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Fristam Pumps FKL 15, Original Instructions Manual, Page: 40 / 40

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Fristam Pumps FKL 15 Original Instructions Manual Download Page 40

FRISTAM Pumpen KG (GmbH & Co.)

Kurt-A.-Körber-Chaussee 55

21033 Hamburg

GERMANY

Tel.: +49 (0) 40 / 7 25 56 -0

Fax: +49 (0) 40 / 7 25 56 -166

E-Mail: [email protected]

 FKL Pump Series  EN(US) 10-2020 Rev. 3.4

Summary of Contents for FKL 15

Page 1: ...Original Instructions Assembly Instructions Positive Displacement Pump FKL Series Pump Type Pump No ...

Page 2: ... other laws for the protection of intellectual property The publication and modification of the contents are not authorised Moreover you may not copy publish and alter the contents therein for commercial purposes or transmit the information to a third party The German version is the original version of the operating instructions manual Other languages are translations of the original operating man...

Page 3: ...ty Instructions 11 6 2 Installation Location 11 6 3 Reduction of Sound and Vibration 11 6 4 Pump Fixation 11 6 5 Installation of Pipes 11 6 6 Electrical Connection 12 6 7 Connection of Sealing or Quenching Liquid Optional 12 6 8 Cleaning 13 7 Operation 13 7 1 Safety Instructions 13 7 2 Commencement of Operation 13 7 3 Monitoring of Operation 13 7 4 Stopping of Operation 14 7 5 Pump Decommissioning...

Page 4: ...oting Table 29 11 4 Number Key 30 11 5 EC Declaration of Conformity 32 11 6 EG Declaration of Incorporation 32 12 Appendix 2 Assembly Instructions Optional 33 12 1 Safety Instructions 33 12 2 Scope 33 12 3 Rating Plate 33 12 4 Moving Without Motor 33 12 5 Installation Location 34 12 6 Pump Installation 34 ...

Page 5: ... includes the following items This operator s manual Appendix 1 with maintenance lubrication and tighten ing torque tables Appendix 2 with assembly instructions Attached documents Order Related Documents Supplier documentation motor coupling etc Documentation on Fristam accessories if applicable Certificates materials certificates etc if applicable Declaration of Conformity or Declaration of Incor...

Page 6: ...n this opera tor s manual If nonstandard items or extras are installed the op erator assumes the responsibility for operation Modifications and changes to the pump are only permissible with the consent of Fristam 2 4 Pump Specific Safety Instructions Impermissible Pressure Range Personal injury and material damage from leakage or bursting of pump Maintain the pump pressure within the specified pre...

Page 7: ...ispose of oil and objects saturated with oil in an environ mentally friendly manner in accordance with applicable reg ulations 2 7 4 Disposal of Pump 1 Dispose of dangerous or toxic residue in an environmentally friendly manner in accordance with applicable regulations 2 Carefully clean the pump 3 Dismantle the pump into its constituent parts 4 Dispose of the pump parts in an environmentally frien...

Page 8: ...le shaft seals With the double shaft seal there are two additional connec tions for the sealing liquid on the pump casing These con nections are not shown in the figures in this operator s man ual High temperature rotors High temperature rotors are special rotors that can be used in FKL Pump Series to pump media at elevated tempera tures The clearance is larger in high temperature rotors See Table...

Page 9: ...Pipe Fittings Material damage from contamination impact or moisture in the pump Remove the pipe fitting covers just prior to connection to the pipes 4 2 Moving With Industrial Truck WARNING Unsecured Parts Serious injuries pinching of extremities material damage Before moving the pump secure it to prevent it from tipping over Secure the pump to the pallet with tie down straps or screw the pump to ...

Page 10: ...g page 10 2 Wrap the other end of the round sling around the pump cas ing see Fig 10 Moving with round sling page 10 3 For double shaft seal Note Round sling compresses sealing water tubes Material damage to double shaft seal Do not lay the round sling on the sealing water tubes 4 Guide both loops to the crane hook rotate and hook over the hook to ensure that the belt will not slip on the hook 5 P...

Page 11: ...in the optimum working range Operate the pump without cavitation see Chapter 6 5 Installation of Pipes page 11 Decouple the suction and discharge lines from vibrations Support lines Align lines Install vibration dampers 6 3 2 Secondary Measures Take structural measures such as the following Acoustic paneling Enclosure in housing 6 4 Pump Fixation 6 4 1 Pump With Base Frame Screw the pump on the ba...

Page 12: ...otor fan wheel see Fig 14 Direction of rotation left page 12 and Fig 15 Direction of ro tation right page 12 Ensure that the pump is filled with me dium to prevent dry running of the shaft seal Fig 14 Direction of rotation left Fig 15 Direction of rotation right 5 Reverse the polarity if the direction of rotation is incorrect 6 7 Connection of Sealing or Quenching Liquid Optional For versions with...

Page 13: ...eal The Order related documents are included in this op erating manual Negative pressure in the seal chamber is not allowed If no pressure is noted in the Sectional drawing of the shaft seal the following applies A max pressure of 0 2 bar is allowed for seals to which sealing fluid is applied without pressure or which are flushed The temperature of the sealing liquid is maintained at T 70 C 1 Open...

Page 14: ...rocess The following guidelines apply to the CIP pro cess Example of a Cleaning Cycle 1 Perform preliminary flush with water 2 Perform caustic flush with lye NaOH see Table 2 CIP cleaning page 14 3 Perform intermediate flush with water 4 Perform acid flush with nitric acid HNO3 seeTable 2 CIP cleaning page 14 5 Flush with water The pump s differential pressure should be 2 3 bar so that ade quate f...

Page 15: ...mber stamped into pump 2 For replacement parts and materials designations please see Order Related Documents in the attached documents 10 3 Inspection of Sealing and Quenching Liq uid Optional For pumps equipped for locking system or quenching sys tem the sealing liquid head must be checked For information on maintenance intervals please see Table 26 on page 29 Check the sealing liquid head and co...

Page 16: ...Sealing or quenching liquid leaks into the pumping medi um Procedure 1 Remove the pump casing see Chapter 10 8 Pump Casing Removal page 16 2 Replace the shaft seal see Chapter 10 9 1 Mounting of the Shaft Seals page 19 Preassemble the pump casing Mount the shaft seal 3 Mount the pump casing 4 Mount the rotors 5 Attach the pump cover The exact procedure is described in the following sections 10 8 P...

Page 17: ...ove the keys for the rotors from the shafts Fig 19 Removal of pump casing from gearbox 7 Loosen and remove the hex cap screws 30 on the pump casing 8 Carefully detach the pump casing 31 from the gearbox 32 Note If the pump casing is hard to detach from the gearbox Tap on the suction and discharge side connections lightly with a plastic hammer 9 Remove the rotating seal rings 34 and the O rings 33 ...

Page 18: ...of shaft seal 1 Lay the pump casing 45 onto the workbench with the inte rior facing downward 2 Remove the socket screws 47 on the mechanical seal chamber 46 3 Please check the attached Sectional Drawing of the Shaft Seal to determine the remaining shaft seal disassembly steps 10 9 Mounting of the Pump Casing The pump assembly is dependent on the respective pump size and model as well as the respec...

Page 19: ... the rotating seal ring so that it fits onto the shaft face Preassembly of pump casing Fig 25 Mounting the pump casing 3 Insert the rotating seal ring 412 65 in the pump casing 101 4 Slide the key 477 60 onto the stationary seal ring 475 60 and insert the seal ring and key into the pump casing CAUTION Align the key and the stationary seal ring to the cylindrical pins 562 60 of the pump casing 5 Mo...

Page 20: ...rews in the pump casing to the gearbox 8 Subsequently mount the shaft seal of the rotor for details see Chapter 10 9 2 Mounting of the Rotors page 24 Case C Preassembly on shaft Fig 28 Rotating seal ring with O ring 1 Mount the O ring 412 63 on the shaft 2 Slide the rotating seal ring 472 60 onto the shaft CAUTION Mount the rotating seal ring so that it fits onto the shaft face Preassembly of mech...

Page 21: ...2 63 on the shaft 2 Slide the rotating seal ring 472 60 onto the shaft CAUTION Mount the rotating seal ring so that it fits onto the shaft face Preassembly of mechanical seal chamber Fig 31 Assembly of mechanical seal chamber 3 Equip the mechanical seal chamber 47 2 60 with O rings 412 65 and 412 60 Note O ring 412 60 is only installed in FKL 205 580 4 Slide the key 477 60 onto the stationary seal...

Page 22: ...he rotor for details see Chapter 10 9 2 Mounting of the Rotors page 24 Case E Preassembly on shaft Fig 32 Rotating seal ring with O ring 1 Mount the O ring 412 63 on the shaft 2 Slide the rotating seal ring 472 60 onto the shaft CAUTION Slide the rotating seal ring to the cylindrical pins 562 68 on the shaft Preassembly of mechanical seal chamber Fig 33 Assembly of mechanical seal chamber 3 Equip ...

Page 23: ...mount the ro tors see Chapter 10 9 2 Mounting of the Rotors page 24 Case F Preassembly on shaft Fig 34 Rotating seal ring with O ring 1 Mount the O ring 412 63 on the shaft 2 Slide the rotating seal ring 472 60 onto the shaft CAUTION Slide the rotating seal ring onto the cylindrical pins 562 68 on the shaft Preassembly of mechanical seal chamber Fig 35 Assembly of mechanical seal chamber 3 Equip t...

Page 24: ...tors Note Only for pump size 15 20 Insert the keys for the rotors into the shafts CAUTION Mixing up of the two rotors 48 Material damage during pump operation from rotor blockage or scraping The rotors have been adapted to the synchronizing shaft or the drive shaft and are marked by prick punch marks inden tations One indentation for drive shaft Two indentations for synchronizing shaft Before inst...

Page 25: ...he angular and parallel misalign ment Realign or shim the shafts if necessary 11 Screw the pump and gear motor to the base frame or the foundation 12 Fasten the coupling according to the coupling manufactur er s specifications 13 Mount the coupling guard 10 12 Gear Motor Replacement Coupling The coupling installation manual can be found in the supplier documentation NOTICE Gear Motor Oversized Use...

Page 26: ...ances for 14 bar rotors 20 bar Rotors Pump size Axial Clearance mm Radial Clearance mm FKL 25 0 11 0 14 0 14 0 18 FKL 50 0 12 0 17 0 16 0 22 FKL 75 0 13 0 18 0 17 0 23 FKL 150 0 13 0 18 0 22 0 28 FKL 205 0 14 0 19 0 23 0 30 Table 19 Clearances for 20 bar rotors FKL 250 0 14 0 19 0 23 0 30 FKL 400 0 15 0 20 0 25 0 31 30 bar Rotors Pump size Axial Clearance mm Radial Clearance mm FKL 50 0 14 0 20 0 ...

Page 27: ...alipers 2 Compare the measurements with the tabulated values on page 26 3 Check whether the drive shaft rotates freely using a tool attached to the rotor fastener 4 Compare the measurements with the tabulated values in 10 13 1 Required Clearances page 26 10 13 4 Measurement Results Based on the result of the measurements take one of the fol lowing procedures Measurements are within the range of ta...

Page 28: ... 34 34 34 34 68 88 88 88 88 108 Pump Casing 149 Pump Casing socket screw 5 5 13 5 13 5 61 61 61 61 61 61 Mechanical Seal Chamber 3 4 3 4 3 4 3 4 3 4 3 4 13 5 19 19 Table 23 Tightening torques for screws Pump Size Maximum Discharge Pressure bar FKL 15 14 FKL 20 14 FKL 25 21 FKL 50 35 FKL 75 35 FKL 150 35 FKL 205 35 FKL 250 35 FKL 400 35 FKL 580 21 FKL 600 21 Table 24 Maximum discharge pressures Rot...

Page 29: ...mp interior not completely filled with liquid pump interior not vented discharge valve closed Fill pump interior with liquid open discharge valve Suction line blocked or clogged Open or clean suction line Pump with geodesic suction head1 liquid falls at standstill and casing runs dry Install foot valve in suction line Suction line leaky seal on pump cover leaky and drawing in air Seal suction line...

Page 30: ...orm maintenance at regular intervals see Table 26 on page 29 Motor power consumption too high Resistance in discharge line too high pump throttled too much flow rate too low Increase nominal size of discharge line open throttle valve reduce speed using frequency con verter on motor or control gear Viscosity and or density of pumping medium too high Consult Fristam Rotors installed with inadequate ...

Page 31: ...23 Shaft sleeve 524 Shaft protective sleeve 525 Spacer sleeve 54 1 Cover bushing 54 2 Bushing 54 3 Stationary bushing 540 Bushing 543 Spacer bushing 55 1 Serrated lock washer 550 Washer 551 Spacer washer 554 Washer 561 Grooved pin 56 1 Roll pin 56 2 Grooved pin with round head 560 Pin 562 Cylindrical pin 59 2 Dished type lock washer 59 3 Shrink ring 59 4 Lantern 59 5 Membrane 642 Oil level sight g...

Page 32: ... FKL PUMP SERIES 32 940 Key 941 Woodruff key 950 spring Part Number Name ...

Page 33: ... without motor centrifugal pump types FP FPE FP V FPH FPEH FPH V FSPE FSP V FM FZ FC CF and CFE Positive displacement pump types FK FKL FL FL2 and FL3 Powder mixer type PM for serial number see cover page of operating manual is an incomplete machine in accordance with the Machinery Di rective 2006 42 EC Annex II B The relevant basic safety and health requirements of Annex I of the above mentioned ...

Page 34: ...ortation Leakage of caustic toxic or contaminating liquids Personal in jury and material damage from contamination Always move the pump in the installation condition Open Unsealed Pipe Fittings Material damage from contamination impact or moisture in the pump Remove the pipe fitting covers just prior to connection to the pipes 12 4 2 Moving With Industrial Trucks WARNING Unsecured Parts Death from...

Page 35: ...ing with round sling Procedure 1 Warning Round sling damage and tearing Death from crushing severe pinching material damage Do not lay the round sling over any sharp edges or cor ners Wrap the round sling around the casing and the drive shaft see Fig 45 Moving with round sling page 35 2 For double shaft seal Note Round sling compresses sealing water tubes Material damage to double shaft seal Do no...

Page 36: ...ed fastener slightly into the pump base 4 Check the parallel and angular misalignment of the drive and gear shafts 5 Minimize deviations from the angular and shaft misalign ment If necessary realign or add shims 6 Screw the pump and gear to the base frame or the founda tion 7 Fasten the coupling according to the coupling manufactur er s specifications 8 Install a noncontact barrier providing prote...

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Page 38: ... FKL PUMP SERIES 38 ...

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Page 40: ...FRISTAM Pumpen KG GmbH Co Kurt A Körber Chaussee 55 21033 Hamburg GERMANY Tel 49 0 40 7 25 56 0 Fax 49 0 40 7 25 56 166 E Mail info fristam de FKL Pump Series EN US 10 2020 Rev 3 4 ...

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