KRAL K Series Operating Instructions Manual
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Summary of Contents for KRAL K Series
- Page 1 Operating instructions KRAL screw pumps. Series K Magnetic coupling Observe safety instructions for persons with cardiac pacemaker, metallic implant or neurostimulator. OIK 09en-GB Edition 2019-11 Original instructions www.kral.at...
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Page 2: Table Of Contents
Table of contents 1 About this document ............. 4 10.2 Commissioning ............ 20 10.2.1 Cleaning the pipe system ........ 20 General information ............ 4 10.2.2 Filling and venting the pump...... 21 Associated documents .......... 4 10.2.3 Checking the direction of rotation .... 22 Target groups .............. 4 10.2.4 Commissioning the pump ........ 23 Symbols................. 4 10.3 During operation ............ 24... - Page 3 Table of contents 16.2.4 Maintenance kit magnetic coupling KF/ KV 2200 – 2900 .......... 48 16.2.5 Maintenance kit magnetic coupling KFN/KFT/ KVT .............. 49 16.3 Repair kits.............. 50 16.3.1 Repair kit overflow valve KF/KH/KV 5 – 660 and KFT/KVT/KFN/KFA ......... 50 16.3.2 Repair kit overflow valve KF/KH/KV 851 – 1301 ................ 51 16.3.3 Repair kit overflow valve KF/KH/KV 1500 – 1700 ................ 52 16.3.4 Repair kit overflow valve KF/KH/KV 2200 – 2900 ................ 53...
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Page 4: About This Document
1 About this document 1.1 General information 1 About this document 1.1 General information These instructions form part of the product and must be kept for future reference. Furthermore please observe the associated documents. 1.2 Associated documents o Declaration of conformity according to EU Directive 2006/42/EC o Manufacturer's declaration according to EU Directive 2014/68/EU o Data sheet of the pump o Technical documentation of the supplied components... -
Page 5: Danger Signs
2 Safety 2.1 Proper use 1.4.2 Danger signs Meaning Source and possible consequences of non-observance Electrical voltage Electrical voltage causes serious physical injury or death. Magnetic field Magnetic field can cause serious physical injury or death. Raised load Falling objects can result in serious physical injury or death. Heavy load Heavy loads can result in serious back problems. -
Page 6: Foreseeable Misuse
2 Safety 2.2 Foreseeable misuse 2.2 Foreseeable misuse o Any use that extends beyond the proper use or any other use is misuse. o The product is not suitable for pumping liquids outside the operational limits. o Any bypassing or deactivation of safety equipment during operation is prohibited. 2.3 Obligations of the operator-owner The operator-owner is the person who operates the product commercially or permits a third party to use it and who bears the legal responsibility for the product, the protection of the personnel and third... -
Page 7: Identification
3 Identification 3.1 Type code 3 Identification 3.1 Type code KF - 1301.DBA.000372 Fig. 1: Type code Item Classification Description o Pump with free shaft end Type o Pump with inline flanges PN16 o Pump unit with or without pump bracket foot KFA o Pump with free shaft end o Pump with overhead flanges in special design PN16 o Pump unit with or without pump bracket foot... -
Page 8: Rating Plate
ºC ¹ Serial number max. / p max. mm²/s Type Jahr | Year Gewicht | Weight KRAL GmbH, 6890 Lustenau, Austria KRAL GmbH, 6890 Lustenau, Austria www.kral.at www.kral.at Article number Fig. 2: Rating plate Differential pressure Nominal delivery rate Rated speed... -
Page 9: Sound Pressure Level
5 Function description 4.3 Sound pressure level 4.3 Sound pressure level Guide values at 1 m distance, 1450 min , 10 bar Size 5 – 32 – 55 – 160 – 370 – 550 – 851 – 1500 – 2200 – 1301 1700 2900 Max. sound pressure level ±3 [dB(A)] Pump 56.0 59.0... -
Page 10: Pump Unit Structure
5 Function description 5.2 Pump unit structure 5.2 Pump unit structure Fig. 4: Pump unit structure Pump Inner rotor Containment can Motor Outer rotor 5.3 Functional principle Screw pumps are rotating pumps. Their displacement effect results from three rotating screws 6 and 11 and the enclosing pump housing 3. -
Page 11: Overflow Valve
5 Function description 5.5 Overflow valve Housing Type Description KFN/KFT/KVT Flange arrangement: Overhead flange PN6/PN16 Flange arrangement: Overhead flange in special design PN16 Tab. 5: Housing variants 5.5 Overflow valve 1 Screw plug 2 Adjusting screw 3 Pressure spring 4 Valve body Fig. 5: Overflow valve The integrated overflow valve ensures that very high pressures that could result in housing parts burst- ing do not arise. -
Page 12: Transportation, Storage
6 Transportation, storage 6.1 Dangers during transportation 6 Transportation, storage 6.1 Dangers during transportation The following safety instructions must be observed: o Have all work only carried out by authorized transport personnel. o Use intact and correctly dimensioned hoisting equipment. o Ensure that the means of transport is in a flawless state. -
Page 13: Storing The Pump
6 Transportation, storage 6.5 Storing the pump Fig. 6: Fastening of hoisting equipment - principle diagrams Attach the hoisting equipment to the pump/pump unit and tighten. Ensure that the centre of grav- ity lies exactly under the crane hook. Lift the pump/pump unit carefully and put it down shock-free. Before loosening the transport belts ensure that the pump/pump unit is secured against tilting. -
Page 14: Preservation
7 Preservation 7.1 Preservation table 7 Preservation 7.1 Preservation table Preservation has to be carried out additionally under the following conditions: Type of delivery Condition Standard delivery o Storage time exceeding six weeks o Unfavourable storage conditions such as high humidity, salty air, etc. -
Page 15: Removing The Preservation
8 Installation, removal 7.4 Removing the preservation ® Brush calcium complex grease corrosion protection (for example TEVIER FETT WAWE 100 with adhesive additive) to the mounting surfaces. Brush or spray preservative (for example Castrol Rustilo DWX 33) onto the process connections and remaining plain and unpainted parts. -
Page 16: Installing The Pump
8 Installation, removal 8.3 Installing the pump 8.3 Installing the pump The pumps can be operated in horizontal and vertical installation position. Notice Soiling in the pipe system impair the service life of the pump. If the pipe system is flushed using the pump during the initial commissioning, an additional commissioning filter has to be installed temporarily before the pump at the system (mesh width: 0.02 mm). -
Page 17: Removing The Pump
8 Installation, removal 8.4 Removing the pump Requirement: ü Pump connections protected against soiling, for example by using the protective cover mounted in the factory ü If required, hoisting equipment prepared Bring the pump in the installation position, while observing the position of the motor and the ar- rows for the flow direction on the pump housing (1 pressure connection, 2 suction connection). -
Page 18: Connection
9 Connection 9.1 Dangers during connection work 9 Connection 9.1 Dangers during connection work The following safety instructions must be observed strictly: o Have all work on the pump and pipe system only carried out by authorized qualified personnel. o Ensure that impurities cannot get into the pump and pipe system. o Ensure that mechanical connections are mounted stress-free. -
Page 19: Insulating The Pump
9 Connection 9.3 Insulating the pump Before carrying out welding work mount a protective cover on the suction connection and pres- sure connection. Place the piping in position and support the weight of the piping. Check the linear, height and angular offset and correct if necessary. ð... -
Page 20: Operation
10 Operation 10.1 Dangers during operation Ensure that the operating data on the rating plate of the motor agree with the operating data of the pump and with the local power supply. Carefully earth the pump bracket foot, base frame or pedestal via the screwing. Connect the motor in accordance with the operating instructions and circuit diagram in the motor terminal block. -
Page 21: Filling And Venting The Pump
10 Operation 10.2 Commissioning 10.2.2 Filling and venting the pump Possibilities There are two possible ways to fill the pump: o Via the suction connection or pressure connection o Via the vent holes Filling and venting the pump via the suction connection or pressure connection o Fitter Personnel qualification: Personal protective equipment:... -
Page 22: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimulator perform work on the pump/pump unit. WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. -
Page 23: Commissioning The Pump
10 Operation 10.2 Commissioning ATTENTION Dry running can damage pump equipment. ► Ensure that the pump is filled properly. ► Switch the pump on for a maximum of one second and then off again immediately. Switch on the power supply and then turn it off again immediately. Compare the direction of rotation of the fan impeller with the arrow indicating the direction of rota- tion 1. -
Page 24: During Operation
10 Operation 10.3 During operation WARNING Hot surface. Touching of uninsulated hot surfaces results in burns. ► Insulate components and pipings in which hot liquids (> 60 °C) flow before commissioning. ATTENTION Dry running can damage pump equipment. ► Ensure that the pump and the connected pipe system are filled properly. ►... -
Page 25: Monitoring Filters And/Or Strainers
10 Operation 10.3 During operation Open the pressure gauge shut-off valve. Read the operating pressure and close the pressure gauge shut-off valve. 10.3.2 Monitoring filters and/or strainers Notice The manufacturer recommends protecting the pump against soiling by means of a filter and/or strainer installed at the system end (mesh width 0.5 mm). -
Page 26: Switching Off The Pump Unit
10 Operation 10.4 Decommissioning WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. ► Wear personal protective clothing during all the work. Ensure face protection. ► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations. -
Page 27: Recommissioning
10 Operation 10.5 Recommissioning WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. ► Wear personal protective clothing during all the work. Ensure face protection. ► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations. -
Page 28: Maintenance
11 Maintenance 11.1 Dangers during maintenance 11 Maintenance 11.1 Dangers during maintenance The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before beginning work, let the pump unit cool down slowly to the ambient temperature. Avoid rapid temperature changes. -
Page 29: Maintaining The Magnetic Coupling
12 Servicing 11.5 Maintaining the magnetic coupling Check the pump visually and acoustically every four weeks. If there are signs of wear, eliminate the cause Ä Servicing, Page 29. 11.5 Maintaining the magnetic coupling o Fitter Personnel qualification: DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►... -
Page 30: Wear
12 Servicing 12.2 Wear 12.2 Wear 12.2.1 Signs of wear The following table lists signs of progressive wear of individual pump elements: Finding Cause Elimination Increased running noises Incipient damage to bearing Replace the ball bearing. Reduction in the delivery rate or Advanced wear of screws and Replace the pump. -
Page 31: Replacing The Magnetic Coupling
12 Servicing 12.4 Replacing the magnetic coupling Position the end cover 3 and tighten the socket screws 2 with torque. Set the overflow valve Ä During operation, Page 24. 12.4 Replacing the magnetic coupling 12.4.1 Removing the outer rotor o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Safety boots... -
Page 32: Removing The Inner Rotor
12 Servicing 12.4 Replacing the magnetic coupling Lift the motor off the pump bracket. Depending on the motor size remove the threaded pin 6 or the countersunk screw 4. Pull the outer rotor support 5 and outer rotor 7 off from the motor shaft using mounting levers. Remove the socket screws 8 between the outer rotor support and the outer rotor. - Page 33 12 Servicing 12.4 Replacing the magnetic coupling Notice The inner rotor can be mounted more easily if it is heated to 80 °C. Carefully clean the contact surfaces of the inner rotor 13, oil the tensioning element 12 lightly. Manually turn out the screws of the tensioning element by a few turns and insert the tensioning element in the inner rotor.
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Page 34: Installing The Outer Rotor
12 Servicing 12.4 Replacing the magnetic coupling 12.4.4 Installing the outer rotor Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Hoisting equipment Aids: DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►... -
Page 35: Replacing The Ball Bearing And Screw Set
12 Servicing 12.5 Replacing the ball bearing and screw set Fixate the pump 1 with suitable measures, so that the pump cannot tilt during mounting of the motor. Attach the hoisting equipment to the motor 2 and position it above the pump. Place the motor slowly on the pump bracket 3 of the pump. -
Page 36: Installing The Ball Bearing And Screw Set
12 Servicing 12.5 Replacing the ball bearing and screw set Drive the main screw 2 out of the pump flange 4 with light blows from a plastic hammer. Remove the circlip 6 in the pump flange. Pull the ball bearing 10 out of the pump flange 4 using a suitable extractor. -
Page 37: Disposal
13 Disposal 13.1 Dismantling and disposing of the pump 13 Disposal 13.1 Dismantling and disposing of the pump Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Face protection o Protective gloves o Safety boots o Solvents or industrial cleaners suitable for the pumped liquid Aids: o Collection tank DANGER... -
Page 38: Troubleshooting
14 Troubleshooting 14.1 Possible faults 14 Troubleshooting 14.1 Possible faults Faults can have different causes. The following tables list the symptoms of a fault, the possible causes and measures for troubleshooting. Identifica- Fault tion No pump suction Delivery rate too low Pump too loud Motor overload Uneven delivery rate... - Page 39 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – 2 – 4 – – – Speed/frequency/voltage of the motor false Ensure that the motor frequency and voltage match the operating voltage. Ensure that the speed of the motor matches the rating plate of the pump. If necessary ad- just the speed.
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Page 40: Accessories
15 Accessories 15.1 Heating 15 Accessories 15.1 Heating 15.1.1 Possible types of heating The pump can optionally be equipped with a heating system. The manufacturer recommends a heating system at high-viscosity pumped liquids that do not flow sufficiently if not heated. This can result in ex- cessive wattage or in problems arising through cavitation or sealing. - Page 41 15 Accessories 15.1 Heating Installing the electrical heating system Personnel qualification: o Electrician o Work clothing Personal protective equipment: o Protective gloves o Safety boots DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►...
- Page 42 15 Accessories 15.1 Heating Commissioning the electrical heating system DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimulator perform work on the pump/pump unit. DANGER Risk of injury through emitted pumped liquid.
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Page 43: Heating System Special Design
15 Accessories 15.1 Heating Installing the fluid heating system Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►... -
Page 44: Spare Parts
16 Spare parts 16.1 Overview 16 Spare parts 16.1 Overview Model/Size Type Variant Internal KF/KV Maintenance kit Magnetic coupling OPW 16 5 – 660 KF/KV Maintenance kit Magnetic coupling OPW 17 851 – 1301 KF/KV Maintenance kit Magnetic coupling OPW 18 1500 – 1700 KF/KV Maintenance kit Magnetic coupling OPW 19 2200 – 2900 KFN/KFT/KVT... -
Page 45: Maintenance Kits
16 Spare parts 16.2 Maintenance kits 16.2 Maintenance kits 16.2.1 Maintenance kit magnetic coupling KF/KV 5 – 660 Notice The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 471.3 055* 914.1 165.2 165.2 729.6 729.5 471.2* 165.3 165.1 729.7 729.4 914.2... -
Page 46: Maintenance Kit Magnetic Coupling Kf/Kv 851 - 1301
16 Spare parts 16.2 Maintenance kits 16.2.2 Maintenance kit magnetic coupling KF/KV 851 – 1301 Notice The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 471.3 914.1 165.2 729.6 729.5 165.2 729.4 914.2 914.8 165.3 729.7 165.2 165.2 165.1 914.9* Qty. -
Page 47: Maintenance Kit Magnetic Coupling Kf/Kv 1500 - 1700
16 Spare parts 16.2 Maintenance kits 16.2.3 Maintenance kit magnetic coupling KF/KV 1500 – 1700 Notice The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 471.3 914.1 165.2 165.2 165.3 729.6 729.5 729.4 165.1 914.2 729.7 165.2 914.8 165.2 914.9* Qty. -
Page 48: Maintenance Kit Magnetic Coupling Kf/Kv 2200 - 2900
16 Spare parts 16.2 Maintenance kits 16.2.4 Maintenance kit magnetic coupling KF/KV 2200 – 2900 Notice The maintenance kit contains only the numbered parts and is only supplied complete. 914.1 165.2 165.3 165.2 471.3 729.6 729.5 729.4 914.2 914.8 729.7 165.2 165.1 165.2 914.9* Qty. -
Page 49: Maintenance Kit Magnetic Coupling Kfn/Kft/Kvt
16 Spare parts 16.2 Maintenance kits 16.2.5 Maintenance kit magnetic coupling KFN/KFT/KVT Notice The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 471.3 055* 914.1 729.7 729.6 729.5 165.2 165.2 471.2* 165.3 914.2 165.2 165.2 729.4 165.1 471.1... -
Page 50: Repair Kits
16 Spare parts 16.3 Repair kits 16.3 Repair kits 16.3.1 Repair kit overflow valve KF/KH/KV 5 – 660 and KFT/KVT/KFN/KFA Notice The repair kit contains only the numbered parts and is only supplied complete. 729.4 914.2 165.1 Qty. Item No. Part Qty. Item No. Part Adjusting screw Pressure spring 165.1... -
Page 51: Repair Kit Overflow Valve Kf/Kh/Kv 851 - 1301
16 Spare parts 16.3 Repair kits 16.3.2 Repair kit overflow valve KF/KH/KV 851 – 1301 Notice The repair kit contains only the numbered parts and is only supplied complete. 729.4 914.2 914.5 165.1 914.6* Qty. Item No. Part Qty. Item No. Part Supporting ring Valve housing Adjusting screw 729.4... -
Page 52: Repair Kit Overflow Valve Kf/Kh/Kv 1500 - 1700
16 Spare parts 16.3 Repair kits 16.3.3 Repair kit overflow valve KF/KH/KV 1500 – 1700 Notice The repair kit contains only the numbered parts and is only supplied complete. 729.4 914.2 165.1 914.5 914.6* Qty. Item No. Part Qty. Item No. Part Supporting ring Valve housing Adjusting screw 729.4... -
Page 53: Repair Kit Overflow Valve Kf/Kh/Kv 2200 - 2900
16 Spare parts 16.3 Repair kits 16.3.4 Repair kit overflow valve KF/KH/KV 2200 – 2900 Notice The repair kit contains only the numbered parts and is only supplied complete. 729.4 914.2 914.5 165.1 914.6* Qty. Item No. Part Qty. Item No. Part Sleeve Pressure spring Supporting ring Valve housing... -
Page 54: Repair Kit, Screw Set
16 Spare parts 16.3 Repair kits 16.3.5 Repair kit, screw set Notice The repair kit is only supplied in combination with a maintenance kit. 471.1 Qty. Item No. Part Qty. Item No. Part Balancing cylinder Screw set 471.1 Circlip Tab. 29: Repair kit, screw set Operating instructions OIK 09en-GB Edition 2019-11... -
Page 55: Repair Kit Magnetic Coupling
16 Spare parts 16.3 Repair kits 16.3.6 Repair kit magnetic coupling Notice The repair kit contains only the numbered parts and is only supplied complete. 884** 914.4 063** 917** 917.1** 914.5 Qty. Item No. Part Qty. Item No. Part Containment can O-ring Distance sleeve 884**... -
Page 56: Completions
16 Spare parts 16.4 Completions 16.4 Completions 16.4.1 Completion Type KF 914.6 914.3 914.7 914.3 Qty. Item No. Part Qty. Item No. Part Pump bracket 914.3 Socket screw Pump bracket foot 914.6 Socket screw Hexagon nut 914.7 Socket screw Tab. 31: Completion Type KF Operating instructions OIK 09en-GB Edition 2019-11... -
Page 57: Completion Type Kv
16 Spare parts 16.4 Completions 16.4.2 Completion Type KV 914.6 914.3 914.9 Qty. Item No. Part Qty. Item No. Part Pump bracket 914.6 Socket screw Pedestal 914.9 Socket screw 914.3 Socket screw Tab. 32: Completion Type KV Operating instructions OIK 09en-GB Edition 2019-11... -
Page 58: Appendix
17 Appendix 17.1 Tightening torques for screws with metric screw threads with and without wedge lock washers 17 Appendix 17.1 Tightening torques for screws with metric screw threads with and without wedge lock washers Notice In the case of galvanised screw plugs and screw plugs made of stainless steel the inner thread and outer thread have to be greased thorough before mounting in order to prevent threads from seizing. -
Page 59: Tightening Torques For Screws Of Tensioning Elements
17 Appendix 17.3 Tightening torques for screws of tensioning elements 17.3 Tightening torques for screws of tensioning elements Tightening torque [Nm] Thread 12.9 16.0 37.0 M 10 73.0 M 12 Tab. 35: Tightening torques tensioning elements 17.4 Contents of the Declaration of Conformity The products described in these instructions are machinery in the sense of the Directive 2006/42/EC. - Page 60 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...
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