Viking Pump TSM285 User Manual

TECHNICAL SERVICE MANUAL

SECTION TSM 285

CLASSIC+ SERIES ROTARY LOBE PUMPS

MODELS CP10, CP20, CP30, CP40 & CP50

CONTENTS

1.0 Safety Information........................................................................ 2

Risk Assessment Relating to the Use of Viking Pump

1.1

Classic+ Rotary Lobe Pumps and Pump Units in

Potentially Explosive Atmospheres ..............................................

Introduction. .................................................................................3

2.0

2.1 General. .......................................................................................3

2.2 Viking Pump Distributors. ............................................................3

2.3 Receipts and Storage. ................................................................. 3

2.4 Cleaning....................................................................................... 3

2.5 Pump Model Designation............................................................. 4

2.5.1 AtexIdenticationPlate ...............................................................4

2.5.2 Equipment Groups & Categories .................................................4

2.6 Pump Model and Serial Number. ................................................. 4

Standard Pump Component Terms .............................................5

2.7

General. .......................................................................................5

3.0

3.1 Classic+ Pumping Principal. ........................................................5

3.2 Classic+ Range Operating Parameters. ......................................5

3.3 System Design............................................................................. 6

3.3.1 System Design and Installation. .................................................. 6

3.3.2 Installations with In-Line Cleaning Systems. ............................... 7

3.4 Start Up Procedure. .....................................................................8

3.5 Shutdown Procedure. .................................................................. 8

3.6 Routine Maintenance. .................................................................. 8

3.7 Heating and Cooling Jackets .......................................................8

3.8 Integral Pressure Relief Valves ..................................................10

3.8.1 Setting and Operating Spring Loaded Valves ............................ 10

3.8.2 Setting and Operating Air Loaded Integral

Pressure Relief Valves ...............................................................

Classic+ Disassembly and Assembly. .......................................12

4.0

4.1 CP10, CP20 & CP30 Pump - Disassembly and Assembly. .......12

4.1.1 CP10, CP20 & CP30 Head and Rotor Removal ........................ 12

4.1.2 CP10, CP20 & CP30 Casing Removal ...................................... 13

4.1.2.1 CP10, CP20 & CP30 Casing Removal - Single

 Un-ushedMechanicalSealsandSingleO-RingSeals ............

4.1.2.2 CP10, CP20 & CP30 Casing Removal - Single Flushed

or Double Flushed Mechanical Seals. .......................................

4.1.3 CP10, CP20 & CP30 Gearbox Disassembly .............................14

4.1.4 CP10, CP20 & CP30 Gearbox Assembly .................................. 15

4.1.5 CP10, CP20 & CP30 Casing, Rotor and

Head Assembly ..........................................................................

4.2 CP40 Pumps - Disassembly and Assembly...............................17

4.2.1 CP40 Head and Rotor Removal ................................................17

4.2.2 CP40 Casing Removal .............................................................. 17

4.2.2.1 CP40CasingRemoval-SingleUn-ushedMechanical

Seals and O-Ring Seals ............................................................

4.2.2.2 CP40 Casing Removal - Single Flushed or Double

Flushed Mechanical Seals. ........................................................

4.2.3 CP40 Gearbox Disassembly...................................................... 18

4.2.4 CP40 Gearbox Assembly........................................................... 19

4.2.5 CP40 Casing, Rotor and Head Assembly .................................. 20

4.3 CP50 Pumps - Disassembly and Assembly...............................21

4.3.1 CP50 Head and Rotor Removal ................................................21

4.3.2 CP50 Casing Removal .............................................................. 21

4.3.2.1 CP50CasingRemoval-SingleUn-ushedMechanical

Seals and O-Ring Seals ............................................................

4.3.2.2 CP50 Casing Removal - Single Flushed and Double

Flushed Mechanical Seals .........................................................

4.3.3 CP50 Gearbox Disassembly...................................................... 22

4.3.4 CP50 Gearbox Assembly........................................................... 23

4.3.5 CP50 Casing, Rotor and Head Assembly .................................. 24

Classic+ Mechanical Seal Removal & Replacement. ................ 25

5.0

5.1 General Procedures for Installing Mechanical Seals. ................ 25

10

13

14

16

17

18

21

21

PAGE 1 OF 36

ISSUE A

5.2 CP10, CP20, CP30 & CP40 Mechanical Seals ......................... 25

5.2.1 CP10, CP20, CP30 & CP40

Single Mechanical Seal Removal ..............................................

5.2.2 CP10, CP20, CP30 & CP40

3

Single Mechanical Seal Replacement .......................................

5.2.3 CP10, CP20, CP30 & CP40

Single Flushed Mechanical Seal Removal ................................

5.2.4 CP10, CP20, CP30 & CP40

Single Flushed Mechanical Seal Replacement .........................

5.2.5 CP10 Double Flushed Mechanical Seal Removal ..................... 26

5.2.6 CP10 Double Flushed Mechanical Seal Replacement .............. 27

5.2.7 CP20, CP30 & CP40

Double Flushed Mechanical Seal Removal ...............................

5.2.8 CP20, CP30 & CP40

Double Flushed Mechanical Seal Replacement ........................

5.3 CP50 Mechanical Seals............................................................. 28

5.3.1 CP50 Single Mechanical Seal Removal ....................................28

5.3.2 CP50 Single Mechanical Seal Replacement .............................28

5.3.3 CP50 Single Flushed Mechanical Seal Removal ...................... 28

5.3.4 CP50 Single Flushed Mechanical Seal Replacement ............... 28

5.3.5 CP50 Double Flushed Mechanical Seal Removal ..................... 29

5.3.6 CP50 Double Flushed Mechanical Seal Replacement .............. 29

Classic+ Single O-Ring Seals .................................................... 29

6.0

6.1 General Procedures for Fitting Single O-Ring Seals ................. 29

6.2 O-Ring Seals for CP10, CP20, CP30 & CP40 Pumps............... 29

6.2.1 CP10, CP20, CP30 & CP40 O-Ring Seal

Assembly and Removal .............................................................

6.3 O-Ring Seal for CP50 Pump...................................................... 30

6.3.1 CP50 O-Ring Seal Assembly and Removal............................... 30

Flushed Product Seals Auxiliary Services ................................. 30

7.0

7.1 Single Mechanical Seal (for Low-Pressure Quench or Flush) ... 30

7.2 Double Mechanical Seal (for High Pressure Flush) ................... 30

Specications............................................................................. 31

8.0

Clearance Chart......................................................................... 31

8.1

Fasteners and Torque Settings .................................................. 32

8.2

Lubricants .................................................................................. 33

8.3

Troubleshooting ......................................................................... 33

8.4

8.5 MaterialSpecications ...............................................................

Foundation Dimensions and Weights ........................................ 34

8.6

Typical Noise Emission Data - CP10, CP20 & CP30 Pumps .... 35

8.7

Typical Noise Emission Data - CP40 & CP50 Pumps ............... 35

8.8

Classic+ Series CP20 Pump

25

25

26

26

27

27

29

33

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

1.0 SAFETY INFORMATION

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

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

Symbol
Legend :

Danger - Failure to follow the listed

precautionary measures identified by
this symbol may result in serious injury

!

or death.

WARNING

Warning - Safety instructions which

shall be considered for reasons of safe
operation of the pump or pump unit and/
or protection of the pump or pump unit
itself are marked by this symbol.

!

!

!

!

WARNING

!

!

WARNING

WARNING

WARNING

DO NOT OPERATE PUMP IF:

- The head is not installed correctly.

- Any guards are missing or incorrectly installed.

- The suction or discharge piping is not connected.

DO NOTplace ngers,etc. intothepumping chamber

or its connection ports or into any part of the gearbox if
there is ANY possibility of the pump shafts being rotated.
Severe injury will occur.

DO NOT exceed the pumps rated pressure, speed, and
temperature, or change the system/duty parameters
from those for which the pump was originally supplied,

withoutconrmingitssuitabilityforthenewduty.Running

the pump outside of its operation envelope can cause
mechanical contact, excessive heat and can represent a
serious risk to health and safety.

Installation and operation of the pump must always
comply with health and safety regulations.

A device must be incorporated into the pump, system,
or drive to prevent the pump exceeding its stated duty
pressure. It must be suitable for both directions of pump
rotation where applicable. Do not allow pump to operate
with a closed/blocked discharge unless a pressure
relief device is incorporated. If an integral relief valve is
incorporated into the pump, do not allow re-circulation
through the relief valve for extended periods (refer to
section 3.8).

The mounting of the pump or pump unit should be solid
and stable. Pump orientation must be considered in
relation to drainage/cavity ventilation requirements.
Once mounted, shaft drive elements must be checked for
correct alignment. Rotate pump shaft by at least one full
revolution to ensure smoothness of operation. Incorrect
alignment will produce excessive loading and will create
high temperatures and increased noise emissions. It
may also be necessary to earth the pump head to avoid
the build up of a potential charge difference that could
cause a spark.

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

Fill all gearboxes with the recommended grades and
quantities of lubricant (refer to section 3.4 and 8.3).

Beware ofover/underlling the gearbox as this could

cause the pump to overheat and mechanical damage
to occur.

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

Be sure that pump rotation is correct for the desired
directionofow(refer to section 3.4).

WARNING

WARNING

!

!

!

!

!

!

WARNING

!

DO NOT install the pump into a system where it will run
dry (i.e. without a supply of pumped media) unless it is

equippedwithaushedshaftsealarrangementcomplete
withafullyoperationalushingsystem.Mechanicalseals
requirea thin uid lmtolubricate thesealfaces. Dry

running can cause excessive heat and seal failure.

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

Caution must be taken when lifting the pump. Suitable
lifting devices should be used as appropriate. Lifting eyes
installed on the pump must only be used to lift the pump,
not pump with drive and/or base plate. If pump is base
plate mounted, the base plate must be used for all lifting
purposes. If slings are used for lifting, they must be safely
and securely attached. For weights of bare shaft pumps,
refer to section 8.6.

DO NOT attempt any maintenance or disassembly of the
pump or pump unitwithoutrstensuringthat:

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

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

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

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

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

Pumps and/or drives can produce sound power levels
exceeding 85dB (A) under certain operating conditions.
When necessary, personal protection against noise must
be taken. Typical noise emission data can be found in
sections 8.7 and 8.8.

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

When cleaning, either manually or by an in-line cleaning
method, the operator must ensure that a suitable
procedure is used in accordance with the system
requirements. During a in-line cleaning cycle, a pump
differential pressure of between 2 and 3 bar (30 and 45
psi) is recommended to ensure suitable velocities are
reached within the pump head. The exterior of the pump
should be cleaned periodically.

Surface temperature of pump is also dependent on the
temperature of pumped medium.

heat-tracing,

SECTION TSM 285 ISSUE A PAGE 2 OF 36

1.1 RISK ASSESSMENT RELATING
TO THE USE OF VIKING PUMP
CLASSIC+ ROTARY LOBE
PUMPS AND PUMP UNITS IN
POTENTIALLY EXPLOSIVE
ATMOSPHERES

NOTE

For a feature to be suitable for an application, the

feature must be t for its designated purpose and also

suitable for the environment where it is to be installed.

Source

of Hazards

Unvented

Cavities

Casing /

Rotors /

Head

Pump

External

Surfaces

Cover

O-Ring

Pump

Casing / Cover

Shaft Seals

Auxiliary

System for

Shaft

Sealing

Rotation
Direction

Test

Closed

Valve

Condition

Shaft

Mechanical

Shaft

Coupling

(Torque

Protection)

Mechanical

Shaft

Coupling

(Standard)

Potential

Hazards

Build up of explosive gas

Unintended mechanical

contact

Excess temperature.

Electrostatic charging

Pump liquid leakage.

Build up of explosive gas

Pump liquid leakage.

Build up of explosive gas

Excessive temperature.

Unintended mechanical

contact. Leakage.

up of explosive gas

Pump liquid leakage.

Build up of explosive gas

Excess Temperature

Excess Temperature.

Excess Pressure.

Mechanical Contact

Random induced current

Temperature from

friction. Sparks from

break up of shear pins.

Electrostatic charging

Break up of spider.

Unintended

mechanical contact.

Electrostatic charging

Build

Frequency

of Hazards

Very Rare

Rare

Rare

Very Rare

Very Rare

Rare

Rare

Very Rare

Rare

Very Rare

Rare

Rare

Recommended

Measures

Ensure that pump is totally

lled. Consider mounting

ports vertically.

See Chapter 1.0

Ensure that operating

pressures are not

exceeded. Ensure that

sufcient NPSH to prevent

cavitation. See Chapter

1.0 / 3.3.1 Service Plan

User must ensure

temperature limits. Do not

overll gearboxes with

lubricant. Provide a ground

contact for pump. See

Chapter 1.0 / Service plan

Check selection of

elastomers are suitable for

application. Ensure cover

retaining nuts are tight.

Service plan

Stainless Steel.

Corrosion Resistant

Selection of seal system

must be suitable for

application. See Chapter

5.0. Service plan. Seals

must never run dry

Selection of auxiliary seal

system must be suitable

for application. Seals must

never run dry

If ushed seals are

installed, ensure that

ush is applied to seal
assemblies. Only allow

pump to run for minimum

period - just a few seconds

Can cause excessive

pressure, heat and

mechanical contact.

See Chapter 1.0

Provide a ground contact

for pump. See Chapter 1.0

Coupling selection must

suit application.

See Chapter 1.0

Coupling selection must

suit application. Service

plan. See Chapter 1.0

2.0 INTRODUCTION

2.1 GENERAL

Classic+ rotary lobe pumps are manufactured by Johnson
Pump (UK) Ltd. a subsidiary of Viking Pump Inc., Cedar Falls,
USA, (a unit of the IDEX Corporation).

This manual includes all the necessary information for the
Classic+ and should be read prior to beginning installation,
operation, or maintenance.

Should you require any additional information regarding
the Classic+ contact Viking Pump or their local authorized
distributor, refer to section 2.2.

When asking for assistance please provide the pump model
and serial number. This information can be obtained from the
pump nameplate which is located on the side of the pump
gearbox cover, refer to section 2.6.

Should the nameplate be unreadable or missing, the serial
number is also stamped on either side of the casing refer to
section 2.6.

If the system or product characteristics are to be changed from
the original application for which the pump was selected, Viking
Pump or their authorized distributor should be consulted to
ensure the pump is suitable for the new application.

2.2 VIKING PUMP DISTRIBUTORS

Viking Pump distributes its products internationally via a network
of authorized distributors. Throughout this manual where
reference is made to Viking Pump, service and assistance will
also be provided by any Viking Pump authorized distributor for
Classic+.

2.3 RECEIPTS AND STORAGE

Upon receipt of the pump, immediately examine it for any signs
of visible damage. If any damage is noted, contact Viking
Pump or your Viking Pump distributor and clearly mark upon
the carriers’ paperwork that the goods have been received in a
damaged condition, with a brief description of damage.

If the pump is not required for immediate installation then it
should be stored in a clean, dry environment. It is recommended
that storage temperature should be between –10° and 40°C
(14°F and 105°F).

Further to the above, if the pump is not intended for installation
or use within 18 months or more then refer to Viking Pump,
or the Viking Pump authorized distributor for storage
recommendations.

2.4 CLEANING

The Classic+ pump series is suitable for both manual cleaning
and in-line cleaning, refer to section 3.3.2.

It is recommended that the exterior of the pump be cleaned
periodically with a non-aggressive, non-abrasive cleaning
solution.

SECTION TSM 285 ISSUE A PAGE 3 OF 36

2.5 PUMP MODEL DESIGNATION

The designations of pump models in the Classic+ range are

asfollows:

CP10S CP20S CP30S CP40S

CP50S
CP10M CP20L CP30L CP40L CP50L
CP10L

This information, together with the pump serial number, should
be provided when requesting additional information on the
pump or when ordering spare parts. The pump serial number
is stamped on the pump nameplate and the casing, (refer to
section 2.6, Figures 2 and 3).

For the maximum operating pressures, temperatures and
speeds refer to section 3.2, Figure 6.

CP 30 / 0069 / 12

2.6 PUMP MODEL AND SERIAL
NUMBER

Should you require any information regarding your Classic+
rotary lobe pump contact Viking Pump or your Viking Pump
distributor, providing the pump model and serial number as

statedonthepumpnameplate,seeFigure2,whichisxedto

the pump gearbox cover.

Should this be damaged or missing, the pump serial number
is also stamped on opposite corners of the casing, (see
Figure 3).

Pump

Range

Model

Size

Displacement

(Ltrs/Rev)

Max Pressure

(Bar)

Figure 1

CP Designated Models Only

2.5.1 ATEX IDENTIFICATION PLATE

Unit is suitable

for environments

Temperature

Class

Group II Category 2

containing dust

or gas

2.5.2 EQUIPMENT GROUPS
& CATEGORIES

Equipment-groups (Annex I of the EC-Directive 94/9/EC)

Group I

(mines, mine gas & dust)

Category M Category 1 Category 2 Category 3

1 2

for equipment

providing a
very high level
of protection

when
endangered by

an explosive
atmosphere

for equipment

providing a
high level of

protection when
likely to
be endangered
by an explosive

atmosphere

(gas)

(Zone 0)

for equipment providing
a very high level of

protection when used
in areas where an

explosive atmosphere

is very likely to occur

(other explosive atmospheres gas/dust)

G

D

(dust)

(Zone 20)

Group II

G

(gas)

(Zone 1)

for equipment providing
a high level of

protection when used
in areas where an

explosive atmosphere

is likely to occur

D

(dust)

(Zone 21)

G

(gas)

(Zone 2)

for equipment providing

a normal level of

protection when used
in areas where an

explosive atmosphere

is less likely to occur

(dust)

(Zone 22)

VIKING P UMP, INC.
A Unit of IDE X Corporati on
CEDAR FAL LS, IOWA USA

Phone:( 319)266-17 41
Fax:(31 9)273-815 7

Figure 2

Nameplate

12345/A/67

Figure 3

Serial Number Position on Casing

D

SECTION TSM 285 ISSUE A PAGE 4 OF 36

2.7 STANDARD PUMP

ROTORS

FRONT COVER

ROTOR
RETAINER

ROTORCASE

BEARING
HOUSING

FRONT
BEARINGS

GEARBOX
COVER

BREATHER

/FILLER CAP

REAR
BEARINGS

DRIVE
SHAFT

DRIVEN
SHAFT

TIMING
GEARS

COMPONENT TERMS

Figure 4

Pump Component Terms

3.0 GENERAL

3.1 CLASSIC+ PUMPING PRINCIPAL

The pumping action of the rotary lobe pump principle is
generated by the contra rotation of two pumping elements
(rotors) within a chamber (casing) - see Figure 5. The rotors are
located on shafts, which in turn are mounted within an external
gearbox and supported by the bearings; the timing gears are
also located on the shafts. The timing gears transfer the energy
from the drive shaft to the driven shaft, synchronizing the rotors
such that they rotate without contact with each other.

As the rotors pass the suction port, see Figure 5a, the cavity
generated increases creating a pressure decrease, which

inducesthepumpedmediumtoowintothecasing.

The pumped medium is carried around the casing by the rotors;
see Figure 5b and 5c, to the discharge side of the pump, Figure
5d. Here the cavity decreases and the pumped medium is
discharged from the casing, Figure 5e.

For pump component terms, see Figure 4.

3.2 CLASSIC+ RANGE OPERATING
PARAMETERS

The maximum pressure and speed operating parameters are
given in Figure 6. In practice these may be limited due to the
nature of the product to be pumped and/or design of the system
in which the pump is to be installed. Consult Viking Pump or
your Viking Pump distributor for assistance.

The operating temperature limit of the pump is determined
by the rotor clearance. For the CP10, CP20, CP30 and CP40
series pumps there are three rotor clearance bands (class A,
B and C), and two (class B and D) for the CP50 series pumps.

WARNING

The pump should not be subjected to sudden temperature
changes to avoid the risk of damage from sudden expansion/
contraction of components. Care should be taken when
selecting pumps for handling liquids containing abrasive
particles as these may cause wear of pump head components.
For advice or assistance contact Viking Pump or your Viking
Pump distributor.

If the system or product characteristics are to
be changed from the original application for
which the pump was selected, Viking Pump or
their authorized distributor should be consulted
to ensure the pump is suitable for the new
application.

Figure 5

Rotary Lobe Pumping Principle

SECTION TSM 285 ISSUE A PAGE 5 OF 36

Pump Range Theoretical Displacement

10.0 Meters (32.8 Feet) Water Column

Suction Lift

Or Vacuum

Atmospheric

Pressure

Suction

Head

NPSH

Available

Suction Line

Friction Loss

Vapour

Pressure

NPSH

Available

Suction Line

Friction Loss

Vapour

Pressure

For Suction Lift

Or Vacuum

Conditions.

For Conditions

With Positive

Suction Head.

Atmospheric

Vacuum

Imp.gal

ltr/rev

CP10S 0.046 1.01 1.22 25 1 12 175 1400 1000 8.5 120
CP10M 0.083 1.83 2.19 38 1.5 8 120 1400 1000 5.5 75

CP10L 0.111 2.44 2.93 38 1.5 5 70 1400 1000 3.5 50

CP20S 0.202 4.44 5.34 38 1.5 12 175 1000 750 8.5 120

CP20L 0.313 6.89 8.27 50 2 7 100 1000 750 5.0 70

CP30S 0.694 15.27 18.34 50 2 12 175 750 550 8.5 120

CP30L 1.125 24.75 29.72 76 3 7 100 750 550 5.0 70

CP40S 1.800 39.60 47.56 76 3 12 175 700 520 8.5 120

CP40L 2.500 55.00 66.05 101 4 7 100 700 520 5.0 70

CP50S 3.514 77.31 92.84 101 4 12 175 650 420 8.5 120

CP50L 5.250 115.50 64.20 152 6 8 115 600 420 5.5 75

CP20/CP30 High Efciency Operating Parameters.

CP20S 0.202 4.44 5.34 38 1.5 7 100 1000 750 5.0 70

CP20L 0.313 6.89 8.27 50 2 4 55 1000 750 3.0 40

CP30S 0.694 15.27 18.34 50 2 7 100 750 520 5.0 70

CP30L 1.125 24.75 29.72 76 3 4 55 750 520 3.0 40

Classic+ Series

CP10, 20, 30, 40 70 100 150 N/A

CP50 N/A 100 N/A 180

/100 rev

Class A Class B Class C Class D

Nominal

Connection

Size

US gal

mm in. bar psi

/100 rev

Operating Temperature Limit (°C)

Max

Differential

Pressure

Max.

Speed

rev/
min

Max
Speed @
Max Diff.
Pressure

rev/min bar psi

Figure 6

Operating Parameters

3.3 SYSTEM DESIGN

Max Diff.
Pressure

@ Max
Speed

WARNING

WARNING

WARNING

WARNING

- Incorporation of a torque-limiting device in the
drive system.

It is recommended that all piping and associated
equipment from the tank to the discharge point
is thoroughly cleaned before installation of the
pump to avoid the possibility of debris entering
the pump and causing damage.

Pressure gauges should be installed adjacent to
the pump suction and discharge connections such
that system pressures can be monitored. These
gauges will provide a clear indication of changes
in operating conditions and where a relief valve
is incorporated in the system, will be necessary
for setting and checking the functioning of the
valve.

It is imperative that the suction condition at the
pump inlet meets the Net Positive Suction Head
required (NPSHr) by the pump. Failure to observe
this could cause cavitation, resulting in noisy

operation,reductioninowrateandmechanical

damage to the pump and associated equipment.

The Net Positive Suction Head available
(NPSHa) from the system must always exceed
the Net Positive Suction Head required (NPSHr)
by the pump.

3.3.1 SYSTEM DESIGN AND
INSTALLATION

When incorporating any pump into a system it is considered
good practice to minimize piping runs and the number of pipe

ttings (tees, unions, bends etc.) and restrictions.  Particular

care should be taken in designing the suction line, which
should be as short and straight as possible with a minimum of

pipettingstominimiserestrictingproductowto the pump.

The following should be considered at the design stage of any
system.

Be sure ample room is provided around the pump

!

!

WARNING

Valves should be provided adjacent to the pump suction and
discharge connections to allow the pump to be isolated from
the system for routine inspection and maintenance.

!

SECTION TSM 285 ISSUE A PAGE 6 OF 36

toallowfor:

- Access to the pump and drive for routine
inspection and maintenance, i.e. to remove
pump head and rotors.

- Ventilation of the drive to prevent over
heating.

The exterior of the pump unit may exceed 68°C
(154°F); Appropriate measures must be taken to
warn or protect operators.

The pump must not be used to support piping.
All piping to and from the pump unit must be
independently supported. Failure to observe
this may distort the pump head components
or assembly and cause serious consequential
damage to the pump.

Rotary lobe pumps are of the positive displacement
type and therefore an overload protection device

mustbeprovided.Thiscantaketheformof:

- An in-line pressure relief system, i.e. external
to the pump.

Figure 7

NPSH

Observing the following general guidelines should ensure the
best possible suction condition is created.

- Suction piping is at least the same diameter
connections.

- The length of suction piping is kept to the
minimum.

- The minimum number of bends, tees and

restrictions are used.

- Calculations to determine system NPSHa are
the worst condition see below.

Should advice on pump or system NPSH characteristics be
required contact the factory or their authorized distributor.

When installing a pump complete with base plate, motor and

drive,thefollowingguidelinesmustbeobserved:

a) The preferred drive arrangement for any

is in-line direct coupled. If an alternative is required please
contact Viking Pump or your Viking Pump distributor.

b) Flexible couplings must always be

!

!

!

!

f) When using electric motor drives, ensure

supply is compatible with the drive and controls and that the
method of wiring is correct for the type of starting required
by the motor i.e. Direct On Line, or other similar method.
Ensure all components are correctly grounded.

incorporated and correctly aligned within
the limits recommended by the coupling
manufacturer. To check coupling alignment
rotate the shaft by at least one full revolution
and ensure that the shaft rotates smoothly.

Couplings of a non-flexible design must never
be used.

c) Couplings must always be enclosed in a

suitable guard to prevent contact with rotating
parts, which could result in personal injury.
Guards should be of suitable material, (see d)

and of sufciently rigid design to prevent

contact with rotating parts under normal
operating conditions.

d) Whenthepumpisinstalledinaammableor

explosive environment, or is used for handling

ammable or explosive materials, special

consideration must be given. Not only to the
safety aspects of the drive unit enclosure
but also to the materials used for both the
coupling and the guard to eliminate the risk of
explosion.

e) Base plates must be secured to a at level

surface such that distortion and misalignment
are avoided. Once base plates are fastened
in position the drive alignment must be re­checked, (see b).

as the pump

absolute

pipework

carried out for

rotary lobe pump

that the electrical

When installing a pump complete with base plate, motor and

drive,thefollowingguidelinesmustbeobserved:

a) The preferred drive arrangement for any

is in-line direct coupled. If an alternative is required please
contact Viking Pump or your Viking Pump distributor.

b) Flexible couplings must always be

!

!

!

!

f) When using electric motor drives, ensure

supply is compatible with the drive and controls and that the
method of wiring is correct for the type of starting required
by the motor i.e. Direct On Line, or other similar method.
Ensure all components are correctly grounded.

incorporated and correctly aligned within
the limits recommended by the coupling
manufacturer. To check coupling alignment
rotate the shaft by at least one full revolution
and ensure that the shaft rotates smoothly.

Couplings of a non-flexible design must never
be used.

c) Couplings must always be enclosed in a

suitable guard to prevent contact with rotating
parts, which could result in personal injury.
Guards should be of suitable material, (see d)

and of sufciently rigid design to prevent

contact with rotating parts under normal
operating conditions.

d) Whenthepumpisinstalledinaammableor

explosive environment, or is used for handling

ammable or explosive materials, special

consideration must be given. Not only to the
safety aspects of the drive unit enclosure
but also to the materials used for both the
coupling and the guard to eliminate the risk of
explosion.

e) Base plates must be secured to a at level

surface such that distortion and misalignment
are avoided. Once base plates are fastened
in position the drive alignment must be re­checked, (see b).

rotary lobe pump

that the electrical

3.3.2 Installations with
CIP SYSTEMS

The Classic+ pump range is designed to be effectively cleaned
by the CIP procedures recommended for in place cleaning of
process plant. It is recommended that a differential pressure
of 2 to 3 Bar (30 to 45 psi) be developed across the pump

headduringcleaninginordertodevelopthenecessaryuid

velocities required for thorough cleaning.

SECTION TSM 285 ISSUE A PAGE 7 OF 36

3.4 Start Up Procedure

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

- Before beginning operation, it is considered
to momentarily start/stop the pump to check the direction of
rotation and ensure that the pump is free of obstructions.
Once this has been carried out, begin operation keeping a
visual check on suction and discharge pressure gauges and
monitor the pump temperature and absorbed power where
possible.

- Check that all piping and associated equipment
are clean and free from debris and that all pipe
connections are secure and leak free.

- For pumps tted with ushed product seals

check all auxiliary services are in place

and connected and provide sufcient ow
and pressure for ushing purposes, refer to

section 7.0.

- Ensure lubrication is provided for both pump
and drive. The Classic+ is shipped without oil

as standard and should be lled to the level

of the oil sight glass - refer to section 8.3 for
pump oil capacities and grades.

- If an external relief valve is incorporated in the
system, check that it is set correctly. For start up
purposes, it is considered good practice to set
the relief valve lower than the system design
pressure. On completion of start up, the relief
valve should be reset to the required setting
for the application. The required setting should
never exceed the lower of either the pumps
maximum pressure rating or the system design
pressure. For setting integral relief valves refer
to sections 3.8.1 and 3.8.2.

- Be sure both suction and discharge valves are
fully opened and that pipe work is free from
all obstructions. The Classic+ is a positive
displacement type pump and should therefore
never be operated against a closed valve as this
would result in pressure overload, resulting in
damage to the pump and possibly the system.

- Make sure that the drive shaft rotation is correct

forthedirectionofowrequired.SeeFigure8.

- Be sure product is available in the suction
vessel before starting the pump. This is very

important for pumps tted with un-ushed

product seals, as these sealing arrangements
must never be allowed to run dry.

good practice

3.5 SHUTDOWN PROCEDURE

When shutting the pump down, stop pump, close

!

both the suction and discharge valves and ensure

thatthenecessarysafetyprecautionsaretaken:

- The prime mover power source has been
isolated.

- If installed, pneumatically operated integral
relief valve has been depressurized.

- Flushed product seal auxiliary services have
been isolated and depressurized.

- Pump head and piping have been drained and
purged.

- Before undertaking any work on the pump refer
to sections 4, 5, 6 and 7.

3.6 ROUTINE MAINTENANCE

WARNING

- Change the oil every 12 months or 3000
whichever is the sooner.

- For lubricant capacities and grades refer to

- Check oil levels regularly.

operating hours,

section 8.3.

3.7 HEATING AND COOLING

JACKETS

SeeFigure9andFigure10.

The Classic+ can be supplied with a jacketed head and casing
for circulation of a heating/cooling media.

The jacketed head and casing ports are strategically positioned
such that the required thermal effect acts on the pumping
chamber.

The pressure rating of the Classic+ series jacketed

!

Heating/cooling of the pump head is used to maintain, rather
than increase/decrease the temperature of the pumped media
and should be used as part of a complete system where suction
and discharge lines and vessels are also heated/cooled.

Where heating/cooling devices are employed, the heating/
cooling media should be circulated 15-20 minutes prior to pump
start-up and should be allowed to continue for a similar period
of time after the pump has been shut down. Where an in-line
cleaning cycle is employed as part of the process, then the
heating/cooling media should continue to be circulated during
the cleaning cycle.

head and casing is 3 Bar (50 psi) and this should
not be exceeded without consulting Viking Pump
or your local Viking Pump distributor.

Figure 8

Rotation Against Suction and Discharge

SECTION TSM 285 ISSUE A PAGE 8 OF 36

Figure 9

Dimensions of Jacketed Head

for Heating/Cooling

Model

CP10/0005/12 50.0 52.0 1.97 2.05 ¼”
CP10/0008/08 50.0 61.0 1.97 2.40 ¼”

CP10/0011/05 50.0 61.0 1.97 2.40 ¼”
CP20/0020/12 64.0 71.0 2.52 2.80 ½”
CP20/0031/07 64.0 81.0 2.52 3.19 ½”
CP30/0069/12 92.5 81.0 3.64 3.19 ½”

CP30/0113/07 92.5 96.0 3.64 3.78 ½”
CP40/0180/12 130.0 108.0 5.12 4.25 ½”
CP40/0250/07 130.0 123.0 5.12 4.84 ½”
CP50/0351/12 175.0 115.0 6.89 4.53 ½”
CP50/0525/08 175.0 138.0 6.89 5.43 ½”

A6 M1 A6 M1 Y4

Millimeters Inches

Figure 10

Dimensions of Jacketed Casing

for Heating/Cooling

Model

CP10/0005/12 70.0 56.0 156.0 3.0 2.76 2.20 6.14 0.12 ¼
CP10/0008/08 70.0 56.0 156.0 2.0 2.76 2.20 6.14 0.08 ¼
CP10/0011/05 70.0 56.0 156.0 7.5 2.76 2.20 6.14 0.30 ¼
CP20/0020/12 80.0 64.0 216.0 0.0 3.15 2.52 8.50 0.00 ¼
CP20/0031/07 80.0 64.0 216.0 1.0 3.15 2.52 8.50 0.04 ¼
CP30/0069/12 118.0 93.0 280.0 1.0 4.65 3.66 11.02 0.04 ½
CP30/0113/07 118.0 93.0 280.0 3.5 4.65 3.66 11.02 0.14 ½
CP40/0180/12 156.0 125.0 352.0 2.5 6.14 4.92 13.86 0.10 ½
CP40/0250/07 156.0 125.0 352.0 3.5 6.14 4.92 13.86 0.14 ½
CP50/0351/12 191.0 155.0 430.0 8.0 7.52 6.10 16.93 0.31 ½
CP50/0525/08 191.0 155.0 430.0 10.0 7.52 6.10 16.93 0.39 ½

A7 BJ D1 M2 A7 B J D1 M2 Y5

Millimeters Inches

SECTION TSM 285 ISSUE A PAGE9 OF 36

3.8 INTEGRAL PRESSURE RELIEF
VALVES

See Figures 11, 12, 13 and 14.

The Classic+ models CP10, CP20, CP30 and CP40 can be
supplied with integral pressure relief valves. For the CP10,
CP20 and CP30 both spring and air loaded versions are
available. The function of the valves can be further enhanced
with the option of manual or airlift override, offering particular

benetswhere CIPorSIPproceduresareemployed.Valves
incorporating this option can be opened to regulate the ow

of the cleaning media through the pump chamber, thereby
avoiding the need for manual cleaning or external bypass.

Where the pump is mounted onto a portable base plate,
complete with motor and drive to be used as a mobile set, an
integral pressure relief valve should be installed.

TheClassic+integralpressurereliefvalvesavailableinclude:

Spring Loaded - see Figure 11.

- Valve can be set to the required pressure relief setting.

Spring Loaded with Manual Lift - see Figure 12.

- Valve can be set to the required pressure relief setting.

Manual lift override can be used to open valve without
disturbing pressure relief setting.

Spring Loaded with Air Lift - see Figure 13.

- Valve can be set to the required pressure relief setting. Air

override, which operates on an air supply of up to 7 Bar (102
psi) depending on pressure relief setting, can be used to
open valve without disturbing pressure relief setting.

Air Loaded with Air Lift - see Figure 14.

- Valve, which operates on an air supply of up to 7 Bar

psi) regulated for required setting, can be set to the required
pressure relief setting. Airlift override, which operates on an
air supply of up to 7 Bar (102 psi) depending on pressure
relief setting, can be used to open valve without disturbing
pressure relief setting.

Air actuated relief valves can be operated remotely and inter­faced with other elements of the system or process control.

WARNING

Ifthepumponwhichthevalveisttedistobeinstalledwithin

either a pressurised system or one incorporating a vessel under
vacuum then the application of the valve should be referred to
Viking Pump.

Integral pressure relief valves are normally used
to protect the pump from the effects of increases
in system pressure caused, for example, by a
restricted or closed discharge line. In response
to a pressure increase, the valve opens and
internally circulates the pumped media within the
pump chamber. When the valve opens, because
the volume of liquid circulating is relatively small,
the temperature of the liquid in the pump chamber
may rise if the pump continues to operate for
an extended period. In severe cases, this may
result in temperatures in excess of the pumps
operating limits, or vaporisation of the liquid, both
of which should be avoided. For these reasons
when the valve is activated the cause of the
system pressure increase should be eliminated
as continuous operation of the pump with the
valve open is not recommended and may cause
severe damage to the pump.

lift

(102

The selection, setting and application of integral relief valves is

inuencedbytheviscosityandnatureofthepumpedmedia,the

pumps operating speed and the required pressure relief setting
and mode of operation. For these reasons and to cover the
diverse range of products, the conditions under which they are
pumped and application demands, it is not practical to factory­set integral relief. Valves and the setting of the valves should
be carried out on site, under the proposed duty conditions for
which the pump and valve were selected.

For setting and operating Classic+ integral relief valves refer
to sections 3.8.1 and 3.8.2. Before beginning the relief valve
setting procedure the pump should be installed, refer to section

3.3.1, paragraph (vi), with a pressure gauge in the discharge
line adjacent to the pump discharge port.

3.8.1 SETTING AND OPERATING
SPRING LOADED VALVES

See Figures 11, 12 and 13.

- Remove cover (108). For integral relief valve with manual lift,

seeFigure12;rstremovenut(129)andhandwheel(111).

- Unscrew nut (107) using pry bar in holes

!

- Start pump. - refer to section 3.4.

- Screw in nut (107) using pry bar in holes provided until the

required pressure relief setting is reached.

WARNING

- Reinstall cover (108). For integral relief valve with manual

lift,seeFigure12;reinstallhandwheel(111)andnut(129).

- The relief valve is now set.

For Integral Relief Valve with Manual Lift - see Figure 12.

- To operate the manual lift, turn the hand wheel (111)

which will lift the valve head (102/128). To resume normal
relief valve operation, turn the hand wheel (111) counter­clockwise.

For Integral Relief Valve with Air Lift - see Figure 13.

- To actuate the airlift, connect an air supply not exceeding

7 Bar (102 psi) to the cylinder (123), connection ‘B’, which
will lift the valve head (112). To resume normal relief valve
operation, exhaust the cylinder (123).

provided to relieve spring compression. For
integral relief valve with airlift, see Figure 13,
the air cylinder must be exhausted prior to
unscrewing the nut (107).

Note: Care should be taken not to exceed the
lower of either the pump’s maximum pressure
rating or the system design pressure.

clockwise,

3.8.2 SETTING AND OPERATING
AIR LOADED INTEGRAL
PRESSURE RELIEF VALVES

See Figure 14.

- Connect an air supply, not exceeding 7 Bar (102 psi), via

a regulating valve to the relief valve connection ‘A’ in the
cylinder (114). Do not turn on the air supply.

- Start the pump, refer to section 3.4.

- Using the regulating valve, gradually increase the air

pressure until required pressure relief setting is reached. The
air pressure must not exceed 7 Bar (102 psi).

- The relief valve is now set.

SECTION TSM 285 ISSUE A PAGE 10 OF 36

WARNING

!

! !

Note: Care should be taken not to exceed the
lower of either the pump’s maximum pressure
rating or the system design pressure.

- To use the air lift system, the regulated air
supply must be routed through a change-over
valve in order to transfer air from the relief valve
load air chamber, connection ‘A’, to the lift air
chamber, connection ‘B’, while depressurizing
the load chamber and vice versa. The change­over valve will actuate the air lift which will lift
when the air supply is diverted to connection
‘B’, and will close, restoring normal relief valve
operation, when the air supply is diverted back
to connection ‘A’.

DANGER !

Under no circumstances should any
attempt be made to dismantle a pressure
relief valve which has not had the spring
pressure relieved, is still connected to a
pressurized air supply, or is mounted on a
pump that is operating. Serious personal
injury or pump damage may occur.

Figure 12

Spring Loaded Integral Pressure Relief Valve

with Manual Lift

CP10, CP20 and CP30

Figure 11

Spring Loaded Integral Pressure Relief Valve

CP10, CP20, CP30, CP40

Figure 13

Spring Loaded Integral Pressure Relief Valve with Air Lift

CP10, CP20 and CP30

Figure 14

Air Loaded Integral Pressure Relief Valve with Air Lift

CP10, CP20, CP30 and CP40

SECTION TSM 285 ISSUE A PAGE 11 OF 36