KRAL K Series User manual

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/KV5–
660..................................................................45
16.2.2 Maintenance kit magnetic coupling KF/KV851–
1301................................................................46
16.2.3 Maintenance kit magnetic coupling KF/
KV1500–1700...............................................47
2OIK 09en-GB Edition 2019-11 Operating instructions

Table of contents
16.2.4 Maintenance kit magnetic coupling KF/
KV2200–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/KV5–660 and
KFT/KVT/KFN/KFA .........................................50
16.3.2 Repair kit overflow valve KF/KH/KV851–1301
........................................................................51
16.3.3 Repair kit overflow valve KF/KH/KV1500–1700
........................................................................52
16.3.4 Repair kit overflow valve KF/KH/KV2200–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
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
These instructions form part of the product and must be kept for future reference. Furthermore please
observe the associated documents.
1.2 Associated documents
oDeclaration of conformity according to EU Directive 2006/42/EC
oManufacturer's declaration according to EU Directive 2014/68/EU
oData sheet of the pump
oTechnical documentation of the supplied components
1.3 Target groups
The instructions are intended for the following persons:
oPersons who work with the product
oOperator-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
Transporting,
unloading, setting up
Qualified personnel for transport, mobile crane operators,
crane operators, forklift operators
Fitter Mounting,
connection
Qualified personnel for mounting
Electrician Electrical connection Qualified personnel for electric installation
Trained
personnel
Delegated task Personnel trained by the operator-owner who know the task
delegated to them and the possible dangers arising through im-
proper behaviour.
Tab.1: Target groups
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
4OIK 09en-GB Edition 2019-11 Operating instructions

2 Safety
2.1 Proper use
1.4.2 Danger signs
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.
kg
Heavy load Heavy loads can result in serious back problems.
Risk of slipping Discharging pumped liquid and oils on the foundation or tread sur-
faces can cause falls with serious physical injury or death.
Flammable substances Discharging pumped liquid and oils can be easily inflammable and
can result in serious burns.
Hot surface Hot surfaces of the pump unit can cause 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
oUse the pump solely for transporting lubricating liquids that are chemically neutral and that do not
contain gas or solid components.
oUse 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.
oThe 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 2bar. 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
oAny use that extends beyond the proper use or any other use is misuse.
oThe product is not suitable for pumping liquids outside the operational limits.
oAny bypassing or deactivation of safety equipment during operation is prohibited.
2.3 Obligations of the operator-owner
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 ob-
served.
2.4 Safety instructions
2.4.1 Fundamental safety instructions
The following safety instructions must be observed strictly:
oRead these operating instructions carefully and observe them.
oRead the operating instructions of the components carefully and observe them.
oHave work only carried out by qualified personnel/trained personnel.
oWear personal protective equipment and work carefully.
oPumped 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.
oPumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
oObserve the associated data sheets and safety regulations when handling dangerous materials.
oAvoid skin contact with system parts carrying liquids at operating temperatures exceeding 60°C.
oCollect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations. Neutralize residues.
oKeep the mounting surfaces, scaffolding, ladders, lifting platforms and tools clean in order to pre-
vent slipping or stumbling.
oIf 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:
oKeep 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.
oPersons 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
oDo not bring the MCS in the immediate area of PCs, data carriers and other electronic
components.
oKeep the MCS away from clocks, magnetized tools and measuring equipment as well as all mag-
netizable parts.
oDo not bring both the MCS parts together, as this can destroy the magnetic coupling system.
6OIK 09en-GB Edition 2019-11 Operating instructions

3 Identification
3.1 Type code
3 Identification
3.1 Type code
KF - 1301.DBA.000372
1
2
3
4
5
6
Fig.1: Type code
Item Classification Description
1Type KF oPump with free shaft end
oPump with inline flanges PN16
oPump unit with or without pump bracket foot
KFA oPump with free shaft end
oPump with overhead flanges in special design PN16
oPump unit with or without pump bracket foot
KFN oPump with free shaft end
oPump with overhead flanges PN6
oPump unit with or without pump bracket foot
KFT oPump with free shaft end
oPump with overhead flanges PN16
oPump unit with or without pump bracket foot
KH oPump with foot for horizontal mounting
oPump with inline flanges PN16
oPump unit on base frame
KV oPump with pedestal for vertical mounting
oPump with inline flanges PN16 for vertical mounting
oPump unit on pedestal for vertical mounting
KVT oPump with pedestal for vertical mounting
oPump with overhead flanges PN16 for vertical mounting
oPump unit on pedestal for vertical mounting
2Size Corresponds to delivery rate in [l/min] at 1450 min-1
3Shaft seal A Standard mechanical seal
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
4Pressure stage over-
flow valve
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
5Heating A Without heating
B Electrical heating system
C Fluid heating system
X Special design
6Version index For internal administration
Tab.2: Type code
Operating instructions OIK 09en-GB Edition 2019-11 7

4 Technical data
3.2 Rating plate
3.2 Rating plate
KRAL GmbH, 6890 Lustenau, Austria www.kral.at KRAL GmbH, 6890 Lustenau, Austria www.kral.at
pSmax. / pDmax.
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
Fig.2: Rating plate
1Construction year
2Max. operating overpressure
suction-side / Max. operating
overpressure pressure-side
3Temperature range
4Serial number
5Type
6Article number
7Differential pressure
8Nominal delivery rate
9Rated speed
10 Nominal viscosity
11 Weight
4 Technical data
4.1 Operating limits
Size
Parameter Unit 5–
20
32–
42
55–
118
160–
275
370–
450
550–
660
851–
1301
1500–
1700
2200–
2900
Max. operating overpressure
oPump with flange PN6 [bar] 6
oPump with flange PN16 [bar] 16
Max. temperature of the
pumped liquid
oStandard magnetic coupling [°C] 180
oHigh-temperature magnetic
coupling
[°C] 250
Min. temperature for pump
materials
[°C] -20
Ambient temperature
min.–max.
[°C] -20 ... 50
Viscosity min.–max. [mm2/s] 1.5–10000
Speed max.
oAt 50Hz [min-1] 2900 1450
oAt 60Hz [min-1] 3500 1750
Max. inlet pressure [bar] Up to 16
Tab.3: Operating limits
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
8OIK 09en-GB Edition 2019-11 Operating instructions

5 Function description
4.3 Sound pressure level
4.3 Sound pressure level
Guide values at 1 m distance, 1450 min-1, 10 bar
Size
5–
20
32–
42
55–
118
160–
275
370–
450
550–
660
851–
1301
1500–
1700
2200–
2900
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,Page40.
5 Function description
5.1 Pump structure
2
1
11
10
3 4 5
9 8 7 6
Fig.3: Pump structure
1Screw plug 7Flange cover
2Overflow valve 8Vent hole
3Pump housing 9Thrust pin
4Balancing cylinder 10 End cover
5Ball bearing 11 Idle screw
6Main screw
Operating instructions OIK 09en-GB Edition 2019-11 9

5 Function description
5.2 Pump unit structure
5.2 Pump unit structure
12 13 14 15 16
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 screws6 and11
and the enclosing pump housing3.
Radial support of the screw set is effected through the sliding contact in the pump housing that de-
pends 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 pump-
ing 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 pres-
sure, 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
10 OIK 09en-GB Edition 2019-11 Operating instructions

5 Function description
5.5 Overflow valve
Housing Type Description
KFN/KFT/KVT Flange arrangement: Overhead flange PN6/PN16
KFA Flange arrangement: Overhead flange in special design
PN16
Tab.5: Housing variants
5.5 Overflow valve
3 42
1
Fig.5: Overflow valve
1Screw plug
2Adjusting screw
3Pressure spring
4Valve body
The integrated overflow valve ensures that very high pressures that could result in housing parts burst-
ing 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 ad-
verse 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 overpres-
sure always lies under the opening pressure of the overflow valve.
Notice The opening pressure of the overflow valve is set to 110% of the differential pressure in the factory.
The overflow valve is accessible through a screw plug1 and can be adjusted from the outside Ä Dur-
ing operation,Page24.
Notice oA function test of the overflow valve at least every 5 years is essential for the safe operation Ä Dur-
ing operation,Page24.
oScope 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)).
oThe first function test must take place directly after the commissioning.
oAfter 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:
oHave all work only carried out by authorized transport personnel.
oUse intact and correctly dimensioned hoisting equipment.
oEnsure that the means of transport is in a flawless state.
oEnsure that the centre of gravity of the load is taken into consideration.
oDo not stand under raised loads.
6.2 Dangers during storage
The following safety instructions must be observed:
oObserve the storage conditions.
6.3 Unpacking and checking the state of delivery
Personnel qualification: oTrained 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: oTransport personnel
Personal protective equipment: oWork clothing
oProtective helmet
oProtective gloves
oSafety boots
Aids: oMobile 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.
► 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.
12 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 grav-
ity 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 preser-
vative effect. Pressure connection and suction connection are closed with protective caps. Unless oth-
erwise specified, the outer surfaces of the pump are preserved with a single-coat PU-based two-com-
ponent paint.
The preservative applied at the factory will protect the pump for about six weeks, if it is stored in a dry
and clean location.
The manufacturer offers a long-term preservation for storage times of up to 60months. The pump is
additionally packed in hermetically sealing anti-corrosion paper.
Personnel qualification: oTransport personnel
Aids: oMobile 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.
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,Page14.
Operating instructions OIK 09en-GB Edition 2019-11 13

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 oStorage time exceeding six weeks
oUnfavourable storage conditions such as high humidity,
salty air, etc.
Delivery with long-term preservation oOpened or damaged packaging
Tab.6: Conditions for additional preservation
7.2 Preserving the inner surfaces
Personnel qualification: oTrained personnel
Personal protective equipment: oWork clothing
oProtective gloves
oSafety boots
Aids: oPreservative (acid-free and resin-free oil)
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, en-
sure 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.2cm 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: oTrained personnel
Personal protective equipment: oWork clothing
oFace protection
oProtective gloves
oSafety boots
Aids: oCalcium complex grease (for example
TEVIER®GREASEWAWE100 with adhesive additive)
oCastrol Rustilo DWX 33 or other preservative offering compar-
able 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.
14 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: oTrained personnel
Personal protective equipment: oWork clothing
oFace protection
oProtective gloves
oSafety boots
Aids: oSolvent
oCollection tank
oSteam-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:
oHave all work carried out only by authorized qualified personnel.
oBefore installation ensure that the operating limits, NPSH values and ambient conditions are ob-
served.
oObserve the tightening torques Ä Appendix,Page58.
oEnsure that all the components can be accessed and that maintenance work can be carried out
easily.
8.2 Dangers during removal
The following safety instructions must be observed strictly:
oHave all work carried out only by authorized qualified personnel.
oBefore beginning work, let the pump unit cool down to the ambient temperature.
oCollect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
oEnsure that the collection tank for discharging pumped liquids is sufficiently large.
Operating instructions OIK 09en-GB Edition 2019-11 15

8 Installation, removal
8.3 Installing the pump
8.3 Installing the pump
The pumps can be operated in horizontal and vertical installation position.
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 (mesh width: 0.02mm).
Personnel qualification: oTransport personnel
oFitter
Personal protective equipment: oWork clothing
oProtective helmet
oProtective gloves
oSafety boots
Aids: oMobile 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.
2
1
Fig.7: Flow direction
1Pressure connection
2Suction connection
16 OIK 09en-GB Edition 2019-11 Operating instructions

8 Installation, removal
8.4 Removing the pump
Requirement:
üPump connections protected against soiling, for example by using the protective cover mounted in
the factory
üIf required, hoisting equipment prepared
1. Bring the pump in the installation position, while observing the position of the motor and the ar-
rows for the flow direction on the pump housing (1pressure connection, 2suction connection).
2. Fasten the pump with fastening elements securely on the underground.
8.4 Removing the pump
Personnel qualification: oTransport personnel
oFitter
oElectrician
Personal protective equipment: oWork clothing
oProtective helmet
oFace protection
oProtective gloves
oSafety boots
Aids: oMobile crane, forklift, hoisting equipment
oCollection 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.
Requirement:
üPump 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, stor-
age,Page12.
Operating instructions OIK 09en-GB Edition 2019-11 17

9 Connection
9.1 Dangers during connection work
9 Connection
9.1 Dangers during connection work
The following safety instructions must be observed strictly:
oHave all work on the pump and pipe system only carried out by authorized qualified personnel.
oEnsure that impurities cannot get into the pump and pipe system.
oEnsure that mechanical connections are mounted stress-free.
oObserve the tightening torques Ä Appendix,Page58.
oHave all the work on the electrical equipment only carried out by electricians.
oBefore beginning work on the pump ensure that the electrical power supply is deenergized and is
secured against being switched back on.
oIf 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: oTransport personnel
oFitter
Personal protective equipment: oWork clothing
oProtective gloves
oProtective helmet
oSafety boots
Aids: oMobile 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 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.
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,Page38.
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9 Connection
9.3 Insulating the pump
2. Before carrying out welding work mount a protective cover on the suction connection and pres-
sure 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.
ðIf 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 Ap-
pendix,Page58.
9.3 Insulating the pump
Personnel qualification: oFitter
Personal protective equipment: oWork clothing
oProtective gloves
oSafety boots
Aids: oInsulation 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: oElectrician
Aids: oOperating instructions of the motor
oMotor 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.
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 OIK 09en-GB Edition 2019-11 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
the pump and with the local power supply.
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
terminal block.
4. When connecting the pump unit to the complete system continue equipotential bonding.
10 Operation
10.1 Dangers during operation
The following safety instructions must be observed strictly:
oHave all work carried out only by authorized qualified personnel.
oBefore commissioning ensure that a safety valve has been installed in the pipe system on the
pressure side before the first shut-off device.
oBefore commissioning, make sure that the suction line and pump are filled.
oPumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
oEnsure that the pump station is only operated within the operating limits.
oWear hearing protection if you work for a longer time directly at the pump.
oEnsure that the maximum permissible system pressure is not exceeded.
oEnsure that during cooling down or heating up the pump is only subjected to slow temperature
changes.
oEnsure that existing safety equipment is not bypassed or activated during operation.
oBefore decommissioning ensure that the electrical power supply is deenergized and is secured
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: oFitter
Personal protective equipment: oWork clothing
oProtective gloves
oSafety 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/commis-
sioning strainer.
► Calculate the flow resistance and determine the remaining pump intake.
► Monitor the suction-side pressure.
► Check the commissioning filter/commissioning strainer regularly.
Requirement:
üIf required, commissioning filter installed (mesh width0.02 mm)
1. Clean the complete pipe system before commissioning in order to protect the pump.
2. Flush the pipe system at least 50 – 100hours.
20 OIK 09en-GB Edition 2019-11 Operating instructions