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Operating instructions
KRAL screw pumps.
Series L
Mechanical seal/radial shaft seal
OIL 01en-GB
Edition 2019-03
Original instructions
X-Cel House, Chrysalis Way, Langley Bridge, Eastwood, Nottinghamshire NG16 3RY
Tel: +44 (0) 1773 302 660 | Email: sales@northridgepumps.com | Website: www.northridgepumps.com
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Table of Contents
Troubleshooting
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Summary of Contents for KRAL L Series
- Page 1 Operating instructions KRAL screw pumps. Series L Mechanical seal/radial shaft seal OIL 01en-GB Edition 2019-03 Original instructions X-Cel House, Chrysalis Way, Langley Bridge, Eastwood, Nottinghamshire NG16 3RY Tel: +44 (0) 1773 302 660 | Email: sales@northridgepumps.com | Website: www.northridgepumps.com...
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Page 2: Table Of Contents
Table of contents 1 About this document ............. 4 Installing the pump ............ 19 General information ............ 4 Removing the pump ............. 20 Associated documents .......... 4 9 Connection .............. 21 Target groups .............. 4 Dangers during connection work ......... 21 Symbols................. 5 Connecting the pump to the pipe system..... 22 1.4.1 Danger levels ............ 5 Assembling the pump and motor ......... 22... - Page 3 Table of contents 13.1 Dismantling and disposing of the pump ...... 44 14 Troubleshooting............ 44 14.1 Possible faults ............. 44 14.2 Troubleshooting............ 45 15 Accessories .............. 47 15.1 Heating ................ 47 15.1.1 Possible types of heating ........ 47 15.1.2 Electrical heating system ........ 47 15.1.3 Fluid heating system ........ 48 15.1.4 Heating system special design ....... 49 16 Spare parts ..............
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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: Symbols
1 About this document 1.4 Symbols 1.4 Symbols 1.4.1 Danger levels Signal word Danger level Consequences of non-observance DANGER Immediate threat of danger Serious personal injury, death WARNING Possible threat of danger Serious personal injury, invalidity CAUTION Potentially dangerous situation Slight personal injury ATTENTION Potentially dangerous situation... -
Page 6: Safety
2 Safety 2.1 Proper use 2 Safety 2.1 Proper use o Use the pump solely for transporting lubricating liquids that are chemically neutral and that do not contain gas or solid components. o Use the pump only within the operating limits specified on the rating plate and in the chapter "Tech- nical data". -
Page 7: Safety Instructions
2 Safety 2.4 Safety instructions 2.4 Safety instructions 2.4.1 Fundamental safety instructions The following safety instructions must be observed strictly: o Read these operating instructions carefully and observe them. o Read the operating instructions of the components carefully and observe them. o Have work only carried out by qualified personnel/trained personnel. -
Page 8: Dangers During Connection Work
2 Safety 2.4 Safety instructions 2.4.6 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 9: Dangers During Disposal
3 Identification 3.1 Type code 2.4.10 Dangers during disposal The following safety instructions must be observed strictly: o Neutralize residues. 3 Identification 3.1 Type code LFI - 42.ACAP.00001 Fig. 1: Type code Item Classification Description Type o Pump with free shaft end o Pump with inline flanges PN25/PN63 o Pump unit with or without pump bracket foot o Pump with free shaft end... - Page 10 Tmin. / Tmax. ºC l/min Serial number max. / ps max. ¹ Type Jahr | Year mm²/s KRAL AG, 6890 Lustenau, Austria www.kral.at Article number Fig. 2: Rating plate Differential pressure Nominal delivery rate Rated speed 10 Nominal viscosity 4 Technical data 4.1 Operating limits...
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Page 11: Sound Pressure Level
4 Technical data 4.2 Sound pressure level 4.2 Sound pressure level Guide values at 1 m distance, 1450 min , 20 bar Size 5 – 54 55 – 84 Max. sound pressure level ±3 [dB(A)] Pump 58.0 59.0 Motor 62.0 62.0 Pump unit 63.5 64.0 Tab. 4: Sound pressure level 4.3 Required NPSH values The following table lists the required NPSH values during operation with a low-volatile pumped liquid such as lubricating oil or hydraulic liquid. -
Page 12: Weights
4 Technical data 4.4 Weights 4.4 Weights Model type LFI/LFM/LFT/LFW Size of Size of pump motor Weight of pump with free shaft end [kg] 16.0 20.0 33.0 Weight of pump bracket with pump bracket foot, coupling and screws [kg] – –... -
Page 13: Materials
5 Function description 4.5 Materials 4.5 Materials Part Material designation Material number Pump housing EN-GJS-400-15 5.3106 Seal housing EN-GJS-400-15 5.3106 End cover 16MnCrS5 1.7139 Screw set 16MnCrS5 1.7139 Tab. 8: Materials 4.6 Accessories Notice The technical data of the accessories are specified separately Ä Accessories, Page 47. 5 Function description 5.1 Pump structure Fig. 3: Pump structure... -
Page 14: Pump Unit Structure
5 Function description 5.2 Pump unit structure 5.2 Pump unit structure Fig. 4: Pump unit structure Pump Motor-side coupling half Pump-side coupling half Motor Coupling intermediate ring 5.3 Functional principle Screw pumps are rotating pumps. Their displacement effect results from three rotating screws 1 and 9 and the enclosing pump housing 2. -
Page 15: Housing Variants
5 Function description 5.4 Housing variants 5.4 Housing variants Housing Type Description LFI/LVI Flange arrangement: Inline flange PN25/ PN63 LFT/LVT Flange arrangement: Overhead flange PN25/PN63 Flange arrangement: Overhead flange PN25/PN40 Flange arrangement: Overhead flange PN6/PN40 Tab. 9: Housing variants 5.5 Shaft seal The following types of shaft seals are used: o Mechanical seal standard or hard material o Mechanical seal with quench... -
Page 16: Overflow Valve
6 Transportation, storage 5.6 Overflow valve 5.6 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 17: Transporting The Pump/Pump Unit
6 Transportation, storage 6.4 Transporting the pump/pump unit 6.4 Transporting the pump/pump unit o Crane operators, forklift operators Personnel qualification: o Transport personnel o Work clothing Personal protective equipment: o Protective helmet o Protective gloves o Safety boots Aids: o Mobile crane, forklift o Hoisting equipment WARNING Risk of injury and damage to equipment through falling and toppling parts. -
Page 18: Preservation
7 Preservation 7.1 Preservation table The manufacturer offers a long-term preservation for storage times of up to 60 months. The pump is additionally packed in hermetically sealing anti-corrosion paper. ATTENTION Damage to equipment and corrosion if stored improperly and during longer standstills. ►... -
Page 19: Removing The Preservation
8 Installation, removal 7.4 Removing the preservation 7.4 Removing the preservation o Trained personnel Personnel qualification: o Work clothing Personal protective equipment: o Face protection o Protective gloves o Safety boots Aids: o Solvent o Collection tank o Steam-jet cleaning device with wax-dissolving additives CAUTION Risk of injury through emitted preservative. -
Page 20: Removing The Pump
8 Installation, removal 8.4 Removing the pump WARNING Risk of injury and damage to equipment through falling and toppling parts. ► Only fasten the pump on a stable load-bearing underground or stable load-bearing load support. ► Ensure that fastening elements and pipings are fastened sufficiently. ATTENTION Damage to motor through emitted pumped liquid. -
Page 21: Connection
9 Connection 9.1 Dangers during connection work DANGER Risk of death resulting from electric shock. ► Ensure that the electrical power supply is de-energized and is secured against being switched back on. ► Observe the operating instructions of the electrical components. DANGER Risk of death through emitted pumped liquid. -
Page 22: Connecting The Pump To The Pipe System
9 Connection 9.2 Connecting the pump to the pipe system 9.2 Connecting the pump to the pipe system o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Protective helmet o Safety boots Aids: o Mobile crane, forklift o Hoisting equipment ATTENTION Damage to device through impurity in the pipe system. - Page 23 9 Connection 9.3 Assembling the pump and motor max. ΔKa min. ΔKw (mm) = L max. - L min. max. = L + ΔKa Fig. 9: Coupling alignment measuring points Outer diameter Coupling dis- Max. axial displace- Max. radial displace- Max. tance ment ment...
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Page 24: Connecting The Pump Unit To The Power Supply
10 Operation 9.4 Connecting the pump unit to the power supply 9.4 Connecting the pump unit to the power supply o Electrician Personnel qualification: o Operating instructions of the motor Aids: o Motor circuit diagram DANGER Risk of death resulting from electric shock. ►... -
Page 25: Commissioning
10 Operation 10.2 Commissioning 10.2 Commissioning 10.2.1 Cleaning the pipe system 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. - Page 26 10 Operation 10.2 Commissioning 1 Pressure connection 2 Seal housing vent hole 3 Suction connection Open the screw plug of the vent hole seal housing 2 by a max. of two rotations so that air can es- cape during the filling process. Open the suction-side or pressure-side shut-off device and fill the pump via the suction connec- tion 1 or pressure connection 3 until pumped liquid is emitted at the vent hole seal housing.
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Page 27: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning During the filling process turn the pump shaft or the fan impeller of the motor by hand to speed up the filling process: Filling via the suction-side vent hole: Turn the pump shaft in the direction of the arrow on the pump flange. -
Page 28: 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 flow before commissioning. WARNING Danger of injury through rotating parts. ► Ensure that the coupling protection is mounted. WARNING Risk of injury through emitted pumped liquid. -
Page 29: Monitoring Filters And/Or Strainers
10 Operation 10.3 During operation ATTENTION Leak in the pressure gauge through permanently opened pressure gauge shut-off valve. ► Close the pressure gauge shut-off valve immediately after completing reading. 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 30: Switching Off The Pump Unit
10 Operation 10.4 Decommissioning 10.3.4 Switching off the pump unit Personnel qualification: o Trained personnel ATTENTION Seal damage through pressurizing during standstill. ► During a standstill ensure that the pressure in the pump does not exceed the feed pressure. Switch off the motor. Close the pressure- and suction-side shut-off devices. -
Page 31: Recommissioning
11 Maintenance 10.5 Recommissioning Behaviour of the pumped li- Duration of the operation interruption quid Short Long o Solids sediment Rinse the pump. Rinse the pump. o Congealed/frozen Heat or drain the pump. Drain the pump. o No corrosive burden o Congealed/frozen Heat or drain the pump. -
Page 32: Maintaining The Pump
11 Maintenance 11.4 Maintaining the pump 11.4 Maintaining the pump o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Face protection WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. ►... -
Page 33: Servicing
12 Servicing 12.1 Dangers during servicing 12 Servicing 12.1 Dangers during servicing The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before beginning work on the pump ensure that the electrical power supply is deenergized and is secured against being switched back on. -
Page 34: Replacing The Overflow Valve
12 Servicing 12.3 Replacing the overflow valve 12.3 Replacing the overflow valve 12.3.1 Removing the overflow valve Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots 165.1 914.1 Remove the screw plug 165.1 and socket screws 914.1. Remove the end cover 2 and flat gasket 222 from the pump housing 1. -
Page 35: Replacing The Coupling
12 Servicing 12.4 Replacing the coupling 12.4 Replacing the coupling 12.4.1 Removing the coupling Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Extractor Aids: WARNING Risk of injury and damage to equipment through falling and toppling parts. ►... -
Page 36: Installing The Coupling
12 Servicing 12.4 Replacing the coupling 12.4.2 Installing the coupling Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Measuring stick Aids: o Silicone oil Notice The coupling halves can be mounted more easily if they are heated to 80 °C–100 °C. Requirement: ü... -
Page 37: Replacing The Ball Bearing
12 Servicing 12.5 Replacing the ball bearing 12.5 Replacing the ball bearing 12.5.1 Removing the ball bearing Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Forcing screws Aids: o Plastic hammer o Extractor Requirement: ü... -
Page 38: Installing The Ball Bearing - Mechanical Seal Version
12 Servicing 12.5 Replacing the ball bearing 12.5.2 Installing the ball bearing – mechanical seal version Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Tool set, mechanical seal Ä Spare parts, Page 50 Aids: Notice For secure mounting the manufacturer recommends the mounting tool from the tool set. - Page 39 12 Servicing 12.5 Replacing the ball bearing 661.1 661.1 Slide the positioning sleeve E and the mounting sleeve main screw A onto the main screw 661.1, and slide the main screw into the seal housing 134. Remove the mounting sleeve main screw. 055.2* Size 5 – 26 and 55 – 85: Slide the supporting ring 055.2* onto the main screw. Slide the ball bearing 817 onto the main screw.
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Page 40: Replacing The Mechanical Seal
12 Servicing 12.6 Replacing the mechanical seal 12.6 Replacing the mechanical seal 12.6.1 Removing the mechanical seal Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Plastic hammer Aids: o Extractor o Industrial cleaner Aids: Requirement: ü... -
Page 41: Replacing The Radial Shaft Seal
12 Servicing 12.7 Replacing the radial shaft seal 457.2 055.2* Lightly grease the O-ring of the stationary seal ring 457.2. Size 5 – 26 and 55 – 85: Press the supporting ring055.2* into the seal housing 134. Press the stationary seal ring with O-ring into the seal housing using the mounting arbour C. Take the position of the recess for the dowel pin (anti-rotation screw). -
Page 42: Installing The Radial Shaft Seal
12 Servicing 12.8 Replacing the screw set 12.7.2 Installing the radial shaft seal Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Tool set, radial shaft seal Ä Spare parts, Page 50 Aids: o Thread sealant (for example Loctite 572) o Molybdenum disulphide paste (for example Fenkart T4) Notice The thread sealant serves during installation of the radial shaft seal as a lubricant, and after it has cured as an anti-rotation measure. -
Page 43: Installing The Screw Set
12 Servicing 12.8 Replacing the screw set 914.1 879.2 661.2 Remove the socket screws 914.1 at the end cover 070 and take off the end cover. Remove the balancing bushes 048, straight pin 879.2 and idle screws 661.2 from the pump hous- ing 131. Carefully remove the residues of the flat gasket 222 from the end cover and pump housing. 12.8.2 Installing the screw set o Fitter Personnel qualification:... -
Page 44: 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 WARNING... -
Page 45: Troubleshooting
14 Troubleshooting 14.2 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy 1 – – – – – – Pump suction line closed Check the shut-off devices. If required, open. 1 2 3 – 5 – – Parts soiled (filter, suction line, suction valve, strainer) Clean parts. - Page 46 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – – – – – – 7 Advanced wear of sealing surfaces Replace the seal and check the pumped liquid for abrasive substances. If required, re- place the filter/strainer. -or- Contact the manufacturer. –...
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Page 47: 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 48 15 Accessories 15.1 Heating ATTENTION Damage to the electrical heating system through leakage currents or flashovers at the emission point of the connecting cable. ► Protect the area of the connecting head against liquid and pasty liquids (lubricants, oil, plastics, etc.) as well as their vapours.
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Page 49: Heating System Special Design
15 Accessories 15.1 Heating Heating liquid operating data Parameter Unit Value Max. operating overpressure [bar] Max. temperature [°C] Tab. 21: Heating liquid operating data Heating-up period Required heating-up period for the temperature difference of 50 °C at a liquid temperature of 200 °C: Size Heating-up period [min] at a temperature difference of 50 °C 5 – 54... -
Page 50: Spare Parts
16 Spare parts 16.1 Overview 16 Spare parts 16.1 Overview Model/Size Type Variant Internal LFI/LVI/LFT/LVT Maintenance kit Mechanical seal standard/hard material OPW 34 Maintenance kit Mechanical seal standard/hard material OPW 21 Maintenance kit Mechanical seal standard/hard material OPW 22 LFI/LVI/LFT/LVT Maintenance kit Radial shaft seal standard/high-temperature OPW 35 LFI/LVI/LFT/ Repair kit... -
Page 51: Maintenance Kits
16 Spare parts 16.2 Maintenance kits 16.2 Maintenance kits 16.2.1 Maintenance kit mechanical seal standard/hard material LFI/LVI/LFT/LVT Notice The maintenance kit contains only the numbered parts and is only supplied complete. 165.3 165.2 914.2 471.1 055.2* 165.2 729.1 055.1 914.1 729.2 165.2 165.2... -
Page 52: Maintenance Kit Mechanical Seal Standard/Hard Material Lfw
16 Spare parts 16.2 Maintenance kits 16.2.2 Maintenance kit mechanical seal standard/hard material LFW Notice The maintenance kit contains only the numbered parts and is only supplied complete. 165.2 165.3 165.2 471.1 165.2 914.2 055.2* 165.2 055.1 914.1 165.1 457** 879.2 055.3 Fig. 15: OPW 21... -
Page 53: Maintenance Kit Mechanical Seal Standard/Hard Material Lfm
16 Spare parts 16.2 Maintenance kits 16.2.3 Maintenance kit mechanical seal standard/hard material LFM Notice The maintenance kit contains only the numbered parts and is only supplied complete. 165.2 165.3 165.2 729.2 471.1 165.2 729.1 914.2 055.2* 165.2 055.1 914.1 165.1 457** 879.2... -
Page 54: Maintenance Kit Radial Shaft Seal Standard/High-Temperature Lfi/Lvi/Lft/Lvt
16 Spare parts 16.2 Maintenance kits 16.2.4 Maintenance kit radial shaft seal standard/high-temperature LFI/LVI/LFT/LVT Notice The maintenance kit contains only the numbered parts and is only supplied complete. 165.3 914.2 471.1 165.2 055.2* 165.2 729.1 055.1 914.1 729.2 745.1 745.2 165.2 165.1 165.2... -
Page 55: Repair Kits
16 Spare parts 16.3 Repair kits 16.3 Repair kits 16.3.1 Repair kit screw set LFI/LVI/LFT/LVT/LFM Notice The repair kit is only supplied in combination with a maintenance kit. 471.2 879.2 Qty. Item No. Part Qty. Item No. Part Balancing cylinder Screw set Balancing bush 879.2... -
Page 56: Tool Sets
16 Spare parts 16.4 Tool sets 16.4 Tool sets 16.4.1 Tool set, mechanical seal Qty. Part Mounting arbour stationary seal ring Mounting sleeve main screw Mounting sleeve ball bearing 16.4.2 Tool set, radial shaft seal Qty. Part Mounting arbour radial shaft seal ring Mounting sleeve main screw Mounting sleeve ball bearing Positioning sleeve... -
Page 57: Completions
16 Spare parts 16.5 Completions 16.5 Completions 16.5.1 Completion type LFI/LFT/LFM/LFW 914.3 914.5 914.4 Qty. Item No. Part Qty. Item No. Part Coupling Hexagon nut Pump bracket 914.3 Socket screw Coupling intermediate ring 914.4 Socket screw Pump bracket foot 914.5 Socket screw Tab. 30: Completion type LFI/LFT/LFM/LFW Operating instructions... -
Page 58: Completion Type Lvi/Lvt
16 Spare parts 16.5 Completions 16.5.2 Completion type LVI/LVT 914.3 914.5 914.6 Qty. Item No. Part Qty. Item No. Part Coupling 914.3 Socket screw Pump bracket 914.5 Socket screw Coupling intermediate ring 914.6 Socket screw Pedestal Tab. 31: Completion type LVI/LVT Operating instructions OIL 01en-GB Edition 2019-03... -
Page 59: Appendix
17 Appendix 17.1 Tightening torque for screws with metric screw threads and head contact surfaces 17 Appendix 17.1 Tightening torque for screws with metric screw threads and head contact surfaces Tightening torque [Nm] + Wedge lock wash- Stainless steel screws A2 and A4 Thread 10.9... -
Page 60: Contents Of The Declaration Of Conformity
17 Appendix 17.3 Contents of the Declaration of Conformity 17.3 Contents of the Declaration of Conformity The products described in these instructions are machinery in the sense of the Directive 2006/42/EC. The original of the EC Declaration of Conformity is enclosed with the machinery at delivery. The machinery fulfils all the relevant provisions of the following directives: Number Name... - Page 61 Directory of figures Directory of figures Fig. 1 Type code..................................Fig. 2 Rating plate ................................... Fig. 3 Pump structure ................................Fig. 4 Pump unit structure ............................... Fig. 5 Overflow valve ................................Fig. 6 Fastening of hoisting equipment - principle diagrams ....................Fig.
- Page 62 Directory of tables Tab. 28 Repair kit screw set LFI/LVI/LFT/LVT/LFM ........................Tab. 29 Repair kit overflow valve LFI/LVI/LFT/LVT/LFM......................Tab. 30 Completion type LFI/LFT/LFM/LFW ..........................Tab. 31 Completion type LVI/LVT .............................. Tab. 32 Tightening torques metric screw thread ........................Tab. 33 Tightening torques, thread measured in inches ......................
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