Table of Contents
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Operating instructions
KRAL screw pumps.
Series L
Magnetic coupling
Observe safety instructions for persons with cardiac pacemaker, metallic implant or
neurostimulator.
OIL 02en-GB
Edition 2019-03
Original instructions
Tel: +44 (0) 1773 302 660 | Email: sales@northridgepumps.com | Website: www.northridgepumps.com
X-Cel House, Chrysalis Way, Langley Bridge, Eastwood, Nottinghamshire NG16 3RY
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Table of Contents
Related Manuals for KRAL LFM Series
Summary of Contents for KRAL LFM Series
- Page 1 Operating instructions KRAL screw pumps. Series L Magnetic coupling Observe safety instructions for persons with cardiac pacemaker, metallic implant or neurostimulator. OIL 02en-GB Edition 2019-03 Original instructions X-Cel House, Chrysalis Way, Langley Bridge, Eastwood, Nottinghamshire NG16 3RY Tel: +44 (0) 1773 302 660 | Email: sales@northridgepumps.com | Website: www.northridgepumps.com...
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Page 2: Table Of Contents
Table of contents 1 About this document ............. 4 Dangers during removal.......... 21 General information ............ 4 Installing the pump ............ 21 Associated documents .......... 4 Removing the pump ............. 22 Target groups .............. 4 9 Connection .............. 23 Symbols................. 5 Dangers during connection work ......... 23 1.4.1 Danger levels ............ 5 Connecting the pump to the pipe system..... 24... - Page 3 Table of contents 16 Spare parts .............. 50 16.1 Overview.............. 50 16.2 Maintenance kits............ 51 16.2.1 Maintenance kit magnetic coupling.... 51 16.3 Repair kits.............. 52 16.3.1 Repair kit screw set LFI/LVI/LFT/LVT/LFM.. 52 16.3.2 Repair kit overflow valve LFI/LVI/LFT/LVT/LFM ................ 52 16.3.3 Repair kit magnetic coupling...... 53 16.4 Completions.............. 54 16.4.1 Completion type LFI/LVI/LFT/LVT/LFM .. 54 17 Appendix...............
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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: Symbols
1 About this document 1.4 Symbols 1.4 Symbols 1.4.1 Danger levels Signal word Danger level Consequences of non-observance DANGER Immediate threat of danger Serious personal injury, death WARNING Possible threat of danger Serious personal injury, invalidity CAUTION Potentially dangerous situation Slight personal injury ATTENTION Potentially dangerous situation... -
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: Safety Instructions
2 Safety 2.4 Safety instructions 2.4 Safety instructions 2.4.1 Fundamental safety instructions The following safety instructions must be observed strictly: o Read these operating instructions carefully and observe them. o Read the operating instructions of the components carefully and observe them. o Have work only carried out by qualified personnel/trained personnel. -
Page 8: Dangers During Installation
2 Safety 2.4 Safety instructions 2.4.5 Dangers during installation The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before installation ensure that the operating limits, NPSH values and ambient conditions are ob- served. -
Page 9: Dangers During Servicing
2 Safety 2.4 Safety instructions 2.4.9 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 10 3 Identification 3.1 Type code 3 Identification 3.1 Type code LFI - 42.DCAP.00001 Fig. 1: Type code Item Classification Description Type o Pump with free shaft end o Pump with inline flanges PN25/PN63 o Pump unit with or without pump bracket foot o Pump with free shaft end o Pump with overhead flanges PN25/PN63 o Pump unit with or without pump bracket foot...
- Page 11 ºC l/min Temperature range max. / ps max. ¹ Serial number Jahr | Year mm²/s Type KRAL AG, 6890 Lustenau, Austria www.kral.at Article number Fig. 2: Rating plate Differential pressure Nominal delivery rate Rated speed 10 Nominal viscosity 4 Technical data 4.1 Operating limits...
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Page 12: Sound Pressure Level
4 Technical data 4.2 Sound pressure level 4.2 Sound pressure level Guide values at 1 m distance, 1450 min , 20 bar Size 5 – 54 55 – 84 Max. sound pressure level ±3 [dB(A)] Pump 58.0 59.0 Motor 62.0 62.0 Pump unit 63.5 64.0 Tab. 4: Sound pressure level 4.3 Required NPSH values The following table lists the required NPSH values during operation with a low-volatile pumped liquid such as lubricating oil or hydraulic liquid. -
Page 13: Weights
4 Technical data 4.4 Weights 4.4 Weights Weights type LFI/LFT/LFM Size of pump Weight of pump with free shaft end [kg] 14.0 17.5 33.0 Weight of pump bracket with magnetic coupling and screws [kg] – – – – – – –... -
Page 14: Materials
4 Technical data 4.5 Materials Weights type LVI/LVT Size of pump Weight of pump with free shaft end [kg] 14.0 17.5 33.0 Weight of pedestal [kg] Weight of pump bracket with magnetic coupling and screws [kg] – – – – –... -
Page 15: Accessories
5 Function description 4.6 Accessories 4.6 Accessories Notice The technical data of the accessories are specified separately Ä Accessories, Page 47. 5 Function description 5.1 Pump structure Fig. 3: Pump structure Idle screw Shaft end pump (main screw) Pump housing Overflow valve Balancing cylinder Screw plug Bearing cover Balancing bush... -
Page 16: Functional Principle
5 Function description 5.3 Functional principle 5.3 Functional principle Screw pumps are rotating pumps. Their displacement effect results from three rotating screws 1 and 6 and the enclosing pump housing 2. Radial support of the screw set is effected through the sliding contact in the pump housing that de- pends on lubrication by the pumped liquid. -
Page 17: Overflow Valve
6 Transportation, storage 5.6 Overflow valve 5.6 Overflow valve 1 Screw plug 2 Adjusting screw 3 Pressure spring 4 Valve body Fig. 5: Overflow valve The integrated overflow valve ensures that very high pressures that could result in housing parts burst- ing do not arise. -
Page 18: Transporting The Pump/Pump Unit
6 Transportation, storage 6.4 Transporting the pump/pump unit 6.4 Transporting the pump/pump unit o Crane operators, forklift operators Personnel qualification: o Transport personnel o Work clothing Personal protective equipment: o Protective helmet o Protective gloves o Safety boots Aids: o Mobile crane, forklift o Hoisting equipment DANGER Magnetic field. -
Page 19: Storing The Pump
7 Preservation 6.5 Storing the pump 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. Pressure connection and suction connection are closed with protective caps. Unless oth- erwise specified, the outer surfaces of the pump are preserved with a single-coat PU-based two-com- ponent paint. -
Page 20: Preserving The Outer Surfaces
7 Preservation 7.3 Preserving the outer surfaces 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. Open the packaging carefully. -
Page 21: Installation, Removal
8 Installation, removal 8.1 Dangers during installation CAUTION Risk of injury through emitted preservative. ► Wear personal protective clothing 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 22: Removing The Pump
8 Installation, removal 8.4 Removing the pump ATTENTION Damage to motor through emitted 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 23: Connection
9 Connection 9.1 Dangers during connection work 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 emitted pumped liquid. -
Page 24: 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 Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Protective helmet o Safety boots Aids: o Mobile crane, forklift o Hoisting equipment DANGER Magnetic field. -
Page 25: Connecting The Pump Unit To The Power Supply
10 Operation 9.3 Connecting the pump unit to the power supply 9.3 Connecting the pump unit to the power supply o Electrician Personnel qualification: o Operating instructions of the motor Aids: o Motor circuit diagram DANGER Risk of death resulting from electric shock. ►... -
Page 26: Commissioning
10 Operation 10.2 Commissioning 10.2 Commissioning 10.2.1 Cleaning the pipe system Notice Soiling in the pipe system impair the service life of the pump. If the pipe system is flushed using the pump during the initial commissioning, an additional commissioning filter has to be installed temporarily before the pump at the system. - Page 27 10 Operation 10.2 Commissioning DANGER Risk of death through emitted 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. ►...
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Page 28: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning Suction connection Seal housing vent hole Pressure-side vent hole Pressure connection Suction-side vent hole Fig. 9: Vent holes Requirement: ü Shut-off devices of the suction line and pressure line closed Open the screw plug of the vent hole seal housing 2 by a max. of two rotations so that air can es- cape during the filling process. -
Page 29: Commissioning The Pump
10 Operation 10.2 Commissioning 10.2.4 Commissioning the pump Personnel qualification: o Fitter o Electrician o Work clothing Personal protective equipment: o Face protection o Protective gloves o Safety boots o Collection tank Aids: DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►... -
Page 30: During Operation
10 Operation 10.3 During operation Requirement: ü Pump unit set up correctly ü Connections connected sealingly ü Motor connected correctly ü Pipe system is free of impurities ü Safety valve in accordance with EN ISO 4126-1 installed in the pressure-side pipe system before the first shut-off device ü... -
Page 31: Monitoring Filters And/Or Strainers
10 Operation 10.3 During operation 10.3.2 Monitoring filters and/or strainers Notice The manufacturer recommends protecting the pump against soiling by means of a filter and/or strainer installed at the system end (mesh width 0.5 mm). The degree of soiling of the filter and/or the strainer can be monitored by means of a suction-side pressure gauge or a differential pressure indicator. -
Page 32: 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. ► During a standstill ensure that the pressure in the pump does not exceed the feed pressure. Switch off the motor. Close the pressure- and suction-side shut-off devices. -
Page 33: Recommissioning
11 Maintenance 10.5 Recommissioning Carry out the following measures during operation interruptions: Scope of the operation interruption Measure o Shutting down the pump for longer period Depending on the pumped liquid o Draining the pump Close the pressure-side and suction-side shut-off devices. -
Page 34: 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 Pump 4 weeks o Acoustic inspection... -
Page 35: Servicing
12 Servicing 12.1 Dangers during servicing 914.7 917** 914.6 914.5 884** Check the tightening torques of the following parts of the magnetic coupling once a year. Repla- cing the magnetic coupling Ä Servicing, Page 35. Tightening torques Ä Appendix, Page 55. Item No. Part Tensioning element 884** Threaded pin outer rotor support... -
Page 36: Replacing The Overflow Valve
12 Servicing 12.3 Replacing the overflow valve 12.3 Replacing the overflow valve 12.3.1 Removing the overflow valve Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots 165.1 914.1 Remove the screw plug 165.1 and socket screws 914.1. Remove the end cover 2 and flat gasket 222 from the pump housing 1. -
Page 37: Replacing The Magnetic Coupling
12 Servicing 12.4 Replacing the magnetic coupling 12.4 Replacing the magnetic coupling 12.4.1 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 DANGER Magnetic field. -
Page 38: Removing The Inner Rotor
12 Servicing 12.4 Replacing the magnetic coupling Pull the outer rotor support and the outer rotor off from the motor shaft using mounting levers. 914.6 Remove the socket screws 914.6 between the outer rotor support and the outer rotor. 12.4.2 Removing the inner rotor o Fitter Personnel qualification: o Work clothing... -
Page 39: Installing The Inner Rotor
12 Servicing 12.4 Replacing the magnetic coupling To replace the inner rotor 518, screw two screws M into the empty threaded holes of the tension- ing element 585 as anti-rotation screws. Remove the screws of the tensioning element. Turn the screws back into the existing threaded holes. ð... -
Page 40: Installing The Outer Rotor
12 Servicing 12.4 Replacing the magnetic coupling When the position is correct, first tighten the screws of the tensioning element with half the torque crosswise. Subsequently tighten several times crosswise with the full torque. ð The screws are tightened correctly when they no longer turn when being tightened with the full torque. - Page 41 12 Servicing 12.4 Replacing the magnetic coupling Clean and grease the shaft end of the motor 2. Place the outer rotor support 052 with the outer rotor 515 on the shaft end of the motor. 884** 917** 917** 884** Ensure that the shaft end of the motor 2 is flush with the front surface of the outer rotor sup- port 052.
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Page 42: Replacing The Ball Bearing And Screw Set
12 Servicing 12.5 Replacing the ball bearing and screw set 12.5 Replacing the ball bearing and screw set 12.5.1 Removing the ball bearing and screw set Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Plastic hammer Aids: o Extractor... -
Page 43: Installing The Ball Bearing And Screw Set
12 Servicing 12.5 Replacing the ball bearing and screw set 661.2 879.2 914.1 Remove the socket screws 914.1 and end cover 070. Remove the balancing bushes 048 with straight pin 879.2 and idle screws 661.2 from the pump housing. Remove the residues of the flat gasket 222 from the end cover and pump housing. 12.5.2 Installing the ball bearing and screw set o Fitter Personnel qualification:... -
Page 44: Disposal
13 Disposal 13.1 Dismantling and disposing of the pump Press the ball bearing 817 into the bearing cover and mount the circlip 472. 914.2 661.1 Slide the main screw with premounted bearing cover into the pump housing until the main screw engages into the idle screws. Turn the main screw in the process. Tighten the socket screws 914.2 with torque Ä... -
Page 45: 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 46 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.
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Page 47: 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 48 15 Accessories 15.1 Heating Installing the electrical heating system Personnel qualification: o Electrician o Work clothing Personal protective equipment: o Protective gloves o Safety boots DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►...
- Page 49 15 Accessories 15.1 Heating 15.1.3 Fluid heating system Heating cover Pipe connection Fig. 13: Fluid heating system The fluid heating system consists of a heating cover 072 attached additionally to the end cover through which a heating fluid (for example vapour, thermal oil) flows. Scope of delivery: Size 5 – 85 1 heating cover...
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Page 50: Heating System Special Design
16 Spare parts 16.1 Overview Commissioning the fluid heating system Take the required heating-up periods into account Ä Accessories, Page 47. When setting the pressure and temperature of the heating fluid take the permissible operating limits of the pump into account Ä Technical data, Page 11. 15.1.4 Heating system special design Please contact the manufacturer for special designs. -
Page 51: Maintenance Kits
16 Spare parts 16.2 Maintenance kits 16.2 Maintenance kits 16.2.1 Maintenance kit magnetic coupling Notice The maintenance kit contains only the numbered parts and is only supplied complete. 165.3 471.1 165.2 914.2 055.2* 165.2 729.1 055.1 165.1 914.1 729.2 165.2 879.2 165.2 914.8***... -
Page 52: Repair Kits
16 Spare parts 16.3 Repair kits 16.3 Repair kits 16.3.1 Repair kit screw set LFI/LVI/LFT/LVT/LFM Notice The repair kit is only supplied in combination with a maintenance kit. 471.2 879.2 Qty. Item No. Part Qty. Item No. Part Balancing cylinder Screw set Balancing bush 879.2... -
Page 53: Repair Kit Magnetic Coupling
16 Spare parts 16.3 Repair kits 16.3.3 Repair kit magnetic coupling Notice The repair kit contains only the numbered parts and is only supplied complete. 914.6 884** 063** 917** 917.1** 914.7 Fig. 14: Repair kit magnetic coupling LFI/LVI/LFT/LVT/LFM Qty. Item No. Part Qty. -
Page 54: Completions
16 Spare parts 16.4 Completions 16.4 Completions 16.4.1 Completion type LFI/LVI/LFT/LVT/LFM 914.3 914.6 884** 063** 917** 917.1** 914.4 914.7 914.5 Fig. 15: Completion Qty. Item No. Part Qty. Item No. Part Containment can 884** Threaded pin Distance sleeve Hexagon nut Outer rotor support 914.3 Socket screw 063**... -
Page 55: Appendix
17 Appendix 17.1 Tightening torque for screws with metric screw threads and head contact surfaces 17 Appendix 17.1 Tightening torque for screws with metric screw threads and head contact surfaces Tightening torque [Nm] + Wedge lock wash- Stainless steel screws A2 and A4 Thread 10.9... -
Page 56: Contents Of The Declaration Of Conformity
17 Appendix 17.4 Contents of the Declaration of Conformity 17.4 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 57 Directory of figures Directory of figures Fig. 1 Type code..................................Fig. 2 Rating plate ................................... Fig. 3 Pump structure ................................Fig. 4 Pump unit structure ............................... Fig. 5 Overflow valve ................................Fig. 6 Fastening of hoisting equipment - principle diagrams ....................Fig.
- Page 58 Directory of tables Tab. 28 Tightening torques metric screw thread ........................Tab. 29 Tightening torques, thread measured in inches ......................Tab. 30 Tightening torques tensioning elements........................Tab. 31 Directives observed ............................... Operating instructions OIL 02en-GB Edition 2019-03...
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