Wangen KL Series User manual

Original instructions
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Technical Documentation
Table of contents
Certificates (optional)
Data Sheet
Dimension Drawing (optional)
Instruction Handbook
Additional Valid Documents:
Exploded View Drawing with Parts List
Accessories
Drive Unit Documentation

Instruction Handbook KL
Table of Contents
Chapter
Data Sheet
Dimension drawing (option)
1 Safety Notes
2 Set-up and General Description
3 Transportation, Packaging, Storage
4 Installation
5 Commissioning
6 Shutdown
7 Service and Maintenance
8 Faults and Remedies
9 Disassembly and reassembly
10 Replacement Parts Stock

Instruction Handbook KL
Chapter 1
BA KL V11 en 10/2014 page 1-1
Safety Notes1
1.1 Important Hints
Read these instructions before installation and start-up.
This instruction describes the use in all its life cycle.
Comply at all times with the safety notes contained herein
Never install damaged products.
The safety notes in these instructions Handbook are structured as follow:
Symbol
Signal word
Meaning
Consequences if disregarded
Example:
General danger
Specific danger,
e.g. electric shock
Danger
Imminent danger
Severe or fatal injuries
Warning!
Possible dangerous situation
Severe or fatal injuries
Caution!
Possible dangerous situation
Minor injuries
Notice
Possible damage to property
Damage to the pump or its
environment
Important information about
explosion protection
Removal of explosion protection
and resulting dangers
Tip!
Useful information or tip
1.2 Qualified Personnel
The operator has to instruct the user on the basis of instruction handbook. The minimum age is
16 years. At the work on the machine an expert person has to supervise youth and trainees.
All mechanical work must be carried out by trained specialists only. Specialists in this context are
persons who familiar with the setup, mechanical installation, maintenance and repair works for
progressing cavity pumps. Further, they are qualified as follow:
They are trained in mechanical engineering e.g. as a mechanic (final examinations have been
passed) and they are familiar with this instruction handbook.
All electrical engineering work may be carried out by qualified electricians only. Qualified electricians
in this context are persons who are familiar with the electronic installation, start-up, and maintenance
and troubleshooting for pump aggregates. Further, they are qualified as follow:
They are trained in electrical engineering, e.g. as an electrician or mechatronics technician (final
examination must have been passed) and they familiar with the instruction handbook.
All works in further areas of transportation, storage, operation and waste disposal may be carried out
only by persons who familiar with this instruction handbook and are trained appropriately.
ATTENTION

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Chapter 1
BA KL V11 en 10/2014 page 1-2
1.3 Other applicable documentation
Observe following added documents:
Document
Description
Data sheet
Technical data, performance- and operation limits, application conditions
Dimension sheet
Dimension sheet of pump with fixing points
Parts list
Exploded view with parts list
Mounting instruction
Special design or incomplete Machine
ATEX - instruction
Operation of pump in an explosive area
Drive unit documentations
Instruction handbook for Drive unit
Documentation of Accessories
Instruction handbook for accessories
Declaration of decontamination
Repair of pump
1.4 Safety instructions for operation, maintenance, inspection and assembly work
Warning!
During operation, pump and drive unit may have rotating or movable parts as
well pressurised parts and possible hot surfaces!
Possible dangerous situation: Severe or fatal injuries!
Prior to carrying out any work on the machine, this must be shut down.
Switch the drive unit into a voltage-free condition and secure against any unauthorized
and accidental restart.
During and after operation pumps have hot surfaces (may be the case)
Before opening up the pump, ensure that the plant has been depressurised!
When opening up the pump, comply with all regulations concerning the flow medium.
Refit all safety devices before restarting the pump.
When restarting the machine, follow the instructions and safety notes contained in
the chapter “Start-up”.
Warning!
The pump or parts thereof may fall or tip over.
Possible dangerous situation: Severe or fatal injuries!
The pump or parts of it can be very heavy and must be moved with a suitable lifting
device.

Instruction Handbook KL
Chapter 1
BA KL V11 en 10/2014 page 1-3
1.5 Designed Use
The pumps are intended for industrial use and may only be used in accordance with the information
provided in the instruction handbook. Its may only be used to pump of stipulated medium.
The working points (Flow rate, nominal pressure, rotation speed) in the pump specification
(data sheet) are defined as values limits, which must not be exceeded.
A change in delivery conditions (e. g. flow rate, flow path, pressure level, pipe diameter, throttle
devices) may cause major changes in the operating conditions. In such cases, compare the new
operating conditions with the details provided in the pump specification. If the changed conditions
should exceed the details provided in the pump specification, it will be necessary to contact the
manufacturer for advice.
Using this pump in potentially explosive atmosphere is prohibited, unless explicitly specified
otherwise.
1.6 Predictable Misuse
Only use the pump for pumping of the stipulated medium.
Do not exceed the stipulated rotational range.
The contents of solids in the medium to be pumped must not be exceeding definite value limits of
particle size and solid content.
Make sure that no foreign matter or particles e.g. metal parts, stones, etc. can get into the pump.
Medium contamination by foreign matter may cause damage to the pump elements!
Do not use a non-operative pump as a shutoff device!

Instruction Handbook KL
Chapter 1
BA KL V11 en 10/2014 page 1-4
1.7 Operating Restrictions
The progressing cavity pump is a positive displacement pump, which is theoretically capable of
building up an infinitely high pressure. In the event of a pressure line being closed, pressure built up
in this way can reach a multiple of permissible plant pressure values. This may cause serious
damage to plant components and involve a risk of personal injury.
Possible damage
Do not operate against closed shutoff devices!
There is a risk of fracture as well as personal injury!
Secure the pump by means of approved safety devices (excess pressure protection)!
KL 100 –pump with reinforced bearing is only allowed for normal flow direction. (Counter-
clockwise direction). If a clockwise rotation should be required, then only with a maximum
pressure of 1 bars.
Do not use a non-operative pump as a shutoff device! With a shutdown drive unit, any one-sided
pressurisation of the pump may cause to rotate independently. Damage to the pump cannot be
excluded in such cases.
The continuous application of alternating loads on the pump (e.g. motor/generator operation or
right/left-handed rotation) reduces the service life of the pump and the gear unit as a result of
heavy loading of the rotating parts and of the seal and must be avoided.
Comply with all statutory regulations applying to the delivery of dangerous media.
Medium contamination by foreign matter (metal parts, stones, etc.) may cause damage to the
pump elements! Take suitable action to ensure that no foreign matter or particles likely to cause
damage can ingress into the pump!
Comply with all statutory regulations applying to the delivery and storage of hazardous
substances, all local construction supervisory regulations, and any resulting conditions and
restrictions for the operation of eccentric screw pumps (requirements regarding dry-run
protection, drive unit equipment etc.
1.8 Special Safety Notes for Hopper Pumps / open able housings
For taking up the flow medium, the hopper in hopper pumps is open at the top. The hopper pump
has been designed to be fitted into a machine or plant and must not be operated without appropriate
protective devices on the hopper.
Pumps, which are for cleaning purposes designed with an open able housing, must not be used
without appropriate protective devices either.
Pumps that will be driven by a plug-in shaft or quick change units must be only driven in left-hand
direction. The contrariwise direction of rotation will drive out the rotor and plug-in shaft.
ATTENTION

Instruction Handbook KL
Chapter 1
BA KL V11 en 10/2014 page 1-5
Danger!
Rotating cardan shafts or rotating screw conveyors in the pump
can trap hands and other body parts.
Imminent danger: Severe or fatal injuries.
During pump operation, it must not be possible to insert your hands or other body parts
into
the hopper!
Screw conveyor operation may cause serious hand and other bodily injuries!
Secure any flexible parts of the hopper and suction housing with suitable limit switches,
which comply with EC-guidelines.
Use suitable fixed or locked/separating protective devices to ensure that it is impossible to
reach the screw conveyor with any limb, or that any opening of protective devices will
cause the plant to shut down immediately!
Make sure that pumps with plug-in shaft or quick change units run only at the given
direction.
Prior to carrying out any cleaning and maintenance work on the drive unit, this must be
switched into a voltage-free condition and secured against any unauthorized and
accidental restart!
1.9 Special Safety Notes for Immersion pumps
Immersion pumps take up the medium directly over the pumping set.
This danger area is in the medium at normal working process.
Use suitable fixed protective device to ensure that it is impossible to reach the pump inlet
of vertical pumps with any limb!
1.10 Special Safety Notes for Pumps with Heating Jacket
The suction casing / hopper of these pumps are equipped with a heating jacket and corresponding
connections for medium to flow through. This allows the pump casing to be heated.
The casing is designed for a pressure up to 3 bars, unless a different pressure has been permitted
in the data sheet.
Possible damage
The heating circuit is to be run exclusively with water.
Make sure by proper pressure control devices the nominal pressure will not be exceeded.
The medium which may escape while the pressure control device is responding must be
drained riskless into a pressure-free area. Make sure in this draining path no shutoff
devices are installed
Danger!
Rotating cardan shafts or rotating screw conveyors in the pump
can trap hands and other body parts.
Imminent danger: Severe or fatal injuries.
Attention

Instruction Handbook KL
Chapter 2
BA KL V11 en 10/2014 page 2-1
Set-up and General Description2
2.1 Pump set-up KL 20
Only for information
Suction Pump
Hopper Pump
A Drive Unit
1 Bearing Chair
2 Sealing Unit
3 Joint (by Hopper Pump with Feed Screw)
4 Suction Housing / Hopper Housing
5 Pump Set (Rotor/Stator)
6 Discharge Nozzle

Instruction Handbook KL
Chapter 2
BA KL V11 en 10/2014 page 2-2
2.2 Pump set-up KL 30 –KL 100
Suction pump
Hopper pump
A Drive Unit
1 Bearing Chair
2 Sealing Unit
3 Joint (by Hopper Pump with Feed Screw)
4 Suction Housing / Hopper Housing / Immersion Tube
5 Pump Set (Rotor/Stator)
6 Discharge Nozzle / Outlet Nozzle
Vertical pump

Instruction Handbook KL
Chapter 2
BA KL V11 en 10/2014 page 2-3
2.3 General Description
WANGEN helical progressing cavity pumps are rotating displacement pumps for delivering low to high
viscosity media.
The pump elements proper comprise a rotor made of steel materials and a stator made of elastomer
materials. The rotation of the rotor within the stator causes the delivery chambers to be opened and
closed in a continuous sequence. This causes the medium to be delivered continuously from the
inlet/suction end through to the pressure end.
The special delivery principle of these pumps enables low pulsation and a delivery, which is
approximately proportional to pump speed. A correct dimensioning of the pump is decisive for perfect
functionality. The pump will be customized by the manufacturer in line with the details specified by the
customer regarding the medium to be pumped.
Pumps for use in the foodstuffs and beverage industry are designed and built to the recommendations
of DIN EN 1672-2 ‘Food processing machinery - Basic concepts’. This does not include pipe
connections, which require special cleaning procedures. These must be cleaned manually by the
operator. The cleaning cycle is dependent on the food and the relevant hazard from. This is set by the
operator. Correspond to the pipe connections according to DIN 11864, according to DIN EN 1672-2
there is no health risk. The operator does not define any special cleaning measures.
Non-corroding materials suitable for cleaning and/or disinfection are being used for the product-
contacting parts of these pumps. Elastomer materials and seals correspond to the BfR (German
Federal Institute for Risk Assessment) recommendations and the FDA guidelines respectively (US
Food and Drug Administration) and the Regulation (EC) No 1935/2004.
WANGEN pumps or pump assemblies are designed and constructed to comply with all health and
safety requirements of the EC Machine Directive. When compliance with all requirements has been
shown, each machine will be certified by an EC Declaration of Conformity (including CE marking) or a
Declaration for partly completed machines (if the machine is not yet ready to be used).
The declaration of conformity issued by Pumpenfabrik Wangen applies to the supplied
machine in connection with the use, according to regulations, of the drive (helical geared
motor, helical gear to be assembled to an IEC standard motor) as described in the data sheet
with defined power and defined torque as prime mover of the pump. Subsequent
interventions or changes made on the pump are subject to the sole responsibility of the
customer who, in this event, becomes liable for warranting the conformity with the EC
regulations.
2.4 Distinctive features of hopper pumps
Mediums without flow ability demand a feeding device to the rotor / stator system to assure a
sufficient filling of the pump chamber. It is realized through a feed screw, which is mounted on the
cardan shaft. Instead of a suction housing as a pick-up for the material to be conveyed, a hopper
feed casing with added tunnel is used. There is a large rectangular opening in the hopper feed
casing which picks up the mainly as filling occurring material. In the conic / cylindrical designed
tunnel, a supply pressure in interplay with the feed screw is build up, which supports the filling of the
pump chamber.
2.5 Noise Emissions
Each pump will be manufactured and tested according to the currently applicable technical
documentation. The A-evaluated permanent noise level will normally be < 70 dB (A).
This does not include the drive unit and pipe system.
It is also assumed that the pump operates without cavitation, and that the pump unit is properly
mounted on a level concrete plate or steel construction resistant to torsion flexing.

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Chapter 3
BA KL V11 en 10/2014 page 3-1
Packaging, Transportation, Storage, Disposal3
3.1 Packaging
If there are no specific customer requirements in this regard, one-way packaging will be used for
shipping WANGEN progressing cavity pumps. Examine the shipment immediately upon receipt for
any transportation damage. If any such damage is found, immediately inform the shipping and
forwarding company. Damaged products must not be taken into service.
3.2 Transportation
Warning!
By an incorrect transport the pump can fall down or upset.
Possible dangerous situation: Severe or fatal injuries.
Only use lifting gear and load lifting facilities with sufficient load carrying capacity for
loading / unloading!
Lift pumps only by load handling attachment (chains, tightropes) (see following pictures).
3.2.1 Transport of horizontal pumps
Possible damage
Please note that some drive units may cause pump assemblies to be very top-heavy.
Never use the eyebolts of the drive unit to lift the entire assembly. These attachment
points are to be used only for the engine and/or transmission!
Fig. 3-1 KL-S Pump
Fig. 3-2 KL-R Pump with base plate and drive unit
ATTENTION

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Chapter 3
BA KL V11 en 10/2014 page 3-2
3.2.2 Transport of vertical pumps
Possible damage
Never use the eyebolts of the drive unit to lift the entire assembly. These attachment
points are to be used only for the engine and/or transmission!
Basically, the pump is to be transported via the hanging bracket.
In cases in which the pump has no hanging bracket, it must be transported properly using
suitable load handling attachments (ropes, chains) as shown in Figures 3-4 and 3-5.
Fig. 3-3 KLT with hanging bracket Fig. 3-4 KLT with mounting flange Fig.3-5 KLT with console on immersion tube
ATTENTION

Instruction Handbook KL
Chapter 3
BA KL V11 en 10/2014 page 3-3
3.3 Storage
WANGEN progressing cavity pumps are sufficiently preserved for storage in normal environmental
conditions.
If the pump is to be stored for a longer period, prepare the unit as follows:
Smear stator with silicon oil (factory preservation of new pumps).
Protect pump against dust, dirt, water, direct sunlight and other damaging environmental
influences. All non-painted surfaces are to be covered by means of acid-free and resin-free
grease.
For pumps with rotors not made out of stainless steel (e.g. from 1.2436), remove the stator and
cover the rotor in grease.
If the pump is to be taken out of use for periods in excess of 6 months, remove the stator in order to
avoid pressure marks in the elastomeric material.
3.4 Disposal
Housing components, rotors, shaft-sealing rings are to be disposed of as scrap steel (“stainless steel
scrap metal”). Stators, O-rings, and parts of the mechanical seal made of carbon/ceramics are to be
disposed of as residual waste materials. Oil and grease from joints and seals is to be collected and
to be disposed of according to local regulations.

Instruction Handbook KL
Chapter 4
BA KL V11 en 10/2014 page 4-1
Installation4
4.1 Direction of Rotation
The direction of rotation is stated in the data sheet as well as on the pump type plate and must be
absolutely kept for the avoidance of damage of the shaft seal (dependent on direction of rotation
mechanical seals). The direction of delivery (flow direction) will be determined by means of the
direction of pump rotation.
4.2 Fastening of horizontal pumps
The pump is mounted by means of the mounting lugs on the base plate or the mounting holes
provided on bearing chair (KL20);
the mounting lugs on the base plate or the mounting holes provided on bearing chair and discharge
nozzle. (KL30 - KL 80). The pump has to be mounted on firm and level ground, e.g.
sufficiently dimensioned level concrete base plate;
a level and warp resistant steel construction.
The foundation must be designed so that it can take the weight of the pump aggregate on the entire
surface. It must fully absorb the load exerted on the foundations and ensure the stability of the pump
aggregate.
The diameter of holes at bearing chair and discharge nozzle support or the straight plates of the
base plate describe the bolt diameter respectively the diameter of the anchor dowels.
4.3 Fastening of vertical pumps
As a rule vertical pumps or pumps are mounted vertically get fixed on a hanging bracket or special
devices. (E.g. fixing flanges see Data Sheet).
For all KLT pumps from series KLT 50 onwards, the fastening must be made as described in the
following:
by suspending on the hanging bracket (fixed setting) or
using the fastening on the lower bracket on the immersion tube and fixation via the bearing block
of the pump.
using the mounting flange, with which the pump is firmly attachment via this flange, or
using a 'tripod' which stands upright and is secured against slipping and using the bearing block
of the pump.
For immersion pumps (with a mounting flange and a homogeniser) whose discharge height is over 5
metres, an additional collection basket must be installed on the tank floor that securely prevents the
oscillation of the pump.
Possible damage
With sizes KL50T, KL65T, KL80T and KL100T, fastening via the bearing block of the pump
alone may result in a fracture of the bearing block housing.
ATTENTION

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Chapter 4
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The adjacent figure shows attachments for different forms of the KLT pump.
Possible damage
Use suitable screw connections and concrete anchors for the connections in the concrete
of the silo wall.
In so doing, use the hole diameters of the flanges, brackets and drill holes on the bearing
block as a basic orientation.
Fig. 4-1 KLT with hanging bracket Fig. 4.2 KLT with mounting flange 4.3 KLT fixed to bearing chair and bracket
ATTENTION

Instruction Handbook KL
Chapter 4
BA KL V11 en 10/2014 page 4-3
Normally, the mounting is done by using a screw connection
(machine bolts and anchor dowels). Note the following
bolt dimensions and maximum torques:
bolt dimensions
Maximal torque
M 8
25 Nm
M 10
50 Nm
M 12
90 Nm
M 16
220 Nm
M 20
430 Nm
(The values apply to shoulder studs of strength class 8.8, according to DIN 931-B or EN 24014
Possible damage
Check the tightening moments of the tie rods after remounting with a torque wrench. Keep
belongs tightening moments on.
Type of pump
Tightening moment
KL 20 (M 8)
25 Nm
KL 30 (M 12)
50 Nm
KL 50 (M 16)
90 Nm
KL 50 (M 20)
150 Nm
KL 65 (M 24)
210 Nm
KL 80 (M 24)
240 Nm
KL 100 (M 24)
280 Nm
ATTENTION

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Chapter 4
BA KL V11 en 10/2014 page 4-4
4.4 Fixing the KLT “Elephant”
The KLT "Elephant" is a special submersible pump, which is suitable for vertical fixation (using
excavators, telescopic handlers, jib cranes, etc.).
For horizontal mounting of the pump, see Chapter 4.2.
Warning!
Improper fixation can lead to the pump falling or tipping over.
Possible consequences: Death or severe injury.
Use only lifting gear with sufficient lifting capacity.
Hoists must have a safety hook which prevents the load slipping out.
For fixation of the pump, use only suitable lifting tackle (steel cables according to the
norm DIN EN1792 or chains complying with DIN 81814) with adequate load-bearing
capacity.
Make the pressure connection of the pump as far as possible via a flexible pressure pipe.
Bear in mind that these can cause unexpected blows by sudden surges of pressure.
The danger zone around pump and hoist areas is to be made secure, so that it is out of the
reach of the upper and lower limbs.
Example of fixing the KLT ELEPHANT

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Chapter 4
BA KL V11 en 10/2014 page 4-5
4.5 Piping
Correctly dimensioning the piping for use at the pressure end of the pump will be imperative in order
to ensure that any unnecessary pressure build-up is avoided when pumping viscous media. The
pressure provided in the data sheet must not be exceeded.
Observe the supply pressure stated in the data sheet with regard to pressure resistance in the pipe.
Flush out pipe system and supply devices before fitting, and remove all foreign matter.
If possible, pass the intake or suction pipe such that the pipe cannot empty itself in the event of a
pump shutdown (shutoff devices, siphon, etc.). This avoids dry-running at start-up.
4.5.1 Connecting the pipes
Flush out und clean the pipes.
About elastic seals connect pump with Pipe system.
For dismantling the pump, provide shutoff devices and adjusting pieces for use on the piping at the
pressure end of the pump.
Directly behind the discharge nozzle secure the pump by means of approved safety valve or
pressure monitoring.
Possible damage
Do not use the pump unit to support pipes! Pipes are to be mounted as much as possible
free of all forces and torques.
When making pipe connections, observe the permissible forces and torques at these
connections (see following table)!
Bolted connections must not be loaded with torques resulting in the pipe becoming
clamped or loosened inside the pump housing.
ATTENTION

Instruction Handbook KL
Chapter 4
BA KL V11 en 10/2014 page 4-6
with and
4.5.2 Series KL 20 Suction nozzle
nom. pipe 
F (x,y,z) [N]
F (tot) [N]
M (x) [Nm]
M (y, z) [Nm]
M (tot) [Nm]
1 ¼“
50
87
5
20
29
32 mm
50
87
5
20
29
65 mm
70
121
7
28
40
Discharge nozzle
nom. pipe 
F (x,y,z) [N]
F (tot) [N]
M (x) [Nm]
M (y, x) [Nm]
M (tot) [Nm]
1 ¼“
35
61
3
12
17
32 mm
35
61
3
12
17
65 mm
50
87
4
16
23
4.5.3 Series KL 30 –KL 100
nom. pipe 
F (x,y,z) [N]
F (tot) [N]
M (x,y,z) [Nm]
M (tot) [Nm]
80
700
1000
310
450
100
840
1200
380
550
150
1190
1700
560
800
200
1540
2200
730
1050
222 FzFyFxFtot 
222 MzMyMxMtot 