Dover EnviroGear S1-24-DI User manual

ENVIROGEAR PUMP COMPANY 2ENV-10000-E-02
TABLE OF CONTENTS
SECTION 1 CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 TECHNICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 INSTALLATION & STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 REPAIR PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 5 PUMP ADJUSTMENTS AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 6 PUMP DISASSEMBLY & REPAIR PROCESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 7 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 8 HOW TO RETURN PUMP TO FACTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SECTION 9 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

ENV-10000-E-02 3ENVIROGEAR PUMP COMPANY
SECTION 1
CAUTIONS
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 before 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 lbs (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:
CAUTION: Carbon-graphite bushings are very
brittle, so they must be handled and assembled
using great care.
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.
• Crane, hoist or other suitable lifting device
capable of generating at least 400 lbs
(182 kg), and
• 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 lbs (182 kg), and is strong enough
to resist a lifting force of up to 400 lbs (182
kg). Pump Disassembly Tool F-00096 or
F-00097.
• Always use an arbor during assembly to
guide and align the bushings.
• When pressing bushings, use a light
lubricant.
• When pressing bushings, always use a
smooth, continuous motion – stopping with
the bushing partially exposed can crack the
bushing.
• After assembly, always inspect the bushings
closely for cracks.

ENVIROGEAR PUMP COMPANY 4ENV-10000-E-02

ENV-10000-E-02 5ENVIROGEAR PUMP COMPANY
SECTION 2
TECHNICAL INFORMATION
Models Available
(lb) (kg)
S1-24-DI 2" NPT 24.3 780 75 152 69
S1-32-DI 2" NPT 32.6 780 100 152 69
S1-55-DI 3" ANSI 150# RF 54.9 640 135 307 139
S1-69-DI 3" ANSI 150# RF 68.7 640 170 307 139
S1-82-DI 3" ANSI 150# RF 82.4 640 200 307 139
Nomimal
Flowrate
(usgpm at
max s
p
eed
)
Pump Weight
Ductile Iron
Model Std Port Size
Capacity
(cu. inches
per revolution)
Max Pump
Speed (rpm)
Max Differential Pressure = 200 psi (13.8 bar)
Figure 2.1 – ductile iron models
(lb) (kg)
S1-2-CS 1 1/2" NPT 2.19 1800 15 53 24
S1-4-CS 1 1/2" NPT 4.34 1800 30 53 24
S1-24-CS 2" NPT 24.3 780 75 152 69
S1-32-CS 2" NPT 32.6 780 100 152 69
S1-55-CS 3" ANSI 150# RF 54.9 640 135 307 139
S1-69-CS 3" ANSI 150# RF 68.7 640 170 307 139
S1-82-CS 3" ANSI 150# RF 82.4 640 200 307 139
Nomimal
Flowrate
(usgpm at
max s
p
eed
)
Pump WeightCarbon Steel
Model Std Port Size
Capacity
(cu. inches
per revolution)
Max Pump
Speed (rpm)
Max Differential Pressure = 200 psi (13.8 bar)
Figure 2.2 – carbon steel models
(lb) (kg)
S1-2-SS 1 1/2" ANSI 150# RF 2.19 1200 10 53 24
S1-4-SS 1 1/2" ANSI 150# RF 4.34 1200 20 53 24
S1-24-SS 2" ANSI 150# RF 24.3 640 55 152 69
S1-32-SS 2" ANSI 150# RF 32.6 640 80 152 69
S1-55-SS 3" ANSI 150# RF 54.9 520 110 307 139
S1-69-SS 3" ANSI 150# RF 68.7 520 140 307 139
S1-82-SS 3" ANSI 150# RF 82.4 520 160 307 139
Nomimal
Flowrate
(usgpm at
max s
p
eed
)
Pump WeightStainless
Steel Model Std Port Size
Capacity
(cu. inches
per revolution)
Max Pump
Speed (rpm)
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.

ENVIROGEAR PUMP COMPANY 6ENV-10000-E-02
TECHNICAL INFORMATION
Temperature Ratings
O-Rings Temperature Ratings
-50 0 50 100 150 200 250 300 350 400 450 500 550
Kalrez®
FEP-encapsulated
Viton®
Viton®
fluid temperature (°F)
Figure 2.4 – o-rings temperature ratings
Magnets Temperature Ratings
-50 0 50 100 150 200 250 300 350 400 450 500 550
M6H , M7H
(Samarium-Cobalt)
M6M, M7M
(S-C inner mags,
N-I-B outer mags)
M6, M7
(Neodymium-Iron-Boron)
fluid temperature (°F)
Figure 2.5 – magnets temperature ratings
Internal Clearances Temperature Ratings
-50 0 50 100 150 200 250 300 350 400 450 500 550
high-temperature
standard
fluid temperature (°F)
Figure 2.6 – internal clearances temperature ratings

ENV-10000-E-02 7ENVIROGEAR PUMP COMPANY
TECHNICAL INFORMATION
Magnetic Coupling Strengths

ENVIROGEAR PUMP COMPANY 8ENV-10000-E-02
TECHNICAL INFORMATION
Relief Valve Performance

ENV-10000-E-02 9ENVIROGEAR PUMP 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
h
Note: Consult factory at low differential pressures to ensure proper cooling path circulation.
as three functions:
1. cool the inner magnets,
2. keep fluid in the magnet area from becoming stagnant,
3. lubricate and cool the rotor and idler bushings.
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. The casing block-off plug is solid (no hole). It belongs 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.
Casing orifice
plug ( wi th hole )
SUCTION
SUCTION
DISCHARGE
DISCHARGE
Casing block-off
plug (no hole)
Head block-off
plug ( no ho le)
This hole
left open
Figure 2.12 – special cooling circuit plugs in correct positions
Internal Cooling Circuit

ENVIROGEAR PUMP COMPANY 10 ENV-10000-E-02
SECTION 3
INSTALLATION & 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.

ENV-10000-E-02 11 ENVIROGEAR PUMP COMPANY
INSTALLATION & STARTUP
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:
xthe pipe or other discharge line components bursts,
xthe drive stalls,
xthe pump’s inner and outer magnets decouple,
xa 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:
xexternal relief valve,
xrupture disc,
xpressure regulator,
xpressure 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.
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
Rotation and Port Orientation
Pressure Relief
To change the orientation, see Chapter 5.

ENVIROGEAR PUMP COMPANY 12 ENV-10000-E-02
INSTALLATION & STARTUP

ENV-10000-E-02 13 ENVIROGEAR PUMP COMPANY
INSTALLATION & 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:
xMounting and grouting of the foundation.
xAssembly 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.
xBearing 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).
xPumping 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).
Figure 3.3 – optional sensor locations Figure 3.4 – optional sensor locations
Location for
Canister
Temperature
Sensor
Location for
Bearing
Vibration
Sensor
Location for
Pumping
Chamber
Vibration
Sensor

ENVIROGEAR PUMP COMPANY 14 ENV-10000-E-02
INSTALLATION & STARTUP
Now the pump is ready to be started.
Startup

ENV-10000-E-02 15 ENVIROGEAR PUMP COMPANY
SECTION 4
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.
Repair Parts

ENVIROGEAR PUMP COMPANY 16 ENV-10000-E-02
REPAIR PARTS
Part ID # Qty. Part Name
11Head
21Casing
3 1 Spindle
4 1 O-Ring for Canister*
5 1 O-Ring for Head*
6 1 Canister
7 1 Support Plate
81Key
9 4 Bolts for Head
10 4 Bolts for Outer Drive
11 1 Orifice Plug
12 1 Plug for Casing
13 2 Plugs for Vent/Drain
14 1 Plug for Head
100 1 Outer Drive Assembly
200 1 Rotor Assembly
300 1 Idler Assembly
400 1 Relief Valve Assembly
*Recommened spares.
400
300
200
1
2
3
4
5
6
7
8
9
10
11
12
13
14
100

ENV-10000-E-02 17 ENVIROGEAR PUMP COMPANY
REPAIR PARTS
101
102
103
104**
105
106
108
105
201
202
204
205
206
207
208208
203**
*Recommened spares.
**Magnet quantities may vary depending on
pump configuration.
Part ID # Qty. Part Name
101 1 Magnet Housing
102 1 Outer Ring
103 1 Shaft
104 ** Magnet Segment
105 2 Ball Bearing
106 1 Wave Spring
107 - Adhesive (not shown)
108 1 Retaining Ring
201 1 Rotor
202 1 Inner Ring
203 ** Magnet Segment
204 1 Sleeve
205 1 O-Ring for back of sleeve
206 1 O-Ring for front of sleeve
207* 1 Thrust Bushing
208* 2 Radial Rotor Bushing

ENVIROGEAR PUMP COMPANY 18 ENV-10000-E-02
REPAIR PARTS
501
502
503
504505
601
602
603
401
402
403
404
405
Part ID # Qty. Part Name
301 1 Idler
302 1 Idler Busing*
401 1 Valve Body
402 1 Poppet
403 2 Spring
404 1 O-Ring for Valve*
405 4 Screws for Valve
501 1 Jacket for Casing
502 1 Jacket for Valve
503 1 Jacket Brackets
504 4 Screws
505 2 Screws
506 - Thermal Cement (not shown)
601 1 Jacket for Head
602 1 O-Ring for Jacket*
603 4 Screw for Jacket
*Recommened spares.
301
302

ENV-10000-E-02 19 ENVIROGEAR PUMP COMPANY
SECTION 5
PUMP ADJUSTMENTS AND MAINTENANCE
How To Change Port Orientation Only
(Shaft Rotation Unchanged)

ENVIROGEAR PUMP COMPANY 20 ENV-10000-E-02
PUMP ADJUSTMENTS AND MAINTENANCE
How To Change Port Orientation And Shaft Rotation