Table of Contents
Related Manuals for KRAL CL Series
Summary of Contents for KRAL CL Series
- Page 1 Operating instructions KRAL screw pumps. Series CL Magnetic coupling Observe safety instructions for persons with cardiac pacemaker, metallic implant or neurostimulator. OIC 13en-GB Edition 2020-02 Original instructions www.kral.at...
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Page 2: Table Of Contents
Table of contents 1 About this document ............. 3 10.2 Commissioning ............ 20 10.2.1 Cleaning the pipe system ........ 20 General information ............ 3 10.2.2 Filling and venting the pump...... 20 Associated documents .......... 3 10.2.3 Checking the direction of rotation .... 21 Target groups .............. 3 10.2.4 Commissioning the pump ........ 21 Symbols................. 3 10.3 During operation ............ 23... -
Page 3: 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 4: 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 5: 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 6: Identification
3 Identification 3.1 Type code 3 Identification 3.1 Type code CLC-210.DZAAP.00021 Fig. 1: Typenschlüssel Item Classification Description Type o Pump with free shaft end o Pump unit with flanges, small flange o Pump unit with or without pump bracket foot o Pump with free shaft end o Pump unit with flanges, large flange o Pump unit with or without pump bracket foot o Pump with free shaft end with foot... -
Page 7: Rating Plate
Temperature range mm²/s max. / p max. Serial number Jahr | Year Gewicht | Weight Type 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 8: Required Npsh Values
The required NPSH values of the pump depend on the size, the viscosity of the pumped liquid and the speed. The NPSH values are available on the website of the manufacturer: www.kral.at/en/screw-pumps 4.3 Sound pressure level Guide values at 1 m distance, 1450 min... -
Page 9: Pump Unit Structure
5 Function description 5.2 Pump unit structure 5.2 Pump unit structure Fig. 4: Pump unit structure Pump Outer rotor Containment can Motor Inner rotor 5.3 Functional principle Screw pumps are rotating displacement pumps. Their displacement effect results from three rotating screws and the enclosing pump housing. Radial support of the screw set is effected through the sliding contact in the pump housing that de- pends on lubrication by the pumped liquid. - Page 10 5 Function description 5.5 Overflow valve Screw plug Adjusting screw Pressure spring Valve body Fig. 5: Overflow valve, integrated The overflow valve ensures that very high pressures that could result in housing parts bursting do not arise. The overflow valve is purely there as a safety element for the pump and should not be used for control or regulation purposes such as maintaining pressure.
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Page 11: 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 12: 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 13: 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 14: 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 15: Dangers During Removal
8 Installation, removal 8.2 Dangers during removal 8.2 Dangers during removal 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 to the ambient temperature. o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations. -
Page 16: Removing The Pump
8 Installation, removal 8.4 Removing the pump Pressure connection Suction connection Fig. 7: Flow direction Requirement: ü Pump protection: Integrated overflow valve or system-side overflow valve/safety valve installed. ü Pump connections protected against soiling, for example by using the protective cover mounted in the factory ü... -
Page 17: Connection
9 Connection 9.1 Dangers during connection work Requirement: ü Pump unit cooled down to the ambient temperature Close the pressure-side and suction-side shut-off devices. Empty the pump at the lowest point. Collect the discharging pumped liquid in a collection tank. Dismantle the pressure-side and suction-side connecting flange. -
Page 18: Insulating The Pump
9 Connection 9.3 Insulating the pump ATTENTION Damage to device through mechanical stress. ► Ensure that the pump is mounted free of mechanical stresses in the pipe system. ► Observe the tightening torques. Fig. 8: Connection to pipe system Turn the pump shaft or the fan impeller of the motor. This tests that the pump runs smoothly. If the pump shaft cannot be turned by hand, remedy the fault before installing the pump Ä... -
Page 19: 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 20: 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 21: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning Connect the suction connection or pressure connection of the surrounding pipe system for ex- ample with a higher tank. Vent the pipe system at the highest point, for example via a pressure gauge shut-off device. Open the suction-side or pressure-side shut-off device and fill the pump via the suction connec- tion or pressure connection until pumped liquid is emitted at the vent hole. - Page 22 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 neurostimu- lator perform work on the pump/pump unit. DANGER Risk of death resulting from bursting components and discharging pumped liquid.
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Page 23: During Operation
10 Operation 10.3 During operation Switch on the pump unit. ð The pump delivers when the pressure on the pressure side of the pump rises or a flow indic- ator at the system side triggers. If the pump does not deliver after 10 – 15 seconds of operation, abort commissioning. Eliminate the cause for the fault and only then continue with commissioning. -
Page 24: Adjusting The Overflow Valve
10 Operation 10.3 During operation 10.3.3 Adjusting the overflow valve Personnel qualification: o Fitter o Hexagon key Aids: Notice o The protection of the pump must be ensured either through an integrated overflow valve or through an overflow valve/safety valve installed on the system side. o Observe the associated operating instructions and dimensioning sheet of the pump to set an over- flow valve/safety valve installed on the system side. -
Page 25: Decommissioning
10 Operation 10.4 Decommissioning 10.4 Decommissioning 10.4.1 Decommissioning the pump Decommissioning is an operation interruption that requires different measures depending on the scope of duration and the interruption as well as the properties of the pumped liquid. o Fitter Personnel qualification: o Electrician o Work clothing Personal protective equipment:... -
Page 26: Recommissioning
11 Maintenance 10.5 Recommissioning Behaviour of the pumped liquid Duration of the operation interruption Short Long o Remains liquid – – o No corrosive burden o Remains liquid – Drain the pump. o Corrosive burden Preserve the pump. Tab. 7: Measures depending on the behaviour of the pumped liquid Drain the pump via the pressure line, suction line, vent screws and screw plugs. -
Page 27: 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 DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►... -
Page 28: Servicing
12 Servicing 12.1 Dangers during servicing Item No. Part Tensioning element Threaded pin outer rotor support Countersunk screw outer rotor support Socket screws pump bracket – pump Socket screws outer rotor support – outer rotor Socket screws containment can – pump Depending on motor size Tab. 9: Magnetic coupling: Parts to be maintained Play of the ball bearing (bearing clearance) Radial bearing clearance... -
Page 29: 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 30: Removing The Inner Rotor
12 Servicing 12.3 Replacing the magnetic coupling Attach the hoisting equipment to the motor 2. Loosen the socket screws 17 between the motor 2 and the pump bracket 3. Lift the motor 2 from the pump 1 with pump bracket 3 and rotate. 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 the motor shaft using mounting levers. -
Page 31: Installing The Inner Rotor
12 Servicing 12.3 Replacing the magnetic coupling Remove the socket screws 10 between the containment can 11 and the pump 1 and remove the containment can and O-ring 15. Hold the inner rotor 13 firmly using a strap spanner. Loosen and remove all the socket screws 14 in the tensioning element 12. -
Page 32: Installing The Outer Rotor
12 Servicing 12.3 Replacing the magnetic coupling Press the containment can 11 onto the pump flange and tighten with socket screws 10 using torque. Place the pump bracket 3 on the pump and tighten the socket screws 9 with torque. 12.3.4 Installing the outer rotor o Fitter Personnel qualification: Personal protective equipment:... -
Page 33: Replacing The Ball Bearing And Screw Set
12 Servicing 12.4 Replacing the ball bearing and screw set Carefully clean the outer rotor 7 with compressed air. Tighten the socket screws 8 between the outer rotor 7 and outer rotor support 5 with torque. Clean and grease the shaft end of the motor 2. Place the outer rotor support 5 with outer rotor 7 on the shaft end of the motor 2. -
Page 34: Installing The Ball Bearing And Screw Set
12 Servicing 12.4 Replacing the ball bearing and screw set Remove the socket screws 1 at the intermediate flange 2* and loosen the intermediate flange us- ing light "rebound" blows. Tension the main screw 5. Lift the pump housing 3 off the flange cover 6. While doing so, hold the main screw 5 and idle screws 4 tight with one hand. - Page 35 12 Servicing 12.4 Replacing the ball bearing and screw set Slide the balancing cylinder 9 onto the shaft of the main screw 5 and press on the ball bear- ing 10. Slide the supporting ring 12 onto the shaft and mount the circlip 11. Turn and tension the main screw 5. Slide the flange cover 6 onto the main screw. Clean the sealing surfaces thoroughly.
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Page 36: 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 37: 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 38 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 39: 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 40 15 Accessories 15.1 Heating Heating-up period Required heating-up period for temperature differences of 20 °C or 50 °C at pumps without thermal in- sulation: Size Wattage Heating-up period [min] at a temperature difference of 20 °C 50 °C 5 – 42 2 x 100 55 – 85 1 x 180 105 – 210 1 x 250 235 – 275...
- Page 41 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 neurostimu- lator perform work on the pump/pump unit. DANGER Risk of injury through emitted pumped liquid.
- Page 42 15 Accessories 15.1 Heating Heating-up period Required heating-up period for temperature differences of 20 °C or 50 °C at pumps without thermal in- sulation and a liquid temperature of 200 °C: Size Steam amount Heating-up period [min] at a temperature difference of [kg/h] 20 °C 50 °C 5 – 26...
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Page 43: Heating System Special Design
16 Spare parts 16.1 Overview 15.1.4 Heating system special design Please contact the manufacturer for special designs. 16 Spare parts 16.1 Overview 914.3 222.2 222.3 914.5 914.6 471.2 661.2 1037 661.2 661.1 Qty. Item No. Part Qty. Item No. Part Containment can Inner rotor Balancing cylinder... -
Page 44: Overflow Valve
16 Spare parts 16.2 Overflow valve 16.2 Overflow valve 222.3 914.6 Qty. Item No. Part Qty. Item No. Part Adjusting screw Pressure spring Screw plug Valve housing 222.3 Flat gasket Seal ring Valve cone 914.6 Socket screw Operating instructions OIC 13en-GB Edition 2020-02... -
Page 45: 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 46: 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. 20: 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 47 Notes Operating instructions OIC 13en-GB Edition 2020-02...
- Page 48 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...
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