Wangen KL Series Original Instructions Manual Download Page 3

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Instruction Handbook KL

Table of Contents

Chapter

Data Sheet

Dimension drawing (option)

Safety Notes

Set-up and General Description

Transportation, Packaging, Storage

Installation

Commissioning

Shutdown

Service and Maintenance

Faults and Remedies

Disassembly and reassembly

Replacement Parts Stock

Summary of Contents for KL Series

Page 1: ...Original instructions Service Hotline EU 49 7522 997 997 USA 847 201 3121 E Mail mail wangen com Pumpenfabrik Wangen GmbH Simoniusstra e 17 88239 Wangen Tel 49 0 7522 997 0 Serial No Type...

Page 2: ...cumentation Table of contents Certificates optional Data Sheet Dimension Drawing optional Instruction Handbook Additional Valid Documents Exploded View Drawing with Parts List Accessories Drive Unit D...

Page 3: ...eet Dimension drawing option 1 Safety Notes 2 Set up and General Description 3 Transportation Packaging Storage 4 Installation 5 Commissioning 6 Shutdown 7 Service and Maintenance 8 Faults and Remedie...

Page 4: ...age is 16 years At the work on the machine an expert person has to supervise youth and trainees All mechanical work must be carried out by trained specialists only Specialists in this context are per...

Page 5: ...ration pump and drive unit may have rotating or movable parts as well pressurised parts and possible hot surfaces Possible dangerous situation Severe or fatal injuries Prior to carrying out any work o...

Page 6: ...w operating conditions with the details provided in the pump specification If the changed conditions should exceed the details provided in the pump specification it will be necessary to contact the ma...

Page 7: ...duces the service life of the pump and the gear unit as a result of heavy loading of the rotating parts and of the seal and must be avoided Comply with all statutory regulations applying to the delive...

Page 8: ...horized and accidental restart 1 9 Special Safety Notes for Immersion pumps Immersion pumps take up the medium directly over the pumping set This danger area is in the medium at normal working process...

Page 9: ...1 Set up and General Description 2 2 1 Pump set up KL 20 Only for information Suction Pump Hopper Pump A Drive Unit 1 Bearing Chair 2 Sealing Unit 3 Joint by Hopper Pump with Feed Screw 4 Suction Hous...

Page 10: ...2 2 2 2 Pump set up KL 30 KL 100 Suction pump Hopper pump A Drive Unit 1 Bearing Chair 2 Sealing Unit 3 Joint by Hopper Pump with Feed Screw 4 Suction Housing Hopper Housing Immersion Tube 5 Pump Set...

Page 11: ...C No 1935 2004 WANGEN pumps or pump assemblies are designed and constructed to comply with all health and safety requirements of the EC Machine Directive When compliance with all requirements has been...

Page 12: ...ation Warning By an incorrect transport the pump can fall down or upset Possible dangerous situation Severe or fatal injuries Only use lifting gear and load lifting facilities with sufficient load car...

Page 13: ...are to be used only for the engine and or transmission Basically the pump is to be transported via the hanging bracket In cases in which the pump has no hanging bracket it must be transported properl...

Page 14: ...means of acid free and resin free grease For pumps with rotors not made out of stainless steel e g from 1 2436 remove the stator and cover the rotor in grease If the pump is to be taken out of use for...

Page 15: ...ity of the pump aggregate The diameter of holes at bearing chair and discharge nozzle support or the straight plates of the base plate describe the bolt diameter respectively the diameter of the ancho...

Page 16: ...amage Use suitable screw connections and concrete anchors for the connections in the concrete of the silo wall In so doing use the hole diameters of the flanges brackets and drill holes on the bearing...

Page 17: ...25 Nm M 10 50 Nm M 12 90 Nm M 16 220 Nm M 20 430 Nm The values apply to shoulder studs of strength class 8 8 according to DIN 931 B or EN 24014 Possible damage Check the tightening moments of the tie...

Page 18: ...ng gear with sufficient lifting capacity Hoists must have a safety hook which prevents the load slipping out For fixation of the pump use only suitable lifting tackle steel cables according to the nor...

Page 19: ...of a pump shutdown shutoff devices siphon etc This avoids dry running at start up 4 5 1 Connecting the pipes Flush out und clean the pipes About elastic seals connect pump with Pipe system For disman...

Page 20: ...0 29 32 mm 50 87 5 20 29 65 mm 70 121 7 28 40 Discharge nozzle nom pipe F x y z N F tot N M x Nm M y x Nm M tot Nm 1 35 61 3 12 17 32 mm 35 61 3 12 17 65 mm 50 87 4 16 23 4 5 3 Series KL 30 KL 100 nom...

Page 21: ...o provide some additional free space for adequate ventilation of the drive motor see drive unit documentation The open space for the pump should at least be in flow direction 1 5 times stator length o...

Page 22: ...et These protecting covers can be removed only with a tool 4 9 2 Coupling elements Wangen eccentric screw pump with a bare shaft cylindrical shaft with key has to connect about an elastic coupling Pos...

Page 23: ...nstructions provided by the drive unit manufacturer 4 11 Mounting and adjusting of additional equipment components Mount additional equipment components odometers dry run protectors etc according to t...

Page 24: ...al direction unless the mechanical seal is made for both rotational directions data sheet Make sure the permissible pressure load of the seal unit is not passed Make sure the mechanical seal really do...

Page 25: ...seal filled correctly 3 Are connect double acting mechanical seals to a lock pressure system Possible damage Ventilated single mechanical seal at vertical pumps and verticaly mounted pumps during comm...

Page 26: ...to the cleaning process or the cleaning medium must under the CIP cleaning by disassembling the pump the effectiveness of cleaning to be checked i e whether the pump is clean A recommended C I P proc...

Page 27: ...he pump supplier that the pump is suitable for the process in question where there is any doubt In this connection pay special attention to the elastomeric material and pump design 5 2 ATEX pumps In a...

Page 28: ...or the liquid substrate re circulated material slurry separated medium etc simultaneously with the Bio Mix pump 2 After switching on both pumps start feeding in the well disintegrated solid phase maiz...

Page 29: ...pump unit 3 Open valves full 4 Switch on drive unit 5 After first start check at nominal pressure pump and pipe connection are leak proof 5 5 Operation Warning Do not operate against closed shut off...

Page 30: ...mping medium to freeze due to weather conditions The pumping medium is prone to deposit formation or cooling or if the pumping medium hardens due to a chemical reaction taking place 6 3 Decommissionin...

Page 31: ...ication intervals defined for this pump Their bearing points are equipped with maintenance free roller bearings which have all been permanent lubricated It is recommended to replace these bearings aft...

Page 32: ...t oil viscosity class SAE 90 or lubricant for foodstuffs industry Food industry oil If a change of the sleeve is necessary the lubricant will have to be exchanged as well A special filling is possible...

Page 33: ...luid should be checked regularly as a fall in pressure below the pressure level in the intake chamber can cause the medium to penetrate the sealing compartment For mechanical seals double acting tande...

Page 34: ...per each side of the joint KL 80S T 0 90 per each side of the joint Table 2 Lubricant quantity for drive unit seal LWD Line of products series Lubricant quantity Litre KL 20S T R 0 015 KL 30S T R 0 03...

Page 35: ...lves 3 Let the pump cooling 4 Drain pump Collect and depollute leakages 5 Switch the plant into a voltage free condition and secure against any unauthorized and accidental restart 6 For pumps with dri...

Page 36: ...clean pump Medium hardens due to temperature or chemical conditions Solids contents is too high Check conveying conditions if necessary change engineering data Stator swollen up Check temperature of...

Page 37: ...nical seal GRD Seal rings worn Replace mechanical seal Excessive pressure in suction housing Reduce pressure Spring action from medium Medium settles into the spring of the seal This prevents the adju...

Page 38: ...ng pump Switch the drive unit into a voltage free condition and secure against any unauthorized and accidental restart Drain the pump and all connected pipes and check surface temperature before openi...

Page 39: ...ing bolt before restarting the pump If the drive unit is switched on when in a locked condition there is a risk of fracture and a personal injury hazard Always use a new plug to close off the locking...

Page 40: ...rods 1041 5 Withdraw stator 1037 by turning it right handed by looking from the direction of the drive Mounting 1 Fit stator by turning it left handed by looking from the direction of the drive greas...

Page 41: ...1037 by means of a rotary movement use a piece of wood for support Ensure that the stator slides into spacer ring 1040 on the suction casing flange Remove stud bolts start with the bottom bolts and sc...

Page 42: ...ounting 1 Place spacer ring 1040 complete with inserted o ring onto the hopper casing flange 1389 adjust by means of stud bolts 2 Smear rotor with lubricant e g silicon oil soft soap if it is compatib...

Page 43: ...040 complete with inserted O ring onto immersion pipe flange adjust by means of stud bolts 2 Smear rotor with lubricant e g silicon oil soft soap if it is compatible with the medium and slide on stato...

Page 44: ...f the pump For larger stators it is recommended to use chain tongs for this purpose Arrest pump set Fig 9 1 5 Take down second spacer ring 1040 Renew the o rings 1039 at both spacer rings and the clam...

Page 45: ...e secured with protective glue Replace those bolts as follows Dismounting 1 Undo and remove both screws 1957 of a side of the joint with a screwdriver 2 Remove washers 1961 and O rings 1958 Washers 19...

Page 46: ...ut rivet and dowel pin in order to avoid damage to the drive shaft or the mechanical seal Dismounting 1 Remove stator chapter 9 2 2 Pull off suction hopper housing 3 Drive out rivet pin 1959 from the...

Page 47: ...ull bearing chair 1511 with joint and rotor out of housing immersion pipe 5 Undo and remove both screws 1957 of a side of the joint with a screwdriver Allen key 6 Remove washers 1961 and O rings 1958...

Page 48: ...tened over the spacer ring and or joint Hold on spacer ring during pull off the joint Dismounting 1 Remove rotor 2 Drive out rivet pin 1959 from the joint at the rotor end 3 Remove old joint 4 Clean p...

Page 49: ...nge it 4 When you change the connecting parts drive out rivet pins 1959 with a punch Mounting 1 Fix new connecting parts with new rivet pins 2 Insert a new joint 3 Insert rotor Possible damage Pumps w...

Page 50: ...nd O rings 1958 Washers 1961 only to types KL65 4 Push out bolt 1959 and pull off joint from drive shaft Mounting 1 Slide joint onto drive shaft and make sure the bores on joint and drive shaft match...

Page 51: ...the joint with a screwdriver Allen wrench Push out connecting bolt 1959 3 Remove joint 2094 4 Undo and remove both screws 1957 of the drive side of the joint Push out connecting bolt 1959 5 Check con...

Page 52: ...oint Mounting 1 Slide new sleeve onto joint and mount the middle sleeve clamp 2 Bring joint to a vertical position fill the top joint part with oil chapter 7 3 Push the sleeve clamp onto sleeve and fi...

Page 53: ...ng 1 Slide new sleeve over joint and mount clamps The clamps will be closed by means of a trade standard BAND IT closing tool Joints with joint oil stainless steel cardan joint 2 Just mount the middle...

Page 54: ...he replacement of the sensitive parts For this reason we recommend to leave these special seals in the manufacturer replacement Only so we can guarantee for the quality of the shaft sealing 9 7 1 LWD...

Page 55: ...he O rings by using the mounting tube onto the seal housing 1107 and the shaft receptacle 1106 Push seal casing 1107 on the drive shaft and turn till the charging hole faces upwards Possible damage En...

Page 56: ...ge from shaft 6 Renew O ring 1018 Clean and lightly grease drive shaft 1000 and seal seat in the bearing chair Mounting 1 Slide on LWD cartridge groove of seal seat 1106 must engage in tension pin 102...

Page 57: ...yed 3 Clean seat of the barrier ring and the housing 4 Grase slightly a new ring and fit it into the housing 5 Push a feeler gauge 0 1 mm between seal seat and barrier ring 6 Careful insert the barrie...

Page 58: ...the seal casing 1059 The groove in the sealing body must engage in dowel pin 1058 2 Push dynamic sealing unit onto the shaft 3 Slide on conical spring in winding direction The wire lug on the spring...

Page 59: ...t complete with O ring evenly into the seal plate 1029 The groove in the sealing body must engage in dowel pin 1030 Insert mechanical seal housing 1028 with O Ring 1019 in bearing Slide dynamic sealin...

Page 60: ...s 1056 into stuffing box 1027 ensure that the rings are each offset by 90 Fit gland and turn in gland nuts 3 Grease inside stuffing box and set into bearing chair 4 Reassemble pump lightly hand tighte...

Page 61: ...low pump to operate for 10 minutes in normal operating conditions in order to settle the packing In the event of major leakage re tighten the gland nuts Possible damage The gland must be allowed to le...

Page 62: ...t and set in new cartridge The groove in shaft sleeve must engage in dowel pin 1021 2 Insert new O ring 1019 into cartridge 3 Reassemble pump by following the instructions for disassembly in reverse o...

Page 63: ...ith its seal ring 4 Clean drive shaft carefully Mounting 1 Insert counter ring with seal ring into the seal housing 1029 Using low surface tension water minimal detergent content push the elastomeric...

Page 64: ...aling 5 Clean seal housing 1028 and driving shaft 1000 carefully Check of damages Mounting 1 Mount the mechanical seal carefully while keeping it scrupulously clean Insert seal plate1029 to bearing ch...

Page 65: ...1018 Mounting 1 Grease shaft sleeve lightly and pull onto the drive shaft The groove in shaft sleeve must engage in dowel pin 1021 2 Insert shaft sealing rings Slide on sealing housing 3 Insert new O...

Page 66: ...1000 check on firm seat of snap ring 1017 the back one if necessary exchange it Mounting 1 Grease drive shaft easily and push on new sealing cartridge Groove of shaft sleeve 1024 must engage in dowel...

Page 67: ...cing two levers into the recesses provided in the drive unit flange for this purpose Flange diameter 200 mm and larger 1 Use lifting gear to secure drive unit against tilting over 2 Undo and remove mo...

Page 68: ...ss to press out drive shaft 1000 in drive end direction 7 Remove snap ring 1009 and withdraw drive end bearing 1007 8 Press out roller bearing 1003 9 Replace shaft seal 1002 Mounting 1 Press new rolle...

Page 69: ...d remove both screws 1957 on drive side Remove washers 1961 and O rings 1958 washers 1961 only at range KL65 5 Pull out connecting joint 1959 6 Undo and remove screws 1625 on the discharge nozzle and...

Page 70: ...crews Fit the second part and adjust with the screw Apply some locking agent to all the screws e g Loctite 270 company locking agent and screw in the screws and tighten Mounting 1 To assemble the pump...

Page 71: ...s stator 1 2 rotor 1 2 set of seals O ring 1 2 cardan shaft complete 1 2 shaft seal 1 2 joint sealing oil 1 2 depending on type of pump data sheet Possible damage Use exclusively original WANGEN repla...

Page 72: ...Instruction Handbook Additional valid documents Exploded View Drawing with Parts List...

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Wangen KL Series, Original Instructions Manual

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