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KRAL CKC, Operating Instructions Manual

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KRAL CKC Operating Instructions Manual Download Page 35

14 Troubleshooting

14.2 Troubleshooting

Fault identification

Cause

Remedy

–

–

–

–

–

–

7

Differential pressure is too high and has overloaded the idle screws

 Contact the manufacturer.

–

–

–

–

–

–

7

Viscosity is too low and has overloaded the idle screws

 Contact the manufacturer.

1

2

3

4

–

–

7

Pump damaged through dry running

 Contact the manufacturer.

1

–

–

–

–

–

–

Pump does not vent

 Vent the pressure line at the highest point.

Tab. 12: Fault table

Operating instructions

OIC 01en-GB Edition 2019-11

35

Summary of Contents for CKC

Page 1: ...Operating instructions KRAL screw pumps Series C Type CKC Radial shaft seal OIC 01en GB Edition 2019 11 Original instructions www kral at ...

Page 2: ...pe system 20 10 2 2 Filling the pump 21 10 2 3 Checking the direction of rotation 21 10 2 4 Commissioning the pump 22 10 3 During operation 23 10 3 1 Checking the operating pressure 23 10 3 2 Monitoring filters and or strainers 24 10 3 3 Adjusting the overflow valve 24 10 3 4 Switching off the pump unit 25 10 4 Decommissioning 25 10 4 1 Decommissioning the pump 25 10 5 Recommissioning 26 10 5 1 Re...

Page 3: ...nd on the basis of the relevant provisions Information on the required qualification of the personnel is provided separately at the beginning of the individual chapters in these instructions The following table provides an overview Target group Activity Qualification Transport personnel Transporting unloading setting up Qualified personnel for transport mobile crane operators crane operators forkl...

Page 4: ...ms Risk of slipping Discharging pumped liquid and oils on the foundation or tread surfaces can cause falls with serious physical injury or death Flammable substances Discharging pumped liquid and oils can be easily inflam mable and can result in serious burns Hot surface Hot surfaces can cause burns 1 4 3 Symbols in this document Meaning Warning personal injury Safety instruction Request for actio...

Page 5: ...erator owner is therefore subject to the statutory obligations concerning occupational health and safety In addition to the safety instructions in these instructions the regulations on safety accident prevention and environmental protection respectively valid for the range of application of the product are to be ob served 2 4 Safety instructions 2 4 1 Fundamental safety instructions The following ...

Page 6: ...ner mesh width 0 5 mm C Connection for suction pipe Z Without accessories X Special design 5 Housing material A Silafont B Spheroidal cast iron X Special design 6 Version index For internal administration Tab 2 Type code 3 2 Rating plate KRAL GmbH 6890 Lustenau Austria www kral at KRAL GmbH 6890 Lustenau Austria www kral at pS max pD max Typ Type SN Serial no Tmin Tmax ºC l min mm s kg min bar bar...

Page 7: ... Standard radial shaft seal C 90 o High temperature radial shaft seal C 150 Min temperature for pump materials C 10 Min max ambient temperature C 10 50 Viscosity min max mm2 s 4 5000 4 3000 4 2000 Speed max Depending on viscosity suction head NPSH value and size In case of any doubt please con tact the manufacturer Max inlet pressure o Radial shaft seal bar 1 5 Tab 3 Operating limits Operating ins...

Page 8: ...160M 160L 142 148 32 42 80 75 168 55 85 100L 112M 105 202 90S 90L 75 168 132S 132M 132 202 100L 112M 98 168 160M 160L 156 202 132S 132M 137 168 180M 180L 183 202 160M 160L 142 168 200L 183 202 105 118 100L 112M 106 244 160 210 100L 112M 101 290 132S 132M 135 244 132S 132M 130 290 160M 160L 157 244 160M 160L 173 290 180M 180L 185 244 180M 180L 180 290 200L 185 244 200L 180 290 225 2 168 244 225 2 1...

Page 9: ...e 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 2900 min 1 20 bar 21 mm2 s Size 5 7 5 10 15 20 26 32 42 55 74 85 Max sound pressure level 3 dB A Pump 49 51 52 53 55 56 54 56 57 58 60 Size 105 118 160 210 235 275 370 450 550 660 880 Max sound pres...

Page 10: ... therefore not suitable for dry running and can only be used up to specific pressure limits and viscosity limits Due to the narrow tolerances pump ing of suspended solids is not possible Axial support of the main screws is effected out by a lifetime lubricated ball bearing 10 One radial shaft seal 9 for sealing the main screw is inserted at the outlet from the housing In order to reduce the pres s...

Page 11: ...reduces viscosity and can ultimately lead to pump failure It therefore has to be ensured through a safety valve at the system that the maximum operating pres sure always lies under the opening pressure of the overflow valve Notice The opening pressure of the overflow valve is set to 110 of the differential pressure in the factory The overflow valve is accessible through a screw plug 1 and can be a...

Page 12: ...tion immediately to the manufacturer 3 Dispose of packaging material in accordance with the locally applicable regulations 6 4 Transporting the pump pump unit Personnel qualification o Transport personnel Personal protective equipment o Work clothing o Protective helmet o Protective gloves o Safety boots Aids o Mobile crane forklift hoisting equipment WARNING Risk of injury and damage to equipment...

Page 13: ... coat PU based two com ponent paint The preservative applied at the factory will protect the pump for about six weeks if it is stored in a dry and clean location The manufacturer offers a long term preservation for storage times of up to 60 months The pump is additionally packed in hermetically sealing anti corrosion paper Personnel qualification o Transport personnel Aids o Mobile crane forklift ...

Page 14: ...sure connection of the pump with a new blind flange 5 Close the packaging carefully 6 After about six months storage check the filling level of the preservative and if necessary top up 7 3 Preserving the outer surfaces Personnel qualification o Trained personnel Personal protective equipment o Work clothing o Face protection o Protective gloves o Safety boots Aids o Calcium complex grease for exam...

Page 15: ...ues Ä Appendix Page 38 o Ensure that all the components can be accessed and that maintenance work can be carried out easily 8 2 Dangers during removal The following safety instructions must be observed strictly o Have all work carried out only by authorized qualified personnel o Before beginning work let the pump unit cool down to the ambient temperature o Collect any discharging pumped liquid saf...

Page 16: ... suction pipe and suction strainer 2 Wall mounting vertical 5 Setup vertical with suction strainer mounting panel and external overflow valve 3 Setup vertical with suction strainer Notice At a vertical setup suction operation the manufacturer recommends the installation of a foot valve This way the suction process is facilitated coarse soiling is kept away and emptying of the suction line is preve...

Page 17: ...nning work let the pump unit cool down to the ambient temperature Ensure that the pump is depressurized Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations Requirement ü Pump unit cooled down to the ambient temperature ü Pump unit disconnected from the electrical power supply deenergized and secu...

Page 18: ...vice through impurity in the pipe system During welding work attach protective covers in front of the connecting flanges Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and the pump Ensure that a commissioning filter is installed when the pipe system is flushed and cleaned using the pump ATTENTION Damage to device through mechanical stress Ensure that the p...

Page 19: ...tective gloves o Safety boots ATTENTION Damage to coupling and bearing through incorrect alignment of the coupling To guarantee a long service life of the coupling align shaft ends exactly After assembly check permissible displacement figures of the coupling according to table below DH E L ΔKa L max L ΔKa H D r K Δ E H D ΔKw mm Lmax L L min min Δ K w max L Fig 9 Coupling alignment measuring points...

Page 20: ... the motor terminal block 4 When connecting the pump unit to the complete system continue equipotential bonding 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 th...

Page 21: ...sure Wear personal protective equipment 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 ATTENTION Dry running can damage pump equipment Ensure that the pump is filled properly 1 Before commissioning fill the piping and pump via the suction connection...

Page 22: ... components and emitted pumped liquid As a result of impermissibly high pressure components can burst with high energy for example through the pressure side pipe system being shut off Wear personal protective equipment during all the work Before carrying out commissioning ensure that a safety valve is installed in the pressure side pipe system at the system end WARNING Risk of injury through emitt...

Page 23: ...tem side triggers 2 If the pump does not deliver after 10 15 seconds of operation abort commissioning Eliminate the cause for the fault and only then continue with commissioning Take the information from the fault table into account Ä Troubleshooting Page 33 3 Run the pump for a few minutes to allow the pipe system to vent fully ð The pipe system is fully vented when the pump operating noise is sm...

Page 24: ...onal 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 1 2 2 Fig 11 Overflow valve fig left integrated fig right external 1 Screw plug 2 Adjusting screw Requirement ü Pressure side pressure gauge installed 1 At an integrated overflo...

Page 25: ...ble 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 ATTENTION Damage to equipment through excessively fast temperature change Subject the pump only to slow temperature changes Under no circumstances heat ...

Page 26: ... o Pumped liquids can be hot poisonous combustible and caustic Use corresponding protective equipment o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations o Ensure that the collection tank for discharging pumped liquids is sufficiently large o Observe the operating instructions and data sheets o...

Page 27: ...e changes o Pumped liquids can be hot poisonous combustible and caustic Use corresponding protective equipment o Ensure that the pump is depressurized and that shut off devices are not operated uncontrolled o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations o Ensure that the collection tank fo...

Page 28: ...ling Do not stand under raised loads Requirement ü Pump unit disconnected from the electrical power supply deenergized and secured against being switched back on 1 2 7 3 6 5 4 8 1 Secure the motor 7 with eye bolts hoisting equipment in such a way that the motor can be pulled out horizontally 2 Remove the socket screws 8 between the motor and pump bracket 3 and pull out the motor 3 Loosen the fixin...

Page 29: ... surface with torque 6 Measure and write down the distance X between the face of the coupling claws and the fitting surface of the pump bracket 1 2 7 3 6 5 4 8 7 Ensure that the fixing screw 6 of the motor side coupling half 5 is loosened 8 Slide the motor side coupling half onto the shaft end of the motor 7 X E 9 Check the distance between the face of the coupling teeth pump side and the fitting ...

Page 30: ...ite 572 o Molybdenum disulphide paste for example Fenkart T4 Notice The thread sealant serves during installation of the radial shaft seal as a lubricant and after it has cured as an anti rotation measure 1 3 4 5 6 7 8 9 2 11 10 1 Clean the contact surface of the radial shaft seal ring 4 in the end cover 6 carefully 2 Apply a thread sealant for example Loctite 572 as a lubricant Ensure that the th...

Page 31: ...0 3 Remove the idle screws and keep for mounting 4 Remove the edge sealing rings 5 from the flange cover and keep for mounting 5 Lift the flange cover 3 from the main screw 4 and the remove flat gasket 7 6 Unclamp the main screw rotate by 180 and remove the circlip 10 as well as the supporting ring 9 7 Use the extractor to pull the ball bearing 8 off the main screw 12 5 2 Installing the ball beari...

Page 32: ...ment o Work clothing o Face protection o Protective gloves o Safety boots Aids o Solvents or industrial cleaners suitable for the pumped liquid o Collection tank WARNING Danger of poisoning and environmental damage through residues Wear personal protective clothing during all the work Ensure face protection Before disposal collect any pumped liquid still present safely and dispose of it in an envi...

Page 33: ...ection or Heat up the pumped liquid or Install a filter strainer with a larger mesh width Ensure that the permissible mesh width is not exceeded 1 3 Level in the intake container too low Fill the intake container 1 Too little pumped liquid in the pump Fill the pump with pumped liquid 1 Incorrect pump direction of rotation Swop the two electrical connection phases Ä Connection Page 18 4 Differentia...

Page 34: ...oes not exceed 3 m s or Set the flow speed in the suction line so that it does not exceed 1 m s or Contact the manufacturer 3 4 7 Ball bearing damaged Replace the ball bearing Ä Servicing Page 27 2 3 4 7 Superficial damage to pump parts coming into contact with the liquid Contact the manufacturer 7 Shaft seal damaged through dry running Replace the shaft seal Ä Servicing Page 27 7 Inlet pressure t...

Page 35: ... the idle screws Contact the manufacturer 7 Viscosity is too low and has overloaded the idle screws Contact the manufacturer 1 2 3 4 7 Pump damaged through dry running Contact the manufacturer 1 Pump does not vent Vent the pressure line at the highest point Tab 12 Fault table Operating instructions OIC 01en GB Edition 2019 11 35 ...

Page 36: ...s only the numbered parts and is only supplied complete 817 739 2 739 1 222 3 866 222 1 222 2 062 869 745 870 735 915 1 Qty Item No Part Qty Item No Part 1 062 Spacer 1 866 Feather key 1 222 1 Flat gasket 1 869 Circlip 1 222 2 Flat gasket 1 870 Circlip 1 222 3 Flat gasket 4 915 1 Socket screw 4 735 Copper seal 1 739 1 O ring suction side 1 745 Radial shaft seal 1 739 2 O ring pressure side 1 817 B...

Page 37: ...d complete 304 751 166 165 1 Qty Item No Part Qty Item No Part 1 165 1 Screw plug 1 304 Valve body 1 166 Adjusting screw 1 751 Pressure spring Tab 15 Repair kit overflow valve 15 4 Tool sets 15 4 1 Tool set radial shaft seal Qty Part 1 Mounting arbour radial shaft seal ring 1 Mounting sleeve main screw Operating instructions OIC 01en GB Edition 2019 11 37 ...

Page 38: ...3 5 4 7 5 M 6 4 7 10 3 14 0 7 6 6 0 8 0 9 M 8 11 3 25 0 34 0 18 4 16 0 22 0 14 M 10 23 0 47 0 68 0 36 8 32 0 43 0 36 M 12 39 0 84 0 117 64 0 56 0 75 0 60 M 14 62 0 133 186 101 90 M 16 96 0 204 285 155 135 180 100 M 18 133 284 390 224 M 20 187 3999 558 313 280 370 135 M 24 322 687 960 540 455 605 360 Tab 16 Tightening torques metric screw thread When screwing into aluminium the tightening torque re...

Page 39: ... fulfils all the relevant provisions of the following directives Number Name Remark 2006 42 EC Machinery Directive 2014 68 EU Pressure Equipment Directive 2014 30 EU Directive on Electromagnetic Compatibility Only for machinery with electrical components 2014 35 EU Low Voltage Directive Only for machinery with electrical components 2014 34 EU Directive on Use in Potentially Explosive Areas ATEX On...

Page 40: ...KRAL GmbH 6890 Lustenau Austria Tel 43 5577 86644 0 E Mail kral kral at www kral at ...

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