SERVICE MANUAL - Techniques Des Fluides
Contents
1. EnviroGear RNAL G es PUM E DOVER COMPANY PUMP DISASSEMBLY amp REPAIR PROCESSES How To Install Rotor Assembly Into Outer Drive Assembly Models 51 24 51 32 51 55 S1 69 amp 51 82 1 Loosely fit the two rods into opposite holes on the outer drive assembly 100 2 Loosely position the two rod ends into the channel 3 Twist the two rods to tighten the channel nuts and clamp the rods to the channel Figure 6 32 rods and channel assembled 4 Assemble the two wing nuts onto the two rods to hold them to the outer drive assembly PEE 5 Carefully lift the outer drive assembly with the tool kit attached and set it on a suitable workbench vertically with the rotor teeth facing up 6 Firmly affix the channel to the workbench surface so that it can safely resist a lifting force of up to 400 Ibs 182 kg Firmly affix to workbench Figure 6 33 outer drive assembly mounted to tool 7 Insert the canister 6 containing the support plate into the outer drive assembly The support plate has no top or bottom so its orientation doesn t matter 687 Figure 6 34 insert canister and support plate ENVIROGEAR PUMP COMPANY 36 ENV 10000 E 01 Envir rdGear E DOVER company PUMP DISASSEMBLY amp REPAIR PROCESSES 8 Attach the puller plate to the rotor assembly using three of the pump s 1 2 13 screws 9 or 10 Figure 6 35 puller plate on rotor assembly 9 Su2. d Rotor Assembly dler Assembly Relief Valve Assembly E EM 5 _ 6 100 400 Recommened spares ENVIROGEAR PUMP COMPANY 16 ENV 10000 E 01 ENV 10000 E 01 17 Part ID EnviroGear company Oty Part Name Magnet Housing Shaft xx Magnet Segment Wave Spring En EE EE Ka EM E 1 KR m su a LES Inner Ring Sleeve 0 2 Recommened spares Magnet quantities may vary depending on pump configuration ENVIROGEAR PUMP COMPANY EnviroGear RES INTERNAL GEAR PUMPS a BOVER REPAIR PARTS EE d 302 N 403 2 O Ring for Valve 5 crews for Valve Jacket for Casing EN EN EN 1 JacketforValve EN Ea Part ID 2 Screws Thermal Cement not shown 1 JacketforHead 1 O RingforJacket 4 jScrewforJacket Lam Lam am NN EN EM EM NN Recommened spares ENVIROGEAR PUMP COMPANY 18 ENV 10000 E 01 E DOVER company SECTION S 5 SIMPLE PUMP ADJUSTMENTS Hovw To Change Port Orientation Only Shaft Hotation Unchanged This instruction applies for changes when the direction of shaft rotation will not change such as changing from RT to TL Since the shaft rotation is unchanged the discharge and suction positions relative to the casing and head will not change and therefore the cooling circuit pl
3. any leaks in the piping If so stop the pump and fix them Are there any unusual noises or vibrations If so stop the pump See Troubleshooting section to help solve the problem ls the pump performing as expected proper flowrate and pressure If not see Troubleshooting section to help solve the problem ENVIROGEAR PUMP COMPANY 14 ENV 10000 E 01 SECTION 4 REPAIR PARTS E DOVER company Repair Parts The parts used in this pump are designed and manufactured with exacting tolerances material specifications and production techniques Always use authentic repair parts supplied by EnviroGear or its authorized selling partners Use of any other parts may void the pump s warranty This EnviroGear pump was specifically configured for your unique application conditions conditions EnviroGear can supply a detailed bill of material that includes the part numbers for your specific pump configuration identified by serial number Use these part numbers when ordering repair parts ENV 10000 E 01 15 ENVIROGEAR PUMP COMPANY EnviroGear RES INTERNAL GEAR PUMPS a DOVER REPAIR PARTS Part ID Qty Part Name EN Head Casing Spindle Es O Ring for Canister O Ring for Head 11 Canister H Support Plate Bolts for Head Bolts for Outer Drive 1 Orifice Plug Plug for Casing Plugs for Vent Drain 2 Plug for Head Outer Drive Assembly En
4. layer of lubricant on the spindle and bushing surfaces In some other cases the pump will contain residual petroleum oil from the factory testing EnviroGear can provide more details for your specific pump upon request 2 Verify that the piping components are all tightened and in their final position 3 Ensure the pressure relief device is installed and working correctly 4 Verify that the shaft alignment is correct see Shaft Alignment section above 5 Verify that the pump freely turns by hand 6 Verify that the driver rotates the pump shaft in the correct direction 7 Openor close all valves in the suction piping to ensure that liquid will reach the pump 8 Openor close all valves in the discharge piping to ensure that liquid will reach the intended location 9 Ifthe suction is not flooded add a small volume of compatible liquid into the pump This will improve the priming ability and lubricate the pump during a dry startup 10 Verify that all guards and other safety equipment is installed and working correctly 11 If the driver includes a gearbox check the manual from the gearbox manufacturer to confirm that the lubricant is at the proper level and for any additional startup procedures related to the gearbox Now the pump is ready to be started Once started check the following Is the pump moving liquid If it doesn t within 60 seconds stop the pump See Troubleshooting section to help solve the problem e Are there
5. of abrasion erosion or corrosion No returns will be accepted by EnviroGear unless accompanied by EnviroGear s written authorization and EnviroGear will assume no field expense for service or parts unless authorized in writing by EnviroGear in advance All warranty replacement or repairs must be performed by EnviroGear or a EnviroGear Authorized Service Organization EnviroGear 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 EnviroGear products by the purchaser the purchaser s employees or others This warranty is exclusively for the benefit of the first purchaser of the product other than a purchaser for resale and cannot be transferred or assigned THERE SHALL BE NO OTHER WARRANTY EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER OBLIGATION ON THE PART OF ENVIROGEAR WITH RESPECT TO PRODUCTS EXCEPT THE WARRANTY OR WARRANTIES CONTAINED HEREIN ENV 10000 E 01 45 ENVIROGEAR PUMP COMPANY EnviroGear INTERNAL GEAR PUMPS A DOVER company 22069 Van Buren Street e Grand Terrace CA 92313 5607 Phone 909 422 1731 Fax 909 783 3440 website www enviropump com ENVIROGEAR MEIVIBER OF PUMP SOLUTIONS GROUP A COMPANY TECHNIQUES DES FLUIDES 7 rue de la Fosse aux Loups 95100 ARGENTEUIL T l 01 34 11 13 73 Fax O1 3
6. 182 kg Pump Disassembly Tool F 00096 or F 00097 ENV 10000 E 01 SECTION 1 CAUTIONS EnviroGear company CAUTION Carbon graphite bushings are very brittle so they must be handled and assembled using great care e Always use an arbor during assembly to guide and align the bushings e When pressing bushings use a light lubricant e When pressing bushings always use a smooth continuous motion stopping with the bushing partially exposed can crack the bushing e After assembly always inspect the bushings closely for cracks CAUTION You must press the bearing by its inner ring to avoid damaging it CAUTION Failure to have each magnet segment in opposite polarity with adjacent magnets will cause a significant reduction of coupling torque CAUTION Maximum temperature limits are base upon mechanical stress only Certain chemicals will significantly reduce maximum safe operating temperatures Consult Chemical Resistance Guide for chemical compatibility and temperature limits CAUTION Prevention of static sparking if static sparking occurs fire of explosion could result Pump valves and containers must be grounded to a proper grounding point when handling flammable fluids and whenever discharge of static electricity is a hazard CAUTION Always wear safety glasses when operating pump ENVIROGEAR PUMP COMPANY E DOVER COMPANY Always read the most current version
7. 4 11 96 35 www techniquesfluides fr Printed in the U S A Copyright 2011 EnviroGear Pump Company ENV 10000 E 01
8. Envi c ear INTERNAL GEAR PUMPS DOVER company SERVICE MANUAL r EV SEAT TABLE OF CONTENTS SECTION 1 CAUTIONS 3 SECTION 2 TECHNICAL SECTION INSTALLATION amp 5 10 SECTION 4 REPAIR 15 SECTION 5 SIMPLE PUMP ADJUSTMENTS 19 SECTION 6 PUMP DISASSEMBLY amp REPAIR PROCESSES 24 SECTION 7 TROUBLESHOOTING 41 SECTION 8 HOW TO RETURN PUMP TO FACTORY 44 SECTION 9 45 ENVIROGEAR PUMP COMPANY 2 ENV 10000 E 01 CAUTION In any positive displacement pump system a reliable pressure protection device must be used in the discharge piping to avoid a dangerous pressure increase which could cause the pump or any component in the discharge piping to burst which could cause serious injury A pump mounted integral relief valve is not intended to be used in this manner CAUTION This pump contains powerful permanent magnets that can cause serious injury Read the appropriate section of this service manual bef
9. ION amp STARTUP Pressure Relief This is a positive displacement pump As such for each shaft revolution it will move a specific volume of fluid from the suction side to the discharge side If the discharge line is severely restricted or blocked a dangerous increase in pressure and drive torque will occur rapidly between the discharge port and the restriction which will lead to one or more of the following events e the pipe or other discharge line components bursts e drive stalls the pump s inner and outer magnets decouple e a pump component breaks A reliable pressure protection device must be used in the discharge piping with any positive displacement pump It should be located as close as possible to the discharge port of the pump Several common devices are e external relief valve e rupture disc e pressure regulator e pressure switch that stops the pump driver Torque limiting devices cannot react precisely to discharge pressure and therefore must not be used as the primary pressure protection device Rotation and Port Orientation The pump is configured in one of the 8 possible orientations shown in Figure 3 1 and it has labels on it which indicate direction of rotation suction port and discharge port Figure 3 1 eight possible port orientations To change the orientation see Chapter 5 ENV 10000 E 01 11 ENVIROGEAR PUMP COMPANY E DOVER COMPANY INSTA
10. LLATION amp STARTUP Piping Excessive pipe stress can cause reduced pump durability and reliability by affecting shaft alignment and or distorting pump components Isolate the pump from any pipe stress Here are several suggestions that help isolate the pipe stress e Properly support all piping with suitable pipe hangars or supports not with the pump e Install flexible lines near the pump e lf the pumped liquid will be hot be sure to calculate pipe expansion and provide provisions for it All discharge piping components must be designed to safely handle the maximum system pressure Make sure all the pipes and other components are clean before installation A reliable pressure protection device must be used in the discharge piping with this positive displacement pump See section Pressure Helief above for more details Pressure gauges are valuable tools for troubleshooting pump related problems Install gauges near both pump ports some pumps have gauge ports for this purpose Also install gauges on both sides of high restriction components such as filters heat exchangers or flowmeters Hemember it is much easier to include gauges when the piping is first installed than to add gauges later Suction Piping The suction piping must be able to supply liquid to the pump at the desired flowrate with sufficient pressure at the pump to avoid cavitation To ensure this you should calculate the NPSHa available for the suction piping de
11. OCESSES Hovw To Heplace Outer Ball Bearing 1 Position the outer drive assembly 100 on blocks in a suitable press with the shaft facing upward 2 Remove the snap ring 108 from its groove in the shaft 3 Press the shaft downward until the outer bearing 105 disengages from the shaft 4 Remove the outer ring assembly 102 with shaft and inner bearing 105 attached wave spring 106 and outer bearing 5 Remove the inner bearing from the shaft with a suitable gear puller 6 Apply a light oil to the shaft and press the new inner bearing onto the shaft The new bearing inner race should be flush with the outer ring Be careful to avoid disrupting the shaft position relative to the outer ring 7 Insert the wave spring into the inner bearing counterbore of the magnet housing 8 Insert the outer ring shaft inner bearing assembly into the magnet housing 9 Press the outer bearing onto the shaft until the distance from the end of the shaft to the face of the bearing meets the following specification 51 2 51 4 1 898 48 21 mm 51 24 51 32 51 55 51 69 2 536 64 41mm 51 82 3 911 99 34 10 Install the snap ring its groove the shaft ENVIROGEAR PUMP COMPANY Figure 6 21 bearing area components Figure 6 22 outer bearing location 32 ENV 10000 E 01 EnviroGear PUMP DISASSEMBLY amp REPAIR PROCESSES 75 How To Replace Inner Magnets 1 There ar
12. UMP COMPANY Enviro Gear E DOVER COMPANY PUMP DISASSEMBLY amp REPAIR PROCESSES How To Assemble Relief Valve 1 Check the valve body o ring 404 for damage and replace it if necessary Position the valve body o ring in its groove in the valve body 401 If necessary use small amount of light adhesive to keep the o ring properly positioned Position the spring and poppet inside the valve body Determine which pocket in the head is aligned with the discharge port The relief valve poppet 402 must be positioned on the discharge pocket for the valve to Figure 6 43 relief valve assembly function correctly Position the valve body spring poppet onto the pump head with the poppet over the discharge pocket and loosely assemble the valve body screws Tighten the screws in an alternating pattern until the valve body is fully contacting the head Torque the screws to to their final values 3 8 screws 40 ft lbs 54 e 1 2 screws 65 ft lbs 88 N m ENVIROGEAR PUMP COMPANY 40 ENV 10000 E 01 SECTION 7 TROUBLESHOOTING Symptom or Problem Pump is excessively noisy Possible Cause s Air in the inlet fluid stream Relief valve is opening Pump has decoupled Pump components are damaged or worn Pump is cavitating Discharge line is too restrictive Cooling path is plugged Ball bearings are worn or damaged Symptom or Problem Pump does not prime Possible Cause s Di
13. asing s alignment counterbore Figure 6 39 casing plugs and o ring If necessary rotate the casing to get the ports in the preferred position Insert the screws 10 that hold the outer drive assembly to the casing a First torque them to 5 10 ft lbs 7 14 N m in an alternating pattern b Next torque them to 20 ft lbs 27 N m in an alternating pattern c Finally torque them to their final values in an alternating pattern 3 8 screws 40 ft lbs 54 N m 1 2 screws 65 ft lbs 88 N m ENVIROGEAR PUMP COMPANY 38 ENV 10000 E 01 EnvirdGear E DOVER company PUMP DISASSEMBLY amp REPAIR PROCESSES 6 Ifthe pump is not equipped with a relief valve make sure the head block off plug 14 is in the correct location on the DISCHARGE side of the head DISCHARGE 7 Slide the head o ring 5 onto the head Take care to avoid scratching the o ring 8 Position the head with the crescent facing up and set idler assembly 800 and spindle 9 in place 9 Carefully insert the head idler spindle unit into the rotor Take care to avoid cracking or chipping the carbon bushings 10 Rotate the head so that the rotor and idler mesh between the ports 11 Insert the screws B that hold the head to the casing and torque them to their final values i e 3 8 screws 40 ft lbs 54 N m e 1 2 screws 65 ft lbs 88 N m Figure 6 42 insert head idler spindle ENV 10000 E 01 39 ENVIROGEAR P
14. blem Relief valve does not open Possible Cause s e Pump is running in the wrong direction e Relief valve is stuck closed Symptom or Problem Leakage from head casing area Possible Cause s e O ring material is not compatable with the pumped fluid e Sealing surfaces for the o rings are damaged e Bolt s are loose or missing e O ring is damaged or missing Symptom or Problem Leakage from casing magnet housing area Possible Cause s e O ring material is not compatable with the pumped fluid Sealing surfaces for the o rings are damaged Casing or magnet housing mounting flanges are cracked Bolt s are loose or missing O ring is damaged or missing Symptom or Problem Leakage from head valve body area Possible Cause s e O ring material is not compatable with the pumped fluid e Sealing surfaces for the o rings are damaged e Bolt s are loose or missing e O ring is damaged or missing Symptom or Problem Leakage from drive shaft area Possible Cause s e Canister is damaged and leaking Symptom or Problem Excessive vibration Possible Cause s e Air in the inlet fluid stream Relief valve is opening Pump has decoupled Pump components are damaged or worn Pump is cavitating Ball bearings are worn or damaged Inner magnets have weakened Cooling path is plugged ENVIROGEAR PUMP COMPANY 42 ENV 10000 E 01 El DOVER company TROUBLESHOOTING Symptom or Problem Pump draws to
15. e two methods to remove the sleeve from the rotor a Support the rotor assembly on the front edge of the sleeve 204 with the teeth facing down Leave at least 1 inch 25 mm of clearance beneath the teeth Then press the rotor down separating it from the sleeve b Carefully cut the sleeve as shown in Figure 6 24 Be careful to avoid damaging the rotor in the area around the front o ring The sleeve will easily pull off the rotor after this cut is in place 204 204 Do not damage rotor in the front O ring area Figure 6 23 method a Figure 6 24 method b 2 Remove the old magnet segments from the inner ring 202 a In most cases the magnets are held place only by their magnetic attraction to the inner ring b In a few other cases they are held place with epoxy Contact EnviroGear for instructions for removing the epoxy 3 Remove the front and rear 205 sleeve o rings from the grooves in the rotor 4 Install new o rings in the grooves in the rotor Figure 6 25 sleeve removed 5 Slowly bring one end of a new magnet segment into contact with the end of one flat on the inner ring such that only a short length of the magnet is in contact with the inner ring Figure 6 26 assembling magnet segments ENV 10000 E 01 33 ENVIROGEAR PUMP COMPANY PUMP DISASSEMBLY amp REPAIR PROCESSES 6 Slide the magnet segment along the length of the inner ring until it touches the sma
16. ed 16719 1 2 CS_ 11 2 NPT 219 180 15 53 4 S1 4 CS 11 2 NPT Carbon Steel Model S1 55 CS 3 ANSI150 RF 549 60 15 307 139 51 69 5 3 ANSI150 RF 68 7 640 10 307 139 S1 82 CS 3 ANSI 150 RF Max Differential Pressure 200 psi 13 8 bar Figure 2 2 carbon steel models Capacity Nomimal Std Port Size cu inches Max Pump Flowrate Pump Weight Speed rpm usgpm at D max speed 15 l S1 2 SS 11 2 ANSI150 RF 2 19 120 10 53 24 Stainless Steel Model 51 69 55 3 ANSI 150 RF_ 6750 10 307 139 51 82 55 3 ANSI 150 RF Max Differential Pressure 150 psi 10 3 bar Figure 2 3 stainless steel models Notes 1 Recommended pump speeds may be lower than the maximum shown in Figures 2 1 2 2 and 2 3 based on specific application conditions 2 Pump weights shown in Figures 2 1 and 2 2 are based on standard pumps with a relief valve This weight will vary depending on specific pump options 3 EnviroGear will supply more specific flowrate values for your application conditions upon request ENV 10000 E 01 5 ENVIROGEAR PUMP COMPANY h Enviro r TECHNICAL INFORMATION Temperature Ratings O Rings Temperature Ratings Viton FEP encapsulated Viton Kalrez 50 0 50 100 150 200 250 300 350 400 450 500 550 fluid temperature F Figure 2 4 o rings temperature ratings Magnets Tempera
17. et and or spring for the desired relief valve setting Consult factory for assistance 2 Disassemble relief valve per the instructions in Chapter 6 How To Disassemble Relief Valve 3 Reassemble the relief valve using the new poppet and or spring per the instructions in Chapter 6 How To Assemble Relief Valve ENVIROGEAR PUMP COMPANY 22 ENV 10000 E 01 El DOVER company SIMPLE PUMP ADJUSTMENTS Hovw To Change Helief Valve Pressure Setting In order to maintain the integrity of the relief valve setting the EviroGear relief valve is not externally adjustable Instead the setting is adjusted by changing the poppet and or spring 1 Obtain a new poppet and or spring for the desired relief valve setting Consult factory for assistance 2 Disassemble relief valve per the instructions in Chapter 6 How To Disassemble Relief Valve 3 Reassemble the relief valve using the new poppet and or spring per the instructions in Chapter 6 How To Assemble Relief Valve ENV 10000 E 01 23 ENVIROGEAR PUMP COMPANY Envir SECTION 6 ear PUMP DISASSEMBLY amp REPAIR PROCESSES es INTERNAL GEAR PUMPS come How To Disassemble Relief Valve 1 Remove the screws 405 that hold the valve body to the head It is normal for the valve spring 403 to push the valve body away from the head during this step the spring will be fully relaxed just before the screws are fully removed 2 Re
18. ll stop at the front end of the inner ring 7 Repeat steps 5 and 6 for the other magnet segments making sure that each magnet is in opposite polarity with adjacent magnets Figure 6 27 magnet in proper position 8 Align the new sleeve over the back of the rotor such that the sleeve indentations are lined up with the magnets 9 Press the sleeve over the magnets and o rings until it contacts the rear of the inner ring 10 Visually inspect the front and rear of the sleeve to verify that the o rings did not get damaged by the sleeve Figure 6 29 assembled rotor ENVIROGEAR PUMP COMPANY 34 ENV 10000 E 01 company PUMP DISASSEMBLY amp REPAIR PROCESSES How To Install Rotor Assembly Into Outer Drive Assembly Models 51 2 amp 51 4 1 Insert the canister El and support plate Z into the outer drive assembly 100 The support plate has no top or bottom so it s orientation doesnt matter 2 Use Tool F 00097 to firmly grab the rotor assembly in the bushing bore area 3 Bring the rotor assembly toward the canister until the back of the rotor is about 2 inches 5 cm from the front of the outer drive assembly 4 Slowly let the outer magnets pull the rotor into the canister while using moderate resisting force The pulling force is about 40 60 pounds 18 27 kg 5 Remove the puller tool Figure 6 31 rotor assembly in place ENV 10000 E 01 35 ENVIROGEAR PUMP COMPANY
19. mage Any small scratches or nicks must be filed smooth before installing the new bushings 3 Press the front radial bushing into the rotor leading with the tapered edge The bushing is in its proper location when the front face of the bushing is flush with the nearest rotor face These surfaces must be flush Figure 6 17 front radial bushing installed 4 Press the thrust bushing into the rotor leading with the tapered edge until it bottoms out 207 Figure 6 18 thrust bushing installed ENVIROGEAR PUMP COMPANY 30 ENV 10000 E 01 EnvirdGear E DOVER company PUMP DISASSEMBLY amp REPAIR PROCESSES 5 Press the rear radial bushing into the rotor leading with the tapered edge The bushing is in its proper location when the rear face of the bushing is flush with the nearest rotor face These surfaces must be flush Figure 6 19 rear radial bushing installed How Replace Idler Bushings tungsten carbide or silicon carbide Due to the brittle nature of tungsten carbide and silicon carbide bushings we recommend they be replaced in the EnviroGear factory How To Replace Rotor Bushings tungsten carbide or silicon carbide Due to the brittle nature of tungsten carbide and silicon carbide bushings we recommend they be replaced in the EnviroGear factory ENV 10000 E 01 31 ENVIROGEAR PUMP COMPANY EnviroGear RNAL G es PUMP E DOVER COMPANY PUMP DISASSEMBLY amp REPAIR PR
20. move the valve body spring poppet and o ring 404 Figure 6 2 disassembled relief valve ENVIROGEAR PUMP COMPANY 24 ENV 10000 E 01 EnvirdGear E DOVER company PUMP DISASSEMBLY amp REPAIR PROCESSES Hovw To Disassemble Pumping Chamber 1 Remove the screws 9 that hold the head to the casing 2 Remove the head Note when the head or spindle is removed the pump will be difficult to turn by hand This is normal 3 Remove the head o ring 5 from the head 4 Remove the idler assembly by sliding it off the spindle 8 5 Pullthe spindle out of the rotor assembly 200 Figure 6 4 idler and spindle removed 6 Remove the screws 10 that hold the outer drive assembly 100 to the casing 7 Separate the casing and outer drive assembly 8 Remove the canister o ring 4 from its groove in the casing Figure 6 5 casing removed ENV 10000 E 01 25 ENVIROGEAR PUMP COMPANY EnviroGear BUMP DISASSEMBLY 8 REPAIR PROCESSES How To Remove Rotor Assembly From Outer Drive Assembly Models S1 2 S1 4 Figure 6 6 pump disassembly tool F 00097 1 Use Tool F 00097 to firmly grab the rotor assembly 200 in the bushing bore area Figure 6 7 tool inserted in rotor assembly 2 Pull the rotor assembly out of the outer drive assembly 400 using moderate force It takes about 40 60 pounds of force 18 27 kg 3 Remove the tool and set the rotor assembly aside awa
21. ng a strainer to protect the pump from any contaminant particles that could be present in the liquid Be sure the strainer is properly sized so it doesn t cause excessive restriction lowers NPSHa ENVIROGEAR PUMP COMPANY 12 ENV 10000 E 01 EnviroGear INSTALLATION amp STARTUP Be sure the suction piping is air tight Air leakage into the suction line can cause low flow noise similar to cavitation and priming problems Shaft Alignment Accurate alignment of the pump shaft and driver shaft is essential for optimal reliability and durability Misalignment causes vibrations that reduce the life of bearings in both the pump and driver and the life of couplings Final shaft alignment must be done AFTER the following events since both of them can change the alignment e Mounting and grouting of the foundation e Assembly of the piping Use of precision alignment equipment based on lasers or dial indicators is strongly recommended Checking the alignment using a straight edge on the couplings is inaccurate and not recommended For pumps that will operate at elevated temperature the alignment at room temperature will change as the pump warms Be sure to measure or calculate this effect and adjust the alignment so that it is accurate at operating temperature Pump Condition Monitoring There are several pump conditions that can be monitored e Canister Temperature Heat is generated in the canister when the pump i
22. ngs in the casing hole behind the SUCTION port 3 The head block off plug is solid no hole It is only used in pumps that have no relief valve and it belongs in the head hole on the DISCHARGE side DISCHARGE Casing orifice t3 plug with hole Casing block off plug no hole SUCTION I This hole d left open SUCTION DISCHARGE Head block off plug no hole Figure 2 12 special cooling circuit plugs in correct positions ENV 10000 E 01 9 ENVIROGEAR PUMP COMPANY EnvirdiG SECTION 3 INSTALLATION amp STARTUP Pump Location It is always best to minimize suction line losses so the best location for any pump is as close as practical to the liquid supply source Also it is best to locate the pump below the liquid supply if practical to maximize inlet pressure to the pump A proper location should leave enough room around the pump to allow for inspection or repair of the pump without removing it from the foundation Pump Foundation With any pump a rigid foundation is essential for optimal reliability and durability Always mount the pump on a foundation that is rigid enough to keep the pump from moving during operation or in the event of any stress or impact that may occur during the life of the pump Please contact EnviroGear for more information on premium EnviroBase base plates ENVIROGEAR PUMP COMPANY 10 ENV 10000 E 01 EnviroGear INSTALLAT
23. ntains only three parts It addresses the problem of over pressurization by cracking poppet lifts off the seat at the nominal pressure relief setting allowing pumped fluid to recirculate internally from the discharge side back to the suction side To maintain the integrity of the relief valve setting the EnviroGear relief valve is not adjustable by means of an external jack screw Rather seven relief valve settings are fixed at the factory and adjusted by changing the poppet and spring combinations Available relief valve settings crack pressure e 50 psi 3 4 bar 7 5 psi 5 2 bar e 100 psi 6 9 bar e 125 psi 8 6 bar 150 psi 10 3 bar e 175 psi 12 1 bar e 200 psi 13 8 bar TECHNICAL INFORMATION n4 im PRESSURE SHOE spring poppet valve body SUC TION SHOE head Figure 2 10 relief valve Model 51 32 with 100 psi valve setting 150 cst N 99 crack EU RO oo pm oar Amen pressure 3 7 m 520 rpm 7 NE 5 3 full bypass pn n 50 A pressures 25 0 0 25 50 100 125 150 differential pressure psi Figure 2 11 relief valve performance To properly size the integral relief valve it is important to understand the differences between crack pressure and full bypass pressure e Crack pressure is the pressure at which the poppet just begins to lift of the seat This press
24. o much power Possible Cause s Pump components are damaged or worn Relief valve is stuck closed Ball bearings are worn or damaged Viscosity is higher than expected ENV 10000 E 01 43 ENVIROGEAR PUMP COMPANY A HOW TO RETURN PUMP TO FACTORY E DOVER COMPANY If a pump must be returned to the EnviroGear factory a Return Goods Authorization RGA must be obtained from EnviroGear or its authorized distributor No RGA can be issued without a review of the appropriate Material Safety Data Sheets MSDS Pumps must be cleaned of all fluids and the ports plugged to prevent foreign material from getting into the pump ENVIROGEAR PUMP COMPANY 44 ENV 10000 E 01 SECTION 9 WARRANTY E DOVER company EnviroGear warrants that on the day of delivery all products manufactured by it shall be free from defects in materials and workmanship For a period twenty four 24 months from the date of shipment EnviroGear will at its sole and exclusive discretion either replace or repair any products found by EnviroGear to be defective in workmanship or material at no charge to the Purchaser The warranty does not apply to any products which have been modified or altered by persons other than EnviroGear or any products subjected to any misuse neglect misapplication improper installation or accidental damage or any goods manufactured by a third party or any products damaged by the effects
25. of this manual before performing any work with this pump The most current version is freely available on the web at www envirogearpump com EnviroGear pumps are specifically configured for your unique application conditions Those application conditions and the details of the pump configuration were documented during the ordering process Keep that information available in a safe place as it may be needed when troubleshooting pump problems or when ordering spare parts or repairs EnviroGear pumps are covered by one or more of the following patents U S Patent Nos 7549205 7137793 7183683 Australian Patent No AU2005233534B2 Korean Patent No 10 2006 7023162 Mexican Patent No PA a 2006 01 1436 Russian Patent No 2006138540 06 041952 and other patents pending ENVIROGEAR PUMP COMPANY 4 ENV 10000 E 01 SECTION 2 EnviroG TECHNICAL INFORMATION ar company Miodels Available Nomimal Max Pump Flowrate Pump Weight Speed rpm usgpm at max speed Ib kg Capacity Std Port Size cu inches per revolution Ductile Iron Model 51241 2NPT 243 780 75 152 51 3201 _ 2 NPT 26 780 10 152 69 51 69 01 3 ANSI150 RF 68 7 640 170 307 139 S1 82 DI 3 ANSI 150 RF Max Differential Pressure 200 psi 13 8 bar Figure 2 1 ductile iron models Capacity Nomimal Std Port Size cu inches Max Pump Flowrate Pump Weight Speed rpm usgpm at max spe
26. ore doing any service work DANGER Magnetic Field Can disrupt medical im plantssuchaspacemakers Implantwearersshould remain a minimum of 1ft 0 3m away from pump and 3ft 1m away from disassembled magnets Pinch Point Inner and Outer magnets strongly at tract each other which can crush and cut CAUTION Magnets inside pump can damage electronic equipment or magnetic media CAUTION This pump is designed to rotate only in the direction indicated Do not run the pump in the opposite direction for long periods because internal passageways that control axial thrust will not work correctly causing premature wear and reduced pumping efficiency CAUTION The inner magnets on the back of the rotor assembly are strongly attracted to the outer magnets in the outer drive assembly During the separation process there will be a strong force of up to 300 Ibs 136 kg trying to pull them back together which can create a powerful pinch point To safely separate the rotor assembly from the outer drive assembly follow the instructions below and use the following equipment e Crane hoist or other suitable lifting device capable of generating at least 400 Ibs 182 kg and e Sturdy workbench that has the following features is positioned beneath the lifting device and is firmly anchored to the floor or if unanchored the workbench must weigh at least 400 Ibs 182 kg and is strong enough to resist a lifting force of up to 400 Ibs
27. pport the rotor assembly using a crane hoist or other suitable lifting device and position it above the canister about 4 inches 10 mm from the front of the outer drive assembly Figure 6 36 rotor assembly ready for lowering 10 Slowly lower the rotor assembly into the canister Note During this process the inner magnets on the rotor assembly will be strongly attracted to the outer magnets in the outer drive assembly Figure 6 37 rotor assembly in place ENV 10000 E 01 37 ENVIROGEAR PUMP COMPANY Enviro Gear RNAL G wee PUM E DOVER COMPANY PUMP DISASSEMBLY amp REPAIR PROCESSES 11 Carefully lift the outer drive assembly with the tool kit A 12 Remove the tool rods and puller plate attached and set it on a workbench resting on the pump foot Figure 6 38 remove tool How To Assemble Pumping Chamber 1 Make sure the casing orifice plug and casing block off plug are in the correct locations Install the casing orifice plug if required 11 behind the DISCHARGE port Install the casing block off plug 12 behind the SUCTION port Position the canister o ring 4 in its groove in the casing Bl If necessary use a small amount of light adhesive to keep the o ring properly positioned Slide the casing over the rotor 200 the lip of the canister and magnet housing 101 It may take some wiggling of the casing to get the canister and magnet housing positioned within the c
28. s running because of moving magnetic fields that pass thru it The pump has an internal cooling path that pulls heat away from the canister If this cooing path is obstructed the canister and magnet area could become very hot which could damage the magnets and or the canister o ring The canister temperature can be monitored with a temperature probe attached to an optional access port in the magnet housing near the casing e Bearing Vibration The pump shaft is supported by rolling element bearings The condition of the bearings can be monitored with a vibration sensor attached to the magnet housing near the bearings see Figure 3 3 e Pumping Chamber Vibration The pumping gears rotate within the casing and are supported by journal bushings The condition of the gears and bushings can be monitored with a vibration sensor attached to the pump head see Figure 3 4 Location for Canister Temperature Sensor Location for Pumping Chamber Locationfor Masse En gt Vibration Bearing SES Sensor Vibration net S Sensor Figure 3 3 optional sensor locations Figure 3 4 optional sensor locations ENV 10000 E 01 13 ENVIROGEAR PUMP COMPANY E DOVER COMPANY INSTALLATION amp STARTUP Startup Before starting the pump follow this procedure 1 Thoroughly clean the pump pipes and other components Note In most cases the pump is shipped clean of any contaminants except for a thin
29. scharge line is too restrictive Suction lift is too great Pump is not wetted Air leak in the suction line Pump is running in the wrong direction Head is positioned incorrectly Cooling path plugs are not installled Pump is locked up with hardened fluid or foreign items Pump components are damaged or worn Pump has decoupled Inner magnets have weakened Cooling path is plugged Relief valve is stuck open Symptom or Problem Flowrate is too low Possible Cause s ENV 10000 E 01 41 Head is positioned incorrectly Cooling path plugs are not installled Discharge line is too restrictive Viscosity is lower than expected Air in the inlet fluid stream Pump is cavitating Relief valve is opening Pump components are damaged or worn Bypass or auxiliary line in the discharge piping is open Cooling path is plugged Relief valve is stuck open Envi Gear El DOVER company ENVIROGEAR PUMP COMPANY E DOVER COMPANY TROUBLESHOOTING Symptom or Problem Pump does not develop enough pressure Possible Cause s e Air in the inlet fluid stream Viscosity is lower than expected Pump is cavitating Relief valve is opening Pump components are damaged or worn Bypass or auxiliary line in the discharge piping is open Head is positioned incorrectly Cooling path plugs are not installled Cooling path is plugged Relief valve is stuck open Symptom or Pro
30. sign and compare it to the NPSHr required value for the pump the piping NPSHa must be greater than the pump NPSHr to avoid cavitation Here are several suggestions that help maximize suction piping NPSHa e Locate the pump below the liquid supply Keep the suction piping short e Use large diameter piping The difference in pipe friction between small and large pipe sizes can be dramatic especially for high viscosities e Avoid high restriction components such as filters heat exchangers or flowmeters Try to install these components in the discharge piping instead sure to consider the full range of operating conditions especially the highest viscosity conditions Changes in viscosity can have a dramatic effect on pipe friction If your suction piping requires a long run and a rise pump is higher than the liquid level at the supply it is best to keep most of the run at the lower level and position the rise as close to the pump as possible This allows gravity to fill most of the piping If your suction piping must detour around an obstacle it is best to go around it instead of over it This lowers the vacuum needed for priming If your suction has a lift and it can drain back to the supply between runs consider using a foot valve or check valve This will keep the suction line filled between runs and ease priming But be sure the valve is large enough that it doesn t cause excessive restriction lowers NPSHa Consider usi
31. th a relief valve disassemble the relief valve per the instructions in Chapter 6 How To Disassemble Relief Valve 2 Disassemble pumping chamber per the instructions in Chapter 6 How To Disassemble Pumping Chamber ENVIROGEAR PUMP COMPANY 20 ENV 10000 E 01 EnvirdGear E DOVER company SIMPLE PUMP ADJUSTMENTS 3 Remove the casing orifice plug H not used on all configs and casing block off plug DISCHARGE 4 Install the casing orifice if required plug behind the DISCHARGE port 5 Install the casing block off plug behind the SUCTION port Figure 5 3 Casing plugs 6 Ifthe pump is not equipped with a relief valve remove the head block off plug 14 and move it to the DISCHARGE side DISCHARGE SUCTION Figure 5 4 head block off plug 7 Assemble pumping chamber in the new orientation per the instructions in Chapter 6 How To Assemble Pumping Chamber 8 Ifthe pump is equipped with a relief valve assemble relief valve in the new orientation per the instructions in Chapter 6 How To Assemble Relief Valve ENV 10000 E 01 21 ENVIROGEAR PUMP COMPANY E DOVER COMPANY SIMPLE PUMP ADJUSTMENTS Hovw To Change Helief Valve Pressure Setting In order to maintain the integrity of the relief valve setting the EviroGear relief valve is not externally adjustable Instead the setting is adjusted by changing the poppet and or spring 1 Obtain a new popp
32. tor assembly up and away from the outer drive assembly using a crane hoist or other suitable lifting device 9 Remove the puller plate and set the rotor assembly aside away from any magnetic material e g iron steel 10 Remove the canister 9 containing the support plate 0 from the outer drive assembly ENV 10000 E 01 29 EnvirdGear E DOVER company Firmly affix to workbench Figure 6 13 tool fully assembled Figure 6 14 pull rotor assembly up Figure 6 15 remove canister ENVIROGEAR PUMP COMPANY EnvirdiGe ear TERNAL G A PUMP DISASSEMBLY amp REPAIR PROCESSES How To Replace Idler Bushings carbon graphite 1 Remove the old bushing by pressing it These surfaces out of the idler It is not unusual for Fauci ba flush the bushing to crack or break apart during both sides removal 2 Inspect the idler bore for any damage Any small scratches or nicks must be filed smooth before installing the new bushing 3 Press the new idler bushing into the idler leading with the tapered edge The bushing is in its proper location when both ends of the bushing are flush or slightly EM recessed from the idler faces Figure 6 16 idler assembly How To Replace Rotor Bushings carbon graphite 1 Remove the old bushings by pressing them out of the rotor 201 It is not unusual for the bushings to crack or break apart during removal 2 Inspect the rotor bore for any da
33. ture Ratings M6 M7 Neodymium lron Boron M6M M7M S C inner mags N I B outer mags M6H M7H Samarium Cobalt 50 0 50 100 150 200 250 300 350 400 450 500 550 fluid temperature F Figure 2 5 magnets temperature ratings Internal Clearances Temperature Ratings standard high temperature 50 0 50 100 150 200 250 300 350 400 450 500 550 fluid temperature F Figure 2 6 internal clearances temperature ratings ENVIROGEAR PUMP COMPANY 6 ENV 10000 E 01 EnvirdGear TECHNICAL INFORMATION Magnetic Coupling Strengths Models S1 2 amp S1 4 Models S1 24 amp S1 32 ftp O O D oO 5 450 O O O O Figure 2 7 Figure 2 8 models 51 2 amp 51 4 models S1 24 amp S1 32 magnetic coupling strength magnetic coupling strength Models 51 55 51 69 amp 51 82 700 500 A O O magnet torque ft lb Figure 2 9 models 51 55 51 69 amp S1 82 magnetic coupling strength _ 2 COMPANY EnviroGear Relief Valve Performance Optional integral relief valves provide pump protection from over pressure conditions While not intended for continuous use internal relief valves protect the pump from closed discharge valves or other intermittent over pressurization in the system The EnviroGear design is spring loaded and co
34. ugs will not be moved see nternal Cooling Circuit in Chapter 2 Figure 5 1 port orientation change when shaft rotation does not change 1 Ifthe pump is equipped with a relief valve disassemble the relief valve per the instructions in Chapter 6 How To Disassemble Relief Valve For Models 51 24 51 32 51 55 51 69 or 51 82 the relief valve does not need to be disassembled leave the relief valve attached to the head 2 Disassemble pumping chamber per the instructions in Chapter 6 How To Disassemble Pumping Chamber 3 Assemble pumping chamber in the new orientation per the instructions in Chapter 6 How To Assemble Pumping Chamber 4 fthe pump is equipped with a relief valve assemble relief valve per the instructions in Chapter 6 How To Assemble Relief Valve ENV 10000 E 01 19 ENVIROGEAR PUMP COMPANY Envi Gear RES INTERNAL GEAR PUMPS a BOVER SIMPLE PUMP ADJUSTMENTS DOVER company How To Change Port Orientation And Shaft Rotation This instruction applies for changes when the direction of shaft rotation will change such as changing from RT to LT Since the shaft rotation will change the discharge and suction positions relative to the casing and head will also change and therefore the cooling circuit plugs must be moved see nternal Cooling Circuit in Chapter 2 Figure 5 2 port orientation change when shaft rotation changes 1 Ifthe pump is equipped wi
35. ure is not affected by variations in fluid viscosity or pump speed The pump will provide full flowrate at all pressures below the cracking pressure see Figure 2 10 e Full bypass pressure is the pressure that occurs when 100 of the pump s flowrate is bypassing internally through the valve and no flow is exiting the pump see Figure 2 10 This pressure is higher than crack pressure and varies depending on fluid viscosity and pump speed ENVIROGEAR PUMP COMPANY 8 ENV 10000 E 01 EnvirdGear E DOVER company TECHNICAL INFORMATION Internal Cooling Circuit This pump has an internal cooling circuit that circulates some of the pumped fluid through the magnet chamber The circuit starts at the discharge port and ends at the suction port This circuit has three functions 1 coolthe inner magnets 2 keep fluid in the magnet area from becoming stagnant 3 lubricate and cool the rotor and idler bushings Note Consult factory at low differential pressures to ensure proper cooling path circulation There are special plugs in the casing and head that must be in the correct position to complete the circuit 1 The casing needs to be vented on the DISCHARGE side In some cases this is done with an orifice plug that has a hole in it positioned in the casing hole behind the DISCHARGE port In other cases this is done by leaving the casing hole behind the DISCHARGE port open 2 he casing block off plug is solid no hole It belo
36. y from any magnetic material e g steel iron ENVIROGEAR PUMP COMPANY 26 ENV 10000 E 01 company 4 Remove the canister 6 containing the support plate 2 from the outer drive assembly Figure 6 9 canister removed ENV 10000 E 01 27 ENVIROGEAR PUMP COMPANY ear PUMP DISASSEMBLY amp REPAIR PROCESSES How To Remove Rotor Assembly From Outer Drive Assembly Models 51 24 51 32 51 55 S1 69 amp 51 82 Figure 6 10 pump disassembly tool F 00096 1 Attach the puller plate to the rotor assembly 200 using three 200 of the pump s 1 2 13 screws 9 or 10 puller lt E plate Figure 6 11 puller plate attached 2 Loosely fit the two rods into opposite holes on the outer drive assembly 100 3 Loosely position the two rod ends into the channel 4 Twist the two rods to tighten the channel nuts which locks the rods to the channel 8 Figure 6 12 rods and channel attached ENVIROGEAR PUMP COMPANY 28 ENV 10000 E 01 PUMP DISASSEMBLY amp REPAIR PROCESSES 5 Assemble the two wing nuts onto the two rods to hold them to the outer drive assembly 6 Carefully lift the outer drive assembly with the tool kit attached and set it on a suitable workbench vertically with the rotor teeth facing up 7 Firmly affix the channel to the workbench surface so that it can safely resist a lifting force of up to 400 lbs 182 kg 8 Slowly pull the ro
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