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Vogelsang VX Series, Manual

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Vogelsang VX Series Manual Download Page 41

Startup Checklist

Vogelsang requires a completed 
checklist to be filled out and 
submitted back to us. The warranty 
on the product does not initiate until 
we receive the startup form back.

This form confirms to us that the 
product we installed properly. This 
form can be downloaded at:

www.vogelsangusa.com/startup.pdf

Vogelsang Service Webinar | 

Startup Checklist

Summary of Contents for VX Series

Page 1: ...Best Practices for Installation of VX Rotary Lobe Pumps WELCOME TO VOGELSANG FACTORY TRAINING ...

Page 2: ...If you are not installing your new pump right away there are steps you must take to ensure the pump remains in working condition when it comes time for startup Vogelsang Service Webinar Storage Storage ...

Page 3: ...on in a dry area 4 Temperature must not go below 23 F and the relative humidity not less than 60 5 No direct exposure to sunlight or UV light 6 No aggressive corrosive substances contaminated air ozone gases solvents acids alkalis salts radioactivity etc in the immediate vicinity 7 No constant vibration or oscillation Vogelsang Service Webinar Storage Short Term Storage ...

Page 4: ...e and even coating of the surfaces in contact every 30 days 5 After rotation spray again all bright pump internals with the long term preservative 6 Close the pump cover plate 7 Seal pump connectors carefully with metallic full face blind flanges and gaskets 8 Spray the long term preservative on all exposed metallic parts of the complete unit 9 Fill the pump gear box nearly full with the proper ge...

Page 5: ...ording to the O M manual 3 Drain the gear oil of the drive gear box to the rated oil level according to the O M manual 4 Check the seals and gaskets properly if any changes regarding shape color hardness or sealing effect are detected they must be replaced Vogelsang Service Webinar Storage Recommissioning ...

Page 6: ...Follow all best practices for safety when working on Vogelsang Equipment Preparing for Installation ...

Page 7: ...ore any work is performed on the pump 2 This sticker or one similar on older models came with your pump Make sure your pump is ready to be serviced by performing steps 1 7 3 Be sure to depressurize the pump before any work is performed Vogelsang Service Webinar Safety ...

Page 8: ...t not be exceeded at any time Observe and implement the recommendations in for installation in pipelines Protect the pump assembly against excess pressure For example the following safety devices can be used current limiter on the motor pressure relief valve cut off with a pressure switch overload coupling Vogelsang Service Webinar Safety ...

Page 9: ...d new pump may develop friction during the break in period Friction could lead to heat and should be avoided Avoid pump dry running during startup Prevent the pump from running dry using for example temperature monitor level gauge flow rate gauge Vogelsang Service Webinar Safety ...

Page 10: ...ation assemblies may be moved in a variety of ways Always follow basic safety practices when moving heavy equipment All assemblies come with factory installed lifting points and should not be removed or relocated Vogelsang Service Webinar Offloading ...

Page 11: ...Q Pump Simply lift a Q Series pump by the lifting ring located in the center Removing the Oil Bottle is a best practice when moving the pump but is not always necessary for short moves Vogelsang Service Webinar Offloading ...

Page 12: ... the Q Series and the other will be located on the outboard end of the pump The fitting at the outboard end may be a ring or a tab depending on pump model Removing the Oil Bottle is a best practice when moving the pump but is not always necessary for short moves Vogelsang Service Webinar Offloading ...

Page 13: ...d to the four slots located in the channel base Do not use the lifting rings to move a completed assembly They are only rated to move the individual component they are attached to Removing the Oil Bottle is a best practice when moving the pump but is not always necessary for short moves Vogelsang Service Webinar Offloading ...

Page 14: ...y will require straps to be threaded under the motor mounting plate Make sure your straps are rated for the weight of the complete assembly Do not use the lifting ring on top of the motor It is only rated to lift the motor itself Vogelsang Service Webinar Offloading ...

Page 15: ...Installation ...

Page 16: ...mage during shipping All hardware will be included such as hex bolts washers and flange gaskets Simply insert the gasket between the pump and flange Then thread each bolt in and secure Vogelsang Service Webinar Installation All piping must be supported The flanges and pump are not designed to support connected piping ...

Page 17: ...t any vibration Our pumps are pulsation free which means grouting is not a requirement but is an acceptable installation method It is recommended that only the flanges at the bottom of the base be grouted This will ensure accessibility to underside of the base for maintenance purposes Vogelsang Service Webinar Installation Grout along edges over flange ...

Page 18: ...cations The belt drive configuration must be aligned by verifying that both sheaves are aligned using a straight edge Inline assemblies use a three part coupling device that must also be aligned to avoid any vibration or unnecessary wear Vogelsang Service Webinar Alignment ...

Page 19: ...ies The alignment of the coupling must be periodically checked If there is vibration during operation alignment is sometimes the cause Alignment can be verified by using a straight edge or other devices Vogelsang Service Webinar Alignment ...

Page 20: ...heck parallel alignment by placing a straight edge across the two flanges and measuring the maximum offset at various points around the periphery without rotating the coupling Vogelsang Service Webinar Alignment Parallel Alignment ...

Page 21: ...angular alignment with a micrometer or caliper Measure from the outside of one flange to outside of the other at intervals around the periphery of the coupling Don t rotate the coupling Vogelsang Service Webinar Alignment Angular Alignment ...

Page 22: ...0 015 070 2 375 010 016 2 375 7 5250 020 081 2 563 012 020 2 563 8 4500 020 094 2 938 015 025 2 938 9 3750 025 109 3 500 017 028 3 500 10 3600 025 128 4 063 020 032 4 063 11 3600 032 151 4 875 022 037 4 875 12 2800 032 175 4 688 025 042 5 688 13 2400 040 195 6 688 030 050 6 625 14 2200 045 242 7 750 035 060 7 750 16 1500 062 330 10 250 Note Values shown above apply if the actual torque Vogelsang S...

Page 23: ... is mounted the orientation of the motor is controlled via four mounting bolts as shown Using a straight edge align the top sheave to the bottom sheave by adding or removing turns Once the sheaves are aligned belt tension is added by tightening each nut equally until the proper belt tension is achieved Vogelsang Service Webinar Alignment ...

Page 24: ...Pressurizing the Pump ...

Page 25: ...buffer chamber The pressure is achieved via a semi opaque bottle where air is pumped inside the bottle creating pressure on the oil inside the bottle and buffer chamber The reason for this is to Maintain equilibrium at the seal face Buffer pressure spikes changes Assure longer seal life span Test seals after rebuild or maintenance ...

Page 26: ...ottle consists of 1 Metal Cap with integrated Pressure Gauge 2 Threaded Ring to hold the cap to the bottle 3 A Plastic Bottle with integrated threaded fitting on the bottom for mounting to the pump Vogelsang Service Webinar Pressurized Oil Bottle ...

Page 27: ... must be connected to the Buffer Chamber Port Not the Gear Box Chamber Port As shown on this VX Q Pump the Buffer Chamber port is the closest to wet end of the pump Buffer Chamber Port Gear Box Chamber Port Wet End Chamber Vogelsang Service Webinar Pressurized Oil Bottle ...

Page 28: ...t As shown on this VX QD Pump the Buffer Chamber port is the closest to wet end of the pump There is also a second Buffer Chamber on the outboard side of the wet end as well This requires a second pressurized oil bottle Buffer Chamber Port Gear Box Chamber Port Buffer Chamber Port Wet End Chamber Vogelsang Service Webinar Pressurized Oil Bottle ...

Page 29: ...e Located On piggy back assemblies or installations where the top of the pump is obstructed the bottle is threaded to an external mount and connected to the pump via a high pressure hose Vogelsang Service Webinar Pressurized Oil Bottle ...

Page 30: ...pletely using a factory recommended oil 2 Attached the Pressurized Oil bottle to the buffer chamber or assemble the hose and bottle assembly for piggy back installations 3 Remove the Bottle Cap 4 Fill the Pressurized Oil Bottle approximately full with oil 5 Replace the Cap and hand tighten Vogelsang Service Webinar Pressurized Oil Bottle ...

Page 31: ...al suction and discharge pressure A simple formula is used to determine the pressure You need to know your suction and discharge pressure To pump air into the bottle simply attach the hand pump to the nipple on the opposite side of the gauge Never pressurize the Oil Bottle past 72psi Vogelsang Service Webinar Pressurized Oil Bottle ...

Page 32: ...tep Suction Pressure Plus Discharge Pressure Equals Operating Pressure a Operating Pressure Divided by Equals Differential Pressure b 2 Differential Pressure Plus PSI Equals Gauge Pressure c 7psi Vogelsang Service Webinar Pressurized Oil Bottle ...

Page 33: ...If the oil level rises during operation or at idle then it is likely that the pressure in the buffer chamber is too low Increase the pressure in increments of 7psi until the level stabilizes Do not pressurize past 72 psi 3 A rise or drop in oil level may also indicate a problem with the mechanical seal 4 Contamination of oil in the Bottle is indicative of a mechanical seal failure Vogelsang Servic...

Page 34: ...rtan EP220 Exxon Mobile Mobilgear 600 XP220 Lubrication Engineers 1605 Duolec Vari Purpose Gear Lubricant NAPA SAE 80W 90 GL5 Gear Oil Shell Spirax 80W 90 Gear Oil Chevron s RPM Universal GL SAE 80W 90 API GL 5 Gear Oil Vogelsang Service Webinar Pressurized Oil Bottle ...

Page 35: ...gas 700 Doty Street Fond Du Lac WI 54935 J F Ahern Co 855 Morris St Fond Du Lac WI 54936 920 921 9020 VX186 130H4Q 316 Stainless Steel HiFlo NBR 4 VX186 130H4Q Other Medium not on the list pH 7 0 316 Stainless Steel 90 Bend 316 Stainless Steel Straight Motor Drive Information Motor HP Voltage Gear Box Gearbox Ratio Gearbox Ouput Baldor Electric Company 20 0 230 460 RPM 1800 5 25 NORD Gear Corp Hou...

Page 36: ...Direction of flow Startup Checklist Startup ...

Page 37: ...ngle shaft electric motor as the drive unit for VX Series Pumps The rotation of the shaft determines the direction of flow The wiring configuration and or VFD setting will determine which way the shaft will spin Vogelsang Service Webinar Direction of Flow ...

Page 38: ... reversed on the fly If your pump has standard or injection housings the pump can run in either direction However our injection II housing is asymmetrical and should be run in the direction that the pump was configured for Vogelsang Service Webinar Direction of Flow Injection l Injection ll Standard ...

Page 39: ...tion of Flow The flow direction is initially determined by the way the motor is wired Refer to the wiring diagram on the motor for instructions on which way to wire the motor Vogelsang Service Webinar Wiring ...

Page 40: ...Control Panels Operating parameters are set by a certified controls representative per the motor specification All panels must be set to constant torque Vogelsang Service Webinar Controls ...

Page 41: ...d submitted back to us The warranty on the product does not initiate until we receive the startup form back This form confirms to us that the product we installed properly This form can be downloaded at www vogelsangusa com startup pdf Vogelsang Service Webinar Startup Checklist ...

Page 42: ...dentification Each Vogelsang product has an affixed tag that shows the model and serial number Always have the model and serial number ready when making a service call This will ensure that you get the right parts in the proper material for your pump ...

Page 43: ...ooting Matrix Service Web Page Contact Service at 330 510 1557 330 296 3820 x226 or service vogelsangusa com Download this presentation at www vogelsangusa com pumpinstall pdf Vogelsang Service Webinar Operation Troubleshooting ...

Page 44: ......

Page 45: ...2012 12 19 WBV PU 002 EN WBV PU 002 EN V5 0 1 68 2012 12 19 WBV PU 002 EN WBV PU 002 EN V5 0 Operating instructions Rotary lobe pump VX100Q VX136Q QD QDM2 VX186Q QD QDM2 VX230Q QD ...

Page 46: ...or partial reproduction of this document in any form is prohibited We reserve the right to make technical modifications to the diagrams and information presented in this document in the event that such modifications become necessary for the enhancement of the machine 2012 Hugo Vogelsang Maschinenbau GmbH Registered trademarks of Vogelsang Vogelsang Vogelsang Logo RotaCut HiFlo ACC CFC BioCrack XTi...

Page 47: ...Buffer chamber 25 7 1 1 Buffer or quenching fluid type 25 7 1 2 Buffer or quenching fluid quantity 25 7 1 3 Buffer or quenching fluid inspection and change 26 7 2 Buffer chamber assemblies 27 7 2 1 Pressurisable buffer fluid tank 27 7 2 2 Depressurised quenching fluid tank 28 7 2 3 Pressure valve 29 7 2 4 Plug 29 7 2 5 Dry buffer chamber 30 7 2 6 Circulation system on the cartridge mechanical seal...

Page 48: ...njectionSystem 14 Fig 7 Transport aids pump type Q 15 Fig 8 Transport aids pump types QD and QDM2 15 Fig 9 Transport aids pump with flange mounted electric motor 16 Fig 10 Transport aids pump on base type inline 16 Fig 11 Transport aids pump on base type belt drive 16 Fig 12 Orientation procedure 18 Fig 13 Installation versions 19 Fig 14 Tightening sequence 20 Fig 15 Long suction lines 21 Fig 16 B...

Page 49: ...st be understood and observed by those persons responsible for the installation operation maintenance and repair of the machine Vogelsang does not accept any liability for damage resulting from failure to comply with these maintenance and operating instructions 1 2 Warning signs danger symbols information This warning warns you of possible hazards to the health and life of yourself and other peopl...

Page 50: ...in the Installation chapter The declaration of installation is part of these operating instructions The pumps described in these operating instructions are not intended for use in potentially explosive atmospheres 3 Safety 3 1 General safety notes Before assembly commissioning start up maintenance and repair of the pump read the operating instructions completely and carefully observe the warning a...

Page 51: ...g out To protect against fluids spraying out carefully and slowly open the buffer chamber the bearing cover on the QD cover and the gearbox Cover the valves or screws to be removed with a cloth or similar item where appropriate Danger of burning or scalding by auxiliary materials operating materials and medium starting at 60 C is present when there is direct contact with hot auxiliary materials op...

Page 52: ...resent especially before maintenance and repair work on the pump or the pump unit Caution when temperatures are below freezing keep workplace free of ice Closed pipe Pumping must not take place against a closed pipe The pump shaft seals or even the pump housing or the pipe may be damaged or destroyed by the resulting high pressure A pressure monitoring unit is optionally available from us setting ...

Page 53: ...ion X X X Maintenance X X X Repair X Legend X allowed not permitted 1 A person who can take over a specific tasks and is authorized to carry it out for a company that is accordingly qualified 2 Whoever has been instructed and if necessary trained about the tasks assigned to them and possible risks associated with incorrect behaviour and has been instructed about the required protective equipment a...

Page 54: ...safety of persons who work with and on the pump The warning and safety stickers must not be removed and must be replaced immediately if damaged or lost Positioning of the warning and safety stickers VX100Q VX136Q VX186Q VX230Q VX136QD VX186QD VX230QD VX136QDM2 VX186QDM2 Fig 1 Warning and safety stickers The figures shown here are examples only and do not reflect the precise positioning of the stic...

Page 55: ...3 VAU 115 Only used for pumps with a mechanical seal consisting of the mating materials SiC SiC Text see sticker Attention In the case of new pumps that are not started up immediately the shaft needs to be rotated approximately every two months at least one revolution to prevent the sealing surfaces on the mechanical seal rings from adhering to one another 4 VAU0050 Lifting with cross beam on the ...

Page 56: ... motor Fig 2 Flow direction with motor drive 4 2 PTO drive If you are using tractor driven pumps with two drive shafts connect either the upper or lower the cardan shafts thus determining the direction of flow Fig 3 Flow direction with PTO drive Risk of noise and vibration due to incorrect connection and orientation of the cardan shafts Generation of noise and vibrations can cause impairment of co...

Page 57: ...rating torque must be limited With cardan shafts with a profile Operating torque limited to 1 3 8 6 part 1 600 Nm 1 3 4 6 part 3 200 Nm 1 3 4 20 part 3 200 Nm No overpressure protection via operating torque limitation This operating torque limitation is not a safety device to prevent pump overpressure see Theoretical operating torque in the chapter Technical data 4 3 Marathon pumps The marathon pu...

Page 58: ...jury from bursting components and medium spraying out under high pressure A connection with sight glass has to be installed on the suction side If the sight glass is on the pressure side when pumping backwards the pressure may not exceed 2 bars 29 psi A Sight glass Fig 5 Flow direction with pump units 4 5 InjectionSystem Injection S The direction of transport is variable Injection A The constructi...

Page 59: ...15 68 5 Assembly 5 1 Transport VX100Q VX136Q VX186Q VX230Q Dismount buffer fluid tank prior to transport and then screw back in again Fig 7 Transport aids pump type Q VX136QD VX136QDM2 up to size 280 VX136QDM2 size 420 VX186QD VX186QDM2 VX230QD Fig 8 Transport aids pump types QD and QDM2 ...

Page 60: ...nstructions VX100Q VX136Q QD QDM2 VX186Q QD QDM2 VX230Q QD 16 68 VX100Q Fig 9 Transport aids pump with flange mounted electric motor Fig 10 Transport aids pump on base type inline Fig 11 Transport aids pump on base type belt drive ...

Page 61: ...ried out by specially trained persons Standing under raised loads is prohibited Direct persons out of the danger area Suspended transport If the pump is transported in suspension use the fitted suspension points for hoisting gear Fig Transport aids indicated with arrows Lifting eye bolts Note load capacity and lifting capacity of the lifting eye bolts Table Lifting eye bolts Quantity of lifting ey...

Page 62: ...tallation the orientation of the coupling must be checked and if necessary corrected before start up Fig Orientation procedure Retighten all motor and pump mounting screws on the base after 20 operating hours Fig 12 Orientation procedure Technical Information TINF PU 020 xx accompanying sheet for belt drives For pumps with belt drive check the belt tension acc to the accompanying sheet At start up...

Page 63: ... which the filling and emptying of the gearbox and the buffer chamber are described If the pump is to be suspended please contact us When installing the pump ensure that there is easy access for maintenance work If the hexagon head screw plugs for draining the gear oil and buffer or quenching fluid are not easy to reach drain hoses may be used part nos PBT 013 and or PBT 014 Ensure that the pump i...

Page 64: ... the fluid remains in the pump after it is switched off Keep the pipeline as free as possible from foreign matter stones wood residues etc in order to prevent wear on rotary lobe and housing Danger of breakage Note on installation of connections Flange connections can exert excessive forces on the unit Risk of breakage The connectors must therefore be mounted free of stress i e the connectors must...

Page 65: ...e pipeline can never run dry Fig Long suction lines Fig 15 Long suction lines 5 4 2 Discharge pipes Risk of injury from bursting parts and medium spraying out under high pressure Follow recommendations for pipes Only use high pressure pipes on the discharge side up to nominal diameter DN 150 PN 16 bar pipes from nominal diameter 200 PN 10 bar pipes except when the permissible operating pressure of...

Page 66: ... make the network connections in AC4 Please contact us with regards to the correct programming of the control system Variable frequency drive operation In general rotary lobe pumps can be designed for variable frequency drive operation Advantages Adaptation to operating conditions viscosity delivery rate NPSHa Wear compensation Speed proportional delivery rate see characteristic line Increasing ac...

Page 67: ...rating instructions geared motor 5 6 2 Hydraulic drive Danger of infection due to hydraulic oil under pressure escaping on pumps with hydraulic drive The connection to the power supply must be done by qualified personnel Leakages can occur due to seal faults Wear protective goggles On injuries with hydraulic oil seek out a doctor immediately Hydraulic motors and hydraulic hose lines Before connect...

Page 68: ...en installed and their proper functioning ensured Is the motor connected correctly to the power supply see documents provided by the motor manufacturer Star or delta connection voltage frequency see name plate and inside of terminal box Motor protection ensured e g by a circuit breaker A short switching time should be set for star delta starting if present A short start ramp should be set for the ...

Page 69: ...chamber 7 1 1 Buffer or quenching fluid type For optimum functioning of the mechanical seal we recommend for standard pumps the oils listed in Chapter Oils and lubricants Please check your order confirmation to see whether the buffer chamber of your pump is filled with a buffer or quenching fluid differing from this chapter In that case use only the oil specified on your order confirmation Health ...

Page 70: ...is severe contamination When there is intense leakage replace the cartridge mechanical seal Chap Changing cartridge mechanical seal Chap Maintenance plan Buffer Quenching fluid A slight contamination of buffer quenching fluid as well as a slight rise or fall of buffer quenching fluid level is determined by the hydrodynamic lubrication film of mechanical seal and temperature fluctuations Environmen...

Page 71: ...on the suction side 0 4 bar pressure on the discharge side 2 0 bar Tank pressure 0 5 bar 2 bar 2 bar 4 0 1 3 bar In this example the tank pressure is 1 3 bar Independently of this the tank pressure with a single mechanical seal must be max 5 bar and max 10 bar with a double mechanical seal Rotary lobe change Before changing the rotary lobes depressurise the tank pressure and prime it again after c...

Page 72: ...xpansion The level of quenching fluid in the tank can vary because of operational conditional heating of the pump Unscrew the upper housing of the quenching fluid tank to top up the tank hold the union nut tight so that the lower screw connection does not come loose 6 Hexagon head screw plug installation tightening torque 60 Nm 7 Quenching fluid tank A Filling B Emptying Fig 17 Pump with quenching...

Page 73: ... medium from escaping from the pressure valve due to thermal expansion 5 Pressure valve C Air buffer D Oil level Fig 18 Pump with pressure valve without buffer fluid tank 7 2 4 Plug for special designs only for example submersible pumps Dismount the upper plug instead of pressure valve to top up small quantities in the buffer chamber Buffer fluid level Fig Pump with pressure valve without buffer f...

Page 74: ...hambers Medical white oil part no BSS 010 can be used as gear oil in these pumps Chapter Oils and lubricants Attention BSS 010 oil is not permitted for high performance applications and continuous operation over a maximum of 50 of the permitted pump pressure Please contact us Avoid dry running To protect against seal damage dry running of the pump must be avoided on pumps with a dry buffer chamber...

Page 75: ... leakage The fluid level in the buffer chamber tank should come up no further than the bottom edge of the buffer chamber 1 Wing nut 2 Union nut 3 Buffer chamber tank 4 Connecting pipe 5 Vent screw Fig 19 Installation example dry buffer chamber Monitoring the buffer chambers If the buffer chamber tank 3 is filled with leakage e g pump medium or condensed water loosen the wing nuts 1 unscrew the tan...

Page 76: ...ction of the cartridge mechanical seal depends on the flushing medium Flushing pressure and volumetric flow setting Fig Flushing operation connection example for flushing pressure and volumetric flow setting The flushing pressure can be set and monitored with a pressure gauge The pressure setting is done as indicated in the Chapter Pump with pressurised buffer fluid tank below heading Tank pressur...

Page 77: ... Before changing a cartridge mechanical seal drain the buffer chamber and clean it if it is contaminated severely Chapter Changing cartridge mechanical seal Chapter Maintenance plan Procedure 1 In case of buffer chamber assemblies with a pressurised buffer fluid tank or pressure valve depressurise the buffer chamber before draining or cleaning 2 Remove buffer chamber assemblies Chapter Buffer cham...

Page 78: ...pection and change Skin and eye irritation caused by auxiliary materials operating materials and medium To protect against fluids spraying out carefully and slowly open the gearbox Cover the valves or screws to be removed with a cloth or similar item where appropriate Fig Gear oil change Inspect the gear oil and top up small quantities up to the seal indicator pipe C only top up when the gearbox i...

Page 79: ...lectric motor Upright installation Fig 21 Gear oil change VX100 1 Hexagon head screw plug A fill 2 magnetic hexagon head screw plug B drain B alternatively empty via B1 C check The hexagon head screw plug 1 must always be on top of the pump the magnetic hexagon head screw plug 2 on the bottom of the pump Tightening torque for assembling the hexagon head screw plug 60 Nm ...

Page 80: ...nge VX136 VX186 VX230 1 Hexagon head screw plug A fill 2 magnetic hexagon head screw plug B drain 3 Grease nipple at gearbox side B alternatively empty via B1 4 Grease nipple at the VX186QD cover C check The hexagon head screw plug 1 must always be on top of the pump the magnetic hexagon head screw plug 2 on the bottom of the pump Tightening torque for mounting the hexagon head screw plugs 60 Nm ...

Page 81: ...l prevents the lubrication channel from clogging To ensure effective distribution of the lubricant always lubricate while the machine is running and not when it is stationary Lubricant type We recommend the lubricating grease listed in Chapter Oils and lubricants Lubricating grease quantity Grease nipple at gearbox side Series VX136 VX186 5 shots per nipple with a lube gun Series VX230 8 shots per...

Page 82: ...ISO 3104 Flash point 260 C DIN ISO 2592 Pour point 42 C DIN ISO 3016 Water hazard class Slightly hazardous to waters when using BSS0021 oil for the pump gearbox the maintenance interval for inspection and gear oil change may be doubled Chapter Maintenance plan Part number BSS 010 Description Medical white oil water white non fluorescent tasteless and odourless mixture of hydrocarbons Trade name Fu...

Page 83: ...s 6 9 mm s DIN EN ISO 3104 Flash point 210 C DIN ISO 2592 Pour point 24 C DIN ISO 3016 Water hazard class Slightly hazardous to waters Part number BSS 016 Description Biodegradable environmentally friendly multigrade hydraulic oil based on rape seed oil as per ISO 15308 type HETG Trade name Fuchs Hydraulic oil 40 N Characteristics Test acc to ISO VG 46 DIN 51519 Viscosity index 220 DIN ISO 2909 Ki...

Page 84: ...y synthetic EP industrial gear oil on the basis of selected polyglycols PAG Trade name Fuchs Renolin PG 46 Characteristics Test acc to ISO VG 46 DIN 51519 Viscosity index 203 DIN ISO 2909 Kinematic viscosity at 40 C 46 mm s DIN 51562 Flash point 240 C DIN ISO 2592 Water hazard class Slightly hazardous to waters 5 Lubricant for pump grease nipples Part number BSS 008 Description Lithium soap grease...

Page 85: ...ations these materials or the medium can enter the buffer chamber or gearbox Before opening covers connectors etc the pump assembly must be depressurised to prevent the medium from spraying out To protect against fluids spraying out carefully and slowly open the buffer chamber the bearing cover on the QD cover and the gearbox Cover the valves or screws to be removed with a cloth or similar item wh...

Page 86: ...e dismounted 2 Loosen hexagon nuts 1 or hexagon head screws 1 on VX230 series on the Q cover 5 3 Remove Q cover and remove the O ring 6 8 4 Closing the Q cover Fig Opening Closing the Q cover 1 Thoroughly clean the contact surfaces before installing the Q cover 5 2 Pull the O ring 6 onto the Q cover 3 Set the Q cover in place 4 Screw four hexagon nuts 1 onto the threaded rod and tighten or on VX23...

Page 87: ... housing Cover the screws to be dismounted with a cloth or similar item where appropriate 4 Loosen anti fatigue bolts 3 5 Using the screws or threaded rods for the QDM2 series use the screws that are appropriate the QD cover can be pressed off via the threads 4 until the QD cover is sitting loose Use M12 hexagon head screws on VX230 series Attention Do not tilt the cover but press it evenly by han...

Page 88: ... nuts 1 of the twelve hexagon head screws or threaded rods note tightening torques Attention Do not tilt the cover while doing this but press it evenly by hand Watch for correct seating of the O ring Tightening torques VX136 series M10 10 9 70 Nm M10 A4 70 40 Nm VX186 series M12 12 9 140 Nm M12 A4 70 stainless steel 60 Nm VX230 series M16 8 8 200 Nm 6 Tighten anti fatigue screws 3 Chapter Tighteni...

Page 89: ...s VX100Q VX136Q QD QDM2 VX186Q QD QDM2 VX230Q QD 45 68 8 7 Rotary lobe change HiFlo arrangement HiFloplus arrangement Marathon arrangement VX136QDM2 VX186QDM2 Fig 26 Arrangement of HiFlo and HiFloplus L left rotary lobe R right rotary lobe ...

Page 90: ...pulled off the shafts using a commercially available universal puller with a span width of 200 mm and a span depth of 150 mm Pull HiFlo and HiFloplus rotary lobes off the upper and lower shaft in pairs 4 Install the new rotary lobes in reverse sequence Fig HiFlo and HiFloplus arrangement Before installing the new rotary lobes thoroughly clean the contact surfaces of rotary lobes and seal component...

Page 91: ... pressure disk and spring washer VX136Q series Correct position Attention Incorrect assembly VX100Q VX186Q and VX230Q series Correct position Attention Incorrect assembly Fig 28 Position of pressure disc and spring washer 1 Pressure disc 2 Spring washer 1 piece for VX100Q VX186Q and VX230Q and 2 pieces for VX136Q ...

Page 92: ...cover 2 Pull the rotary lobes 11 from the shafts using a rotary lobe puller see spare parts list Assemble HiFlo and HiFloplus Rotary lobes in pairs i e simultaneously to the upper and the lower shaft 3 Install the new rotary lobes in reverse sequence Fig HiFlo and HiFloplus arrangement 4 Close QD cover chap Closing the QD cover 5 Apply pressure to buffer chamber chap Buffer chamber Fig 29 Rotary l...

Page 93: ...e and below and take off the fixing plate 17 4 With the VX186QDM2 series remove the top bottom angle rings 18 and the sealing plate 19 5 Take off the shims 20 and the O rings 21 6 Remove spacer washer 22 incl O ring 23 7 Pull off the O ring 24 8 Take off the fixing plate 25 incl screwed on wear plate 26 9 Pull the rotary lobes 11 from the shafts using a rotary lobe puller see spare parts list Pull...

Page 94: ...s Clean the threads and contact surfaces Apply Anti Seize Paste Part No BKL 014 BAS 001 evenly and in sufficient quantity to the screw head nut contact surface and the thread using a brush or putty knife etc to avoid seizing of stainless steel 8 8 Change of wear plates Wear plate installation position The wear plates of the VX100 VX136 and VX186 series have a defined curvature To prevent premature...

Page 95: ... Change O ring 30 in the bearing seal housing fig c 10 Carefully remove the burrs on the keyways and clean the cartridge sealing ring seat in the housing before installing the new cartridge sealing ring 11 Push new cartridge mechanical seal onto the shaft Carefully oil the outer O rings on the seal carrier Pos 34 in fig b before installation Attention Do not use oil for EPDM O rings 12 If a circul...

Page 96: ...2 68 a b a Hexagon socket set screw b Hexagon socket head cap screw c Hexagon head screw 30 O ring bearing seal housing 34 O ring seal carrier D Installation tool Complete kit part no VX100 WKZ0455 VX136 WKZ0456 VX186 WKZ0457 VX230 WKZ0462 c Fig 32 Cartridge mechanical seal on the gearbox ...

Page 97: ...over 8 Place washer 2 on the hex head screw 3 and push it through the bearing cover 9 Change O ring in the bearing seal housing 10 Clean the cartridge seat in the housing 11 Insert the new cartridge 12 If a circulation system is present the bore holes in the cartridge mechanical seal must be aligned with the flushing connections in the QD cover 13 Put on tool G with the large boring facing the car...

Page 98: ...s Fig Adjustment of pump housing segments 4 Before installation of the pump housing segments apply flange sealant set an asbestos free gasket in place and coat this with flange sealant as well The asbestos free gaskets do not apply to the VX230 series here you only need to apply flange sealant 5 Screw all screws back on at the pump and the connectors 6 Install Q or QD cover Chapter Closing the Q c...

Page 99: ...ries excluded Gap increase 1 mm VX136Q At gearbox side Wear plate PFL B009 T1 4 mm replaces wear plate PFL B009 5 mm Cover side Wear plate PFL B002 T1 3 mm replaces wear plate PFL B002 4 mm VX186Q At gearbox side Wear plate PFL A017 T1 5 mm replaces wear plate PFL A017 6 mm Cover side Wear plate PFL A002 T1 4 mm replaces wear plate PFL A002 5 mm Gap increase 0 3 mm VX136Q At gearbox side Wear plat...

Page 100: ...ncreasing the gap using shims Procedure as in Chapter Increasing the gap on the Q cover and or Chapter Increasing the gap on the gearbox Attention If more than two shims are placed on each distance nut of the Q cover you have to mount a thicker O ring under the Q cover to attain continued reliable sealing VX100Q O ring part no DOR 092 VX136Q O ring part no DOR 093 VX186Q O ring part no DOR 094 Inc...

Page 101: ...en there is severe contamination Lubricate grease nipple X X Check belt tension for pumps with belt drive acc to accompanying sheet X X X X Tighten the screws for the base X Checking buffer fluid tank or quenching fluid tank X X Changing buffer fluid or quenching fluid X X Change gearbox oil X X Check gearbox oil X chap Checklist before start up Pumps with a mechanical seal consisting of the mater...

Page 102: ...c to Chap Service instructions have been followed and performed Serial number nameplate Lubricate grease nipple Checking belt tension Tighten the screws for the base Checking buffer fluid tank or quenching fluid tank Changing buffer fluid or quenching fluid Check gearbox oil Change gearbox oil Other operating hours Overall delivery rate Date Name Signature ...

Page 103: ... S V Irregular pump delivery D E G J Pump performance too low D G J R S T U Pump blocked C F J K M R U V Power consumption too high C M R S V Drive belt slips F H M R S Leakage at the pump C R U Pressure and level variations in the buffer chamber O U V Extreme pressure and level changes in the buffer chamber P With dry buffer chamber buffer chamber tank more than half full Q Pump too hot A C M N R...

Page 104: ...uipment Connection to the power supply Error in the hydraulic system Check the hydraulics L Motor speed too low during variable frequency drive operation Install external fan increase motor speed Variable frequency drive operation M Stiff running caused by swollen lobe elastomer Check the medium resistance of the lobe elastomer Material description for rotary lobes Stiff running caused by accumula...

Page 105: ...de PU PU Werobust Polyurethane vulcanised 50 C abrasive medium wear resistant PUR PUR Polyurethane cast 80 C abrasive medium highly wear resistant CSM CSM Hypalon Chloro sulfonyl polyethylene rubber 80 C Petrol oil acids alkali solutions wear resistant acid resistant and alkali resistant FPM FPM Fluorocarbon gum 80 C Solvents salt water oil petrol acids acid resistant and alkali resistant Steel lo...

Page 106: ... operating pressure bar 2 0 3 0 4 0 6 7 8 5 9 7 Theoretical capacity m h 12 9 11 3 9 8 13 1 11 4 9 9 64Q Displacement 0 42 l max operating pressure bar 1 1 1 8 2 4 4 3 5 6 6 8 Theoretical capacity m h 18 7 16 3 14 2 19 0 16 6 14 4 90Q Displacement 0 59 l max operating pressure bar 2 8 3 6 4 5 Theoretical capacity m h 26 7 23 3 20 2 128Q Displacement 0 84 l max operating pressure bar 1 7 2 3 2 9 Th...

Page 107: ...e of series Theoretical capacity Max operating pressure Theoretical operating torque with max operating pressure and water VX186 VX186QD Marathon nmax 600 min 1 VX QD VX Q VX QD Marathon VX QD VX Q VX QD Marathon l m 3 h bar bar bar Nm Nm Nm 92 184 92 92 3 56 125 10 16 675 1100 130 260 130 130 5 03 180 12 10 16 1100 940 1510 184 368 184 184 7 12 250 12 8 14 1540 1090 1850 260 520 260 260 10 06 360...

Page 108: ... 3 h bar bar Nm Nm 226 13 45 435 12 8 2900 2000 320 19 04 615 10 5 3470 1960 640 38 08 1230 6 4260 Free passage For the VX230 series the maximum free passage is Ø 75 mm All data refer to theoretical capacity The actual capacity is lower it depends on the various operating conditions Valid only for short operation times For continuous operation please contact our Service department The service life...

Page 109: ...hould be dry relative humididty under 65 and the temperature should be between 5 C and 30 C The pump chamber can be sealed with a preservative that is suitable for the lobe and sealing material The products should be protected against light especially direct sunlight and strong artificial light with a high proportion of ultraviolet From a storage period of over 5 years and before start up we recom...

Page 110: ...k under spring energy In order to prevent risk of injury due to crushing or falling carefully loosen screws Wear protective clothing 3 Empty auxiliary materials and supplies and residual medium Empty pump gearbox Observe notes and safety notes Chapter Checking and replacing the gear oil Emptying the buffer chamber Observe notes and safety notes Chapter Emptying and cleaning the buffer chamber Empt...

Page 111: ...ents according to Annex I of the Machinery Directive 2006 42 EC are applied and observed 1 1 3 1 1 5 1 5 4 1 5 13 1 6 1 1 7 1 1 1 7 3 1 7 4 Applied harmonised standards EN 349 1993 A1 2008 EN 1037 1995 A1 2008 EN ISO 12100 2010 EN ISO 13857 2008 Applied national standards and technical specifications DIN 4844 1 2012 06 DIN 4844 2 2001 A1 2004 DIN ISO 3864 1 2012 06 EN 809 2012 10 EN 12162 2010 05 ...

Page 112: ... A R L vogelsang fr Indien Vogelsang India Private Limited vogelsangindia com Finnland Vogelsang Oy vogelsang fi Italien Vogelsang Italy Srl vogelsang srl it Tschechische Republik Vogelsang CZ s r o vogelsang czech cz Irland Vogelsang Irland vogelsang ie Polen Vogelsang Poland Sp z o o vogelsang pl Dänemark Vogelsang A S vogelsang as dk Deutschland Niederlassung Ost Vogelsang Lutherstadt Eisleben ...

Page 113: ...urs Every 500 operating hours or 3 months Every 2000 operating hours After Exposure to strong contamination New Pump w Mechanical Seal combination of metals SiC Si TC One Rotation when not in service X Remove plastic plug from breather on V100 QHD Pumps X Check belt tension for belt drive pumps according to specification for all pumps configured with V Belt Drives X X Tighten all mounting bolts X ...

Page 114: ...c Operator Laborer Lobe Change 1 0 2 0 Seal Change 1 0 2 5 Wear Plate Change 1 0 1 5 Housing Adjustment 1 0 2 5 Complete Wet End Rebuild all of the above tasks 1 0 4 0 Check Oils 25 Change Oils 75 Number of Personnel Required for Preventative Routine Maintenance All Q Series Pumps Time in Man Hours Title Electrician Mechanic Operator Laborer Check Oils 25 Change Oils 75 ...

Page 115: ... initial startup 20 operating hours after initial startup Every 200 operating hours Every 500 operating hours or 3 months Every 2000 operating hours After Exposure to strong contamination New Pump w Mechanical Seal combination of metals SiC Si TC One Rotation when not in service X Tighten all mounting bolts X Check buffer chamber oil level X X Change buffer chamber oil X X Change Gear Oil X X Chec...

Page 116: ...r make sure you understand the safety instructions provided with any piece of rotating equipment There is a specific section in this manual that deals with safety concerns related to the Vogelsang Pump Make sure you read and understand this section completely prior to starting any repair If you have questions please contact 800 984 9400 ...

Page 117: ...etween the rotors and the casing The lobes mesh tightly together in the center of the pump and have a very small clearance at the radial housing As the lobes continue to turn the fluid and objects are moved along the outer perimeter of the pump As the pump completes a full cycle the fluid is pumped through to the discharge side of the pump The direction of flow is determined by the rotation of the...

Page 118: ... Identification Each Vogelsang pump is tagged with an identification label on the gearbox end of the pump This tag shows the full model designation serial number year of manufacture and maximum operating conditions if applicable Refer to the illustrations below ...

Page 119: ...o obstructions in the pipelines X X X Pressure relief system valves etc must be in good working order and set to the appropriate relief pressure X X X Under no circumstances should the pump or its flanges be used to support external loads All piping must be supported X X X Pump should be filled with liquid before initial startup and any restart X X Liquid should be drained from the wet end of the ...

Page 120: ... Series Q Pumps Pre startup checks Startup Normal Operation Shutdown Emergency Shutdown Rotate the pump one complete turn each month to insure proper lubrication of mechanical seals X X X X Clean wet end of unit to insure a smooth re start X X X ...

Page 121: ...Service Manual Service Manual Pump Models VX Series Q Pumps ...

Page 122: ...Service Manual Service Manual Pump Models VX Series Q Pumps ...

Page 123: ...Service Manual Service Manual Pump Models VX Series Q Pumps ...

Page 124: ...ons 1 Open all suction and discharge valves 2 Assure completion of all startup checks in table above 3 Assure compliance with any electrical checklist for this application 4 Engage pump 5 Assure normal operation parameters 6 Upon shutdown observe shutdown advisories in chart above ...

Page 125: ...uges to monitor pressures for diagnostic purposes Depending on your requirements the pump and drive if supplied may arrive mounted on a baseplate Our standard baseplates have pre drilled mounting holes to accept base retaining bolts All mounting holes are required for best results against vibration and noise To provide a permanent rigid support for securing the pump unit a foundation is required T...

Page 126: ...g After mounting the alignment of coupling must be checked and corrected prior to operation Retighten all motor and pump mounting screws on the frame after 20 initial operating hours For pumps with belt drive check the belt tension as described earlier After the first 10 operating hours Then every 2000 operating hours Use the eye bolts on the pumps only for lifting the pump without any additional ...

Page 127: ...t install equipment Special Rigging Pump Motor assemblies may exceed 3090 lbs and so require some lifting device with chain and hooks to engage lifting eyes on pump and motor Assemblies should never be lifted by pump alone or by motor alone Special Test Equipment No special test equipment is required for the installation of the pump assembly ...

Page 128: ...peration if the suction and pressure pipes are connected so that access to the pumping chamber is not possible Before pump is set in operation ensure that access to the rotating parts the drive shaft is not possible The drive shaft must be completely covered by a coupling guard Before setting into operation ensure that the discharge pipe is not completely closed off Otherwise the pump shaft seals ...

Page 129: ...ries Q Pumps Lubrication Lubrication Points Lubrication Reservoirs There is a buffer chamber on the VX Q pump that is filled with oil and pressurized using a pressurized oil bottle The gearbox is filled halfway with oil to lubricate the drive gears ...

Page 130: ...nged Every 2000 operating hours however not more than 3 months between fill ups See section 2 F 1 for information on using the pressurized oil bottle Lubricant Vogelsang Standard Oil Mineral Oil Titan Gear MP90 SAE 90 Combustion point 215 C Art No BSS 006 See the table of alternative oils on the following page 1 Pressurized Oil Bottle A Fill 2 Hex Head Screw Plug B Empty 3 Magnetic Hex Head Screw ...

Page 131: ...x MP90 Mineral Oil SAE 90 GC 5 Pennzoil 80W 90 GL 5 Fuchs RENOLIN EP 220 Valvoline HP Gear Oil 80W 90 Quaker State FCIGL 5 MT 1 80W 90 BP Oil BP HYPO U 80W 90 Titan Gear MP90 Gearplus Buffer Chamber MP90 Mineral Oil SAE 90 GC 5 Pennzoil 80W 90 GL 5 Lubrication Quantity Chart VX Q Series Pumps Location Model Quantity Buffer Chamber VX 136 Q Series 1 5 quarts 1 5 liter Gearbox VX 136 Q Series 2 1 qu...

Page 132: ...Service Manual Service Manual Pump Models VX Series Q Pumps Operational Startup Testing Shown below is the standard we use to test each pump before it leaves the factory ...

Page 133: ...Service Manual Service Manual Pump Models VX Series Q Pumps Operational Startup Testing continued ...

Page 134: ...ould be noted on the Start Up checklist for comparison with design specifications Differences should be noted Flow meters pressure gauges and similar instruments may be used or installed in the system for observation of application conditions Any request for technical assistance from Vogelsang will require this data Certified Factory tests will be conducted on all products per the specification an...

Page 135: ...hours Every 500 operating hours or 3 months Every 2000 operating hours After Exposure to strong contamination New Pump w Mechanical Seal combination of metals SiC Si TC One Rotation when not in service X Remove plastic plug from breather on V100 QHD Pumps X Check belt tension for belt drive pumps according to specification for all pumps configured with V Belt Drives X X Tighten all mounting bolts ...

Page 136: ...nic Operator Laborer Lobe Change 1 0 2 0 Seal Change 1 0 2 5 Wear Plate Change 1 0 1 5 Housing Adjustment 1 0 2 5 Complete Wet End Rebuild all of the above tasks 1 0 4 0 Check Oils 25 Change Oils 75 Number of Personnel Required for Preventative Routine Maintenance All Q Series Pumps Time in Man Hours Title Electrician Mechanic Operator Laborer Check Oils 25 Change Oils 75 ...

Page 137: ...er initial startup 20 operating hours after initial startup Every 200 operating hours Every 500 operating hours or 3 months Every 2000 operating hours After Exposure to strong contamination New Pump w Mechanical Seal combination of metals SiC Si TC One Rotation when not in service X Tighten all mounting bolts X Check buffer chamber oil level X X Change buffer chamber oil X X Change Gear Oil X X Ch...

Page 138: ...Prior to starting any repair make sure you understand the safety instructions provided with any piece of rotating equipment There is a specific section in this manual that deals with safety concerns related to the Vogelsang Pump Make sure you read and understand this section completely prior to starting any repair If you have questions please contact 800 984 9400 ...

Page 139: ...stallation Install a pressurized oil bottle at the empty buffer chamber port at the top of the pump With the provided hand pump or other air source pressurize the bottle no oil in chamber to approximately 21 psi 1 5 bar and observe the gauge Pressure should hold steady for at least 15 minutes Then depressurize the bottle remove it re fill the buffer chamber and re install the pressurized oil bottl...

Page 140: ... bottle Install the pressurized oil bottle screwing it directly to the buffer chamber On belt drive units a hose kit is necessary to mount the bottle in a remote location 3 Fill the pressurized oil bottle about 1 4 full with buffer chamber oil see above Using the supplied hand pump pressurize the buffer chamber using the formula 1 2 of normal pump operating pressure plus 7 psi For example if your ...

Page 141: ...e a drain pan under the pump to catch the quenching oil Remove the buffer chamber drain bolt Fig 1 located on the bottom of the pump This part will be reused Inspect the oil for foreign bodies or other evidence of contamination as this may indicate mechanical seal failure Remove the top bolt on the gear case of the pump and save for re use Place an oil collection pan under the pump and loosen and ...

Page 142: ...remove and set aside The pump end plate sometimes referred to as the door can be heavy Use care removing it from the fluid end of the pump The pump end plate will also consist of the outer wear plate and may retain the sealing o ring Remove as a unit Inspect the wear plate and replace if necessary Fig 3 Note Some wear is expected on the outer wear plate Excessive wear means pump flow is no longer ...

Page 143: ...ig 4 Note The caps are not required for proper pump operation Insert the strain bolt socket provided with the optional lobe puller With the lobes blocked so they will not rotate loosen the lobe retention bolts They will be very tight so take care not to strip them The bolt will loosen from the shaft then seem to turn freely in the hole Fig 5 Note It is very easy to strip the strain bolt heads Take...

Page 144: ... in a back and forth motion wiggle the disk free Save the disk for re use Remove and retain washers if loose for re use Note the washers are generally fixed to the locking disk Note also the o ring on the outer edge of the locking disk and the one on the inner edge of the locking disk These should be replaced at each lobe change but can be re used if not severely compressed In the event that the d...

Page 145: ...t of stacked lobes removing lobes from both shafts Fig 9 Note Lobes must be pulled together in pairs Using two sets of pullers is recommended as it will save you a significant amount of time Lobe Pullers We recommend ordering two sets VX136 Short Lobe Puller Part PBA B001 TK for models 70 105 VX136 Long Lobe Puller Part PBA B001 TL for models 140 210 VX186 Short Lobe Puller Part PBA A001 TK for mo...

Page 146: ... the inner core which mates with the seal These lobes may show small bits or pieces of the coating in a jagged appearance around the surface which is not acceptable when using Block Ring seals New lobes have a smooth clean machined appearance and show no jagged bits of coating If lobes are being reused with the Block Ring seal attention must be given to the condition of the lobe core assuring that...

Page 147: ...to injure yourself on the sharp edges of the keyway Carefully reach into the pump and remove the wave washers Fig 67 from the shaft If replacing the cartridge or block ring mechanical seal assembly these parts will be included and should be replaced If changing just the lobes they may be re used but replacement is recommended Note Washers Fig 14 go on top and bottom shaft Re install them in the sa...

Page 148: ...rvice Manual Pump Models VX Series Q Pumps Using a dental pick o ring puller or similar sharp instrument remove and discard the o ring Fig 15 16 located around the pump shaft Note Never re use this o ring Fig 16 Fig 15 ...

Page 149: ...use If damaged replace As with the outer wear plate some wear is expected Excessive wear is determined by loss of flow performance When pump flow is unsatisfactory the plate must be replaced This plate can never be turned over for re use Note The back wear plate has a slight convex bend to it Fig 18 The plate is installed one way only with the ends of the plate pushing the center up slightly The r...

Page 150: ...cal seal assembly if the cartridge is being replaced Cartridge and block ring seal assemblies are supplied with 2 small set screws on opposite sides of the outer carrier of the assembly Remove these small screws using a 2 5mm allen wrench Fig 20 These set screws are installed to help keep material out of the threaded holes in the carrier used by the cartridge removal tool Part PBA A014 N1 VX186Q P...

Page 151: ...p housing the ring will pull the cartridge assembly out of the seal bore Pull entire seal assembly up off the lobe shaft Repeat the procedure for the other mechanical seal assembly Use an even slow pressure with the jacking bolts to avoid bending the assembly tool ring Turn each screw one or two turns at a time and rotate around the ring increasing pressure with the jacking screws Fig 22 Note If r...

Page 152: ...ame size However the o ring located directly behind the wear plate may be of different material depending on the elastomers used in the pump All elastomers are standard as NBR but optional elastomers may be provided if specified to combat reaction to specific chemicals being pumped Note This completes the mechanical seal removal procedure The entire wet end is now disassembled If you need to work ...

Page 153: ...ch Block Ring Mechanical Seal Kit Includes Block Ring Mechanical Seal 4 o rings flat washer Do not reuse your old parts Note If you are upgrading to our new Block Ring mechanical seal you may have our old style non pressurized oil bottle All Block Ring seals require a pressurized oil bottle The pressure setting will depend on your particular application Follow the instructions in the Oil Bottle In...

Page 154: ...ich mates with the seal These lobes may show small bits or pieces of the coating in a jagged appearance around the surface which is not acceptable when using Block Ring seals New lobes have a smooth clean machined appearance and show no jagged bits of coating If lobes are being reused with the Block Ring seal attention must be given to the condition of the lobe core assuring that it has not been d...

Page 155: ...hamber oil Fig 27 and slide the cartridge seal and seal removal tool no bolts onto shaft and push into the pump body as far as possible by hand Fig 28 Lubricate the shaft and slide in the lobe without key in keyway against the removal tool Fig 29 Use the existing pressure disks and strain screw and draw the lobe against the pump body thereby seating the mechanical seal Fig 30 Remove the screw pres...

Page 156: ...eal body and the pump body This will occur upon final assembly and tightening of the wear plates Fig 31 Coat the smaller o ring with oil and slide over shaft and against the seal inner race Take care that the o ring is not cut by the sharp edges of the keyway do not attempt to seat the o ring Fig 32 Install the flat washer over the shaft and against the o ring Fig 33 Fig 31 Fig 32 Fig 33 ...

Page 157: ...ce wear plate Fig 34 into the pump insuring that the chromed or ceramic side is facing both you and the wet end of the pump Install the two screws Fig 35 that hold the wear plate in place and tighten securely Rotary Lobes are now ready to be installed Fig 35 Fig 34 ...

Page 158: ...Fig 37 taking care that the inside lip is facing you Pumps equipped with only two lobes should have a right lobe on the top and left lobe on the bottom shaft For pumps with multiple sets of lobes mounted on each shaft start with a right lobe on the top shaft and a left lobe on the bottom shaft Install the next set using a left lobe on the top shaft and the right lobe on the bottom Alternate this w...

Page 159: ...ve and replace the o rings on the pressure disk Fig 38 With the aid of a brush lube the inside of the lobes and the inside and outside o ring of the pressure disk with hydraulic oil Then carefully drive into place with a rubber or plastic mallet Fig 39 Fig 38 Fig 39 ...

Page 160: ... strain screw with oil and install by hand only until it cannot be tightened any further by hand Repeat on other shaft fig 40 Fit lobe socket to torque wrench and torque each of the strain screws to the following Torque Required VX136 Series 147 f lbs VX186 Series 147 f lbs Then loosen each strain screw and re torque each to 100 f lbs Fig 41 Fig 40 Fig 41 ...

Page 161: ...umps Front Cover Installation Replace the o ring and inspect the wear plate for signs of wear If wear is present replace the wear plate Place the cover on the pump insure it is seated into it s groove and securely tighten the four locking nuts Fig 42 Fig 42 ...

Page 162: ...x with oil until begins to run out of the side hole which translates to filling the gearbox up about halfway Replace the side drain plug and tighten Fig 43 Fill the blocking chamber completely to the top with oil Fig 44 Note Refer back to the instructions regarding the use of the Pressurized Oil Bottle The appropriate pressure must be set to your particular pump to help ensure maximum mechanical s...

Page 163: ...s and replace if necessary The bolts may be re used Fig 45 Note If the shafts will be removed it is necessary to remove the lobes and mechanical seal assemblies first To service the bearings or gears the shafts must be removed With the aid of a hammer and chisel carefully tap the key from its keyway and remove from the pump Fig 46 Remove any burrs from the shaft with the aid of a file or emery clo...

Page 164: ...p The gear case uses four dowels to position and hold the case to the body It may require several blows against the drift at various points around to loosen the case Once the cover has been loosened the use of a chisel or similar tool can aid in further removing the case from the 4 dowels used to hold it in place Use care to loosen the case evenly around the pump body Fig 48 Fig 47 Fig 48 ...

Page 165: ...put aside Two bearings reside in the case as well as the lip seal for the outboard shaft end and the cap seal for the inboard shaft opening These will be serviced later if necessary Fig 49 Assembly tool for floating bearing PBA A013 Assembly tool for bearing ring PBA A012 Assembly tool for seal PBA A007 Seal support puller PBA A017 Fig 49 ...

Page 166: ...d and does not indicate excessive compression it may be re used Drive the two shafts from the wet end of pump through the gear end of pump Use appropriate drift and heavy hammer as shaft is a tight fit through the double roller bearing Fig 51 Note Provide soft landing for the shafts as they leave the pump body or use a helper to hold shafts as they are driven out of the pump Fig 50 Fig 51 ...

Page 167: ...ual Service Manual Pump Models VX Series Q Pumps Pump body with shafts removed Fig 52 Use a hammer and chisel to bend the locking washers away from the retainer bolts Fig 53 The bolts may be re used Fig 52 Fig 53 ...

Page 168: ...to remove the bolts around the bearing retainers Fig 54 Discard the locking washers and replace with new Drive the roller bearings from the pump body Fig 55 Note use of special tool to avoid damaging the bearing if it is to be re used See tool list on previous page Fig 54 Fig 55 ...

Page 169: ... Q Pumps The bearing assembly should emerge from the pump body bore intact Fig 56 Thoroughly clean the area with a fast drying solvent We typically use a good quality brake cleaning product to remove all traces of old oil and grease Fig 57 Fig 56 Fig 57 ...

Page 170: ...els VX Series Q Pumps Reassembly of Gearbox Apply liberal coats of oil to all parts during re assembly of pump Fig 58 Drive bearing assembly fully into the pump body using an appropriate tool to avoid damage to bearing Fig 59 Fig 58 Fig 59 ...

Page 171: ...anual Pump Models VX Series Q Pumps The bearing housing should be flush with the pump housing when fully seated Fig 60 Install bearing retainers using new locking washers Fig 61 Bolts may be re used if undamaged Fig 61 Fig 60 ...

Page 172: ...ct assembly to assure that no locking washer edge extends over the o ring seat on the corners as this may impede the re assembly of the gear case If it is necessary to replace the shaft or gear it will be necessary to build an entire new shaft assembly Carefully inspect the parts list for correct parts for the shaft being rebuilt First install the key for the gear Fig 63 Fig 62 Fig 63 ...

Page 173: ...ntil the key aligns with the face of the gear Fig 64 The shaft must be driven through the gear so that the keyways are aligned with the X or XX facing upwards Final position of gear is created when spacers and bearing race have been installed Fig 65 Arrow points to either the X or XX depending on which shaft you re working on Fig 64 Fig 65 ...

Page 174: ...e bearing race for the bearing over the shaft and past the cut groove in the shaft Fig 66 Install the circlip into the groove to hold the bearing race in place Fig 67 Install the bearing side spacer If the drive shaft is being assembled note that a race must be installed above the circlip to accommodate the lip seal installed later Fig 66 Fig 67 ...

Page 175: ...st Vogelsang pumps are top shaft driven which puts the idle shaft at the bottom closest to the feet of the pump Be sure to verify the position of the shafts when re assembling the pump Drive shaft into pump until spacer is bottomed against the double roller bearing race and the gear face Fig 69 Flip the shaft over and press the gear so that the spacers are fitted tightly Fig 68 Fig 69 ...

Page 176: ... aligning the single tooth marked with an X on one gear between the two teeth marked with an X on the second gear Fig 70 Failure to properly align the gear teeth will render the pump inoperable Second shaft installed with gear teeth properly aligned for correct timing Fig 71 Note Gears are always sold in sets as one part number Fig 70 Fig 71 ...

Page 177: ... Pump Models VX Series Q Pumps To prepare the gear box for re assembly remove the retainer clip Fig 72 on the lip seal for the outboard shaft This clip fits snugly in the machined groove just above the lip seal Fig 73 Fig 73 Fig 72 ...

Page 178: ... Discard the seal it will be replaced in a later step Fig 74 If the case bearing must be replaced it will have to be removed with a blunt drift against the bearing housing The bearing race must be replaced on the outboard shaft Fig 75 See previous instructions regarding the rebuild of the shafts Fig 75 Fig 74 ...

Page 179: ...n roller cage Fig 76 This is typical when attempting to remove the bearing therefore remove this bearing only when it will be replaced with a new part Remove the retaining clip from the packing disk only if you are replacing the bearing or if the packing disk is leaking oil This part does not require routine service Fig 77 Fig 76 Fig 77 ...

Page 180: ... removed drive it out through the outside of the gearbox case using a suitable tool to avoid bending the disk Fig 78 Replace the o ring before re installing the packing disk Assure proper seating of the o ring in the packing disk groove before inserting back into case Fig 79 Fig 78 Fig 79 ...

Page 181: ...til it bottoms against the casing Use a suitable tool to avoid damaging the packing disk Re install the retaining clip Fig 80 Place new lip seal in the appropriate bore and seat fully against the gearbox casing Re install retaining clip Fig 81 The gearbox housing is now ready for reassembly Fig 81 Fig 80 ...

Page 182: ...grease will keep the o ring in place during assembly Be sure the o ring is seated all the way around the pump body Fig 82 Carefully replace the gear housing to the pump Fig 83 To properly seat the gear housing place an allen bolt on opposite sides diagonally Alternate tightening until the gear housing is seated and snug Install the remaining bolts Fig 82 Fig 83 ...

Page 183: ...vice Manual Pump Models VX Series Q Pumps Re install the drain plug on the gearbox taking care to also re install the copper washer Fig 83 Note Proceed to next section regarding the proper method to add lubricants Fig 83 ...

Page 184: ...om the top fill the gearbox with oil until its begins to run out of the side hole Replace the side drain plug and tighten Fig 84 Fill the blocking chamber completely to the top with oil Fig 85 Note Refer back to the instructions regarding the use of the Pressurized Oil Bottle The appropriate pressure must be set to your particular pump to help ensure maximum mechanical seal liftetime Fig 84 Fig 85...

Page 185: ...p The rate of wear on lobes and wet end parts is dependent upon pump speed and the abrasion quality of material being pumped Consequently no normal wear characteristics can be identified Generally pump lobes are worn out when the output flow no longer meets acceptable expectations At this point lobes are replaced or housing segments are adjusted to regain acceptable flow rates 2 F 4 Critical Torqu...

Page 186: ...ly line diameter Increase suction head Simplify piping and or reduce length Reduce pump speed Decrease liquid temperature Check effect of increased viscosity on available and permitted power inputs X X X X X Air entering supply line Remake pipe work X X X X Gas Supply Expel gas from supply line and pumping chamber to introduce liquid X X X X X Insufficient head above supply vessel outlet False pro...

Page 187: ...ion Simplify supply line Seal flushing inadequate Check that fluid flows freely into seal Increase flow rate X X X X Pump speed above rated figure Decrease pump speed Pump speed below rated figure Increase pump speed X X X X X X X Rotor case strained by pipe work Align pipes Add flexible pipes or expansion fittings X X X X Belt Drive Slipping Tighten belt to specified tension X Flexible coupling m...

Page 188: ...aw Noise Vibration Pump Element Water Excessive Seal Wear Seizure Causes Solution X X Metal to metal contact of pumping element Check rated and duty pressures X X Worn pumping element Install new components X X Relief valve leakage Adjust pressure setting Examine clean seating surfaces Install new components X X Relief valve chatter Check water sealing surfaces guides Install new components ...

Page 189: ...Service Manual Service Manual Pump Models VX Series Q Pumps Warranties 4 A 1 Warranty Information ...

Page 190: ...Service Manual Service Manual Pump Models VX Series Q Pumps Field Testing Records 5 A 1 Documents for Testing at Initial Startup ...

Page 191: ...Service Manual Service Manual Pump Models VX Series Q Pumps 5 A 1 Documents for Testing at Initial Startup continued ...

Page 192: ...Service Manual Service Manual Pump Models VX Series Q Pumps 5 A 1 Documents for Testing at Initial Startup continued ...

Page 193: ...plify piping and or reduce length Reduce pump speed Decrease liquid temperature Check effect of increased viscosity on available and permitted power inputs X X X X Product vaporizing in supply line X X X X X Air entering supply line Remake pipe work X X X X Gas Supply Expel gas from supply line and pumping chamber to introduce liquid X X X X X Insufficient head above supply vessel outlet False pro...

Page 194: ...ion Simplify supply line Seal flushing inadequate Check that fluid flows freely into seal Increase flow rate X X X X Pump speed above rated figure Decrease pump speed Pump speed below rated figure Increase pump speed X X X X X X X Rotor case strained by pipe work Align pipes Add flexible pipes or expansion fittings X X X X Belt Drive Slipping Tighten belt to specified tension X Flexible coupling m...

Page 195: ...aw Noise Vibration Pump Element Water Excessive Seal Wear Seizure Causes Solution X X Metal to metal contact of pumping element Check rated and duty pressures X X Worn pumping element Install new components X X Relief valve leakage Adjust pressure setting Examine clean seating surfaces Install new components X X Relief valve chatter Check water sealing surfaces guides Install new components ...

Page 196: ...ent Coating None Material Mechanical Seal 1 Duronit Housing Segment Form Straight Material Mechanical Seal 2 None Direction of Flow Bi Directional Thrust Washer Material Mild Steel Rotary Lobe Material NBR Strain Bolt Material Galvanized Rotary Lobe Coating Pump Shaft Top Motor Shaft Long Rotary Lobe Form HiFlo Pump Shaft Bottom Motor Shaft Short Rotary Lobe of Wings 6 Pump Length 14 7 inch O Ring...

Page 197: ... 55 TEFC Speed at 90 Hz Gearbox Service Factor 2 70 Temp Rise Class B Motor Service Factor 1 15 Coupling Manufacturer TB Woods Coupling Flange Drive 6S1 Coupling Sleeve 6HS Coupling Flange Pump 6S28MM Flange Size 2 5 inch Right Flange Type Mild Steel Galvanized Straight Left Flange Part Number GPA 370 Right Flange Material Hot Dipped Galvanized Steel Left Flange Type Mild Steel Galvanized Straight...

Page 198: ... tolerances acc to ANSI Std 0 71 created with CAPSlogik Date 249 Base Plate US GBO 028 TV1 0025 Drive Type In Line Geared Motor Guard Type Coupling Guard Galvanized Total Weight W 20 63 inch required 32 44 inch recommended L 1 L 3 L H L 2 Raised Face Flange Data Inches VX100 45Q Cloacina LLC 8441202 1 Vogelsang Data Pump Type Sales Order No Straight Customer Quote ID Position No Connector left L C...

Page 199: ... Power in HP Flowrate in GPM Speed in RPM Flowrate Speed at Constant Pressure VX100 45Q Theorethical Flowrate New Pump Pump with Gap Operating Points Water Curve Operating Power Permeate 22 PSI Differential Pressure Project Quote No NPSH R 40 GPM UF Membrane 6 82 ft 8441202 Viscosity not Provided Medium ...

Page 200: ...xpressed limited warranty and remedy are exclusive of all other warranties and remedies including but not limited to all implied warranties of merchantability or fitness for particular purpose and all other remedies and damages for breach of such warranties are specifically excluded The warranties of Vogelsang do not cover and Vogelsang makes NO Warranty with respect to A Materials of construction...

Page 201: ...epted Vogelsang USA LLC reserves the right to make deliveries in installments and contracts shall be severable as to such installments A delay in delivery or default of any installment shall not relieve Buyer of its obligation to accept and pay for remaining deliveries Claims for shipment shortage or damage shall be deemed waived unless presented to Vogelsang USA LLC in writing within ten 10 days ...

Page 202: ...triment of Vogelsang USA LLC and Comtech EF Data Corp shall have no liability to Buyer or any third parties arising out of or relating to Vogelsang USA LLC rendering technical advice facilities or service in connection with such assistance CONTROLLING LAW This document shall be governed by the internal laws of Ohio as applied to contracts entered into and performed within Ohio by residents of Ohio...

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