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Summary of Contents for KRAL G Series
- Page 1 Operating instructions KRAL screw pumps. G series Mechanical seal OIG 02en-GB Edition 2025-04 Original instructions www.kral.at...
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Page 2: Table Of Contents
Table of contents 1 About this document........... 3 10 Operation ..............21 General information............ 3 10.1 Dangers during operation ........... 21 Associated documents ..........3 10.2 Commissioning ............21 10.2.1 Cleaning the pipe system ....... 21 Target groups ............. 3 10.2.2 Filling and venting the pump ...... -
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. 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... -
Page 5: 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 6: 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 Fig. 2: Rating plate Differential pressure Nominal delivery rate Rated speed 10 Nominal viscosity... - Page 7 4 Technical data 4.1 Operating limits Size Parameter Unit 15 – 20 32 – 42 55 – 85 105 – 118 160 – 210 235 – 275 o Mechanical [°C] seal of hard material o Standard [°C] radial shaft seal o High-tem- [°C] perature ra- dial shaft seal o Shaft seal [°C] Customer-specific, contact the manufacturer special design...
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Page 8: Limit Values For Tank Installation
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 4.4 Sound pressure level Guide values at 1 m distance, 1450 min... -
Page 9: Function Description
5 Function description 5.1 Pump structure 5 Function description 5.1 Pump structure Fig. 4: Pump structure Suction side Flange cover Suction cover Leakage vent hole Pump housing Ball bearing Pressure side Balancing cylinder Venting sealing chamber Overflow valve (optional) Main screw Idle screw Mechanical seal 5.2 Pump unit structure... -
Page 10: Functional Principle
5 Function description 5.3 Functional principle 5.3 Functional principle Screw pumps are rotating displacement pumps. The displacement effect results from three rotating screws 6 and 13 and the enclosing pump housing 3. Radial support of the screw set is provided through the sliding contact in the pump housing that de- pends on lubrication by the pumped liquid. -
Page 11: Overflow Valve (Optional)
5 Function description 5.6 Overflow valve (optional) This leakage level depends on various factors, mainly including size, rotation speed and differential pressure. A leakage of less than 10 drops/hour (≈ 0.5 cm /h) is normal and is no reason for replacing the mechanical seal. -
Page 12: Transportation, Storage
6 Transportation, storage 6.1 Dangers during transportation 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. o Ensure that the means of transport is in a flawless state. -
Page 13: Storing The Pump
6 Transportation, storage 6.5 Storing the pump Fig. 8: Fastening of hoisting equipment - principle diagrams Attach the hoisting equipment to the pump/pump unit and tighten. Ensure that the centre of grav- ity lies exactly under the crane hook. 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. -
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 ATTENTION Damage to motor through discharging pumped liquid. ► Do not install the pump above the motor. ATTENTION Damage to device through impurity in the pipe system. ► During welding work attach protective covers in front of the connecting flanges. ►... -
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: Turning The Radial Suction Cover
9 Connection 9.2 Turning the radial suction cover 9.2 Turning the radial suction cover o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Safety boots Aids: o Torque wrench Remove the screws 1 and remove the radial suction cover 2. Ensure that the O-ring 3 is inserted in the pump housing. -
Page 19: Insulating The Pump
9 Connection 9.4 Insulating the pump Fig. 10: Connection to pipe system Turn the pump shaft or the fan impeller of the motor. This tests that the pump runs smoothly. If the pump shaft cannot be turned by hand, remedy the fault before installing the pump Ä Troubleshooting, Page 36. -
Page 20: Connecting The Pump Unit To The Power Supply
9 Connection 9.6 Connecting the pump unit to the power supply max. ΔKa min. ΔKw (mm) = L max. - L min. max. = L + ΔKa Fig. 11: Coupling alignment measuring points Outer diameter Coupling dis- Max. axial displace- Max. radial displace- Max. -
Page 21: 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 22: Filling And Venting The Seal-Less Pump
10 Operation 10.2 Commissioning 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. ► Wear personal protective equipment during all the work. Ensure face protection. ►... -
Page 23: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning Pressurise the pump. ð Air and pumped liquid 1 exit via the seal-less shaft end. Maintain the venting process for two minutes. 10.2.4 Checking the direction of rotation The direction of rotation is indicated by an arrow on the pump flange/pump housing. The direction of ro- tation of the motor specifies the direction of rotation of the pump. - Page 24 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.
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Page 25: During Operation
10 Operation 10.3 During operation 10.3 During operation 10.3.1 Checking the operating pressure Personnel qualification: o Trained personnel Fig. 13: Pressure gauge shut-off valves closed/open - principle diagram ATTENTION Leak in the pressure gauge through permanently opened pressure gauge shut-off valve. ►... -
Page 26: Test The Overflow Valve
10 Operation 10.3 During operation Turn the adjusting screw 2 to set the opening pressure: Turning clockwise: Increase the opening pressure Turning counter-clockwise: Reduce the opening pressure Repeat Steps 2 and 3 until the desired opening pressure is reached. Tighten the screw plug 1 again. 10.3.3 Test the overflow valve Personnel qualification: o Trained personnel... -
Page 27: 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 28: Recommissioning
11 Maintenance 10.5 Recommissioning 10.5 Recommissioning 10.5.1 Recommissioning the pump Depending on the extent and duration of the interruption of operation, carry out steps as for com- missioning Ä Commissioning, Page 21. 11 Maintenance 11.1 Dangers during maintenance The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. -
Page 29: Cleaning The Leakage Vent Hole
12 Servicing 11.5 Cleaning the leakage vent hole Check the pump visually and acoustically every four weeks. If there are signs of wear, eliminate the cause Ä Servicing, Page 29. 11.5 Cleaning the leakage vent hole The regular small amounts of leakage can result in deposits that can prevent free draining of further leakage liquids after a longer operating period. -
Page 30: Mechanical Seal
12 Servicing 12.3 Replacing the coupling Finding Cause Elimination Increased play in the coupling Advanced wear of the coupling Replace the coupling inter- intermediate ring mediate ring. Reduction in the delivery rate or Advanced wear of screws and Replace the pump. pressure under constant operat- housing ing conditions... -
Page 31: Installing The Coupling
12 Servicing 12.3 Replacing the coupling Secure the pump 2 with eye bolts/hoisting equipment in such a way that the pump bracket can be pulled exactly horizontally from the pump. Remove the socket screws between the pump bracket foot and the mounting surface. Pull out the socket screws 9 between the pump and pump bracket and remove the pump bracket. -
Page 32: Replacing The Mechanical Seal And Ball Bearing
12 Servicing 12.4 Replacing the mechanical seal and ball bearing Ensure that the fixing screw 6 of the motor-side coupling half 5 is loosened. Slide the motor-side coupling half onto the shaft end of the motor 7. Check the distance between the face of the coupling teeth pump-side and the fitting surface of the motor flange. -
Page 33: Installing The Mechanical Seal And Ball Bearing
12 Servicing 12.4 Replacing the mechanical seal and ball bearing Mark the position of the vent hole 15 on the pump housing. Remove the socket screws 2 and take off the flange cover 3. Remove the O-ring 4. Remove the screw set (main screw 6 with idle screws 7) with ball bearing 13 and mechanical seal 9 with spring from the pump housing 8 . - Page 34 12 Servicing 12.4 Replacing the mechanical seal and ball bearing 10 11 Clean the fitting surfaces of the flange cover 3, lightly grease the O-ring of the stationary seal ring 14. Press the counter ring 14 with mounted O-ring into the flange cover 3 using the counter ring as- sembly mandrel A.
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Page 35: Disposal
13 Disposal 13.1 Dismantling and disposing of the pump Clean the sliding surfaces of the mechanical seal carefully and grease with silicone grease. Lightly grease the O-ring 4 and position it on the pump housing 8. Warning: When installing the flange cover 3, ensure that the vent hole 15 is positioned in the same place as before removal (see mark on the pump housing 8). -
Page 36: Troubleshooting
14 Troubleshooting 14.1 Possible faults 14 Troubleshooting 14.1 Possible faults Faults can have different causes. The following tables list the symptoms of a fault, the possible causes and measures for troubleshooting. Identifica- Fault tion No pump suction Delivery rate too low Pump too loud Motor overload Uneven delivery rate... - Page 37 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – 2 – 4 – – – Speed/frequency/voltage of the motor false Ensure that the motor frequency and voltage match the operating voltage. Ensure that the speed of the motor matches the rating plate of the pump. If necessary ad- just the speed.
- Page 38 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – – – 4 – – 7 Foreign bodies in the pump Contact the manufacturer. – – 3 – – 6 – Differential pressure is too high and has overloaded the idle screws Contact the manufacturer.
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Page 39: Spare Parts
15 Spare parts 15.1 Maintenance kit GF, GH 15 Spare parts 15.1 Maintenance kit GF, GH Note The maintenance kit contains only the numbered parts and is only supplied complete. 739.3 739.1 739.4 066* 739.2 914.2 914.1 914.3 056.2 056.1 739.1 739.4 739.1... -
Page 40: Maintenance Kit Gt
15 Spare parts 15.2 Maintenance kit GT 15.2 Maintenance kit GT Note The maintenance kit contains only the numbered parts and is only supplied complete. 739.3 739.1 066* 739.4 739.5 914.1 914.6 056.2 056.1 Qty. Item No. Part Qty. Item No. Part 056.1 Supporting ring Ball bearing... -
Page 41: 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 42: Contents Of The Declaration Of Conformity
16 Appendix 16.3 Contents of the Declaration of Conformity 16.3 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 43 Notes Operating instructions OIG 02en-GB Edition 2025-04...
- Page 44 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...
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