Related Manuals for KRAL CL Series
Summary of Contents for KRAL CL Series
- Page 1 Operating instructions KRAL screw pumps. Series CL Type CLF/CLL OIC 02en-GB Edition 2022-06 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 ............20 10.2.1 Cleaning the pipe system ....... 20 Associated documents ..........4 10.2.2 Filling and venting the pump ......21 Target groups ............. - Page 3 Table of contents 15.1.3 Fluid heating system ........48 15.1.4 Heating system special design ...... 49 16 Spare parts ..............50 16.1 Overview of inner bearing .......... 50 16.2 Overview of outer bearing .......... 51 16.3 Repair kit, overflow valve ........... 52 16.4 Overview of accessories ..........
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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. 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 3 Identification 3.1 Type code Item Classification Description Shaft seal Standard mechanical seal Hard material mechanical seal Standard radial shaft seal Magnetic coupling Mechanical seal with receiver Shaft seal PTFE with quench High-temperature radial shaft seal Mechanical seal balanced Stuffing box packing Mechanical seal with throttle ring Special design Pressure stage overflow...
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Page 8: Rating Plate
ºC ¹ Serial number max. / p max. mm²/s Type Jahr | Year Gewicht | Weight 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 9: Sound Pressure Level
5 Function description 4.3 Sound pressure level 4.3 Sound pressure level Guide values at 1 m distance, 1450 min , 20 bar, 21 mm Size 5 – 15 – 32 – 55 – 105 – 160 – 235 – 370 – 550 – Max. sound pressure level ±3 [dB(A)] Pump 53.0 57.0 59.0... -
Page 10: Shaft Seal
5 Function description 5.3 Shaft seal 5.3 Shaft seal The following types of shaft seals are offered: o Mechanical seal standard or hard material o Mechanical seal with quench o Mechanical seal with throttle ring o Radial shaft seal standard or high-temperature 5.3.1 Seal variants inner bearing Mechanical seal standard/hard material The lubrication of the mechanical seal 1 inevit-... -
Page 11: Seal Variants Outer Bearing
5 Function description 5.4 Overflow valve 5.3.2 Seal variants outer bearing Mechanical seal standard/hard material The lubrication of the mechanical seal 1 inevit- ably results in a low leak, that as a rule evapor- Mechanical seal ates. However, at low-volatile liquids such as Leakage vent hole heavy fuel oil the leak becomes visible. -
Page 12: Housing Variant/Accessories
6 Transportation, storage 5.5 Housing variant/accessories It therefore has to be ensured through a safety valve at the system that the maximum operating pres- sure always lies under the opening pressure of the overflow valve. Note The opening pressure of the overflow valve is set to 110% of the differential pressure in the factory. The overflow valve is accessible through a screw plug 1 and can be adjusted from the outside Ä... -
Page 13: Dangers During Storage
6 Transportation, storage 6.2 Dangers during storage 6.2 Dangers during storage The following safety instructions must be observed: o Observe the storage conditions. 6.3 Unpacking and checking the state of delivery o Trained personnel Personnel qualification: Upon delivery check the pump/pump unit for damage during transportation. Report damage during transportation immediately to the manufacturer. -
Page 14: Storing The Pump
7 Preservation 6.5 Storing the pump 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. 6.5 Storing the pump During the test run, the internal components of the pump are wetted with test oil, which has a preser- vative effect. -
Page 15: Preserving The Outer Surfaces
8 Installation, removal 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: Dangers During Removing
8 Installation, removal 8.2 Dangers during removing 8.2 Dangers during removing 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 17: Removing The Pump
8 Installation, removal 8.4 Removing the pump 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 If required, hoisting equipment prepared Bring the pump in the installation position, while observing the position of the motor and the ar- rows for the flow direction on the pump housing (1 pressure connection, 2 suction connection). -
Page 18: Connection
9 Connection 9.1 Dangers during connection work 9 Connection 9.1 Dangers during connection work The following safety instructions must be observed strictly: o Have all work on the pump and pipe system only carried out by authorized qualified personnel. o Ensure that impurities cannot get into the pump and pipe system. o Ensure that mechanical connections are mounted stress-free. -
Page 19: Insulating The Pump
9 Connection 9.3 Insulating the pump 9.3 Insulating the pump o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Safety boots Aids: o Insulation material WARNING Hot surface. Touching of uninsulated hot surfaces results in burns. ►... -
Page 20: Connecting The Pump Unit To The Power Supply
10 Operation 9.5 Connecting the pump unit to the power supply Check the radial displacement ΔKr of the coupling using a hairline gauge and feeler gauge. Check several points along the periphery of the coupling. Check the angular displacement ΔKw of the coupling using a hairline gauge. Check the axial displacement ΔKa of the coupling using a slide gauge or feeler gauge. -
Page 21: Filling And Venting The Pump
10 Operation 10.2 Commissioning ATTENTION Damage to equipment through additional pressure loss in the commissioning filter/commis- sioning strainer. ► Calculate the flow resistance and determine the remaining pump intake. ► Monitor the suction-side pressure. ► Check the commissioning filter/commissioning strainer regularly. Requirement: ü... -
Page 22: Commissioning The Pump
10 Operation 10.2 Commissioning Compare the direction of rotation of the fan impeller with the arrow for the direction of rotation 1. If the directions do not match, swap the two electrical connection phases. Repeat Steps 1 and 2. 10.2.4 Commissioning the pump o Fitter Personnel qualification: o Electrician... -
Page 23: During Operation
10 Operation 10.3 During operation ATTENTION Dry running can damage pump equipment. ► Ensure that the pump and the connected pipe system are filled properly. ► If the pump does not deliver after 10 – 15 seconds, abort commissioning. Note Ensure an oil level of at least 60 - 70 cm over the suction strainer in case of operation with a suction strainer. -
Page 24: Monitoring The Filter And/Or Strainer
10 Operation 10.3 During operation 10.3.2 Monitoring the filter and/or strainer Personnel qualification: o Trained personnel After commissioning monitor the degree of soiling of the filter and/or strainer by means of a suc- tion-side pressure gauge or a differential pressure indication. Also check the filters/strainers in the event of a pressure drop on the suction side. -
Page 25: Switching Off The Pump Unit
10 Operation 10.4 Decommissioning 10.3.4 Switching off the pump unit Personnel qualification: o Trained personnel ATTENTION Seal damage through pressurizing during standstill. ► Ensure that the maximum permissible system pressure is not exceeded. Switch off the motor. Close the pressure-side shut-off device. 10.4 Decommissioning 10.4.1 Decommissioning the pump Decommissioning is an operation interruption that requires different measures depending on the scope... -
Page 26: Recommissioning
11 Maintenance 10.5 Recommissioning Behaviour of the pumped liquid Duration of the operation interruption Short Long o Solids sediment Rinse the pump. Rinse the pump. o Congealed/frozen Heat or drain the pump. Drain the pump. o No corrosive burden o Congealed/frozen Heat or drain the pump. -
Page 27: Ball Bearing (Inner Bearing)
12 Servicing 11.3 Ball bearing (inner bearing) 11.3 Ball bearing (inner bearing) The ball bearings used are lubricated by the pumped liquid. Maintenance is therefore not required. The manufacturer recommends renewing the ball bearings every 20,000 operating hours. When using the pump in lubrication oil applications a bearings replacement at the latest after 5 years (40000 h) is suffi- cient. -
Page 28: 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. Increased leaking Incipient damage to seal Replace the shaft seal. -
Page 29: Installing The Coupling
12 Servicing 12.3 Replacing the coupling Secure the motor with eye bolts/hoisting equipment in such a way that the motor can be pulled out exactly axially. Remove the socket screws 1 between the motor 7 and the pump bracket 3 and pull off the motor. Loosen the fixing screw 6 at the motor-side coupling half 5. -
Page 30: Replacing The Mechanical Seal (Inner Bearing)
12 Servicing 12.4 Replacing the mechanical seal (inner bearing) Ensure that the fixing screw 11 of the pump-side coupling half 10 is loosened. Slide the pump-side coupling half onto the shaft until it stops and tighten the fixing screw. Tighten the socket screws 9 between the pump 2 and pump bracket 3 with torque. Measure and write down the distance X between the face of the coupling claws and the fitting surface of the pump bracket. -
Page 31: Installing The Mechanical Seal
12 Servicing 12.4 Replacing the mechanical seal (inner bearing) Remove the feather key 5 from the main screw 1. Remove the socket screws 4 and seal housing 3. Remove the flat gasket 7 and carefully clean the fitting surface of the seal housing. Attention: Ensure that the adapter sleeve 2 is not damaged. Mechanical seal standard/hard material: Press the stationary seal ring 12 from the seal housing. - Page 32 12 Servicing 12.4 Replacing the mechanical seal (inner bearing) Ensure that all parts of the mechanical seal are dismantled so that the supporting ring 18 with circlip 19 is visible on the shaft of the main screw 1. Clean the main screw around the mechanical seal carefully and grease it, and push the mounting sleeve main screw B onto the main screw.
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Page 33: Replacing The Radial Shaft Seal (Inner Bearing)
12 Servicing 12.5 Replacing the radial shaft seal (inner bearing) Position the flat gasket 7 at the seal housing. Attention: Ensure that the spring ring 2 is not damaged while mounting the seal housing. Take the holes in the pump flange into account. Carefully slide the seal housing with flat gasket until the pump flange stops at the main screw. -
Page 34: Installing The Radial Shaft Seal
12 Servicing 12.5 Replacing the radial shaft seal (inner bearing) 12.5.2 Installing the radial shaft seal Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Tool set, radial shaft seal Ä Spare parts, Page 50 Aids: o Torque wrench o Thread sealant (for example Loctite 572) -
Page 35: Replacing The Ball Bearing And Screw Set (Inner Bearing)
12 Servicing 12.6 Replacing the ball bearing and screw set (inner bearing) Position the flat gasket 7 on the seal housing. Attention: Ensure that the adapter sleeve 2 is not damaged while mounting the seal housing. Take the recess into account. Slide the seal housing 3 onto the main screw until it stops. Tighten the socket screws 4 between the seal housing and pump with torque. -
Page 36: Installing The Ball Bearing And Screw Set
12 Servicing 12.6 Replacing the ball bearing and screw set (inner bearing) Take the bearing bush set 9, consisting of bearing bush and segment washer, off the idle screws and keep it for mounting. Remove the edge sealing rings 8 from the flange cover. Remove the flat gasket 11 at the flange cover. -
Page 37: Replacing The Mechanical Seal And Ball Bearing (Outer Bearing)
12 Servicing 12.7 Replacing the mechanical seal and ball bearing (outer bearing) 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. - Page 38 12 Servicing 12.7 Replacing the mechanical seal and ball bearing (outer bearing) Secure the position of the main screw 1 in the pump housing 2. To do so, mount the main screw stop for the outer bearing F to the pump housing. Remove the feather key 7 from the main screw 1. Size 32 – 42: Remove the circlip 23 and supporting ring 22 from the main screw.
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Page 39: Installing The Mechanical Seal And Ball Bearing
12 Servicing 12.7 Replacing the mechanical seal and ball bearing (outer bearing) Mechanical seal standard/with quench: Remove the rotary seal ring 20 from the main screw. -or- Mechanical seal of hard material (without figure): Loosen the fixing screw of the mechanical seal (quantity depends on size) and remove the rotary seal ring from the main screw. -
Page 40: Replacing The Screw Set (Outer Bearing)
12 Servicing 12.8 Replacing the screw set (outer bearing) housing 3 and mount the circlip 16. Use the mounting arbour stationary seal ring A to press the stationary seal ring 14 with mounted O-ring into the seal housing. Clean the sliding surfaces of the mechanical seal carefully and grease with silicone grease. 11 13 Size 32 – 42: Insert the O-ring in the seal housing. -
Page 41: Installing The Screw Set
12 Servicing 12.8 Replacing the screw set (outer bearing) Requirement: ü Cartridge pump removed ü Shaft seal removed Clamp the pump at the main screw 2. Ensure that the shaft is not damaged in the process. Remove the socket screws 6 at the flange cover 5. Lift the cartridge housing 1 of the flange cover. - Page 42 12 Servicing 12.8 Replacing the screw set (outer bearing) Press the balancing cylinder 12 onto the shaft of the main screw 2. Slide the circlip ring 15 and supporting ring 14 onto the main screw. Unclamp the main screw, rotate it by 180° and clamp again. Mount the flange cover 5 onto the main screw.
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Page 43: 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 WARNING... - Page 44 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy 1 2 3 – 5 – – Suction head too high Reduce the level difference. -or- Reduce the line length. -or- Increase the line cross-section. -or- Heat up the pumped liquid. -or- Install a filter / strainer with a larger mesh width.
- Page 45 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – – 3 – – – – Vibrations/pulsations in the system Bear the pump unit elastically. -or- Make the connections with hoses. – – 3 – – – – Flow speed in the pressure line or suction line too high Set the flow speed in the pressure line so that it does not exceed 3 m/s.
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Page 46: 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 47 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...
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Page 48: Fluid Heating System
15 Accessories 15.1 Heating Commissioning the electrical heating system DANGER Risk of injury through discharging pumped liquid. The pump housing may burst through heat expansion of the pumped liquid. ► Open all the valves during the heating process. Switch on the electric heating system. Take the required heating-up periods into account Ä... -
Page 49: Heating System Special Design
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... -
Page 50: Spare Parts
16 Spare parts 16.1 Overview of inner bearing 16 Spare parts 16.1 Overview of inner bearing 745.1 884° 745.1 859.1° 869.2 222.1 056.1 056.1 056.2 915.1 735* 428** 056.3 869.2 869.1 859.3 869.2 745.2 859.2 056.3 222.2 915.2 1037 Mechanical seal standard/hard material Mechanical seal with receiver Radial shaft seal standard/high-temperature Mechanical seal with throttle ring... -
Page 51: Overview Of Outer Bearing
16 Spare parts 16.2 Overview of outer bearing 16.2 Overview of outer bearing 056.5* 869.3* 222.1 859.1 056.4 739.3**** 056.3 306** 054** 464*** 307** 884° 915.1 428° 869.1 869.2 745.2 859.3 056.3 222.2 915.2 859.2 1037 Mechanical seal standard/hard material Mechanical seal with receiver Qty. -
Page 52: Repair Kit, Overflow Valve
16 Spare parts 16.3 Repair kit, overflow valve 16.3 Repair kit, overflow valve Note The repair kit contains only the numbered parts and is only supplied complete. 165.1 Qty. Item no. Part Qty. Item no. Part 165.1 Screw plug Valve cone Adjusting screw Pressure spring Tab. 20: Repair kit, overflow valve... -
Page 53: Overview Of Accessories
16 Spare parts 16.4 Overview of accessories 16.4 Overview of accessories 739.2 739.1 137.1 915.4 165.1* 751* 222.4 304* 166* 222.4 915.3 Pressure housing Suction housing Suction strainer Connection for suction pipe Qty. Item no. Part Qty. Item no. Part Suction cover (suction pipe connection) Hose clamp Pressure housing... -
Page 54: 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 Note 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 55: 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 56 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...
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