Viking Pump TSM285 User Manual

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Page 1

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

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

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

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

Page 2

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

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

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

Page 3

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

Very Rare

Rare

Very Rare

Rare

Very 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

Page 4

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)

(dust)

(Zone 20)

Group II

(gas)

(Zone 1)

for equipment providing a high level of

protection when used in areas where an

explosive atmosphere

is likely to occur

(dust)

(Zone 21)

(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

SECTION TSM 285 ISSUE A PAGE 4 OF 36

Page 5

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.

Figure 5

Rotary Lobe Pumping Principle

SECTION TSM 285 ISSUE A PAGE 5 OF 36

Page 6

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

- 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

Page 7

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

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

Page 8

3.4 Start Up Procedure

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

Page 9

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

Page 10

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

Page 11

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

Page 12

4.0 CLASSIC+ DISASSEMBLY AND ASSEMBLY

Before starting any work on the pump the

During disassembly or before assembly, all components should

beinspectedfort,wearanddamage.Ifwornordamagedthe

components should be replaced.

Thepositionofallpartsshouldbeidentiedastheyareremoved

to ensure they are reinstalled in the same position.

Lipseals and O-rings are incorporated within the gearbox assembly to contain the lubricant for the bearings and timing gears. Regular inspection and correct maintenance of these items will ensure that the lubrication is sustained and the pump maximum working life is achieved. To ensure this, it is extremely important that care is taken when removing and replacing new O-rings and lipseals. When removing and replacing lipseals ensure that the location bore for the outside diameter and the seat for the back of the lipseal is not damaged as this may create a leak path for the lubricant.

When removing lipseals or O-rings care should be taken to avoid cutting or tearing the sealing faces as they pass over keyways, splines, threads or other potentially sharp or abrasive edges. All lipseals and O-rings should be carefully examined and if damaged in any way, be replaced.

All O-rings and sealing lips of lipseals should be lightly lubricated with an appropriate lubricant (suitable for application) before installing.

When installing lipseals do not allow the rear face to come into contact with bearings or other rotating parts.

Prior to beginning assembly, ensure all parts are clean and free from burrs or damage. Where a vice is to be used then this should be installed with protective jaws to avoid damage to components. Do not hammer or apply undue force to install or position components.

WARNING

Under no circumstances should bearing cones or cups be hammered into position.

recommended Shutdown Procedure should be followed, refer to section 3.5.

While disassembling or assembling the pump it is essential to ensure that the pump and/or components are secured to provide adequate stability.

Large pump components or sub-assemblies should be installed using suitable devices. Use threaded holes for the attachment of lifting eyes where appropriate.

All fasteners are required to be tightened to the required torque setting during assembly, refer to section 8.2.

The preferred method of installing bearing cones is that they are heated to approximately 125°C (250°F) prior to installation. During this operation protective gloves should be used. Once bearing cones are installed in the correct position they should be allowed to cool before proceeding with assembly. As an alternative, bearing cones may be pressed into position providing the proper equipment is utilized and the necessary procedures are used to prevent component damage.

4.1 CP10, CP20 AND CP30 PUMP - DISASSEMBLY AND ASSEMBLY

4.1.1 CP10, CP20 AND CP30 HEAD AND ROTOR REMOVAL

Figure 15

CP10 Exploded View of Casing and Rotor Assembly

- Follow recommended shutdown procedure.

- For CP10 Pump – refer to Figure 15.

- For CP20 Pump – refer to Figure 16.

- Remove dome nuts (1.03).

WARNING

- Failure to observe this will result in damage to the pump.

- Remove head (1.01) using lever slots where

the head O-ring (1.02) or optional gasket (not shown).

- Remove rotor retainers’ (2.02) with socket supplied (not

shown).

Refer to section 3.5.

- Gradually loosen head retaining dome (1.03). Care should be taken as there may still be residual product and pressure in the pump head and as the dome nuts are loosened, this will vent to atmosphere.

Note: CP10 Pump Only - Do not rotate shafts at this stage as the casing is held in place by the head retaining dome nuts (1.03).

necessary and

nuts

SECTION TSM 285 ISSUE A PAGE 12 OF 36

Page 13

CP10 Pump Only

(After completing section 4.1.1)

- Slide casing (3.01) from bearing housing (4.01), noting it is located on dowels (4.03), keep arch shims (4.05) in appropriate sets if they are to be reused.

CP20 and CP30 Pump Only

(After completing section 4.1.1)

- Remove casing retention socket cap head screws (4.04) with appropriate metric allen key (not supplied).

- Slide casing (3.01) from bearing housing (4.01), noting it is located on dowels (4.03), keep arch shims (4.05) in appropriate sets if they are to be reused.

Single Un-Flushed Mechanical Seal as shown in Figure 17.

- See section 5.2.1 for removal and section 5.2.2 for replacement.

Figure 16

CP20/CP30 Exploded View of Casing

and Rotor Assembly

WARNING

- Remove retainer O-rings (2.03).

- Remove rotors (2.01) from shafts (5.01 and 5.02).

- Remove rotor O-rings (2.04) – Not fitted on O-ring seal version of CP10.

Note: If the pump is tted with O-ring Seals (instead of

mechanical seals) then the O-ring seal will now be visible – Chapter 6.0 for further information.

Note: The socket tool should always be used, the use of other tools may damage the retainer.

4.1.2 CP10, CP20 AND CP30

CASING REMOVAL

WARNING

Note: Ensure all pipe work is disconnected before commencing casing removal.

4.1.2.1 CP10, CP20 AND CP30

CASING REMOVAL FOR PUMPS FITTED WITH SINGLE UN-FLUSHED MECHANICAL SEALS AND SINGLE O-RING SEALS

Figure 17

Single Un-Flushed Mechanical Seal

Single O-ring Seal as shown in Figure 18 – see section 6.2.1 for removal and replacement.

- Remove rotor (2.01).

- Remove O-ring seal (7.04) from casing (3.01).

Figure 18

O-ring Seal

SECTION TSM 285 ISSUE A PAGE 13 OF 36

Page 14

4.1.2.2 CP10, CP20 AND CP30 CASING REMOVAL FOR PUMPS FITTED WITH SINGLE FLUSHED OR DOUBLE FLUSHED MECHANICAL SEALS.

Prior to removal of casing (3.01) for CP10, CP20 and CP30, remove seal housing screws (7.10) and separate housing

(7.06)fromcasing(3.01)notingitislocatedondowels(7.09).

CP10 Pump Only

(After completing section 4.1.1) - see Figure 15.

- Slide casing (3.01) from bearing housing (4.01), noting

it is located on dowels (4.03), keep arch shims (4.05) in appropriate sets if they are to be reused.

CP20 and CP30 Only

(After completing section 4.1.1) - see Figure 16.

- Remove casing retention socket cap head screws (4.04)

with appropriate metric allen key (not supplied).

- Slide casing (3.01) from bearing housing (4.01), noting

it is located on dowels (4.03), keep arch shims (4.05) in appropriate sets if they are to be reused.

SingleFlushedMechanicalSealasshowninFigure19.

- See section 5.2.3 for removal and section 5.2.4 for

replacement.

Double Flushed Mechanical Seal as shown in Figure 20 and Figure 21.

- CP10 Pump - see section 5.2.5 for removal and 5.2.6 for

replacement.

- CP20 and CP30 Pumps – see section 5.2.7 for removal and

5.2.8 for replacement.

4.1.3 CP10, CP20 AND CP30 GEARBOX DISASSEMBLY

(After completing 4.1.1 or 4.1.2)

Figure 19

Single Flushed Mechanical Seal

SECTION TSM 285 ISSUE A PAGE 14 OF 36

Page 15

Figure 23

CP20 and CP30

Component Parts

- CP10 Pumps Only

(5.16), keep shims and spacers in sets and identify position.

- CP30 Pumps Only

identify position.

- Remove screws (5.07) and retainers (5.06) from bearing housing (4.01).

- Remove shafts (5.01 and 5.02) from bearing housing (4.01) Shafts (5.01 and 5.02) will be complete with bearings (5.05) and shims (5.04), keep shims in sets and identify position.

- Remove oil seals (5.03) from bearing housing (4.01).

- Remove bearing cups (5.05) and any associated shims (5.04) from bearing housing (4.01), keep bearing cups (5.05) and shims (5.04) in sets and identify position.

- Remove bearing cones (5.05) from shafts (5.01 and 5.02).

- Remove shims (5.08) and spacers

- Remove shims (5.08) in sets and

4.1.4 CP10, CP20 AND CP30

GEARBOX ASSEMBLY

Refer to Figure 22 for CP10 or Figure 23 for CP20 and CP30.

- Install bearing cones (5.05) to shafts (5.01 and 5.02) they locate against shaft shoulder. The cones are installed as shown in Figure 24.

ensuring

Before starting disassembly of the gearbox remove product seals; refer to section 5.0 for Mechanical Seals, or section 6.0 for O-ring seals.

The following procedure describes complete disassembly of the gearbox.

- Refer to Figure 22 for CP10; Refer to Figure 33 for CP20 CP30.

- Remove guard (5.06).

- Remove drive key (6.12).

- Removeoildrainplug(6.09)andbreather(6.10),drain

suitable container and retain if later inspection is required.

- Remove screws (6.11) and separate gearbox cover (6.00) from bearing housing (4.01). The gearbox cover (6.00) is located on dowels (6.06)

Note: The bearing housing (4.01) is provided with two jacking holes (tapped M8 on CP10; M10 on CP20; M12 on CP30), which can be used to separate the gearbox cover (6.00) from the bearing housing (4.01).

- Remove gasket (6.05) from gearbox cover (6.00) or bearing housing (4.01) depending upon which part the gasket is adhered to.

- Remove oil seal (6.03) and blanking cap (6.04) from gear cover (6.00).

- Remove retaining rings (6.01) from gearbox cover (6.00) press out bearing outer rings (6.02).

- Remove bearing inner ring (6.02) from shafts (5.01 and

- CP10 & CP20 Pumps Only

tab washers’ (5.11).

- CP30 Pumps Only

nuts (5.12).

- Removetiminggears(5.09)andgearkeys(5.10).

– Loosen locking screws from and lock

- Remove lock nuts (5.12) and

and

oil into

box

and

5.02).

Figure 24

Installation of bearing cones onto shafts

- Install two bearing cups (5.05) to bearing housing (4.01).

- Install shafts (5.01 and 5.02) in bearing housing (4.01).

- Install remaining bearing cups (5.05), shims (5.04) to nomi value of 0.60mm (0.024”), retainers (5.06) and secure with screws (5.07) tightened to correct torque refer to section

8.2.

- Using a torque wrench, check the rolling torque of each shaft assembly, referring to section 8.2. If necessary, adjust amount of shim (5.04), either by adding shim (5.04) to increase rolling torque or removing shim (5.04) to decrease rolling torque, until correct rolling torque has been achieved. If shim (5.04) is adjusted ensure screws (5.07) are tightened to correct torque before final check of rolling torque.

- Install rotors (2.01) on to shafts (5.01 and 5.02) with rotor retainers (2.02).

Note: The socket tool (not shown) should always be used, the use of other tools may damage the retainer.

- Using a depth micrometer or similar device measure any difference (X) in rotor front face alignment, see Figure 25. If a difference is found move shims (5.04) of thickness equal to the difference (X) from beneath the forward rotor’s bearing retainer (5.06) and reposition under the front bearing (5.05) cup.

SECTION TSM 285 ISSUE A PAGE 15 OF 36

nal

Page 16

- After adjusting shim (5.04) check rotor front face alignment and rolling torque.

- Remove rotor retainers’ (2.02) and rotors (2.01).

- CP10 Pumps Only

(5.10) to shafts (5.01 and 5.02).

- CP20 and CP30 Pumps Only

shafts (5.01 and 5.02).

Rotor / Bearing abutment setting

- Install spacers (5.16) and gear keys

- Install gear keys (5.10) to

Figure 25

- Install rotors (2.01) and rotor retainers (2.02)

- Check mesh clearance against the Clearance Chart (refer section 8.1).

- To adjust mesh clearance shims (5.08) will need to be

betweenthespacer(5.16)andthegear(5.09).Asaguidefor

a mesh clearance change of one unit (say 0.1mm or 0.004”), shims (5.08) of four units’ thickness (say 0.4mm or 0.016”) need to be inserted. Further, for clockwise movement of the rotor (when viewed from the rotor end) insert shim (5.08) in between the spacer (5.16) on the CP10; or bearing (5.05) on

theCP20andCP30;andthegear(5.09)havingarighthand

helix, and vice versa, see Figure 27.

- Having installed shim (5.08) ensure lock nuts (5.12) are tightened to correct torque (refer to section 8.2), before checking mesh clearance (refer to section 8.1).

- CP10 and CP20 Pumps Only

mesh clearances the tab washers’ (5.11) can be secured.

- CP30 Pump Only

clearances the lock screws in the locknuts (5.12) can be secured.

- Having achieved optimum mesh

- Having achieved optimum

inserted

- CP10 Pumps Only - Timing marks and gear marks ‘D’ and

‘L’ on gears (5.09) should be visible when viewed on the

drive end of the drive shaft.

- CP20 and CP30 Pumps Only

marks ‘D’ and ‘L’ on gears (5.09) should be visible when

viewed on the drive end of the shafts (5.01 and 5.02), and

the tapered shoulder on the gear (5.09) should face the

bearings (5.05).

- Install gears(5.09)to shafts(5.01and5.02).Gearmarked

‘D’ should be installed to drive shaft (5.01). Gear marked ‘L’ should be installed to lay shaft (5.02) ensuring correct alignment of timing marks, see Figure 26.

- CP10 and CP20 Pumps Only

and lock nuts (5.12) tightened to correct torque, refer to section 8.2. Do not secure tab washers (5.11).

- CP30 Pumps Only

correct torque (refer to section 8.2).

Install, but do not tighten lock-screws (5.12) which are fitted

in the locknuts (5.12).

- Install locknuts (5.12) and tighten to

- Timing marks and gear

- Install tab washers (5.11)

- Remove rotor retainers’ (2.02) and rotors (2.01).

- Install bearing (6.02) inner races to shafts (5.01 and 5.02), positioning against shoulder on shaft.

- Install inner retaining rings (6.01), bearing (6.02) outers, retaining rings (6.01), lipseal (6.03), blanking cap (6.04), filler

plug(6.10),sightglass(6.07)anddrainplug(6.09)tocover

(6.00).

- Install cover (6.00) to bearing housing (4.01) with gasket (6.05), locating on dowels (6.06), and secure with screws (6.11) tightened to correct torque, refer to section 8.2.

outer

4.1.5 CP10, CP20 AND CP30 CASING,

ROTOR AND HEAD ASSEMBLY

- see Figure 15 for CP10.

- see Figure 16 for CP20 and CP30.

- Install casing (3.01) to bearing housing (4.01) locating on dowels (4.03).

- CP10 Pump Only

nuts(1.03)usingfourtemporaryspacers(12mmlongx9mm

bore or 0.472” long x 0.354” bore).

- Secure casing (3.01) in position with

SECTION TSM 285 ISSUE A PAGE 16 OF 36

Page 17

- CP20 and CP30 Pumps Only.

Secure casing (3.01) in position with socket cap head screws (4.04) using appropriate metric allen key (not supplied), tightened to correct torque, refer to section 8.2. For additional clamping whilst checking the clearances clamp the casing on the opposite corners to the socket cap screws using washers (not supplied) and nuts (1.03).

WARNING

- Install rotors (2.01) to shafts (5.01 and 5.02) with retainers (2.02).

- Using a depth micrometer or similar device measure front clearance (refer to section 8.1 Clearance Chart) between the casing and rotor front faces and check that this corresponds to the appropriate clearance as indicated on the Clearance Chart.

- To adjust front clearance, remove rotors (2.01) and (3.01) and insert arch shims (4.05) between the casing (3.01) and bearing housing (4.01).

WARNING

- Install product seals; refer to section 5.0 or 6.0.

- Install guard (5.06).

- Install casing (3.01) securing in position with temporary spacers (CP10) or socket cap head screws, washers and nuts (CP20 and CP30) as before.

- Install rotors (2.01) with O-rings (2.03 and 2.04) and (2.02) tightened to correct torque, refer to section 8.2, using socket tool (not shown).

- Check all rotor clearances i.e. front, rear, top/bottom, sides’ and mesh. (Refer to section 8.1 Clearance Chart.)

- CP10 Pump Only

casing (3.01).

- CP10, CP20 and CP30 Pumps Only

with O-ring (1.02) or gasket and secure with nuts (1.03) tightened to correct torque, refer to section 8.2.

Note: The casing must be clamped in position as above to enable front and rear rotor clearances to be checked.

casing

Note: It is essential that the thickness of arch shim (4.05) inserted is the same at both the top and bottom of the casing (3.01).

retainers

- Remove temporary spacers retaining

- Install head (1.01)

Note: The socket tool supplied (not shown) should always be used to remove the retainer. The use of other tools may damage the retainer.

- Remove retainer O-rings (2.03).

- Remove rotors (2.01) from shafts (5.01 and 5.02).

- Remove rotor O-rings (2.04).

Figure 28

Head and Casing Removal for CP40

4.2.2 CP40 CASING REMOVAL

WARNING

Note: Ensure all pipe work is disconnected before commencing casing removal.

4.2 CP40 PUMPS - DISASSEMBLY

AND ASSEMBLY

4.2.1 CP40 HEAD AND

ROTOR REMOVAL

Follow recommended shutdown procedure -

- Refer to Figure 28.

- Remove dome nuts (1.03).

- Remove head (1.01), using lever slots as necessary.

- Remove head O-ring (1.02).

- Remove rotor retainers’ (2.02) with socket (not shown).

refer to section 3.5.

nuts

4.2.2.1 CP40 CASING REMOVAL FOR PUMPS FITTED WITH SINGLE UNFLUSHED MECHANICAL SEALS AND O-RING SEALS

(After completing 4.2.1)

- Remove dome nuts (4.08) fastening casing (3.01) to

(4.01).

SingleUn-ushedMechanicalSealforCP40-seeFigure29and

sections 5.2.1 for removal and section 5.2.2 for replacement.

- Slide casing (3.01) from gearbox (4.01) noting it is

dowels (4.03), keep arch shims (4.05) in appropriate sets if they are to be reused.

Single O-ring Seal as shown in Figure 30 – see section 6.2.1 for removal and replacement.

- Remove O-ring seal (7.04) from casing (3.01).

SECTION TSM 285 ISSUE A PAGE 17 OF 36

gearbox

located on

Page 18

Figure 30

O-ring Seal

- Slide casing (3.01) from gearbox (4.01) noting it is located on dowels (4.03), keep arch shims (4.05) in appropriate sets if they are to be reused.

4.2.2.2 CP40 CASING

REMOVAL FOR PUMPS FITTED WITH SINGLE FLUSHED OR DOUBLE FLUSHED MECHANICAL SEALS

- Prior to removal of casing (3.01) remove seal housing screws (7.10) and separate housing (7.06) from casing (3.01) noting

itislocatedondowels(7.09).

- Slide casing from bearing housing (4.01), noting it is lo on dowels (4.03), keep arch shims (4.05) in appropriate sets if they are to be re-used

Single Flushed Mechanical Seal as shown in Figure 31 and see sections 5.2.3 for removal and 5.2.4 for replacement.

Double Flushed Mechanical Seal as shown in Figure 32 and see section 5.2.7 for removal and 5.2.8 for replacement.

cated

Figure 31

Single Flushed Mechanical Seal - CP40

4.2.3 CP40 GEARBOX DISASSEMBLY

(After completing 4.3.1 and 4.3.2) - See Figure 33.

Before proceeding with disassembly of the gearbox remove product seals; refer to sections 5.0 for Mechanical Seals or section 6.0 for O-ring seals.

The following procedure describes complete disassembly of the gearbox, refer to Figure 33.

- Removedrivekey(6.12),oildrain(6.09)andbreatherplugs

(6.10), drain oil into suitable container and retain if later inspection is required.

- Remove screws (6.11) and gearbox cover (6.00). The

gearbox cover (6.00) is located on dowels (6.06) and sealed with suitable liquid sealer.

- Remove oil seal (6.03) from gearbox cover (6.00).

- Loosen by 2 full turns all screws in retainer (5.16). Once

done, the retainer may release its grip. If it does not become free, remove the two screws, which differ in color (these may also have a washer under the head). Once these screws are removed, tapped holes will be revealed. Insert two jacking M8 x 40 setscrews into the tapped holes and tighten until the retainer’s grip is broken. Remove the retainer.

this is

SECTION TSM 285 ISSUE A PAGE 18 OF 36

Page 19

- Install spacers (5.17), tab washers (5.20) and lock nuts (5.14) to shafts (5.01 and 5.02) tightening to correct torque, refer to section 8.2. Secure tab washers.

- Install bearing (6.02) inner races to shafts (5.01 and 5.02) positioning against shoulder on shaft.

- Install bearing (6.02) outer races and retaining rings (6.01)

gearbox (4.01).

- Install two bearing cups (5.05) to gearbox (4.01).

- Support gearbox (4.01) in a vertical position and install

shafts

(5.01 and 5.02) to gearbox (4.01).

- Install remaining bearing cups (5.05), shims (5.04) to nomi

nal value of 0.6mm (0.024”), O-rings (5.21), retainers (5.06) and secure with screws (5.07) tightening to correct torque, refer to section 8.2.

- Using a torque wrench, check rolling torque of each shaft assembly, refer to section 8.2, if necessary adjust amount of shim (5.04) either by adding shim (5.04) to increase rolling torque or removing shim (5.04) to decrease rolling torque until correct rolling torque has been achieved. If shim is adjusted ensure screws (5.07) are tightened to correct torque before final check of rolling torque.

- Install rotors (2.01) onto shafts (5.01 and 5.02) with rotor retainers (2.02).

Note: The socket tool (not shown) should always be used to remove the retainer. The use of other tools may damage the retainer.

- Using a depth micrometer or similar device measure any difference (X) in rotor front face alignment, see Figure 35. If a difference is found move shims (5.04) of thickness equal

- Remove lock nut (5.12) and tab washer (5.11).

- Removetiminggears(5.0---󼿑󱾣󶾡󻏰󹺤󳀭󶯥󾪑󲎩󺾡󹝥󳽐󷮡󳒛󽿕󹒛󽾥󺾦󺾦

to the difference (X) from beneath the lower rotors bearing retainer (5.06) and reposition under the front bearing (5.05) cup.

SECTION TSM 285 ISSUE A PAGE19 OF 36

Page 20

Figure 35

Rotor face alignment

- Lubricate retainer (5.16) with oil and mount to timing gear

(5.09).Donottighten.

- Install rotors (2.01) and rotor retainers (2.02) to shafts (5.01 and 5.02).

- Check rotor mesh clearance against Clearance Chart - refer to section 8.1. To adjust the mesh clearance rotate shafts (5.01 and 5.02). Having achieved optimum mesh clearance, retainer (5.16) can be tightened to correct torque, refer to section 8.2, taking note of typical tightening sequence, see Figure 37.

- After tightening of retainer (5.16) check mesh clearance, refer to section 8.1, Clearance Chart.

- Remove rotors (2.01) and retainers (2.02).

- Install oil seal (6.03) to gearbox cover (6.00).

- Apply liquid sealant (Loctite 573 or similar) to sealing gearbox cover (6.00) and install to gearbox (4.01), locating on dowels (6.06) and securing with screws (6.11), tightened to correct torque, refer to section 8.2.

area of

4.2.5 CP40 CASING, ROTOR AND

HEAD ASSEMBLY

Figure 36

Missing spline alignment

Figure 37

Retainer Tightening Sequence

SECTION TSM 285 ISSUE A PAGE 20 OF 36

Figure 38

CP40 Casing Assembly

Page 21

- Install product seals; refer to section 5.0 or section 6.0.

- Install casing (3.01) to gearbox (4.01), noting it locates dowels (4.03), securing with dome nuts (4.08).

- Install rotors (2.01) with O-rings (2.03 and 2.04) and retain (2.02) tightening to correct torque, refer to section 8.2, using socket tool supplied (not shown).

- Check all rotor clearances, front, rear, top/bottom, sides’ mesh, refer to section 8.1, Clearance Chart.

- Install head (1.01) with O-ring (1.02) and secure with (1.03) tightened to correct torque, refer to section 8.2.

and

nuts

4.3 CP50 PUMPS - DISASSEMBLY

AND ASSEMBLY

4.3.1 CP50 HEAD AND

ROTOR REMOVAL

ers

- Remove rotor caps (2.02) with tool (supplied, not shown).

Note: The tool provided should always be used to remove the rotor cap. The use of

other tools may damage the rotor cap.

- Remove rotor cap O-rings (2.03).

- Loosen by 2 full turns all screws in rotor retainer (2.05). this is done the retainer may release its grip. If it does not, loosen further the screws until the assembly becomes free to remove.

(On some brands of locking device there are two screws that are different in color (these may also have a washer under the head). Once these screws are removed tapped holes will be revealed. By inserting two jackscrews (M8 x 40 setscrews), into the tapped holes and tightening, the retainer’s grip is broken. Remove the retainers’ (2.05).

- Remove rotors (2.01) from shafts (5.01 and 5.02).

- Remove O-rings (2.04) and keys (2.06).

Once

4.3.2 CP50 CASING REMOVAL

Note: Ensure all pipe work is disconnected before commencing casing removal.

4.3.2.1 CP50 CASING REMOVAL

FOR PUMPS FITTED WITH SINGLE UN-FLUSHED MECHANICAL SEALS AND O-RING SEALS

(After completing 4.3.1)

- Remove dome nuts (4.08).

- Slide casing (3.01) from gearbox (4.01), noting it is on dowels (4.03).

Single Un-ushed Mechanical Seals as shown in Figure 40

and see sections 5.3.1 for removal and 5.3.2 for replacement.

Single O-ring Seal for CP50 see Figure 41 and see section

6.3.1 for removal and replacement.

- Remove O-ring seal (7.04) from casing (3.01).

- Slide casing (3.01) from gearbox (4.01) noting it is lo dowels (4.03).

located

cated on

Figure 39

Head and Rotor Components

Follow recommended shutdown procedure - refer to section 3.5.

- RefertoFigure39.

- Remove dome nuts (1.03).

- Remove head (1.01), using lever slots where neces the head O-ring (1.02).

nuts

sary and

4.3.2.2 CP50 CASING REMOVAL FOR PUMPS FITTED WITH SINGLE FLUSHED AND DOUBLE FLUSHED MECHANICAL SEALS

- Refer to Figure 42 for Single flushed mechanical seal for

CP50.

- Refer to Figure 43 for Double flushed mechanical seal for

CP50.

- Prior to removal of casing (3.01), remove seal housing

(7.18) from studs (7.17) and separate housing (7.06) from casing (3.01).

- Remove dome nuts (4.08).

- Slide casing from bearing housing (4.01), noting it is

on dowels (4.03).

SECTION TSM 285 ISSUE A PAGE 21 OF 36

nuts

located

Page 22

Figure 40

Single Un-ushed Mechanical Seal – CP50

4.3.3 CP50 GEARBOX DISASSEMBLY

(After completing 4.3.1 and 4.3.2)

Before proceeding with disassembly of the gearbox remove product seals; refer to section 5.3 for Mechanical Seals and

6.3 for O-ring Seals.

The following procedure describes complete disassembly of the gearbox, refer to Figure 44.

- Remove guard (4.06) and shaft slingers (7.03) if fitted.

- Remove drive key (6.12).

- Remove oil drain plugs (6.09) and breather plugs (6.10),

drain oil into suitable container and retain (inspection may later be required).

Figure 41

Single O-ring Seal CP50

Figure 42

Single Flushed Mechanical Seal for CP50

Figure 43

Double Flushed Mechanical Seal for CP50

- Remove screws (6.11) and gearbox cover (6.00). The

gearbox cover (6.00) is located on dowels (6.06) and sealed with suitable liquid sealant.

- Remove oil seal (6.03) from gearbox cover (6.00).

- Loosen by two full turns all screws in retainer (5.16) on the

lay shaft (5.02). Once this is done the retainer may release its grip. If it does not become free identify and remove the three screws which differ in color (these may also have a washer under the head). Once these screws are removed tapped holes will be revealed. Insert three jackscrews (M10 x 40 setscrews), into the tapped holes and tighten until the retainer’s grip is broken. Remove the retainer.

- Remove lock nut (5.12) and tab washer (5.11), then remove

timing gears (5.09), gear key (5.10), spacer (5.18), O-ring

(5.22) and lipseal (83).

SECTION TSM 285 ISSUE A PAGE 22 OF 36

Page 23

- Support pump with shafts in the vertical position with rotor end up.

- Remove screws (5.07), and then remove bearing retainers’ (5.06) and O-rings (5.21), then remove lipseals (5.03) from bearing retainers’ (5.06).

- Remove shafts (5.01 and 5.02) from gearbox (4.01). Shafts (5.01 and 5.02) will be complete with pins (5.23), spacers (5.24), bearings (5.05), spacers (5.05), tab washers (5.20),

locknuts(5.19),bearings(6.02)andspacers(6.02).

- Remove bearings (6.02) complete with spacers (6.02) from shafts (5.01 and 5.02) keep them in matched sets and identify position.

- Removelocknuts(5.19)andtabwashers’(5.07).

- Remove bearings (5.05) complete with spacers (5.05) from shafts (5.01 and 5.02), keep them in matched sets and identify position.

- Remove shaft sleeve drive pins (5.23) from shafts (5.01 and

5.02), remove spacers (5.24), note fitting position.

4.3.4 CP50 GEARBOX ASSEMBLY

The following procedure describes the assembly of the gearbox, refer to Figure 44.

- Install bearings (5.05) complete with spacers (5.05) to shafts (5.01 and 5.02) ensuring correct positioning of all components as either removed in 4.3.3. Above or supplied as new replacement set, see Figure 45.

- Install spacers (5.24), product seal sleeves (28 or 66), ro keys (78) and rotors (41) to shafts (5.01 and 5.02) and secure with rotor retainers (35) using tool (58).

- Install tabwashers (5.07)andlocknuts(5.19)tighteningto

correct torque, refer to section 8.2. Secure tab washers.

Note: Ensure that the cups of the rear most bearings (5.05) are in position on inner races before proceeding.

- Install bearings (6.02) complete with spacers (6.02) to shafts (5.01 and 5.02) ensuring correct positioning of all components as either removed in 4.3.3 above or as supplied as new replacement set, see Figure 46.

- Support gearbox (4.01) in a vertical position and install (5.01 and 5.02) to gearbox (4.01).

- If not already installed install cups of front most bearings (5.05).

- Installlipseals(5.03)tobearingretainers’(5.09).

- Install retainers’ (5.09) and O-rings (5.21) and secure with

screws (5.07) tightening to correct torque, refer to section

8.2.

- Return pump to normal horizontal mounting position.

- Installlipseal(6.19)togearbox(4.01).InstallO-ring(5.22),

spacer (5.18) and key (5.10) to drive shaft (5.01).

- Installtiminggears(5.09)toshafts(5.01and5.02).

- Install tab washer (5.11) and lock nut (5.12) tightening to correct torque, refer to section 8.2. Secure tab washer (5.11).

- Rotate shafts (5.01 and 5.02) such that keyways for rotor keys are vertically upwards.

- Lubricate retainer (5.16) with oil and install to timing gear

(5.09).Donottighten.

tor

shafts

Note: Pins (5.23) should not be installed at this stage.

- Clamp gear (5.09)toshaft(5.02) using tool(supplied)

associated stud and nut, ensuring that two screws in retainer (5.16) are visible through holes in tool.

- Check rotor mesh clearance against Clearance Chart, refer to section 8.1. Adjustment of mesh clearance is made by rotating the shafts (5.01 and 5.02). Having achieved optimum mesh clearance, partially tighten visible screws in retainer (5.16), to clamp gear in place. Remove tool and associated studs and nuts. Fully tighten screws in retainer (5.16) to correct torque, refer to section 8.2, taking note of typical tightening sequence, see Figure 47.

- After tightening of retainer (5.16) check rotor mesh clear refer to section 8.1 (Clearance Chart).

Figure 45

Front Bearing Assembly - CP50

Figure 46

Rear Bearing Assembly - CP50

and

ance;

SECTION TSM 285 ISSUE A PAGE 23 OF 36

Page 24

Figure 47

Retainer Tightening Sequence

- Install oil seal (6.03) to gearbox cover (6.00).

- Install drive key (6.12).

- Installdrainplugs(6.09)andbreatherplugs(6.10).

- Remove rotor retainers (2.02) using tool, rotors (2.01) and spacers (5.24)

area of

4.3.5 CP50 CASING, ROTOR AND

HEAD ASSEMBLY

Referring to Figure 33 and Figure 44.

- Install spacers’ (5.24) and product seal sleeves (7.15) to shafts (5.01 and 5.02).

Note: Pins (5.23) should not be installed at this stage.

- Install casing (3.01) to gearbox (4.01) locating on dowels (4.03) and secure with dome nuts (4.08) tightened to correct torque, refer to section 8.2.

- Install rotors (2.01) to shafts (5.01 and 5.02).

- Clamp one rotor (2.01) to shaft (5.01 or 5.02) using tool and associated stud and nut see Figure 48.

- Using a depth micrometer or similar device, measure front clearance; refer to section 8.1, Clearance Chart, between the casing and clamped rotors front face and check that this corresponds to the appropriate clearance as indicated on the Clearance Chart. Note any discrepancy in front clearance.

- Remove tool and associated stud and nut (shown above).

- Repeat clamping and front clearance measurement for rotor (again note any discrepancy in front clearance.

- Remove tool and associated stud and nut.

- Remove rotors (2.01), casing (3.01) and product seal (7.15).

- If any discrepancies were noted in front clearances, rotors and front face of casing, then spacers (5.24) will require machining to shorten them to achieve the correct front clearance, refer to section 8.1.

Note: If it is found that the measured front clearance is greater than that shown in the Clearance Chart, refer to section 8.1, then new spacers (5.24) will need to be obtained and machined to the correct lengths to achieve correct front clearance.

other

sleeves

between

Figure 48

Rotor Clamping Tool Fitment

- Be sure faces of spacers’ (5.24) are parallel after machining.

- After any machining of spacers’ (5.24), check front clear for both rotors, refer to section 8.1, Clearance Chart.

- Install spacers (5.24) to shafts (5.01 and 5.02) ensuring are correctly located.

- Install pins (5.23) to shafts (5.01 and 5.02) using a liquid retainer (Loctite 648 or similar).

- Install product seals; refer to section 5.3 and 6.3.

- Install casing (3.01) to gearbox (4.01) locating onto (4.03) and securing with dome nuts (4.08) tightened to correct torque, refer to section 8.2.

- Install O-rings (2.05) and rotors (2.01) to shafts (5.01 and

5.02).

- Lubricate retainers’ (53) with oil and install to shafts (5.01 and 5.02).

- Clamp one rotor (2.01) to shaft (5.01 or 5.02) using tool and associated stud and nut, see Figure 48, ensuring that two of the screws in retainer (2.05) are visible through holes in tool.

- Moderately tighten visible screws in retainer (2.05) in rotor to lock rotor in position. Remove tool and associated stud and nut, tighten fully screws in retainer (2.05) to correct torque, refer to section 8.2, taking note of typical tightening sequence, see Figure 47.

- Repeat clamping and retainer (2.05) tightening procedure other rotor.

- Remove tool and associated stud and nut.

- Install O-rings (2.03) and retainers (2.02) tightening to cor torque refer to section 8.2, using tool.

- Check all rotor clearances, front, rear, top/bottom, sides’ mesh, refer to section 8.1, Clearance Chart.

- Install head (1.01) with O-ring (1.02) and secure with (1.03) tightened to correct torque, refer to section 8.2.

ances

they

dowels

clamped

for

rect

and

nuts

SECTION TSM 285 ISSUE A PAGE 24 OF 36

Page 25

5.0 CLASSIC+ MECHANICAL SEAL REMOVAL & REPLACEMENT

5.1 GENERAL PROCEDURES FOR INSTALLING MECHANICAL SEALS

“Quick summary” of mechanical seal installation

- Mechanical seals are precision-engineered assemblies

incorporating finely lapped seal faces and seats. They must be handled with care and will not give optimum performance unless installed carefully and according to instructions.

- When mechanical seals are to be reused, ensure seal

components are kept in their appropriate sets. Do not mix old and new seal faces on the same seal.

- Remove any sharp corners and burrs that may damage any

elastomers such as O-rings or lipseals.

- Be sure that all seal component fitting bores and housings

are thoroughly cleaned before installation.

- The seal faces and seats must be handled with care and

cleaned thoroughly before installation.

- Be sure that seal faces are undamaged and the O-rings are

not cut, swollen or cracked.

- All O-rings should be lightly lubricated with a suitable

lubricant (silicon grease, soap etc.) before installation but ensure there is no excessive amount of lubricant especially around the seal face area.

- Ensure when installing seals with brittle faces and seats

such as silicon carbide that extra care is taken.

- Do not use any excessive force to install a mechanical

seal. If it is difficult to position and assemble the seal then something is wrong.

- If you drop or damage a seal, do not install it before an

inspection has been carried out.

WARNING

- Do not run a mechanical seal dry.

- Remove head (1.01), rotor retainers (2.02), O-rings (2.04) and casing (3.01), refer to section 4.1.2.1 (CP10, CP20 and CP30) or section 4.2.2.1 (CP40).

- Loosen but do not remove screws in rotary cartridge as (7.05) which secure rotary seal cartridges to shafts (5.01 and

5.02).

- Remove rotary seal cartridges (7.05) with O-ring (7.02) from shafts (5.01 and 5.02).

- Remove stationary seal seats (7.04) and O-rings (7.01) casing (3.01).

sembly

from

5.2.2 CP10, CP20, CP30 AND CP40

SINGLE MECHANICAL SEAL REPLACEMENT

Refer to Figure 50 for CP10, CP20, CP30 and CP40

- Install O-rings (7.01) to stationary seal seat (7.04).

- Install stationary seal seats (7.04) to casing (3.01) correct location of O-rings (7.01).

WARNING

- Install rotary seal cartridges (7.05) with O-ring (7.02) to shafts (5.01 and 5.02) positioning to correct setting distance, see Figure 50 and tighten screws (7.05) to correct torque, refer to section 8.2.

Note: On CP10 models the stationary seal seat (7.04) has a location recess which fits over the anti-rotation washer (7.13).

Note: On CP20, CP30 and CP40 models the stationary seal seat (7.04) has a triangular shape, which must locate fully into the casing (3.01) bore.

ensuring

5.2 CP10, CP20, CP30 AND CP40 MECHANICAL SEALS

5.2.1 CP10, CP20, CP30 AND CP40 SINGLE MECHANICAL SEAL REMOVAL

Figure 49

Single Un-ushed Mechanical Seal

Pump Model X (mm) X (inches)

CP10 14.3 0.5630

CP20 10.8 0.4252

CP30 13.4 0.5276

CP40 17.5 0.6890

Figure 50

Setting Distance for Seals

- Install casing (3.01), O-rings (2.04), rotors (2.01), O-rings (2.03), rotor retainers (2.02) and head (1.01), refer to sections

4.1.4 (CP10, CP20 and CP30) or 4.2.5 (CP40).

SECTION TSM 285 ISSUE A PAGE 25 OF 36

Page 26

5.2.3 CP10, CP20, CP30 AND CP40 SINGLE FLUSHED MECHANICAL SEAL REMOVAL

Refer to Figure 51 for CP10, CP20, CP30 and CP40

Figure 51

Single Flushed Mechanical Seal

- Install lipseals (7.08) and O-rings (7.07) to housing(s) (7.06).

- Install housing(s) (7.06) to shafts (5.01 and 5.02).

- Install rotary seal cartridges (7.05) to shafts (5.01 and 5.02) positioning to correct setting distance, see Figure 50 and tightening screws in rotary seal cartridge assemblies (7.05) to correct torque, refer to section 8.2.

Note: Access to screws in rotary cartridge seal assemblies

(7.05) is through the ush pipe connections of housing

(7.06).

- Install casing (3.01), O-rings (2.04), rotors (2.01), O-rings (2.03), rotor retainers (2.02) and head (1.01), refer to sections

4.1.4 (CP10, CP20 and CP30) or 4.2.5 (CP40).

- Secure housing(s) (7.06) to casing (3.01) with screws

ensuringcorrectlocationontodowels(7.09).

(7.10)

5.2.5 CP10 DOUBLE FLUSHED

MECHANICAL SEAL REMOVAL

Refer to Figure 52.

- Remove head (1.01), rotor retainers’ (2.02), O-rings rotors (2.01), O-rings (2.04) and casing (3.01), refer to sections 4.1.2.1 and 4.1.2 (CP10, CP20 or CP30) or 4.2.2.1 (CP40).

- Loosen but do not remove screws in rotary seal cartridge assemblies (7.05), which secure rotary seal cartridges to shafts (5.01 and 5.02).

Note: Access to screws in rotary seal cartridge (7.05) is

through the ush pipe connections of housing (7.06).

- Remove rotary seal cartridges (7.05) with O-ring (7.02) from shafts (5.01 and 5.02).

- Remove housing(s) (7.06) complete with lipseals (7.08) and O-Ring(s) (7.07) from shafts (5.01 and 5.02).

- Remove lipseals (7.08) and O-ring (s) (7.07) from (7.06).

- Remove stationary seal seats (7.04) and O-rings (7.01) casing (3.01).

(2.03),

housing(s)

from

5.2.4 CP10, CP20, CP30 AND CP40

SINGLE FLUSHED MECHANICAL SEAL REPLACEMENT

Refer to Figure 51 for CP10, CP20, CP30 and CP40

- Install O-rings (7.01) to stationary seal seats (7.04).

- Install stationary seal seats (7.04) to casing (3.01) correct location of O-rings (7.01).

WARNING

Note: On CP10 models the stationary seal seat (7.04) has a location recess which fits over the anti-rotation washer (7.13).

Note: On CP20, CP30 and CP40 models the stationary seal seat (7.04) has a triangular shape, which must locate fully into the casing (3.01) bore.

ensuring

Figure 52

Double Flushed Mechanical Seal

- Remove head (1.01), rotor retainers’ (2.02), O-rings rotors (2.01), O-rings (2.04) and casing (3.01), refer to sections 4.1.1 and 4.1.2.

- Loosen but do not remove screws (7.11), which secure seal cartridge assemblies (7.11) to shafts (5.01 and 5.02).

Note: Access to screws (7.13) is through the ush pipe connections of housing (7.06)

- Remove rotary seal cartridges (7.11) with O-rings (7.02) shafts (5.01 and 5.02).

- Remove housing (7.06) complete with O-ring (7.07), stationary seal seats (7.12) and O-rings (7.01) from shafts (5.01 and 5.02).

- Remove stationary seal seats (7.12), O-rings (7.01) and ring (7.07) from housing (7.06).

- Remove stationary seal seats (7.04) and O-rings (7.01) casing (3.01).

(2.03),

rotary

from

O-

from

SECTION TSM 285 ISSUE A PAGE 26 OF 36

Page 27

5.2.6 CP10 DOUBLE FLUSHED MECHANICAL SEAL REPLACEMENT

Refer to Figure 52

- Install O-rings (7.01) to stationary seal seats (7.04 and

7.12).

- Install stationary seal seats (7.04) to casing (3.01)

correct location of O-rings (7.01).

WARNING

- Install O-rings (7.01) to stationary seal seats (7.11).

- Install stationary seal seats (7.11) to housing (7.06) ensur

correct location of O-ring (7.01).

- Install housing (7.06) to shafts (5.01 and 5.02).

- Clean faces of outboard seal (7.11 and 7.12) use a soft tis

and suitable solvent based cleaner for best results.

- Install rotary seal cartridges (7.11) with O-ring (7.02) to

(5.01 and 5.02).

Note: For pumps installed with ange type casing (3.01) connections, it may be easier to set the position of the rotary seal cartridge (7.11) onto the shafts (5.01 and

5.02) using the setting distance, see gure 50, before

installing the casing (3.01). Screws in rotary seal cartridge assemblies (7.11) must be tightened to the correct torque refer to section 8.2.

- Install casing (3.01), O-rings (2.04), rotors (2.01), O-rings

(2.03), rotor retainers (2.02) and head (1.01) - refer to section

4.1.4.

- Secure housing (7.06) to casing (3.01) with screws

ensuringcorrectlocationontodowels(7.09).

- Rotate pump shafts by two or three full revolutions.

- If not already tightened, tighten screws (7.11) to correct

torque, refer to section 8.2.

Note: Access to screws (7.11) is through the ush pipe connections of housing (7.06)

Note: The stationary seal seat (7.04) has a location recess which fits over the antirotation washer (7.13).

ensuring

ing

sue

shafts

(7.10)

5.2.7 CP20, CP30 AND CP40 DOUBLE FLUSHED MECHANICAL SEAL REMOVAL

- Remove head (1.01), rotor retainers’ (2.02), O-rings (2.03),

rotors (2.01), O-rings (2.04) and casing (3.01), refer to sections 4.1.1 and 4.1.2 (CP20/CP30) or sections 4.2.1 and

4.2.2 (CP40).

- Loosen but do not remove screws in rotary seal cartridge

assemblies (7.11), which secure rotary seal cartridge assemblies (7.11) to shafts (5.01 and 5.02).

Note: Access to screws (7.11) is through the ush connections of housings (7.06).

- Remove rotary seal cartridge assemblies (7.11) with O-ring

(32) from shafts (5.01 and 5.02).

- Remove housings (7.06) from shafts (5.01 and 5.02)

complete with stationary seal seats (7.12), O-rings (7.01) and O-rings (7.07).

Figure 53

Double Flushed Mechanical Seal

- Remove stationary seal seats (7.04), O-rings (7.01) and rings (7.07) from housings (7.06).

- Remove stationary seal seats (7.04) and O-rings (7.01) casing (3.01).

O-

from

5.2.8 CP20, CP30 AND CP40

DOUBLE FLUSHED MECHANICAL SEAL REPLACEMENT

Refer to Figure 53.

- Install O-rings (7.01) to stationary seal seats (7.04).

- Install stationary seal seats (7.04) to casing (3.01) correct location of O-rings (7.01).

WARNING

- Install O-rings (7.01) to stationary seal seats (7.12).

- Install stationary seal seats (7.12) to housings (7.06) ensur both correct locations of O-ring (7.01) and stationary seal seats (7.04) in housings (7.06).

WARNING

- Install housings (7.06) to shafts (5.01 and 5.02).

- Clean faces of outboard seal (7.11 and 7.12) use a soft tis and a suitable solvent based cleaner for best results.

- Install rotary seal cartridge assemblies (7.11) to shafts (5.01 and 5.02).

Note: For pumps installed with ange type casing (3.01) connections, it may be easier to set the position of the rotary seal cartridge (7.11) onto the shafts (5.01 and

5.02) using the setting distance, see Figure 50, before

installing the casing (3.01). Screws in rotary seal cartridge assemblies (7.11) must be tightened to the correct torque refer to section 8.2.

Note: The stationary seal seats (7.04) have a triangular shape which must locate fully into the casing (3.01) bore.

Note: The stationary seal seats (7.12) have a triangular shape which must locate fully into the housing (7.06) bore.

ensuring

ing

sue

SECTION TSM 285 ISSUE A PAGE 27 OF 36

Page 28

- Install casing (3.01), O-rings (2.04), rotors (2.01), O-rings (2.03), rotor retainers (2.02) and head (1.01) refer to sections

4.1.4 (CP20/CP30) or 4.2.5 (CP40).

- Secure housings (7.06) to casing (3.01) with screws

ensuringcorrectlocationontodowels(7.09).

- Rotate pump shafts by two or three full revolutions.

- If not already tightened, tighten screws in rotary seal car assemblies (7.11) to correct torque, refer to section 8.2.

Note: Access to screws in rotary seal cartridge assemblies

(7.11) is through the ush connections of housings (7.06).

(7.10)

tridge

5.3 CP50 MECHANICAL SEALS

5.3.1 CP50 SINGLE MECHANICAL

SEAL REMOVAL

Figure 54

Single Un-Flushed Mechanical Seal CP50

- Remove head (1.01), rotor caps (2.02), O-rings (2.03), retainers’ (2.05), rotors (41), O-rings (2.04) and casing (3.01), refer to sections 4.3.1 and 4.3.2.

- Remove rotary seal cartridge assemblies (7.11) with O-ring (7.01) from shafts (5.01 and 5.02) by simply sliding off. Do not loosen screws in rotary seal cartridge assemblies (7.05).

- Remove stationary seal seats (7.04) and O-rings (7.02) from casing (3.01).

5.3.2 CP50 SINGLE MECHANICAL

SEAL REPLACEMENT

- Install O-rings (7.02) to stationary seal seats (7.04).

- Install stationary seal seats (7.04) to casing (3.01) correct location of O-rings (7.02).

WARNING

- Install rotary seal cartridge assemblies (7.11) with O-ring (7.01) to shafts (5.01 and 5.02) ensuring engagement of drive slots with pins (5.23) in shafts (5.01 and 5.02).

- Install casing (3.01), O-rings (2.04), rotors (2.01), (2.05), O-rings (2.03), rotor caps (2.02) and head (1.01)

- refer to section 4.3.5.

Note: The stationary seal seat (7.04) has a triangular shape, which must locate fully into the casing (3.01), bore.

ensuring

retainers

5.3.3 CP50 SINGLE FLUSHED MECHANICAL SEAL REMOVAL

Refer to Figure 55.

Figure 55

Single Flushed Mechanical Seal CP50

- Remove head (1.01), rotor caps (2.02), O-rings (2.03),

retainers (2.05), rotors (2.01), O-rings (2.04) and casing (3.01) refer to sections 4.3.1 and 4.3.2.

- Remove rotary seal cartridge assemblies (7.05) with O-ring

(7.01) from shafts (5.01 and 5.02) by simply sliding off. Do not loosen screws in rotary seal cartridge assemblies (7.05).

- Remove housings (7.06) complete with lipseals (7.08) and

O-rings (7.07) from shafts (5.01 and 5.02).

- Remove lipseals (7.08) and O-rings (7.07) from housings

(7.06).

- Remove stationary seal seats (7.04) and O-rings (7.02) from

casing (3.01).

5.3.4 CP50 SINGLE FLUSHED MECHANICAL SEAL REPLACEMENT

Refer to Figure 55

- Install O-rings (7.02) to stationary seal seats (7.04).

- Install stationary seal seats (7.04) to casing (3.01)

correct location of O-rings (7.02).

WARNING

- Install lipseals (7.08) and O-rings (7.07) to housings (7.06).

- Install housings (7.06) to shafts (5.01 and 5.02).

- Install rotary seal cartridge assemblies (7.05) with O-ring

(7.01) to shafts (5.01 and 5.02) ensuring engagement of drive slots with pins (5.23) in shafts (5.01 and 5.02).

- Install casing (3.01), O-rings (2.04), rotors (2.01), retain

(2.05), O-rings (2.03), rotor caps (2.02) and head (1.01) refer to section 4.3.5.

- Secure housings (7.06) to casing (3.01) with nuts (7.18).

Note: The stationary seal seat (7.04) has a triangular shape, which must locate fully into the casing (3.01), bore.

ensuring

ers

SECTION TSM 285 ISSUE A PAGE 28 OF 36

Page 29

5.3.5 CP50 DOUBLE FLUSHED MECHANICAL SEAL REMOVAL

Figure 56

Double ushed mechanical seal CP50

- Remove head (1.01), rotor caps (2.02), O-rings (2.03),

retainers (2.05), rotors (2.01), Orings (2.04) and casing (3.01), refer to sections 4.3.1 and 4.3.2.

- Remove rotary seal cartridge assemblies (7.11) with O-rings

(7.01) and (7.16) from shafts (5.01 and 5.02) by simply sliding off. Do not loosen screws in rotary seal cartridge assemblies (7.11).

- Remove housings (7.06) from shafts (5.01 and 5.02)

complete with stationary seal seats (7.04), O-rings (7.02) and O-rings (7.07).

- Remove stationary seal seats (7.04), and O-rings (7.07) from

housings (7.06).

- Remove stationary seal seats (7.04) and O-rings (7.02) from

casing (3.01).

5.3.6 CP50 DOUBLE FLUSHED MECHANICAL SEAL REPLACEMENT

Refer to Figure 56.

- Install O-rings (7.02) to stationary seal seats (7.04).

- Install stationary seal seats (7.04) to casing (3.01)

correct location of O-rings (7.02).

WARNING

- Install O-rings (7.02) to stationary seal seat (7.04).

- Install stationary seal seats (7.04) to housings (7.06) ensur

correct locations of O-rings (7.02) and stationary seal seats (7.04) in housings (7.06).

WARNING

- Install housings (7.06) to shafts (5.01 and 5.02).

- Clean faces of outboard seal (7.11 and 7.04) use a soft tis

and a suitable solvent based cleaner for best results.

- Install rotary seal cartridge assemblies (7.11) with O-

and (7.16) to shafts (5.01 and 5.02) ensuring engagement of drive slots with pins (5.23) in shafts (5.01 and 5.02).

Note: The stationary seal seat (7.04) has a triangular shape, which must locate fully into the casing (3.01), bore.

Note: The stationary seal seat (7.04) has a triangular shape, which must locate fully into the housing (7.06), bore.

ensuring

ing

sue

ring (7.01)

- Install casing (3.01), O-rings (2.04), rotors (2.01), retain (2.05), O-rings (2.03), rotor caps (2.02) and head (1.01), refer to section 4.3.5.

- Secure housings (7.06) to casing (3.01) with nuts (7.18).

ers

6.0 CLASSIC+ SINGLE O-RING

SEALS

6.1 GENERAL PROCEDURES

FOR FITTING SINGLE O-RING SEALS

“Quick Summary” of O-Ring seal installation.

- O-ring seals are a simple but effective means of shaft seal They will provide optimum performance only if installed carefully in accordance to the following instructions below and sections 6.2 and 6.3.

- Remove any sharp corners and burrs that could damage O-rings.

- Always inspect for wear, the diameter on the rotor where the O-ring seal is located.

- Be sure that all seal component fitting bores, housings, followers, sleeves etc. are thoroughly cleaned before installation.

- All O-rings should be lightly lubricated with an appropriate lubricant (suitable for application) before installation.

WARNING

Note: Do not run an O-ring seal dry.

ing.

6.2 O-RING SEALS FOR CP10,

CP20, CP30 AND CP40 PUMPS

6.2.1 CP10, CP20, CP30 AND CP40

O-RING SEAL ASSEMBLY AND REMOVAL

- Before assembly or disassembly of the seals,

- Install O-ring (7.04) into the casing (3.01).

- Install O-ring (2.04) onto shaft (5.01 and 5.02).

Note: During installing of the rotors to shafts care must be taken not to damage or unseat the O-ring seal when inserting the rotor (2.01) into O-ring (7.04).

- To disassemble reverse the above procedure.

ensure pump is fully shutdown, refer to section

3.5.

Figure 57

O-Ring Seal for a CP10, CP20, CP30 and CP40

SECTION TSM 285 ISSUE A PAGE29 OF 36

Page 30

6.3 O-RING SEAL FOR CP50 PUMP

6.3.1 CP50 O-RING SEAL ASSEMBLY AND REMOVAL

Figure 58

CP50 O-ring Seal

- Before assembly or disassembly of the seals,

- Install O-ring (7.04) into the casing (3.01).

- Install rotary seal sleeves (7.15) onto shafts (5.01 and 5.02),

ensuring engagement of slots in rotary seal sleeves (7.15) and drives pins (5.230

- Install O-ring (2.04 onto shaft (5.01 and 5.02).

Note: During installing of the rotors to shafts care must be taken not to damage or unseat the O-ring seal when inserting the rotor (2.01) into O-ring (7.04).

- To disassemble reverse the above procedure.

ensure pump is fully shutdown, refer to section 3.5.

7.0 FLUSHED PRODUCT SEALS AUXILIARY SERVICES

i) Terminology.

a) “Quench”

- To provide a liquid barrier that is not induced to flow

through the seal area by any external means.

b) “Flush”

- To provide a liquid barrier that is induced to flow

through the seal area by an external means.

Quench or Flush Media

ii)

WARNING

The media used for quenching or flushing a seal area must be fully compatible with the pumped media, and the relevant materials of construction of the pump.

Special consideration must be given to the temperature limitations of the media to ensure that no hazards are created, e.g. risk of fire or explosion.

7.1 SINGLE MECHANICAL SEAL (FOR LOW-PRESSURE QUENCH OR FLUSH)

See Figure 17 (CP10), Figure 27 (CP20, CP30, CP40) and Figure 50 (CP50).

Refer to section 4.3.3.

This seal arrangement requires a supply of media to the

outboard side of the mechanical seal to quench or ush the sealarea.Thenatureofthe pumped media and the specic dutyconditionswill determinewhethera quenchoraush is

required.

A quench provides a static head. The quench media vessel should be mounted a minimum of 0.5m (1.5 Feet) above the pump, preferably directly above the seal area. The interconnecting pipe work should be as straight as possible, avoiding horizontal runs, and with the minimum number of bends and restrictions.

Forasuitableush,themediamustbesuppliedataowrate

of 4.5 Liters per minute per shaft seal.

WARNING

Note: The limiting flush or quench pressure in any application is 0.7 Bar (10 psig).

7.2 DOUBLE MECHANICAL SEAL (FOR HIGH PRESSURE FLUSH)

See Figure 18 (CP10) and Figure 28 (CP20, CP30, CP40) and Figure 51 (CP50)

Refer to section 4.3.4.

This seal arrangement requires a supply of media to be circulated between the inboard and outboard mechanical seals.

Theushmediamustbesuppliedataowrateof4.5Litersper

minute per shaft seal assembly.

Theushpressuremustbeaminimumof1Bar(15psi)greater

than the maximum discharge pressure created by, or the maximum suction pressure applied to, the pump, whichever is the greater.

WARNING

Note: The liquid supply connections to ushed seals are made using the threaded ports on the sides of the seal housings (two per seal, except CP10 & CP20 models, which have common seal housings encompassing both shaft seals). For models CP30 to CP50 inclusive, one

port on each housing should be used for ush ‘in’ and the other for ush ‘out’. The pipe work should be arranged to provide an independent ush to each seal.

Note: The limiting flush pressure in any application is 13 Bar (188 psig).

SECTION TSM 285 ISSUE A PAGE 30 OF 36

Page 31

8.0 SPECIFICATIONS

8.1 CLEARANCE CHART

Pump Model

CP10S

CP10M

CP10L

CP20S

CP20L

CP30S

CP30L

CP40S

CP40L

CP50S

CP50L

Millimeters x 0.01

Rotor

Max

Class

Temp °C

A 70 7 9 3 10 5 13 13 19 18

B 100 9 11 5 12 7 14 15 21 18

C 150 11 13 7 14 9 16 17 23 18

A 70 10 12 6 13 8 15 17 22 18

B 100 12 14 9 16 10 17 18 24 18

C 150 15 17 11 18 13 20 21 27 18

A 70 13 15 9 16 11 18 19 25 18

B 100 16 18 13 20 13 20 21 27 20

C 150 20 22 17 24 16 24 24 30 20

A 70 14 16 10 17 15 25 23 31 20

B 100 16 18 13 20 18 28 25 33 25

C 150 18 20 14 21 20 30 28 36 25

D 180 19 21 15 22 23 33 31 39 25

A 70 15 17 16 23 23 33 30 38 25

B 100 19 21 19 26 29 39 37 45 28

C 150 21 23 22 29 32 42 39 47 28

D 180 23 25 25 32 36 46 43 51 28

A 70 18 20 17 24 22 35 30 40 28

B 100 22 24 21 28 27 40 35 46 35

C 150 24 26 24 31 33 46 40 51 35

D 180 27 29 26 33 37 50 45 55 35

A 70 24 26 25 32 44 58 51 63 35

B 100 29 31 30 37 47 61 54 66 38

C 150 33 35 33 40 53 67 60 72 38

A 70 32 37 28 39 30 45 46 57 38

B 100 35 40 32 43 35 51 51 63 40

C 150 40 45 38 49 42 57 57 69 40

A 70 40 45 40 53 45 55 61 68 40

B 100 49 54 46 59 50 65 66 78 45

C 150 55 60 53 66 59 74 75 86 45

B 100 43 46 41 54 41 64 66 86 45

D 180 58 61 56 69 41 64 66 86 55

B 100 50 53 48 62 51 74 76 86 55

D 180 65 68 63 77 51 74 76 86 55

Front Rear Top/Bottom Side

Min Max Min Max Min Max Min Max

Nominal

Mesh

Pump Model

CP10S

CP10M

CP10L

CP20S

CP20L

CP30S

CP30L

CP40S

CP40L

CP50S

CP50L

Inches x 0.001

Rotor

Max

Class

Temp °F

A 150 2.76 3.54 1.18 3.94 1.97 5.12 5.12 7.48 7.09

B 210 3.54 4.33 1.97 4.72 2.76 5.51 5.91 8.27 7.09

C 300 4.33 5.12 2.76 5.51 3.54 6.30 6.69 9.06 7.09

A 150 3.94 4.72 2.36 5.12 3.15 5.91 6.69 8.66 7.09

B 210 4.72 5.51 3.54 6.30 3.94 6.69 7.09 9.45 7.09

C 300 5.91 6.69 4.33 7.09 5.12 7.87 8.27 10.63 7.09

A 150 5.12 5.91 3.54 6.30 4.33 7.09 7.48 9.84 7.09

B 210 6.30 7.09 5.12 7.87 5.12 7.87 8.27 10.63 7.87

C 300 7.87 8.66 6.69 9.45 6.30 9.45 9.45 11.81 7.87

A 150 5.51 6.30 3.94 6.69 5.91 9.84 9.06 12.20 7.87

B 210 6.30 7.09 5.12 7.87 7.09 11.02 9.84 12.99 9.84

C 300 7.09 7.87 5.51 8.27 7.87 11.81 11.02 14.17 9.84

D 356 7.48 8.27 5.91 8.66 9.06 12.99 12.20 15.35 9.84

A 150 5.91 6.69 6.30 9.06 9.06 12.99 11.81 14.96 9.84

B 210 7.48 8.27 7.48 10.24 11.42 15.35 14.57 17.72 11.02

C 300 8.27 9.06 8.66 11.42 12.60 16.54 15.35 18.50 11.02

D 356 9.06 9.84 9.84 12.60 14.17 18.11 16.93 20.08 11.02

A 150 7.09 7.87 6.69 9.45 8.66 13.78 11.81 15.75 11.02

B 210 8.66 9.45 8.27 11.02 10.63 15.75 13.78 18.11 13.78

C 300 9.45 10.24 9.45 12.20 12.99 18.11 15.75 20.08 13.78

D 356 10.63 11.42 10.24 12.99 14.57 19.69 17.72 21.65 13.78

A 150 9.45 10.24 9.84 12.60 17.32 22.83 20.08 24.80 13.78

B 210 11.42 12.20 11.81 14.57 18.50 24.02 21.26 25.98 14.96

C 300 12.99 13.78 12.99 15.75 20.87 26.38 23.62 28.35 14.96

A 150 12.60 14.57 11.02 15.35 11.81 17.72 18.11 22.44 14.96

B 210 13.78 15.75 12.60 16.93 13.78 20.08 20.08 24.80 15.75

C 300 15.75 17.72 14.96 19.29 16.54 22.44 22.44 27.17 15.75

A 150 15.75 17.72 15.75 20.87 17.72 21.65 24.02 26.77 15.75

B 210 19.29 21.26 18.11 23.23 19.69 25.59 25.98 30.71 17.72

C 300 21.65 23.62 20.87 25.98 23.23 29.13 29.53 33.86 17.72

B 210 16.93 18.11 16.14 21.26 16.14 25.20 25.98 33.86 17.72

D 350 22.83 24.02 22.05 27.17 16.14 25.20 25.98 33.86 21.65

B 210 19.69 20.87 18.90 24.41 20.08 29.13 29.92 33.86 21.65

D 350 25.59 26.77 24.80 30.31 20.08 29.13 29.92 33.86 21.65

Front Rear Top/Bottom Side

Min Max Min Max Min Max Min Max

Nominal

Mesh

SECTION TSM 285 ISSUE A PAGE 31 OF 36

Page 32

8.2 FASTENERS & TORQUE SETTINGS

Item Description Position

1.03 Dome Nut

2.02 Rotor Retainer Rotor / Shaft

2.05

3.03 Stud

4.02 Stud

4.04

5.01 Drive Shaft

5.02 Driven Shaft

5.07

5.12 Locknut

5.12 Grub Screw

5.14

5.16

5.19 Locknut Shaft / Bearing

6.11

6.15

7.11 Grub Screw

Ring Feder

Retainer

Socket Cap

Head Screw

Socket Cap

Head Screw

Hex Head

Screw

Socket Cap

Head Screw

Ring Feder

Retainer

Socket Cap

Head Screw

Socket Cap

Head Screw

Hammer

Drive Screw

Head / Casing

Rotor / Shaft

Head / Casing

Bearing Housing /

Head

Casing /

Bearing Housing

Bearing Housing / Gearbox Housing

Bearing Retainer

Timing Gear /

Shaft

Timing Gear /

Locknut

Feet

Timing Gear /

Shaft

Gearbox Halves

Rotor Cover /

Gearbox

Nameplate

Rotary Seal

Cartridge

Quantity / Pump 8 4 4 10 10

Size - mm M8 M12 M12 M16 M20

Torque Nm 28 101 101 115 150

Torque lbf ft 20.650 74.488 74.488 84.813 110.625

Quantity / Pump 2 2 2 2 2

Size - mm D13-2051-01 D23-2051-01 D33-2051-01 D43-2051-01 D53-2051-01

Torque Nm 27 30 40 60 50

Torque lbf ft 19.913 22.125 29.500 44.250 36.875

Quantity / Pump

Size - mm -

Torque Nm 15

Torque lbf ft

Quantity / Pump 4

Size - mm M8 x 31 M16 x 55 M16 x 70

Torque Nm 30 130 160

Torque lbf ft 22.125 95.875 118

Quantity / Pump 4 4 4

Size - mm M8 M12 M12

Torque Nm 30 107 107

Torque lbf ft 22.125 78.913 78.913

Quantity / Pump

Size - mm M6 M6

Torque Nm 16 16

Torque lbf ft 11.8 11.8

Rolling Torque Nm 0.4 - 0.6 1.2 - 1.5 4 - 5 5 - 6

Rolling Torque lbf ft 0.295-0.442 0.885 - 1.106 2.950-3.687 3.687 - 4.425

Rolling Torque Nm 0.4 - 0.6 1.2 - 1.5 4 - 5 5 - 6

Rolling Torque lbf ft 0.295-0.442 0.885 - 1.106 2.950-3.687 3.687 - 4.425

Quantity / Pump 8

Size - mm M6 x 16 M8 x 20 M8 x 25

Torque Nm 16 29 29

Torque lbf ft 11.800 21.388 21.388

Quantity / Pump

Size - mm M5 x 16 M5 x 16

Torque Nm 9.5 9.5

Torque lbf ft 7.006 7.006

Quantity / Pump 2 2 2 1 1

Size - mm M25 M30 D33-0141-04 M55 M65

Torque Nm 25 35 55 50 50

Torque lbf ft 25.813 40.563

Quantity / Pump

Size - mm M8 x 8

Torque Nm 20

Torque lbf ft 14.750

Quantity / Pump 2 4 4 4 4

Size - mm M8 x 16 M8 x 16 M10 x 25 M12 x 30 M16 x 40

Torque Nm 39 39 45 80 180

Torque lbf ft 28.763 33.188

Quantity / Pump

Size - mm - -

Torque Nm 34 34

Torque lbf ft

Quantity / Pump

Size - mm M60 M80

Torque Nm 50 60

Torque lbf ft 36.875 44.250

Quantity / Pump 4 4 6

Size - mm M8 x 20 M10 x 25 M12 x 25

Torque Nm 39 57 100

Torque lbf ft 42.038 73.750

Quantity / Pump

Size - mm M10 x 30 M12 x 25

Torque Nm 60 70

Torque lbf ft

Quantity / Pump 4 4 4 4 4

Size - mm

Torque Nm

Torque lbf ft

Quantity / Pump 6 or 8 6 or 8 6 or 8 6

Size - mm M5 M5 M6 M8

Torque Nm 1.5 1.5 4 9.5

Torque lbf ft 1.106 2.950

CP10 CP20 CP30 CP40 CP50

N/A N/A N/A N/A

N/A N/A

2 2

N/A

N/A N/A

8 8

N/A

N/A N/A

N/A N/A N/A

Pump Model

6 6

N/A N/A

8 8

N/A N/A

1 1

2 2

N/A N/A

4 4

N/A

SECTION TSM 285 ISSUE A PAGE 32 OF 36

Page 33

8.3 LUBRICANTS

Gearbox oil recommended for use with Classic+ is an ‘EP (Extreme Pressure) grade gear lube’ for the following temperature ranges.

EP150 -2 – 0°C (0 – 32°F) EP220 0 – 30°C (32 - 85°F) EP320 30°C (85°F) and higher

ApproximatelubricantcapacitiesfortheClassic+:

Mounting Attitude with Suction and Discharge ports in:

8.4 TROUBLESHOOTING

Pump Model

Horizontal Plane Vertical Plane

Liters US Pints Liters US Pints

CP10 0.25 0.44

CP20 0.50 0.88

CP30 1.00 1.76

CP40*

(Top Cavity)

CP40*

(Bottom Cavity)

CP50*

(Top Cavity)

CP50*

(Bottom Cavity)

0.75 1.32

1.75 3.08

0.60 1.05

0.80 1.41

To be advised - Fill to Sight

Glass level (see below)

To be advised - Fill to Sight

Glass level (see below)

To be advised - Fill to Sight

Glass level (see below)

To be advised - Fill to Sight

Glass level (see below)

To be advised - Fill to Sight

Glass level (see below)

To be advised - Fill to Sight

Glass level (see below)

To be advised - Fill to Sight

Glass level (see below)

* Note: The CP40 and CP50 have two gearbox cavities that should be subject to the same maintenance program.

Always add oil to the level of the sight glass. The sight glass must be located in the uppermost position on the side of the gearbox.

Causes Action

Reduce Length. Reduce Pump Speed & Product Temperature

Incorrect Direction of Rotation Reverse Motor

Pump Not Primed Expel Gas From Suction Line / Pump Chamber & Prime

Insufficient NPSH Available Increase Line Diameter & Static Suction Head. Simplify Suction Line &

Product Vaporizing in Suction Line

Air Entering Suction Line Remake Piping Joints

Gas in Suction Line Expel Gas From Suction Line / Pump Chamber

Insufficient Static Suction Head Raise Product Level to Increase Static Suction Head

Product Viscosity Too High Decrease Pump Speed / Increase Product Temperature

Product Viscosity Too Low Increase Pump Speed / Decrease Product Temperature

Product Temperature Too High Cool Product / Pumping Chamber

Product Temperature Too Low Heat Product / Pumping Chamber

Unexpected Solids in Product Clean the System / Fit Strainer on Suction Side of Pump

Discharge Pressure Too High Check for Blockages / Simplify Discharge Line

Casing Strained by Piping Check Pipe Alignment / Support Piping

Pump Speed Too High Decrease Pump Speed

Pump Speed Too Low Increase Pump Speed

Seal Flush Inadequate Increase Seal Flush to Required Pressure / Flow

Pump Stalls on Startup

Seizure

Noise / Vibration

Excessive Seal Wear

Excessive Rotor Wear

Motor Overheats

Pump Overheats

Under Capacity

Irregular Flow

No Flow

Bearing / Timing Gear Wear Replace Worn Components

8.5 MATERIAL SPECIFICATIONS

Pump Model Casing

CP10

CP20

CP30

CP40

CP50

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

Front

Cover Rotors

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

Retainers Shafts

Stainless Steel

Rotor

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

316

Stainless Steel

Shaft

Sleeves Gearbox

N/A

316

Stainless Steel

SECTION TSM 285 ISSUE A PAGE 33 OF 36

Cast Iron Cast Iron

Cast Iron

Bearing

Housing

N/A Mild Steel

Gearbox

Cover

N/A

Page 34

8.6 FOUNDATION DIMENSIONS AND WEIGHTS

MODEL

CP10S

CP10M

CP10L

CP20S

CP20L

CP30S

CP30L

CP40S

CP40L

CP50S

CP50L

① ②

V 5.16 9.08 7.24 0.71 8.66 - - - - - - 8.98 10.75

V 131 230.75 184 18 220 - - - - - - 228 273

V 5.89 9.08 7.24 0.71 8.66 - - - - - - 8.98 10.75

V 149.5 230.75 184 18 220 - - - - - - 228 273

V 6.61 9.49 9.37 0.79 10.94 - - - - - - 9.84 11.81

V 168 241 238 20 278 - - - - - - 250 300

V 7.72 9.49 9.37 0.79 10.94 - - - - - - 9.84 11.81

V 196 241 238 20 278 - - - - - - 250 300

⑤B1⑤B2⑤B3⑤B4⑤

in 1 3.5 3.5 4.06 4.06 4.06 2.91 6.18 0.39181.10

mm 25 89 89 103 103 103 74 157 10 28

in 1.5 3.5 4.37 4.06 4.06 4.06 2.91 6.18 0.39 1.10

mm 40 89 111 103 103 103 74 157 10 28

in 1.5 3.5 4.37 4.06 4.06 4.06 2.91 6.18 0.39 1.10 1.89

mm 40 89 111 103 103 103 74 157 10 28 48

3.86 4.72 4.41 4.41 4.41 4.29 8.62 0.79242.32 3.07

1.5

mm 40 98 120 112 112 112 109 219 20 59 78

in 2 3.86 4.72 4.41 4.41 4.72 4.29 8.62 0.79 2.32 3.07

mm5098 120 112 112 120 109 219 20 59 78

in 2 4.88 5.75 5.43 5.43 5.75 5.26 10.71 0.98382.74 3.43

mm50124 146 138 138 146 133.5 272 25 69.5 87

in 3 4.88 6.14 5.43 5.75 5.95 5.26 10.71 0.98 2.74 3.43

mm80124 156 138 146 151 133.5 272 25 69.5 87

in 3 6.26 7.52 6.81 7.13 7.32 6.97 13.50 0.91484.33 4.49

mm 80 159 191 173 181 186 177 343 23 110 114

in 4 6.42 8.11 6.81 7.13 7.32 6.97 13.50 0.91 4.33 4.49

mm 100 163 206 173 181 186 177 343 23 110 114

in 4 7.4 9.25 7.95 8.27 8.47 8.46 16.61 1.18604.09 5.32

mm 100 188 235 202 210 215 215 422 30 104 135

③

N/A N/A 7.17 7.17 N/A 8.46 16.61 1.18 4.09 5.32

③

N/A N/A 182 182 N/A 215 422 30 104 135

150

C D E

④

G HB HS HT J

1.89 2.48 3.94 48 63 100

2.48 3.94 63 100

3.49 5.51

88.75 140

3.49 5.51

88.75 140

4.38 7.09

111.3 180

4.38 7.09

111.3 180

6.89 9.45

175 240

6.89 9.45

175 240

8.07 11.61

205 295

8.07 11.61

205 295

④

L M N P Q

0.9869.80 1.87 4.58 1.77 0.39 25 249 47.5 116.40 45 10

0.98 10.39 2.15 4.58 1.77 0.39 25 264 54.5 116.40 45 10

0.98 10.87 2.58 4.58 1.77 0.39 25 276 65.5 116.40 45 10

1.26813.74 1.38 6.32 3.78 0.47 32 349 35 160.50 96 12

1.26 14.53 1.81 6.32 3.78 0.47 32 369 46 160.50 96 12

1.571017.44 2.39 7.74 4.53 0.59 40 443 60.6 196.50 115 15

1.57 18.82 3.17 7.74 4.53 0.59 40 478 80.6 196.50 115 15

3.541425.47

90 647

3.54 26.73

90 679

2.321829.72

59 755

2.32 32.09

59 815

6.42 10.35 4.72 0.89

163 262.80 120 22.5

7.14 10.35 4.72 0.89

181.3 262.80 120 22.5

8.35 11.22 5.91 0.98

212 285 150 25

9.45 11.22 5.91 0.98

240 285 150 25

S T U V W

2.56

5.75 4.96 0.33 6.40

146 126 8.50 162.5

2.56

5.75 4.96 0.33 6.40

146 126 8.50 162.5

2.56

5.75 4.96 0.33 6.40

146 126 8.50 162.5

4.72

7.68 6.57 0.43 8.17

120

195 167 11 207.5

4.72

7.68 6.57 0.43 8.17

120

195 167 11 207.5

5.71

10.16 8.98 0.51 10.72

145

258 228 13 272.3

5.71

10.16 8.98 0.51 10.72

145

258 228 13 272.3

6.50

8.66 7.24

165

220 184

6.50

8.66 7.24

165

220 184

7.87

10.24 8.66

200

260 220

7.87

10.24 8.66

200

260 220

0.71

0.79

7.20 1.02 28.6 183 26 13

7.20 1.02 30.8 183 26 14

7.20 1.02 33.0 183 26 15

9.27 1.22 61.6

235.5 31 28

9.27 1.22 68.2

235.5 31 31

11.90 1.83 156.2

302.3 46.5 71

11.90 1.83 169.4

302.3 46.5 77

- - -

Wt.

Lb Kg

2.48 330.0

63 150

2.48 356.4

63 162

3.15 554.4

80 252

3.15 602.8

80 274

① H= Horizontal Mounting V=Vertical mounting ② Pumps standard with external NPT ports, except where noted otherwise. ③

Ports are suitable for use with 150# ANSI stainless steel companion flanges or flanged fittings.

④ Metric shaft coupling and key required.

SECTION TSM 285 ISSUE A PAGE 34 OF 36

⑤

B1 applies for all threaded connections except BSPT or NPT

B2 applies for BSPT and NPT threaded connections B3 applies for all flange connections except ASA150, BS4504 & ASA300 B4 applies for ASA150 and BS4504 ange connections B5 applies for ASA300 ange connections

Page 35

8.7 TYPICAL NOISE EMISSION DATA - CP10, CP20 AND CP30 PUMPS

8.8 TYPICAL NOISE EMISSION DATA - CP40 AND CP50 PUMPS

SECTION TSM 285 ISSUE A PAGE 35 OF 36

Page 36

TECHNICAL SERVICE MANUAL

SECTION TSM 285

CLASSIC+ SERIES ROTARY LOBE PUMPS

MODELS CP10, CP20, CP30, CP40 & CP50

WARRANTY

Viking warrants all products manufactured by it to be free from defects in workmanship or material for a period of one (1) year from date of startup, provided that in no event shall this warranty extend more than eighteen (18) months from the date of shipment from Viking. If, during said warranty period, any products sold by Viking prove to be defective in workmanship or material under normal use and service, and if such products are returned to Viking’s factory at Cedar Falls, Iowa, transportation charges prepaid, and if the products are found by Viking to be defective in workmanship or material, they will be replaced or repaired free of charge, FOB. Cedar Falls, Iowa.

Viking assumes no liability for consequential damages of any kind and the purchaser by acceptance of delivery assumes all liability for the consequences of the use or misuse of Viking products by the purchaser, his employees or others. Viking will assume no field expense for service or parts unless authorized by it in advance.

Equipment and accessories purchased by Viking from outside sources which are incorporated into any Viking product are warranted only to the extent of and by the original manufacturer’s warranty or guarantee, if any.

THIS IS VIKING’S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, WHICH ARE HEREBY EXCLUDED, INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No officer or employee of IDEX Corporation or Viking Pump, Inc. is authorized to alter this warranty.

PAGE 36 OF 36

ISSUE A

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