KRAL K Series Operating Instructions Manual
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KRAL K Series Operating Instructions Manual

Screw pumps
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Operating Instructions
Screw pumps
K Series
OIK 08B
02_02/2005 Edition
Kräutler GmbH & Co., Bildgasse 40, A-6893 Lustenau, Austria, Telefon: +43 / (0) 55 77 / 8 66 44-0, Telefax: +43 / (0) 55 77 / 8 84 33
www.kral.at, E-mail: kral@kral.at

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  • Page 1 Operating Instructions Screw pumps K Series OIK 08B 02_02/2005 Edition Kräutler GmbH & Co., Bildgasse 40, A-6893 Lustenau, Austria, Telefon: +43 / (0) 55 77 / 8 66 44-0, Telefax: +43 / (0) 55 77 / 8 84 33 www.kral.at, E-mail: kral@kral.at...

  • Page 3: Table Of Contents

    Table of contents General information About this document General information Symbols used General safety instructions Standards and guidelines Additional standards and guidelines Technical data Labelling Type code Nameplate Operating data Intended use Operational limits Use not as intended Requisite NPSH values Noise levels Weight table for type KF Weight table for type KV...
  • Page 4 Table of Contents Maintenance requirement Maintenance of seal Maintaining the mechanical seal General drawing of the pump with coupling and motor General drawing Replacing the coupling Removing the coupling Installing the coupling General drawing of the pump General drawing Replacing the mechanical seal Removing the mechanical seal Installing the mechanical seal Replacing the radial shaft seal Domsel type...

  • Page 5: General Information

    – Only suitably qualified and trained personnel are allowed to fit, remove and install the equipment. • Do not use KRAL pumps beyond the operational limits stated on the nameplate and in the operating data of the technical data section, see "Operating data", page 4. If the operating data do not match the details on the nameplate, contact the manufacturer to resolve the matter.

  • Page 6: Standards And Guidelines

    • EN 62079 (Preparation of Instructions) • VDMA 24292 (Operating Instructions for Pumps and Pump Units Additional standards and guidelines The enclosed Manufacturer’s Declaration provides information about additional safety regulations and standards that were taken into consideration in the design of KRAL pumps.

  • Page 7: Technical Data

    Technical data Labelling Type code Different types of KRAL pumps are available. The type code specifies the type of pump construction. <1> Model KV - 851.AAA.000372 <2> Size <3> Shaft seal type <4> Pressure stage <5> Heating system <6> Version index Fig.

  • Page 8: Nameplate

    Operating data Intended use KRAL screw pumps of the K series are designed solely to deliver lubricating fluids that are chemically inert and have no gas or solids content. The pumps must only be used within the operational limits described in this section.

  • Page 9: Use Not As Intended

    Technical data Pump sizes K 5– 42 K 55–118 K 160–275 K 370–450 K 550–660 K 851–1301 K 1501–1701 Pressure [bar] Max. temperature [°C] • with standard mechanical seal • with mechanical seal of resistant material • with radial shaft seal NBR •...

  • Page 10: Requisite Npsh Values

    Technical data Falling below or exceeding the Consequences of not keeping within the operational limits limit Suction pressure too low • Noise develops as a result of cavitation • Delivery rate drops Suction pressure too high • Damage to shaft seal •...
  • Page 11 Technical data Pump size Viscosity Rotation speed [1/min] 1450 1750 2900 3500 K 7,5 K 10 K 15 K 20 K 32 K 42 K 55 K 74 K 85 K105...
  • Page 12 Technical data Pump size Viscosity Rotation speed [1/min] 1450 1750 2900 3500 K 118 K 160 K 210 – – K 235 – – K 275 – – K 370 – – K 450 – – – K 550 – –...

  • Page 13: Noise Levels

    Technical data Pump size Viscosity Rotation speed [1/min] 1450 1750 2900 3500 K 1101 – – – – K 1301 – – – – K 1501 – – – – K 1701 – – – – Tab. 3 Requisite NPSH values Noise levels The table below shows the noise levels to be expected from the equipment during operation, in accordance with the pump size:...

  • Page 14: Weight Table For Type Kv

    Technical data Pump size K 15 K 32 K 55 K 105 K 160 K 235 K 370 K 550 K 851 K 1101 K 1501 K 7,5 K 20 K 42 K 74 K 118 K 210 K 275 K 450 K 660 K 951...

  • Page 15: Weight Table For Type Kh

    Technical data Pump size K 15 K 32 K 55 K 105 K 160 K 235 K 370 K 550 K 851 K 1101 K 1501 K 7,5 K 20 K 42 K 74 K 118 K 210 K 275 K 450 K 660 K 951...

  • Page 16: Heating

    Technical data Heating The different pump sizes can be supplied with or without a heating system. The type code gives information about the type of construction, see Fig. 1, page 3. The following types are available: • without ancillary heating •...

  • Page 17: Functional Description

    Functional description Functional description General drawing of a screw pump Fig. 1 Structure of a screw pump <1> setscrew <8> ball bearing <2> overflow valve <9> flange cover <3> pump casing <10>thrust pin <4> compensating cylinder <11>balancing hole <5> vent of seal housing <12>end cover <6>...

  • Page 18: General Drawing Of A Screw Pump With Coupling And Motor

    Functional description General drawing of a screw pump with coupling and motor Fig. 2 Structure of a screw pump with coupling and motor <K1>pump <K4>motorside coupling part <K2>pumpside coupling part <K5>motor <K3>coupling intermediate ring Characteristics of screw pumps • High power density The axial flow allows comparatively good delivery rates relative to the pump size.

  • Page 19: Screw Set And Casing

    Functional description Screw set and casing Screw pumps belong to the group of pumps known as rotary positive displacement pumps. The special shaping of these pumps allows virtually leakproof engagement of the three intermeshing screws <7>, <13>. Closed volumes are formed in conjunction with the pump casing <3> covering the set of screws.
  • Page 20 Functional description Radial shaft seal: Fig. 3 Structure of a K-pump with radial shaft seal <R1>plugscrew <R3>circlip <R2>radial shaft seal <R4>plugscrew At the use of a radial shaft seal the leakage holes are closed, as this type of shaft seal is positioned so close to the motor, that the drain chamber is included in the sealing chamber.

  • Page 21: Main Screw Bearing

    Functional description At the operation of non-volatile media or liquids, which are likely to harden at contact with the atmosphere, a mechanical seal can be used together with a radial shaft seal. Thus the sealing chamber is joined with a quench container via the leakage holes. As a result the liquid side of the mechanical seal can always be hold under exclusion of air.

  • Page 22: Overflow Valve

    KRAL screw pumps of the K series have an integrated valve of this type. The valve is accessible via a plugscrew <1> in the end cover and can be adjusted from the outside. When it leaves the factory, the opening pressure of the valve is set at 110% of the nominal pressure.

  • Page 23: Heating

    Functional description Heating As an option, pumps can be equipped with ancillary heating. This is advisable for high-viscosity media, which unless heated do not flow freely enough, which would lead to excessive power consumption and to problems with cavitation or sealing. Electrical and medium heating systems are described below.
  • Page 24 Functional description...

  • Page 25: Transportation, Storage And Disposal

    Transportation, storage and disposal Transportation Raising the pump Fig. 1 Raising a pump with free shaft end Requirement: • Separate lifting accessories of the correct size • The hoisting gear used must comply with local directives and accident prevention regulations DANGER! Risk of injury and/or damage to equipment should the pump fall.

  • Page 26: Raising The Pump Unit

    Transportation, storage and disposal Raising the pump unit Fig. 2 Raising a pump unit Requirement: • Separate lifting accessories of the correct size • The hoisting gear used must comply with local directives and accident prevention regulations DANGER! Risk of injury and/or damage to equipment should the pump unit fall. Use correctly proportioned and intact separate lifting accessories.

  • Page 27: Storage And Preservation

    Transportation, storage and disposal Storage and preservation Storage During the test run, the internal components of the pump are wetted with test oil, which has a preservative effect. The pipe connections are fitted with protective caps. Unless otherwise specified, the external components of the pump are preserved with a single-coat PU-based two- pack paint.

  • Page 28: Disposal

    Transportation, storage and disposal Disposal Safe disposal It is essential to comply with the following safety instruction during disposal: • Comply with local disposal regulations. Disposing of the pump Resources: • Solvent or industrial cleaner suitable for the pumped medium 1.

  • Page 29: Installation, Removal And Connection

    Installation, removal and connection Installation Locating the pump Screw pumps can be operated in any mounting position. However, we recommend that you do not mount the pump above the motor, as should there be a leak, the pumped medium could get inside the motor.

  • Page 30: Installing The Pump

    Installation, removal and connection Installing the pump If the piping system has to be flushed out with the pump, the pump must be protected by a startup filter to stop particles of dust getting inside. The mesh width of the startup filter is relevant to the size of the pump.

  • Page 31: Aligning And Checking The Shaft Coupling

    Installation, removal and connection WARNING! Any mechanical tension may damage equipment or impair operation. Make sure that the pump mounting on the piping system is free of mechanical stress. 1. Turn the pump shaft or the fan impeller of the motor. This is to test that the pump runs smoothly.

  • Page 32: Electrical Connection

    Installation, removal and connection 1. Check the linear offset <c> of the coupling with a slide gauge or feeler gauge. If the limits in the above table are exceeded, loosen the pump or motor attachment and move the unit to accomodate the linear offset <c>. 2.
  • Page 33 Installation, removal and connection DANGER! Electric shock can endanger life. Only allow authorised and qualified personnel to disconnect the pump. Make sure that the electricity supply is not live. DANGER! When removing the pump, you are at risk of injury from escaping hot, toxic or caustic pumped media.
  • Page 34 Installation, removal and connection...

  • Page 35: Operation

    Operation Startup Filling the pump There are three possible ways to fill the pump: • via the shut-off device on the suction side • via the shut-off device on the pressure side • via the vent holes <1> seal vent hole <2>...

  • Page 36: Checking The Direction Of Rotation

    Operation Checking the direction of rotation The direction of rotation and the direction of flow 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 rotation.

  • Page 37: Commissioning The Pump

    An overflow valve is integrated into KRAL pumps of the K series. The overflow valve prevents too high a pressure building up in the pump. The overflow valve is set to 110 % of nominal pressure at the factory. This opening pressure must not be exceeded in normal pump operation, otherwise the opening pressure of the valve will have to be reset.
  • Page 38 Operation Requirement: • Pump in operation • Pressure gauge on the pressure side of the pump Resource: • Allen key for each pump size in accordance with the following table Pump size DIN 908 Hexagon socket K 5–20 R 1/4 " SW 6 K 32–...

  • Page 39: Pump Shutdown

    Operation Pump shutdown Switching off the pump Requirement: • Pump in operation WARNING! Pressurizing the pump while it is at a standstill may damage the pump seals. Make sure that while the pump is at a standstill, the pressure in the pump does not exceed the inlet pressure during operation.
  • Page 40 Operation...

  • Page 41: Servicing

    Servicing Maintenance Maintenance requirement The service life of the pump is heavily dependent on the pump operating conditions. If the operational limits are adhered to, see "Operating data", page 4, the pump will last for many years. Symptoms of advanced wear in individual pump components can be detected in accordance with the following table.

  • Page 42: Maintenance Of Seal

    Servicing Maintenance of seal Maintaining the mechanical seal When operating the pump with low volatile liquids (e.g. heavy fuel oil) the regular small amounts of leakage may form solid deposits on the atmospheric side of the seal. During long-term operation the increasing abrasive components may pile up to such an extent that a free drainage of the leakage is not ensured anymore.

  • Page 43: General Drawing Of The Pump With Coupling And Motor

    Servicing General drawing of the pump with coupling and motor General drawing Fig. 1 Exploded view of a K-pump with coupling and motor <K1>pump <K7>motor <K2>socket screws <K8>hexagon screws <K3>distance sleeve <K9>socket screws <K4>pump side coupling part <K10>pump bracket <K5>coupling intermediate ring <K11>pump pedestal <K6>motor side coupling part...

  • Page 44: Replacing The Coupling

    Servicing Replacing the coupling Removing the coupling Requirement: • Pump dismantled, see "Removing the Pump", page 28 1. Before starting to disassemble the aggregate use suitable covers to protect the pump internals from dirt and solid bodies. 2. Remove hexagon screws <K8> which connect motor <K7>...
  • Page 45 Servicing 4. Open fixation screw of the motor side coupling part <K6>. 5. Remove coupling part <K6> with suitable extrac- tor. 6. Open socket screws <K2> which connect pump <K1> and pump bracket <K10>. 7. Lift the pump bracket <K10> together with pump pedestal <K11>...
  • Page 46 Servicing 8. Remove fixation screw of the pump side coupling part <K4>. 9. Take off the coupling part <K4> by means of suit- able levers. 10. Take off the coupling distance sleeve <K3> from the shaft.

  • Page 47: Installing The Coupling

    Servicing Installing the coupling Requirement • Replacement coupling available 1. Slide distance sleeve of the coupling <K3> onto the pump shaft until it is flush with the bearing circlip. 2. Slide pump side coupling part <K4> onto the pump shaft until it is flush with the distance sleeve <K3>.
  • Page 48 Servicing 4. Put the pump bracket <K10> with pump pedestal <K11> onto the pump. 5. Tighten connecting screws <K2> of pump and pump bracket. 6. Measure distance X between front face of cou- pling part and connecting surface of pump brack- 7.
  • Page 49 Servicing Check distance between front face of coupling gears and connecting surface of motor flange. Ad- just to the value x - c (see Tab. 2, page 27). 9. Insert elastic coupling intermediate ring <K5> and tighten fixation screw at the coupling part <K6>. 10.
  • Page 50 Servicing 12. Tighten connecting screws <K8> of motor and pump bracket. 13. Remove protective covers only just before con- necting the pump unit to the pipe system.

  • Page 51: General Drawing Of The Pump

    Servicing General drawing of the pump General drawing Fig. 2 Exploded view of a K-pump <1>socket screws <13>flat gasket <25>straight pin <36>spacer <2>plug screw <14>flange cover <26>circlip * <37>circlip <3>flat gasket <15>plug screw * <27>radial shaft seal * <38>balancing cylinder <4>end cover <16>flat gasket * <28>flat gasket...

  • Page 52: Replacing The Mechanical Seal

    Servicing Replacing the mechanical seal Removing the mechanical seal Requirement: • Pump dismantled, see "Removing the Pump", page 28 1. Unscrew the four socket screws <21> on the flange cover <14>. 2. Loosen the flange cover <14> with gentle "re- bound"...
  • Page 53 Servicing 4. Detach the circlip <17>. 5. Remove the support ring <18>. 6. Expel the main screw <39> with the mechanical seal <30>–<35> by gently driving it out of the bearing <20> with a soft hammer. 7. Press the counter ring <31> of the mechanical seal cautiously out of the flange cover <14>...
  • Page 54 Servicing 8. Remove o-ring <30> from flange cover <14> , if it has not been removed together with the coun- ter ring <31>. 9. Gently turn the rotating ring <32> with conical spring <35>, thrust ring <34> and o-ring <33>, to push them down from the main screw <39>.

  • Page 55: Installing The Mechanical Seal

    Servicing Installing the mechanical seal Requirement: • Replacement seal available • New flat gasket available 1. Carefully remove the remains of the flat gasket <9> from the flange cover <14> and pump casing <6>. 2. Carefully clean the supporting surface of the o- ring in the flange cover <14>.
  • Page 56 Servicing 4. Insert the counter ring <31> with drawn-on o-ring <30>into the flange cover <14>. Make sure that the dowel pin <22> for the locking element is sit- ting in the notch of the counter ring. 5. Press the counter ring <31> flush into the flange cover <14>...
  • Page 57 Servicing 8. Carefully clean the slide surfaces of rotating ring <32> and counter ring <31> with cleaning spirit. 9. Administer a drop of resin-free lubricating oil to the slide surfaces of rotating ring <32> and coun- ter ring <31>. Do not touch the slide surfaces thereafter.
  • Page 58 Servicing 12. To fix the main screw <39>, fit the circlip <17>. 13. Place the new flat gasket <9> onto the pump cas- ing <6>. Carefully grease the sealing surfaces. 14. Turn the preassembled unit until the vent hole in the flange cover <14>...
  • Page 59 Servicing 16. Tighten the four socket screws <21> on the flange cover <14>.

  • Page 60: Replacing The Radial Shaft Seal Domsel Type

    Servicing Replacing the radial shaft seal Domsel type Removing the radial shaft seal Requirement: • Pump dismantled, see "Removing the Pump", page 28 1. Unscrew the four socket screws <21> on the flange cover <14>. 2. Loosen the flange cover <14> with gentle "re- bound"...
  • Page 61 Servicing 4. Detach the circlip <17>. 5. Remove the support ring <18>. 6. Expel the main screw <39> by gently driving it out of the bearing <20> with a soft hammer. 7. Remove the circlip <26>.

  • Page 62: Installing The Radial Shaft Seal

    Servicing 8. Remove the radial shaft seal <27>. If manual dis- mantling is impossible, use an appropriate arbor. Normally dismantling destroys the shaft seal. Installing the radial shaft seal Requirement: • Replacement seal available • New flat gasket available 1. Carefully remove the remains of the flat gasket <9>...
  • Page 63 Servicing 3. Prepare a suitable arbor for the assembly of the radial shaft seal. The arbor has to lie flush on the support surface of the seal and must not have any sharp edges in the area of the sealing lip. 4.
  • Page 64 Servicing 7. Grease-in the gap of the radial shaft seal <27> with MoS -paste (type Fenkart T4 or the like). 8. Before mounting the main screw <39> slide-on a suitable sleeve to protect the radial shaft seal <27> against possible damages caused by key or shaft shoulder.
  • Page 65 Servicing 11. Insert the ball bearing <20>. 12. Press-in the ball bearing <20> into the flange cov- er <14>. 13. Slide-on the support ring <18> and mount the cir- clip <17> to fix the main screw. 14. Place the new flat gasket <9> onto the pump cas- ing <6>.
  • Page 66 Servicing 15. Turn the preassembled unit until the vent hole in the flange cover is in the same position as the as- sociated hole in the pump casing. Take care of po- sition of straight pin <25>. 16. Push the preassembled unit comprising the flange cover <14>...

  • Page 67: Replacing The Ball Bearing

    Servicing Replacing the ball bearing Removing ball bearings Requirement: • Pump dismantled, see "Removing the Pump", page 28 1. Unscrew the four socket screws <21> on the flange cover <14>. 2. Loosen the flange cover <14> with gentle "re- bound" blows. 3.
  • Page 68 Servicing 4. Detach the circlip <17>. 5. Remove the support ring <18>. 6. Expel the main screw <39> with the mechanical seal <30>–<35> by gently driving it out of the bearing <20> with a soft hammer. 7. Loosen the circlip <19> in the flange cover <14>.

  • Page 69: Installing Ball Bearings

    Servicing 8. Use an extractor to pull the bearing <20> out of the flange cover <14>. Installing ball bearings Requirement: • Replacement bearing available • New flat gasket available 1. Carefully remove the remains of the flat gasket <9> from the flange cover <14> and pump casing <6>.
  • Page 70 Servicing 3. To attach the ball bearing <20> in the flange cov- er <14>, fit the circlip <19>. 4. Carefully clean the slide surfaces of rotating ring <32> and counter ring <31> with cleaning spirit. 5. Administer a drop of resin-free lubricating oil to the slide surfaces of rotating ring <32>...
  • Page 71 Servicing 7. Slide-on the support ring <18>. 8. To fix the main screw <39>, fit the circlip <17>. 9. Place the new flat gasket <11> onto the pump casing <14>. Carefully grease the sealing surfac- 10. Turn the preassembled unit until the vent hole in the flange cover <14>...
  • Page 72 Servicing 11. Push the preassembled unit comprising flange cover <14> and the main screw <39> into the pump casing <6>, until the main screw engages in the idle screws <40>. Turn the main screw while doing this. 12. Tighten the four socket screws <21> on the flange cover <14>.

  • Page 73: Replacing The Set Of Screws

    Servicing Replacing the set of screws Removing the set of screws Requirement: • Pump dismantled, see "Removing the Pump", page 28 1. Unscrew the four socket screws <21> on the flange cover <14>. 2. Loosen the flange cover <14> with gentle "re- bound"...
  • Page 74 Servicing 4. Detach the circlip <17>. 5. Remove the support ring <18>. 6. Expel the main screw <39> with the mechanical seal <30>–<35> by gently driving it out of the bearing <20> with a soft hammer. 7. Gently turn the rotating ring <32> with conical spring <35>, thrust ring <34>...

  • Page 75: Installing The Set Of Screws

    Servicing Remove the spacer <36> from the main screw . 9. Remove the idle screws <40> from the pump casing <6>. Installing the set of screws Requirement: • Replacement set of screws available • New flat gasket available 1. Carefully remove the remains of the flat gasket <9>...
  • Page 76 Servicing 2. Insert the new idle screws <40> into the pump casing <6>. 3. Carefully clean and grease the new main screw <39> in the region of the shaft seal. 4. Fit the spacer <36>. Carefully push conical spring <35>, thrust ring <34> and rotating ring <32> with o-ring <33>...
  • Page 77 Servicing 6. Administer a drop of resin-free lubricating oil to the slide surfaces of rotating ring <32> and coun- ter ring <31>. Do not touch the slide surfaces thereafter. 7. Press-in the main screw <39> with the seal parts pushed on, until it stops in the ball bearing <20> in the flange cover <14>.
  • Page 78 Servicing 10. Place the new flat gasket <9> onto the pump cas- ing <6>. Carefully grease the sealing surfaces. 11. Turn the preaseembled unit until the vent hole in the flange cover <14> is in the same position as the associated hole in the pump casing <6>. Take care of position of straight pin <25>.

  • Page 79: Assistance With Problems

    Assistance with problems Troubleshooting Faultfinding reference Malfunctions can have different causes. The following table lists the symptoms of a fault, the possible causes and measures for elimination. Findings Cause and remedy No pump suction Pump suction pipe closed Check shut-off devices in the suction pipe and open it, if necessary.
  • Page 80 Assistance with problems Findings Cause and remedy Delivery rate too low Differential pressure at the pump too high Check the installation and reduce the differential pressure. Viscosity of the pumped medium too high Raise the temperature of the medium - or - reduce the rotation speed.
  • Page 81 Assistance with problems Findings Cause and remedy Pump runs noisily Dirty filter Clean the filter. Suction valve or pipe obstructed Check for clear passage through the suction valve and pipe. Leaking suction pipe or shaft seal Check suction pipe or shaft seal for leaks. Pay particular attention to leakage at valves and connection points.
  • Page 82 Assistance with problems Findings Cause and remedy Motor overload Motor running at wrong voltage or frequency 1. Make sure that the motor voltage and frequency match the operating voltage. 2. Compare the speed of the motor with the pump nameplate. If the data does not match, adjust the speed of the motor.
  • Page 83 Assistance with problems Findings Cause and remedy Leaking shaft seal Dry running has damaged the shaft seal Replace the shaft seal, see "Removing the mechanical seal", page 48. When starting up the pump, pay attention to venting. Inlet pressure too high Reduce the inlet pressure at the installation end.
  • Page 84 Assistance with problems...

  • Page 85: Appendix

    Appendix General drawings Exploded view of pump with coupling and motor Fig. 1 Exploded view of a K-pump with coupling and motor Item no. Part Spare part no. Item no. Part Spare part no. <K1> pump <K7> motor <K2> socket screws 914,1 <K8>...

  • Page 86: Exploded View Of The Pump

    Appendix Exploded view of the pump Fig. 2 Exploded view of a K-pump Item no. Part Spare part no. Item no. Part Spare part no. <1> socket screws 914,2 <22> dowel pin <2> plug screw 165,1 <23> flat gasket* 729,3 <3>...
  • Page 87 Appendix Item no. Part Spare part no. Item no. Part Spare part no. <15> plug screw* 165,3 <36> <16> flat gasket* 729,3 <37> plug screw 165,2 <17> circlip 471,2 <38> flat gasket 729,2 <18> support ring <39> valve cone <19> circlip 471,3 <40>...
  • Page 88 Kräutler GmbH. & Co., Bildgasse 40, A-6893 Lustenau, Austria, Telephone: +43 / (0) 55 77 / 8 66 44-0, Telefax: +43 / (0) 55 77 / 8 84 33 www.kral.at, E-mail: kral@kral.at...

This manual is also suitable for:

K 5-42K 55-118K 160-275K 370-450K 550-660K 851-1301 ... Show all

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