Related Manuals for KRAL CG Series
Summary of Contents for KRAL CG Series
- Page 1 Operating Instructions KRAL Screw Pumps. CG Series with magnetic coupling. OIC 10en Edition 2019-11 Original instructions www.kral.at...
-
Page 2: Table Of Contents
Table of contents About this document Installation, removal and connection □ □ General information Safety instructions on installation, removal and connection □ Target groups □ □ Installation Symbols ▪ Installing the pump □ Danger levels ▪ Protect the pump against soiling □... -
Page 3: General Information
The operating instructions form part of the pump or of the pump unit and must be kept for future refe- rence. Furthermore please observe the associated documents. The CG series with mechanical seal/ radial seal ring is described in separate operating instructions. -
Page 4: Danger Levels
Danger levels Danger levels Warning Danger level Consequences of non-observances 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 CAUTION Potentially dangerous situation Material damage Associated documents ATEX supplementary instructions for operation in potentially explosive areas Declaration of conformity according to EU Directive 2006/42/EC... -
Page 5: Proper Use
Proper use Proper use Safety □ Use the pump solely for transporting lubricating liquids that are chemically neutral and that contain no gas or solid components. □ Use the pump only within the operating limits specified on the rating plate and in the "Technical data" section. -
Page 6: Type Code
Type code Type code Identification 1 Model 2 Size 3 Seal type 4 Bearing and heating system CGF- 370.DAADF.00599 5 Housing material 6 Pressure stage 7 Completion 8 Version index Fig. 1 Type code Item Designation Type □ Model Pump with free shaft end □... -
Page 7: Rating Plate
5 Type max. / p max. mm²/s 6 Article number Jahr | Year Gewicht | Weight 7 Differential pressure KRAL GmbH, 6890 Lustenau, Austria www.kral.at 8 Nominal delivery rate 9 Rated speed 10 Nominal viscosity 11 Weight Fig. 2 Rating plate... -
Page 8: Operating Limits
Operating limits Operating limits Technical data Size 1101 1501 2250 2850 1301 1701 3550 Pressure max. [bar] □ Outer housing — spheroidal gra- phite iron □ Outer housing steel Temperature max. [°C] □ Magnetic cou- pling as standard □ Magnetic cou- pling high temperature Temperature min. -
Page 9: Required Npsh Values
Required NPSH values Required NPSH values The following table lists the required NPSH values during operation with a low-volatile liquid such as lubricating oil or hydraulic fluid. When pumped liquids have a readily volatile component content, the required NPSH values increase notably: □... -
Page 10: Weights
Weights Size Viscosity NPSH value [mWC] at Size Viscosity NPSH value [mWC] at Rotation speed [min Rotation speed [min 1450 1750 2900 3500 1450 1750 2900 3500 1301 — — — — — — — — 1501 — — — —... -
Page 11: Structure
Structure Structure Function description Fig. 1 Structure of CG pump 1 End cover 7 Screw plug 12 Ball bearing 2 Vent hole 8 Valve housing 13 Main screw 3 Valve cap 9 Valve body 14 Balancing cylinder 4 Adjusting screw 10 Flange cover cartridge pump 15 Cartridge pump 5 Valve cover... -
Page 12: Magnetic Coupling
Magnetic coupling Magnetic coupling Fig. 2 Structure of a CG pump with magnetic coupling and motor Pump 3 Inner rotor Motor 2 Containment can Outer rotor The shaft end of the pump 1 is enclosed by a containment can 2, that is connected air-tight with the motor-side flange of the pump. -
Page 13: Overflow Valve
Overflow valve Overflow valve The following safety instructions must be observed: □ Pumps of the series CG are only equipped with an overflow valve up to an operating pressure of about 40 bar. ► An external overflow valve has to be installed at pumps that are supplied without an overflow valve. -
Page 14: Heating System
Heating system Heating system The pumps can be equipped optionally with heating systems. The manufacturer recommends heating systems for high-viscosity liquids that do not flow sufficiently if not heated. This can result in excessive power consumption or to problems arising through cavitation or sealing. Method of heating: □... -
Page 15: Safety Instructions On Transportation
Safety instructions on transportation, storage and disposal Safety instructions on transportation, storage and disposal Transportation, storage and disposal The following safety instructions must be observed: □ There is a risk of death for people with pacemakers. ► Under no circumstances may persons with pacemakers perform transport, storage and disposal work. -
Page 16: Storage
Storage Prerequisites: □ Sufficiently dimensioned hoisting equipment □ The used hoisting equipment conforms to the local regulations and regulations for the prevention of accidents DANGER Risk of injury and/or damage to equipment should the pump/pump unit fall. ► Use intact and correctly dimensioned hoisting equipment. ►... -
Page 17: Preserving The Internal Surfaces Of The Pump
Preservation Preserving the internal surfaces of the pump Aids: □ Non-corrosive and resin-free preservative oil 1. Close the suction connection of the pump with a blind flange. 2. Pour non-corrosive, resin-free preservative oil into the pressure connection until it reaches approx. 2 cm under the pressure flange, while slowly turning the main screw against the direction of rotation. -
Page 18: Disposing Of The Pump
Disposing of the pump Disposing of the pump Aids: □ Solvents or industrial cleaners suitable for the pumped liquid □ Vessel to collect pumped liquid WARNING Danger of poisoning and damage to the environment through pumped liquid or oil. ► Wear protective clothing during all the work. ►... -
Page 19: Safety Instructions On Installation, Removal And Connection
Safety instructions on installation, removal and connection Safety instructions on installation, removal and connection Installation, removal and connection The following safety instructions must be observed: □ There is a risk of death for people with pacemakers. ► Under no circumstances may persons with pacemakers perform installation, removal or connec- tion work. -
Page 20: Protect The Pump Against Soiling
Installation CAUTION Damage to the pump and piping through insufficient fastening. ► Only fasten the pump on a stable bearing mounting surface. ► Ensure that the fastening elements are fixed sufficiently. 1. Bring the pump into position. Ensure that the flow direction that is marked by arrows on the flanges is correct, see Fig. -
Page 21: Connecting The Motor
Connecting the motor Connecting the motor DANGER Risk of death resulting from electric shock. ► The motor may only be connected by an authorized electrician. ► Ensure that the power supply is de-energized. ► Ground the pump carefully. 1. Observe the operating instructions of the motor. 2. -
Page 22: Safety Instructions On Operation
Safety instructions on operation Safety instructions on operation Operation The following safety instructions must be observed: □ There is a risk of death for people with pacemakers. ► Under no circumstances may persons with pacemakers perform commissioning work. The following safety instructions must be observed: ►... -
Page 23: Filling The Pump
Commissioning Filling the pump There are two possible ways to fill the pump: □ Pumped liquid already exists at the suction or pressure side: Filling via suction or pressure connection □ There is no pumped liquid at the suction or pressure side: Filling via the vent holes 1 Vent hole Fig. -
Page 24: Checking The Direction Of Rotation
Commissioning Checking the direction of rotation The direction of rotation and the flow direction are indicated by arrows on the pump. The direction of rotation of the motor gives the direction of rotation of the pump. That is to say, the fan impeller of the motor must rotate in the direction in which the arrow on the pump is pointing to indicate direction of rota- tion. -
Page 25: Commissioning The Pump
Commissioning Commissioning the pump Prerequisites: □ Direction of rotation of the pump checked WARNING Risk of injury through emitted pumped liquid. ► Wear protective clothing during all the work. ► Ensure that all the connections are connected sealingly. CAUTION Dry running can damage pump equipment. ►... -
Page 26: During Operation
During operation During operation Checking the operating pressure CAUTION Stopcocks that are opened permanently can result in the pressure gauges leaking. ► Close the pressure gauge stopcocks after completing reading. ► Open the pressure gauge stopcock, read the operating pressure, close the pressure gauge stop- cock. -
Page 27: Switching Off The Pump
Taking the pump out of operation Switching off the pump CAUTION Damage to seals through pressurizing of the pump while it is standing still. ► Ensure that while the pump is at a standstill, the pressure in the pump does not exceed the feed pressure during operation. -
Page 28: Safety Instructions On Maintenance And Repairs
Safety instructions on maintenance and repairs Safety instructions on maintenance and repairs Maintenance The following safety instructions must be observed: □ There is a risk of death for people with pacemakers. ► Under no circumstances may persons with pacemakers perform maintenance or repair work. The following safety instructions must be observed: ►... -
Page 29: Replacing The Magnetic Coupling
Replacing the magnetic coupling Replacing the magnetic coupling Removing the magnetic coupling Dismantling the outer rotor 917* 884* 914.2 Fig. 1 Fig. 2 Motor Coupling hub Pump bracket Outer rotor 914.4 884* Threaded pin 914.2 Socket screw 914.4 Socket screw 917* Countersunk screw Depending on the motor size... - Page 30 Replacing the magnetic coupling Dismantling the inner rotor 914.3 900.1 Fig. 5 Fig. 6 Fig. 7 Containment can Tensioning element 914.3 Socket screw Pump bracket O-ring Inner rotor 900.1 Hexagon screw Aids: □ Strap wrench □ Allen key 1. Loosen the hexagon screws 900.1 between the pump and pump bracket 180 and remove the pump bracket, see Fig.
-
Page 31: Installing The Magnetic Coupling
Replacing the magnetic coupling Installing the magnetic coupling Mounting the inner rotor 914.3 661.1 Fig. 8 Fig. 9 Fig. 10 Containment can Pump bracket Inner rotor Tensioning element 661.1 Main screw O-ring 900.1 Hexagon screw 900.1 914.3 Socket screw Fig. 11 Operating Instructions OIC 10en Edition 2019-11... - Page 32 Replacing the magnetic coupling Aids: □ Allen key □ Hexagon socket torque wrench 1. Carefully clean the contact surfaces of the inner rotor 518, oil the tensioning element 585 lightly. Note: Use only oil without molybdenum sulphide additive, e.g. multifunction spray WD-40. 2.
- Page 33 Replacing the magnetic coupling Mounting the outer rotor 914.4 Fig. 12 Fig. 13 Fig. 14 917* 914.2 Motor Coupling hub 884* Pump bracket Outer rotor 884* Threaded pin 914.2 Socket screw 914.4 Socket screw 917* Countersunk screw Depending on the motor size Fig.
- Page 34 Replacing the magnetic coupling Aids: □ Allen key □ Hexagon socket torque wrench 1. Carefully clean the outer rotor 515. Tighten the socket screws 914.4 of the outer rotor 515 and cou- pling hub 052 with torque, see Tab. 1, page 45. 2.
-
Page 35: Replacing The Ball Bearing And Screw Set
Replacing the ball bearing and screw set Replacing the ball bearing and screw set Removing the ball bearing and screw set 914.6* 914.9 112* 869.2** Fig. 17 Fig. 18 Fig. 19 661.1 661.1 661.2 661.2 661.1 1037 914.1*** Fig. 20 Fig. - Page 36 Replacing the ball bearing and screw set 1. For pumps with intermediate flange: Unscrew the socket screws 914.6* at the intermediate flange 112* and loosen the intermediate flange using light "rebound" blows, see Fig. 17, page 35. Remove the residues of the flat gasket. Screw out the socket screws 914.9 and remove the cartridge pump from the outer housing, see Fig.
-
Page 37: Installing The Ball Bearing And Screw Set
Replacing the ball bearing and screw set Installing the ball bearing and screw set 042*** 661.1 661.1 869.1 Fig. 25 Fig. 26 Fig. 27 661.2 869.2** 1037 914.1*** 222.2 1037 661.1 914.1*** Fig. 28 Fig. 29 Fig. 30 Operating Instructions OIC 10en Edition 2019-11... - Page 38 Replacing the ball bearing and screw set 042*** Balancing cylinder Supporting ring Flange cover 112* Intermediate flange Pump housing 914.6* 222.1* Flat gasket 914.9 222.2 Flat gasket Edge sealing ring 112* 661.1 Main screw 661.2 Idle screw 222.1* Ball bearing 869.1 Circlip 869.2** Circlip...
-
Page 39: Information About Faults
Information about faults Information about faults Troubleshooting Faults can have different causes. The following tables list the symptoms of a fault, the possible causes and measures for troubleshooting. Possible faults Fault Cause/Remedy □ No pump suction 1, 2, 3, 4, 5, 6, 7, 8, 28 □... - Page 40 Information about faults Cause Remedy 11 Viscosity of the pumped liquid too ► Increase the temperature of the liquid. high - or - ► Reduce the rotation speed. 12 Viscosity of the pumped liquid too low ► Decrease the temperature of the liquid. - or - ►...
- Page 41 Information about faults Cause Remedy 27 Dry running can ► Dismantle the pump and clean it. damage the pump ► Smooth the superficial damage to the housing and the rotating parts with an oilstone, if necessary, replace the pump with free shaft end. ►...
-
Page 42: Cartridge Pump
Cartridge pump Cartridge pump Spare parts 914.1* 739.1 859** 222.2 042* 661.2 869.1 1037 661.2 661.1 739.2 Qty. Item No. Part Qty. Item No. Part 042* Balancing cylinder 739.1 O-ring Supporting ring 739.2 O-ring Flange cover Deep-groove ball bearing Pump housing 859** Adapter sleeve 222.2... -
Page 43: Pumpe With Magnetic Coupling
Pump with magnetic coupling Pump with magnetic coupling 914.3 914.10 112*(*) 739.5** 914.9 739.4 739.6** 165.1 914.6*(*) 222.3 222.1* 914.7 869.2*** 165.1 739.3 914.8 Qty. Item No. Part Qty. Item No. Part Containment can 739.3 O-ring End cover 739.4 O-ring 112*(*) Intermediate flange 739.5**... -
Page 44: Overflow Valve
Overflow valve Overflow valve 165.2 222.4 914.11 Qty. Item No. Part Qty. Item No. Part Adjusting screw Valve body 165.2 Screw plug Spring 222.4 Flat gasket Valve housing Valve cap Seal ring Valve cover Hexagon nut Disk spring 914.11 Socket screw OIC 10en Edition 2019-11 Operating Instructions... -
Page 45: Tightening Torques
Tightening torques Tightening torques Appendix Tightening torque [Nm] for screws with metric threads + head contact surfaces With thread measured in inches + wedge lock Stainless steel Screw plugs with washers screws elastomer seal A2 and A4 Rust- 8.8 + proof 10.9 Alu*... -
Page 46: Contents Of The Ec Declaration Of Conformity
Contents of the EC Declaration of Conformity Contents of the EC Declaration of Conformity The screw pumps described in these operating 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 fulfills all the relevant provisions of the following directives: Number Name... -
Page 47: Notes
Notes Notes Operating Instructions OIC 10en Edition 2019-11... - Page 48 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43 / 55 77 / 8 66 44 - 0, E-Mail: kral@kral.at www.kral.at...
Need help?
Do you have a question about the CG Series and is the answer not in the manual?
Questions and answers