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Troubleshooting
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Summary of Contents for KRAL W Series
- Page 1 Operating instructions KRAL screw pumps. Series W Magnetic coupling The safety instructions for persons with cardiac pacemakers, metallic implants or neurostimulators must be observed. OIW 02en-GB Edition 2024-10 Original instructions www.kral.at...
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Page 2: Table Of Contents
Table of contents 1 About this document........... 3 10.2.2 Filling and venting the pump ......18 10.2.3 Checking the direction of rotation....20 General information............ 3 10.2.4 Commissioning the pump....... 21 Associated documents ..........3 10.3 During operation ............22 Target groups ............. -
Page 3: 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 4: 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 5: 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 6: Identification
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 Fig. 2: Rating plate Differential pressure Nominal delivery rate Rated speed 10 Nominal viscosity... -
Page 7: 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 , 10 bar... -
Page 8: Function Description
5 Function description 5.1 Pump structure 5 Function description 5.1 Pump structure Fig. 3: Pump structure Suction cover Balancing cylinder Idle screw Ball bearing Pump housing Bearing cover Pressure housing Shaft end pump (main screw) 5.2 Pump unit structure Fig. 4: Pump unit structure Pump Motor shaft Containment can... -
Page 9: Magnetic Coupling
6 Transportation, storage 5.4 Magnetic coupling Axial support of the main screw 8 is carried out by a deep-groove ball bearing 6. In order to reduce the pressure, a balancing cylinder 5 is mounted at the main screw. The flow direction is marked on the pump housing by an arrow. 5.4 Magnetic coupling The shaft end of the pump 8 is enclosed by a containment can 10 that is connected air-tight with the motor-side flange of the pump. -
Page 10: Storing The Pump
6 Transportation, storage 6.5 Storing the pump 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. WARNING Risk of injury and damage to equipment through falling and toppling parts. -
Page 11: Preservation
7 Preservation 7.1 Preservation table o Transport personnel Personnel qualification: Aids: o Mobile crane, forklift, hoisting equipment 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 12: Preserving The Outer Surfaces
7 Preservation 7.3 Preserving the outer surfaces Close the packaging carefully. After about six months storage check the filling level of the preservative and if necessary top up. 7.3 Preserving the outer surfaces o Trained personnel Personnel qualification: Personal protective equipment: o Work clothing o Face protection o Protective gloves... -
Page 13: Installation, Removal
8 Installation, removal 8.1 Dangers during installation Clean the outside of the pump with solvents, if necessary using a steam-jet cleaning device. Remove the pressure-side blind flange carefully in order to reduce any pressure that may exist in the pump. Drain the pump, collecting the preservative in a suitable vessel. -
Page 14: 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 15: 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 Magnetic field. -
Page 16: Connecting The Pump To The Pipe System
9 Connection 9.2 Connecting the pump to the pipe system 9.2 Connecting the pump to the pipe system o Transport personnel Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Protective helmet o Safety boots Aids: o Mobile crane, forklift, hoisting equipment DANGER... -
Page 17: 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 DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►... -
Page 18: Operation
10 Operation 10.1 Dangers during operation 10 Operation 10.1 Dangers during operation The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before commissioning ensure that a safety valve has been installed in the pipe system on the pressure side before the first shut-off device. - Page 19 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 Aids: o Collection tank DANGER Magnetic field.
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Page 20: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning 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. DANGER Risk of death through discharging pumped liquid. -
Page 21: Commissioning The Pump
10 Operation 10.2 Commissioning ATTENTION Dry running can damage pump equipment. ► Ensure that the pump is filled properly. ► Switch the pump on for a maximum of one second and then off again immediately. Switch on the power supply and then turn it off again immediately. Compare the direction of rotation of the fan impeller with the arrow for the direction of rotation 1. -
Page 22: During Operation
10 Operation 10.3 During operation WARNING Hot surface. Touching of uninsulated hot surfaces results in burns. ► Insulate components and pipings in which hot liquids (> 60 °C) flow before commissioning. WARNING Risk of injury through emitted pumped liquid. Bursting of the containment can due to damage by iron particles in the medium. ►... -
Page 23: Monitoring The Filter And/Or Strainer
10 Operation 10.3 During operation 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 station. ATTENTION Leak in the pressure gauge through permanently opened pressure gauge shut-off valve. -
Page 24: Decommissioning
10 Operation 10.4 Decommissioning 10.4 Decommissioning 10.4.1 Decommissioning the pump Decommissioning is an operation interruption that requires different measures depending on the scope and duration of the interruption as well as the properties of the pumped liquid. o Fitter Personnel qualification: o Electrician o Work clothing Personal protective equipment:... -
Page 25: Recommissioning
11 Maintenance 10.5 Recommissioning Behaviour of the pumped li- Duration of the operation interruption quid Short Long o Remains liquid – – o No corrosive burden o Remains liquid – Drain the pump. o Corrosive burden Preserve the pump. Tab. 7: Measures depending on the behaviour of the pumped liquid Drain the pump via the pressure line, suction line, vent screws and screw plugs. -
Page 26: Ball Bearing
11 Maintenance 11.3 Ball bearing 11.3 Ball bearing When using the pump in lubrication oil applications with a minimum purity class of 21/18/13 according to ISO 4406, a bearings replacement at the latest after 5 years (40000 h) is sufficient. 11.4 Maintaining the pump Personnel qualification: o Fitter o Work clothing... - Page 27 11 Maintenance 11.5 Maintaining the magnetic coupling Check tightening torques of parts of the magnetic coupling annually in accordance with the table below. See also replacing the magnetic coupling Ä Servicing, Page 30, tightening torques to be observed Ä Appendix, Page 44. Carefully clean outer surfaces of the inner rotor, outer rotor and containment can from metallic solids and other adherences Ä...
- Page 28 11 Maintenance 11.5 Maintaining the magnetic coupling Fig. 9: Containment can Left: Outer surface free from grooves Right: Inside free from grooves Fig. 10: Containment can Left: Groove extends over the entire wall thickness Right: several deep grooves in succession Containment can Check the condition of the can, especially the inside.
- Page 29 11 Maintenance 11.5 Maintaining the magnetic coupling Fig. 11: Inner rotor Left: Inner rotor without adhesions Right: Large amount of iron particles accumulated on the inner rotor Inner rotor If iron particles adhere to the surface, degrease the inner rotor with a solvent (acetone) and com- pressed air to remove the particles.
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Page 30: Servicing
12 Servicing 12.1 Dangers during servicing ð The ball bearing must be replaced when the limits of the radial and axial play (bearing clear- ance) are exceeded. The limits of the radial bearing clearance for non-installed bearings are specified in DIN 620-4 or ISO 5753-1. -
Page 31: Replacing The Magnetic Coupling
12 Servicing 12.3 Replacing the magnetic coupling 12.3 Replacing the magnetic coupling 12.3.1 Removing the outer rotor Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Open-end spanner Aids: o Mounting lever o Hoisting equipment o Positive guide DANGER... - Page 32 12 Servicing 12.3 Replacing the magnetic coupling Requirement: ü Pump unit disconnected from the electrical power supply, deenergized and secured against being switched back on Before dismantling close the suction connection and pressure connection of the pump with pro- tective covers. Fixate the pump unit with suitable measures so that the pump cannot tilt after dismantling of the motor.
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Page 33: Removing The Inner Rotor
12 Servicing 12.3 Replacing the magnetic coupling 12.3.2 Removing the inner rotor Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Allen key Aids: o Anti-rotation screw DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►... -
Page 34: Installing The Outer Rotor
12 Servicing 12.3 Replacing the magnetic coupling Carefully clean the contact surfaces of the inner rotor 13, oil the clamping element 12 lightly. Manually turn out the screws of the clamping element by a few turns and insert the clamping ele- ment in the inner rotor. Carefully clean the sealing surfaces. - Page 35 12 Servicing 12.3 Replacing the magnetic coupling WARNING Danger of crushing between motor and pump. When dismantling/assembling the motor with the pump, the strong magnetic forces can cause sudden collision and therefore injuries to hands or fingers. ► Use positive guide for disassembly/assembly. ►...
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Page 36: Replacing The Ball Bearing And Screw Set
12 Servicing 12.4 Replacing the ball bearing and screw set Fix the outer coupling hub with clamping element: First tighten the screws of the clamping element 31 crosswise with half the torque. Subsequently tighten several times crosswise with the full torque. Fig. 15: Use of positive guide - priniciple diagram Fixate the pump 1 with suitable measures, so that the pump cannot tilt during mounting of the motor. -
Page 37: Installing The Ball Bearing And Screw Set
12 Servicing 12.4 Replacing the ball bearing and screw set Pull the bearing cover out of the pump housing together with the main screw. Remove the circlips 8 and 6 as well as the supporting ring 7. Remove the O-ring 5 from the bearing cover. Drive the main screw out of the bearing cover with light blows from a plastic hammer. - Page 38 12 Servicing 12.4 Replacing the ball bearing and screw set Clean the fitting surfaces, clean and grease the screw set carefully. Press the balancing cylinder 10 onto the main screw 2 and mount the circlip 11. Press the ball bearing 9 into the bearing cover and mount the circlip 6. Slide the main screw 2 into the bearing cover 3, mount the supporting ring 7 and circlip 8.
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Page 39: 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 DANGER... -
Page 40: Troubleshooting
14 Troubleshooting 14.2 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy 1 – – – – – – Pump suction line closed Check the shut-off devices. If required, open. 1 2 3 – 5 – – Parts soiled (filter, suction line, suction valve, strainer) Clean parts. - Page 41 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – – 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. -or- Set the flow speed in the suction line so that it does not exceed 1 m/s.
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Page 42: Spare Parts
15 Spare parts 15.1 Overview of spare parts 15 Spare parts 15.1 Overview of spare parts W 15 - 118 914.6 884* 914.7 063* 917.1* 917* 914.4 914.3 914.5 471.4 165.1 739.4 471.3 914.2 739.2 739.3 165.2 739.1 739.1 471.2 914.1** 901*** 894.1***... - Page 43 15 Spare parts 15.1 Overview of spare parts Qty. Item No. Part Qty. Item No. Part Containment can 739.2 O-ring Distance sleeve 739.3 O-ring Balancing cylinder 739.4 O-ring Outer coupling hub Deep-groove ball bearing Supporting ring 884* Threaded pin 063* Supporting ring Hexagon nut 165.1...
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Page 44: Appendix
16 Appendix 16.1 Tightening torques for screws with metric screw threads with and without wedge lock washers 16 Appendix 16.1 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 45: Tightening Torques For Screws Of Tensioning Elements
16 Appendix 16.3 Tightening torques for screws of tensioning elements 16.3 Tightening torques for screws of tensioning elements Tightening torque [Nm] Thread 12.9 17.4 42.2 M 10 83.0 M 12 Tab. 15: Tightening torques tensioning elements 16.4 Contents of the Declaration of Conformity The products described in these instructions are machinery in the sense of the Directive 2006/42/EC. - Page 46 Notes Operating instructions OIW 02en-GB Edition 2024-10...
- Page 47 Notes Operating instructions OIW 02en-GB Edition 2024-10...
- Page 48 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...
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