Product Specification Sheet
X-Cel House, Chrysalis Way, Langley Bridge, Eastwood, Nottinghamshire NG16 3RY
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Operating Instructions
KRAL Screw Pumps.
CLC Series – High viscosity
OIC 12en
Edition 08/2016
Original instructions
Table of contents
About this document
□ General information 3
□ Target groups 3
□ Symbols 3
□ Danger levels 3
□ Associated documents 4
Safety
□ Proper use 5
□ Safety information 5
Identification
□ Type code 6
□ Rating plate 6
Technical data
□ Operating limits 7
□ Sound pressure level 7
□ Required NPSH values 7
□ Weights 7
Heating
□ General 8
□ Fluid heating system 8
▪ Mounting the fluid heating system 8
▪ Commissioning the fluid heating system 8
□ Connecting the motor 17
□ Removing the pump 18
Operation
□ Commissioning 19
▪ Cleaning the pipe system 19
▪ Filling sealing chambers 19
▪ Variant 1: Checking PTFE grease 20
▪ Variant 2: Filling sealing chamber B
with quench liquid via quench tank 20
▪ Variant 3: Filling the sealing chamber B
with quench liquid via the circulation line 21
▪ Filling and venting the pump 22
▪ Checking the direction of rotation 22
▪ Commissioning the pump 23
□ During operation 24
▪ Checking the operating pressure 24
□ Switching off the pump 24
□ Decommissioning the pump 24
□ Recommissioning the pump 25
Servicing
□ Safety instructions 26
□ Required maintenance 26
▪ Maintenance schedule 26
□ Cleaning the pump 27
□ Lubricating the ball bearings 29
□ Lubricating the radial shaft seal 30
□ Refilling quench liquid 31
KRAL Screw Pumps – CLC Series – High viscosity
Function description
□ Structure 9
□ Radial shaft seal 11
□ Direction of rotation and flow direction 11
Transportation, storage and disposal
□ Unpacking and checking the state of
delivery 12
□ Lifting the pump 12
□ Storage 12
□ Preservation 13
▪ Preserving the internal surfaces of the
pump 13
▪ Preserving the external surfaces of the
pump 13
▪ Removing the preservation 13
Troubleshooting
□ Possible faults 32
□ Troubleshooting 32
Appendix
□ General drawings 35
□ Spare parts 37
□ Tightening torques 38
□ Contents of the EC Declaration of
Conformity 38
□ Notes 39
□ Disposing of the pump 14
Installation, removal and connection
□ Installation 15
▪ Installing the pump 15
▪ Protecting the pump against soiling 15
▪ Connecting the pump to the pipe system 16
▪ Assembling the pump and motor 16
2 OIC 12en Edition 08/2016 Operating Instructions
General information
About this document
General information
The operating instructions form part of the pump or pump unit. In the following a distinction between
pump and pump unit is only made when it is relevant for the understanding.
The operating instructions must be kept for future reference.
Furthermore please observe the associated documents.
Target groups
Target group Tasks
Operator-owner □ Keep these instructions available at the system site for future refe-
rence.
□ Ensure that employees read and observe these instructions and the
associated documents, in particular the safety instructions and warnings.
□ Observe additional system-specific directives and regulations.
Specialist personnel, fitters □ Read, observe and follow these instructions and the associated
documents, in particular the safety instructions and warnings.
Symbols
Symbol Meaning
About this document
Warning personal injury
Note
Procedures mechanical installation
Procedures electrical installation
Check or fault table
Request for action
Danger levels
Warning Danger level Consequences of non-observance
DANGER Immediate threat of danger Serious physical injury, death
WARNING Possible threat of danger Serious physical injury, invalidity
CAUTION Potentially dangerous situation Slight personal injury
CAUTION Potentially dangerous situation Material damage
Operating Instructions OIC 12en Edition 08/2016 3
Associated documents
Associated documents
ATEX supplementary instructions for operation in potentially explosive areas
Declaration of conformity according to EU Directive 2006/42/EC
Declaration of conformity according to EU Directive 2014/34/EU
Manufacturer's declaration according to EU Directive 2014/68/EU
Technical documentation for supplied components
About this document
4 OIC 12en Edition 08/2016 Operating Instructions
Proper use
Safety
Proper use
□ Use the pump solely for transporting lubricating liquids that are chemically neutral and that contain
no gas or solid components.
Safety
□ Use the pump only within the operating limits specified on the rating plate and in the chapter "Techni-
cal data". In the case of operating data that do not agree with the specifications on the rating plate,
please contact the manufacturer.
□ The pump is designed specially for the operating pressure named by the customer. If the actual ope-
rating pressure deviates notably from this design pressure, damage can also arise within the specified operating limits. This applies both to notably higher as well as to notably lower operating pressures. Under no circumstances should the operating pressure drop below the minimum pressure of 2
bar. In case of any doubt, please contact the manufacturer.
Safety information
The following general safety instructions must be observed:
□ No liability is accepted for damage arising through non-observance of the operating instruc-
tions.
▪ Read the operating instructions carefully and observe them.
▪ The operator-owner is responsible for the observance of the operating instructions.
▪ Installation, removal and installation work may only be carried out by specialist personnel.
□ Observe the general regulations for the prevention of accidents as well as the local safety
and operating instructions.
□ Observe the valid national and international standards and specifications of the installation
location.
□ In case of systems with an increased potential of danger to humans and/or machines the fai-
lure of a pump may not lead to injuries or damage to property.
▪ Always equip systems with an increased potential of danger with alarm equipment.
▪ Maintain and check the protective/alarm equipment regularly.
□ The pumped liquids can be dangerous (for example hot, caustic, poisonous, combustible).
Observe the safety regulations for handling dangerous materials.
□ Pumped liquids can be subject to high pressure and can cause damage and/or personal
injury should leaks occur.
Operating Instructions OIC 12en Edition 08/2016 5
Type code
CLC-550.FZXXK.00021
1234
5
8
7
6
Serial no.
1
2
3
4
5
6
7
8
Identification
Type code
Identification
Fig. 1 Type code
Item Designation Type
1 Model CLC: □ Pump with free shaft end
2 Size Corresponds to delivery rate in [l/min] at 1450 min-1
3 Shaft seal F: PTFE seal with quench
4 Pressure stage overflow valve Z: without valve
5 Bearing/Heating system/
6 Suction-side accessories X: Special design
7 Completion K: Unit with coupling and pump bracket, without motor
8 Version index For internal administration
1 Model
2 Size
3 Shaft seal
4 Pressure stage
5 Bearing/heating system/
Pump housing material
6 Suction-side accessories
7 Completion
8 Version index
□ Pump unit in flanged version,
with or without pump bracket foot
X: Special design
Pump housing material
Tab. 1 Type code
Rating plate
1 Year of construction
2 Differential pressure/
operating pressure max.
3 Temperature range
4 Serial number
5 Type
6 Nominal delivery rate
7 Rotation speed
8 Nominal viscosity
Fig. 2 Rating plate
6 OIC 12en Edition 08/2016 Operating Instructions
Operating limits
Technical data
Operating limits
Unit CLC 55 CLC 550
Max. operating pressure [bar] 63 63
Max. inlet pressure [bar] 10 10
Max. temperature of pumped liquid [°C] 60 60
Ambient temperature [°C] -10 ... 50 -10 ... 50
Viscosity min. – max. [mm2/s] 3 – 2000000 3 – 2000000
Speed min. – max. [min-1] 50 – 2900 50 – 2900
Tab. 1 Operating limits
Sound pressure level
Guide values at 1 m distance, 1450 min-1, 20 bar
Unit CLC 55 CLC 550
Sound pressure level max. ± 3 [db(A)] 57 70
Tab. 2 Sound pressure level
Required NPSH values
Please contact the manufacturer to determine the necessary NPSH values.
Technical data
Weights
Unit CLC 55 CLC 550
Pump with free shaft end [kg] 30 130
Completion [kg] 17 75
Tab. 3 Weights
Operating Instructions OIC 12en Edition 08/2016 7
General
H
G1/4“
L
241
241
Heating
Heating
General
The pump CLC 55 can optionally be equipped with a heating system (CLC 550 on request). The manufacturer recommends heating systems for high-viscosity liquids that do not flow sufficiently if not heated.
High viscosity can result in excessive power consumption or to problems arising through cavitation or
sealing.
Method of heating:
□ Fluid heating system
Fluid heating system
Fig. 1 Fluid heating system CLC 55
The fluid heating system consists of a heating system 241 attached additionally to the pump housing
through which a heating liquid (for example vapour, thermal oil) flows.
Operating data:
□ Maximum pressure: 16 bar
□ Maximum liquid temperature: 220 °C
Mounting the fluid heating system
Scope of delivery:
CL 55
□ 1 heating cover
□ 2 socket screws
1. Mount the heating cover to the pump housing using the supplied socket screws.
2. Mount the piping.
Commissioning the fluid heating system
Required heating-up period for the temperature difference of 20 °C or 50 °C at a liquid temperature of
200 °C see Fig. 1, page 8:
Size H L G Steam amount
[kg/h] 20 °C 50 °C
CL 55 67 110 1/4" 3 20 40
Tab. 1 Heating-up periods for fluid heating system (values apply for pumps without thermal insulation)
Heating-up period [min] at a temperature difference of
WARNING
Danger of the pump housing bursting and danger of injury through emitted pumped liquid through the
heat expansion of the pumped liquid.
► Open all the valves during the heating process.
► Observe the permissible operating limits of the pump when setting the supplied mass flow and its
temperature, see Tab. 1, page 7.
8 OIC 12en Edition 08/2016 Operating Instructions
Structure
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15
16 15
17
1
2
3
4
5
6
7
8
9
10
11
12
Function description
Structure
Function description
Fig. 1 Structure CLC 55
Fig. 2 Structure CLC 55 with completion
Operating Instructions OIC 12en Edition 08/2016 9
Fig. 3 Structure CLC 550
Structure
Function description
14
13
Fig. 4 Structure CLC 550 with completion
1 Suction cover
2 Pump housing
3 Flange cover
4 Bearing housing
5 Radial shaft seal
6 Ball bearing
KRAL screw pumps of the CLC series – high viscosity are generally suitable for transporting lubricating
liquids with high viscosity.
The design with outside bearings does not come into contact with liquid and is therefore especially suitable for pumped liquids that harden when they cool down, tend to crystallize or are abrasive.
7 Running sleeve
8 Seal housing
9 Balancing cylinder
10 Union flange
11 Insert sleeve
12 Main screw
15
16
15
13 Pressure flange
14 Pump bracket
15 Coupling half
16 Coupling intermediate ring
17 Pump bracket foot
10 OIC 12en Edition 08/2016 Operating Instructions
Radial shaft seal
A
C
1
3
1
3
B
2
2
Radial shaft seal
Function description
Fig. 5 Sealing chambers A, C Fig. 6 Sealing chamber B (View rotated)
The shaft is sealed with a radial shaft seal with three radial shaft sealing rings. Lubrication of the radial
shaft seals is effected via the sealing chambers. The sealing chamber A is filled and vented via the
inlet 1, the sealing chamber B via the inlet 2 and the sealing chamber C via inlet 3.
Depending on the application the six inlets to the three sealing chambers are designed and filled differently.
□ Sealing chamber A: Application-specific, for example PTFE grease for lubrication of the balancing
cylinder
□ Sealing chamber B: PTFE grease or quench liquid (supply via quench tank or circulation line)
□ Sealing chamber C: PTFE grease (in the factory)
Direction of rotation and flow direction
Fig. 7 Direction of rotation and flow direction
Standard direction of rotation:Clockwise, viewed from the drive
Flow direction: Marked on the pump housing by two arrows
Marked on the bearing housing by two arrows
Operating Instructions OIC 12en Edition 08/2016 11
Unpacking and checking the state of delivery
Transportation, storage and dispos al
Unpacking and checking the state of delivery
1. Upon delivery unpack the pump and check for transport damage.
2. Report damage during transportation immediately to the manufacturer.
3. Dispose of packaging material in accordance with the locally applicable regulations.
Lifting the pump
Transportation, storage and disposal
Fig. 1 Fastening hoisting equipment – Principle diagrams
Notice: If the motor and the pump are set up at an angle of 90° to each other, the centre of gravity lies
over the pump, see "Structure", page 9. The pump therefore has to be specifically secured against tilting
at the hoisting equipment after it has been placed and before loosening the hoisting equipment.
DANGER
Risk of injury and/or damage to equipment by tilting and falling of the pump.
► Use intact and correctly dimensioned hoisting equipment in accordance with the total weight to be
transported.
► Fasten hoisting equipment in accordance with the figures and corresponding to the centre of gra-
vity and weight distribution.
► Use at least two load ropes.
► Secure motor additionally against tilting. Separate motor and pump, if necessary.
► Do not stand under raised loads.
1. Attach the hoisting equipment to the pump, and lift the pump.
2. After it has been placed, ensure that the pump is secured against tilting.
Storage
During the test run, the internal components of the pump are wetted with test oil, which has a preservative effect. The pipe connections are fitted with protective covers. Unless otherwise specified, the external components of the pump are preserved with a single-coat PU-based two-component 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. To this
purpose the pump is additionally packed in hermetically sealing anti-corrosion paper.
12 OIC 12en Edition 08/2016 Operating Instructions
Preservation
Preservation
Preservation has to be carried out in the following cases:
□ For standard delivery: For storage periods exceeding six weeks and in case of adverse storage
□ For delivery with long-term preservation: If the packaging has been opened or damaged
Preserving the internal surfaces of the pump
1. Close the suction connection of the pump with a blind flange.
2. Pour non-corrosive, resin-free oil into the pressure connection until it reaches approx. 2 cm under
3. Close the pressure connection of the pump with a blind flange.
Preserving the external surfaces of the pump
Aids:
□ Preservative (e.g. Castrol Rustilo DWX 33)
► Paint or spray the preservative onto all plain and unpainted parts.
conditions such as high humidity, salty air, etc.
the pressure flange, while slowly turning the main screw against the direction of rotation.
After about six months storage check the oil level and if necessary top up oil.
At intervals of about six months check the preservation and if necessary repeat.
Notice: Store the preserved pump cool and dry and protect it against direct sunlight.
Removing the preservation
Aids:
□ Solvent
□ Steam-jet cleaning device with wax-dissolving additives
□ Collection tank
CAUTION
Risk of injury through emitted preservative oil.
► Wear protective equipment during all the work.
► Open the blind flange carefully in order to reduce any pressure that may exist in the pump.
► Collect the emitted preservative oil safely and dispose of it in an environmentally compatible man-
ner.
1. Clean the outside of the pump with solvents, if necessary using a steam-jet cleaning device.
2. Remove the blind flange on the pressure side.
3. Drain the pump, collecting the preservative oil in a collection tank.
4. Remove the blind flange on the suction side.
5. To remove the residual oil, rinse the pump with the pumped liquid.
Transportation, storage and disposal
Operating Instructions OIC 12en Edition 08/2016 13
Disposing of the pump
Disposing of the pump
Aids:
□ Solvents or industrial cleaners suitable for the pumped liquid
□ Collection tank
WARNING
Danger of poisoning and environmental damage from the pumped liquid.
► Wear protective equipment during all the work.
► Before disposing collect the discharging pumped liquid and dispose of in accordance with the
locally applicable regulations.
► Before disposing neutralize the residues of the pumped liquid.
1. Disassemble the pump and collect the residues of the pumped liquid in a collection tank.
2. Clean residues of the pumped liquid from the individual parts.
3. Separate the sealing elements made of elastomer from the pump and dispose of them in the residual waste.
4. Recycle iron parts.
Transportation, storage and disposal
14 OIC 12en Edition 08/2016 Operating Instructions
Installation
Installation, removal a nd connection
Installation
Observe the following instructions:
□ When selecting the location take the operating limits, NPSH values and ambient conditions
into account, see "Technical data", page 7.
□ The function, safety and service life may not be impaired by humidity, temperature influences
or explosive atmospheres.
□ During the installation ensure that the pump is secured against tilting.
□ During the installation ensure that all the parts can be accessed easily and that the main-
tenance work can be carried out easily.
Installing the pump
The pumps can be operated in any mounting position. However, the manufacturer recommends that the
pump not be mounted above the motor since pumped liquid can ingress the motor if a leak occurs.
Requirement:
□ The pump connections are to be protected against soiling, for example by using the protective cover
mounted in the factory
WARNING
Risk of injury and damage to equipment should the pump fall over.
► Observe the centre of gravity of the pump and if necessary secure the pump against falling over.
Installation, removal and connection
CAUTION
Leaking pumped liquid can damage the motor.
► Do not mount the pump above the motor.
CAUTION
Damage to the pump and piping through insufficient fastening.
► Only fasten the pump on a stable bearing underground.
► Ensure that the fastening elements are fixed sufficiently.
1. Place the pump in position, while ensuring that the flow direction that is marked by arrows on the pump housing is correct.
2. Fasten the pump with fastening elements securely on the underground.
Protecting the pump against soiling
CAUTION
Damage to device through impurities 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.
► After the connecting work clean the pipe system thoroughly, see "Cleaning the pipe system",
page 19.
Operating Instructions OIC 12en Edition 08/2016 15
Installation
Connecting the pump to the pipe system
CAUTION
Damage to device or impaired functionality through mechanical stresses.
► Ensure that the pump mounting on the pipe system is free of mechanical stress.
1. Turn the pump shaft or fan impeller of the motor so that smooth running of the pump is checked.
If the pump cannot be turned by hand, remedy the fault before installing the pump, see "Troubleshooting", page 32.
2. During welding work attach protective covers in front of the connecting flanges.
3. Place the piping in position and support the weight of the piping.
Installation, removal and connection
4. Check the clearance and the angular, vertical and linear offset, adjusting where necessary.
If the screws tighten easily, this is a sure sign that the installation is stress-free.
5. Tighten the connecting screws crosswise with torque, see Tab. 2, page 38.
Assembling the pump and motor
a Lateral offset
b Angular offset
c Linear offset
Fig. 1 Measuring points for tolerances of the coupling alignment
Coupling diameter Lateral offset a Angular offset b Linear offset c
[mm] max. [mm] max. [°] min. [mm] max. [mm]
40 0.2 0.9 2.0 3.0
55 0.2 0.9 2.0 3.5
65 0.25 0.9 2.5 4.0
80 0.3 1.0 3.0 4.5
95 0.3 1.0 3.0 5.0
120 0.4 1.1 4.0 6.0
135 0.4 1.2 4.5 7.0
160 0.5 1.2 5.0 8.0
Tab. 1 Limit values for aligning the shaft coupling
16 OIC 12en Edition 08/2016 Operating Instructions
Connecting the motor
CAUTION
Incorrect alignment of the shaft coupling causes noise, vibrations and damage to the coupling and
bearing.
► After the mounting check the alignment of the coupling.
1. Check the linear offset of the coupling using a slide gauge or feeler gauge. If the limit values of the above table are exceeded, loosen the fastening of the pump or motor and move the pump or motor in order to adjust the linear offset.
2. Check the lateral offset of the coupling using a hairline gauge and feeler gauge. Check several
points along the periphery of the coupling.
If the limit values of the above table are exceeded, loosen the fastening of the pump or motor and
move the pump or motor in order to reduce the lateral offset.
3. Check the angular offset of the coupling using a hairline gauge. If the limit values of the above table are exceeded, loosen the fastening of the pump or motor and move the pump or motor in order to reduce the angular offset.
Connecting the motor
DANGER
Risk of death resulting from electric shock.
Installation, removal and connection
► The motor may only be connected by an authorized electrician.
► Ensure that the power supply is de-energized.
► Ground the pump carefully.
1. Observe the operating instructions of the motor.
2. Ensure that the operating data on the rating plate of the motor agree with the operating data of the pump and with the local power supply.
3. Connect the motor in the motor terminal block in accordance with the circuit diagram.
Operating Instructions OIC 12en Edition 08/2016 17
Removing the pump
1
B
2
2
Removing the pump
Installation, removal and connection
1 Screw plug 2 Screw plug
Fig. 2 Draining the pump Fig. 3 Draining sealing chamber B
Aids:
□ Flushing liquid
□ Collecting vessel
DANGER
Risk of death resulting from electric shock.
► Ensure that the power supply is de-energized.
► The motor may only be separated from the power supply by an authorized electrician.
WARNING
Risk of injury through emitted hot, poisonous or corrosive pumped liquid.
► Wear protective equipment during all the work.
► Before beginning work, let the pump cool down to the ambient temperature.
► Ensure that the pump is depressurized.
► Collect the pumped liquid safely and dispose of it in an environmentally compatible manner.
1. Flush pump with flushing liquid.
2. Disconnect the motor from the power supply and secure it against being switched back on.
3. Close the pressure and suction-side shut-off devices.
4. Empty the pump at the lower point using the screw plug 1. While doing so collect the emitted mixture
of flushing liquid and pumped liquid in a collecting vessel, see Fig. 2, page 18.
5. In the case of a design with quench liquid, use the screw plug 2 to drain the quench liquid. While
doing so, collect the emitted quench liquid in a collecting vessel, see Fig. 3, page 18.
6. Loosen the connecting flange.
7. Loosen the fastening of the pump unit on the foundation and dismantle the motor and pump bracket.
18 OIC 12en Edition 08/2016 Operating Instructions
Commissioning
Operation
Commissioning
Be sure to observe the following instructions:
► The pump may only be commissioned by authorized qualified personnel.
► Wear protective equipment during all the work.
► When pumping liquids that harden through humidity flush the pump with dry air before every com-
missioning.
Cleaning the pipe system
Clean the complete pipe system with a low-viscosity flushing medium before commissioning in order to
protect the pump. If this is to be realized by flushing by means of the pump, an additional commissioning
filter has to be installed before the pump.
Mesh width of the commissioning filter:
□ 0.02 mm
CAUTION
Damage to equipment through additional pressure loss in the commissioning filter.
► Calculate the flow resistance and determine the remaining pump intake.
► Monitor the suction-side pressure.
► Check and clean the commissioning filter regularly.
Operation
► Recommended rinsing duration with commissioning filter: 50 – 100 hours.
Filling sealing chambers
Depending on the application the sealing chambers are filled differently. The six accesses to the sealing
chambers are designed differently, for example as grease nipples, quench tank connection or screw
plug, for example, for venting. In the following guidelines the design variants are not taken into account.
The following variants are described:
□ Variant 1: Sealing chamber A application-specific, B and C filled in factory with PTFE grease
□ Variant 2: Sealing chamber A application-specific, C filled in factory with PTFE grease;
Quench liquid in sealing chamber B (filling on location via quench tank)
□ Variant 3: Sealing chamber A application-specific, C filled in factory with PTFE grease;
Quench liquid in sealing chamber B (filling at the system via circulation line)
Operating Instructions OIC 12en Edition 08/2016 19
Commissioning
A
C
1
3
1
3
B
2
2
B
1
2
2
max.
min.
Operation
Fig. 1 Sealing chambers A, C
Variant 1: Checking PTFE grease
►
Ensure that the sealing chamber A is filled application-specifically and vented and sealing
chambers B and C are filled with PTFE grease, see "Lubricating the radial shaft seal", page 30.
Variant 2: Filling sealing chamber B with quench liquid via quench tank
Fig. 2 Sealing chamber B (sectional view rota-
ted)
Fig. 3 Quench tank
Aids:
□ Quench liquid, pH-neutral and resin-free (for example Mesamoll
20 OIC 12en Edition 08/2016 Operating Instructions
1 Quench tank
2 Quench liquid connection, screw plug
B Sealing chamber B
®
)
Commissioning
B
2
2
CAUTION
When quench liquid is missing damage to seals through hardening of the pumped liquid.
► Check filling level of the quench tank every four weeks and refill quench liquid if necessary.
1. Ensure that the sealing chamber A is filled application-specifically and vented and sealing chamber C is filled with PTFE grease, see "Lubricating the radial shaft seal", page 30.
2. Screw out the screw plug 2 at the top of the sealing chamber B and mount the quench tank 1.
3. Open the screw plug 2 of the opposing vent hole by a maximum of two rotations.
4. Fill the quench liquid into the quench tank until it is emitted from the vent hole.
5. Tighten the screw plug again.
6. Then fill the quench tank with quench liquid while observing the maximum and minimum filling level, see Fig. 4, page 21.
Variant 3: Filling the sealing chamber B with quench liquid via the circulation line
Operation
2 Connection circulation line, screw plug
B Sealing chamber B
Fig. 4 Connection circulation line
CAUTION
When quench liquid is missing damage to seals through hardening of the pumped liquid.
► Ensure that the circulation line pumps the quench liquid with sufficient pressure so that the sea-
ling chamber B is filled permanently during operation.
1. Ensure that the sealing chamber A is filled application-specifically and vented and sealing chamber C is filled with PTFE grease, see "Lubricating the radial shaft seal", page 30.
2. Screw out both screw plugs 2 of the sealing chamber B.
3. Connect the system-side circulation line for the quench liquid to both holes (input, output).
4. Ensure that the sealing chambers A and C are filled with PTFE grease, see "Lubricating the radial shaft seal", page 30.
Operating Instructions OIC 12en Edition 08/2016 21
Commissioning
Operation
Filling and venting the pump
Fig. 5 Vent holes
DANGER
Risk of death through emitted pumped liquid.
Pumped liquids can be hot, poisonous or caustic and can spray out under high pressure.
► Wear protective equipment during all the work. Ensure face protection.
► Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible man-
ner.
1. Variant 1: Ensure that the sealing chamber A is filled application-specifically and vented and sealing
chambers B and C are filled with PTFE grease, see "Lubricating the radial shaft seal", page 30.
Variant 2: Ensure that the sealing chamber B is filled with quench liquid and that the filling levels are
observed in the quench tank, see "Refilling quench liquid", page 31. Ensure that the sealing
chamber A is filled application-specifically and vented and sealing chamber C is filled with PTFE
grease, see "Lubricating the radial shaft seal", page 30.
Variant 3: Ensure that the circulation line for the quench liquid is opened and the sealing chamber B
is filled with quench liquid.
Ensure that the sealing chamber A is filled application-specifically and vented and sealing
chamber C is filled with PTFE grease, see "Lubricating the radial shaft seal", page 30.
2. Open the screw plug of the upper vent hole by a max. of two rotations, see Fig. 5, page 22, so that air can escape during the filling process.
3. Open the suction-side shut-off device. Through the inlet pressure the pump fills with pumped liquid.
4. After a short while, tighten the screw plug of the vent hole again, so that no pumped liquid can be emitted.
Checking the direction of rotation
The direction of rotation is indicated by arrows on the pump. The direction of rotation of the motor specifies the direction of rotation of the pump. That is to say, the fan impeller of the motor must rotate in the
direction in which the arrow on the pump is pointing to indicate direction of rotation.
□ Standard direction of rotation:Clockwise (viewed from the drive)
22 OIC 12en Edition 08/2016 Operating Instructions
Commissioning
1
Operation
1
Fig. 6 Indication of direction of rotation
CAUTION
Dry running can damage pump equipment.
► Ensure that the pump is filled properly.
► Switch the pump on for a maximum of 1 second and then off again immediately.
1. Switch on the power supply and then turn it off again immediately.
2. Compare the direction of rotation of the fan impeller with the rotation-direction arrows on the pump flange.
3. If the directions do not match, swap over two electrical connection phases. Repeat Steps 1 and 2.
Commissioning the pump
Requirements:
1 Rotation-direction arrow
□ Pump set up and connected correctly
□ Motor connected correctly
□ Pipe system is free of impurities
□ Sealing chambers A, B and C filled with PTFE grease/quench liquid
□ Pump filled with pumped liquid
□ Shut-off devices in the suction and pressure line opened
□ Variant 3: Circulation line opened for quench liquid
WARNING
Risk of injury through rotating parts.
► Ensure that the coupling protection is mounted.
WARNING
Risk of injury through emitted pumped liquid.
► Wear protective equipment during all the work.
► Ensure that all the connections are connected sealingly.
CAUTION
Dry running can damage pump equipment.
► Ensure that the pump is filled properly.
► If the pump does not deliver after 10 – 15 seconds, abort commissioning.
Operating Instructions OIC 12en Edition 08/2016 23
During operation
bar
bar
Operation
1. Switch on the pump. The pump delivers when the pressure on the pressure side of the pump rises or a flow indicator at the system side triggers.
2. If the pump does not deliver after 10 – 15 seconds of operation, abort commissioning, establish the cause of the fault and only then continue the commissioning procedure. Follow the instructions in the fault table, see "Troubleshooting", page 32.
3. Run the pump for a few minutes to allow the pipe system to vent fully. The pipe system is fully vented when there is a smooth operating noise and a pressure gauge on the pressure side of the pump shows no more fluctuations.
During operation
Checking the operating pressure
Fig. 7 Principle diagram: Open pressure gauge
stopcock
CAUTION
Pressure gauge stopcocks that are opened permanently can result in the pressure gauges leaking.
► Close the pressure gauge stopcocks after completing reading.
► Open the pressure gauge stopcock, read the operating pressure, close the pressure gauge stop-
cock.
Fig. 8 Principle diagram: Close the pressure
gauge stopcock
Switching off the pump
CAUTION
Damage to seals through pressurizing of the pump while it is standing still.
► Ensure that while the pump is at a standstill, the pressure in the pump does not exceed the inlet
pressure during operation.
1. Switch off the motor.
2. Close the pressure and suction-side shut-off devices.
Decommissioning the pump
WARNING
Risk of injury or poisoning through emitted pumped liquid.
► Wear protective equipment during all the work.
► Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible man-
ner.
► Carry out the following measures during operation interruptions:
24 OIC 12en Edition 08/2016 Operating Instructions
Recommissioning the pump
Pump is Measure
□ Shut down for longer period ► Measures depend on pumped liquid, see Tab. 2, page 25.
□ Drained ► Flush pump with flushing liquid.
□ Dismantled ► Disconnect the motor from the power supply and secure it
□ stored ► Observe the measures for storing and preservation, see "Sto-
Tab. 1 Measures for operation interruption
Behaviour of the pumped liquid Duration of the operation interruption
□ Solids sediment ► Rinse the pump. ► Rinse the pump.
□ Congealed/frozen
□ No corrosive burden
□ Congealed/frozen
□ Corrosive burden
□ Remains liquid
□ No corrosive burden
□ Remains liquid
□ Corrosive burden
Operation
► Close the pressure and suction-side shut-off devices.
against being switched back on, see "Removing the pump",
page 18.
rage", page 12 and see "Preservation", page 13.
Short Long
► Drain the pump. ► Drain the pump.
► Drain the pump. ► Drain the pump.
► Preserve the pump.
— —
— ► Drain the pump.
► Preserve the pump.
Tab. 2 Measures depending on the behaviour of the pumped liquid
► Drain the pump via the pressure and suction line.
Recommissioning the pump
► Carry out all the steps as for the commissioning process, see "Commissioning", page 19.
Operating Instructions OIC 12en Edition 08/2016 25
Safety instructions
Servicing
Servicing
Safety instructions
Observe the following safety instructions at all the work:
► All the work may only be carried out by authorized qualified personnel.
► Wear protective equipment during all the work.
► Switch off the motor and secure it against being switched back on.
► Before beginning work, let the pump cool down to the ambient temperature.
► Ensure that the pump is depressurized.
► Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible man-
ner.
► Also observe the general drawings during all the work on the pump, see "General drawings",
page 35.
Required maintenance
The service life of the pump depends to a great extent on the operating conditions. If the operating limits
are observed, the pump has a service life of many years.
Signs of progressive wear of individual pump elements:
Finding Cause Elimination
Increased running noises Incipient damage to bearing Replace the bearing.
Increased leaking Incipient damage to seal Replace the shaft seal.
Deposits on the seal Low-volatile liquids Clean the seal.
Increased play in the shaft coupling
Advanced wear of the coupling
intermediate ring
Remove coupling intermediate
ring.
Reduction in the delivery rate or
pressure under constant operating conditions
Tab. 1 Check table for required maintenance
1. Check the pump visually and acoustically every four weeks.
2. Check for signs of wear as listed in the table above and eliminate the cause.
Maintenance schedule
Component Activity Interval
Pump □ Clean □ Before every liquid change
Ball bearing □ Lubricate □ CLC 55: 7500 operating hours
Advanced wear of screws and
housing
see "Cleaning the pump", page 27
Replace the pump.
□ CLC 550: 6000 operating hours
see "Lubricating the ball bearings",
page 29
□ Replace in the factory □ After 20,000 operating hour
Radial shaft seal PTFE grease
□ Lubricate
Quench liquid:
□ Check filling level
□ Refill
□ 1000 operating hours
see "Lubricating the radial shaft seal",
page 30
□ 3000 operating hours
□ When necessary
see "Refilling quench liquid", page 31
Tab. 2 Maintenance schedule
26 OIC 12en Edition 08/2016 Operating Instructions
Cleaning the pump
914.1
090
222.3
914.2
112
B
1x
131
A
B
042
074.2
Cleaning the pump
Fig. 1
Fig. 2 Fig. 3
Servicing
Fig. 4 Fig. 5
042
Balancing cylinder
074.2
Flange cover
090
Suction cover
112
Union flange
Size Reduced torque [Nm]
CLC 55 46
CLC 550 150
Tab. 3 Reduced torque
Aids:
131
222.3
661
914.1
Pump housing
Flat gasket
Screw set
Socket screw
□ Screw support, included in scope of delivery
□ Extractor
131
914.2
A
B
661
Socket screw
Extractor
Screw support
Operating Instructions OIC 12en Edition 08/2016 27
Cleaning the pump
Servicing
CAUTION
Loss of hardening through excessive heating.
► Don't heat up pump materials over 350 °C during cleaning process.
► Preferably clean screws and pump housings with solvents or water jet.
CAUTION
Damage of union flange and pump housing through excessive surface pressure
► Tighten the socket screws of the union flange with reduced torque, see "Reduced torque",
page 27.
CAUTION
Damaging of the screw set because of falling down.
► While dismantling the screw set hold it so that the loose idle screws cannot fall down.
1. Remove the pump from the pipe system, see "Removing the pump", page 18.
2. Dismantle the suction cover 090 and socket screws 914.2 of the union flange 112, see Fig. 1, page
27.
3. Support the idle screws with the screw support B and dismantle the pump housing with a suitable extractor A, see Fig. 3, page 27. Ensure that the idle screws do not fall down.
4. Clean the screws and pump housing.
5. A PTFE grease film has to be visible between the balancing cylinder 042 and flange cover 074.2,
see Fig. 4, page 27. Before carrying out assembly check the presence of this grease film and, if
necessary, re-lubricate the screw plug/grease nipple, see "Lubricating the radial shaft seal",
page 30, sealing chamber A.
6. Position the idle screws at the main screw in such a way that the bearing bushes are flush with the flange cover. Slide on the pump housings, see Tab. 3, page 27.
7. Tighten the socket screws 914.2 of the union flange with reduced torque, see Tab. 3, page 27.
8. Check the flat gasket 222.3 for damage and replace if necessary.
9. Mount the suction cover. Ensure that the thrust washers in the suction cover are flush with the suction covers of the idle screws.
10. Connect the pump to the pipe system, fill and vent, see "Filling and venting the pump", page 22.
28 OIC 12en Edition 08/2016 Operating Instructions
Lubricating the ball bearings
Lubricating the ball bearings
Be sure to observe the following instructions:
► Re-lubrication may only be carried out while the pump is running.
► First re-lubrication after an hour running time.
Size Temperature [°C] Lubricate interval [h] with
speed 1450 min
CLC 55 100 7500 6 SKF LGWA 2
CLC 550 100 6000 16 SKF LGWA 2
Tab. 4 Lubricating intervals of ball bearings
A
B
Fig. 6 Lubricating the ball bearings
Aids:
-1
A Grease gun
B Grease nipple of ball bearings
Grease amount
3
]
[cm
Recommended
grease
□ Grease gun
Servicing
CAUTION
Damage to bearing because of lack of lubrication.
► It is imperative that the lubrication intervals be observed.
► Re-lubricate the ball bearing with the recommended amount of grease via the grease nipple B.
Operating Instructions OIC 12en Edition 08/2016 29
Lubricating the radial shaft seal
4
1
3
2
A C
B
Lubricating the radial shaft seal
Servicing
Be sure to observe the following instructions:
► The manufacturer recommends lubricating the radial shaft seal while the pump is running.
Depending on the application the sealing chambers are filled differently. The six accesses to the sealing
chambers are realized differently, for example as grease nipples, connection quench tank or screw
plugs, for example for venting. In the following guidelines the design variants are not taken into account.
1
Screw plug Sealing
chamber A
2
Screw plug Sealing
chamber B
3
Screw plug Sealing
chamber C
4
Grease gun
Fig. 7 Lubricating the radial shaft seal
Size Lubricating interval
[h]
CLC 55 1000 2.0 1.0 1.0 PTFE grease
CLC 550 1000 4.0 2.0 2.0 PTFE grease
Amount of grease [cm3] for screw plug Recommended
grease
1 2 3
Tab. 5 Lubricating intervals of radial shaft seals
□ Variant 1: Application-specific for example PTFE grease;
Screw plug 1, 2, 3 (Sealing chamber A, B and C), see table above, see Tab. 5, page 30
□ Variant 2: Quench liquid, screw plug 2 (Sealing chamber B – filling via quench tank), see "Refilling
quench liquid", page 31
PTFE grease screw plug 1 and 3 (Sealing chamber A and C), see Tab. 5, page 30
□ Variant 3: Quench liquid: Screw plug 2 (Sealing chamber B – filling via circulation line);
PTFE grease screw plug 1 and 3 (Sealing chamber A and C), see Tab. 5, page 30
30 OIC 12en Edition 08/2016 Operating Instructions
Refilling quench liquid
B
1
2
2
max.
min.
Aids
□ Grease gun
CAUTION
Damage to sealing because of lack of lubrication.
► It is imperative that the lubrication intervals be observed.
► Variant 1: Re-lubricate the recommended amount of grease via the grease nipple in the sequence
1, 2 and 3, see Tab. 5, page 30.
Variant 2: Ensure that the filling limits of the quench tank are observed. If necessary refill the
quench liquid, see "Refilling quench liquid", page 31.
Re-lubricate the recommended amount of grease via the grease nipples 1 and 3,
see Tab. 5, page 30.
Variant 3: Check and correct the pressure of the circulation line if necessary.
Re-lubricate the recommended amount of grease via the grease nipples 1 and 3,
see Tab. 5, page 30.
Refilling quench liquid
Servicing
1 Quench tank
Operating Instructions OIC 12en Edition 08/2016 31
Fig. 8 Filling level of the quench tank
CAUTION
When quench liquid is missing damage to seals through hardening of the pumped liquid.
► Check the filling level of the quench tank every four weeks and refill quench liquid if necessary.
► If necessary top up the quench liquid, while observing the minimum and maximum filling level, see
"Variant 2: Filling sealing chamber B with quench liquid via quench tank", page 20.
2 Screw plug
B Sealing chamber B
Possible faults
Troubleshooting
Possible faults
Faults can have different causes. The following tables list the symptoms of a fault, the possible causes
and measures for troubleshooting.
Fault Cause/Remedy
□ No pump suction 1, 2, 3, 4, 5, 6, 7, 8, 32
Troubleshooting
□ Delivery rate too low 2, 3, 4, 9, 10, 11, 12, 13, 14
□ Pump runs noisily 2, 3, 4, 6, 10, 12, 16, 17, 18, 19, 20
□ Motor overload 9, 10, 13, 20, 21
□ Uneven delivery rate 2, 3, 4, 6, 10, 12
□ Shaft seal leaks 15, 22, 23, 24, 25, 26, 27
□ Pump has got stuck 28, 29, 30, 31
Troubleshooting
No. Cause Remedy
1 Pump suction line closed ► Check shut-off devices in the suction line and open
2 Suction valve or line obstructed ► Check the suction valve and line for clear passage.
3 Suction line or shaft seal leaks ► Check suction line or shaft seal for leaks. Pay
4 Suction head too high ► Reduce difference of level
5 Level of liquid in the intake container
too low
6 Soiling of the filters/strainers ► Clean the filter/strainer.
7 Pump suction capacity reduced by
inadequate wetting
them, if necessary.
particular attention to leakage at valves and
connection points. If necessary, replace parts.
- or ► Reduce pipe length
- or ► Increase pipe diameter
- or ► Heat the liquid to reduce viscosity
- or ► Install filter with greater mesh width. Ensure that
the permissible mesh width is not exceeded, see
"Protecting the pump against soiling", page 15.
► Supplement the liquid.
► Fill pump with liquid.
8 Incorrect pump direction of rotation ► Carry out the electrical connection so that the
direction of pump rotation matches that of the arrow
on the flange cover, see "Connecting the motor",
page 17.
9 Differential pressure too high ► Check the system and reduce the differential
pressure.
10 Viscosity of the liquid too high ► Increase the temperature of the liquid
- or ► Reduce the rotation speed.
32 OIC 12en Edition 08/2016 Operating Instructions
Troubleshooting
No. Cause Remedy
11 Viscosity of the liquid too low ► Decrease the temperature of the liquid
12 Airlock or gas in the liquid ► Test the pipe system for air admission and replace
13 Motor running at wrong voltage or
14 Advanced wear of rotating pump
15 Advanced wear of sealing surfaces ► Replace the seal and check the pumped liquid for
16 Inadequate alignment of
17 Pump deflected ► Support the weight of the pipe system.
18 Resonance in the system ► Provide a flexible bearing arrangement for the pump
19 Speed of flow in suction or pressure
20 Ball bearing damaged ► Replace the ball bearing.
21 Lack of lubrication or foreign bodies
22 Shaft seal damaged through dry
23 Inlet pressure too high ► Reduce the inlet pressure at the system side.
24 Thermal or chemical loading of
25 Cold start when delivering high-
26 Seal overload during heating
frequency
components
shaft coupling
line too high
have caused superficial damage to
rotating pump components
running
elastomer seals exceeded
viscosity liquids
process
- or ► Increase the rotation speed.
parts if necessary.
► Reduce the suction head
- or ► Increase the inlet pressure.
► Ensure that the motor voltage and frequency match
the operating voltage.
► Compare the speed of the motor with the pump
rating plate. If the data do not match, adjust the
speed of the motor.
► Check screw set and housing and replace if
necessary.
abrasive content.
► Align the shaft coupling correctly, see "Assembling
the pump and motor", page 16.
► Loosen pipe connections and mount stress-free, see
"Connecting the pump to the pipe system", page 16.
unit
- or ► Make the connections with hoses.
► Set the flow speed in the suction line so that it does
not exceed 1 m/s.
► Set the flow speed in the pressure line so that it does
not exceed 3 m/s.
► Check the screw set and the housing. If necessary
replace the pump with free shaft end.
► Replace the shaft seal. When starting up the pump,
pay attention to venting.
► Check the maximum operating temperature.
► Check the resistance of the elastomers with regard
to the pumped liquid.
► Install the heating system.
► To prevent thermal expansion of the liquid causing a
build-up of pressure, open the pressure- or suctionside shut-off device.
Troubleshooting
Operating Instructions OIC 12en Edition 08/2016 33
Troubleshooting
No. Cause Remedy
27 Leaking return valve causes seal
overload when pump is at a
standstill
28 Foreign bodies in the pump ► Dismantle the pump and clean it.
Troubleshooting
29 Differential pressure is too high and
has overloaded the sleeve bearing
30 Viscosity is too low and has
overloaded the sleeve bearing
31 Dry running can damage the pump ► Dismantle the pump and clean it.
32 Pump does not vent ► Vent the pressure line at the highest point.
► Clean the return valve and if necessary, replace it.
► Smooth the superficial damage to the housing and
the rotating parts with an oilstone. If necessary,
replace the pump.
► Dismantle the pump and clean it.
► Smooth the superficial damage to the housing and
the rotating parts with an oilstone. If necessary,
replace the pump.
► Reduce the differential pressure.
► Dismantle the pump and clean it.
► Smooth the superficial damage to the housing and
the rotating parts with an oilstone. If necessary,
replace the pump.
► Increase the viscosity, for example by reducing the
operating temperature.
► Smooth the superficial damage to the housing and
the rotating parts with an oilstone. If necessary,
replace the pump.
► When resuming operation, take action to prevent dry
running, see "Recommissioning the pump", page 25.
Tab. 1 Fault table
34 OIC 12en Edition 08/2016 Operating Instructions
General drawings
914.1
090
222.3
914.2
112
131
222.2
074.2
872*
062
821
464*
127
057
914.4
914.3
222.1
134
471
472
039*
059
745
049.1
739
471
042
040***
866
1037
661
074.1
165.1
879
061
049.2
879
525
052
180
526
Appendix
General drawings
Appendix
Fig. 1 CLC 55
Fig. 2 Completion CLC 55
Operating Instructions OIC 12en Edition 08/2016 35
General drawings
914.1
090
222.3
914.2
112
131
222.2
074.2
062
821
127
057
914.4
914.3
222.1
134
471
472
056**
059
745
049.1
739
471
040***
042
866
1037
661
074.1
165.1
879
061884**
049.2
525
052
180
Appendix
Fig. 3 CLC 550
Fig. 4 Completion CLC 550
36 OIC 12en Edition 08/2016 Operating Instructions
Spare parts
Spare parts
Item No. Part Item No. Part
039* Distance sleeve 222.1 Flat gasket
040*** Usage sleeve 222.2 Flat gasket
042 Balancing cylinder 222.3 Flat gasket
049.1 Running sleeve 464* Nilos ring
049.2 Bearing bush 471 Circlip
052 Coupling 472 Circlip
056** Supporting ring 525 Coupling intermediate ring
057 Threaded ring 526 Pump bracket foot
059 Support ring 661 Screw set
061 Thrust washer 739 O-ring
062 Spacer 745 Radial shaft seal
074.1 Flange cover 821 Four-point contact bearings
074.2 Flange cover 866 Feather key
090 Suction cover 872* Securing ring
112 Union flange 879 Straight pin
127 Bearing housing 884** Threaded pin
131 Pump housing 914.1 Socket screw
134 Seal housing 914.2 Socket screw
165.1 Screw plug 914.3 Socket screw
165.2 Screw plug 914.4 Socket screw
180 Pump bracket 1037 Bearing bush set
Appendix
* Only for size CLC 55
** Only for size CLC 550
*** Depending on pumped liquid
Tab. 1 Spare parts
Operating Instructions OIC 12en Edition 08/2016 37
Tightening torques
Appendix
Tightening torques
Tightening torque [Nm] for screws with metric threads + head contact surfaces With thread measured
in inches
+ wedge lock
washers
Rust-
8.8 +
5.6 8.8 10.9
Thread
M 3 0.6 1.5 – 1.2 1.5 1.1 – – G 1/8" 13
M 4 1.4 2.9 4.1 2.3 3 2 – – G 1/4" 30
M 5 2.7 6.0 8.0 4.8 6.0 3.9 3.5 4.7 G 3/8" 60
M 6 4.7 9.5 14 7.6 10.3 6.9 6 8 G 1/2" 80
M 8 11.3 23.1 34 18.4 25 17 16 22 G 3/4" 120
M 10 23 46 68 36.8 47 33 32 43 G 1" 200
M 12 39 80 117 64 84 56 56 75 G 1 1/4" 400
M 14 62 127 186 101 133 89 – – G 1 1/2" 450
M 16 96 194 285 155 204 136 135 180
M 18 133 280 390 224 284 191 – –
M 20 187 392 558 313 399 267 280 370
M 24 322 675 960 540 687 460 455 605
Alu*
8.8
proof
A4-70
Stainless steel
screws
A2 and A4
Property class 70
Property class 80
Screw plugs with
elastomer seal
Thread
* Reduced tightening
torque when screwing
into aluminium
Galvanized +
Stainless steel
Tab. 2 Tightening torques
Contents of the EC Declaration of Conformity
The screw pumps described in these operating 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 Remark
2006/42/EC Machinery Directive –
2014/68/EU Pressure Equipment Directive –
2014/30/EU Directive on Electromagnetic
Compatibility
2014/35/EU Low Voltage Directive Only for machinery with electrical
2014/34/EU Directive on Use in Potentially Explosive
Areas (ATEX)
Tab. 3 Directives observed
Only for machinery with electrical
components
components
Only for machinery in ATEX version
38 OIC 12en Edition 08/2016 Operating Instructions
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