VARISCO M Series Specification sheet

Varisco S.p.A.
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INSTRUCTIONS FOR THE USE AND
MAINTENANCE OF VARISCO “M”
SERIES PROGRESSING CAVITY PUMPS
SUMMARY
1 PREMISE 3
1.1 CE MARKING 3
1.2 NOISE 3
1.3 SAFETY WARNINGS 3
1.4 PERSONNEL QUALIFICATION AND TRAINING 3
1.5 TRANSPORT 3
1.6 STARTUP, USE AND MAINTENANCE 3
1.7 REPAIRING 4
1.8 RISKS IN THE EVENT OF NON-COMPLIANCE WITH SAFETY WARNINGS 4
1.9 SAFE WORKING 4
1.10 WARNINGS CONCERNING THE SAFETY OF THE OPERATOR/USER 4
1.11 WARNINGS CONCERNING SAFETY DURING MAINTENANCE, INSPECTION AND ASSEMBLY 4
1.12 TRANSFORMATION AND ARBITRARY PRODUCTION OF SPARE PARTS 4
1.13 PROPER USE 4
1.14 SPECIFIC WARNINGS FOR PROGRESSING CAVITY PUMPS 5
2 FUNCTIONING 5
3 BRIEF DESCRIPTION OF THE PRODUCT 6
3.1 MAIN TECHNOLOGICAL FEATURES OF PROGRESSING CAVITY PUMPS 6
3.2 CLASSIFICATION 6
3.3 MOTORS 6
3.4 AVAILABLE CONFIGURATIONS 7
4 COMPONENTS OF THE PRODUCT 7
4.1 ROTOR 7
4.2 STATOR 7
4.3 COUPLINGS 7
4.3.1 BEARING HOUSING COUPLING 7
4.3.2 CLOSED COUPLING 8
4.4 CONNECTING ROD JOINTS 8
4.5 SEALING SYSTEMS 8
4.6 ACCESSORIES 8
4.6.1 DRY-RUN PROTECTION 8
4.6.2 PROTECTION AGAINST DELIVERY OVERPRESSURE 9
4.6.3 RETURN VALVE IN DELIVERY 9
4.6.4 ELECTRIC BOARD 9
5 PACKING, TRANSPORT, STORAGE 9
5.1 PACKING AND TRANSPORT 9
5.2 STORAGE 10
6 ELECTRIC CONNECTION – PIPELINE CONNECTION 10
6.1 INSTALLATION OF MOTOR 10
6.1.1 ELECTRIC CONNECTION 10
6.1.2 PUMP-MOTOR COUPLING 10
6.1.2.1 CLOSE COUPLED VERSION 10
6.1.2.2 BEARING HOUSING VERSION (WITH ELASTIC JOINT) 11
6.1.3 DIRECTION OF ROTATION 11
6.2 PIPE ASSEMBLY 12
6.2.1 IMPORTANT PREMISE 12
6.2.2 MAX ALLOWED PRESSURE 12
6.2.3 USEFUL ADVICE 12

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7 STARTUP 13
7.1 ADVICE FOR OPTIMAL OPERATION 13
7.2 PUMPS FOR FOOD 13
7.2.1 WHEN TO PERFORM CLEANING 13
7.2.2 CIP CYCLE 14
7.3 TEMPORARY REST 14
7.3.1 PROCEDURES 14
7.3.1.1 STATOR 14
7.3.1.2 ROTOR 14
8 MAINTENANCE 14
8.1 SUPERFICIAL CLEANING 14
8.2 STATORS AND SEALING SYSTEMS 15
8.2.1 STATORS 15
8.2.2 SEALS 15
8.2.2.1 PACKING SEALS 15
8.2.2.2 SINGLE MECHANICAL SEAL 15
8.2.2.3 MECHANICAL SEALS FOR VERTICAL PUMPS 15
8.3 CONTROL AND REPLACEMENT OF ARTICULATED JOINTS 15
8.4 LUBRICATION 16
8.4.1 IN GENERAL 16
8.4.2 BEARINGS 16
8.4.3 PROPELLER SHAFT JOINTS 16
8.4.4 MOTOR VARIATOR 16
8.5 MALFUNCTIONING 16
9 DISASSEMBLY AND ASSEMBLY OF COMPONENTS 17
9.1 DISASSEMBLY OF ROTOR-STATOR 17
9.1.1 CERAMIC ROTOR 18
9.2 ROTOR-STATOR RE-ASSEMBLY 18
9.3 ROTOR/JOINT DISASSEMBLY AND JOINT REPLACEMENT 19
9.3.1 PRELIMINARY MEASURES 19
9.3.2 JOINT TYPE SN1 19
9.3.3 JOINT TYPE SN2 19
9.3.4 JOINT TYPE SN3 20
9.3.5 JOINT TYPE SN4 20
9.3.6 JOINT TYPE SN5 21
9.3.7 JOINT TYPE SN6 21
9.3.8 JOINT TYPE SN7 21
9.3.9 JOINT TYPE SN8 22
9.3.10 JOINT TYPE SN9 22
9.4 REPLACEMENT OF SEALS 23
9.4.1 PACKING SEAL 23
9.4.2 MECHANIC SEAL REPLACEMENT 24
9.4.2.1 SMALL-SIZED PUMPS (MOD. 010 – 015 – 020 – 022) 24
9.4.2.2 MEDIUM AND LARGE SIZED PUMPS 24
9.4.2.2.1.1 DISASSEMBLY 24
9.4.2.2.1.2 RE-ASSEMBLY 25
9.4.2.2.1.3 DISASSEMBLY 25
9.4.2.2.1.4 RE-ASSEMBLY 26
9.5 MOTORS 26
9.5.1 USEFUL INFORMATION 26
9.5.1.1 TYPE OF SERVICE (SEC. IEC 34-1) 26
9.5.1.2 WORKING CONDITIONS 26
9.5.2 MOTORS CONNECTION 27

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1 PREMISE
This Functioning and Maintenance Manual (hereinafter named “Manual”) was written according to
par. 1.7.4 of the E.C.C. Directive 891391/ C.E.E., par. 1.7.4 of D.P.R. 459 of 24 July 1996
considering the normal operating conditions of the machine, with the purpose to inform, as set out
in the instructions attached to the machine itself, the operators/users on the risks deriving from its
use.
Note: the Manual is an integral part of the machine, must be carefully read before any operation is
carried out and is to be kept for future reference.
1.1 CE MARKING
The CE marking has been applied according to the Directive of the Board 93/68/CEE (GUCE L 220
of 30/08/1993), and to the annex. III of Directive 89/392 (GUCE L 183 of 23/06/1989) and to any
later modifications of it.
The documentation meant as technical file in compliance with the CE statement of conformance for
this machine was drawn up according to the provisions set out in the Annex. V of ECC Directive
89/392 and its modifications, as well as in full complance with D.P.R. 459 of 24 July 1996, which
takes in the above-mentioned EU Directive, and is kept by the Manufacturer.
1.2 NOISE
The noise made by the machine is: Leq=<80dB.
Based on the results assessed according to D.L.vo 277/91 and the provisions of D.L. 459/96, a list
of obligations to be fulfilled by employers, executives and operators must be drawn up according to
the degree of exposure to the noise by the workers.
The noise made by the machine is within range 1, wherein the noise risk is considered null.
1.3 SAFETY WARNINGS
These instructions contain basic warnings to be complied with during installation, operation and
maintenance. Therefore, these instructions must absolutely be read by the assembler, the technical
staff and by operators before assembly and startup, and must be kept available at any time on the
site where the machine or plant is used.
1.4 PERSONNEL QUALIFICATION AND TRAINING
The staff in charge of operation, maintenance, inspection and assembly must be qualified. The plant
manager must precisely set out any responsibilities, qualifications and control related to the
personnel. If the personnel is not adequately informed, it is to be trained and informed. This can be
made, if necessary, by the manufacturer/supplier on behalf of the machine user. Moreover, the user
must check that the contents of these instructions are fully understood by the personnel.
1.5 TRANSPORT
The customer must be aware of the use of lifting devices and harnessing techniques in compliance
with the relevant rules concerning accident prevention.
See par. 5.1 (Packing and transport).
1.6 STARTUP, USE AND MAINTENANCE
The customer must be aware of the features and working characteristics of the plant in which the
pump is to be fixed. Moreover, he must get information on the pump functioning in advance, be
informed of the safety warnings, startup and maintenance instructions.
The service staff shall be instructed on the use of the pump and related plant.

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1.7 REPAIRING
The customer shall gather in advance detailed information on the pump, as illustrated in the
repairing instructions.
The service staff shall be trained and repairing work shall be monitored.
1.8 RISKS IN THE EVENT OF NON-COMPLIANCE WITH SAFETY WARNINGS
Non-compliance with safety warnings may put people, the environment and the machine itself at
risk.
In particular, for instance, non-compliance may lead to:
• Failure to perform important functions by the machine/plant.
• Malfunctioning of the methods prescribed for maintenance and repairing.
• Risk vs. people due to electric, mechanical and chemical effects.
• Environmental risks due to leakage of harzardous substances.
1.9 SAFE WORKING
It is necessary to observe the safety warnings set out in these instructions, the national rules on
accident prevention and possible regulations concerning the work, service and safety of the
operator.
1.10 WARNINGS CONCERNING THE SAFETY OF THE OPERATOR/USER
• In the event that cold or hot parts of the machine may lead to risks, the customer must
provide protection against accidental contact (according to European regulation EN 563).
• The protection against accidental contact on the moving parts (e.g. joint) may not be
removed when the machine is working.
• Leakage of hazardous materials (e.g. from shaft seal) such as explosive, poisonous and
overheated materials, shall be disposed of without causing danger to both people and the
environment. Provisions of the law shall be compiled by.
1.11 WARNINGS CONCERNING SAFETY DURING MAINTENANCE, INSPECTION AND
ASSEMBLY
The customer shall make it sure that any maintenance, inspection and assembly operations are
carried out by authorized, specialized and qualified staff, and that said personnel must be adequately
informed by fully detailed service instructions.
The work on the machine shall be executed only when the machine is not working. The machine
shall not be under pressure and shall be cooled. The procedure for machine stop shall be absolutely
complied with.
Those pumps or units feeding hazardous materials shall be decontaminated.
After work is completed, every safety and protection devices shall be immediately refitted and
reactivated.
Before restarting, the provisions of the chapter Startup shall be compiled by.
1.12 TRANSFORMATION AND ARBITRARY PRODUCTION OF SPARE PARTS
Any transformation or modification of the machine is allowed only by prior agreement with the
manufacturer. Original spare parts and authorized accessories are required for safety. The use of
other parts releases any responsibility for related damages.
1.13 PROPER USE
The safety of the machine is guaranteed only when the use of the machine is carried out according
to the rules.

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This machine has been designed considering its nominal working performance. Any indication
concerning the nominal working performance is to be meant as a limit value, and shall not be
exceeded in any case.
1.14 SPECIFIC WARNINGS FOR PROGRESSING CAVITY PUMPS
Progressing cavity pumps must be used only according to their destination, i.e. in compliance with
the purpose which was meant for them when they were acquired.
Keep in mind that a progressing cavity pump is a positive displacement pump; hence it may
theoretically produce infinite pressure.
In the event of closed delivery pipe, due for instance to clogging or accidental closing of a valve,
the pump may generate a pressure several times greater than the maximum pressure allowed for the
plant. In this case pipes may burst, which is to be avoided in particular if hazardous fluids are
concerned.
The plant shall therefore be equipped with adequate safety devices, i.e. pressure switches, security
valves and by-pass.
During maintenance and repair on the pump make sure that:
• the motor must be shut-off!
• when dismantling the pump, the rules related to the discharge material handling must be
complied with (i.e., protecting apparel, smoking prohibition, etc.).
• before restarting, all protective devices, mechanical or other (e.g. chain cover or joint cover),
must be regularly refitted.
WARNING
During use, maintenance and repairing, keep in mind your safety and follow the general European
directives concerning machines then transformed into national laws, the European regulation EN
292, specific accident-prevention rules, instructions provided by the mining authorities and comply
with the technical standards concerned.
2 FUNCTIONING
A progressing cavity pump is a rotating volumetric pump. The main parts of the system are a rotary
part called ROTOR (see Abelow) and a fixed part called STATOR (see B).
The rotor is a round thread screw with a very large pitch, a deep thread and a small core diameter.
The stator is double-threaded and has a pitch which is double compared to the rotor, so that between
the stator and the rotor there are delivery chambers. These move continuously from the inlet side
towards the outlet when the rotor is spinning inside the stator.
In progressing cavity pumps the axis of rotation of the rotor A does not coincide with the axis of
rotation of the motor. The rotor is driven by a double-joint shaft. This shaft absorbs eccentric
motions and shifts axial stresses towards the motor shaft.
AB

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The fluid coming from the stator/rotor group is conveyed to the central body, and then ejected
through the outlet.
3 BRIEF DESCRIPTION OF THE PRODUCT
3.1 MAIN TECHNOLOGICAL FEATURES OF PROGRESSING CAVITY PUMPS
• Steady capacity, proportional to motor speed.
• Self-priming, with a min. suction of 4 mt, depending on the number of stages and rpm of the
pump.
• Pumping of non-homogeneus products, containing gas and abrasive or solid and fibrous
material in the fluid.
• Pumping of very high viscous liquids.
• Dosage of liquids.
• No inlet or delivery valves.
• Centrifugation-free pumping with low-tension stress in the pumped material.
• High pumping pressure (6 BAR for each stage). Pumps may have one up to four stages,
according to the pressure required:
(1) (4)
3.2 CLASSIFICATION
Progressing cavity pumps are divided into two main categories, according to the coupling between
pump and motor:
• Progressing cavity pumps WITH BEARING HOUSING.
• Progressing cavity pumps CLOSED COUPLED.
3.3 MOTORS
Motors can be of different kinds; the pump can be fitted to:
• Electric motors
• Hydraulic motors
• Gearmotors
• Torque converters
01 Outlet
02 Rotor
03 Stator
04 Connecting Rod
05 Hollow shaft
06 Pump body
07 Shaft seal
08 Bearing housing
09 Close coupled
10 Male shaft
11 Shaft joints

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3.4 AVAILABLE CONFIGURATIONS
Progressing cavity pumps can be assembled in different configurations, according to the needs:
• Feedbox and screw feeder
• Vibrating feedbox
• Barrel emptier
• Vertical
Note: customizations include specific inlet and delivery orifices, trailer-mounted base, simple base,
electric board, thermal protections etc.
4 COMPONENTS OF THE PRODUCT
4.1 ROTOR
The rotor may be made of different materials, such as carbon steel and stainless steel. It may also be
coated with hardening surface treatments such as chromium plating, ceramic treatment, gas and ion
nitriding, etc.
4.2 STATOR
The stator is built with a steel pipe internally coating with elastomeric material, chemically
compatible with the properties of the fluid to be pumped.
It may be made with different elastomers:
Class MST °C MATERIAL MAX TEMP Class Stator
T4 135 VITON 180°C T4 VITON
T5 100 EPDM 120°C T5 EPDM
T6 85 NBR 90°C T6 NBR - SBR
SBR 90°C
CSM 70°C
MST: Maximum surface temperature allowed for machines of Group II (Cenelec standard EN
50014).
Note: It is possible to manufacture PTFE stators for special applications.
4.3 COUPLINGS
4.3.1 BEARING HOUSING COUPLING
Using the bearing housing coupling the pump is linked to the motor by the male shaft, and it is
mounted on a cast iron support through rolling bearings.
This configuration allows optimal resistance to the axial thrust towards the motor in those models
working under high pressure. The choice of the motor in this case is not affected by axial thrust.
The final coupling between motor and male shaft is made by elastic joints with a protective case.

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4.3.2 CLOSED COUPLING
Closed coupling mounting does not take into account the use of a male shaft, therefore the hollow
shaft of the pump is linked directly to the motor male shaft. In this case, it is necessary to use
motors (or motoreducer in the case) capable of standing axial stresses coming from counter-
pressure reactions during pumping.
Note: It is possible, for a special series of feedbox pumps, to link the propeller shaft directly to an
angular worm screw gearmotor, without any support.
4.4 CONNECTING ROD JOINTS
Depending on the type of pump, the connecting rod can use different types of joints (see par. 9.3):
• Type SN1: Pin joint with elastomeric sleeve for smaller pumps.
• Type SN2: Universal joints with elastomeric sleeve and changeable bushing.
• Type SN3: Homokinetic joint with elastomeric sleeve.
• Type SN4: Pin joint with dual elastomeric sleeve and changeable bushing.
• Type SN5: Universal joint with elastomeric sleeve and changeable bushing for high power.
• Type SN6: Universal joint with elastomeric sleeve and changeable bushing.
• Type SN7: Open Pin joint for use with foods without sleeve.
• Type SN8: Pin joint with short bell and flat sleeve.
• Type SN9: Pin joint with short bell for high power.
4.5 SEALING SYSTEMS
The liquid sealing systems may change according to the type of fluid and to the technologic
conditions of pumping. The following types are available (see par. 9.4 and Service manual):
• Type TEN 01: Packing seal.
• Type TEN 02: Fluxed packing seal.
• Type TEN 03: Oil seal.
• Type TEN 04: Single mechanical seal.
• Type TEN 05: Double fluxed mechanical seal.
Note: Mechanical seals can be fluxed, or employ quench techniques.
On request, it is possible to manufacture mechanical seals complying with API 610 standards.
4.6 ACCESSORIES
All pumps may be equipped with accessories to improve their performance.
4.6.1 DRY-RUN PROTECTION
The protection against dry run prevents stator damage whenever the liquid is missing. A thermal
sensor is fitted to the stator, and linked to the electric board. If there is no fluid in the stator, the
stator rubber overheats and the increase in temperature activates the electric circuit, which stops the
motor. This device may be installed subsequently.

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4.6.2 PROTECTION AGAINST DELIVERY OVERPRESSURE
The overpressure protection consists of a security valve set to the desired pressure and a bypass pipe
which closes delivery or reduces the flow in case the pump may not be stopped.
4.6.3 RETURN VALVE IN DELIVERY
In case it is necessary to convey part of the product back to the tank in order to mix or make the
product more homogeneus, it is possible to fit a valve in the delivery.
4.6.4 ELECTRIC BOARD
Upon request, pumps can be controlled by an elecric board, consisting of a main switch, a pilot
light, a liter counter, two-position forward/backward selector and a reset emergency switch. The
boards are also equipped with a safety lock. All boards are supplied with the Statement of
Conformance required by the Law 46/90.
5 PACKING, TRANSPORT, STORAGE
5.1 PACKING AND TRANSPORT
Progressing cavity pumps are shipped in containers (boxes on pallets, cases or cages), unless the
customer requires something different.
The parcels are marked and supplied with handling instructions.
Upon receipt, check for possible damages.
Transport damages are to be reported immediately to the carrier.
Pumps are to be brought packed as near as possible to the installation site and kept packed as long
as possible.
Horizontal axis pumps, once unpacked, can be lifted exclusively with the base. Use external holes
and eyebolts on the base. (For dimensions, see drawing in the Service Manual).
Vertical axis pumps can be lifted using the holes in the support plate or eyebolts or in the bracket.
The motor is usually at the top end. (For dimensions, see drawing in the Service Manual).
WARNING: do not lift machines with weight on top (with center of gravity above the lifting
point). Make sure they do not capsize.
Vertical axis pumps must never rest in upright position without adequate fixing!
Warning: they may fall! Always arrange them horizontally. Absolutely do not lift the pump using
the motor or reduction gear eyebolts. They are meant for transport of motor or reduction gear
only.
Due to the diversification of configurations, these are to be considered as general instructions,
usually meant for skilled personnel in charge of transport and assembly.
If more detailed instructions were needed, instructions related to specific machine can be supplied.
For trailer-mounted pumps follow this:

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• Make sure that the motor is not running and that it cannot be accidentally started.
• Move the unit slowly and carefully, especially if over irregular ground.
Overturning hazard!
• Make sure that the position in the new resting location is steady; lock all stopping devices
on wheels/rolls, in order to avoid unwanted motion.
• Consider the reaction forces and the movements of flexible piping occuring during pump
working.
• Possibly fix the unit with additional wedges.
5.2 STORAGE
The pumps, unless otherwise agreed, are protected during transport.
In case of prolonged storage prior to the assembly:
• Stator: In case of prolonged stop, the rotor may permamently buckle the stator on the contact
surface (compression-set). This requires a greater pickup torque. Therefore, remove the
stator, pack it in order to shelter it from light and air, and store it in a cool, dry place.
• Rotor: Rest it on wooden blocks and cover it for protection against mechanical damage.
• Shaft packing: Remove the gland, and grease the shaft.
• Stainless steel parts: No protection needed.
• Other non-painted pump parts: Grease.
• Motors: see manufacturer’s instructions.
6 ELECTRIC CONNECTION – PIPELINE CONNECTION
6.1 INSTALLATION OF MOTOR
6.1.1 ELECTRIC CONNECTION
The work relating to electric connections shall be carried out by authorized and specialized
personnel, in compliance with local rules and directives issued by the authorities.
Control apparatus must comply with the latest edition of the Machine Directive EEC, Appendix 1,
Chap. 1.2 (Control apparatuses).
The power supply must be equipped with a thermal magnetic overload cutout, or a fuse, and a
compulsory earthing system, as mentioned above.
The electric wire shall be double-insulated and fire-retardant and with an adequate cross-section for
every phase. It is necessary to properly ground the circuit, and, in compliance with the law and the
rules of good technique, it is forbidden to connect the Neutral with the Ground.
Before starting the pump, check:
• tension, frequency and number of phases conform with the electric motor
• motor connections (star/triangle) conform with the alimentation available.
• wire section conform with the amperage concerned.
6.1.2 PUMP-MOTOR COUPLING
6.1.2.1 CLOSE COUPLED VERSION
The coupling of a progressing cavity pump with its motor is not difficult, though problems may
arise since the mechanical seal (or packing) is installed on the hollow shaft which, if not coupled to
the motor/converter, can easily break the seal.

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Therefore, during assembly, it is necessary to be careful not to move excessively the axis of the
hollow shaft. Oil the male shaft of the motor/converter, place it so that its key is in line with the
corrispondant bore.
Engage the propeller shaft until the two flanges (the motor’s and the pump’s) were connect. Then
turn the motor/converter until the bolts holes of the flanges coincide. Let the pump shaft hit the
motor shaft and tighten the grub screw (line it up with the cavity set it up on the gearmotor shaft).
6.1.2.2 BEARING HOUSING VERSION
(WITH ELASTIC JOINT)
Insert the half-joints (or pulleys, if belt drive is employed) at the ends of the shaft without using a
hammer or other tools which may damage parts inside the support. For assembly, use the threaded
hole on the end of the shaft.
The accurate alignment of motor and the male shaft of the pump is an essential condition for a
proper operation.
If the pump is delivered completed, the alignment has already been carried out at the factory.
Nonetheless, it is possible that during the positioning on the floor a misalignment may occur,
therefore it is necessary to remove the joint cover and check its alignment by means of a ruler
before startup. If the foundation is not properly leveled, the base may buckle. The tolerances usually
allowed in joints used by the company are:
• Allowed radial variation = 1%
• Allowed angular variation = 1°
6.1.3 DIRECTION OF ROTATION
The direction of pump rotation is shown on the label pump and described on the order
confirmation.
The direction of pump rotation sets the direction of the flow through the progressing cavity pump.
Any different setup must be agreed with the supplier and approved by the same.
By changing the direction of pump rotation, the product flow reverses.
If the pump turns clockwise, seen from the motor side, it intakes from the orifice at the end and
delivers from the middle one; if the pump turns counterclockwise it intakes from the middle orifice
and delivers from the one at the end (see below).
Usually, the pump can work in both directions, be it mounted with packing or with a mechanical
seal (unless it uses omokinetic joints which allow just one direction).
It is advisable, though, to use the pump turning counterclockwise to prevent that the packing rings
(or the mechanical seal) or other parts were subject to high pressure that could be difficult to
monitor.
The pumps with a mechanical seal, though reversing, shall always turn in the direction indicated on
the pump label.
This direction of rotation shall be preset upon the order while the seal assembled shall be preset at
the factory.

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Contact Varisco if you need to change the direction of rotation for pumps that use mechanical seal.
IMPORTANT:
In close coupled versions, it is necessary to check periodically that the shaft grub screw were well
tightened and fits properly in the propeller shaft cavity, especially if the pump is employed in both
directions. To this purpose, see par. 6.1.2.1 of this Manual.
6.2 PIPE ASSEMBLY
6.2.1 IMPORTANT PREMISE
• Intake and outlet diameters must be adequate, according to viscosity and delivery involved.
• Accurately clean the pipes before connecting them to the pump.
• Pipes must be connected to the pump so that no external force may be applied to the pump
itself.
• Fit adequate compensators between pump and pipes to protect the pump from vibrations
which may damage the pump body.
• Intake and outlet pipes shall be fitted so that, the pump is not working, there is some fluid
upstream and downstream, in order to ensure that there is always enough fluid in the pump
to provide lubrication at startup.
• Minimize the air intake in the body pump.
Note: In case fluxed packing glands or fluxed mechanical seals or quenches were used, the feeding
system connections and system tuning must to be carried out prior to the first startup.
6.2.2 MAX ALLOWED PRESSURE
Unless otherwise set out in the order confirmation, it is understood that the maximum pressure
inside the pump body (i.e. with pump turning clockwise) is 6 bar per stage. The maximum
allowed pressure at delivery is related its features:
• flange: not exceeding nominal pressure (i.e. PN 16)
• female thread: not exceeding 25 bar
• sanitary male thread according to DIN 11851, up to DN 100:
single and double stage pumps: not exceeding 12 bar
multiple stage pumps: not exceeding 25 bar
Other configurations: In any case not exceeding 6 bar per stage of the stator being used.
6.2.3 USEFUL ADVICE
It is advisable to fit to the pipe union a stub pipe of L length. This will allow the replacement of the
stator without the need of disassembling the pump. The L value is shown in the table below,
according to the size of the pump and the number of stages:

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7 STARTUP
IMPORTANT
• Never operate the pump when dry - this is mandatory, otherwise the stator, made of
elastomeric material will overheat and may burn. A few seconds are enough to cause
damage to the stator.
• The eccentric screw pump is of the positive displacement type; therefore it shall NEVER
be operated with a closed delivery valve. Since the theoretical pressure is infinite, this
would cause excessive stress with partial or total damage to the pump or piping.
• Before startup, check that the direction of rotation were correct.
7.1 ADVICE FOR OPTIMAL OPERATION
To achieve long life and high performance, it is useful to follow these recommendations:
• The pump is self-priming, but it is advisable to fill its body with the liquid to be pumped
before the first startup.
• Control the rate of delivery by modifying the rpm of the motor instead of setting choking
valves.
• Install an immediate stop device in case of absence of liquid at intake, by means of a
temperature sensor on the stator, to stop the pump after a few seconds of dry operation.
7.2 PUMPS FOR FOOD
The startup of pumps to be used with food requires the plant to be perfectly clean. Cleaning may be
performed in two ways:
• Disassemble the pump and wash every part of it with suitable detergent. Re-assemble the
parts making sure they stay clean.
• Perform Cleaning in Place (CIP) if the pump is suitable for this kind of cleaning.
7.2.1 WHEN TO PERFORM CLEANING
• Before startup
• After a prolonged stop
• After replacing parts
• After use if a prolonged stop is foreseen
LENGTH L
PUMP 1 STAGE 2 STAGE 3 STAGE 4 STAGE
010 - 80 - -
015 80 160 - -
020 110 170 - 360
030 160 300 - -
040 200 420 - -
050 260 - 530 -
053 - - - 530
055 270 550 - 980
060 440 - - 1230
062 320 630 - -
080 440 880 - -
120 500 - - -
200 540 - - -
300 540 1050 - 2110
400 660 1260 - -
500 820 1580 - -

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Several companies supply products for CIP cleaning. Make sure the products used are compatible
with the material to be pumped.
7.2.2 CIP CYCLE
• Pre-washing with clean water, to empty the pump
• Basic washing with caustic soda (1-2% at 60-80°C for 10-20 min.)
• Intermediate washing with clean water for 5-10 min.
• Washing with nitric acid (1-1.5%) at 50-70° C for 5-10 min.
• Final washing with clean water for 5-10 min.
Note: The washing speed of liquid detergents should not exceed 2 m/s at any point.
In this cycle the stator is subject to high chemical and thermal stress. Therefore, in this CIP cycle
the pump shall stop and restart, that is, change the relative position of rotor and stator every 2-3
minutes, turning just a few times to make sure that every part of the stator gets cleaned.
7.3 TEMPORARY REST
After stopping the pump, empty it and possibly wash it if:
• The fluid may solidify.
• The mechanical seal may get encrusted.
• The liquid inside the pump may freeze due to the low ambient temperature.
7.3.1 PROCEDURES
7.3.1.1 STATOR
In case of prolonged stop, the rotor may permanently deform the stator on the contact surfaces
(compression-set). In this case a greater pickup torque is required at restart.
It is therefore better to dismount the stator from the pump, pack it to shelter it from air and light and
store it in a cool, dry place.
7.3.1.2 ROTOR
After the stator has been disassambled, rest the rotor on wooden blocks and cover it to prevent
damage.
Before reassembly, degrease and clean the rotor to prevent conflicts with the stator material or with
the product to be pumped.
8 MAINTENANCE
IMPORTANT: All maintenance and cleaning operations must be performed with the
machine at a standstill and cut out from any energy source.
After a stop and before restarting, the machine must be inspected to determine the cause of the stop
command, and act with appropriate measures in order to prevent that from happening again.
The inherent vibrations of a progressing cavity pump are below 2.5 m/sec², therefore they hardly
cause risk or trigger possible failures. The vibrations, though, may lead to the loosening of the
screws of the pump. It is therefore essential to regularly check the tightening of them.
8.1 SUPERFICIAL CLEANING
It is important to schedule regular cleaning operations, depending on the liquid to be pumped. The
pump may be cleaned:

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• Through the cleaning windows if present on the pump body.
• Manually, disassembling the pump
• Automatically (CIP) for pumps with suitable connectors.
8.2 STATORS AND SEALING SYSTEMS
8.2.1 STATORS
Approx. every 900 hours of operation, it is necessary to check the wear, especially for the stator and
the sealing system (packing or mechanical seal).
The frequency of control operations will be determined according to the wear of both of them, not
exceeding anyway 1500 working hours.
8.2.2 SEALS
8.2.2.1 PACKING SEALS
Packing seals limit the leakage of product, but do not prevent it entirely. A small leakage is
necessary to prevent excessive friction and subsequent possible overheating.
At startup, after replacement, tighten the gland bush lightly until it is set and in ideal working
conditions (for 10-15 min.), then tighten it more strongly to obtain the smallest possible leakage.
FUNCTIONING ERRORS AND THEIR CONSEQUENCES
In case the pack were excessively compressed, the following damages may arise:
• Dry working
• Burnt pack
• Scored shaft (with subsequent leakage of fluid).
NOTE: The packing seal is in optimal working condition if constantly damped by the product to be
pumped.
8.2.2.2 SINGLE MECHANICAL SEAL
The type and brand of the mechanical seal used is specified in the order confirmation. In case of
significant leakage, check the surfaces of the seal faces and seat. Replace them if necessary.
8.2.2.3 MECHANICAL SEALS FOR VERTICAL PUMPS
Use particular caution on vertical pumps with motor on top (type SV/VM).
At startup, the mechanical seal has not yet been in contact with the fluid and briefly works dry until
the air in the pump body has been expelled.
At first startup or after a prolonged stop, lubricate the mechanical seal before starting the pump.
Lubricate with water, glycerine or oil, depending on the product to be pumped: check for
compatibility with the elastomers of the mechanical seal.
8.3 CONTROL AND REPLACEMENT OF ARTICULATED JOINTS
The driveline joint is one of the most stressed parts of the pump, therefore needs regular and
adequate controls.
On any kind of joint, it is always necessary, though the pump may work normally, to immediately
replace damaged sleeves, even if the damage is slight.
Sleeves of any kind are to be kept in warm water for some minutes before replacement, in order to
soften them and ease the fitting to both ends of the joint and prevent damage on the elastomer they
are made of.

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8.4 LUBRICATION
8.4.1 IN GENERAL
The Nova Rotors progressing cavity pump is supplied with lubricant for about 3250 working hours.
In case of replacement of parts involving lubrication, it is advisable to re-lubricate. To this purpose,
see the table below:
Universal joints: VN 2461 C
Chrome steel joints (Universal joint and Pin joint): Agip SM2 - Esso Beacon Q2
AISI stainless steel joints (Universal joint and Pin joint): Agip SM2 - Esso Beacon Q2
Bearings: Agip MU3
Rubber stators for food: Agip vaseline 1718
Steel Universal Joints Molycote VN 2461 C
Chromed steel, universal joint and pin joint Agip SM2 - Esso Beacon Q2
Stainless steel, universal and pin joints Agip SM2 - Esso Beacon Q2
Bearings Agip MU3
Food grade stators Agip vaseline 1718
8.4.2 BEARINGS
The male shaft bearings are greased at NR. In case they were removed, their seat shall be filled with
grease according to the table above.
8.4.3 PROPELLER SHAFT JOINTS
Pin joints with sleeve are to be periodically lubricated.
Moreover, every time parts were replaced with original spare parts, their grease shall be replaced.
IMPORTANT: The pumps that uses sleeves over joints for food are supplied with food-compatible
grease.
8.4.4 MOTOR VARIATOR
See Service Manual
8.5 MALFUNCTIONING
Below you can find a synthetic table
Malfuntioning References:
A The pump does not work F The pump stops
B The pump does not intake G Faulty stator
C Wrong delivery H Faulty rotor
D Uneven flow I The seal leaks
E Noisy pump J Low delivery pressure
A B C D E F G H I J POSSIBLE CAUSE
1 X X New stator and rotor are stuck together
2 X X Faulty electrical contact
3 X X X X X Excessive delivery pressure
4 X X X X Unknown matter in the pump
5 X X X X X High temperature, the stator squeezed
6 X X X Stator of wrong material. Check the order
7 X X X X X Product granulometry too high.
8 X X X X X X X The product sediments when the pump is stopped

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9 X X X Air leakage at intake
10 X X X X Difficult intake
11 X X X X Air intake from seal or packing
12 X X X X Too Low speed
13 X X X X Wrong direction of rotation
14 X X X Available NPSH below required
15 X X X X X X The pump is working dry
16 X X X The stator is faulty – burned-over
17 X X X X X Spoilt stator. Check rubber
18 X X X X X Faulty rotor
19 X X X X Faulty connecting rod
20 X X The pump is not aligned to the elastic joint
21 X X Broken connecting rod
22 X X Spoilt bearings
23 X X X Too high speed
24 X X X X X Excessive viscosity
25 X X X X X X X The gland needs to be adjusted
26 X X X Inadequate sealing system
Reference for malfunctioning removal:
1) Fill the pump with suitable product, gliceryn or soap (DO NOT USE any kind of oil if an EPDM rubber stator is
used).
2) Check on the order for details concerning electric connections and compare.
3) Measure pressure with a manometer and compare that with the order.
4) Remove unknown material and replace damaged parts.
5) If the temperature can not be lowered, install a downsized rotor.
6) Check if the fluid corresponds to the order, change stator rubber.
7) Increase the liquid percentage. Install a grid at intake.
8) Clean the pump and repeat the operation after each single use.
9) Increase the level of liquid at intake to prevent air intake.
10) Check seals and carefully tighten the pipes unions.
11) Tighten or replace the gland. If a mechanical seal is used, carefully clean and replace it if necessary.
12) Increase rpm.
13) Modify electric connections.
14) Increase the pressure at the inlet lowering the pump position and lower the inlet fluid temperature.
15) Fill the pump, install a device preventing dry working.
16) Replace the stator.
17) Replace the stator, check if the fluid corresponds to the order and if necessary change stator rubber.
18) Replace the rotor and try to identify the cause, which may be abrasion, corrosion or cavitation.
19) Replace worn parts.
20) Re-align pump and elastic joint.
21) Replace broken part and re-align.
22) Replace bearings, lubricate and tight.
23) Lower rpm through variator.
24) Check viscosity and compare it with the order.
25) Check specific weight and compare it with the order.
26) Choose a different mechanical seal or packing.
Note: For any query, please contact Nova Rotors or our local agent.
9 DISASSEMBLY AND ASSEMBLY OF COMPONENTS
PREMISE
1. Comply with the safety measures set out in Chapter 2 of this Manual.
2. The pump and its piping shall be emptied and cooled.
9.1 DISASSEMBLY OF ROTOR-STATOR
1. Disconnect the pump from intake and delivery pipes.
2. Support the pump body (01) with wooden blocks (02) under the stator (03).

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3. Remove the screws holding outlet flange (04) and the housing (05) (bearing housing or close
coupled housing pumps) to the base (06).
4. Remove the oulet flange by taking off the nuts and their washers.
5. Loosen the nuts and screw out the tie rods (07).
6. Remove the second foot (08) if present.
7. Extract the stator from the rotor by slowly turning the stator and pulling in the direction of
the black arrow (see below) until they were completely free.
9.1.1 CERAMIC ROTOR
Ceramic rotors require particular care and no force of any kind. In particular, hammer strikes,
concussions and collisions are to be avoided.
When the stator is extracted out of a ceramic rotor, the latter must be held to prevent it from
toppling downwards and hitting the body edge (09), thus suffering damage.
The rotor shall not collide with the pump body under any circumstances. Struck parts become
critical, and could trigger early failures.
9.2 ROTOR-STATOR RE-ASSEMBLY
1. Before re-assembly, it is necessary to carefully clean visible and disassembled parts.
2. Insert the stator on the rotor, lubricating it with glycerine, vaseline or neutral silicon oil.
Assembly is carried out as described in Chap 9.1, with reversed order of operations.
3. The operation is completed by re-inserting the pump body, stator, tie rods and pipe union.
NOTE: Certain types of stators have at their end an integrated sealing profile.
In this case no O-Ring washers are needed (see picture Chap. 9.1.1), neither at the union side nor at
the pump body side. In any other case, they shall be replaced every time the parts are disassembled.
WARNING: Do not tighten the pump body threaded cap too strongly (11) (pic. Chap. 9.1.1), since
its cone-shaped thread could damage the pump body itself. The tightening torque is about 40-50
Nm. Do not over-tighten screws and tie rods. See table below:
Screw Dia M6 M8 M10 M12 M16 M20 M24 M30
Torque (Nm) 8 15 30 45 75 80 100 12

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WARNING When inserting the rotor into the stator, your fingers may get hurt.
9.3 ROTOR/JOINT DISASSEMBLY AND JOINT REPLACEMENT
WARNING When re-assembling joints with sleeves, sleeves shall be dipped into hot water in order
to soften them, thus easing their fitting in their cavities. To re-assemble them, follow the
disassembling instructions backwards.
9.3.1 PRELIMINARY MEASURES
1. To remove the stator, follow instructions in Chap. 9.1.
2. Extract the pump body in the direction of the black arrow (see below). Then the drive joint
connected to the rotor will be visible.
3. Follow the instructions given in this paragraph for each type of joint.
9.3.2 JOINT TYPE SN1
1. Move the sleeve backwards (1), following the direction of the arrow.
2. Remove the Pin (2). The rotor or hollow shaft drive then will be free.
SN1
This kind of joint has no spare parts available. In case of malfunctioning it shall be fully replaced.
9.3.3 JOINT TYPE SN2
1. Remove the clamps (3).
2. Remove the sleeve (4) by levering with a screwdriver.
3. Remove the 2 retaining rings (5) that holds the pin. Then, after removing the pin and the
spider, the rotor will be free and it will be possible to replace it.
SN2

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9.3.4 JOINT TYPE SN3
1. Remove the screws (6) that hold the joint to the rotor.
2. Extract the propeller shaft (6b) in the direction of the black arrow.
SN3
If the pump is equipped with this kind of joint, intake of fluid from the outlet is not possible (only
counterclockwise rotation is allowed).
This kind of joint has no spare parts available. In case of malfunctioning it shall be fully replaced.
9.3.5 JOINT TYPE SN4
This type of joint shall be almost completely disassembled to be removed from the rotor.
Follow these steps:
1. Remove the two clamps (08) that hold the sleeve.
2. Force the rubber sleeve backwards (09) in the direction of the black arrow.
3. Remove the internal flat sleeve (10) by operating on the larger part, then move it in the
direction of the black arrow.
4. Remove the grub screw (11).
5. Move the metallic cover (12) backwards in the direction of the arrow. The bushes and pin
(13) will be visible.
6. Beat the pin with care, taking care not to damage the bell (14). Then, if necessary, the pin
and the bushes can be replaced.
7. Pull the sphere in the direction of the black arrow. Since it is integral with the propeller shaft
(15), they’ll both be free of the joint. Then, the hexagonal-head screws that hold the bell to
the rotor (or hollow shaft depending on the joint involved) will be visible.
8. Unscrew the screws (7). The bell will be completely free of the rotor (or hollow shaft, as
mentioned above).
SN4
IMPORTANT: Bushes increase the life of the system but are integral with the pin, hence when the
pin is replaced, they shall always be replaced as well.