KRAL K Series Operating Instructions Manual
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Summary of Contents for KRAL K Series
- Page 1 Operating instructions KRAL screw pumps. Series K Radial shaft seal OIK 07en-GB Edition 2022-11 Original instructions www.kral.at...
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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 ...... - Page 3 Table of contents 16.2.2 Maintenance kit radial shaft seal standard or high-temperature KF/KH/KV 851 – 1301 ..43 16.2.3 Maintenance kit radial shaft seal standard or high-temperature KF/KH/KV 1500 – 1700 ..44 16.2.4 Maintenance kit radial shaft seal standard or high-temperature KF/KH/KV 2200 – 2900 ..45 16.2.5 Maintenance kit radial shaft seal standard or high-temperature KFT/KVT/KFN....
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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
1 About this document 1.4 Symbols 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. -
Page 6: Safety
2 Safety 2.1 Proper use 2 Safety 2.1 Proper use o Use the pump solely for transporting lubricating liquids that are chemically neutral and that do not contain gas or solid components. o Use the pump only within the operating limits specified on the rating plate and in the chapter "Tech- nical data". -
Page 7: Identification
3 Identification 3.1 Type code 3 Identification 3.1 Type code KF-1301.CBA.003297 Fig. 1: Type code Item Classification Description Type o Pump with free shaft end o Pump with inline flanges o Pump unit with or without pump bracket foot o Pump with free shaft end o Pump with overhead flanges in special design o Pump unit with or without pump bracket foot o Pump with free shaft end... -
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 , 10 bar Size 5 – 32 – 55 – 160 – 370 – 550 – 851 – 1500 – 2200 – 1301 1700 2900 Max. sound pressure level ±3 [dB(A)] Pump 53.0 57.0... -
Page 10: Pump Unit Structure
5 Function description 5.2 Pump unit structure 5.2 Pump unit structure 15 16 17 Fig. 4: Pump unit structure Pump Motor-side coupling half Pump-side coupling half Motor Coupling intermediate ring Pump bracket 5.3 Functional principle Screw pumps are rotating displacement pumps. The displacement effect results from three rotating screws 7 and 12 and the enclosing pump housing 3. -
Page 11: Shaft Seal
5 Function description 5.5 Shaft seal Housing Type Description KFN/KFT/KVT Flange arrangement: Overhead flange PN6/PN16 Flange arrangement: Overhead flange in special design PN16 Tab. 5: Housing variants 5.5 Shaft seal The following types of shaft seals are used: o Radial shaft seal, standard or high-temperature Radial shaft seal Screw plug Depending on the material used, radial shaft... -
Page 12: Transportation, Storage
6 Transportation, storage 6.1 Dangers during transportation 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 Dur- ing operation, Page 24. -
Page 13: Storing The Pump
6 Transportation, storage 6.5 Storing the pump ATTENTION Damage to equipment through improper transportation. ► Protect the pump against damage, heat, sunlight, dust and moisture. Fig. 6: Fastening of hoisting equipment - principle diagrams Attach the hoisting equipment to the pump/pump unit and tighten. Ensure that the centre of gravity lies exactly under the crane hook. -
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 discharging preservative. ► Wear personal protective equipment 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 WARNING Risk of injury and damage to equipment through falling and toppling parts. ► Only fasten the pump on a stable load-bearing underground or stable load-bearing load support. ► Ensure that fastening elements and pipings are fastened sufficiently. ATTENTION Damage to motor through discharging pumped liquid. -
Page 17: Connection
9 Connection 9.1 Dangers during connection work 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 death through emitted pumped liquid. -
Page 18: Insulating The Pump
9 Connection 9.3 Insulating 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 19: Connecting The Pump Unit To The Power Supply
9 Connection 9.5 Connecting the pump unit to the power supply ATTENTION Damage to coupling and bearing through incorrect alignment of the coupling. ► To guarantee a long service life of the coupling, align shaft ends exactly. ► After assembly check permissible displacement figures of the coupling according to table below. max. -
Page 20: Operation
10 Operation 10.1 Dangers during operation Ensure that the operating data on the rating plate of the motor agree with the operating data of the pump and with the local power supply. Carefully earth the pump bracket foot, base frame or pedestal via the screwing. Connect the motor in accordance with the operating instructions and circuit diagram in the motor terminal block. - Page 21 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 Risk of death through discharging pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic and can spray out under high pres- sure.
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Page 22: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning Sealing chamber vent hole Suction-side vent hole Pressure-side vent hole Requirement: ü Shut-off devices in the suction line and pressure line closed Remove the screw plug of the vent hole 1 so that the air can escape during the filling process. Remove the screw plug of the pressure-side vent hole 3. - Page 23 10 Operation 10.2 Commissioning DANGER Risk of death resulting from bursting components and discharging pumped liquid. As a result of impermissibly high pressure, components can burst with high energy, for example through the pressure-side pipe system being shut off. ► Wear personal protective equipment during all the work. ►...
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Page 24: During Operation
10 Operation 10.3 During operation Run the pump for a few minutes to allow the pipe system to vent fully. ð The pipe system is fully vented when the pump operating noise is smooth and a pressure gauge on the pressure side shows no more fluctuations. Checking overflow valve functions Ä... -
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 inter- Measure ruption... -
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 Leakage vent hole 4 weeks o If required, clean... -
Page 28: 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 29: Installing The Overflow Valve
12 Servicing 12.4 Replacing the coupling 12.3.2 Installing the overflow valve Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots Clean the fitting surface carefully and bond a new flat gasket 4 to the fitting surface. Insert the valve body 6, pressure spring 7 into the pump housing 5 and secure the pressure spring with the adjusting screw 8. -
Page 30: Installing The Coupling
12 Servicing 12.4 Replacing the coupling Remove the socket screws 8 between the pump 1 and pump bracket 3 and remove the pump bracket. Loosen the fixing screw 9 at the pump-side coupling half 10 and pull off the coupling half using a suitable tool. 12.4.2 Installing the coupling o Fitter Personnel qualification:... -
Page 31: Replacing The Ball Bearing And Radial Shaft Seal
12 Servicing 12.5 Replacing the ball bearing and radial shaft seal 12.5 Replacing the ball bearing and radial shaft seal 12.5.1 Removing the ball bearing and 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... -
Page 32: Mounting The Ball Bearing And Radial Shaft Seal
12 Servicing 12.5 Replacing the ball bearing and radial shaft seal 12.5.2 Mounting the ball bearing and 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 41 Aids: o Thread sealant (for example Loctite 572) o Molybdenum disulphide paste (for example Fenkart T4) -
Page 33: Replacing The Screw Set
12 Servicing 12.6 Replacing the screw set Size 851 – 2900: Insert the supporting ring 11 into the pump flange 4. Press the ball bearing 10 with mounting sleeve ball bearing C into the pump flange 4 up to the end position. Fix the ball bearing with the circlip 6 . Turn the pump flange 4 and press the main spindle 2 into the ball bearing 10 . -
Page 34: Installing The Screw Set
13 Disposal 13.1 Dismantling and disposing of the pump 12.6.2 Installing the screw set 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 41 Aids: o Thread sealant (for example Loctite 572) o Molybdenum disulphide paste (for example Fenkart T4) Clean the fitting surfaces carefully. -
Page 35: 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 36 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy 1 – 3 4 5 – – Viscosity of the pumped liquid too high Increase the temperature of the pumped liquid. -or- Decrease the speed. – 2 – – – – – Viscosity of the pumped liquid too low Reduce the temperature of the pumped liquid.
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Page 37: Accessories
15 Accessories 15.1 Heating Fault identification Cause Remedy – – – – – – 7 Inlet pressure too low Install a non-return valve at the pressure side. – – – – – – 7 Shaft seal is overloaded through thermal/chemical influences Check the maximum operating temperature. - Page 38 15 Accessories 15.1 Heating Size 5 – 118 Size 160 – 2900 1 heating element 2 heating elements 1 heating cover 1 heating cover 4 socket screws 4 socket screws Tab. 14: Scope of delivery of electrical heating system Operating data Parameter Unit Value Voltage Frequency [Hz] 50/60 Wire cross-section 2 x 1...
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Page 39: Fluid Heating System
15 Accessories 15.1 Heating Heating cover Heating element Connecting cable Fig. 13: Installation of electrical heating system Remove the socket screws and rating plate at the end cover of the pump. Mount the heating cover 072 to the end cover using the supplied socket screws. Screw the heating element 481 into the heating cover 072. -
Page 40: Heating System Special Design
15 Accessories 15.1 Heating Heating liquid operating data Parameter Unit Value Max. allowable working pressure [bar] Max. temperature [°C] Tab. 18: Heating liquid operating data 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... -
Page 41: Spare Parts
16 Spare parts 16.1 Overview 16 Spare parts 16.1 Overview Model/Size Type Variant Internal KF/KH/KV Maintenance kit Radial shaft seal OPW 09 5 – 660 Standard/High-temperature KF/KH/KV Maintenance kit Radial shaft seal OPW 10 Standard/High-temperature 851 – 1303 KF/KH/KV Maintenance kit Radial shaft seal OPW 11 1500 – 1700 Standard/High-temperature KF/KH/KV Maintenance kit... -
Page 42: Maintenance Kits
16 Spare parts 16.2 Maintenance kits 16.2 Maintenance kits 16.2.1 Maintenance kit radial shaft seal standard or high-temperature KF/KH/KV 5 – 660 Note The maintenance kit contains only the numbered parts and is only supplied complete. 165.5 471.2 471.3 914.1 055* 165.2 165.3 165.2 729.5 729.6... -
Page 43: Maintenance Kit Radial Shaft Seal Standard Or High-Temperature Kf/Kh/Kv 851 - 1301
16 Spare parts 16.2 Maintenance kits 16.2.2 Maintenance kit radial shaft seal standard or high-temperature KF/KH/KV 851 – 1301 Note The maintenance kit contains only the numbered parts and is only supplied complete. 165.2 165.5 165.2 471.3 471.2 914.1 165.3 729.6 729.5 729.4 914.5 914.2 165.1... -
Page 44: Maintenance Kit Radial Shaft Seal Standard Or High-Temperature Kf/Kh/Kv 1500 - 1700
16 Spare parts 16.2 Maintenance kits 16.2.3 Maintenance kit radial shaft seal standard or high-temperature KF/KH/KV 1500 – 1700 Note The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 165.5 914.1 471.3 165.2 165.3 165.2 729.5 729.6 729.4 914.2 165.4 165.1... -
Page 45: Maintenance Kit Radial Shaft Seal Standard Or High-Temperature Kf/Kh/Kv 2200 - 2900
16 Spare parts 16.2 Maintenance kits 16.2.4 Maintenance kit radial shaft seal standard or high-temperature KF/KH/KV 2200 – 2900 Note The maintenance kit contains only the numbered parts and is only supplied complete. 165.5 914.1 165.2 165.2 165.3 729.5 729.6 471.3 729.4 914.2 165.4 914.5 165.5... -
Page 46: Maintenance Kit Radial Shaft Seal Standard Or High-Temperature Kft/Kvt/Kfn
16 Spare parts 16.2 Maintenance kits 16.2.5 Maintenance kit radial shaft seal standard or high-temperature KFT/KVT/KFN Note The maintenance kit contains only the numbered parts and is only supplied complete. 471.2 165.5 471.3 055* 729.7 914.1 729.6 165.3 729.5 165.2 165.2 471.2* 914.2... -
Page 47: 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 Note 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 48: 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 Note 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 49: 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 Note 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 50: 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 Note 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 51: Tool Sets
16 Spare parts 16.4 Tool sets 16.4 Tool sets 16.4.1 Tool set, radial shaft seal Qty. Part Mounting arbour radial shaft seal ring Mounting sleeve main screw Mounting sleeve ball bearing 16.5 Completions 16.5.1 Completion Type KF 914.7 914.3 914.4 Qty. -
Page 52: 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 07en-GB Edition 2022-11... -
Page 53: 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 07en-GB Edition 2022-11... -
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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