TECHNICAL SERVICE MANUAL
Contents
1. SIGHT SCREW CAP GLASS lt OIL RESERVOIR ADJUSTING SCREW THRUST OUTER CASING BEARING END LOCKNUT LOCK WASHER LOCKNUT SHAFT A END CAP IDLER PIN POPPET RETURN TO TANK RELIEF VALVE IDLER BUSHING VALVE COVER PLATE HEAD IDLER SETSCREWS DOUBLE MECHANICAL SEAL OIL DRAIN ROTOR PLUGS BRACKET BRACKET BUSHING FIGURE 9 SECTION TSM 420 ISSUE E PAGE 8 OF 18 W ay _ FQ m d s as o FIGURE 10 Exploded View Series 4925 a faa Ss Dee ecanical Seat 29 roras i Ca fims Sao Reser tara o0 ier Bushing Ca fenco oun or Te Fangs Rea o1 ierann SSC Y 4 ip Sear Bearna osna Revs 18 Heravave 92 O Ring Gastar eas 5 searing Spacer corar Ouen 49 None fos erin tbe EEE Ce feasan o ripe rug o check vane Re Bearing Spacer Collar Inner 24 Reservoir with Sight Glass amp Plug 35 Head Idler Pin 8 _ Rng Hat Round Rea Caz Nope 38 Gapscrew for Head 6 Rea 9 End Cap Inner 23 Bracket and Bushing Pipe Plug 10 Seal Holder Plate 24 Bracket Bushing 38 O Ring Valve Gasket 2 Req d EE Seal Cap 25 Capscrew for Bracket 8 Req d 39 Capscrew for Valve amp Cover Plate 8 Req d 12 Nut for Seal Holder Plate 2 Req d 26 Pipe Plug 4 Req d 40 Return To Tank Relief Valve amp Cover Plate 13 Capscrew for Seal Holder Plate 2 Req d O Ring Gasket Bracket 41 Cover Plate Relief Valve 14 Gr2. from the high pressure side of the system to the double seal oil reservoir ALWAYS LISTEN FOR THE PSST AT ANY POINT LOOSENED TO PROVIDE VENTING Carefully loosen the fill plug 5 in Figure 5 in the top of the double seal oil reservoir After the ammonia has stopped venting turn the pump shaft 6 in figure 5 over for at least 10 complete revolutions This will make sure that there is no pocket of accumulated ammonia that has not been exposed to a venting point Carefully loosen the plugs 4 in figure 6 and 7 in figure 5 in the suction and discharge ports of the pump If ammonia continues to vent wait until the venting stops When venting from all the loosened connections stops then complete the loosening of the fittings and complete the removal of the plugs FIGURE 6 Viking K4925 Refrigeration Ammonia Pump with Internal Pressure Relief Valve 12 When all venting has stopped continue with removing the pump from the system or disassembly of the pump in place See asterisk page 6 DISASSEMBLY DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir etc Be sure 1 Thatany pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections See detailed procedure for venting the pumps pages 4 5 and 6 That the driving means motor turbine engine etc has been locked out or made otherwise non o
3. inadvertently started while work is being done on the pump That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precautionary measures may result in serious injury or death DISASSEMBLY NOTE Mark the valve and head or casing to be sure they are reassembled in the same relative position 1 Remove valve cap 2 Measure and record the length of extension of the adjusting screw 3 Loosen the lock nut and back out adjusting screw until spring pressure is released 4 Remove the bonnet spring guide spring and poppet from valve body Clean and inspect all parts for wear or damage and repair or replace as necessary ASSEMBLY Reverse the procedure outlined under disassembly If valve is removed for repairs be sure to replace in same position OUT RETURN TO TANK OUT CASING FIGURE 19 CASING iN RETURN TO TANK IN VALVE PORT COVER PLATE FIGURE 20 Figure 19 shows the standard pump rotation clockwise When viewing the shaft end the inlet port is on the right and the outlet on the top If the pump rotation is reversed as shown on figure 20 to give counter clock rotation is reversed as shown in figure 20 to give counter clockwise rotation when viewing the shaft end the inlet port is on the top and the outlet
4. safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precautionary measures may result in serious injury or death 1 PUMP WILL NOT START TO ROTATE A Motor not hooked up or hooked up correctly check wiring B Something has gotten into pump and has jammed rotating parts remove head and take out obstruction C End clearance has been set too close adjust end clearance D Drive equipment jammed remove obstruction 2 PUMP FAILS TO PUMP A Suction line valve not open open valve B Suction strainer is plugged clean strainer C Pump vapor bound vent discharge lines Relief valve bypassing remove obstruction or open valve Weld bead or other foreign material under poppet disassemble valve and remove foreign material Valve setting too low for differential pressure required increase setting or get heavier spring Pump rotating wrong way change direction of motor rotation or change piping No liquid in accumulator check controls Drive equipment broken repair or replace 3 PUMP IS NOISY A Cavitation liquid vaporizing on suction side of pump increase head of liquid on pump reduce line loss in suction piping insulate suction line reduce pump speed Liquid all out of accumulator pump is starved adjust floats or time cycle Relief valve chattering increase pressure setting of relief valve Binding check ali
5. 28 F Liquid Density at 28 F Liquid Density at 28 F Latent heat of vaporization at 28 F TABLE 1 Number of Btu s to change one pound liquid ammonia from liquid to gas Ammonia like LP Gas and other vapor high pressure liquids has to be kept in a closed container to keep it from boiling away For a given temperature the pressure built up within the container is equal to the vapor pressure or saturation pressure Conversely for any given pressure there is a temperature at which the liquid and vapor are in equilibrium saturation temperature see table 1 If the pressure in the container is held constant and the vapor is withdrawn the ammonia will vaporize boil As it boils it picks up heat from the area around the container since over 500 Btu s are necessary to change one pound of ammonia from liquid to vapor If the pressure over the ammonia is reduced the boiling temperature will be reduced the boiling temperature will be lowered SECTION TSM 420 ISSUE E PAGE 16 OF 18 Thus the temperature around the container can be controlled by the pressure maintained in the container Table 2 shows the ammonia vapor pressure for various temperatures The same phenomena takes place to lower the boiling point of water when the pressure is lowered This explains the low boiling point of water on a mountain top The saturation properties of ammonia make it desirable for use as a refrigerant The temperatures necessar
6. cap lip seal and bearing spacer collar Use a spanner wrench to 1 Loosen two axial set screws in the outer face of the remove the end cap bearing housing and turn the thrust bearing assembly clockwise until it can no longer be turned by hand Back off counter clockwise until the rotor and shaft can be turned by hand with a slight noticeable drag 2 Remove the double row ball bearing The bearing should be washed thoroughly and examined If there is any evidence of wear or damage a new bearing should be used 2 For standard end clearance back off the thrust bearing assembly the required number of notches or an equivalent length measured on the outside of the bearing housing See the following table 3 Examine the lip seal in the bearing housing and end cap These lip seals are important to the assembly and should be replaced if not in first class condition They are a grease seal for the ball bearing and also act as a shield to keep dirt and other abrasive particles from entering Turn Outer End Cap C C W the bearing When installing new lip seals be sure they are assembled with the lips facing toward the shaft end See figure 22 Return to page 8 step 8 for further disassembly ko ASSEMBLY 3 Tighten the two axial set screws in the out board face of 1 Place the inner bearing spacer collar on the shaft as far the bearing housing with equal force against the bracket as it will go Your pump is now set with standard end
7. clearance and NOTE First replace the snap ring or keeper rings if locked furnished in your pump See figure 22 NOTE Be sure the shaft can rotate freely If not back off 2 Install the bearing housing with inner lip seal into the additional notches and check again bracket 4 NOTE If bearing housing has not been disassembled or has been pre assembled skip items 3 and 4 Each additional notch or each on the outside diameter of the bearing housing is equivalent to an extra end clearance of 002 on HL size pumps and 0015 on K 3 Pack the ball bearing with grease place on the shaft and KK LQ and LL size pumps push or gently drive into place in the housing 5 Insert the pipe plug drain into the bracket Close the 4 Turn the bearing housing end cap with lip seal and hand valve and fill with oil reservoir with 172 of the top bearing collar inside into the bearing housing until it is with lighter Refrigeration Oil It is recommended that the tight against the bearing Lock in place by tightening the oil be drained and the reservoir be refilled after the first radial set screws in the outside diameter of the bearing 100 hours of operation and then after every 1000 hours housing NOTE Re open the hand valve before the pump is into 5 Turn the bearing housing assembly clockwise until pump operation The double mechanical seal will not function shaft can no longer be turned by hand The rotor is now properly if it is expose
8. evaporator temperature at 5 F this is the saturation temperature corresponding to 19 PSIG 3 EVAPORATOR The evaporator is the main purpose for the existence of the refrigeration system It is through the evaporator that heat is picked up by the ammonia The temperature in the evaporator area will be pulled down to the saturation temperature of ammonia at the pressure maintained by the compressor The ammonia enters as a liquid at the temperature in the receiver it leaves as a vapor gas at the saturation temperature For the system being considered the pressure in the evaporator would have to be maintained at 19 PSIG This is the pressure corresponding to a saturation temperature of 5 F WATER COOLING PIPES 86 F 154 PSIG 6 5 F 19 PSIG PUMPS USED IN THIS PORTION a OF SYSTEM TO WITHDRAW LIQUID AMMONIA FROM THE ACCUMULATOR SEE FIGURES 2 amp 3 86 F 154 PSIG FIGURE 23 Schematic of a Simple Vapor Compression Ammonia Refrigeration System l fal ACCUMULATOR VIKING REFRIGERATION AMMONIA f 77 COMPRESSOR The compressor pulls the ammonia vapors from the evaporator The pressure or vacuum pulled in the evaporator by the compressor will determine the pressure at which the evaporator works The compressor compresses the ammonia gas to the pressure corresponding to the saturation pressure of the ammonia at the temperature maintained in the condenser The compressed ammonia g
9. port on the right On HL size pumps equipped with Return To Tank pressure valves see figure 17 the cap should point towards the suction side of pump On K LL size pumps equipped with return to tank pressure relief valves see figure 18 the valve must always be mounted on the valve port nearest the pump discharge port see figure 21 Valve port nearest the pump inlet port must be covered with the valve cover plate PRESSURE ADJUSTMENT If the pressure setting of the valve is to be changed from that which the factory has set the following instructions should be carefully followed DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings orconnections See detailed procedure for venting the pumps pages 4 5 and 6 That the driving means motor turbine engine etc has been locked out or made otherwise non operational so that it cannot be inadvertently started while work is being done on the pump That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precautionary measures may result in serious injury or death IN R
10. E Re open the hand valve before the pump is put into operation The double mechanical seal will not function properly if it is exposed to ammonia pressure with this valve closed THRUST BEARING ADJUSTMENT 1 Loosen the square head setscrews over the outer and inner end caps two for the HL size four for the K thru HL size pumps Turn the inner end cap clockwise viewed from shaft end until it projects slightly from the bracket exposing approximately three threads Turn the outer end cap clockwise until the rotor is tight against the head and the rotor shaft cannot be turned Make a reference mark on the bracket end opposite a notch on the other end cap Back off the outer end cap the required number of notches shown in the table see figure 16 Tighten the inner end cap with a spanner wrench Tap the spanner wrench lightly but DO NOT OVER TIGHTEN as it will only damage the threads Tighten all the square head setscrews that hold the inner and outer end caps to prevent their turning in the bracket The rotor and shaft should turn smoothly for one complete revolution If the rotor and shaft doesn t turn smoothly go back and repeat the Thrust Bearing Adjustment steps 1 thru 7 Turn Outer End Cap C C W No of Notches or Length on O D Inches v2 22 FIGURE 16 SECTION TSM 420 ISSUE E PAGE 11 OF 18 INSTALLATION OF CARBON GRAPHITE BUSHINGS When installing a new carbon graphite idler or gra
11. ER INNER LIP SEALS OUTER BALL LIP SEAL BEARING FIGURE 8 NOTE The inner end cap can be removed through the side opening in the bracket For Viking old series 924 Heavy Duty Refrigeration Ammonia Pumps go to page 16 for bearing housing disassembly instructions SECTION TSM 420 ISSUE E PAGE 7 OF 18 8 The seal sets and rotary members of the seal may be removed from the side opening of the bracket see step 11 for removal of the double mechanical seal 9 Clean all parts thoroughly and examine for wear or damage Check lip seals ball bearing bushings and mechanical seal and replace as necessary Check all other parts for nicks burrs excessive wear and replace if necessary NOTE Be sure that the shaft is free from burrs and foreign particles that might damage the bracket bushing Scratches on the shaft in the seal area will provide leakage paths under the mechanical seal 10 Check casing for wear or damage while mounted to the bracket DOUBLE MECHANICAL SEAL See figure 11 The mechanical seal consists of five basic parts They are inner and outer seal seats with O ring gaskets inner and outer rotary members and spring When pump is running the seal cap and inner and outer seal seats with O ring gaskets remain stationary in the bracket seal housing bore the inner and outer rotary members turn with the shaft 11 The pump has now been disabled to the point where the double mechanical seal may be removed from
12. ETURN LINE TO TANK CONNECTS VALVE PORT HERE COVER PLATE FIGURE 21 Remove the valve cap which covers the adjusting screw and loosen the lock nut which locks the adjusting screw so pressure setting will not change during operation of pump A pressure gauge somewhere in the discharge line must be used for actual adjustment operation The adjusting screw should be turned for increasing the pressure or turned out for decreasing the pressure With the discharge line closed at a point beyond the pressure gauge the gauge will show the maximum pressure the relief valve will allow while the pump is in operation SECTION TSM 420 ISSUE E PAGE 13 OF 18 The Viking Over Pressure Relief Valve is strictly an over BALL BEARING pressure relief valve it is not a pressure regulating valve SPACER BEARING HOUSING In ordering parts for relief valve on head always be sure SETSCREW to give Model and Serial Number of the pump as it appears SPACER on the nameplate secured to the pump and the name of f SAN COLLAR the part wanted When ordering springs be sure to give the h Cow OUTER pressure setting desired a VIKING OLD SERIES 924 HEAVY DUTY REFRIGERATION AMMONIA PUMPS THRUST BEARING DISASSEMBLY ASSEMBLY AND ADJUSTMENT LIP SEALS END CAP SNAP RING OR KEEPER RING DISASSEMBLY FIGURE 22 1 Loosen radial set screws in the outer ring of the bearing TH RUST BEARING ADJUSTMENT housing and remove the bearing housing end
13. Electronic copies of the most current TSM issue can be found on the Viking Pump website at www vikingpump com TECHNICAL SERVICE MANUAL HEAVY DUTY REFRIGERATION AMMONIA PUMPS CONTENTS Installation General Comments 1 Pump Installation 0 3 Preventative Maintenance 4 Safe Practices 22 2204 5 Venting the Pump 00 5 Disassembly tatana darn 7 ASSOMDIY o ss oe PAs whee ea a Re amp we SES 10 Thrust Bearing Adjustment 11 Installation of Carbon Graphite Bushings 12 Pressure Relief Valve Instructions 12 Troubleshooting 2 00004 15 AMMON gee sie x og a es eae etek E nee es 16 INTRODUCTION The illustrations in this manual are for identification purposes only and cannot be used for ordering parts Obtain a parts list from the factory or a Viking representative Due to the nature of the pump and the close manufacturing tolerances certain replacement parts are only available in assemblies Always give complete name of part part number or material with model number and series number of pump when ordering repair parts The pump or pump unit model number and serial number are on the nameplate In the Viking model number system the basic size letters are combined with the series 4925 indicating either an unmounted pump or mounted pump unit Model Chart Number UNMOUNTED UNITS MECH SEAE Units are de
14. PERTY LOSS OF INFORMATION OR DATA LOSS OF PRODUCTION DOWNTIME OR INCREASED COSTS IN CONNECTION WITH ANY PRODUCT EVEN IF VIKING HAS BEEN ADVISED OR PLACED ON NOTICE OF THE POSSIBILITY OF SUCH DAMAGES AND NOTWITHSTANDING THE FAILURE OF ANY ESSENTIAL PURPOSE OF ANY PRODUCT THIS WARRANTY IS AND SHALL BE VIKING S SOLE AND EXCLUSIVE WARRANTY AND SHALL BE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ALL WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE AND NON INFRINGEMENT ALL OF WHICH OTHER WARRANTIES ARE EXPRESSLY EXCLUDED See complete warranty at www vikingpump com All rights reserved 3 2013 Viking Pump Inc
15. as as it leaves the compressor is hot and is in a super heated vapor state The vapor pulled into the compressor is at 5 F the vapor as it leaves is at a temperature of approximately 210 F and a pressure of 154 PSIG The pressure of 154 PSIG is the saturation pressure of the ammonia at the 86 F condenser temperature CONDENSER The condenser cages the super heated ammonia vapors back to liquid ammonia It does this by transferring the heat from the ammonia to a cooling liquid such as water flowing through the condenser tubes The pressure that the compressor must develop is determined by the saturation pressure of the ammonia at the temperature maintained in the condenser The temperature maintained in the condenser by the cooling medium is 86 F the saturation at the temperature pressure is 154 PSIG which is the pressure that must be maintained in the condenser to change the ammonia vapor back to liquid The liquid ammonia coming from the condenser is stored in the receiver From here it is ready to start the cycle over again ACCUMULATOR The accumulator or low pressure receiver is not one of the essential pieces of equipment in the simple system but in practice it serves a very important function For the proper operation of the compressor it is important that no liquid ammonia can be carried over from the evaporator The accumulator serves as a trap to keep liquid ammonia from being entered with the ammonia vapors that are
16. d to ammonia pressure with the forced against the head valve closed 6 Install the lockwasher and locknut on the shaft tighten 6 Return to installation of Carbon Graphite Bushings page lock nut and bend down tang of the lockwasher into slot 13 and continue on of locknut NOTE A piece of brass or wood inserted through the port opening between the rotor teeth will keep the shaft from turning SECTION TSM 420 ISSUE E PAGE 14 OF 18 TROUBLESHOOTING A Viking pump that is properly installed and maintained will give long satisfactory performance If trouble does develop one of the first steps toward finding the difficulty is to in stall a vacuum gauge in the suction line and a pressure gauge in the discharge line Readings on these gauges often give a clue on where to start looking for trouble DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections See detailed procedure for venting the pumps pages 4 5 and 6 That the driving means motor turbine engine etc has been locked out or made otherwise non operational so that it cannot be inadvertently started while work is being done on the pump That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid Obtain a material
17. ded on both sides of pump Relief valve adjusting screw caps must always point towards suction side of the pump If pump rotation is reversed position of the relief valve must be changed Pressure relief valves cannot be used to control pump flow or regulate discharge pressure For additional information refer to Viking Pump s Technical Service Manual TSM 000 and Engineering Service Bulletin ESB 31 THE PUMP must be installed in a matter that allows safe access for routine maintenance and for inspection during operation to check for leakage and monitor pump operation 4 PUMP SPEED The slower the operating speed the longer the longer the service life This is particularly true on refrigeration ammonia pumps where 4 1 the liquid has virtually no lubrication value or film strength to prevent surface to surface contact and 4 2 the heat generated by friction can cause the ammonia to vaporize which in turn causes cavitation 5 TESTING All Viking Ammonia pumps are tested prior to shipment but it is good practice to pressure test the pump along with the rest of the system before adding the ammonia Shipping storage and installation all have strange ways of producing detrimental effects on sound equipment 6 SYSTEM CLEANLINESS Ammonia is a good detergent as such it has a tendency to remove all the dirt pipe scale weld beads and loose or foreign material in the system Unfortunately not all of this material settles ou
18. der plate For parts identification see figure 7 5 Drive the shaft forward approximately 72 and check the pair of half round rings K LL size under the inner bearing spacer collar or a snap ring HL size at the end of the inner bearing spacer collar see figure 8 NOTE The snap ring HL size or half round rings K LL size must be removed before the rotor and shaft can be removed from the pump These rings will not pass through the mechanical seal and bracket bushing 6 Carefully remove the rotor and shaft As the shaft is being removed decreasing shaft diameters tend to allow the shaft to drop onto the bracket bushing To avoid damaging the bracket bushing support the rotor and do not allow either end of the shaft to tilt downward NOTE Considerable force may be required to remove the rotor and shaft from the pump Be careful as not to damage seal parts as the rotor and shaft is removed Some of the seal parts may fall off when the rotor and shaft are removed Place them to the side to be put with other mechanical seal parts when they are removed 7 Loosen the four setscrews over the outer and inner end caps Remove both end caps ball bearing and bearing spacer collars See figure 8 GREASE FITTING LOCATION NYLON INSERT SETSCREWS OUTER END CAP wy ee oY A mma LOCKWASHER C Z BL ied ENN UUU RINGS INNER SPACER f COLLAR Lad OUTER SPAC
19. ease Fitr fes S SSS SEAL HOUSING BORE INNER ROTARY MEMBER SPRING OUTER ROTARY MEMBER OUTER SEAL SEAT amp GASKET SEAL SEAT PIN ROTOR amp SHAFT BRACKET BUSHING INNER SEAL SEAT amp GASKET FIGURE 11 SECTION TSM 420 ISSUE E PAGE 9 OF 18 ASSEMBLY 1 Installing a new seal The seal is simple to install and good performance will result if care is taken in installation see figure 11 page 9 for parts identification Seals made by different manufacturers are used in these pumps and are used interchangeably though they may look different and have a different spring After all parts have been examined and cleaned or replaced as necessary the first step in reassembling the pump is installation of the inner seal seat Good performance will result if care is taken during installation NOTE Never touch the sealing faces with anything except the fingers cardboard or clean soft cloth COAT WITH LIGHT OIL SEAL HOUSING BORE INNER SEAL SEAT FIGURE 12 Clean the bracket seal housing bore making sure it is free of dirt and grit Coat the outside of the inner seal seat and O ring gasket and also the inside diameter of the real housing bore with light Refrigeration Oil not grease see figure 12 Press the inner seal seat with O ring gasket into place in the seal housing bore with your fingers or by putting a piece of card board over the face of the face of the seal seat and press with a bloc
20. er tail section of the bellows with a sleeve or smooth piece of pipe having an inside diameter no more than 22 inch larger than the shaft diameter and a wall thickness of at least inch Be sure to install correct end against seal seat see figure 11 page 9 Be sure carbon face does not fall out of the rotary member Slide the spring along the shaft and make sure it seats properly over the inner rotary member It may be helpful to stand pump on end to facilitate centring the spring Coat the outer seal seat and O ring gasket with light Refrigeration Oil Spread a thin film of grease on the seal cap Place the outer seal seat in position on the seal cap Make sure the pin in the seal seat engages the hole in the seal cap The film of grease will hold these two parts together set them aside temporarily Coat the inside diameter of the outer rotary member with light Refrigeration Oil Place it over the shaft and slide it far enough to engage the spring Be sure to install the correct end towards the spring see figure 11 page 9 Quickly install the outer seal seat and cap prepared in step 11 over the shaft and press down against the outer rotary member until the seal cap hits the end of the bracket This compresses the spring and positions the outer rotary member Do not release the seal cap 14 15 16 INNER SPACER Zh cl Still holding the seal cap against the end of the bracket place half moon shaped seal holder plate in posi
21. from an in line mounted safety relief valve to the accumulator or the valve in a pressurizing line 2 in figure 5 from the high pressure side of the system to the pump double sea oil reservoir Allow ice on pump to melt This process can be speeded up by running cold water over the pump Start the venting process as soon as convenient after the ice has been removed from the pump This will prevent venting the ammonia at the lower pressures of a cold pump rather than at the high vapor pressures in a room temperature pump For systems with vent purge or bleed valves e g D figure 4 go to step 6 for systems without a vent valve go to step 7 A hose should be connected to any vent valve e g D in figure 4 in the blocked off portion of the system The open end of the horse should be placed under water ina tank containing at least 10 times as much water as there is ammonia in the blocked off portion of the system or the end of the hose should be lead to a safe well ventilated area After the hose has been attached to the open end properly located then open the vent valve Check the open end of the hose to make sure the ammonia is venting After ammonia has stopped venting continue with step 8 FIGURE 5 Viking K4925 Refrigeration Ammonia Pump with Return To Tank Pressure Relief Valve If there are no vent valves in the blocked off piping the Viking Model 4925 ammonia pump should be vented by carefully loosening the fitting 1
22. g In addition to possible serious injury or death failure to follow the indicated instruction may cause damage to pump and or other equipment INSTALL pressure gauges sensors next to the pump suction and discharge connections to monitor pressures USE extreme caution when lifting the pump Suitable lifting devices should be used when appropriate Lifting eyes installed on the pump must be used only to lift the pump not the pump with drive and or base plate If the pump is mounted on a base plate the base plate must be used for all lifting purposes If slings are used for lifting they must be safely and securely attached For weight of the pump alone which does not include the drive and or base plate refer to the Viking Pump product catalog DO NOT attempt to dismantle a pressure relief valve that has not had the spring pressure relieved or is mounted on a pump that is operating AVOID contact with hot areas of the pump and or drive Certain operating conditions temperature control devices jackets heat tracing etc improper installation improper operation and improper maintenance can all cause high temperatures on the pump and or drive THE PUMP must be provided with pressure protection This may be provided through a relief valve mounted directly on the pump an in line pressure relief valve a torque limiting device or a rupture disk If pump rotation may be reversed during operation pressure protection must be provi
23. gnment of unit check for pipe strain Drive equipment worn or damaged repair or replace 4 LOW CAPACITY Motor running at wrong speed check wiring Speed too slow change drive or get motor with faster rated speed Too much end clearance adjust end clearance Internal wear replace worn parts Pump too small use a larger pump or two small ones Suction line too small reduce length or increase size Relief valve opening increase pressure setting Bypass line valve open adjust valve 5 RAPID WEAR A B Dirt in the system install suction line strainer temporarily until system is clean Cavitation liquid vaporizing on suction side of pump increase head of liquid on pump reduce line loss in suction piping insulate suction line reduce pump speed Pump misaligned or distorted check pump drive or alignment remove any piping strain on pump Running too fast change drive or use larger pump that could run slower Pump runs dry part of time check level controls to be sure there is always liquid in the pump 6 RELIEF VALVE DOES NOT FUNCTION A Installed incorrectly return to tank type relief valve should be mounted on the head opening toward the discharge side of pump Internal type relief valve should be mounted so end cap points toward suction port of pump SECTION TSM 420 ISSUE E PAGE 15 OF 18 B Setting too high reduce setting or get lighter spring C Valve po
24. he pump by an eccentric reducer with the offset or eccentric portion down when suction to the pump is horizontal 2 3 is as short as practical for the installation 2 4 has no strainer sometimes a temporary strainer is used during start up to keep weld beads etc ffom going through the pump 2 5 uses a long sweep elbow if any elbow is unnecessary 2 6 has a full flow shut off valve 2 7 and is fully insulated to prevent head pickup 3 INSULATION Insulation on the suction line and on the pump helps reduce the amount of heat pickup by the heat pickup by the liquid ammonia VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA SAFETY INFORMATION AND INSTRUCTIONS IMPROPER INSTALLATION OPERATION OR MAINTENANCE OF PUMP MAY CAUSE SERIOUS INJURY OR DEATH AND OR RESULT IN DAMAGE TO PUMP AND OR OTHER EQUIPMENT VIKING S WARRANTY DOES NOT COVER FAILURE DUE TO IMPROPER INSTALLATION OPERATION OR MAINTENANCE THIS INFORMATION MUST BE FULLY READ BEFORE BEGINNING INSTALLATION OPERATION OR MAINTENANCE OF PUMP AND MUST BE KEPT WITH PUMP PUMP MUST BE INSTALLED OPERATED AND MAINTAINED ONLY BY SUITABLY TRAINED AND QUALIFIED PERSONS THE FOLLOWING SAFETY INSTRUCTIONS MUST BE FOLLOWED AND ADHERED TO AT ALL TIMES Symbol Legend SECTION TSM 420 A or death BEFORE opening any liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc be sure that e Any pressure in
25. in figure 5 on the lower end of the tubing that runs from the pump bracket to the double seal oil reservoir THERE SHOULD BE A DISTINCT PSST SOUND WHEN THE AMMONIA VAPOR LIQUID STARTS TO VENT LEAVE THE AREA UNTIL THE VENTING IS COMPLETE If there is rigid pipe instead of tubing running from the pump bracket to the double seal oil reservoir the pipe union should be loosened carefully until the psst is heard ISSUE E PAGE 6 OF 18 10 11 If there is no line from the bracket to the reservoir carefully loosen the pipe plug drain 3 in figure 6 towards the bottom of he bracket This pipe plug is found only on the K KK LQ and LL 4925 pumps The small HL 4925 does not have one When working on the HL 4925 that has no trouble fitting between the bracket and double seal oil reservoir carefully loosen the pipe plug 4 in figure 6 in the suction port of the pump This segment of line E in figure 4 between the return to tank pressure relief valve and the shutoff valve C should include a pressure relief valve vented to a safe area Carefully loosen any unions or tubing fittings in any other lines to the pump that have been blocked off by closing the shutoff valves so that venting from these segments of the system can be accomplished Typical of such lines would be that from the pump mounted return to tank relief valve to the accumulator E in figure 4 or a line 2 in figure 5
26. k of wood or squared off piece of pipe Remove the cardboard Figure 13 shows how the inner seal seat pin fits into either of the slots in the end of the bracket bushings Be sure the pin engages one of these slots in the bushing when you have finished pushing the seal seat into the seal housing bore Check by looking through the bracket bushing from the casing end x f 5 y 4 5 i ig ee i FIGURE 13 SECTION TSM 420 ISSUE E PAGE 10 OF 18 Clean and coat the pump shaft with light Refrigeration Oil Check to be sure no scratches have been cot into the shaft in the seal area MECHANICAL SEAL OUTER ROTARY MEMBER _ i SPRING fi TAPERED SLEEVE COAT WITH LIGHT OIL BEFORE ASSEMBLY 10 11 12 13 FIGURE 14 After replacing the casing on the bracket place the rotor and shaft into the casing NOTE If the casing is removed from the bracket be sure the bracket O ring is in place before placing casing on bracket Place the O ring or head gasket on the head Start the head assembly with idler and bushing in place into the pump push in as far as it will go then replace the capscrews and tighten Place the tapered installation sleeve furnished with replacement seals K LL size on the shaft as shown in figure 14 Clean and oil the I D of the inner rotary member place on shaft and slide over the tapered installation sleeve into position against the inner seal seat Push against the rubb
27. lose manual valve and remove lubrication pump from filler to valve To change oil proceed as indicated in steps A thru G except vent pumping chamber to atmosphere before changing oil 2 END CLEARANCE ADJUSTMENT After long term operation it is sometimes possible to improve the performance of pump without major repair through adjustment of end clearance of the pump Refer to instruction under thrust bearing Adjustment page 11 for information regarding this procedure MANUAL VALVE FIGURE 3 3 CLEANING THE PUMP It is good practice to keep the pump as clean as possible This will facilitate inspection adjustment and repair work to help prevent over looking a covered grease fitting 4 STORAGE f the pump has to be stored or not used for an appreciable length of time it should be drained and a light coat of lubricating and preventive oil should be applied to the internal parts Lubricate all fittings MAINTENANCE IMPORTANT READ THE FOLLOWING BEFORE REMOVING A PUMP FROM AN AMMONIA SYSTEM OR BEFORE STARTING REPAIR WORK ON A PUMP DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections See detailed procedure for venting the pumps pages 4 5 and 6 That the driving means motor turbine engine etc has been locked ou
28. monia Refrigeration System with the major pieces of equipment named and numbered Each piece of equipment is described briefly and its function in the system discussed in the following paragraphs To illustrate temperatures and pressures that would exist in a actual illustration there is given with the discussion of each piece of equipment the actual temperature and pressure for a system operating with a condenser temperature of 86 F and an evaporator temperature of 5 F 1 RECEIVER A storage tank for ammonia and ambient temperatures The receiver receives the liquid ammonia as it comes from the condenser The pressure in the receiver will correspond to the vapor pressure of the ammonia at the temperature of the cooling medium used in the condenser In this case with an 86 F condenser temperature the ammonia pressure would be 154 PSI the saturation pressure corresponding to a temperature of 86 F 2 EXPANSION VALVE A throttling valve that controls the amount of liquid that flows into the evaporator It cannot be controlled manually or by thermostats located in the evaporator The temperature and pressure of the liquid on the inlet side of the expansion valve is the same as that in the receiver 86 F and PSI the pressure on the outlet side of the extension valve is that maintained in the evaporator by the compressor the compressor would have to pull down and hold the pressure in the evaporator at 19 PSIG to maintain the
29. nuously as long as there is a load on the evaporators The evaporators are flooded with several times the amount of ammonia needed this helps maintain an even temperature in the evaporators The pressure or head differential across the pump is generally very low the only head the pump must develop is that required to over come any elevation head and any line losses CORPORATION VIKING PUMP INC e A Unit of IDEX Corporation Cedar Falls IA 50613 USA SECTION TSM 420 PAGE 18 OF 18 SERIES 4925 ISSUE SIZES HL LL VIKING PUMP CORPORATION 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 The warranty period for Universal Seal series pumps ONLY Universal Seal models listed below is three 3 years from date of startup provided that in no event shall this warranty extend more than forty two 42 months from the date of shipment from Viking UNDER NO CIRCUMSTANCES SHALL VIKING BE LIABLE UNDER THIS WARRANTY OR OTHERWISE FOR SPECIAL INCIDENTAL INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST OR UNREALIZED SALES REVENUES PROFITS INCOME COST SAVINGS OR BUSINESS LOST OR UNREALIZED CONTRACTS LOSS OF GOODWILL DAMAGE TO REPUTATION LOSS OF PRO
30. of the spacer collar on the shaft or the end cap becomes disengaged with the threads see figure 15 Pack the ball bearing with multi purpose grease place on the shaft and push or gently drive into place in the bracket Install the lip seal lip toward end of shaft and bearing spacer in the outer end cap and turn the end cap to the bracket until tight against the bearing see figure 15 For Viking Old Series 924 Heavy Duty Refrigeration Pumps see page 16 for bearing housing disassembly assembly and adjusting instructions Put lockwasher and locknut on shaft Insert length of hardwood or brass through port opening between rotor teeth to keep shaft from turning Tighten locknut to 50 70 ft lbs Torque HL or 100 130 ft Ibs Torque K LL 21 22 Bend one tang of lockwasher into slot of locknut If tang does not line up with slot tighten locknut until it does Failure to tighten locknut or engage lockwasher tang could result in early bearing failure and cause damage to rest of pump Remove length of hardwood or brass from port opening Adjust the pump end clearance as indicated in THRUST BEARING ADJUSTMENT below Insert the pipe plug drain into the bracket Close the hand valve and fill the reservoir to within 1 inches of the top with the light Refrigeration Oil It is recommended that the oil be drained and the reservoir be refilled after the first 200 hours of operation and then after every 1000 hours NOT
31. perational so that it cannot be inadvertently started while work is being done on the pump That you know what pump has been handling and the precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood liquid the Failure to follow above listed precautionary measures may result in serious injury or death NOTE BE SURE TO READ PAGES 4 THRU 7 PRIOR TO PUMP DISASSEMBLY 1 Mark head and casing before disassembly to insure proper reassembly The idler pin which is offset in pump head must be positioned toward and equal distance between port connections to allow for proper flow of liquid through pump Remove head from pump Do not allow idler to fall from idler pin Tilt top of head back when removing to prevent this Avoid damaging head gasket If pump is furnished with pressure relief valve it need not be removed from head or disassembled at this point Refer to Pressure Relief Valve Instructions page 12 Remove idler and bushing assembly from the idler pin Bend up the tang on the lockwasher and using a spanner wrench remove the lockwasher and locknut NOTE A piece of brass or wood inserted through the port opening and between the rotor teeth will keep the shaft from turning SEAL CAP _S S SEAL HOLDER PLATE SHAFT LOCKNUT amp CAPSCREW FIGURE 7 4 Loosen the two locknuts and remove the seal hol
32. phite bushing extreme care should be taken to prevent breaking as it is a brittle material and easily cracked If cracked the bushing will simply disintegrate NOTE Using a lubricant and adding a chamfer in the bushing and the matting part will help in the installation of carbon graphite bushings An arbor press should always be used for installing carbon graphite bushings Be sure bushing is started straight and DO NOT STOP pressing operation until bushing is in proper position Starting and stopping will invariably result in a cracked bushing PRESSURE RELIEF VALVE INSTRUCTIONS w4 Wand ERA OLNU Valve Cap Valve Body Adjusting Screw Lock Nut Spring Guide Valve Spring Poppet Pressure Relief Plug Bonnet Cap Gasket SECTION TSM 420 ISSUE E PAGE 12 OF 18 T FAN AO LNA ZENA Valve Cap Valve Spring Adjusting Screw Lock Nut Spring Guide Poppet Pressure Relief Plug Cap Gasket Bonnet Bonnet Gasket Valve Body DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir etc Be sure 1 That any pressure in the chamber has been completely vented through the suction or discharge lines or other appropriate openings orconnections See detailed procedure for venting the pumps pages 4 5 and 6 That the driving means motor turbine engine etc has been locked out or made otherwise non operational so that it cannot be
33. ppet binding remove poppet check for burrs or foreign material D Shut off valve in relief valve return line closed open valve would apply only to pumps with return to tank type relief valves 7 MECHANICAL SEAL LEAK A Normal wear replace seal B Improper installation review installation procedure outlined on pages 11 and 12 C Abrasive material in liquid if abrasive material on ammonia side use traps or strainer to clean system if on oil side change oil more frequently and use clean oil D Pump operating at very low temperature causing oil to become heavy use lighter oil use immersion heater to heat oil or consider a packed pump AMMONIA Ammonia Anhydrous Ammonia NH3 Ammonia is a colorless gas or liquid has a pungent odor as a gas is lighter than air is easily liquefied by pressure alone and is very soluble in water or alcohol Ammonia is one of the best known and widely used refrigerants in use today in ice plants food lockers cold storage warehouses and other industrial cooling processes Ammonia has a higher refrigeration effect per unit of liquid volume than any other type of commonly used refrigerant other advantages are low initial cost and low pipe friction losses PHYSICAL PROPERTIES Boiling point atmospheric pressure 28 F Freezing point atmospheric pressure 107 9 F Viscosity at 28 F 0 27 centipose 0 68 42 6 lbs gal 5 7 lbs gal 589 BTU Specified Gravity at
34. pulled from the evaporator by the compressor The temperature and pressures are the same as they are in the evaporator As the liquid is collected or accumulated in the accumulator it must be removed THE REMOVAL OF THE LIQUID AMMONIA FROM THE ACCUMULATOR IS WHERE THE VIKING REFRIGERATION AMMONIA PUMP IS USED 210 F 154 PSIG COMPRESSOR 4 EVAPORATOR 3 REFRIGERATOR SS 5 F 19 PSIG EXPANSION VALVE 2 SECTION TSM 420 ISSUE E PAGE 17 OF 18 TECHNICAL SERVICE MANUAL HEAVY DUTY REFRIGERATION AMMONIA PUMPS Figure 24 shows a typical schematic of a Continuously Recirculating System with vertical accumulator Space or other physical requirements may make a horizontal accumulator more practical As long as the minimum submergence requirement of 4 of liquid is maintained the arrangement of the accumulator is of little consequence to good pump operation The schematic is intended only to show in a general way piping and connections directly related to the pump No attempt has been made to show all the necessary controls valves regulators gauges etc that are necessary for successful operation of this portion of an ammonia refrigeration system AMMONIA MAKE UP LINE FROM HIGH PRESSURE RECEIVER RETURN LINE FROM PUMP MOUNTED RELIEF VALVE VIKING REFRIGERATION THROTTLE VALVE AMMONIA PUMP FIGURE 24 Schematic of Liquid Ammonia Recirculating System Pumps on this system run conti
35. ressure has a different value for each temperature The saturated vapor pressure of water at 212 F waters boiling point is 14 7 PSIA In other words when handling Refrigeration Ammonia we are handling a liquid which is at its boiling point A slight reduction in the pressure being exerted on the liquid will cause boiling and thus vapor formation With this information in mind let us examine figure 2 which illustrates one of the most important considerations when installing a pump to handle Refrigeration Ammonia The pressure P1 in the accumulator is equal to the saturated vapor pressure of the ammonia When the pump is not running the pressure P2 at the pump inlet is equal to the tank pressure P1 plus the static head H P2 P1 H FIGURE 2 As soon as the pump started and the liquid begins to flow the pressure at the pump P2 will drop by an amount equal to the pressure loss in the piping between the accumulator and the pump When liquid is flowing P2 P1 H pressure loss in the piping In order to have an installation in which the pump handles all liquid and no vapor the pressure drop in the piping must be equal to or less than the static head H on the pump inlet If the piping loss is greater than the static head the liquid ammonia will start to boil or vaporize and the pump will be required to take in a mixture of liquid and vapor Since a given weight of vapor takes up a much greater volume than the same weigh
36. s not above 5 PSIG when filling reservoir If pressure is higher pumping chamber should be bled down to reduce pressure to 5 PSIG or below Before bleeding pump read SAFE PRACTICES page 4 and VENTING THE PUMP page 4 Pressure above 5 PSIG in the pump may cause inner seal seat to be unseated or may force the faces of the inner seal apart allowing any dirt accumulated around the inner seat to be forced between the faces When the pump is started the seal may leak SECTION TSM 420 ISSUE E PAGE 4 OF 18 B Remove inch NPT oil filler plug in top of reservoir carefully and allow the small amount of ammonia trapped in the reservoir to vent C Open oil drain plug and allow old oil to drain D Replace oil drain plug and fill reservoir with light Refrigeration Oil to within 1 inch of the top approximately 1 pint Replace inch NPT oil filler plug in top of reservoir m Open hand valve Wait one minute then star the pump and allow it to run from two to three minutes before the liquid is introduced onto the pump This will allow the seat to seal itself properly before the pressure is applied NOTE If your pump has an automatic snap on filler valve arranged similar to that shown in figure 3 it is not necessary to stop the pump to add oil to the reservoir Merely connect lubrication pump to automatic filler valve Open manual valve and fill reservoir with light Refrigeration Oil to approximately 1 inch from the top C
37. signated by the HL4925 unmounted pump model numbers K4925 followed by a letter s indicating KK4925 drive style LQ4925 LL4925 P Commercial Speed Reducer This manual deals exclusively with Series 4925 Heavy Duty Refrigeration Ammonia Pumps Refer to Figures 1 thru 24 for general configuration and nomenclature used in this manual NOTE DO NOT OPERATE SERIES 4925 PUMPS AT SPEEDS HIGHER THAN THOSE STATED IN CATALOG SECTION 420 Series 4925 Heavy Duty Refrigeration Ammonia Pumps NOTE Single reservoir sight glass is standard Images are shown with optional reservoir fittings CORPORATION SECTION TSM 420 PAGE 1 OF 18 SERIES 4925 ISSUE E SIZES HL LL FIGURE 1 Series 4925 Unmounted Pump INSTALLATION GENERAL COMMENTS Consideration of the following points during design and installation of the system will help insure successful operation of the Viking Refrigeration Ammonia Pump 1 SUBMERGENCE Submergence is the head of liquid ammonia above the centerline of the pump suction port A liquid head is necessary to keep the ammonia from flashing as it goes into the pump The minimum liquid head or submergence for good pump operation is 4 feet this is assuming a large short suction line 2 SUCTION LINE A large short suction line is necessary for good operation A good suction line 2 1 is a suction line that is at least one size larger than the pump suction port connection 2 2 is connected to t
38. t or otherwise made non operational so that it cannot be inadvertently started while work is being done on the pump That you know what liquid the pump has been handling and the precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow above listed precautionary measures may result in serious injury or death AMMONIA Anhydrous Ammonia NH3 Ammonia is a colorless gas or liquid has a pungent odor as a gas is lighter than air is easily liquefied by pressure alone and is very soluble in water It boils at 28 F vapor pressure is 16 PSIG at 0 F 45 PSIG at 30 F 93 PSIG at 60 F and 138 PSIG at 80 F DANGER Exposure to ammonia causes intense irritation to the surface tissue of the eyes nose throat and lungs Exposure to high concentrations of ammonia may blind burn strangle or kill SAFE PRACTICES Basic safety practices and equipment should always be used when working with ammonia Only personnel familiar with ammonia systems should work on these pumps A listing of safe practices and equipment are available from many sources including those listed below A copy of such a listing and safe practices and equipment should be made available to everyone working where ammonia is used Safety Department The Safety Department of any company using ammonia should have information about
39. t of liquid handling both liquid and vapor will reduce the liquid output from the pump The vapor is compressed back to a liquid on the discharge side of the pump causing it to be noisy and to wear rapidly Values for pipe friction losses for calculating suction line pressure drop can be found in refrigeration hand books Since Viking pumps are of the positive displacement type be sure that there is no obstruction in the discharge line and that all valves are in operating position before starting the pump Factory assembled port will have right hand port suction and top port discharge unless otherwise specified Port location is determined by looking at shaft end of pump The pressure relief valve on the pump provides over pressure protection Return to Tank pressure relief valves should be mounted on the discharge side of the pump Internal type pressure relief valves should be mounted with the cap pointing towards the suction side of pump Also see formation under Relief Valve Instructions page 12 The Viking pump mounted return to tank pressure relief valve See Figure 16 PAGE 11 amp Figure 17 page 12 is fitted with a pressure relief plug to keep a valid off return line from building up excessive pressures SECTION TSM 420 ISSUE E PAGE 3 OF 18 DANGER Include provision for a pressure relief device in any part of a pump and piping system that can be valved off and thus completely isolated Cold liquid ammonia when isolated
40. t in traps or can be caught in strainers and as a result a considerable amount goes through the pump the abrasive solids going through the pump will of course cause excessive wear during the start up of a new system thus the cleaner a new system is before start up the less wear and trouble with the pump 7 STAND BY EQUIPMENT Stand by equipment is always good insurance when possible breakdown of any single piece of equipment could be jeopardise the operation of the entire system Often on circulating two pumps are used with operation of the pumps alternated by day or week Alternating operation of the pumps is not always considered the best practice since both pumps may both wear out at the same time If operation of the pumps is not alternated the stand by pump should be run for several hours at least once a month to make sure it is in good operating condition Sometimes on large systems three pumps are used two running continuously with the third for use as a standby and for peak loads PUMP INSTALLATION One of the most important considerations on any circulation Refrigeration Ammonia pump installation is proper design of the pump inlet line Refrigeration Ammonia when stored in a closed container will exert a pressure within the container equal to its saturated vapor pressure The saturated pressure of a liquid may be defined as the pressure at which both liquid and vapor exist in equilibrium in the same container The vapor p
41. the basic safety practices and equipment to use when working with ammonia The supplier of the ammonia should always have the same information ANSI American National Standard Institute Inc 1430 Broadway New York New York 10018 Bulletin ANSI K61 1 CGA The Compressed Gas Association Inc 500 Fifth Avenue New York New York 10036 Pamphlet G 2 on Anhydrous Ammonia IAR International Institute of Ammonia Refrigeration 1 Illinois Centre 111 East Wacker Drive Chicago Illinois 60601 The above references give specifics on safety practices and equipment In addition to those some general precautions include WORK CAREFULLY DO NOT HURRY LOOK AT ANY PRESSURE GAUGES TO DETERMINE CONDITIONS IN THE SYSTEM HAVE PLENTY OF WATER AVAILABLE VENTING THE PUMP 1 Stop the pump some maintenance people close the inlet shutoff valve before stopping the pump but this is not recommended practice 2 Close the inlet suction side shutoff valve A in figure 4 3 Close the discharge side shutoff valve B in figure 4 ACCUMULATOR SEE THE ON PAGE 6 FIGURE 4 Schematic of Piping and Valves For a Liquid Ammonia Recirculating Pump in a Refrigeration System SECTION TSM 420 ISSUE E PAGE 5 OF 18 SECTION TSM 420 Close all other shut off valves in lines connected to the pump Typical would be valve C in line E in figure 4 from the pump mounted return to tank type relief valve to the accumulator or the valve
42. the chamber has been completely vented through the suction or discharge lines or other appropriate openings or connections The pump drive system means motor turbine engine etc has been locked out or otherwise been made non operational so that it cannot be started while work is being done on the pump You know what material the pump has been handling have obtained a material safety data sheet MSDS for the material and understand and follow all precautions appropriate for the safe handling of the material BEFORE operating the pump be sure all drive guards are in place DO NOT operate pump if the suction or discharge piping is not connected DO NOT place fingers into the pumping chamber or its connection ports or into any part of the drive train if there is any possibility of the pump shafts being rotated DO NOT exceed the pumps rated pressure speed and temperature or change the system duty parameters from those the pump was originally supplied without confirming its suitability for the new service BEFORE operating the pump be sure that e Itis clean and free from debris e all valves in the suction and discharge pipelines are fully opened All piping connected to the pump is fully supported and correctly aligned with the pump Pump rotation is correct for the desired direction of flow ISSUE E PAGE 2 OF 18 Danger Failure to follow the indicated instruction may result in serious injury Warnin
43. the seal housing bore of the bracket HAND Pa 12 13 14 15 NOTE Pay particular attention to the location arrangement and construction of the seal parts as it will help considerably when the pump is re assembled Remove the seal cap if it was not removed in step 6 A light tap may be necessary to loosen it The O ring gaskets of the seal sets may have become slightly sealed against the side of the housing and require extra effort If this happens apply light oil in the seal housing bore in front of the seats so they will slide freely After removing the outer seal seat the outer rotary member the spring and the inner rotary member can be removed Remove the inner seal seat and gasket by bending the ends of the two lengths of wire and then by inserting the bent end in the slots in the bushing and pulling the seal seat through the housing from the shaft end If removal is difficult an arbor press may be used to push the bracket bushing seal seat and gasket out of the bore from the rotor end Another coating of light oil may be helpful to ease the seal seat out of the housing Another way of removing the inner seal seat is to drive it out while inserting a screwdriver through the bracket bushing from the casing end so it hits the seal seat at the notches in the bracket bushing Be careful and do not damage the bracket bushing when removing the inner seal seat in this manner OIL FILLER PLUG ADJUSTING
44. tion and tighten the two locknuts uniformly This holds the seal cap in position and insures proper positioning of seal NOTE Do not permit either the inner or outer rotary member to remain in the shaft in any position other than their final position for more than 30 seconds since the rubber bellows of the rotary members have a tendency to stick to the shaft If the bellows are not in correct position the rotary member will be improperly seated Remove tapered sleeve Place the inner bearing spacer collar on the shaft as far as it will go NOTE First replace the snap ring HL size or half round rings K LL size if furnished see figure 15 GREASE FITTING LOCATION NYLON INSERT 1 SETSCREWS INNER END CAP HALF ROUNE RINGS OUTER END CAP iy N va gt Dy LOCKWASHER 4 f ikatan RN ZUIN L 4 COLLAR Zac za OUTER SPACER INNER LIP SEAL N OUTER BALL LIP SEAL BEARING 17 18 19 20 FIGURE 15 Press the lip seal lip toward end of shaft into the inner cap and insert the end cap through the shaft end of bracket With two fingers turn it clock wise looking at end of shaft until it engages the threads The spanner holes in the wrench cap must be toward the rotor Turn the end cap with a spanner wrench until it projects slightly into the opening on the side of the bracket NOTE The end cap must not be turned so far that the lip of the seal drops off the end
45. will as it warms up to room temperature expand and exert tremendous pressures which may rupture the pump or piping unless relieved See Viking Technical Service Manual TSMO000 for additional general installation information PREVENTATIVE MAINTENANCE Series 4925 pumps are designed for long trouble free life under a wide variety of application conditions with a minimum of maintenance however the following should be considered 1 LUBRICATION 1 1 Periodic external lubrication should be applied slowly with a hand gun at all lubrication fittings A good quality of general purpose grease is satisfactory in the majority of cases however applications involving very low temperatures may require other types of lubricants suggested frequency of lubrication is once every 500 hours of operation Do not over grease Consult the factory if you have specific lubrication questions 1 2 Double Mechanical Seal Reservoir After replacing seal and or before letting ammonia into new or rebuilt pump fill oil reservoir with one pint of light Refrigeration Oil Before opening valves and allowing ammonia to fill the pump be sure the hand valve on the reservoir shown in figure 8 is open Change the oil in your double seal pump reservoir after first 200 hours of operation and then every 1000 hours by the method mentioned below A Stop pump and close hand valve on oil reservoir see figure 8 DANGER Be sure ammonia pressure in pump i
46. y for freezing and keeping food products can be quiet easily achieved with pressures or vacuums readily developed by available equipment F Vacuum Gage Absolute Pe tat Ta 180 24 3 2 74 60 18 6 5 55 ps m ter 40 8 7 10 4 s ss 28 0 14 7 a s 10 9 0 23 7 owo o ar w 10 23 8 38 5 o s 30 45 0 59 7 ow s m3 50 74 5 89 2 oea l 2s we 80 138 153 ow da l a AMMONIA VAPOR PRESSURE TABLE 2 Grades of Ammonia Available commercial grade 99 5 refrigeration grade 99 95 Explosive Limit in Air by Volume 16 0 to 25 Corrosion Ammonia will not attack iron or steel ever in the presence of moisture it will attack copper brass bronze and zinc in the presence of moisture Toxicity Concentrations of ammonia in air as low as 53 parts per million can be detected by the sharp penetrating odor Exposure to ammonia causes intense irritation to the surface tissues of the eyes nose throat and lungs Exposure to high concentration of ammonia may blind burn strangle or kill The effect of ammonia on the skin is that of a caustic burn varying in severity with the concentration of ammonia and the length of time exposed Changes in respiratory and heart action produced as reflex actions resulting from the irritation of the respiratory tract For information on the safe handling of ammonia see SAFE PRACTICES page 5 Figure 23 is a schematic of a simple Vapor Am
Download Pdf Manuals
Related Search