Operating instructions
KRAL screw pumps.
Series K
Magnetic coupling
Observe safety instructions for persons with cardiac pacemaker, metallic implant or
neurostimulator.
OIK 09en-GB
Edition 2019-11
Original instructions
www.kral.at
Table of contents
1 About this document ..................................................... 4
1.1 General information .......................................................4
1.2 Associated documents ..................................................4
1.3 Target groups ................................................................4
1.4 Symbols.........................................................................4
1.4.1 Danger levels ....................................................4
1.4.2 Danger signs.....................................................5
1.4.3 Symbols in this document .................................5
2 Safety .............................................................................. 5
2.1 Proper use .....................................................................5
2.2 Foreseeable misuse ......................................................6
2.3 Obligations of the operator-owner .................................6
2.4 Safety instructions .........................................................6
2.4.1 Fundamental safety instructions .......................6
2.4.2 Dangers at magnetic coupling systems ............6
3 Identification................................................................... 7
3.1 Type code......................................................................7
3.2 Rating plate ...................................................................8
4 Technical data ................................................................ 8
4.1 Operating limits..............................................................8
4.2 Required NPSH values..................................................8
4.3 Sound pressure level.....................................................9
4.4 Weights..........................................................................9
4.5 Accessories ...................................................................9
5 Function description...................................................... 9
5.1 Pump structure ..............................................................9
5.2 Pump unit structure .....................................................10
5.3 Functional principle......................................................10
5.4 Housing variants..........................................................10
5.5 Overflow valve .............................................................11
6 Transportation, storage............................................... 12
6.1 Dangers during transportation .....................................12
6.2 Dangers during storage ...............................................12
6.3 Unpacking and checking the state of delivery .............12
6.4 Transporting the pump/pump unit................................12
6.5 Storing the pump .........................................................13
7 Preservation ................................................................. 14
7.1 Preservation table........................................................14
7.2 Preserving the inner surfaces......................................14
7.3 Preserving the outer surfaces......................................14
7.4 Removing the preservation..........................................15
8 Installation, removal .................................................... 15
8.1 Dangers during installation ..........................................15
8.2 Dangers during removal ..............................................15
8.3 Installing the pump ......................................................16
8.4 Removing the pump ....................................................17
9 Connection ................................................................... 18
9.1 Dangers during connection work .................................18
9.2 Connecting the pump to the pipe system ....................18
9.3 Insulating the pump .....................................................19
9.4 Connecting the pump unit to the power supply ...........19
10 Operation ...................................................................... 20
10.1 Dangers during operation ............................................20
10.2 Commissioning ............................................................20
10.2.1 Cleaning the pipe system ................................20
10.2.2 Filling and venting the pump............................21
10.2.3 Checking the direction of rotation ....................22
10.2.4 Commissioning the pump ................................23
10.3 During operation ..........................................................24
10.3.1 Checking the operating pressure.....................24
10.3.2 Monitoring filters and/or strainers ....................25
10.3.3 Adjusting the overflow valve ............................25
10.3.4 Switching off the pump unit .............................26
10.4 Decommissioning.........................................................26
10.4.1 Decommissioning the pump ............................26
10.5 Recommissioning.........................................................27
10.5.1 Recommissioning the pump ............................27
11 Maintenance...................................................................28
11.1 Dangers during maintenance.......................................28
11.2 Required maintenance.................................................28
11.3 Ball bearing ..................................................................28
11.4 Maintaining the pump...................................................28
11.5 Maintaining the magnetic coupling...............................29
12 Servicing ........................................................................29
12.1 Dangers during servicing .............................................29
12.2 Wear ............................................................................30
12.2.1 Signs of wear...................................................30
12.2.2 Magnetic coupling............................................30
12.3 Replacing the overflow valve .......................................30
12.3.1 Removing the overflow valve...........................30
12.3.2 Installing the overflow valve.............................30
12.4 Replacing the magnetic coupling .................................31
12.4.1 Removing the outer rotor.................................31
12.4.2 Removing the inner rotor .................................32
12.4.3 Installing the inner rotor ...................................32
12.4.4 Installing the outer rotor...................................34
12.5 Replacing the ball bearing and screw set ....................35
12.5.1 Removing the ball bearing and screw set........35
12.5.2 Installing the ball bearing and screw set..........36
13 Disposal..........................................................................37
13.1 Dismantling and disposing of the pump ......................37
14 Troubleshooting ............................................................38
14.1 Possible faults..............................................................38
14.2 Troubleshooting ...........................................................38
15 Accessories ...................................................................40
15.1 Heating.........................................................................40
15.1.1 Possible types of heating.................................40
15.1.2 Electrical heating system.................................40
15.1.3 Fluid heating system........................................42
15.1.4 Heating system special design ........................43
16 Spare parts.....................................................................44
16.1 Overview ......................................................................44
16.2 Maintenance kits ..........................................................45
16.2.1 Maintenance kit magnetic coupling KF/KV5–
660..................................................................45
16.2.2 Maintenance kit magnetic coupling KF/KV851–
1301................................................................46
16.2.3 Maintenance kit magnetic coupling KF/
KV1500–1700...............................................47
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Operating instructions
16.2.4 Maintenance kit magnetic coupling KF/
KV2200–2900 ..............................................48
16.2.5 Maintenance kit magnetic coupling KFN/KFT/
KVT .................................................................49
16.3 Repair kits....................................................................50
16.3.1 Repair kit overflow valve KF/KH/KV5–660 and
KFT/KVT/KFN/KFA .........................................50
16.3.2 Repair kit overflow valve KF/KH/KV851–1301
........................................................................51
16.3.3 Repair kit overflow valve KF/KH/KV1500–1700
........................................................................52
16.3.4 Repair kit overflow valve KF/KH/KV2200–2900
........................................................................53
16.3.5 Repair kit, screw set........................................54
16.3.6 Repair kit magnetic coupling...........................55
16.4 Completions.................................................................56
16.4.1 Completion Type KF .......................................56
16.4.2 Completion Type KV .......................................57
17 Appendix....................................................................... 58
17.1 Tightening torques for screws with metric screw threads
with and without wedge lock washers .........................58
17.2 Tightening torques for screw plugs with thread meas-
ured in inches and elastomer seal...............................58
17.3 Tightening torques for screws of tensioning elements
.....................................................................................59
17.4 Contents of the Declaration of Conformity...................59
Table of contents
Operating instructions
OIK 09en-GB Edition 2019-11
3
1 About this document
1.1 General information
1 About this document
1.1 General information
1.2 Associated documents
1.3 Target groups
These instructions form part of the product and must be kept for future reference. Furthermore please
observe the associated documents.
o Declaration of conformity according to EU Directive 2006/42/EC
o Manufacturer's declaration according to EU Directive 2014/68/EU
o Data sheet of the pump
o Technical documentation of the supplied components
The instructions are intended for the following persons:
o Persons who work with the product
o Operator-owners who are responsible for the use of the product
Persons who work with the product must be qualified. The qualification ensures that possible dangers
and damage to property that are connected to the activity are detected and avoided. These persons
are qualified personnel who carry out the work properly due to their training, knowledge and experience
and 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
Fitter Mounting,
Electrician Electrical connection Qualified personnel for electric installation
Trained
personnel
Tab.1: Target groups
Transporting,
unloading, setting up
connection
Delegated task Personnel trained by the operator-owner who know the task
Qualified personnel for transport, mobile crane operators,
crane operators, forklift operators
Qualified personnel for mounting
delegated to them and the possible dangers arising through improper behaviour.
1.4 Symbols
1.4.1 Danger levels
Signal word Danger level Consequences of non-observance
DANGER Immediate threat of danger Serious personal injury, death
WARNING Possible threat of danger Serious personal injury, invalidity
CAUTION Potentially dangerous situation Slight personal injury
ATTENTION Potentially dangerous situation Material damage
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Operating instructions
1.4.2 Danger signs
kg
Meaning Source and possible consequences of non-observance
Electrical voltage Electrical voltage causes serious physical injury or death.
Magnetic field Magnetic field can cause serious physical injury or death.
Raised load Falling objects can result in serious physical injury or death.
Heavy load Heavy loads can result in serious back problems.
Risk of slipping Discharging pumped liquid and oils on the foundation or tread sur-
Flammable substances Discharging pumped liquid and oils can be easily inflammable and
Hot surface Hot surfaces of the pump unit can cause burns.
2 Safety
2.1 Proper use
faces can cause falls with serious physical injury or death.
can result in serious burns.
1.4.3 Symbols in this document
Meaning
Warning personal injury
Safety instruction
Prohibition sign cardiac pacemaker
Request for action
1.
2.
3.
Multi-step instructions for actions
Action result
Cross-reference
2 Safety
2.1 Proper use
o Use the pump solely for transporting lubricating liquids that are chemically neutral and that do not
contain gas or solid components.
o Use the pump only within the operating limits specified on the rating plate and in the chapter "Tech-
nical data". In the case of operating data that do not agree with the specifications on the rating
plate, please contact the manufacturer.
o The pump is designed specially for the operating pressure named by the customer. If the actual op-
erating pressure deviates notably from this design pressure, damage to the pump 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 may the minimum pressure lie below 2bar. In case
of any doubt, please contact the manufacturer.
Operating instructions
OIK 09en-GB Edition 2019-11
5
2 Safety
2.2 Foreseeable misuse
2.2 Foreseeable misuse
2.3 Obligations of the operator-owner
2.4 Safety instructions
2.4.1 Fundamental safety instructions
o Any use that extends beyond the proper use or any other use is misuse.
o The product is not suitable for pumping liquids outside the operational limits.
o Any bypassing or deactivation of safety equipment during operation is prohibited.
The operator-owner is the person who operates the product commercially or permits a third party to
use it and who bears the legal responsibility for the product, the protection of the personnel and third
parties during its operation.
The product is used in industrial applications. The operator-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 observed.
The following safety instructions must be observed strictly:
o Read these operating instructions carefully and observe them.
o Read the operating instructions of the components carefully and observe them.
o Have work only carried out by qualified personnel/trained personnel.
o Wear personal protective equipment and work carefully.
o Pumped liquids can be subject to high pressure and can result in personal injury and damage to
property in case of incorrect operation or damaged components.
o Pumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
o Observe the associated data sheets and safety regulations when handling dangerous materials.
o Avoid skin contact with system parts carrying liquids at operating temperatures exceeding 60°C.
o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations. Neutralize residues.
o Keep the mounting surfaces, scaffolding, ladders, lifting platforms and tools clean in order to pre-
vent slipping or stumbling.
o If pressurized or energized components are damaged, shut down the pump immediately. Replace
the components or pump.
2.4.2 Dangers at magnetic coupling systems
Magnetic fields from magnetic coupling systems (MCS) can influence the function and operational
safety of electrical and electronic devices. The following safety instructions must be observed.
The following safety instructions must be observed:
o Keep the MCS away from cardiac pacemakers. There is a danger to life!
§ Under no circumstances may persons with cardiac pacemakers perform installation, dismantling
or maintenance work.
o Persons with cardiac pacemakers must comply with the following safe distances to the MCS:
§ 3 m distance to the openly accessible MCS
§ 1 m distance to pump units with installed MCS
o Do not bring the MCS in the immediate area of PCs, data carriers and other electronic
components.
o Keep the MCS away from clocks, magnetized tools and measuring equipment as well as all mag-
netizable parts.
o Do not bring both the MCS parts together, as this can destroy the magnetic coupling system.
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Operating instructions
3 Identification
KF - 1301.DBA.000372
1
2
3
4
5
6
3.1 Type code
Fig.1: Type code
Item Classification Description
1 Type KF
2 Size Corresponds to delivery rate in [l/min] at 1450 min
3 Shaft seal A Standard mechanical seal
4 Pressure stage over-
flow valve
5 Heating A Without heating
6 Version index For internal administration
Tab.2: Type code
o Pump with free shaft end
o Pump with inline flanges PN16
o Pump unit with or without pump bracket foot
KFA
o Pump with free shaft end
o Pump with overhead flanges in special design PN16
o Pump unit with or without pump bracket foot
KFN
o Pump with free shaft end
o Pump with overhead flanges PN6
o Pump unit with or without pump bracket foot
KFT
o Pump with free shaft end
o Pump with overhead flanges PN16
o Pump unit with or without pump bracket foot
KH
o Pump with foot for horizontal mounting
o Pump with inline flanges PN16
o Pump unit on base frame
KV
o Pump with pedestal for vertical mounting
o Pump with inline flanges PN16 for vertical mounting
o Pump unit on pedestal for vertical mounting
KVT
o Pump with pedestal for vertical mounting
o Pump with overhead flanges PN16 for vertical mounting
o Pump unit on pedestal for vertical mounting
B Mechanical seal of hard material
C Standard radial shaft seal
D Magnetic coupling
E Mechanical seal with quench
F High-temperature radial shaft seal
X Special design
A Pressure stage 3.0– 5.9 bar
B Pressure stage 6.0– 9.9 bar
C Pressure stage 10– 16 bar
X Special design
B Electrical heating system
C Fluid heating system
X Special design
3 Identification
3.1 Type code
-1
Operating instructions
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7
4 Technical data
KRAL GmbH, 6890 Lustenau, Austria
www.kral.at
KRAL GmbH, 6890 Lustenau, Austria
www.kral.at
pS max. / pD max.
Ty p
| Type
SN | Serial no.
Tmin. / Tmax.
ºC
l/min
mm²/s
kg
min
-
¹
bar
bar
∆p
Jahr | Year Gewicht | Weight
n
Q
Art.-Nr. | Item no.
1
2
3
5
4
10
7
9
8
6
11
3.2 Rating plate
3.2 Rating plate
Fig.2: Rating plate
4 Technical data
4.1 Operating limits
1 Construction year
2 Max. operating overpressure
suction-side / Max. operating
overpressure pressure-side
3 Temperature range
4 Serial number
5 Type
6 Article number
7 Differential pressure
8 Nominal delivery rate
9 Rated speed
10 Nominal viscosity
11 Weight
Size
Parameter Unit 5–
20
32–
42
Max. operating overpressure
o Pump with flange PN6
o Pump with flange PN16
[bar] 6
[bar] 16
Max. temperature of the
pumped liquid
o Standard magnetic coupling
o High-temperature magnetic
[°C] 180
[°C] 250
coupling
Min. temperature for pump
[°C] -20
materials
Ambient temperature
[°C] -20 ... 50
min.–max.
Viscosity min.–max. [mm2/s] 1.5–10000
Speed max.
o At 50Hz
o At 60Hz
[min-1] 2900 1450
[min-1] 3500 1750
Max. inlet pressure [bar] Up to 16
Tab.3: Operating limits
55–
118
160–
275
370–
450
550–
660
851–
1301
1500–
1700
2200–
2900
8
4.2 Required NPSH values
The required NPSH values of the pump depend on the 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
OIK 09en-GB Edition 2019-11
Operating instructions
5 Function description
2
1
11
10
3 4 5
9 8 7 6
4.3 Sound pressure level
4.3 Sound pressure level
Guide values at 1 m distance, 1450 min-1, 10 bar
Size
5–
20
Max. sound pressure level ±3 [dB(A)]
Pump 56.0 59.0 65.0 71.0 74.0 71.0 76.0 78.5 80.5
Motor 65.0 66.0 77.0 79.0 79.0 67.0 72.0 76.0 78.0
Pump unit 66.0 67.0 78.0 80.0 82.0 73.0 78.0 80.5 82.0
Tab.4: Sound pressure level
4.4 Weights
The weight is specified on the rating plate.
4.5 Accessories
Notice The technical data of the accessories are specified separately Ä Accessories,Page40.
32–4255–
118
160–
275
370–
450
550–
660
851–
1301
1500–
1700
2200–
2900
5 Function description
5.1 Pump structure
Operating instructions
Fig.3: Pump structure
1 Screw plug 7 Flange cover
2 Overflow valve 8 Vent hole
3 Pump housing 9 Thrust pin
4 Balancing cylinder 10 End cover
5 Ball bearing 11 Idle screw
6 Main screw
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9
5 Function description
12 13 14 15 16
5.2 Pump unit structure
5.2 Pump unit structure
Fig.4: Pump unit structure
12 Pump 15 Inner rotor
13 Containment can 16 Motor
14 Outer rotor
5.3 Functional principle
Screw pumps are rotating pumps. Their displacement effect results from three rotating screws6 and11
and the enclosing pump housing3.
Radial support of the screw set is effected through the sliding contact in the pump housing that depends on lubrication by the pumped liquid. Screw pumps are therefore not suitable for dry running and
can only be used up to specific pressure limits and viscosity limits. Due to the narrow tolerances pumping of suspended solids is not possible.
Axial support of the main screw is effected by a deep-groove ball bearing. In order to reduce the pressure, a balancing cylinder is mounted at the main screw. An integrated overflow valve protects against
excessive pressure that could cause housing parts to burst.
The default direction of the rotation of the screw set is clockwise viewed from the motor and is marked
on the pump flange by an arrow.
The flow direction is marked on the pump housing by two arrows.
5.4 Housing variants
Housing Type Description
KF/KV Flange arrangement: Inline flange PN16
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Operating instructions
Housing Type Description
3 42
1
KFN/KFT/KVT Flange arrangement: Overhead flange PN6/PN16
KFA Flange arrangement: Overhead flange in special design
Tab.5: Housing variants
5.5 Overflow valve
5 Function description
5.5 Overflow valve
PN16
1 Screw plug
2 Adjusting screw
3 Pressure spring
4 Valve body
Fig.5: Overflow valve
The integrated overflow valve ensures that very high pressures that could result in housing parts bursting do not arise.
The overflow valve is purely there as a safety element for the pump and should not be used for control
or regulation purposes such as maintaining pressure. If the valve is kept open for too long under adverse operating conditions (high differential pressures and/or low viscosities) it will only take a few
minutes for the overflow valve and the valve seating to become damaged. As a result, the overflow
valve will leak permanently and there will be a corresponding reduction in the delivery rate. In addition
to this, circulation through the overflow valve for too long results in excess heating of the pump. This
reduces viscosity and can ultimately lead to pump failure.
It therefore has to be ensured at the system by a safety valve that the maximum operating overpressure 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 plug1 and can be adjusted from the outside Ä During operation,Page24.
Notice o A function test of the overflow valve at least every 5 years is essential for the safe operation Ä Dur-
ing operation,Page24.
o Scope and if necessary shorter test intervals must be specified by the operator-owner in accord-
ance with the requirements and national provisions (for example Austrian Ordinance of Safety and
Health (BetrSichV)).
o The first function test must take place directly after the commissioning.
o After longer downtimes (> 4 weeks) the function of the overflow valve must be tested again.
Operating instructions
OIK 09en-GB Edition 2019-11
11
6 Transportation, storage
6.1 Dangers during transportation
6 Transportation, storage
6.1 Dangers during transportation
The following safety instructions must be observed:
o Have all work only carried out by authorized transport personnel.
o Use intact and correctly dimensioned hoisting equipment.
o Ensure that the means of transport is in a flawless state.
o Ensure that the centre of gravity of the load is taken into consideration.
o Do not stand under raised loads.
6.2 Dangers during storage
The following safety instructions must be observed:
o Observe the storage conditions.
6.3 Unpacking and checking the state of delivery
Personnel qualification: o Trained personnel
1. Upon delivery check the pump/pump unit for damage during transportation.
2. Report damage during transportation 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
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
WARNING
12
Risk of injury and damage to equipment through falling and toppling parts.
► Use intact and correctly dimensioned hoisting equipment in accordance with the total weight to be
transported.
► Select the lift points for the hoisting equipment in accordance with the centre of gravity and the
weight distribution.
► Use at least two load ropes.
► In the case of vertical transportation secure the motor against tippling.
► Do not stand under raised loads.
ATTENTION
Damage to equipment through improper transportation.
► Protect the pump against damage, heat, sunlight, dust and moisture.
OIK 09en-GB Edition 2019-11
Operating instructions
6 Transportation, storage
6.5 Storing the pump
Fig.6: Fastening of hoisting equipment - principle diagrams
1. Attach the hoisting equipment to the pump/pump unit and tighten. Ensure that the centre of gravity lies exactly under the crane hook.
2. Lift the pump/pump unit carefully and put it down shock-free.
3. Before loosening the transport belts ensure that the pump/pump unit is secured against tilting.
6.5 Storing the pump
During the test run, the internal components of the pump are wetted with test oil, which has a preservative effect. Pressure connection and suction connection are closed with protective caps. Unless otherwise specified, the outer surfaces 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 60months. The pump is
additionally packed in hermetically sealing anti-corrosion paper.
Personnel qualification: o Transport personnel
Aids: o Mobile crane, forklift, hoisting equipment
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
ATTENTION
Damage to equipment and corrosion if stored improperly and during longer standstills.
► Protect the pump against damage, heat, sunlight, dust and moisture.
► Protect against corrosion during longer standstill.
► Observe measures for storing and preservation.
Operating instructions
1. Store cool and dry and protect against sunlight.
2. Ensure that the anti-corrosion paper is not damaged.
3. Observe the intervals for preservation Ä Preservation,Page14.
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7 Preservation
7.1 Preservation table
7 Preservation
7.1 Preservation table
Preservation has to be carried out additionally under the following conditions:
Type of delivery Condition
Standard delivery
Delivery with long-term preservation
Tab.6: Conditions for additional preservation
7.2 Preserving the inner surfaces
Personnel qualification: o Trained personnel
Personal protective equipment: o Work clothing
Aids: o Preservative (acid-free and resin-free oil)
o Storage time exceeding six weeks
o Unfavourable storage conditions such as high humidity,
salty air, etc.
o Opened or damaged packaging
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
1. Open the packaging carefully. If the pump is protected additionally by anti-corrosion paper, ensure that it is not damaged.
2. Close the suction connection of the pump with a blind flange.
3. Pour the preservative into the pressure connection until it reaches approx.2cm under the rim,
while slowly turning the main screw against the direction of rotation.
4. Close the pressure 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 example
TEVIER®GREASEWAWE100 with adhesive additive)
o Castrol Rustilo DWX 33 or other preservative offering compar-
able protection
14
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
OIK 09en-GB Edition 2019-11
Operating instructions
8 Installation, removal
7.4 Removing the preservation
1. Brush calcium complex grease corrosion protection (for example TEVIER® FETT WAWE 100
with adhesive additive) to the mounting surfaces.
2. Brush or spray preservative (for example Castrol Rustilo DWX 33) onto the process connections
and remaining plain and unpainted parts.
3. At intervals of about six months check the preservation and if necessary repeat.
7.4 Removing the preservation
Personnel qualification: o Trained personnel
Personal protective equipment: o Work clothing
o Face protection
o Protective gloves
o Safety boots
Aids: o Solvent
o Collection tank
o Steam-jet cleaning device with wax-dissolving additives
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
CAUTION
Risk of injury through emitted preservative.
► Wear personal protective clothing during all the work.
► Collect any discharging preservative safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
1. Clean the outside of the pump with solvents, if necessary using a steam-jet cleaning device.
2. Remove the pressure-side blind flange carefully in order to reduce any pressure that may exist in
the pump.
3. Drain the pump, collecting the preservative in a suitable vessel.
4. Remove the blind flange on the suction side.
5. To remove the residual preservative, flush the pump with the pumped liquid.
8 Installation, removal
8.1 Dangers during installation
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before installation ensure that the operating limits, NPSH values and ambient conditions are ob-
served.
o Observe the tightening torques Ä Appendix,Page58.
o Ensure that all the components can be accessed and that maintenance work can be carried out
easily.
Operating instructions
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 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.
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15
8 Installation, removal
2
1
8.3 Installing the pump
8.3 Installing the pump
Notice Soiling in the pipe system impair the service life of the pump. If the pipe system is flushed using the
The pumps can be operated in horizontal and vertical installation position.
pump during the initial commissioning, an additional commissioning filter has to be installed temporarily
before the pump at the system (mesh width: 0.02mm).
Personnel qualification: o Transport personnel
o Fitter
Personal protective equipment: o Work clothing
o Protective helmet
o Protective gloves
o Safety boots
Aids: o Mobile crane, forklift, hoisting equipment
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
WARNING
Risk of injury and damage to equipment through falling and toppling parts.
► Only fasten the pump on a stable load-bearing underground or stable load-bearing load support.
► Ensure that fastening elements and pipings are fastened sufficiently.
ATTENTION
Damage to motor through emitted pumped liquid.
► Do not install the pump above the motor.
ATTENTION
Damage to device 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.
1 Pressure connection
2 Suction connection
Fig.7: Flow direction
16
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Operating instructions
8 Installation, removal
8.4 Removing the pump
Requirement:
ü Pump connections protected against soiling, for example by using the protective cover mounted in
the factory
ü If required, hoisting equipment prepared
1. Bring the pump in the installation position, while observing the position of the motor and the arrows for the flow direction on the pump housing (1pressure connection, 2suction connection).
2. Fasten the pump with fastening elements securely on the underground.
8.4 Removing the pump
Personnel qualification: o Transport personnel
o Fitter
o Electrician
Personal protective equipment: o Work clothing
o Protective helmet
o Face protection
o Protective gloves
o Safety boots
Aids: o Mobile crane, forklift, hoisting equipment
o Collection tank
DANGER
Risk of death resulting from electric shock.
► Ensure that the electrical power supply is de-energized and is secured against being switched
back on.
► Observe the operating instructions of the electrical components.
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
DANGER
Risk of death through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic and can spray out under high
pressure.
► Wear personal protective clothing during all the work. Ensure face protection.
► Before beginning 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.
Operating instructions
Requirement:
ü Pump unit cooled down to the ambient temperature
1. Close the pressure-side and suction-side shut-off devices.
2. Empty the pump at the lowest point. Collect the discharging pumped liquid in a collection tank.
3. Dismantle the pressure-side and suction-side connecting flange.
4. Disconnection the pump unit from the pipe system and empty it. Collect any discharging pumped
liquid.
5. Screw out the fastening elements used to fasten the pump.
6. Dismantle the pump unit on site or transport it to a suitable location Ä Transportation, storage,Page12.
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9 Connection
9.1 Dangers during connection work
9 Connection
9.1 Dangers during connection work
The following safety instructions must be observed strictly:
o Have all work on the pump and pipe system only carried out by authorized qualified personnel.
o Ensure that impurities cannot get into the pump and pipe system.
o Ensure that mechanical connections are mounted stress-free.
o Observe the tightening torques Ä Appendix,Page58.
o Have all the work on the electrical equipment only carried out by electricians.
o Before beginning work on the pump ensure that the electrical power supply is deenergized and is
secured against being switched back on.
o If the insulation of the electrical cables or wires is damaged, disconnect the power supply immedi-
ately.
9.2 Connecting the pump to the pipe system
Personnel qualification: o Transport personnel
Personal protective equipment: o Work clothing
Aids: o Mobile crane, forklift, hoisting equipment
o Fitter
o Protective gloves
o Protective helmet
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
ATTENTION
Damage to device 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 pump is mounted free of mechanical stresses in the pipe system.
► Observe the tightening torques.
18
Fig.8: Connection to pipe system
1. Turn the pump shaft or the fan impeller of the motor. This tests that the pump runs smoothly.
If the pump shaft cannot be turned by hand, remedy the fault before installing the pump Ä
Troubleshooting,Page38.
OIK 09en-GB Edition 2019-11
Operating instructions
9 Connection
9.3 Insulating the pump
2. Before carrying out welding work mount a protective cover on the suction connection and pressure connection.
3. Place the piping in position and support the weight of the piping.
4. Check the linear, height and angular offset and correct if necessary.
ð If the screws tighten easily, this is a sure sign that the installation is stress-free.
5. Tighten the connecting screws crosswise with torque, Table of tightening torques Ä Appendix,Page58.
9.3 Insulating the pump
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
Aids: o Insulation material
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump station.
WARNING
Hot surface.
Touching of uninsulated hot surfaces results in burns.
► Insulate components and pipings in which hot liquids (>60°C) flow before commissioning.
Before commissioning insulate all potentially hot surfaces of the pump and the connected piping
carefully or equip them with suitable contact protection.
9.4 Connecting the pump unit to the power supply
Personnel qualification: o Electrician
Aids: o Operating instructions of the motor
o Motor circuit diagram
DANGER
Risk of death resulting from electric shock.
► Ensure that the electrical power supply is de-energized and is secured against being switched
back on.
► Before commissioning ensure correct grounding and equipotential bonding.
► Observe the operating instructions of the electrical components.
Operating instructions
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
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19
10 Operation
10.1 Dangers during operation
1. Ensure that the operating data on the rating plate of the motor agree with the operating data of
2. Carefully earth the pump bracket foot, base frame or pedestal via the screwing.
3. Connect the motor in accordance with the operating instructions and circuit diagram in the motor
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
o Before commissioning, make sure that the suction line and pump are filled.
o Pumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
o Ensure that the pump station is only operated within the operating limits.
o Wear hearing protection if you work for a longer time directly at the pump.
o Ensure that the maximum permissible system pressure is not exceeded.
o Ensure that during cooling down or heating up the pump is only subjected to slow temperature
o Ensure that existing safety equipment is not bypassed or activated during operation.
o Before decommissioning ensure that the electrical power supply is deenergized and is secured
the pump and with the local power supply.
terminal block.
pressure side before the first shut-off device.
equipment.
changes.
against being switched back on.
10.2 Commissioning
10.2.1 Cleaning the pipe system
Notice Soiling in the pipe system impair the service life of the pump. If the pipe system is flushed using the
pump during the initial commissioning, an additional commissioning filter has to be installed temporarily
before the pump at the system.
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump station.
ATTENTION
Damage to equipment through additional pressure loss in the commissioning filter/commissioning strainer.
► Calculate the flow resistance and determine the remaining pump intake.
► Monitor the suction-side pressure.
► Check the commissioning filter/commissioning strainer regularly.
20
Requirement:
ü If required, commissioning filter installed (mesh width0.02 mm)
1. Clean the complete pipe system before commissioning in order to protect the pump.
2. Flush the pipe system at least 50 – 100hours.
OIK 09en-GB Edition 2019-11
Operating instructions
10.2.2 Filling and venting the pump
1
Possibilities
There are two possible ways to fill the pump:
o Via the suction connection or pressure connection
o Via the vent holes
Filling and venting the pump via the suction connection or pressure connection
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
10 Operation
10.2 Commissioning
o Face protection
o Protective gloves
o Safety boots
DANGER
Risk of death through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic and can spray out under high
pressure.
► 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.
1 Vent hole sealing chamber
1. Open the screw plug of the vent hole1 by a max. of 2 rotations so that air can escape during the
filling process.
2. Open the suction-side or pressure-side shut-off device and fill the pump via the suction connection or pressure connection until pumped liquid is emitted at the vent hole1.
3. During the filling process turn the pump shaft or the fan impeller of the motor by hand to speed up
the filling process:
Filling via suction connection: Turn the fan pump shaft in the direction of rotation of the motor.
Filling via pressure connection: Turn the pump shaft against the direction of rotation of the motor.
4. Retighten the screw plug of the vent hole1.
Operating instructions
Filling and venting the pump via the vent hole
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Face protection
o Protective gloves
o Safety boots
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21
10 Operation
1
3 2
10.2 Commissioning
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible 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.
1 Vent hole sealing chamber
2 Suction-side vent hole
3 Pressure-side vent hole
Requirement:
ü Shut-off devices in the suction line and pressure line closed
1. Remove the screw plug of the vent hole1 so that the air can escape during the filling process.
2. Remove the screw plug of the pressure-side vent hole3.
3. Fill the pump via the pressure-side vent hole3, until the pumped liquid is emitted at the vent
hole1.
4. During the filling process turn the pump shaft or fan impeller of the motor by hand to speed up the
filling process:
Filling of the suction chamber: Turn the pump shaft against the direction of rotation of the motor.
Filling of the sealing chamber: Turn the pump shaft in the direction of rotation of the motor. To
speed up filling of the sealing chamber, fill the sealing chamber of the pump via the vent hole1,
until pumped liquid is emitted.
5. Retighten the screw plug of the pressure-side vent hole3.
6. Retighten the screw plug of the vent hole1.
10.2.3 Checking the direction of rotation
The direction of rotation is indicated by an arrow on the pump flange. The direction of rotation of the
motor specifies the direction of rotation of the pump. The fan impeller of the motor must rotate in the
same direction in which the arrow for the direction of rotation on the pump flange points.
Notice Standard direction of rotation: clockwise (viewed from the motor)
Personnel qualification: o Fitter
DANGER
22
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
OIK 09en-GB Edition 2019-11
Operating instructions
10 Operation
1
10.2 Commissioning
ATTENTION
Dry running can damage pump equipment.
► Ensure that the pump is filled properly.
► Switch the pump on for a maximum of one 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 arrow indicating the direction of rotation1.
3. If the directions do not match, swap the two electrical connection phases. Repeat Steps1 and2.
10.2.4 Commissioning the pump
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Collection tank
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
DANGER
Risk of death resulting from bursting 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.
o Electrician
o Face protection
o Protective gloves
o Safety boots
Operating instructions
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible 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.
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10 Operation
barbar
10.3 During operation
WARNING
Hot surface.
Touching of uninsulated hot surfaces results in burns.
► Insulate components and pipings in which hot liquids (>60°C) flow before commissioning.
ATTENTION
Dry running can damage pump equipment.
► Ensure that the pump and the connected pipe system are filled properly.
► If the pump does not deliver after10–15 seconds, abort commissioning.
Requirement:
ü Pump unit set up correctly
ü Connections connected sealingly
ü Motor connected correctly
ü Pipe system is free of impurities
ü Safety valve in accordance with ENISO4126-1 installed in the pressure-side pipe system before
the first shut-off device
ü Pump filled with pumped liquid
ü Shut-off devices in the suction line and pressure line opened
1. Switch on the pump unit.
ð The pump delivers when the pressure on the pressure side of the pump rises or a flow indic-
ator at the system 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,Page38.
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 smooth and a pressure
gauge on the pressure side shows no more fluctuations.
4. Check the function of the overflow valve Ä During operation,Page24.
10.3 During operation
10.3.1 Checking the operating pressure
Personnel qualification: o Trained personnel
Fig.9: Pressure gauge shut-off valves closed/open - principle diagram
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump station.
ATTENTION
Leak in the pressure gauge through permanently opened pressure gauge shut-off valve.
► Close the pressure gauge shut-off valve immediately after completing reading.
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Operating instructions
10 Operation
3 42
1
10.3 During operation
1. Open the pressure gauge shut-off valve.
2. Read the operating pressure and close the pressure gauge shut-off valve.
10.3.2 Monitoring filters and/or strainers
Notice The manufacturer recommends protecting the pump against soiling by means of a filter and/or strainer
installed at the system end (mesh width 0.5mm). The degree of soiling of the filter and/or the strainer
can be monitored by means of a suction-side pressure gauge or a differential pressure indicator.
Notice The manufacturer recommends protecting the pump against soiling by means of a filter and/or strainer
installed at the system end. The degree of soiling of the filter and/or the strainer can be monitored by
means of a suction-side pressure gauge or a differential pressure indicator. Mesh width Ä Technical
data,Page8.
Personnel qualification: o Trained personnel
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump station.
ATTENTION
Damage to equipment through unsuitable filter and/or strainer.
► Observe the mesh width Ä Technical data,Page8.
1. After commissioning monitor the degree of contamination of the filter and/or strainer by means of
a suction-side pressure gauge or a differential pressure indication.
2. Additionally check the filters and/or strainers at a pressure drop on the suction side. Observe the
dimensioning data of the manufacturer of the filters/strainers.
3. Check the suction-side pressure every two weeks during running operation.
10.3.3 Adjusting the overflow valve
Personnel qualification: o Fitter
Aids: o Hexagon key
Notice The opening pressure of the overflow valve is set to 110% of the differential pressure in the factory.
1 Screw plug
2 Adjusting screw
3 Pressure spring
4 Valve body
Operating instructions
Fig.10: Overflow valve
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25
10 Operation
10.4 Decommissioning
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible 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.
Requirement:
ü Pressure-side pressure gauge installed
1. Switch on the pump and remove the screw plug 1 of the overflow valve.
2. Increase the supply pressure step-by-step to check the opening pressure of the overflow valve.
Keep an eye on the pressure gauge and make sure that the operating limits are observed.
ð The opening pressure is reached, when the displayed pressure falls.
3. Turn the adjusting screw2 to set the opening pressure:
Turning clockwise: Increase the opening pressure
Turning counter-clockwise: Reduce the opening pressure
4. Repeat Steps 2 and 3 until the desired opening pressure is reached.
5. Tighten the screw plug1 again.
10.3.4 Switching off the pump unit
Personnel qualification: o Trained personnel
ATTENTION
Damage to seal through pressurizing during standstill.
► Ensure that the maximum permissible system pressure is not exceeded.
1. Switch off the motor.
2. Close the pressure-side shut-off device.
10.4 Decommissioning
10.4.1 Decommissioning the pump
Decommissioning is an operation interruption that requires different measures depending on the scope
of duration and the interruption as well as the properties of the pumped liquid.
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Collection tank
o Electrician
o Protective gloves
o Safety boots
26
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
OIK 09en-GB Edition 2019-11
Operating instructions
10 Operation
10.5 Recommissioning
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible 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 the pump with an open flame.
Carry out the following measures during operation interruptions:
Scope of the operation interruption Measure
o Shutting down the pump for longer period Depending on the pumped liquid
o Draining the pump Close the pressure-side and suction-side shut-off
devices.
o Dismantling the pump Disconnect the motors from the power supply
and secure against being switched back on.
o Storing the pump Observe measures for storing and preservation
Ä Transportation, storage,Page12.
Tab.7: Measures during operation interruptions
Behaviour of the pumped
liquid
o Solids sediment Rinse the pump. Rinse the pump.
o Congealed/frozen
o No corrosive burden
o Congealed/frozen
o Corrosive burden
o Remains liquid
o No corrosive burden
o Remains liquid
o Corrosive burden
Tab.8: Measures depending on the behaviour of the pumped liquid
Drain the pump via the pressure line, suction line, vent screws and screw plugs.
10.5 Recommissioning
10.5.1 Recommissioning the pump
Carry out all the steps as for the commissioning process, Ä Commissioning,Page20.
Duration of the operation interruption
Short Long
Heat or drain the pump. Drain the pump.
Heat or drain the pump. 1. Drain the pump.
2. Preserve the pump.
– –
–
1. Drain the pump.
2. Preserve the pump.
Operating instructions
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27
11 Maintenance
11.1 Dangers during maintenance
11 Maintenance
11.1 Dangers during maintenance
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 slowly to the ambient temperature. Avoid
rapid temperature changes.
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 of the components.
11.2 Required maintenance
The service life depends on the observance of the operating conditions of the pump and the requirements from the operating instructions of the components.
Component Required maintenance Cycle
Pump
Filter/strainer (system side)
Magnetic coupling
Overflow valve
Tab.9: Required maintenance
o Visual inspection
o Acoustic inspection
o Check of the suction-side
pressure
o Check of the tightening
torques
o Function test
4weeks
2weeks
1year
≤5years
11.3 Ball bearing
When using the pump in lubrication oil applications with a minimum purity class of 21/18/13 according
to ISO4406, a bearings replacement at the latest after 5 years (400000h) is sufficient.
11.4 Maintaining the pump
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
o Face protection
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible 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.
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Operating instructions
11.5 Maintaining the magnetic coupling
6
3*
5
4
2*
1
1. Check the pump visually and acoustically every four weeks.
2. If there are signs of wear, eliminate the cause Ä Servicing,Page29.
11.5 Maintaining the magnetic coupling
Personnel qualification: o Fitter
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
12 Servicing
Check the tightening torques of the following parts of the magnetic coupling once a year. Repla-
cing the magnetic coupling Ä Servicing,Page29. Tightening torques Ä Appendix,Page58.
Item No. Part
1 Tensioning element
2* Threaded pin outer rotor support
3* Countersunk screw outer rotor support
4 Socket screws pump bracket– pump
5 Socket screws outer rotor support– outer rotor
6 Socket screws containment can– pump
* Depending on motor size
Tab.10: Magnetic coupling: Parts to be maintained
12 Servicing
12.1 Dangers during servicing
The following safety instructions must be observed strictly:
o Have all work carried out only by authorized qualified personnel.
o Before beginning work on the pump ensure that the electrical power supply is deenergized and is
secured against being switched back on.
o Before beginning work, let the pump unit cool down slowly to the ambient temperature. Avoid
rapid temperature 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 for discharging pumped liquids is sufficiently large.
o Observe the tightening torques Ä Appendix,Page58.
o Observe the operating instructions and data sheets of the components.
Operating instructions
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29
12 Servicing
8
4
1
2
7 6
3
5
8
4
1
2
7 6
3
5
12.2 Wear
12.2 Wear
12.2.1 Signs of wear
The following table lists signs of progressive wear of individual pump elements:
Finding Cause Elimination
Increased running noises Incipient damage to bearing
Reduction in the delivery rate or
pressure under constant
operating conditions
Tab.11: Signs of wear
12.2.2 Magnetic coupling
When using the pump in lubrication oil applications with a minimum purity class of 21/18/13 according
to ISO4406, an inspection at the latest after 5 years (400000h) is sufficient.
12.3 Replacing the overflow valve
12.3.1 Removing the overflow valve
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Advanced wear of screws and
housing
o Protective gloves
o Safety boots
Replace the ball bearing.
Replace the pump.
1. Remove the screw plug1 and socket screws2.
2. Remove the end cover3 and flat gasket4 from the pump housing5.
3. Carefully screw out the adjusting screw8 and remove the pressure spring7 and valve body6
from the pump housing.
12.3.2 Installing the overflow valve
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
1. Clean the fitting surface carefully and bond a new flat gasket4 to the fitting surface.
2. Insert the valve body6, pressure spring7 into the pump housing5 and secure the pressure
spring with the adjusting screw8.
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Operating instructions
3. Position the end cover3 and tighten the socket screws2 with torque.
7
8
5
1
3
2
4
5
6
7
5
4. Set the overflow valve Ä During operation,Page24.
12.4 Replacing the magnetic coupling
12.4.1 Removing the outer rotor
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Open-end spanner
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
12 Servicing
12.4 Replacing the magnetic coupling
o Protective gloves
o Safety boots
o Mounting lever
o Hoisting equipment
WARNING
Risk of injury and damage to equipment through falling and toppling parts.
► Use intact and correctly dimensioned hoisting equipment in accordance with the total weight to be
transported.
► Select the lift points for the hoisting equipment in accordance with the centre of gravity and the
weight distribution.
► Use at least two load ropes.
► In the case of vertical transportation secure the motor against tippling.
► Do not stand under raised loads.
Notice Outer rotor support and outer rotor can be dismantled more easily if they are heated to 80°C.
Requirement:
1. Before dismantling close the suction connection and pressure connection of the pump with protective covers.
2. Fixate the pump unit with suitable measures so that the pump cannot tilt after dismantling of the
motor.
Operating instructions
3. Attach the hoisting equipment to the motor2.
4. Loosen the socket screws between the motor and the pump bracket3.
OIK 09en-GB Edition 2019-11
31
12 Servicing
3
9
1
13
12
10
11
1
M
12.4 Replacing the magnetic coupling
5. Lift the motor off the pump bracket.
6. Depending on the motor size remove the threaded pin6 or the countersunk screw4.
7. Pull the outer rotor support5 and outer rotor7 off from the motor shaft using mounting levers.
8. Remove the socket screws8 between the outer rotor support and the outer rotor.
12.4.2 Removing the inner rotor
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Hexagon key
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
o Protective gloves
o Safety boots
o Anti-rotation screw
Notice The containment can be dismantled more easily if it is heated to 80°C.
1. Remove the socket screws9 between the pump1 and pump bracket3 and remove the pump
bracket.
2. Remove the socket screws10 between the containment can11 and the pump and remove the
containment can.
3. To replace the inner rotor13, screw two screwsM into the empty threaded holes of the tensioning element12 as anti-rotation screws.
4. Remove the screws of the tensioning element.
5. Turn the screws back into the existing threaded holes.
ð This loosens the tensioning element from the inner rotor and from the pump shaft.
12.4.3 Installing the inner rotor
Personnel qualification: o Fitter
Personal protective
equipment:
Aids: o Oil without molybdenum sulphide additive (e.g. multifunction spray WD-40)
DANGER
32
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
o Work clothing
o Protective gloves
o Safety boots
OIK 09en-GB Edition 2019-11
Operating instructions
12.4 Replacing the magnetic coupling
13
14
15
12
13
12
13
14
7
5
2
12
13
14
11
10
3
9
Notice The inner rotor can be mounted more easily if it is heated to 80°C.
1. Carefully clean the contact surfaces of the inner rotor13, oil the tensioning element12 lightly.
2. Manually turn out the screws of the tensioning element by a few turns and insert the tensioning
element in the inner rotor.
3. Carefully clean the sealing surfaces.
4. Clean and lightly grease the O-ring15. Insert the O-ring and slide the distance sleeve14 onto the
pump shaft.
12 Servicing
5. Place the inner rotor with the premounted tensioning element onto the pump shaft and tighten the
screws of the tensioning element crosswise by hand.
6. Check the position of the tensioning element: The tensioning element has to lie flat on the distance sleeve and inner rotor. Otherwise loosen the screws and reposition the tensioning element.
7. When the position is correct, first tighten the screws of the tensioning element with half the torque
crosswise. Subsequently tighten several times crosswise with the full tightening torque Ä Appendix,Page58.
8. Press the containment can11 onto the pump flange and tighten with socket screws10 using
9. Place the pump bracket3 on the pump and tighten the socket screws9 with torque.
torque.
Operating instructions
OIK 09en-GB Edition 2019-11
33
12 Servicing
7
5
2
7
8
5
4
5
6
7
7
5
2
6 4
12.4 Replacing the magnetic coupling
12.4.4 Installing the outer rotor
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Hoisting equipment
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
WARNING
Danger of crushing when assembling motor and pump.
When the motor approaches the pump, high magnetic forces can produce sudden collisions and thus
injuries to hands or fingers.
► Two persons are required for the assembly.
► Use suitable hoisting equipment (for example chain hoist).
► Carry out assembly in the vertical position as far as possible.
► Fixate the pump with suitable measures.
► When the motor approaches the pump, ensure that hands/fingers are not positioned between mo-
tor and pump.
o Protective gloves
o Safety boots
Notice Outer rotor support and outer rotor can be installed more easily if they are heated to 80°C.
1. Carefully clean the outer rotor7 with compressed air. Tighten the socket screws8 between the
outer rotor and outer rotor support5 with torque Ä Appendix,Page58.
2. Clean and grease the shaft end of the motor.
3. Place the outer rotor support with outer rotor on the shaft end of the motor.
34
4. Ensure that the shaft end of the motor is flush with the front surface of the outer rotor support.
5. Depending on the motor size tighten the threaded pin6 or the countersunk screw4 with torque.
OIK 09en-GB Edition 2019-11
Operating instructions
12 Servicing
1
3
7
2
4
4
2
1
8
7
12.5 Replacing the ball bearing and screw set
6. Fixate the pump1 with suitable measures, so that the pump cannot tilt during mounting of the
motor.
7. Attach the hoisting equipment to the motor2 and position it above the pump.
8. Place the motor slowly on the pump bracket3 of the pump. Ensure that the outer rotor7 does not
strike the containment can.
9. Tighten the socket screwswith torque.
10. Do not remove the protective cover until just before reconnecting the pump to the pipe system.
12.5 Replacing the ball bearing and screw set
12.5.1 Removing the ball bearing and screw set
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
Aids: o Plastic hammer
o Extractor
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
Operating instructions
1. Remove the socket screws at the pump flange4 and remove the pump flange with light "rebound" blows.
2. Pull the withdrawable unit (main screw2 and the pump flange4) out of the pump housing1.
3. Remove the circlip8 and the supporting ring7.
OIK 09en-GB Edition 2019-11
35
12 Servicing
2
10
6
24
A
24
1
10
4
6
2
4
8
7
3
1
4
2
1
12.5 Replacing the ball bearing and screw set
4. Drive the main screw 2 out of the pump flange 4 with light blows from a plastic hammer.
5. Remove the circlip6 in the pump flange. Pull the ball bearing10 out of the pump flange4 using a
suitable extractor.
6. Remove the idle screws24 from the pump housing1.
12.5.2 Installing the ball bearing and screw set
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
Aids: o Mounting sleeve ball bearing
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
1. Clean the fitting surfaces, clean and grease the screw set carefully.
2. Insert the idle screws24 in the pump housing1.
3. Use the ball bearing mounting sleeveA to press the ball bearing10 into the pump flange4, and
fasten using the circlip6.
4. Press the main screw2 into the ball bearing in the pump flange until it stops.
5. Mount the supporting ring7 and circlip8.
6. Bond the new flat gasket3 on the pump housing1.
36
7. Slide the main screw with premounted pump flange into the pump housing until the main screw
8. Tighten the socket screws at the pump flange with torque.
engages into the idle screws. Turn the main screw in the process.
OIK 09en-GB Edition 2019-11
Operating instructions
13.1 Dismantling and disposing of the pump
13 Disposal
13.1 Dismantling and disposing of the pump
Personnel qualification: o Fitter
Personal protective equipment: 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
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
13 Disposal
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 environment-
ally compatible manner in accordance with the applicable local regulations.
► Before disposing neutralize the residues.
Requirement:
ü Disconnect the pump unit from the power supply and secure it against being switched back on
ü Pump unit cooled down to the ambient temperature and disconnected from the pipe system
ü Pump emptied completely
ü Pump placed at a location suitable for dismantling
1. Dismantle the pump and disassemble it into its individual parts.
2. Clean residues of the pumped liquid from the individual parts.
3. Separate sealing elements made of elastomers and ceramics (SiC) from the pump and dispose
of them in separately.
4. Recycle iron parts.
Operating instructions
OIK 09en-GB Edition 2019-11
37
14 Troubleshooting
14.1 Possible faults
14 Troubleshooting
14.1 Possible faults
Faults can have different causes. The following tables list the symptoms of a fault, the possible causes
and measures for troubleshooting.
Identification
1 No pump suction
2 Delivery rate too low
3 Pump too loud
4 Motor overload
5 Uneven delivery rate
6 Pump has seized
7 Magnetic coupling leaks
Fault
14.2 Troubleshooting
Fault identification Cause Remedy
1 – – – – – – Pump suction line closed
Check the shut-off devices. If required, open.
1 2 3 – 5 – – Parts soiled (filter, suction line, suction valve, strainer)
Clean parts.
1 2 3 – 5 – – Suction head too high
Reduce the level difference.
-orReduce the line length.
-orIncrease the line cross-section.
-orHeat up the pumped liquid.
-orInstall 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,Page18.
– – – 4 – – – Differential pressure too high
Reduce the differential pressure.
1 – 3 4 5 – – Viscosity of the pumped liquid too high
Increase the temperature of the pumped liquid.
-orDecrease the speed.
– 2 – – – – – Viscosity of the pumped liquid too low
Reduce the temperature of the pumped liquid.
-orIncrease the speed.
– 2 3 – 5 – – Airlock/gas in the pumped liquid
1. Test the pipe system for air admission, replace leaking parts.
2. Reduce the suction head.
-orIncrease the inlet pressure.
38
OIK 09en-GB Edition 2019-11
Operating instructions
Fault identification Cause Remedy
– 2 – 4 – – – Speed/frequency/voltage of the motor false
1. Ensure that the motor frequency and voltage match the operating voltage.
2. Ensure that the speed of the motor matches the rating plate of the pump. If necessary adjust the speed.
– 2 3 – 5 – – Overflow valve opens during normal operation
Set the opening pressure to 110% of the differential pressure Ä During opera-
tion,Page24.
– 2 – – 5 – – Overflow valve leaks
Contact the manufacturer.
– 2 – – – – – Advanced wear of the housing/screw set
Contact the manufacturer.
– – 3 – – – – Pump subject to mechanical stress
Connect the pump correctly to the pipe system Ä Connection,Page18.
– – 3 – – – – Vibrations/pulsations in the system
Bear the pump unit elastically.
-orMake the connections with hoses.
– – 3 – – – – Flow speed in the pressure line or suction line too high
Set the flow speed in the pressure line so that it does not exceed 3m/s.
-orSet the flow speed in the suction line so that it does not exceed 1m/s.
-orContact the manufacturer.
– – 3 4 – – 7 Ball bearing damaged
Replace the ball bearing Ä Servicing,Page29.
– – – 4 – – 7 Foreign bodies in the pump
Contact the manufacturer.
– – – – – – 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.
– 2 3 – – – – Magnetic coupling interrupted
1. Stop the pump immediately and restart it.
2. Avoid excessive differential pressures.
3. At repeated occurrence check whether pump has got stuck.
1 – – – – – 7 Containment can defective
Replace the containment can Ä Servicing,Page29.
Tab.12: Fault table
14 Troubleshooting
14.2 Troubleshooting
Operating instructions
OIK 09en-GB Edition 2019-11
39
15 Accessories
072
481
1
15.1 Heating
15 Accessories
15.1 Heating
15.1.1 Possible types of heating
The pump can optionally be equipped with a heating system. The manufacturer recommends a heating
system at high-viscosity pumped liquids that do not flow sufficiently if not heated. This can result in excessive wattage or in problems arising through cavitation or sealing.
Possible types of heating:
o Electrical heating system
o Fluid heating system
o Special heating system
15.1.2 Electrical heating system
072 Heating cover
481 Heating element
1 Connecting cable
Fig.11: Electrical heating system
The electrical heating system consists of one or two heating elements481 that are integrated in a heating cover 072 attached additionally to the end cover. The output of the elements corresponds to the radiation losses and convection losses of the pump in the required temperature range so that overheating is not possible.
Size5–118 Size160–2900
1 heating element 2 heating elements
1 heating cover 1 heating cover
4 socket screws 4 socket screws
Tab.13: Scope of delivery of electrical heating system
Operating data
Parameter Unit Value
Voltage [V] 230
Frequency [Hz] 50/60
Wire cross-section [mm2] 2 x 1
Tab.14: Operating data electrical heating system
Heating-up period
Required heating-up period for temperature differences of 30°C or 50°C:
Size Wattage Heating-up period [min] at a temperature difference of
[W] 30°C 50°C
5–42 1 x 100 20 35
55–118 1 x 220 20 35
160–275 2 x 180 25 45
370–450 2 x 180 30 60
550–660 2 x 250 45 75
851–1301 2 x 250 60 90
1500–1700 2 x 250 75 120
2200–2900 2 x 250 90 150
Tab.15: Heating-up period for electric heating system
40
OIK 09en-GB Edition 2019-11
Operating instructions
15 Accessories
072
481
1
15.1 Heating
Installing the electrical heating system
Personnel qualification: o Electrician
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
ATTENTION
Damage to the electrical heating system through leakage currents or flashovers at the emission
point of the connecting cable.
► Protect the area of the connecting head against liquid and pasty liquids (lubricants, oil, plastics,
etc.) as well as their vapours.
Requirement:
ü Area of the connecting head protected against liquid and pasty liquids (lubricants, oil, plastics, etc.)
as well as their vapours.
ü Supply lines protected against mechanical vibrations in the area of the emission from the heating
element. Any vapours arising have to escape freely.
ü Heating element absolutely dry.
072 Heating cover
481 Heating element
1 Connecting cable
Fig.12: Installation of electrical heating system
1. Remove the socket screws and rating plate at the end cover of the pump.
2. Mount the heating cover072 to the end cover using the supplied socket screws.
3. Screw the heating element481 into the heating cover072.
4. Mount the rating plate on the heating cover072.
Connecting the electrical heating system
DANGER
Risk of death resulting from electric shock.
► Ensure that the electrical power supply is de-energized and is secured against being switched
back on.
► Observe the operating instructions of the electrical components.
Operating instructions
DANGER
Risk of injury through emitted pumped liquid.
The pump housing may burst through heat expansion of the pumped liquid.
► Open all the valves during the heating process.
Connect the connecting cable of the heating element.
OIK 09en-GB Edition 2019-11
41
15 Accessories
072
11
15.1 Heating
Commissioning the electrical heating system
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or
neurostimulator perform work on the pump/pump unit.
DANGER
Risk of injury through emitted pumped liquid.
The pump housing may burst through heat expansion of the pumped liquid.
► Open all the valves during the heating process.
1. Switch on the electric heating system.
2. Take the required heating-up periods into account Ä Accessories,Page40.
15.1.3 Fluid heating system
072 Heating cover
1 Pipe connection
Fig.13: Fluid heating system
The fluid heating system consists of a heating cover 072 attached additionally to the end cover through
which a heating fluid (for example vapour, thermal oil) flows.
Scope of delivery:
Size K 5–2900
1 heating cover
4 socket screws
Tab.16: Scope of delivery of the fluid heating system
Heating liquid operating data
Parameter Unit Value
Max. operating overpressure [bar] 16
Max. temperature [°C] 200
Tab.17: Heating liquid operating data
42
Heating-up period
Required heating-up period for the temperature difference of 50°C at a liquid temperature of 200°C:
Size Heating-up period [min] at a temperature difference of 50°C
5–118 20
160–275 45
370–450 60
550–660 90
851–1301 120
1500–1700 150
2200–2900 180
Tab.18: Heating-up period for fluid heating system
OIK 09en-GB Edition 2019-11
Operating instructions
15 Accessories
072
1
1
15.1 Heating
Installing the fluid heating system
Personnel qualification: o Fitter
Personal protective equipment: o Work clothing
o Protective gloves
o Safety boots
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
072 Heating cover
1 Pipe connection
1. Remove the socket screws and rating plate at the end cover of the pump.
2. Mount the heating cover072 to the end cover using the supplied socket screws.
3. Mount the piping at the pipe connections1.
4. Mount the rating plate on the heating cover.
Commissioning the fluid heating system
DANGER
Magnetic field.
Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator.
► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu-
lator perform work on the pump/pump unit.
DANGER
Risk of injury through emitted pumped liquid.
The pump housing may burst through heat expansion of the pumped liquid.
► Open all the valves during the heating process.
1. Take the required heating-up periods into account Ä Accessories,Page40.
2. When setting the pressure and temperature of the heating fluid take the permissible operating
limits of the pump into account Ä Technical data,Page8.
Operating instructions
15.1.4 Heating system special design
Please contact the manufacturer for special designs.
OIK 09en-GB Edition 2019-11
43
16 Spare parts
16.1 Overview
16 Spare parts
16.1 Overview
Model/Size Type Variant Internal
KF/KV
5–660
KF/KV
851–1301
KF/KV
1500–1700
KF/KV
2200–2900
KFN/KFT/KVT
2200–2900
KF/KV/KV
5–660
and
KFT/KVT/KFN/KFA
KF/KH/KV
851–1301
KF/KH/KV
1500–1700
KF/KH/KV
2200–2900
K Repair kit Screw set OPR05
KF/KV/KFT/KVT/KFA Repair kit Magnetic coupling OPR06
KF Spare parts Completion UKF
KV Spare parts Completion UKF
Tab.19: Overview of spare parts
Maintenance kit Magnetic coupling OPW16
Maintenance kit Magnetic coupling OPW17
Maintenance kit Magnetic coupling OPW18
Maintenance kit Magnetic coupling OPW19
Maintenance kit Magnetic coupling OPW20
Repair kit Overflow valve OPR01
Repair kit Overflow valve OPR02
Repair kit Overflow valve OPR03
Repair kit Overflow valve OPR04
44
OIK 09en-GB Edition 2019-11
Operating instructions
16.2 Maintenance kits
165.3
914.9**
471.2
056
817
471.2*
729.7
165.2
165.2
471.3
055*
914.1
729.5
165.2
165.2
729.6
729.4
165.1
914.2
739
16.2 Maintenance kits
16.2.1 Maintenance kit magnetic coupling KF/KV5–660
Notice The maintenance kit contains only the numbered parts and is only supplied complete.
16 Spare parts
Qty. Item No. Part Qty. Item No. Part
1 055* Supporting ring 1 729.5 Flat gasket
1 056 Supporting ring 1 729.6 Flat gasket, suction flange
1 165.1 Screw plug 1 729.7 Flat gasket, pressure flange
4 165.2 Screw plug 1 739 O-ring
1 165.3 Screw plug 1 817 Ball bearing
1 471.2 Circlip 4 914.1 Socket screw
1 471.2* Circlip 4 914.2 Socket screw
1 471.3 Circlip 4 914.9** Socket screw
1 729.4 Flat gasket 1 Mounting sleeve ball bearing
* Only for Size5–20
** Only for Type KV: replaces 914.2
Tab.20: Maintenance kit magnetic coupling KF/KV5–660
Operating instructions
OIK 09en-GB Edition 2019-11
45
16 Spare parts
739
165.3
914.9*
471.2
056
817
729.7
165.2
165.2
471.3
055
914.1
165.2
729.5
165.2
729.6
729.4
165.1
914.2
914.8
16.2 Maintenance kits
16.2.2 Maintenance kit magnetic coupling KF/KV851–1301
Notice The maintenance kit contains only the numbered parts and is only supplied complete.
Qty. Item No. Part Qty. Item No. Part
1 055 Supporting ring 1 729.6 Flat gasket, suction flange
1 056 Supporting ring 1 729.7 Flat gasket, pressure flange
1 165.1 Screw plug 1 739 O-ring
4 165.2 Screw plug 1 817 Ball bearing
1 165.3 Screw plug 4 914.1 Socket screw
1 471.2 Circlip 4 914.2 Socket screw
1 471.3 Circlip 1 914.8 Socket screw
1 729.4 Flat gasket 4 914.9* Socket screw
1 729.5 Flat gasket 1 Mounting sleeve ball bearing
* Only for Type KV: replaces 914.2
Tab.21: Maintenance kit magnetic coupling KF/KV851–1301
46
OIK 09en-GB Edition 2019-11
Operating instructions
16.2 Maintenance kits
165.3
914.9*
471.2
056
817
729.7
165.2
165.2
471.3
055
914.1
165.2
729.5
165.2
729.6
729.4
165.1
914.2
914.8
739
16.2.3 Maintenance kit magnetic coupling KF/KV1500–1700
Notice The maintenance kit contains only the numbered parts and is only supplied complete.
16 Spare parts
Qty. Item No. Part Qty. Item No. Part
1 055 Supporting ring 1 729.6 Flat gasket, suction flange
1 056 Supporting ring 1 729.7 Flat gasket, pressure flange
1 165.1 Screw plug 1 739 O-ring
4 165.2 Screw plug 1 817 Ball bearing
1 165.3 Screw plug 8 914.1 Socket screw
1 471.2 Circlip 7 914.2 Socket screw
1 471.3 Circlip 3 914.8 Socket screw
1 729.4 Flat gasket 4 914.9* Socket screw
1 729.5 Flat gasket 1 Mounting sleeve ball bearing
* Only for Type KV: replaces 914.2
Tab.22: Maintenance kit magnetic coupling KF/KV1500–1700
Operating instructions
OIK 09en-GB Edition 2019-11
47
16 Spare parts
739
729.7
914.9*
057
471.3
055
165.2
165.2
817
914.1
165.3
729.5
165.2
165.2
729.6
729.4
165.1
914.8
914.2
16.2 Maintenance kits
16.2.4 Maintenance kit magnetic coupling KF/KV2200–2900
Notice The maintenance kit contains only the numbered parts and is only supplied complete.
Qty. Item No. Part Qty. Item No. Part
1 055 Supporting ring 1 729.7 Flat gasket, pressure flange
1 057 Threaded ring 1 739 O-ring
1 165.1 Screw plug 1 817 Ball bearing
4 165.2 Screw plug 8 914.1 Socket screw
1 165.3 Screw plug 7 914.2 Socket screw
1 471.3 Circlip 3 914.8 Socket screw
1 729.4 Flat gasket 4 914.9* Socket screw
1 729.5 Flat gasket 1 Mounting sleeve ball bearing
1 729.6 Flat gasket, suction flange
* Only for Type KV: replaces 914.2
Tab.23: Maintenance kit magnetic coupling KF/KV2200–2900
48
OIK 09en-GB Edition 2019-11
Operating instructions
16.2 Maintenance kits
739
165.3
914.9*
471.2
056
817
471.2*
165.2
165.2
471.3
055*
914.1
729.5
729.7
165.2
729.6
165.2
165.1
914.2
729.4
042
471.1
16.2.5 Maintenance kit magnetic coupling KFN/KFT/KVT
Notice The maintenance kit contains only the numbered parts and is only supplied complete.
16 Spare parts
Qty. Item No. Part Qty. Item No. Part
1 042 Balancing cylinder 1 729.4 Flat gasket
1 055* Supporting ring 1 729.5 Flat gasket
1 056 Supporting ring 1 729.6 Flat gasket, suction flange
1 165.1 Screw plug 1 729.7 Flat gasket, pressure flange
4 165.2 Screw plug 1 739 O-ring
1 165.3 Screw plug 1 817 Ball bearing
1 471.1 Circlip 4 914.1 Socket screw
1 471.2 Circlip 4 914.2 Socket screw
1 471.2* Circlip 4 914.9** Socket screw
1 471.3 Circlip 1 Mounting sleeve ball bearing
* Only for Size5–20
** Only for Type KV: replaces 914.2
Tab.24: Maintenance kit magnetic coupling KFN/KFT/KVT
Operating instructions
OIK 09en-GB Edition 2019-11
49
16 Spare parts
164
729.4
165.1
914.2
501
305
16.3 Repair kits
16.3 Repair kits
16.3.1 Repair kit overflow valve KF/KH/KV5–660 and KFT/KVT/KFN/KFA
Notice The repair kit contains only the numbered parts and is only supplied complete.
Qty. Item No. Part Qty. Item No. Part
1 164 Adjusting screw 1 501 Pressure spring
1 165.1 Screw plug 1 729.4 Flat gasket
1 305 Valve body 4 914.2 Socket screw
Type KFA: Pump housing with overhead flanges in special design PN16
Tab.25: Repair kit overflow valve KF/KH/KV5–660 and KFT/KVT/KFN/KFA
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OIK 09en-GB Edition 2019-11
Operating instructions
16.3.2 Repair kit overflow valve KF/KH/KV851–1301
164
729.4
914.2
501
064
305
629
306
914.5
165.1
914.6*
Notice The repair kit contains only the numbered parts and is only supplied complete.
16 Spare parts
16.3 Repair kits
Qty. Item No. Part Qty. Item No. Part
1 064 Supporting ring 1 629 Valve housing
1 164 Adjusting screw 1 729.4 Flat gasket
1 165.1 Screw plug 7 914.2 Socket screw
1 305 Valve body 1 914.5 Socket screw
1 306 Groove nut 4 914.6* Socket screw
1 501 Pressure spring
* Only for Type KV: replaces 4 pieces 914.2
Tab.26: Repair kit overflow valve KF/KH/KV851–1301
Operating instructions
OIK 09en-GB Edition 2019-11
51
16 Spare parts
164
729.4
914.5
064
501
064
305
629
306
914.2
165.1
914.6*
16.3 Repair kits
16.3.3 Repair kit overflow valve KF/KH/KV1500–1700
Notice The repair kit contains only the numbered parts and is only supplied complete.
Qty. Item No. Part Qty. Item No. Part
2 064 Supporting ring 1 629 Valve housing
1 164 Adjusting screw 1 729.4 Flat gasket
1 165.1 Screw plug 7 914.2 Socket screw
1 305 Valve body 3 914.5 Socket screw
1 306 Groove nut 4 914.6* Socket screw
1 501 Pressure spring
* Only for Type KV: replaces 4 pieces 914.2
Tab.27: Repair kit overflow valve KF/KH/KV1500–1700
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OIK 09en-GB Edition 2019-11
Operating instructions
16.3.4 Repair kit overflow valve KF/KH/KV2200–2900
164
914.2
914.6*
039
501
064
305
629
306
729.4
914.5
165.1
Notice The repair kit contains only the numbered parts and is only supplied complete.
16 Spare parts
16.3 Repair kits
Qty. Item No. Part Qty. Item No. Part
1 039 Sleeve 1 501 Pressure spring
1 064 Supporting ring 1 629 Valve housing
1 164 Adjusting screw 1 729.4 Flat gasket
1 165.1 Screw plug 7 914.2 Socket screw
1 305 Valve body 3 914.5 Socket screw
1 306 Groove nut 4 914.6* Socket screw
* Only for Type KV: replaces 4 pieces 914.2
Tab.28: Repair kit overflow valve KF/KH/KV2200–2900
Operating instructions
OIK 09en-GB Edition 2019-11
53
16 Spare parts
661
042
471.1
16.3 Repair kits
16.3.5 Repair kit, screw set
Notice The repair kit is only supplied in combination with a maintenance kit.
Qty. Item No. Part Qty. Item No. Part
1 042 Balancing cylinder 1 661 Screw set
1 471.1 Circlip
Tab.29: Repair kit, screw set
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OIK 09en-GB Edition 2019-11
Operating instructions
16.3.6 Repair kit magnetic coupling
914.5
518
040
739
884**
063**
917**
515
585 038
917.1**
052
914.4
Notice The repair kit contains only the numbered parts and is only supplied complete.
16 Spare parts
16.3 Repair kits
Qty. Item No. Part Qty. Item No. Part
1 038 Containment can 1 739 O-ring
1 040 Distance sleeve 1 884** Threaded pin
1 052 Outer rotor support 1 914.4 Socket screw
4 063** Supporting ring 1 914.5 Socket screw
1 515 Outer rotor 1 917** Countersunk screw
1 518 Inner rotor 4 917.1** Countersunk screw
1 585 Tensioning element
** Depending on motor size
Tab.30: Repair kit magnetic coupling KF/KV/KFT/KVT/KFA
Operating instructions
OIK 09en-GB Edition 2019-11
55
16 Spare parts
914.6
914.3
180
914.7
914.3
894
526
16.4 Completions
16.4 Completions
16.4.1 Completion Type KF
Qty. Item No. Part Qty. Item No. Part
1 180 Pump bracket 4 914.3 Socket screw
1 526 Pump bracket foot 4 914.6 Socket screw
3 894 Hexagon nut 3 914.7 Socket screw
Tab.31: Completion Type KF
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OIK 09en-GB Edition 2019-11
Operating instructions
16.4.2 Completion Type KV
914.6
180
914.3
914.9
663
16 Spare parts
16.4 Completions
Qty. Item No. Part Qty. Item No. Part
1 180 Pump bracket 4 914.6 Socket screw
1 663 Pedestal 4 914.9 Socket screw
8 914.3 Socket screw
Tab.32: Completion Type KV
Operating instructions
OIK 09en-GB Edition 2019-11
57
17 Appendix
17.1 Tightening torques for screws with metric screw threads with and without wedge lock washers
17 Appendix
17.1 Tightening torques for screws with metric screw threads with and without wedge lock
washers
Notice In the case of galvanised screw plugs and screw plugs made of stainless steel the inner thread and
outer thread have to be greased thorough before mounting in order to prevent threads from seizing.
Notice The manufacturer recommends tightening screws with wedge lock washers according to the table
three times after another with the same tightening torque.
Tightening torque [Nm]
Screws with head contact surface Countersunk
Stainless steel screws A2
and A4
Thread 5.6 8.8 10.9 8.8+
Alu*
M 3 0.6 1.5 – 1.2 – – 1
M 4 1.4 3.0 4.1 2.3 – – 2
M 5 2.7 6.0 8.0 4.8 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.33: Tightening torques metric screw thread
Property
class 70
Property
class 80
screws
8.8
*When screwing into aluminium, the tightening torque reduces by 20% when the screw-in depth is less
than double the thread diameter.
17.2 Tightening torques for screw plugs with thread measured in inches and elastomer seal
Notice In the case of galvanised screw plugs and screw plugs made of stainless steel the inner thread and
outer thread have to be greased thorough before mounting in order to prevent threads from seizing.
Tightening torque [Nm]
Thread Galvanized + stainless steel
G 1/8" 13.0
G 1/4" 30.0
G 3/8" 60.0
G 1/2" 80.0
G 3/4" 120
G 1" 200
G 1 1/4" 400
G 1 1/2" 450
Tab.34: Tightening torques, thread measured in inches
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OIK 09en-GB Edition 2019-11
Operating instructions
17.3 Tightening torques for screws of tensioning elements
17.3 Tightening torques for screws of tensioning elements
Tightening torque [Nm]
Thread 12.9
M 3 1.8
M 4 4.0
M 6 16.0
M 8 37.0
M 10 73.0
M 12 126
Tab.35: Tightening torques tensioning elements
17.4 Contents of the Declaration of Conformity
The products described in these 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 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)
Tab.36: Directives observed
Only for machinery in ATEX version
17 Appendix
Operating instructions
OIK 09en-GB Edition 2019-11
59
KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at
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