECTION TSM 685.2 ISSUE C PAGE 5 OF 16

+ 11 hidden pages