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7

Operation start-up

7.1

Safety instructions for start-up

DANGER

Hazardous fluids!

Danger of death when handling hazardous fluids.

1.

Comply with the safety data sheets and regulations on handling haz-
ardous fluids.

2.

Collect and dispose of hazardous fluids so that no hazards arise for
people or the environment.

WARNING

Failure of load-carrying parts due to overload!

Danger of injury from flying parts.
Danger of injury from spurting fluids.

1.

Do not operate the device against closed shut-off devices.

2.

Do not operate the device in the false direction of rotation.

CAUTION

Hot surfaces!

Burn injury to skin if touched.

1.

Wear protective gloves at temperatures

≥

48°C.

7.2

Preparation

●

Before starting the system make sure that a sufficient quantity of the
operating fluid is extant to avoid dry running.

Take this into consideration especially with high output volumes.

●

Check all fastening screws on the device.

●

Fill pump and the suction line with medium.

7.3

Adjustment of the gland packing

Gland packings are particularly vulnerable to high temperatures. Proper func-
tioning and cooling depends on a sufficient amount of leakage. The permis-
sible amount of leakage is defined by the axial compression of the installed
packing rings.

Gear pump BT / BTH

40

2021-02-05 88026290002-04

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Содержание BT 0

Страница 1: ...D 0026290002 Operating instructions Translation Gear pump BT BTH 88026290002 04 Englisch 2021 02 05 ...

Страница 2: ...1 Basic design BT 0 12 3 2 2 Basic design BT 1 7 13 3 2 3 Basic design BTH 1 3 14 3 2 4 Heating connections BTH 15 3 3 Rotation and delivery direction 16 3 4 Type key 17 3 4 1 Type key BT 17 3 4 2 Type key BTH 18 3 5 Important special numbers 19 4 Technical data 20 4 1 General information 20 4 2 Housing connection Connection type 21 4 2 1 Housing connection BT 21 4 2 2 Housing connection Connectio...

Страница 3: ...g Type R 30 6 4 Connection lines 34 6 4 1 General 34 6 4 2 Suction line 35 6 4 3 Pressure line 36 6 4 4 Mounting Connection lines 36 6 5 Change of the direction of rotation 36 7 Operation start up 40 7 1 Safety instructions for start up 40 7 2 Preparation 40 7 3 Adjustment of the gland packing 40 7 4 Further operation start up 41 8 Removal 43 8 1 Safety instructions for removal 43 8 2 Removal 44 9...

Страница 4: ...10 Repairs 48 10 1 Safety instructions for repair 48 10 2 General 48 10 3 Detecting and eliminating failures 51 ...

Страница 5: ...rsonnel near the device at all times If you have any questions about these operating instructions please contact the manufacturer 1 2 Manufacturer s address KRACHT GmbH Gewerbestraße 20 DE 58791 Werdohl phone 49 2392 935 0 fax 49 2392 935 209 email info kracht eu web www kracht eu 1 3 Applicable documents 1 KTR Kupplungstechnik GmbH DE 48407 Rheine KTR N 40210 Coupling operating assembly instructi...

Страница 6: ...ily injury if not avoided CAUTION Identification of a low risk hazard which could lead to minor or medium bodily injury if not avoided NOTICE Flagging of notices to prevent property damage Identification of basic safety instructions Non compliance can lead to haz ards for people and the device Flagging of special user tips and other especially useful or important infor mation Gear pump BT BTH 6 20...

Страница 7: ...an ufacturer 5 In case of any use of the device not according to specification any war ranty is voided 2 2 Personnel qualification and training The staff designated to assemble operate and service the device must be properly qualified This can be through training or specific instruction Per sonnel must be familiar with the contents of this operating instructions Read the operating instructions tho...

Страница 8: ...tarting during all work DANGER Rotating parts Danger of death due to body parts hair or clothing getting trapped or en tangled 1 Take measures against accidental touching of rotating parts WARNING Rotating parts Danger of injury from flying parts 1 Enclose rotating parts so as to avoid any danger from flying parts in the event of breakage or malfunction WARNING Failure of load carrying parts due t...

Страница 9: ...pressure relief valves or rupture discs 3 Design pipework so that no tensions e g caused by changes in length due to fluctuations in temperature are transmitted to the device WARNING Failure of load carrying parts due to overload Danger of injury from flying parts Danger of injury from spurting fluids 1 Do not operate the device against closed shut off devices 2 Do not operate the device in the fa...

Страница 10: ...spond with the theo retical value it is being reduced through losses due to the necessary toler ances The losses are less the lower the operating pressure and the higher the viscosity of the medium Gear pumps are self priming within wide limits The displacement cycle de scribe initially takes place without exhibiting appreciable pressure build up Only after setting external loads for example throu...

Страница 11: ...heater The working chamber of the pump is heated by the heating medium such as heat transfer oil water or steam which will be fed and discharged via dedicated inlets and outlets 1 Heating medium outlet HA 2 Heating chamber 3 Working chamber 4 Pumping medium inlet or outlet 5 Heating medium inlet HE optionally right left right and left Gear pump BT BTH 88026290002 04 2021 02 05 11 ...

Страница 12: ...sic design 3 2 1 Basic design BT 0 Explanation 1 Cover 5 Packing ring 2 Liquid gasket 6 Gland compression ring 3 Driven shaft 7 Cap nut 4 Housing 8 Driving shaft Gear pump BT BTH 12 2021 02 05 88026290002 04 ...

Страница 13: ...sic design BT 1 7 Explanation 1 Front cap 6 Driving shaft 2 Plain bearing bush 7 Gland cap 3 Liquid gasket 8 Packing ring 4 Driven shaft 9 Gland follower 5 Housing Gear pump BT BTH 88026290002 04 2021 02 05 13 ...

Страница 14: ...gn BTH 1 3 Explanation 1 End cover 7 Gland cap 2 End cover 8 Packing ring 3 Driving shaft 9 Gland follower 4 Housing 10 Gasket 5 Driven shaft 11 Gasket 6 Plain bearing bush Gear pump BT BTH 14 2021 02 05 88026290002 04 ...

Страница 15: ...3 2 4 Heating connections BTH HE Heating connection Inlet HA Heating connection Outlet Gear pump BT BTH 88026290002 04 2021 02 05 15 ...

Страница 16: ...w the drive shaft Looking at the pump shaft end the pump ing flow is from left to right when the shaft is moving clockwise Looking at the pump shaft end the pump ing flow is from right to left when the shaft is moving counterclockwise BTH S Suction side P Pressure side BT BT series pumps work independently of the rotational direction Gear pump BT BTH 16 2021 02 05 88026290002 04 ...

Страница 17: ... connection Z Whitworth pipe thread 5 Design serial number specified by manufacturer 6 Housing design and bearing support A Housing EN GJL 200 GG 20 U Housing CuSn12 Bronze Bearing EN GJL 200 GG 20 Bearing CuSn12 Bronze B Housing EN GJL 200 GG 20 R Housing 1 4308 Stainless steel Bearing CuSn7ZnPb Bronze Bearing CY10C Carbon C Housing EN GJL 200 GG 20 Bearing SINT B 00 Sintered iron 7 Gears version...

Страница 18: ...g 1056 cm r 2 100 Vg 393 cm r 3 Direction of rotation R Clockwise L Counterclockwise 4 Housing connection Connection type Z Whitworth pipe thread G Flange connection with counter flange F Flange connection 5 Design serial number specified by manufacturer 6 Housing design and bearing support B Housing EN GJL 200 GG 20 C Housing EN GJL 200 GG 20 Bearing CuSn7ZnPb Bronze Bearing SINT B 00 Sintered ir...

Страница 19: ...ttom mounted 17 BT 1 7 Ni SiC dispersion anti wear corrosion layer on Gears Bearing bush 21 BT 0 7 Diameter of trunnion and outer diameter of gear wheel cut to sub stand ard size 25 BT 3 Drive shaft bottom mounted Housing connection Whitworth pipe thread G 1 1 4 29 BT 1 7 Ni SiC dispersion anti wear corrosion layer on Bearing bush Gear pump BT BTH 88026290002 04 2021 02 05 19 ...

Страница 20: ...ing pressure of suction side and pres sure side Max pressure in side jacket heater ph max 10 bar Max temperature of heating medi um ϑh max 160 C Fluid tempera ture ϑm min 10 C ϑm max 220 C External loads on shaft end Axial and radial forces are not allowed Material See section 3 4 Type key Permissible me dia BT Lubricating fluids without abrasive components Petrols solvents etc are not permissible...

Страница 21: ...dium Flange EN 1092 1 11 DN15 PN16 S Blind flange EN 1092 1 05 DN15 PN16 S 2 100 2 130 Z Pumping medium Whitworth pipe thread G 2 Heating medium Whitworth pipe thread G 3 4 F Pumping medium Flange connection downstream of EN 1092 1 DN50 PN16 Heating medium Flange connection downstream of EN 1092 1 DN20 PN16 G Pumping medium Flange EN 1092 1 11 DN50 PN16 S Heating medium Flange EN 1092 1 11 DN20 PN...

Страница 22: ... suction side does not fall below the permissible pressure pe min 4 4 Operating pressure of suction side and pressure side Bearing Operating pressure Suction side Pressure side pe min bar abs pe max bar pb bar perm continous pressure CuSn7ZnPb Bronze 0 6 8 8 SINT B 00 Sintered iron CuSn12 Bronze CY10C Carbon 5 5 EN GJL 200 GG 20 1 1 4 5 Dimensions Dimensions of the device can be found in the relev...

Страница 23: ...t kg 0 2 1 3 2 5 3 7 4 15 5 20 6 29 7 37 4 6 2 Weight BTH Size Weight kg Housing connection Z F Housing connection Connection type G 1 55 45 48 1 105 46 49 2 100 84 93 2 130 85 94 3 150 142 155 Gear pump BT BTH 88026290002 04 2021 02 05 23 ...

Страница 24: ... Falling or overturning loads Danger of injury while transporting large and heavy loads 1 Use only suitable means of conveyance and lifting tackle with sufficient load bearing capacity 2 Attach lifting tackle only to suitable load points 3 Attach the lifting tackle in such a manner that it cannot slip 4 Pay attention to the load balance point 5 Always avoid jerks impacts and strong vibrations duri...

Страница 25: ...icity and mechanical loading capacity since the glass transition temper ature is fallen below This procedure is reversible A force action on the device is to be avoided in case of storage below the permissible ambient temperature ϑu Devices with EPDM seals are not mineral oil resistant and are not tested for their function There is no preservation of the interior parts If the device is not taken i...

Страница 26: ...commended storage conditions 1 Storage temperature 5 C 25 C 2 Relative air humidity 70 3 Protect elastomer parts from light especially direct sunlight 4 Protect elastomer parts from oxygen and ozone 5 Comply with maximum storage times of elastomeric parts 5 Years AU Polyurethane rubber 7 Years NBR HNBR CR 10 Years EPM EPDM FEP PTFE FEPM FKM FFKM VMQ FVMQ Gear pump BT BTH 26 2021 02 05 88026290002 ...

Страница 27: ... 1 Before all work ensure that existing drives are voltage free and pres sure free 2 Securely prevent restarting during all work DANGER Rotating parts Danger of death due to body parts hair or clothing getting trapped or en tangled 1 Take measures against accidental touching of rotating parts WARNING Rotating parts Danger of injury from flying parts 1 Enclose rotating parts so as to avoid any dang...

Страница 28: ...eedom of movement Remove existing preservatives Use only those cleaning agents that are compatible with the mate rials used in the device Do not use cleaning wool Compare the environmental and ambient conditions at the place of in stallation to the permissible conditions Ensure a sufficiently stable and level foundation Expose the device only to small vibrations see IEC 60034 14 Secure sufficient ...

Страница 29: ...M16 M20 M24 Counter thread Aluminium 4 6 11 22 39 95 184 315 Counter thread Cast iron Steel 10 25 49 85 210 425 730 1 Screws Nuts with min strength class 8 8 8 When operating units with gland packings make sure that the pre stress on the packing rings is not too high If necessary loosen gland follower nuts and re tighten until hand tight Make sure no foreign bodies can get into the device Take mea...

Страница 30: ... that occur during opera tion are effectively dampened and reduced Claw coupling Type R NOTICE Coupling breakage or increased wear An overload can lead to premature failure of the coupling 1 Ensure safe dimensioning when designing the coupling Take vibra tions torque peaks and temperatures into account Gear pump BT BTH 30 2021 02 05 88026290002 04 ...

Страница 31: ...with parallel key the dimension dH of the spider the shaft ends can protrude out into the spider Coupling size 1 14 19 24 28 38 42 48 55 65 75 19 24 24 28 28 38 38 45 42 55 48 60 55 70 65 75 75 90 Coupling clearance E mm 13 16 18 20 24 26 28 30 35 40 dH mm 10 18 27 30 38 46 51 60 68 80 G M4 M5 M5 M8 M8 M8 M8 M10 M10 M10 t mm 5 10 10 15 15 20 20 20 20 25 Tightening torque TA Nm 1 5 2 2 10 10 10 10 ...

Страница 32: ...protective gloves at temperatures 48 C Mount the coupling halves on the shaft ends but avoid impacts on the components Position the coupling halves on the shaft ends so that in later operation the E gap dimension is maintained Secure the coupling halves by tightening the setscrews Insert the spider in a coupling half Gear pump BT BTH 32 2021 02 05 88026290002 04 ...

Страница 33: ...2 1 4 1 5 1 8 2 0 2 1 2 2 2 6 3 0 0 5 0 5 0 5 0 7 0 7 1 0 1 0 1 0 1 0 1 5 ΔKr mm 1500 rpm 0 11 0 13 0 15 0 18 0 21 0 23 0 25 0 27 0 30 0 34 3000 rpm 0 08 0 09 0 1 0 13 0 15 0 16 0 18 0 19 0 21 0 24 ΔKw De gree 1500 rpm 1 1 1 1 0 8 0 8 0 9 0 9 1 0 1 0 1 1 1 1 3000 rpm 1 0 1 0 0 7 0 7 0 8 0 8 0 9 0 9 1 0 1 0 ΔKL mm 1500 rpm 0 57 0 77 0 77 0 90 1 25 1 40 1 80 2 00 2 50 3 00 3000 rpm 0 52 0 7 0 67 0 8...

Страница 34: ... pressure range 2 Securely prevent exceeding the permissible pressure e g by using pressure relief valves or rupture discs 3 Design pipework so that no tensions e g caused by changes in length due to fluctuations in temperature are transmitted to the device Additional connections 1 Provide measurement connections for pressure and temperature as close as possible to device 2 If necessary provide a ...

Страница 35: ...e that the suction opening lies underneath the lowest fluid level in all operating situations When hose lines are used ensure sufficient stability of the hoses so that they cannot become constricted through the sucking action Comply with the recommended flow velocity in the suction line max 1 5 m s NOTICE Cavitation damage Undercutting the permissible suction port pressure results in cavitation 1 ...

Страница 36: ...ine When designing the line take the following points into consideration Select the nominal width of the pressure line so that the maximum per missible pressures are not exceeded If necessary provide a vent nozzle to prevent suction problems 6 4 4 Mounting Connection lines Position of the device connections See chapter 3 Device description Clean all lines Do not use cleaning wool Pickle and flush ...

Страница 37: ...pressurise the device and all connection lines before doing any work 2 Securely prevent the restoration of pressure while working on the de vice NOTICE Leaks or increased wear Damaged sealing surfaces or supports lead to lack of sealing and or faults in later operation 1 When assembling or disassembling housing components be sure not to damage the bearings e g by tilting 2 When disassembling housi...

Страница 38: ...crew 6 Parallel key 13 Hexagonal nut 7 Hexagonal screw When reversing the pump s rotational direction the end cover and bearing cap must be turned 180 Loose fastening screws 7 4x 9 10x Disassemble bearing cap and end cap from the housing turn 180 and re assemble 2 1 1 Do not damage the seal 10 1 Tighten the fastening screws with the stated torque 7 4x 9 10x Remove the parallel key 6 Gear pump BT B...

Страница 39: ...he stated torque 11 10x Slide gland cap with the installed gland follower and gland packing onto the bearing cap 4 5 2 2 Do not damage the seal 8 2 Tighten the fastening screws with the stated torque 12 8x Hand tighten gland packing 13 Insert the parallel key 6 Fastening screws BTH Pump BTH 1 BTH 2 BTH 3 Tightening torques Nm 49 85 When checking pay attention to the following points The leak oil b...

Страница 40: ...e false direction of rotation CAUTION Hot surfaces Burn injury to skin if touched 1 Wear protective gloves at temperatures 48 C 7 2 Preparation Before starting the system make sure that a sufficient quantity of the operating fluid is extant to avoid dry running Take this into consideration especially with high output volumes Check all fastening screws on the device Fill pump and the suction line w...

Страница 41: ...e hexagon nuts will increase the amount of leakage 2 Tightening the hexagon nuts will decrease the amount of leakage The amount of leakage will typically be higher after a disturbance e g unit turned off and on again or after pressure temperature fluctuations In this case the gland packing should not be retightened until the amount of leakage has reached a constant level NOTICE Seal failure Dry ru...

Страница 42: ...s Discharge flow Amount of leakage Operating pressure as close as possible to device Fluid temperature as close as possible to device Device temperature in particular in the area of the bearing points The temperatures determined on the device surface should be a maximum of 20 C above the media temperature Document the operating data of the initial start up for later comparison Check the level of t...

Страница 43: ...g drives are voltage free and pres sure free 2 Securely prevent restarting during all work WARNING Unshielded gearwheels Gearwheels can trap and crush fingers and hands 1 Do not engage gearwheels WARNING Failure of load carrying parts due to overload Danger of injury from flying parts Danger of injury from spurting fluids 1 Depressurise the device and all connection lines before doing any work 2 S...

Страница 44: ...essurise and de energize the system Close existing shut off elements upstream and downstream of the de vice Open existing drain elements and loosen connection lines Collect and dispose of discharging medium so that no hazard arises for persons or environment Dismantle the device Clean the device Close the device connections and lines to prevent dirt penetration Gear pump BT BTH 44 2021 02 05 88026...

Страница 45: ...tarting during all work WARNING Failure of load carrying parts due to overload Danger of injury from flying parts Danger of injury from spurting fluids 1 Depressurise the device and all connection lines before doing any work 2 Securely prevent the restoration of pressure while working on the de vice CAUTION Hot surfaces Burn injury to skin if touched 1 At temperatures 48 C the device must be allow...

Страница 46: ...g maintenance and or repairs 9 3 Maintenance instructions The following information provides recommendations on maintenance work and maintenance intervals for the device being used Depending on the actually occurring loads in operation the type scope and interval of the maintenance work can deviate from the recommendations The equipment builder operator shall write an obligatory maintenance plan W...

Страница 47: ...l of liquid seal if existing 3000 Operating hours Inspection Discharge flow 1 1 Inspection Operating pressure Inspection Fluid temperature Inspection Device temperature Inspection Add on valve function if existing Inspection Check potential equalisation for firm seating and functionality if existing Inspection Condition of operating fluid 6000 Operating hours Visual inspection Condition of gears 1...

Страница 48: ...are voltage free and pres sure free 2 Securely prevent restarting during all work WARNING Failure of load carrying parts due to overload Danger of injury from flying parts Danger of injury from spurting fluids 1 Depressurise the device and all connection lines before doing any work 2 Securely prevent the restoration of pressure while working on the de vice CAUTION Hot surfaces Burn injury to skin ...

Страница 49: ... the device fill in the return notification form The form can be filled in online and is available as a pdf file download Device contains hazardous material If the device was operated with dangerous liquids it must be cleaned before the return If this should not be possible the safety data sheet of the haz ardous material is to be provided beforehand Gear pump BT BTH 88026290002 04 2021 02 05 49 ...

Страница 50: ...ssembly drawings from the manufacturer Use spare parts approved by the manufacturer only Dispose of packing material and used parts in accordance with the local stipulations Warranty In case of improper implementation any warranty is voided Barriers and instructions All barriers and warning signs removed during this must be attached to their original position on completing maintenance and or repai...

Страница 51: ...ir Check oil level in the tank Check suction line Check the shaft seal Shaft seal defective Replace shaft seal Suction connection leaking Retighten or replace threa ded connections Replace seals System not vented Vent system Return line ends above the flu id level Extend return line Heavy foaming in the system e g in gears Use noise optimised pump 1 3 Increased noise Mechanical vibrations Incorrec...

Страница 52: ...on line Open the shut off element Suction line plugged Clean the suction line The air in the suction line can not be compressed in the pressure line Reduce the start up pres sure Vent the pressure line Increase volume of the pres sure line Speed of the pump is too low Check the pump design During frequency inverter operation Check the opera tion line frequency Geodetic suction head too high Check ...

Страница 53: ...ening pres sure Pump sucks air Check oil level in the tank Check suction line Check the shaft seal Wear Replace the device 4 Excessive operating tem perature Cooling and heat dissipation insufficient Increase the cooling capaci ty Not sufficient oil in the system Check the container layout Excess fluid is being delivered into the supply tank via pres sure relief valve under load Check the pump des...

Страница 54: ...ation Replace seals Gland lid not sufficiently tight ened for gland seal Retighten gland lid Loose threaded connections Retighten or replace threa ded connections 7 1 Coupling Coupling wear Alignment error Correct the alignment of the coupling and secure the cou pling halves Spider overloaded Check the operating datas Use harder spider 7 2 Coupling Cam break Spider wear Torque transmission due to ...

Страница 55: ...ncorrectly connected Check motor connection Phase failure Check feed supply Current consumption too high Check the operating datas Check direction of rotation Motor circuit breaker incor rectly designed Check the operating datas Consult the manufacturer for all unidentifiable failures Gear pump BT BTH 88026290002 04 2021 02 05 55 ...

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