KRAL C Series Operating Instructions Manual
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Summary of Contents for KRAL C Series
- Page 1 Operating instructions KRAL screw pumps. Series C / Type CGF/CGH/CGV/CLE Magnetic coupling Observe safety instructions for persons with cardiac pacemaker, metallic implant or neurostimulator. OIC 10en-GB Edition 2020-08 Original instructions www.kral.at...
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Page 2: Table Of Contents
Table of contents 1 About this document ............. 4 10.1 Dangers during operation .......... 20 General information ............ 4 10.2 Commissioning ............ 21 10.2.1 Cleaning the pipe system ........ 21 Associated documents .......... 4 10.2.2 Filling and venting the pump...... 21 Target groups .............. 4 10.2.3 Checking the direction of rotation .... 23 Symbols................. 4 10.2.4 Commissioning the pump ........ 24 1.4.1... - Page 3 Table of contents 17.1 Tightening torques for screws with metric screw threads with and without wedge lock washers ...... 49 17.2 Tightening torques for screw plugs with thread meas- ured in inches and elastomer seal....... 49 17.3 Tightening torques for screws of tensioning elements .................. 50 17.4 Contents of the Declaration of Conformity.... 50 Operating instructions...
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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: 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 6: 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 7: Identification
3 Identification 3.1 Type code 3 Identification 3.1 Type code CGF0055.AAEZP.000001 Fig. 1: Type code Item Classification Description Type o Pump with free shaft end o Pump unit for flange mounting o Pump with free shaft end and pump bracket foot o Pump unit on base frame for horizontal mounting o Pump with free shaft end and pedestal o Pump unit with pedestal for vertical mounting... -
Page 8: 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 Differential pressure Fig. 2: Rating plate Nominal delivery rate Rated speed 10 Nominal viscosity... -
Page 9: 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 10: Function Description
5 Function description 5.1 Cartridge pump structure 5 Function description 5.1 Cartridge pump structure Fig. 3: Cartridge pump structure Main screw Intermediate flange Idle screw Inner rotor Cartridge housing Tensioning element Flange cover Containment can Balancing cylinder Bearing bush Ball bearing 5.2 Pump unit structure Fig. 4: Pump unit structure Outer housing... -
Page 11: Functional Principle
5 Function description 5.3 Functional principle 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 12: Overflow Valve (Optional)
6 Transportation, storage 5.6 Overflow valve (optional) 5.6 Overflow valve (optional) Overflow valve Ä Accessories, Page 42. 5.7 Heating system (optional) Heating Ä Accessories, Page 42. 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. -
Page 13: Storing The Pump
6 Transportation, storage 6.5 Storing the pump WARNING Risk of injury and damage to equipment through falling and toppling parts. ► Use intact and correctly dimensioned hoisting equipment in accordance with the total weight to be transported. ► Select the lift points for the hoisting equipment in accordance with the centre of gravity and the weight distribution. -
Page 14: Preservation
7 Preservation 7.1 Preservation table 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. ATTENTION Damage to equipment and corrosion if stored improperly and during longer standstills. -
Page 15: Preserving The Outer Surfaces
7 Preservation 7.3 Preserving the outer surfaces 7.3 Preserving the outer surfaces o Trained personnel Personnel qualification: o Work clothing Personal protective equipment: o Face protection o Protective gloves o Safety boots Aids: o Calcium complex grease (for example TEVI- ®... -
Page 16: Installation, Removal
8 Installation, removal 8.1 Dangers during installation 8 Installation, removal 8.1 Dangers during installation The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before installation ensure that the operating limits, NPSH values and ambient conditions are ob- served. -
Page 17: Removing The Pump
8 Installation, removal 8.4 Removing the pump ATTENTION Damage to device through impurity in the pipe system. ► During welding work attach protective covers in front of the connecting flanges. ► Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and the pump. -
Page 18: 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 pres- sure. ► Wear personal protective clothing during all the work. Ensure face protection. ►... -
Page 19: Pumpe Isolieren
9 Connection 9.3 Pumpe isolieren ATTENTION Damage to device through impurity in the pipe system. ► During welding work attach protective covers in front of the connecting flanges. ► Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and the pump. -
Page 20: 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 21: 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 22 10 Operation 10.2 Commissioning Filling and venting the pump via the suction connection or pressure connection Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Face protection o Protective gloves o Safety boots DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►...
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Page 23: Checking The Direction Of Rotation
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: Commissioning The Pump
10 Operation 10.2 Commissioning 10.2.4 Commissioning the pump Personnel qualification: o Fitter o Electrician o Work clothing Personal protective equipment: o Face protection o Protective gloves o Safety boots o Collection tank Aids: DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►... -
Page 25: During Operation
10 Operation 10.3 During operation ü System protection: Safety valve in accordance with EN ISO 4126-1 installed in the pressure-side pipe system before the first shut-off device ü Pump protection: Integrated overflow valve or system-side overflow valve/safety valve installed. ü Pump filled with pumped liquid ü... -
Page 26: Setting The Overflow Valve (Optional)
10 Operation 10.4 Decommissioning After commissioning monitor the degree of contamination of the filter and/or strainer by means of a suction-side pressure gauge or a differential pressure indication. Additionally check the filters and/or strainers at a pressure drop on the suction side. Observe the dimensioning data of the manufacturer of the filters/strainers. -
Page 27: Recommissioning
11 Maintenance 10.5 Recommissioning Carry out the following measures during operation interruptions: Scope of the operation interruption Measure o Shutting down the pump for a longer period Depending on the pumped liquid o Draining the pump Close the pressure-side and suction-side shut-off devices. -
Page 28: 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 29: Maintaining The Magnetic Coupling
11 Maintenance 11.5 Maintaining the magnetic coupling 11.5 Maintaining the magnetic coupling o Fitter Personnel qualification: 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. -
Page 30: 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 31: Removing The Inner Rotor
12 Servicing 12.3 Replacing the magnetic coupling WARNING Risk of injury and damage to equipment through falling and toppling parts. ► Use intact and correctly dimensioned hoisting equipment in accordance with the total weight to be transported. ► Select the lift points for the hoisting equipment in accordance with the centre of gravity and the weight distribution. -
Page 32: Installing The Inner Rotor
12 Servicing 12.3 Replacing the magnetic coupling Remove the socket screws 9 between the pump 1 and pump bracket 3 and remove the pump bracket. Remove the socket screws 10 between the containment can 11 and the pump and remove the containment can. To replace the inner rotor 13, screw two screws M into the empty threaded holes of the tension- ing element 12 as anti-rotation screws. -
Page 33: Installing The Outer Rotor
12 Servicing 12.3 Replacing the magnetic coupling Manually turn out the screws of the tensioning element by a few turns and insert the tensioning element in the inner rotor. Carefully clean the sealing surfaces. Insert the O-ring. Place the inner rotor with the premounted tensioning element onto the pump shaft and tighten the screws of the tensioning element crosswise by hand. - Page 34 12 Servicing 12.3 Replacing the magnetic coupling WARNING Danger of crushing when assembling motor and pump. When the motor approaches the pump, high magnetic forces can produce sudden collisions and thus injuries to hands or fingers. ► Two persons are required for the assembly. ►...
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Page 35: Replacing The Cartridge Pump
12 Servicing 12.4 Replacing the cartridge pump Fixate the pump 1 with suitable measures, so that the pump cannot tilt during mounting of the motor. Attach the hoisting equipment to the motor 2 and position it above the pump. Place the motor slowly on the pump bracket 3 of the pump. Ensure that the outer rotor 7 does not strike the containment can. -
Page 36: Installing The Cartridge Pump
12 Servicing 12.4 Replacing the cartridge pump Also secure the outer housing against falling over. Remove the socket screws 1 and loosen the intermediate flange 2 using light "rebound" blows. Remove the socket screws 3, and use forcing screws to detach the cartridge pump 4 from the outer housing 5. -
Page 37: Replacing The Ball Bearing And Screw Set
12 Servicing 12.5 Replacing the ball bearing and screw set Tighten the socket screws 3 with torque. Position the Intermediate flange 2 and tighten the socket screws 1 with torque. 12.5 Replacing the ball bearing and screw set 12.5.1 Removing the ball bearing and screw set o Fitter Personnel qualification: Personal protective equipment:... -
Page 38: Installing The Ball Bearing And Screw Set
12 Servicing 12.5 Replacing the ball bearing and screw set Remove the edge sealing rings 8 from the flange cover and remove the residues of the flat gas- ket 11 at the flange cover.. Remove the O-ring 10 from the flange cover and lift the flange cover off the main screw. Unclamp the main screw 2, rotate it by 180°... -
Page 39: Disposal
13 Disposal 13.1 Dismantling and disposing of the pump Clean the fitting surfaces carefully, position the flat gasket 11 in the flange cover. Position the edge sealing rings 8 in the flange cover. Take the recesses for the edge sealing rings into account. Mount the bearing bush set 9, consisting of the bearing bush and segment washer, on the shafts of the idle screws 3. -
Page 40: Troubleshooting
14 Troubleshooting 14.1 Possible faults WARNING Danger of poisoning and environmental damage through residues. ► Wear personal protective clothing during all the work. Ensure face protection. ► Before disposal collect any pumped liquid still present safely and dispose of it in an environment- ally compatible manner in accordance with the applicable local regulations. - Page 41 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy 1 – – – – – – Too little pumped liquid in the pump Fill the pump with pumped liquid. 1 – – – – – – Incorrect pump direction of rotation Swop the two electrical connection phases Ä...
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Page 42: Accessories
15 Accessories 15.1 Heating Fault identification Cause Remedy – 2 3 – – – – Magnetic coupling interrupted Stop the pump immediately and restart it. Avoid excessive differential pressures. At repeated occurrence check whether pump has got stuck. 1 – – – – – 7 Containment can defective Replace the containment can Ä... - Page 43 15 Accessories 15.1 Heating Size Dimensions [mm] Steam amount [kg/ 32 – 42 R 1/4" 55 – 85 R 1/4" 105 – 118 R 1/4" 160 – 210 R 1/4" 235 – 275 R 3/8" 370 – 450 R 3/8" 550 – 880 R 3/8" Tab. 14: Dimensions and steam amount – outer housing GJS Pump with outer housing steel H1 H1 Size...
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Page 44: Overflow Valve
15 Accessories 15.2 Overflow valve Remove the socket screws 915.9 on the end cover 540.1 of the pump. Remove the flat gasket 222 and carefully clean the fitting surfaces at the outer housing and end cover. Lightly grease the O-ring 739.10 and insert it into the heating cover 483. Bond the new flat gasket onto the fitting surface of the outer housing. -
Page 45: Adjusting The Overflow Valve
15 Accessories 15.2 Overflow valve Notice o A function test of the overflow valve at least every 5 years is essential for the safe operation Ä Dur- ing operation, Page 25. o Scope and if necessary shorter test intervals must be specified by the operator-owner in accord- ance with the requirements and national provisions (for example Austrian Ordinance of Safety and Health (BetrSichV)). -
Page 46: Spare Parts
16 Spare parts 16.1 Overview 16 Spare parts 16.1 Overview 915.2 915.3 739.3 739.4 056.1 041* 661.1 859.2 869.1 859.1 222.2 915.1** 661.2 739.1 739.2 1037 Qty. Item No. Part Qty. Item No. Part Containment can 739.1 O-ring 041* Distance sleeve 739.2 O-ring Balancing cylinder... -
Page 47: Overview Of Motors
16 Spare parts 16.2 Overview of motors 16.2 Overview of motors 884*** 915.4 915.4 917.1** 056.2** 917.2** Qty. Item No. Part Qty. Item No. Part Outer rotor support 915.4 Socket screw 056.2** Supporting ring 917.1** Countersunk screw Outer rotor 917.2** Countersunk screw 884*** Threaded pin... -
Page 48: Overview Of Outer Housing Steel Cgf/Cgh/Cgv
16 Spare parts 16.4 Overview of outer housing steel CGF/CGH/CGV 16.4 Overview of outer housing steel CGF/CGH/CGV 915.7 739.9 915.10 Fig. 15: Spare parts outer housing steel– principle diagram Qty. Item No. Part Qty. Item No. Part Cartridge pump 739.9 O-ring Screw plug 4/6/8 915.7 Socket screw... -
Page 49: 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 50 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 17.4 42.2 M 10 83.0 M 12 Tab. 23: 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 51 Notes Operating instructions OIC 10en-GB Edition 2020-08...
- Page 52 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...
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