KRAL W Series Operating Instructions Manual

KRAL W Series Operating Instructions Manual

Screw pumps
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Operating Instructions
KRAL Screw Pumps.
W Series
OIW 01en
Edition 2019-11
Original instructions
www.northridgepumps.com
www.kral.at

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Summary of Contents for KRAL W Series

  • Page 1 Operating Instructions KRAL Screw Pumps. W Series OIW 01en Edition 2019-11 Original instructions www.kral.at www.northridgepumps.com...
  • Page 2: Table Of Contents

    Table of contents □ About this document Removing the pump ▪ Removing the pump □ General information □ Target groups Operation □ □ Symbols Commissioning □ ▪ Safety instructions for commissioning Danger levels ▪ Protect the pump against soiling □ Associated documents ▪...
  • Page 3: General Information

    General information General information About this document The operating instructions form part of the pump or motor-driven pump. The operating instructions must be kept for future reference. Furthermore please observe the operating instructions for the drive motor. Target groups Target group Tasks □...
  • Page 4: Danger Levels

    Installation, removal and installation work may only be carried out by specialist personnel. □ Do not use KRAL pumps outside the performance limitations specified on the rating plate and in the "Technical data" section. In the case of operating data that does not agree with the specifications on the rating plate, please contact the manufacturer.
  • Page 5: Type Code

    6 Article number max. / p max. mm²/s 7 Differential pressure Jahr | Year Gewicht | Weight 8 Nominal delivery rate KRAL GmbH, 6890 Lustenau, Austria www.kral.at 9 Rated speed 10 Nominal viscosity 11 Weight Fig. 2 Rating plate Operating Instructions OIW 01en Edition 2019-11 www.northridgepumps.com...
  • Page 6: Proper Use

    Proper use Technical data KRAL screw pumps of the W series are used to deliver lubricating liquids or cutting emulsions and cutting oils. Both the concentration and the size of solid particles carried in the emulsion affect the service life of the pump. The maximum size of the particles should not exceed 70 µm. It is always to your advantage to use filters with a higher separation factor.
  • Page 7: Required Npsh Values

    Required NPSH values Required NPSH values The following table shows the required NPSH values to ensure that the various pump sizes can be operated without cavitation. These values are derived from the pump kinematics during operation with a low-volatility pumped liquid such as lubricating oil or hydraulic liquid. The following examples indicate that when pumped liquids have a readily volatile component content the required NPSH values notably increase: □...
  • Page 8: Noise Levels

    Noise levels Noise levels Max. noise level ± 3 dB(A) [dB(A)] W 15-20 W 32-42 W 55-85 W 105-118 W 160-210 W 235-275 Pump (at 2900 r.p.m.) Motor max. – at 40 bar – at 80 bar Pump + motor –...
  • Page 9 Weights Pump size Weight of pump bracket with pedestal, coupling and screws [kg] — — — 100L 112M 28 132S 132M 45 160M 110 — 160L — 180M 165 — 180L — 200L — 225M 280 — 250M 365 — Tab.
  • Page 10: General Drawing Of A Screw Pump

    General drawing of a screw pump General drawing of a screw pump Function description Fig. 1 Structure of a screw pump 1 Suction cover 6 Main screw 2 Back pressure valve 7 Mechanical seal 3 Pressure casing 8 Balancing cylinder 4 Leakage connection 9 Pump casing 5 Ball bearing...
  • Page 11: Function Description

    Function description Function description Screw pumps belong to the rotating displacement group of pumps. In these pumps a special form allows an almost tight engagement of three intermeshing screws 6,10 to be achieved. Together with the pump casing 9 that encompasses the screw package, closed volumes are achieved by this means. The standard direction of rotation of the pump is clockwise as seen from the drive (indicated by an arrow on the pressure casing 3).
  • Page 12: Back Pressure Valve

    Back pressure valve Back pressure valve Fig. 3 Back pressure valve installation position 1 Adapter sleeve 3 Ball 2 Spring 4 Leakage To ensure the proper functioning of mechanical seals, they must be constantly lubricated by the pumped liquid. This also requires greater pressure on the liquid-filled inside of the seal than in the atmosphere. To ensure this even when the pump is installed above the liquid level, a spring-loaded back pressure valve is mounted in the relief line of the seal chamber.
  • Page 13: Unpacking And Checking The State Of

    Unpacking and checking the state of delivery Unpacking and checking the state of delivery Transportation, storage and disposal 1. On delivery unpack the pump/motor-driven pump and check for damage during transportation. 2. Report damage during transportation immediately to the manufacturer. 3.
  • Page 14: Preservation

    Preservation Preservation Preserving the internal surfaces of the pump 1. Set up the pump so that the pressure-side connection is pointing upward. 2. Close the suction-side connection of the pump with a cover plate. 3. Pour non-corrosive, resin-free oil into the pressure flange until the oil reaches the pressure flange and the air bubbles stop rising, while slowly turning the main screw against the direction of rotation.
  • Page 15: Installation

    Installation, removal and connection Installing the pump KRAL pumps of the W series can be used vertically in any position. Operation in the horizontal position requires that the pressure connection of the pump is oriented upward, see Fig. 2, Page 15. W-pumps can be supplied for dry or wet installation.
  • Page 16: Protect The Pump Against Soiling

    Installation Protect the pump against soiling WARNING Damage through impurities in the piping system. ► During welding work attach cover plates in front of the connecting flanges. ► Ensure when welding that welding beads and abrasive dust cannot get into the piping system and the pump.
  • Page 17: Aligning And Checking The Shaft Coupling

    Installation Aligning and checking the shaft coupling Prerequisites: □ Pump, shaft coupling and motor have been mounted by the customer a Lateral offset b Angular offset c Linear offset Fig. 5 Measuring points for tolerances of the coupling alignment Coupling diameter Lateral offset a Angular offset b Linear offset c...
  • Page 18: Electrical Connection

    Electrical connection Electrical connection Connecting the pump Prerequisite: □ Sufficiently dimensioned cables DANGER Risk of death resulting from electric shock. ► The pump may only be connected by an authorized electrician. ► Ensure that the power supply is de-energized. ► Ground the pump carefully. 1.
  • Page 19 Removing the pump 1. In case of operation at higher temperatures wait until the motor-driven pump has cooled down to the ambient temperature. 2. Disconnect the pump from the power supply. 3. Open the terminal box at the motor. 4. Disconnect the connecting cable. 5.
  • Page 20: Commissioning

    Commissioning Commissioning Operation Safety instructions for commissioning The following instructions must always be observed. ► The pump may only be commissioned by authorized qualified personnel. ► Before commissioning, make sure that the pump is filled. Protect the pump against soiling The pump has to be protected against soiling during commissioning.
  • Page 21: Checking The Direction Of Rotation

    Commissioning DANGER Risk of death through emitted pumped liquid. Pumped liquids can be hot, poisonous or caustic and can spray out under high pressure. ► Wear protective clothing during all the work. Ensure face protection. ► Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible man- ner.
  • Page 22: Initial Commissioning The Pump

    Commissioning Prerequisite: □ Pump securely fastened □ Pump connection to the piping system is free of stress □ Pump motor is connected correctly to the electrical power supply □ Piping system is free of contamination □ A commissioning filter of the prescribed mesh width is fitted if the piping system is to be cleaned by the pump □...
  • Page 23: During Operation

    During operation During operation Checking the operating pressure Fig. 3 Schematic diagram: Fig. 4 Schematic diagram: Open pressure gauge stopcock Close pressure gauge stopcock Pressure gauge stopcocks that are opened permanently can result in the pressure gauges leaking. ► Close the pressure gauge stopcocks after completing reading. ►...
  • Page 24: Maintenance

    Maintenance Maintenance Repairs Required maintenance The service life of the pump depends to a great extent on the operating conditions of the pump. If the operating limits are observed, see "Technical data", Page 6, the pump has a service life of many years. Signs of progressive wear of individual pump elements: Finding Cause...
  • Page 25: Removing The Torsionally Elastic Coupling

    Replacing the coupling Removing the torsionally elastic coupling Prerequisite: □ Pump dismantled, see "Removing the pump", Page 18 1. Before starting to dismantle, use suitable covers to protect the inlet and outlets opening of the pump against solid particles and soiling.
  • Page 26: Installing The Torsionally Elastic Coupling

    Replacing the coupling Installing the torsionally elastic coupling Prerequisite □ Replacement coupling available 5. Use light blows with a soft hammer to mount the motor-side coupling 052.2 on the shaft end of the motor. Heating the coupling to 80 °C - 100 °C facilitates mounting. 1.
  • Page 27: Replacing The Mechanical Seal And Ball Bearing

    Replacing the mechanical seal and ball bearing Replacing the mechanical seal and ball bearing 165.1 661.2 661.1 165.2 661.2 901* 879.3 131 894.1* 739.1 055.1 055.2 879.1 739.1 859.2 471.2 471.1 471.3 879.2 914.2 739.2 457.3 457.5 055.3 457.1 457.4 457.2 457.6 Balancing cylinder...
  • Page 28: Removal Of Mechanical Seal And Ball Bearing

    Replacing the mechanical seal and ball bearing Removal of mechanical seal and ball bearing 6. Dismantle the supporting ring 055.2, parts of the mechanical seal 457 and supporting ring 055.3 from the main screw. 1. Remove the socket screws 914.2. 7.
  • Page 29: Replacing The Screw Set

    Replacing the screw set Replacing the screw set Removing the screw set Prerequisite: □ Pump dismantled, see "Removing the pump", 3. Push the main screw with the mounted Page 18. mechanical seal into the seal casing 134. Use the mounting sleeve in the process. 1.
  • Page 30: Installing The Screw Set

    Replacing the screw set Installing the screw set Prerequisite: □ Replacement parts available 1. Press the balancing cylinder 042 onto the 7. Tighten the socket screws 914.2, see Tab. 1, main screw, mount the circlip 471.3. Page 38. 2. Clean the main screw around the mechanical seal carefully and grease it.
  • Page 31: Replacing The Domsel Type Radial Shaft Seal

    Replacing the Domsel type radial shaft seal Replacing the Domsel type radial shaft seal 165.1 661.2 661.1 165.2 661.2 901* 879.3 131 894.1* 471.1 739.1 055.1 055.2 879.1 739.1 471.2 879.2 739.2 914.2 471.3 745.2 745.1 Balancing cylinder 661.2 Idle screw 055.1 Supporting ring 739.1...
  • Page 32: Removing The Radial Shaft Seal

    Replacing the Domsel type radial shaft seal Removing the radial shaft seal Prerequisite: □ Pump disassembled, see "Replacing the mechanical seal and ball bearing", Page 27, removal steps 1–5 2. Prepare a suitable rod for mounting the seal ring. The rod must lie flat on the support body of the seal ring and may not have any sharp edges in the vicinity of the sealing lip.
  • Page 33: 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 elimination. Possible faults Fault Cause / Elimination □ No pump suction 1, 2, 3, 4, 5, 6, 7, 8, 35 □...
  • Page 34 Information about faults Cause Remedy Viscosity of the pumped liquid too ► Increase the temperature of the liquid high - or - ► Reduce the rotation speed. Viscosity of the pumped liquid too ► Decrease the temperature of the liquid - or - ►...
  • Page 35 Information about faults Cause Remedy Cold start when delivering high- ► Install a pump heating. viscosity liquids Seal overload during ► To prevent thermal expansion of the liquid causing a heating process build-up of pressure, open the pressure- or suction- side shut-off devices.
  • Page 36: Maintenance Kits

    Maintenance kits Maintenance kits Spare parts Notice: The maintenance kits contain only the numbered parts and are only supplied complete. W 15 – 118 165.1 165.2 901***** 739.1 914.1**** 471.2 914.2 739.1 471.3 471.1 055.1 055.2*** 894.1***** 739.2 055.3* 457* 745.1** 745.2** Qty.
  • Page 37: Accessories

    Accessories Accessories Tool kits for LFI/LVI/LFT/LVT/LFM/WS Werkzeugsatz Gleitringdichtung /Tool kit mechanical seal Stk./Qty. Teil Part Montagedorn Gegenring Mounting arbor stationary seal ring Montagehülse Hauptspindel Mounting sleeve main screw Montagehülse Kugellager Mounting sleeve ball bearing Werkzeugsatz Radialwellendichtung /Tool kit radial shaft seal Stk./Qty.
  • Page 38: 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 A2 and A4 elastomer seal Rust- 8.8 + proof 10.9 Alu*...
  • Page 39: Notes

    Notes Notes Operating Instructions OIW 01en Edition 2019-11 www.northridgepumps.com...
  • Page 40 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43 / 55 77 / 8 66 44 - 0, E-Mail: kral@kral.at www.kral.at www.northridgepumps.com...

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