Pratissoli SK Series User manual

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SK Series
Use and Maintenance Manual
Menu

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INDEX
1. INTRODUCTION 3
2. SYMBOL DESCRIPTION 3
3. SAFETY 4
3.1 General safety warnings.......................................................................................................4
3.2 Essential safety elements in the high-pressure system.........................................................4
3.3 Safety during operation........................................................................................................4
3.4 Instructions for using nozzles. .............................................................................................4
3.5 Safety during system maintenance.......................................................................................5
4. PUMP IDENTIFICATION 5
5. TECHNICAL CHARACTERISTICS 6
6. DIMENSIONS AND WEIGHT 7
7. INSTRUCTIONS FOR USE 7
7.1 Water temperature................................................................................................................7
7.2 Maximum flow and pressure. ..............................................................................................7
7.3 Running at minimum speed.................................................................................................7
7.4 Recommended brands and types of oil................................................................................8
8. PORTS AND CONNECTIONS 10
8.1 Conical seal pads / ferrules................................................................................................10
9. PUMP INSTALLATION 11
9.1 Installation .........................................................................................................................11
9.2 Direction of rotation...........................................................................................................11
9.3 Hydraulic connections .......................................................................................................12
9.4 Pump supply ......................................................................................................................12
9.5 Inlet line.............................................................................................................................12
9.6 Filtration ............................................................................................................................13
9.7 Outlet line ..........................................................................................................................13
9.8 Calculation of the internal diameter of the pipes in the pipelines......................................14
10. START-UP AND OPERATION 15
10.1 Preliminary checks...........................................................................................................15
10.2 Startup..............................................................................................................................15
10.3 Cooling circuit seal packing.............................................................................................16
11. PREVENTIVE MAINTENANCE 16
12. STOPPING THE PUMP FOR LONG PERIODS 17
12.1 Inactivity for lengthy periods...........................................................................................17
12.2 Method for filling the pump with anticorrosion emulsion or anti-freeze solution using an
external diaphragm pump based on the layout shown in section 9.6.......................................17
12.3 Pipes.................................................................................................................................17
13. PRECAUTIONS AGAINST FREEZING 17
14. WARRANTY TERMS 17
15. OPERATIONAL ANOMALIES AND THEIR POSSIBLE CAUSES 18
16. EXPLODED VIEW AND PART LIST 19

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1. INTRODUCTION
This manual contains the instructions for the use and maintenance of the SK pump. It must be carefully read
and understood before the pump is used.
The proper functioning and lifetime of the pump depends on correct use and proper maintenance.
Interpump Group declines all responsibility for damage caused due to negligence and/or failure to observe
the instructions described in this manual.
Upon delivery, check that the pump is undamaged and complete.
Report any problems before installing and starting the pump.
2. SYMBOL DESCRIPTION
Carefully read the contents of the manual before every operation.
Warning Signal
Danger Signal
Danger of electrocution.
Danger Signal
Use a protective mask.
Danger Signal
Use protective goggles.
Danger Signal
Put on protective gloves before every
operation.
Danger Signal
Use safety boots

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3. SAFETY
3.1 General safety warnings
Improper use of pumps and high-pressure systems, and/or failure to observe the installation and
maintenance instructions, can cause serious injury to persons and/or damage to property. Anyone preparing
to assemble or use high-pressure systems must have the necessary skills to do so, must be aware of the
characteristics of the components to be assembled/used, and must adopt all possible precautions necessary
to ensure maximum levels of safety in any operating condition. No reasonably applicable precaution must be
omitted in the interests of safety, either by the installer or the operator.
3.2 Essential safety elements in the high-pressure system.
1. The pressure line must always have a safety valve.
2. The components of the high pressure system, particularly for systems that operate predominantly
outdoors, must be adequately protected from rain, cold and heat.
3. The electrical parts of the system, as well as being adequately protected from water sprays, must
meet the standards specified in the regulations currently in force.
4. High-pressure pipes must be correctly dimensioned for the maximum operating pressure of the
system, and must always and only be used within the range of working pressures indicated by the
maker of the pipe.
1. These precautions must be observed for all other accessories of the system which are connected in
any way with high pressure.
5. The ends of high-pressure pipes must be sheathed and anchored to a solid structure, to prevent
dangerous whiplashes in the event of bursting or breakage of the connections.
6. Suitable protective casings must be installed at the pump transmission systems (junctions, belts and
pulleys, auxiliary power take-offs).
3.3 Safety during operation.
The environment or area within which a high-pressure system operates must be clearly indicated and access
prohibited to unauthorised personnel and, as far as possible, it must be restricted and/or fenced off.
Personnel who are authorised to access this area must be trained in advance on how to conduct themselves
in this area, and they must be informed of the risks deriving from defects or malfunctions of the high-pressure
system.
Before starting the system, the Operator is required to verify that:
1. The high-pressure system is correctly fed by a minimum pressure of 5-7 bar (metered in the head
flange).
2. The pump inlet filters are perfectly clean; we recommend inserting a device (any type) that indicates
the level of congestion.
3. The electrical parts are adequately protected and in perfect working order.
4. The high-pressure pipes do not show any evident signs of abrasion and the fittings are in perfect
order.
Any anomaly or reasonable doubt that may arise before or during operation must be immediately reported
and checked by qualified and authorised personnel. In such cases the pressure must immediately be
brought down to zero and the high-pressure system must be stopped.
3.4 Instructions for using nozzles.
1. The operator must always put his/her health and safety, and also the health and safety of third
parties that may be directly affected by the operator's actions, above all else and above any other
interest. Everything the operator does must be dictated by good sense and responsibility.
2. The operator must always wear a hard hat with a protective visor, impermeable clothing, and
suitable boots that will provide a good grip on the floor when it is wet.

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Note: proper clothing provides good protection from water sprays, but not from the direct impact of a water
jet or from sprays at extremely close range. In such circumstances further protection will be necessary.
3. It is good practice to work in teams of at least two persons, so as to provide each other with
immediate assistance if necessary, and to take over from each other during long and demanding
tasks.
4. Access to the work area reached by the radius of action of the jet must be absolutely prohibited, and
the area itself must be free from objects which, if inadvertently hit by the pressure jet, could cause
damage and/or create dangerous situations.
5. The water jet must always, and only, be pointed in the direction of the work area. This rule also
applies when conducting tests or preliminary checks.
6. The operator must always pay attention to the trajectory of the debris removed by the water jet.
Where necessary, adequate bulkheads must be installed by the operator to protect anything that
could be accidentally exposed.
7. While working, the operator must not be distracted for any reason whatsoever. Any persons needing
to access the operational area must wait for the operator to suspend activities on his/her own
initiative, and then make their presence known immediately.
8. For reasons of safety, it is essential that all members of the team are always completely aware of
each other's intentions, in order to prevent dangerous misunderstandings.
9. The high pressure system must not be started and brought up to pressure without all members of the
team first being in position and the operator having already directed the nozzle towards the work
area.
3.5 Safety during system maintenance
1. Maintenance of the high-pressure system must be carried out at the time intervals specified by the
maker, who is legally responsible for the entire assembly.
2. Maintenance must always be carried out by authorised specialist personnel.
3. The pump and the various different components must be assembled and dismantled exclusively by
authorised personnel using the proper equipment, in order to prevent damage to the components
and especially to the connections.
4. To guarantee total reliability and safety, only ever use original spare parts.
4. PUMP IDENTIFICATION
Every pump has a rating plate bearing the following information:
Pump model and version
Serial number
Max RPM
Power consumption HP – kW
Pressure in bar – P.S.I.
Flow in l/min – RPM
The model, version and serial number must always be
specified when ordering spare parts.
fig. 1

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5. TECHNICAL CHARACTERISTICS
Flow rate Pressure Power
Model RPM l/min Gpm bar psi kW Hp
1500 43 11.4 1500 21750 123 168
SK 20 1750 44 11.6 1500 21750 126 171
1500 52 13.7 1300 18850 129 176
SK 22 1750 53 14.0 1300 18850 132 179
1500 62 16.4 1100 15950 130 177
SK 24 1750 63 16.6 1100 15950 132 180
1500 73 19.3 900 13050 126 171
SK 26 1750 74 19.6 900 13050 127 173
1500 84 22.3 800 11600 128 175
SK 28 1750 86 22.7 800 11600 132 179
1500 96 25.4 700 10150 128 175
SK 30 1750 98 25.9 700 10150 131 178

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6. DIMENSIONS AND WEIGHT
For dimensions and weight please see fig. 2.
FORI = HOLES
7. INSTRUCTIONS FOR USE
The SK pump is designed to work with filtered water (see paragraph 9.6) and at a maximum
temperature of 30°C.
Other liquids can only be used if previously approved by the Technical Office or Customer
Assistance Service.
7.1 Water temperature.
The maximum water temperature permitted is 30°C.
7.2 Maximum flow and pressure.
The performance figures given in the catalogue are for the maximum performance levels that the pump can
provide. Independently of the power used, the maximum pressure and RPM indicated on the plate cannot
be exceeded unless explicitly authorised by the Technical Office or Customer Assistance Service.
7.3 Running at minimum speed
Any running speed other than the one specified in the performance table (see section 5) must be explicitly
authorised by the Technical Office or Customer Assistance Service.
fig. 2

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7.4 Recommended brands and types of oil
The pump is delivered with oil suitable for use in ambient temperatures of from 0°C to 30°C.
Some recommended types of oil are given in the table below. These are oils combined with additives to
increase protection from corrosion and resistance to fatigue (to DIN 51517 part 2).
Alternatively, Automotive SAE 85W-90 lubricant oils for gearing can be used.
Check the oil level with the oil level lights located on the
sides c, fig.3.
If necessary, top up via the oil plug e, fig.3.
To correctly check the oil level the pump must be at
ambient temperature. To change the oil the pump must be
at operating temperature, and is done by removing the plug
pos.d, fig.3.
Checking and changing the oil must be done as shown in
section 11.
The quantity necessary is ~14 litres.
fig. 3

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The oil must always be changed at least once a year because it can deteriorate due to oxidation.
For ambient temperatures other than 0°C to 30°C, follow the indications in the diagram below, bearing in
mind that the oil must have a minimum viscosity of 180 cSt.
Viscosity / Ambient Temperature diagram
The spent oil must be placed in a suitable container and disposed of properly at an
authorised centre. Do not under any circumstances discard it in the environment.
Viscosity
Ambient temp.

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8. PORTS AND CONNECTIONS
The SK series of pumps have (see fig.4):
c2 inlet ports, "IN", 1”1/2 Gas.
For the pump to work properly, it does not matter which of the two ports the line is connected to. Unused
ports must be hermetically sealed.
d2 outlet ports, “OUT”, Ø14 mm.
e2 service ports, 1/2” Gas. These can be used for the pressure gauge and safety valve.
f1 "DRAIN" port, fitted with an orientable 90° quick-fit connection for polyamide pipes of Øe 12 mm. This
port allows recovery of the drainage from the cooling circuit seal packing, and it must be connected to the
drain, taking care to ensure there is no counterpressure.
8.1 Conical seal pads / ferrules
SK pumps are provided with 4 steel conical pads, for use in the corresponding outlet ports of the pump (see
fig.5) or in the optional connection flanges, to ensure the connection seal. While the seat of the pump's outlet
port is already machined to accept the conical pad, if it is necessary to make the connection for the outlet
connection or the closing plug, these must be specially machined as shown in fig. 5/a.
At every disassembly, the conical pads must be replaced.
PASTIGLIA = PAD
TAPPO = PLUG
TESTATA POMPA = PUMP HEAD
fig. 4
fi
g
. 5 fi
g
. 5/a

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9. PUMP INSTALLATION
9.1 Installation
The pump must be fixed in a horizontal position, using the drilled Ø19 support feet.
The base must be perfectly flat and sufficiently rigid to not permit flexion and de-alignment on the
pump/transmission coupling axis as a result of the torque transmitted during operation.
On the pump two lifting eyebolts are installed to facilitate installation, as shown in the figure below.
The pump shaft (PTO) must not be rigidly connected to the propulsion group.
We recommend the following transmission types:
- Flexible coupling.
- Cardan coupling (follow the maximum working angles recommended by the makers).
9.2 Direction of rotation
The direction of rotation is indicated by an arrow positioned near the power take-off (PTO) shaft.
If you stand in front of the pump head, the direction of rotation should be as in fig.6.
LATO SX = LEFT SIDE
antiorario = anticlockwise
LATO DX = RIGHT SIDE
orario = clockwise
fig. 6

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The power take-off can be taken from either side of the pump.
Generally the pump is supplied with the PTO shank for the right-hand side (see fig.6)
To get the power off-take from the left hand side, the shaft end cover must be taken off and remounted on
the right hand side of the pump (see 2.1.1 in the repair manual).
Vice-versa, the lug must be removed from the right hand side and inserted in the shank of the left hand side.
9.3 Hydraulic connections
To isolate the plant from the vibrations produced by the pump, we recommend building the first section of
pipe adjacent to the pump (for both intake and outlet) with flexible piping. The solidity of the intake section
must be enough to prevent deformation caused by the depression produced by the pump.
9.4 Pump supply
SK pumps require a positive water head (NPSHr) of between 5 and 7 bar at the pump head entrance.
The booster supply pump must have a flow rate at least double that of the rated flow rate of the piston pump,
and a minimum pressure of 5 bar.
These supply conditions must be respected for any and all working regimes.
The booster pump must be independently actuated of the piston pump.
The booster pump must always be started before the piston pump.
We recommend installing a pressure switch on the supply line downstream of the filters, to
protect the pump.
9.5 Inlet line
For the pump to function well, the inlet line must have the following specifications:
1. Minimum internal diameter as specified by the chart in 9.8 and in any case greater than or equal to
that of the pump head.
1. Prevent localised restrictions along the pipe line, as they may cause loss of load with consequent
cavitation. At all costs, do not use 90° elbow corners, connections with other pipes, bottlenecks,
counterslopes, overhead "U" curves, or "T" connections.
2. The layout must be designed to avoid cavitation.
3. It must be completely hermetic and built in such a way as to ensure perfect seals over time.
4. Avoid situations where stopping the pump can result in emptying, even if only partial.
5. Do not use hydraulic fittings, 3 or 4 way connections, adaptors, swivel joints etc. because they could
prejudice the pump's performance.
6. Do not install Venturi pipes or injectors for detergent intake.
7. Avoid the use of foot valves or other types of one-directional valve.
8. Do not recirculate the discharge of the by-pass valve directly to the intake.
9. Have bulkheads in the tank to prevent the water flows coming from the by-pass and from the tank
supply line from creating vortices or turbulence near the pump supply pipe port.
10. Make sure that, before being connected to the pump, the inlet line is absolutely clean inside.
11. Install the pressure gauge for checking the pressure of the booster pump near the inlet port of the
piston pump, and always install the gauge downstream of the filters.

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9.6 Filtration
The level of filtration permitted for this series of pumps must be max. 20 μm (micron). Normally this is
obtained via a battery of at least three filters, positioned as shown in fig. 7.
The filters must be installed as near as possible to the pump. They must be easily accessible for inspection
and they must have the following specifications:
1. Flow rate minimum 3 times greater than the pump's rated flow rate.
2. Diameter of the entry/exit apertures not less than the diameter of the pump's inlet port.
3. Filtration grade:
Filter no. 1: 250 μm
Filter no. 2: 100 μm
Filter no. 3: 20 μm
For the pump to operate efficiently, the filters must be cleaned periodically. The cleaning
frequency should be planned to complement the actual use of the pump, and it should also
take into account the quality of the water used and the effective congestion conditions.
To guarantee the supply pressure required (see 9.4) install a pressure switch.
9.7 Outlet line
For a correctly-installed outlet or delivery line, follow these specifications:
1. The internal diameter of the pipe must be sufficient to ensure the correct speed of the fluid. See
the chart in 9.8.
2. The first section of pipe connected to the pump must be flexible, to isolate the vibrations produced
by the pump from the rest of the system.
3. Use pumps and fittings made for high-pressure use, which guarantee ample safety margins in all
operating conditions.
4. Install a safety valve on the outlet line.
5. Use pressure gauges that are designed to withstand the pulsing loads typical of piston pumps.
6. In the design phase, take account of load loss on the line, which translates to a drop in usage
pressure from the pressure measured at the pump.
7. For applications where the pulsations produced by the pump on the outlet line would be damaging
or undesired, install a suitably-dimensioned pulsation damper.
fig. 7
8 97
65
321
1 Filter no. 1
2 Booster pump
3 Filter no. 3
4 Filter no. 4
6 Prefilter
7 Prefilter piston
8 High-pressure pressure
9 Safety valve
Prefilter
Prefilter
Tank for
water supply
5 Prefilter
4
Drain

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9.8 Calculation of the internal diameter of the pipes in the pipelines.
To determine the internal diameter of the pipeline, refer to the following diagram:
Inlet pipeline
With a flow rate of ~ 99 l/min and a water speed of 0.5 m/sec. The line in the chart joining the two outside
scales meets the centre scale, indicating the diameters, at a value corresponding to ~ 65 mm.
Outlet pipeline
With a flow rate of ~ 99 l/min and a water speed of 5.5 m/sec. The line in the chart joining the two outside
scales meets the centre scale, indicating the diameters, at a value corresponding to ~ 19 mm.
Optimal speeds:
- Inlet: ≤0.5 m/sec.
- Outlet: ≤5.5 m/sec.
linea di aspirazione = inlet line
linea di mandata = outlet line
The chart does not consider: the resistance of the pipes, the valves, the load loss produced by the
length of the pipelines, the viscosity of the liquid pumped or the liquid's temperature.
If necessary contact the Technical Office or Customer Assistance Service.

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10. START- UP AND OPERATION
10.1 Preliminary checks
Before starting up the pump make sure that:
The inlet line is connected and is under pressure (see section 9): the pump must NEVER
operate dry.
1. The inlet line guarantees a hermetic seal over time.
2. All interception valves (if present) between the source of the water supply and the pump are
completely open. The outlet line is open, to allow the air in the pump head to exit quickly and
so favour rapid priming.
3. All fittings and connections, both inlet and outlet, are properly fastened.
4. The coupling tolerances on the pump/transmission axis (de-alignment of half-couplings,
inclination of Cardan joint etc.) are within the limits specified by the maker of the
transmission.
5. The oil in the pump casing is at the correct level, verified using the oil level lights located on
the sides of the casing (pos. 1 fig.8).
If the pump has been in storage or inactive for a lengthy period, ensure the inlet and outlet
valves are working properly.
10.2 Startup
1. At the first startup, verify that the direction of rotation is correct.
2. Check the pump's water supply is correct.
3. Start the pump with no load.
4. Verify that when operating, the rotation speed does not exceed the rated speed.
5. Allow the pump to operate for not less than 3 minutes before putting it under pressure.
6. Before stopping the pump, always bring the pressure down to zero first, using the control valve or (if
present) relief devices.
fig. 8

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10.3 Cooling circuit seal packing
During operation, some water from the cooling circuit seal packings will be discharged from port 1 (fig. 9).
The drainage from this circuit must be redirected to the inlet line upstream of the booster pump (fig. 9), or to
the collection tank.
11. PREVENTIVE MAINTENANCE
To keep the pump reliable and efficient, the maintenance intervals shown in the table below must be
observed.
PREVENTIVE MAINTENANCE
Every 500 hours Every 1500 hours
Check oil level Change oil
Check / Replace: Valves
Valve seats
Valve springs
Check / Replace: H.P. seals
L.P. seals
fig. 9

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12. STOPPING THE PUMP FOR LONG PERIODS
12.1 Inactivity for lengthy periods
If the pump is started for the first time after a long period of inactivity, before putting it into operation
check the oil level, inspect the valves as indicated in section 10, and then follow the prescribed
startup procedures.
12.2 Method for filling the pump with anticorrosion emulsion or anti-freeze solution using an external
diaphragm pump based on the layout shown in section 9.6
a) Close the filter drainage, if it is open.
b) Make sure that the connection pipe is clean. Spread it with grease and connect it to the high-
pressure discharge.
c) Connect the inlet pipe to the diaphragm pump. Open the inlet connection of the pump, and
connect the pipe between this and the diaphragm pump.
d) Fill the container with solution/emulsion.
e) Put the free ends of the high-pressure inlet pipe and outlet pipe in the container.
f) Start the diaphragm pump.
g) Pump the emulsion until you see it coming out of the high-pressure outlet pipe.
h) Continue pumping for at least another minute. The emulsion can be made stronger if
necessary, by adding (e.g.) Shell Donax to the solution.
i) Stop the pump, remove the pipe from the inlet connection and close it with a plug.
j) Remove the pipe from the high-pressure discharge. Clean, grease and plug both connections
and the pipes.
12.3 Pipes
a) Before greasing and protecting the pipes according to the procedure described previously, dry
the connections using compressed air.
b) Cover with polyethylene.
c) Do not wrap them too tightly. Make sure that there are no folds.
13. PRECAUTIONS AGAINST FREEZING
In areas and at times of year where/when cold is a risk, follow the instructions in section 12 (see
point 12.2).
If ice is present, DO NOT start the pump for any reason until the circuit has been completely
thawed. If ice is still present when the pump starts, it could be very seriously damaged.
14. WARRANTY TERMS
The guarantee period and conditions are contained in the purchasing contract.
The guarantee is invalidated if:
a) The pump is used for purposes other than those agreed.
b) The pump is driven with an electric motor or endothermic motor of greater performance than the
levels indicated in the table.
c) The safety devices are unset or disconnected.
d) The pump is used with accessories or parts not supplied by Interpump Group.
e) The damage is caused by:
1) Improper use
2) Failure to follow the maintenance instructions
3) Utilisation other than that described in the operating instructions
4) Insufficient flow
5) Defective installation
6) Incorrect positioning or dimensioning of the pipes
7) Unauthorised modifications to the design
8) Cavitation

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15. OPERATIONAL ANOMALIES AND THEIR POSSIBLE CAUSES
When the pump is started, it gives no flow:
- The pump is not primed and is operating dry.
- No water is supplied to the inlet.
- The valves are blocked.
- The outlet line is closed and this is stopping the air in the pump head from exiting.
The pump pulses irregularly:
- Intake of air.
- Insufficient water supply.
- Curves, elbows, and/or fittings along the inlet line are choking the passage of the liquid.
- The inlet filter or dirty or too small.
- The booster pump provides insufficient pressure or flow.
- The pump is not primed because the water head is insufficient, or the outlet is closed during
priming.
- The pump is not primed because a valve is stuck.
- Worn valves.
- Worn pressure gaskets.
- Imperfect operation of the pressure control valve.
- Problems with the transmission.
The pump does not provide the rated flow / makes excessive noise:
- Insufficient water supply (various different causes listed above).
- The number of revs is lower than the rated RPM.
- Excessive throttling by the pressure control valve.
- Worn valves.
- Excessive throttling by the pressure gaskets.
- Cavitation, due to:
1) Incorrect dimensioning of inlet pipes / underdimensioned diameters.
2) Insufficient flow.
3) High water temperature.
The pressure provided by the pump is insufficient:
- The usage (nozzle) is or has become greater than the pump's capacity.
- The RPM is insufficient.
- Excessive throttling by the pressure gaskets.
- Imperfect operation of the pressure control valve.
- Worn valves.
The pump overheats:
- The pump is working under excess pressure, or the RPM is higher than the rated level.
- The oil in the pump casing is below the correct level, or it is not of the recommended type,
indicated in section 7 (see point 7.4).
- The alignment of the coupling is not perfect.
- The inclination of the pump during operation is excessive.
Vibrations or blows on the pipes:
- Intake of air.
- Imperfect operation of the pressure control valve.
- Malfunction in the valves.
- Non-uniform movement in the transmission.

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16. EXPLODED VIEW AND PART LIST

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Copyright
The copyright of these operating instructions is property of the Interpump Group.
The instructions contain technical descriptions and illustrations that may not be electronically
copied or reproduced, entirely or in part, nor distributed to third parties in any form without
authorised written consent.
Offenders will be prosecuted according to the laws in force.
PRATISSOLI a brand of INTERPUMP GROUP S.P.A.
42049 S.ILARIO - REGGIO EMILIA ( ITALY )
Tel. +39 - 0522 - 904311 Fax +39 - 0522 - 904444
E-mail: [email protected]
http://www.pratissolipompe.com
Code 78.9800.03- rev.0 - Code IE 2860000019 – 20/02/2009 The information contained in this document may change without notice.