KRAL K Series Operating Instructions Manual
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KRAL K Series Operating Instructions Manual

Screw pumps
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Operating instructions
KRAL screw pumps.
Series K
Mechanical seal
OIK 14en-GB
Edition 2019-11
Original instructions
www.kral.at

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Summary of Contents for KRAL K Series

  • Page 1 Operating instructions KRAL screw pumps. Series K Mechanical seal OIK 14en-GB Edition 2019-11 Original instructions www.kral.at...

  • Page 2: Table Of Contents

    Table of contents 1 About this document .............  4 10 Operation................   20 General information ............ 4 10.1 Dangers during operation .......... 20 Associated documents .......... 4 10.2 Commissioning ............ 20 10.2.1 Cleaning the pipe system ........ 20 Target groups .............. 4 10.2.2 Filling and venting the pump...... 20 Symbols................. 4 10.2.3 Checking the direction of rotation .... 22 1.4.1...
  • Page 3 Table of contents 16.2.1 Maintenance kit mechanical seal standard or hard material KF/KH/KV 5 – 660..... 44 16.2.2 Maintenance kit mechanical seal standard or hard material KF/KH/KV 851 – 1301.... 45 16.2.3 Maintenance kit mechanical seal standard or hard material KF/KH/KV 1500 – 1700..... 46 16.2.4 Maintenance kit mechanical seal standard or hard material KF/KH/KV 2200 – 2900..... 47 16.2.5 Maintenance kit mechanical seal standard or hard material KFT/KVT/KFN ...... 48...

  • 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. Raised load Falling objects can result in serious physical injury or death. Heavy load Heavy loads can result in serious back problems. Risk of slipping Discharging pumped liquid and oils on the foundation or tread surfaces can cause falls with serious physical injury or death.

  • Page 6: Obligations Of The Operator-Owner

    3 Identification 2.3 Obligations of the operator-owner 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 parties during its operation.

  • Page 7: Rating Plate

    Serial number max. / p max. mm²/s Type Jahr | Year Gewicht | Weight Article number KRAL GmbH, 6890 Lustenau, Austria KRAL GmbH, 6890 Lustenau, Austria www.kral.at www.kral.at Fig. 2: Rating plate Differential pressure Nominal delivery rate Rated speed 10 Nominal viscosity...

  • Page 8: Technical Data

    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: Function Description

    5 Function description 5.1 Pump structure 5 Function description 5.1 Pump structure Fig. 3: Pump structure Screw plug Ball bearing Overflow valve Pump flange Pump housing Relief line Balancing cylinder Thrust pin Venting sealing chamber Idle screw Shaft seal (mechanical seal) End cover Main screw 5.2 Pump unit structure...

  • Page 10: Functional Principle

    5 Function description 5.3 Functional principle 5.3 Functional principle Screw pumps are rotating pumps. Their displacement effect results from three rotating screws 7 and 12 and the enclosing pump housing 3. 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 11: Overflow Valve

    5 Function description 5.6 Overflow valve Mechanical seal with quench Mechanical seal If low-volatile liquids or liquids that tend to harden when coming into contact with the atmo- Quench tank connection sphere are used, a mechanical seal can also be Ball bearing used in combination with a radial shaft seal ring.

  • 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: Installation, Removal

    8 Installation, removal 8.1 Dangers during installation CAUTION Risk of injury through emitted preservative. ► Wear personal protective clothing during all the work. ► Collect any discharging preservative safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations. Clean the outside of the pump with solvents, if necessary using a steam-jet cleaning device.

  • Page 16: Removing The Pump

    8 Installation, removal 8.4 Removing the pump ATTENTION Damage to motor through emitted pumped liquid. ► Do not install the pump above the motor. ATTENTION Damage to device through impurity in the pipe system. ► During welding work attach protective covers in front of the connecting flanges. ►...

  • Page 17: Connection

    9 Connection 9.1 Dangers during connection work DANGER Risk of death through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic and can spray out under high pressure. ► Wear personal protective clothing during all the work. Ensure face protection. ►...

  • 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

    9 Connection 9.5 Connecting the pump unit to the power supply max. ΔKa min. ΔKw (mm) = L max. - L min. max. = L + ΔKa Fig. 9: Coupling alignment measuring points Outer diameter Coupling Max. axial Max. radial Max. distance displacement displacement...

  • Page 20: Operation

    10 Operation 10.1 Dangers during operation 10 Operation 10.1 Dangers during operation The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before commissioning ensure that a safety valve has been installed in the pipe system on the pressure side before the first shut-off device.
  • Page 21 10 Operation 10.2 Commissioning DANGER Risk of death through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic and can spray out under high pressure. ► Wear personal protective equipment during all the work. Ensure face protection. ►...

  • Page 22: Checking The Direction Of Rotation

    10 Operation 10.2 Commissioning During the filling process turn the pump shaft or fan impeller of the motor by hand to speed up the filling process: Filling of the suction chamber: Turn the pump shaft against the direction of rotation of the motor. Filling of the sealing chamber: Turn the pump shaft in the direction of rotation of the motor.
  • Page 23 10 Operation 10.2 Commissioning 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 24: During Operation

    10 Operation 10.3 During operation 10.3 During operation 10.3.1 Checking the operating pressure Personnel qualification: o Trained personnel Fig. 10: Pressure gauge shut-off valves closed/open - principle diagram ATTENTION Leak in the pressure gauge through permanently opened pressure gauge shut-off valve. ►...

  • Page 25: 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 26: Recommissioning

    11 Maintenance 10.5 Recommissioning ATTENTION Damage to equipment through excessively fast temperature change. ► Subject the pump only to slow temperature changes. ► Under no circumstances heat the pump with an open flame. Carry out the following measures during operation interruptions: Scope of the operation interruption Measure o Shutting down the pump for longer Depending on the pumped liquid...

  • Page 27: Required Maintenance

    11 Maintenance 11.2 Required maintenance 11.2 Required maintenance The service life depends on the observance of the operating conditions of the pump and the require- ments from the operating instructions of the components. Component Required maintenance Cycle o Visual inspection Pump 4 weeks o Acoustic inspection...

  • Page 28: Servicing

    12 Servicing 12.1 Dangers during servicing In case of insufficient permeability clean the leakage vent hole and if existing the leakage vent line. If existing, reconnect the leakage vent line again. 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.

  • Page 29: Installing The Overflow Valve

    12 Servicing 12.4 Replacing the coupling Remove the screw plug 1 and socket screws 2. Remove the end cover 3 and flat gasket 4 from the pump housing 5. Carefully screw out the adjusting screw 8 and remove the pressure spring 7 and valve body 6 from the pump housing. 12.3.2 Installing the overflow valve o Fitter Personnel qualification:...

  • Page 30: Installing The Coupling

    12 Servicing 12.4 Replacing the coupling Requirement: ü Pump unit disconnected from the electrical power supply, deenergized and secured against being switched back on Remove the socket screws 7 between the motor 2 and pump bracket 3 and lift pump 1 with pump bracket from the motor. Loosen the fixing screw 6 at the motor-side coupling half 5.

  • Page 31: Replacing The Ball Bearing

    12 Servicing 12.5 Replacing the ball bearing Tighten the motor-side coupling half 5 on the shaft end of the motor 2. Check the distance between the face of the coupling teeth and the connecting surface of motor flange. The distance has to be adjusted to the value X-E, table Limit values for aligning the shaft coupling Ä...
  • Page 32 12 Servicing 12.5 Replacing the ball bearing Clean the fitting surfaces carefully. Size 5 – 20: Slide the main screw 2 into the pump flange 4. Mount the circlip 16 and supporting ring 11. Press in the ball bearings 10 and fasten with the circlip 6. Mount the supporting ring 7 and circlip 8. Size 851 – 2900: Insert the supporting ring 11 into the pump flange 4.

  • Page 33: 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 Requirement: ü...
  • Page 34 12 Servicing 12.6 Replacing the mechanical seal Standard mechanical seal (figure on the left): Slide the rotary ring 17 with spring onto the main screw 2. To do so use the mounting sleeve main screw B. Mechanical seal of hard material (figure on the right): Slide the rotary seal ring 18 and associ- ated parts of the mechanical seal onto the main screw 2.

  • Page 35: Replacing The Screw Set

    12 Servicing 12.7 Replacing the screw set Slide the withdrawable unit (main screw 2 with premounted pump flange 4) into the pump hous- ing 1 until the main screw engages into the idle screws. Turn the main screw in the process. Take the position of the straight pin 12 into account. Tighten the socket screws 5 with torque.

  • Page 36: Disposal

    13 Disposal 13.1 Dismantling and disposing of the pump Size 5 – 20: Slide the main screw 2 into the pump flange 4. Mount the circlip 16 and supporting ring 11. Press in the ball bearings 10 and fasten with the circlip 6. Mount the supporting ring 7 and circlip 8. Size 851 – 2900: Insert the supporting ring 11 into the pump flange 4.

  • Page 37: Troubleshooting

    14 Troubleshooting 14.1 Possible faults Requirement: ü Disconnect the pump unit from the power supply and secure it against being switched back on ü Pump unit cooled down to the ambient temperature and disconnected from the pipe system ü Pump emptied completely ü...
  • Page 38 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – 2 – – – – – Viscosity of the pumped liquid too low Reduce the temperature of the pumped liquid. -or- Increase the speed. – 2 3 – 5 – – Airlock/gas in the pumped liquid Test the pipe system for air admission, replace leaking parts.

  • Page 39: Accessories

    15 Accessories 15.1 Heating Fault identification Cause Remedy – – – – – – 7 Shaft seal is overloaded through thermal/chemical influences Check the maximum operating temperature. Check the suitability and resistance of the elastomers with regard to the pumped liquid. -or- Contact the manufacturer.
  • Page 40 15 Accessories 15.1 Heating Operating data Parameter Unit Value Voltage Frequency [Hz] 50/60 Wire cross-section 2 x 1 Tab. 15: Operating data electrical heating system Heating-up period Required heating-up period for temperature differences of 30 °C or 50 °C: Size Wattage Heating-up period [min] at a temperature difference of 30 °C 50 °C 5 – 42...
  • Page 41 15 Accessories 15.1 Heating Connecting the electrical heating system 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 injury through emitted pumped liquid.

  • Page 42: Heating System Special Design

    15 Accessories 15.1 Heating 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 – 118 160 – 275 370 – 450 550 – 660 851 – 1301 1500 – 1700 2200 – 2900 Tab. 19: Heating-up period for fluid heating system Installing the fluid heating system Personnel qualification: o Fitter...

  • Page 43: Spare Parts

    16 Spare parts 16.1 Overview 16 Spare parts 16.1 Overview Model/Size Type Variant Internal KF/KH/KV Maintenance kit Mechanical seal OPW 01 5 – 660 Standard/Hard material KF/KH/KV Maintenance kit Mechanical seal OPW 02 851 – 1301 Standard/Hard material KF/KH/KV Maintenance kit Mechanical seal OPW 03 1500 – 1700 Standard/Hard material KF/KH/KV Maintenance kit Mechanical seal...

  • Page 44: Maintenance Kits

    16 Spare parts 16.2 Maintenance kits 16.2 Maintenance kits 16.2.1 Maintenance kit mechanical seal standard or hard material KF/KH/KV 5 – 660 Notice The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 471.3 055* 914.1 165.2 165.2 165.3 729.5 729.6 471.2*...

  • Page 45: Maintenance Kit Mechanical Seal Standard Or Hard Material Kf/Kh/Kv 851 - 1301

    16 Spare parts 16.2 Maintenance kits 16.2.2 Maintenance kit mechanical seal standard or hard material KF/KH/KV 851 – 1301 Notice The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 471.3 914.1 165.2 165.3 165.2 729.6 729.5 729.4 914.2 914.5 165.1 729.7...

  • Page 46: Maintenance Kit Mechanical Seal Standard Or Hard Material Kf/Kh/Kv 1500 - 1700

    16 Spare parts 16.2 Maintenance kits 16.2.3 Maintenance kit mechanical seal standard or hard material KF/KH/KV 1500 – 1700 Notice The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 165.5 165.2 471.3 165.2 165.3 914.1 055* 729.5 729.6 729.4 914.2 165.1...

  • Page 47: Maintenance Kit Mechanical Seal Standard Or Hard Material Kf/Kh/Kv 2200 - 2900

    16 Spare parts 16.2 Maintenance kits 16.2.4 Maintenance kit mechanical seal standard or hard material KF/KH/KV 2200 – 2900 Notice The maintenance kit contains only the numbered parts and is only supplied complete. 914.1 165.3 165.2 165.2 729.5 729.6 471.3 729.4 165.4 914.2 914.5 729.7 165.2...

  • Page 48: Maintenance Kit Mechanical Seal Standard Or Hard Material Kft/Kvt/Kfn

    16 Spare parts 16.2 Maintenance kits 16.2.5 Maintenance kit mechanical seal standard or hard material KFT/KVT/KFN Notice The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 471.3 729.7 055* 914.1 729.6 729.5 165.2 165.2 471.2* 914.2 165.3 165.2...

  • Page 49: 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 50: 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 51: 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 52: 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 53: Repair Kit, Screw Set

    16 Spare parts 16.4 Tool sets 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. 30: Repair kit, screw set 16.4 Tool sets 16.4.1 Tool set, mechanical seal Qty.

  • Page 54: Completions

    16 Spare parts 16.5 Completions 16.5 Completions 16.5.1 Completion Type KF 914.7 914.3 914.4 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 914.7 Socket screw Tab. 31: Completion Type KF Operating instructions...

  • Page 55: Completion Type Kh

    16 Spare parts 16.5 Completions 16.5.2 Completion Type KH 901.2 901.1 Qty. Item No. Part Qty. Item No. Part Coupling Hexagon nut Pipe clip 901.1 Stud screw Base frame 901.2 Stud screw Coupling protection Wedge lock washer Threaded rod Tab. 32: Completion Type KH Operating instructions OIK 14en-GB Edition 2019-11...

  • Page 56: Completion Type Kv

    16 Spare parts 16.5 Completions 16.5.3 Completion Type KV 914.7 914.3 914.6 Qty. Item No. Part Qty. Item No. Part Coupling 914.3 Socket screw Pump bracket 914.6 Socket screw Coupling intermediate ring 914.7 Socket screw Pedestal Tab. 33: Completion Type KV Operating instructions OIK 14en-GB Edition 2019-11...

  • Page 57: 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 58: 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 59 Notes Operating instructions OIK 14en-GB Edition 2019-11...
  • Page 60 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...

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