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Operating instructions

1. d 7 LZ SPILL 61 48 49 2021 22 23 24 25 26 18 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 Tab 3 7 Basic construction KF 4 25 U Description 1 Valve housing Gasket Adapter piece Plain bearing bush O Ring Driven shaft Driving shaft St oo dm SN Plain bearing bush 9 Housing 10 Roller bearing 11 Retaining ring 12 Hexagonal screw 13 Retaining ring 14 15 16 17 18 19 20 21 22 23 24 25 26 KRACHT Valve washer Valve cone Socket head cap screw Socket head cap screw Rotary shaft lip seal Retaining ring Parallel key Cover O Ring Rod Compression spring Centering star Piston See section section 3 3 Types of seals for further seal types BKFOOO4EN_D0024710002 06 2011 01 10 19 KRACHT Transfer Gear Pumps KF 4 112 3 2 4 KF 32 80 U with universal valve Tab 3 8 Basic construction KF 32 80 U gt gt 7 1 LE SIN 77 eea 2 7 Ep pem m n SELLE N J View without connection elbow View without universal device 20 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT Tab 3 9 Basic construction KF 32 80 U Description 1 Hexagonal screw 15 Parallel key 2 Screw plug 16 Retaining ring 3 Gasket 17 Roller bear
2. 0 9 1 0 1 0 1 1 1 1 1 2 1 2 placement n 1500 Example 9 225 14 225 19 RA19 24 225 14 225 24 Dimensions mm BKFOOO4EN_D0024710002 06 Danger of property damage when mounting other types of couplings If other coupling types are used when mounting the coupling the instruc tions from the respective manufacturer is binding e The respective manufacturer s installation instructions must be com plied with when using other coupling types 2011 01 10 45 KRACHT Transfer Gear Pumps KF 4 112 Danger of property damage if installation is not correct Do not strike the shaft when installing the respective coupling half on the motor and pump shaft There is a danger that the built in bearing could be damaged e Do not knock onto the shafts during installation of the clutch halves MER Easing coupling installation e The hubs should be heated for mounting the clutch and slid onto the shaft while hot Using a pinion gear drive it must also be heated and slid onto the shaft end while hot NOTICE Danger of property damage due to displacement of the coupling halves When the coupling hub is not secured against axial displacement on each shaft there is a danger that the coupling hub will shift during operation That can lead to a failure of the coupling e Prevent axial displacement on every coupling hub on cylindrical shafts with a threaded pin t
3. The limit values given must never be exceeded see chapter 4 Technical data National regulations concerning accident prevention and health and safety at work must be observed as well as internal regulations laid down by the operator even if these are not specifically mentioned in this manual The operator must ensure that this operating manual is accessible to the staff responsible at all times 2011 01 10 KRACHT Transfer Gear Pumps KF 4 112 2 4 Hazard statements N DANGER Danger due to breakage or squirting fluids Operating the device with impermissibly high pressures can lead to damage to the device and to the up or downstream plant elements Breakage can lead to parts flying around uncontrolled or to fluids squirting out which can lead to accidents and severe injuries or even result in death e Never allow positive displacement pumps to pump against closed gates e pressure relief valve or other kind of over pressure safeguard must be installed as close as possible to the pump pressure connection The pressure relief device must be dimensioned so that the entire delivery volume can be conducted through it with the lowest possible pressure or must be depressurized e Do not put the device into operation without a pressure relief device EE Danger due to breakage or squirting fluids Using unsuitable connections and lines can lead to breakage Parts flying around uncontrolled or squirting fluids can
4. Too low viscosity Too high speed Too high pressure Pressure relief valve set too low Pump sucks air Pump worn out Too high proportion of air in the oil Universal valve defective Place of installation too high Insufficient Delivery pressure too low work drags in pressure pipe too low Too low viscosity Pressure relief valve set too low or does not shut Too low speed Driving power too low Pump worn out Excessive power con sumption Too high pressure Too high viscosity Driving power too low Motor winding defective Excessive operating temperature Pressure relief valve set too high Speed too high Cooling and heat dissipation insufficient Supply of fluid too low Fluid is being delivered into the supply tank via pressure relief valve under load Impermissi ble pump heating Delivery side valve cone not completely shut Directly mounted pressure relief valve set too low does not apply for the universal valve and T valve versions Too high pressure Too low viscosity Gland lid overtightened Separating can insufficiently bled Admission pressure impermissibly high Pump worn out BKFOOO4EN_D0024710002 06 2011 01 10 69 KRACHT Transfer Gear Pumps KF 4 112 Fault Potential causes Leakages on shaft seal Admission pressure impermissibly high Wrong direction of rotation Too high radial shaft loading Temperature at sealing point too high Wron
5. e Foraqueous dispersions and solvents limit the operating temperature to max 50 C install the pump underneath the liquid level and limit the rotational speed to maximal 1500 rpm 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT The recommended flow velocity in the suction line is max 1 5 m s Tab 6 6 Piping the suction line as siphon If there is a possibility that the suction line can run dry if the pump stops piping the suction line as siphon is an option to avoid suction problems This way the pump will remain permanently filled after initial com missioning The air in the pressure line can be conduc ted directly into the tank via a nozzel see section 6 5 2 Pressure line HQ It is appropriate to employ a foot valve or a non return valve in case of longer suction lines that can run dry while the pump is at rest These must have been designed for use in suction lines and should offer as low a flow resistance as possible Tab 6 7 Suction line at vacuum operation If the pump is to intake from a tank under vacuum the pump must be arranged ap prox 0 8 m below the tank The suction line must run in a straight line and without any resistances The tank may be subjected to vacuum only then when the pipework and the pump have been filled with liquid For this application only pumps designed as a vacuum system may be employed Malfunction due to excessive
6. 10000 20000 30000 gt 1450 1250 1000 750 600 500 400 300 200 100 Speed Nmax in rpm 26 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 4 4 Overview materials Tab 4 4 Materials KF 4 112 KRACHT Seal Housing cover Gear Bearing Shaft seal O Rings type 1 NBR NBR 2 FKM FKM 3 PTFE FEP 4 PTFE FEP 5 CrMo casting FKM Carbon in syn thetic resin FKM 1 4571 1 4401 6 SiC Si SiC Si FEP KF 4 25 SiC DU P10 Si Carbon in Steel synthetic resin J KF 32 80 EN GJL 250 Lk FFKM 1 4571 7 GG 25 Carburising steel Iglidur X FKM FKM 9 ure DP4 EPDM EPDM 18 Steel FKM FKM 19 sintered bronze NBR NBR PTFE 20 SiC Si Carbon EPDM CrNi steel CrNiMo steel 23 FKM low tem FKM low perature tempera ture 30 Without shaft FKM seal 31 FKM low tem FKM low perature tempera ture 32 EPDM EPDM See type key and type designation at pump KF For version in EN GJS 400 15 type designation KF GJS BKFOOO4EN_D0024710002 06 2011 01 10 2 KRACHT Transfer Gear Pumps KF 4 112 4 5 Operating pressure and fluid temperature Tab 4 5 Operating pressure and fluid temperature KF 4 112
7. BKFOOO4EN_D0024710002 06 2011 01 10 9 KRACHT Transfer Gear Pumps KF 4 112 Hazard caused by rotating parts and fluid squirting out During all work on the device rotating parts and squirting fluids can lead to acciedents and severe injuries or even result in death e Depressurize all connection lines during all work on the device e Depressurize or disconnect the driving motor during all work on the de vice e Securely prevent the motor and device from restarting during work e Wear suitable protective clothing Danger due to hazardous fluid Danger of death upon contact with hazardous fluids and when inhaling va pours from these liquids e Comply with the safety data sheets and regulations on handling the hazardous liquids e Collect and dispose leaks of hazardous materials so that no hazards arise for people or the environment e Comply with national and international rules at the place of installation e Wear suitable protective clothing Hazard caused by rotating parts Rotating parts can cause accidents with severe injuries or result in death due to body parts hair or clothing getting caught or wrapped up e Protect rotating parts e g coupling and shaft ends against uninten tional contact e Close any maintenance openings when using bell housings e Do not operate the device without safeguards Danger due to exposed gears Gears can pull in and crush or cut off fingers and hands
8. must be installed as close as possible to the pump pressure connection The pressure relief device must be dimensioned so that the entire delivery volume can be conducted through it with the lowest possible pressure or must be depressurized e Do not put the device into operation without a pressure relief device The nominal width of the pressure line must be selected such that the maxi mum permissible pressures are not exceeded The pressure must be checked by a manometer installed as closely as pos sible to the pressure connection To avoid pump overload caused by an impermissibly high pressure a pres sure relief valve or a rupture disc with return to the supply tank must be installed as closely as possible to the pump s pressure connection Another option of pressure limiting is to mount a pressure relief valve directly to the pump During operation of a pump that has to pump media via a non return valve in a pressurized circuit e g reserve pump in a lubricant circuit intake problems can occur if the inlet pipe is filled with air In this case the pressure pipe must be bled directly upstream of the non return valve This can be carried out by a bleeding valve with return or a throttled bypass for example 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT Tab 6 8 Bleeding valve and throttled bypass Bleeding valve with return If none of the measures described is carried out the volum
9. place by repeated quick on off switching of the driving motor jog mode without reaching full soeed until proper operation of the device is evident This applies particularly when a cold pump is to start with already heated medium The reason for this is to achieve slow heat ing of the pump and prevent the pump seizing through thermal shock Proper function indicated by noise generation or on the pressure gage should be reached after max 30 seconds First of all run the pump at zero pressure or low pressure for a couple of minutes after switching on the motor Bleed the plant on the distribution pipes preferably at the highest point Pressure loading can be gradually increased up to the desired operating pressure max permissible pressures see chapter 4 Technical data Check the temperature of the medium and that of the pump after the intended operating characteristics have been reached Checkpoints on the pump are the bearing locations the housing and the shaft seal The temperatures observed on the pump surface may be approx 10 C above medium temperature Check the fluid level of the plant once more and top up if necessary Check the final operating temperature after several hours running time see chapter 4 Technical for max permissible temperatures Check the static seals on the suction and pressure connections and the pump s joints for leakages Check the threaded connections for leakages Such leakages can be e
10. pumps with universal valve KF 32 80 U2 the following definition shall apply when looking at the pump shaft end Direction of rotation right and left Direction of discharge consistent p Suction side p Pressure side 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT 6 4 Change of the direction of rotation Change of the direction of rotation the case of KF R and KF L pump types i e pure clockwise or anticlockwise rotating pumps is only possible by converting the pump The manufacturer normally carries out the conversion work and the customer should do this only in case of an emergency Pumps in noise optimized version cannot be converted Guarantee and manufacturer responsibility e All warranty claims and manufacturer responsibility shall be void when improper conversation work takes place Danger of property damage due to incorrect installation Improper retrofitting can lead to damages and malfunctions in the unit and in the plant e Permit only expert and technically qualified personnel to work on the device Danger of leaks on the unit When altering the unit seals that are removed damaged or jammed can lead to leaks during operation e Do not remove damage or jam seals Gefahr von Beschadigung am Gerat The cover or pressure relief valve and housing are fixed to each other with adapter sleeves or dwowel pins If the bearings are damaged when a
11. result in death due to body parts hair or clothing getting caught or wrapped up Protect rotating parts e g coupling and shaft ends against uninten tional contact Close any maintenance openings when using bell housings Do not operate the device without safeguards BKFOOO4EN_D0024710002 06 Mount pump to bellhousing foot or housing and pay attention to careful alignment and correct fitting position see chapter 4 Technical data Tighten all fastening screws applying the torque as prescribed by the manufacturer of the bellhousing avoiding any twisting of the pump in the process without fail 2011 01 10 KRACHT 48 Transfer Gear Pumps KF 4 112 e Remove the protective plugs in the pump s suction and pressure con nections Danger due to exposed gears Gears can pull in and crush or cut off fingers and hands e Do not reach into the gears e Put the device into operation with connected lines only Danger due to hazardous fluid Danger of death upon contact with hazardous fluids and when inhaling va pours from these liquids e Comply with the safety data sheets and regulations on handling the hazardous liquids e Collect and dispose leaks of hazardous materials so that no hazards arise for people or the environment e Comply with national and international rules at the place of installation e Wear suitable protective clothing Wet devices interiors with fluid being
12. the device and to the up or downstream plant elements Breakage can lead to parts flying around uncontrolled or to fluids squirting out which can lead to accidents and severe injuries or even result in death e Never allow positive displacement pumps to pump against closed gates e Apressure relief valve or other kind of over pressure safeguard must be installed as close as possible to the pump pressure connection The pressure relief device must be dimensioned so that the entire delivery volume can be conducted through it with the lowest possible pressure or must be depressurized e Do not put the device into operation without a pressure relief device Danger due to hot surfaces When operating the device with hot media there is a danger of being burned and scalded when touching the hot surfaces e At medium temperatures above 60 C take measures against uninten ded contact e Wear safety gloves Danger of malfunctions through polluted medium When filling the storage tank with the medium impurities or small parts can get into the tank and cause damage or malfunctions on the unit and in the system e When filling the storage tank pay attention to the greatest possible cleanliness Before opening clean filler screw and shutoff on fluid transport and stor age tank Check media tank for contamination and clean if necessary On no ac count remove the filter screen on the filler neck or the filter in
13. underpressure Undercutting the permissible underpressure can lead to a decrease in the delivery rate due to short filling of the pump high noise emission and cav itation Furthermore in shaft seals the sealing lip can lift up allowing air to be sucked in e Thepermissible pressure atthe pump inlet shall not be lower than value De min aS stated in the chapter 4 Technical data An exception to this is the pump s starting state during which a pressure of 0 4 bar absolute is tolerable for max 30 minutes BKFOOO4EN_D0024710002 06 2011 01 10 41 KRACHT 6 5 2 Pressure line 42 Transfer Gear Pumps KF 4 112 Damage or failure of the shaft seal due to high supply pressure Exceeding the permissible supply pressure can lead to a failure of the shaft seal or to impermissible heating and increased wear e The permissible pressure at the pump inlet must not exceed the value De max aS Stated in the chapter 4 Technical data NES Danger due to breakage or squirting fluids Operating the device with impermissibly high pressures can lead to damage to the device and to the up or downstream plant elements Breakage can lead to parts flying around uncontrolled or to fluids squirting out which can lead to accidents and severe injuries or even result in death e Never allow positive displacement pumps to pump against closed gates e pressure relief valve or other kind of over pressure safeguard
14. 11 12 13 14 See section section 3 3 Types of seals for further seal types KRACHT Retaining ring Parallel key Hexagonal screw Adapter sleeve Valve Adjusting washer Retaining ring 15 KRACHT Transfer Gear Pumps KF 4 112 3 2 2 KF 4 112 R L D with pressure relief valve Tab 3 4 Basic construction KF 4 112 R L D ZZ 1 3 4 8 g 2 y LAL ES x IN re OS 12227177 J T z K OTE YAN WEN S LLL lt ANN a Z x N Ad 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 Tab 3 5 Basic construction KF 4 112 R L D Description Valve cover O Ring Housing Driven shaft Driving shaft Plain bearing bush Retaining ring Rotary shaft lip seal Set So abe e xc Parallel key 10 11 12 13 14 15 16 17 KRACHT Set screw Hexagonal nut Retaining screw O Ring Compression spring Valve cone Adapter sleeve Hexagonal screw See section section 3 3 Types of seals for further seal types BKFOOO4EN_D0024710002 06 2011 01 10 17 KRACHT Transfer Gear Pumps KF 4 112 3 2 3 KF 4 25 U with universal valve Tab 3 6 Basic construction KF 4 25 U 1 2 345 6 7 8 10 11 12 13 14 15 LALA F i S J ar NN AAA SSNS e cy M N Key PERS desse
15. 4 connections for KF 4 12 SAE 1 connections for KF 16 25 197 Noise optimized version for aerated oils and vacuum 198 Mechanical seal with connection for liquid seal quench 232 SAE 2 connections for KF 50 80 SAE 2 1 2 connections for KF 100 112 304 Bearing bushings Iglidur X APmax 10 bar 317 Noise optimized version for aerated oils and vacuum bearing bushings Iglidur X AP max 10 bar 332 Version for low viscous media only in connection with material GJS bearing bushings Iglidur X Vmin 4 2 5 at Ap 10 bar 353 Noise optimized version for aerated oils and vacuum bearing bushings DP4 leadfree 355 Bearing bushings Iglidur X SAE 34 connections for KF 4 12 SAE 1 connections for KF 16 25 APmax 10 bar 363 Version for low viscous media only in connection with material GJS bearing bushings Iglidur X Vmin 4 2 5 at Ap 10 bar SAE connections for KF 4 12 SAE 1 connections for KF 16 25 391 Noise optimized version for aerated oils and vacuum SAE 2 connections for KF 50 80 SAE 2 1 2 connections for KF 100 112 gt Particularities in noise optimized pumps e Air trapped in the medium or too high negative pressure can result in delivery rate reduction for pumps in noise optimized version e Measures for noise optimisation are only feasible for one rotational di rection and only effective for aerated oils or vacuum 24 2011 01 10 BKFOO04EN D0024710002 06 Transfer Gea
16. Danger due to hot surfaces When operating the device with hot media there is a danger of being burned and scalded when touching the hot surfaces Let the device cool off first wnen the medium temperature is over 48 e Wear safety gloves 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT 3 Device description 3 1 General points BKFOOO4EN_D0024710002 06 KF series pumps are external gear pump types that work according to the positive displacement principle When rotated two gears being engaged with each other cause volume ex pansion by opening the tooth gaps in the pump inlet suction side so that the medium can enter while a corresponding volume is being displaced in the pump outlet pressure side through engagement of the teeth into the filled tooth gap Fluid transport takes place through entrainment in the tooth gaps along the wall of the wheel chamber The so called geometric flow rate V is being displaced per wheel rotation A value that is stated in technical docu ments as rated volume V to specify the pump size The actually delivered amount of liquid does not correspond with the theo retical value it is being reduced through losses due to the necessary toler ances The losses are less the lower the operating pressure and the higher the viscosity Gear pumps are self priming within wide limits The displacement cycle de scribed initially takes place without exhibiting
17. Operating instructions BKFOOO4EN Transfer Gear Pumps KF 4 112 BKF0004EN 00024710002 06 KRACHT Englisch 2011 01 10 Table of Content 1 General points 5 1 1 About the documentation 5 1 2 Manufacturer s address 5 1 3 Intended use o 2 Safety 7 2 1 oafety instructions and symbols 7 2 2 Staff qualification and training T 2 3 General safety instructions 7 2 4 Hazard statements 8 3 Device description 13 3 1 General points 13 9 2 Basic construction 14 3 2 1 KF 4 112 R L B with cover 14 3 2 2 KF 4 112 R L D with pressure relief valve 16 3 2 3 KF 4 25 U with universal valve 18 3 2 4 KF 32 80 U with universal valve 20 3 3 Types of seals 22 3 4 Type key PA 3 5 Important special numbers 24 4 Technical data 25 4 1 General characteristics 25 4 2 Overview of nominal sizes 26 4 3 Permissible speed 26 4 4 Overview materials 2f 4 5 Operating pressure and fluid temperature 20 4 6 Dimensions 29 5 Transport and storage 30 5 1 Transport damage 30 5 2 Transport 30 5 3 Corrosion protection 32 6 Installation 33 6 1 General points 33 6 2 Noise reduction 34 6 3 Definition of the direction of rotation and pumping 34 flow 6 3 1 KF 4 112 with end cover or pressure relief valve 35 6 3 2 KF 4 25 U with universal valve 36 6 3 3 KF 32 80 U with universal valve 36 6 4 Change of the direction of rotation 37 6 5 Design of suction and pressure line 39 6 5 1 Suction line 39 6 5 2 Pres
18. Type of Operating pressure Fluid temperature seal Suction side Pressure side De min bar abs De max bar Pp bar Pb max bar perm conti pressure nous pressure peaks 1 90 woo 2 150 3 2 200 4 5 150 10 6 10 200 7 150 9 0 6 120 0 5 18 150 19 sor 257777 40 90 20 10 120 23 0 5 30 30 25 10 150 31 1 30 32 0 5 120 4 74 200 7 74 10 150 0 1 0 2 19 74 90 32 74 120 See type key and type designation at pump KF Heed restrictions of p 0 65 bar absolute for universal design KF U Temporary during starting state 0 4 bar absolute See table 4 6 for permissible pressures Type of seal 31 p 20 bar 28 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT Tab 4 6 Permissible operating pressures p for seal types 1 2 7 and 19 Max speed Nmax in rpm KF 4 80 KF 100 112 Permissible pressure p max in bar Permissible pressure p in bar 750 6 6 1000 5 5 1500 4 3 5 2000 3 2 5 3000 2 1 5 4 6 Dimensions BKFOOO4EN_D0024710002 06 Danger of property damage due to overload Overloads in pumps with Iglidur X bearings can cause the bearings to wear prematurely e Never exceed the max permissible Ap 10 bar Danger of property damage when simultaneously utilizing multiple operating limits When simultaneously utilizing multiple operating l
19. a stated on the motor type plate must be checked for conformity to the required operating data Adjust the overload protection to the correct value Check the rotational drive direction of the pump before switching on 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT 7 Operation start up 7 1 Preparation BKFOOO4EN_D0024710002 06 Hazard caused by rotating parts Rotating parts can cause accidents with severe injuries or result in death due to body parts hair or clothing getting caught or wrapped up e Protect rotating parts e g coupling and shaft ends against uninten tional contact e Close any maintenance openings when using bell housings e Do not operate the device without safeguards Danger due to exposed gears Gears can pull in and crush or cut off fingers and hands e Do not reach into the gears e Put the device into operation with connected lines only Danger due to hazardous fluid Danger of death upon contact with hazardous fluids and when inhaling va pours from these liquids e Comply with the safety data sheets and regulations on handling the hazardous liquids e Collect and dispose leaks of hazardous materials so that no hazards arise for people or the environment e Comply with national and international rules at the place of installation e Wear suitable protective clothing Danger due to hot surfaces When operating the device with hot media ther
20. anger due to falling and or loads falling over Due to the size and weight of the unit accidents can occur resulting in se vere injuries or death during transport and shipping Compliance with applicable industrial safety requirements is mandatory Use only suitable means of conveyance and lifting tackle with sufficient load bearing capacity Attach lifting tackle only to suitable points see table 5 1 and table 5 2 Attach the lifting tackle in such a manner that it cannot slip The device s centre of gravity must lie between the lifting tackle mount ing points on the device Secure the device so that toppling over and falling down is impossible Always avoid jerks impacts and strong vibrations during transportation Never walk under suspended loads never work under suspended loads To prevent damage to the device be extremely cautious when shipping or transporting Wear suitable protective clothing 30 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT a Handling aid e Whentransporting individuals devices the eyebolts can be screwed into the connectiing flange as a handling aid Tab 5 1 Example for safe transport of pumps H OOF 61 J Hazard from falling and tipping loads Due to the size and weight of the device accidents can occur resulting in severe injuries or death during transport and shipping e For pump devices do not use eye
21. appreciable pressure build up Only after setting external loads for example through delivery head outlet resistances line elements etc the required working pressure will arise to overcome these resistances As usual with so called rigid pumps i e non axial play compensated pumps the lateral clearance between gear and front face has been set in such a way that the maximum allowable operating pressure is managed in an adequate and secure way The medium lubricates the pump s friction bearings and shaft seal The pump s operating life will be reduced if the medium contains abrasive ingre dients The shaft sealing pocket is connected to the pump s suction side Therefore the max permissible suction side pressure is dependent on the type of seal Tab 3 1 Functional principle external gear pumps By p Suction side p Pressure side 2011 01 10 13 KRACHT Transfer Gear Pumps KF 4 112 3 2 Basic construction 3 2 1 KF 4 112 R L B with cover Tab 3 2 Basic construction KF 4 112 1 23 4 5 b 8 9 gt Z im es e 1011 Direction of rotation Right and left 14 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 Tab 3 3 Basic construction KF 4 112 Description 1 f gt ee S Cover O Ring Housing Driven shaft Driving shaft Plain bearing bush Rotary shaft lip seal BKFOOO4EN_D0024710002 06 2011 01 10 8 10
22. asily eliminated by simply retightening the threaded connections Also check all motor and pump fastening screws after a few hours of operation 2011 01 10 57 KRACHT Transfer Gear Pumps KF 4 112 8 Removal 8 1 General points NOTICE Danger of property damage due to insufficiently qualified personnel Improper work can lead to damages and malfunctions in the device and in the plant e Permit only expert and technically qualified personnel to work the device Danger of property damage due to a lack of cleanliness A lack of cleanliness can lead to damages and malfunctions in the device and in the plant e Payattention to cleanliness during all work e Close all openings with protective caps to prevent dirt from penetrating into the system 8 2 Disassembling the pump Hazard caused by rotating parts and fluid squirting out During all work on the device rotating parts and squirting fluids can lead to acciedents and severe injuries or even result in death e Depressurize all connection lines during all work on the device e Depressurize or disconnect the driving motor during all work on the de vice e Securely prevent the motor and device from restarting during work e Wear suitable protective clothing 58 2011 01 10 BKFOOO4EN_D0024710002 06 KRACHT Transfer Gear Pumps KF 4 112 Danger due to hazardous fluid Danger of death upon contact with hazardous fluids and when i
23. be found in the chapter 3 Device description and in the chapter 4 Technical data If you have any questions about this operating manual please contact the manufacturer 1 2 Manufacturer s address 1 3 Intended use BKFOOO4EN_D0024710002 06 Kracht GmbH Gewerbestra 5e 20 58791 Werdohl phone 49 0 23 92 935 0 fax 49 0 23 92 935 209 email info kracht eu web www kracht eu The device is a pump for continuous delivery of liquids The various seal var iants and materials enable use with different media The device has been designed for operation with fluids Dry operation is not permitted The medium must guarantee a minimum lubrication The medium must not contain any abrasive constituents Petrols solvents etc are not permissible Use in explosive areas is not permissible The operator must guarantee that the medium to be conveyed is compatible with the materials used in the device see Overview materials in the chapter 4 Technical data Chemical expertise is required for that 2011 01 10 9 KRACHT Transfer Gear Pumps KF 4 112 The maximum permissible operating data listed in the chapter 4 Technical data must always be observed Deviations from the above mentioned data and operating conditions require express approval by the manufacturer and or are specified on the type plate Type plates or other references on the device must not be removed nor made illegible or irrecognisa
24. ble In cases of noncompliance all warranty claims and manufacturer responsi bility shall be void 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 2 Safety KRACHT 2 1 Safety instructions and symbols N The safety notices in these operating instructions are marked with caution symbols Non compliance can lead to hazards for people and the device In addition the safety instructions are marked with signal words They have the meanings as explained below Caution Identification of a low risk hazard which could lead to minor or medium bodily injury if not avoided Warning Identification of a potential medium risk hazard which would lead to death or severe bodily injury if not avoided Danger Identification of an immediate hazard which would result in death or severe bodily injury if not avoided Notice Flagging of notices to prevent property damage Flagging of special user tips and other especially useful or important infor mation 2 2 Staff qualification and training The staff designated to install operate and maintenance the device must be properly qualified This can be through training or specific instruction Staff must be familiar with the contents of this operating manual 2 3 General safety instructions BKFOOO4EN_D0024710002 06 The operational safety of the device delivered is only guaranteed when it is used for the intended purpose see chapter 1 General points
25. consumption degree of filter soiling etc contributes to early problem detection 60 2011 01 10 BKF0004EN D0024710002 06 KRACHT Transfer Gear Pumps KF 4 112 Danger of property damage due to a lack of cleanliness A lack of cleanliness can lead to damages and malfunctions in the device and in the plant e Pay attention to cleanliness during all work e Close all openings with protective caps to prevent dirt from penetrating into the system NOTICE Malfunctions due to leaking lines and connections Leaks can occur and air can be sucked in if lines or connections are not tight Suctioned air leads to a decrease of the delivery rate and foams up the medium e Make sure all lines and connections are tight AN DANGER Danger due to breakage or squirting fluids Using damaged connections and lines can cause parts to fly around un controlled or fluids to squirt out which can lead to accidents and severe injuries or even result in death e Immediately replace damaged connections pipes and hose lines JN DANGER Danger due to electric voltage Danger of death due to electric shock e Follow the special safety regulations during all work on electrical instal lations e Only allow electricians to work on electrical systems Hazard caused by rotating parts and fluid squirting out During all work on the device rotating parts and squirting fluids can lead to acciedents and severe injuries or e
26. e Do not reach into the gears e Putthe device into operation with connected lines only 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT BKFOOO4EN_D0024710002 06 Danger due to falling and or loads falling over Due to the size and weight of the unit accidents can occur resulting in se vere injuries or death during transport and shipping Compliance with applicable industrial safety requirements is mandatory Use only suitable means of conveyance and lifting tackle with sufficient load bearing capacity Attach lifting tackle only to suitable points see table 5 1 and table 5 2 Attach the lifting tackle in such a manner that it cannot slip The device s centre of gravity must lie between the lifting tackle mount ing points on the device Secure the device so that toppling over and falling down is impossible Always avoid jerks impacts and strong vibrations during transportation Never walk under suspended loads never work under suspended loads To prevent damage to the device be extremely cautious when shipping or transporting Wear suitable protective clothing 2011 01 10 11 KRACHT Transfer Gear Pumps KF 4 112 Danger due to hot surfaces When operating the device with hot media there is a danger of being burned and scalded when touching the hot surfaces At medium temperatures above 60 C take measures against uninten ded contact e Wear safety gloves
27. e from the manufacturer e The tank for the liquid seal must be placed above the pump e The installation position is restricted and the quenching connection shall be directed upward e Check of the fluid level in the tank must be possible at any time a Flushing connection sealing cavity e second port on the device enables purging of the sealing cavity and draining of the seal liquid BKFOOO4EN_D0024710002 06 2011 01 10 o3 KRACHT Transfer Gear Pumps KF 4 112 7 2 2 Seal variants with liquid seal Tab 7 1 KF 4 112 with liquid seal Quench Types of seals Types of seals Triple rotary shaft lip Type of seal 5 4 7 19 32 4 7 19 32 seal Special number 198 Special number 74 on request o4 2011 01 10 BKFOOO4EN D0024710002 06 KRACHT Transfer Gear Pumps KF 4 112 7 3 Setting the pressure relief valve Applies for pumps with built on pressure relief valve Type designation KF D15 or KF D25 Fig 7 1 Pressure setting KF 4 112 D response pressure lower response pressure higher Danger of the pump overheating The series D pressure relief valves are exclusively used to protect the pump The valves must only respond for short durations Permanent drain ing of the volumetric flow through the valve will destroy the pump through overheating e Make sure the valve responds only briefly For pressure setting on the pressure relief valve see fig
28. e is a danger of being burned and scalded when touching the hot surfaces e At medium temperatures above 60 C take measures against uninten ded contact e Wear safety gloves 2011 01 10 51 KRACHT 52 Transfer Gear Pumps 4 112 Danger of property damage due to incorrect commissioning Improper commissioning can lead to damages and malfunctions in the de vice and in the plant Permit only expert and technically qualified personnel to work on the device Comply with the permissible operating data such as rotational speed pressure temperature permissible media etc see chapter 4 Techni cal data Pay attention to cleanliness during all work Before starting the system make sure that a sufficient quantity of the service fluid is extant to avoid dry running Before starting the plant pumps and inlet line must be filled with oper ating fluid to prevent damage to the pump and the shaft seal during dry runs That also guarantees pump suction For pumps with liquid buffer quench fill the sealing cavity with a suit able confining fluid before it is used for the first time Make sure that all lines and connections are tight and that no leakages can occur or air can be sucked in Check the permissible operating data against the operating states to be expected Check all fastening screws on the device Fill the pump and suction line with the operating fluid In the case of
29. e of the pressure pipe between the pump and the non return valve must be at least 75 of the inlet pipe volume BKFOOO4EN_D0024710002 06 2011 01 10 43 KRACHT Transfer Gear Pumps KF 4 112 6 6 Mounting the clutch 44 Danger of property damage due to falsely dimensioned coupling An incorrect design can lead to premature failure of the coupling due to breakage or wear e When dimensioning the coupling pay attention to safe dimensioning to be able to transfer the expected maximum torque reliably and perma nently e Take the vibrations peak torques and temperatures into consideration The permissible values from the coupling manufacturer must not be ex ceeded e Comply with the coupling manufacturer s installation rules When mounting the clutch keeping the E measure exactly is of the essence so that the clutch will remain axially movable when used In order to avoid any frontal pressure against the elastic gear rim measure E should each be considered as minimum in the case of an axial displacement If the shaft clearance is less than clutch clearance E one of the shaft ends can easily extend into the gear rim Size dy corresponds to the max shaft diameter that may extend with the parallel key into the gear size du If there is the chance to offset the parallel key i e only the shaft extends into the gear rim the size of the shaft may be increased up to 2 mm below the specified d s
30. ecked at least befor each shift begins The outer but also the inner shaft seal could be leaking if the filling level should dorp unusually fast within a short period of time The confining fluid will then leak into the coupling space or it will be sucked into the pump thereby mixing with the medium If the filling level should rise the inner shaft seal may probably be leaking and the confining fluid is begin mixed with the pressurised medium Stop plant operation immediately in both cases 9 6 Rotary shaft lip seal Rotary shaft lip seals are particulary prone to wear for functional reasons and must accordingly be carfully checked Excessicely high supply pressure or negative suction pressure wrong rotational direction or pollution leads to in creased wear increased and impermissible temperature rises omall amounts of leakage however are indispensable for function The per missible amount of leakage though is highly dependet on the operational conditions and cannot be quantified If there are excessive amounts of leakage stop pump operation immediately Replace the rotary shaft lip seal BKFOOO4EN_D0024710002 06 2011 01 10 63 KRACHT Transfer Gear Pumps KF 4 112 Increased wear on the rotary shaft lip seal should be taken into account in the case of vertical pump installation 9 7 Mechanical seal 9 8 Clutch 9 9 Screw joints 9 10 Damage Mechanical seals are particularly prone to wear for functional reasi
31. edia temperature at the pump inlet Checkpoints on the pump are the bearing lo cations the housing and the shaft seal If the measured temperatures are higher than the permissible values this is an indication of wear or bearing damages The pump must be replaced in this case 9 12 Bearing gear wheel chamber housing Like shaft seals bearings gear and wheel chamber housings are wear items Wear largely depends on the occurring loads life cycle as well as type and proportion of solids in the medium Wear cannot be identified from the outside The condition of a pump however can be analysed by the volumetric effi ciency factor Decrease of the efficiency factor would normally indicate wear Therefore a check on all operating data such as delivery pressure temper ature drive data degree of filter contamination should also be carried out during maintenance work Further investigations into the cause are necessary in the event of major de viations gt 10 96 to the reference values This helps detecting premature pump failure in time The pump must immediately be taken out of service at a drop of delivery or pressure to 80 9o of the original values The achieved values at initial commissioning serve as reference in this case BKFOOO4EN_D0024710002 06 2011 01 10 65 KRACHT Transfer Gear Pumps KF 4 112 10 Repairs 10 1 General points The term repairs covers e Troubleshooting in other words establishing damage det
32. ermining and localising the reason for the damage e Elimination of the damage in other words eliminating the primary cau ses and replacing or repairing faulty components 10 2 Troubleshooting Leaks are the most frequent problem If these occure on the pipelines they can be eliminated by straightforward tightening of the screw joints If the device itself is leaking the respective seals have to be replaced 10 3 Elimination of damage Repair damage onsite predominantly by replacing the defective device The device itself is generally repaired by the manufacturer If corresponding expertise and sufficient equipment is available the consum er or OEM can also make the repairs For support spare parts lists and sectional drawings are available They can be requested from the manu facturer NOTICE Danger of property damage due to incorrect work and use of non original spare parts Improper work can lead to damages and malfunctions in the device and in the plant That also applies to the use of non original spare parts e Permit only expert and technically qualified personnel to work on the device e Use only genuine original spare parts 10 4 Return If the device has to be repaired or checked over the manufacturer s premises it must be packed suitably for transport In addition a safety data sheet for the medium used must be enclosed with the device In case of well known mineral oils at least the exact t
33. g seal material Missing confining fluid Separating can defective Sealing wear due to poorly lubricating medium Sealing wear through abrasive components in medium Sealing wear through curing medium Gland lid not sufficiently tightened Clutch wear Incorrectly aligned or loose clutch Axial clutch clearance insufficient Clutch overloaded Temperature too high Magnetic coupling torn off Magnetic coupling under dimensioned Pressure too high Driving motor oversized Too high starting torque Too high operating temperature Pump is blocking due to foreign objects Short opera tional lives Wear on bearing gear and housing parts Wear through abrasive components Wear due to poorly lubricating medium Too low viscosity Check corrosion material compatibility Too high operating pressure for the media properties 70 2011 01 10 BKFOOO4EN_D0024710002 06
34. hat presses against the fitting key or the shaft 46 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 6 7 Mechanical installation Hazard caused by rotating parts and fluid squirting out During all work on the device rotating parts and squirting fluids can lead to acciedents and severe injuries or even result in death Depressurize all connection lines during all work on the device Depressurize or disconnect the driving motor during all work on the de vice Securely prevent the motor and device from restarting during work Wear suitable protective clothing NOTICE Malfunctions due to leaking lines and connections Leaks can occur and air can be sucked in if lines or connections are not tight Suctioned air leads to a decrease of the delivery rate and foams up the medium Make sure all lines and connections are tight Before installation the device must be checked for transport damage and soiling Any preserving agents must be removed before installation using ben zine or solvent Clean the pipework of dirt scale sand swarf etc prior to installation Welded pipes in particularly must be pickled or flushed Cotton waste must not be used for cleaning Mount clutch and clutch halves respectively to pump and drive see sec tion 6 6 Mounting the clutch Hazard caused by rotating parts Rotating parts can cause accidents with severe injuries or
35. htening torques for fastening screws Nominal size 4 25 32 80 100 112 Tightening torque 25 Nm 49 Nm 79 Nm See type key and type designation at pump KF In the case of pumps having seal type 6 the mechanical seal must be re placed in addition During this process the spring coiling direction must be observed Heed the assembly instructions of the respective manufacturer when replacing the mechanical seal 2011 01 10 BKFOOO4EN D0024710002 06 KRACHT Transfer Gear Pumps KF 4 112 6 5 Design of suction and pressure line N DANGER Danger due to breakage or squirting fluids Using unsuitable connections and lines can lead to breakage Parts flying around uncontrolled or squirting fluids can lead to accidents with severe injuries or even lead to death Use only connections and lines approved for the expected pressure range Comply with each manufacturer s regulations Danger of property damage due to distortion The load on the device due to impermissible external loads can lead to malfunctions or to breakage of the flange or housing e Pipelines must be fitted absolutely tension free to the device connec tions Pipelines must be designed in such a way that no tension e g caused by changes in length due to fluctuations in temperature can be trans ferred to the device NOTICE Danger of property damage caused by foreign bodies in the device During instal
36. imits see chapter 4 Technical data the pump could become damaged or prematurely wear e Do not use minimum and maximum parameters at the same time For example maximum operating pressure ist not permissible in con nection with low speed and or low viscosity Danger of property damage when pumping aqueous fluids When pumping aqueous dispersions or solvents low pressure on the inlet port can lead to cavitation damage on the pump e Comply with the media specific attributes e When designing the inlet line make sure the inlet port pressure on the pump inlet during operation is always higher than the steam pressure of the pumping fluid While doing so also take the altitude of the site of the device over mean sea level into consideration e For aqueous dispersions and solvents limit the operating temperature to max 50 C install the pump underneath the liquid level and limit the rotational speed to maximal 1500 rpm Dimensions of the device can be found in the relevant technical data sheets 2011 01 10 29 KRACHT Transfer Gear Pumps KF 4 112 5 Transport and storage 5 1 Transport damage Inspect the device for shipping damage as soon as the delivery has been received If shipping damage is discovered inform the shipping company If proper operation of the device is impaired by the damage the device must be replaced or repaired In that case contact the manufacturer 5 2 Transport D
37. ing 4 Socket head cap screw 18 Retaining ring 5 Connection elbow 19 Rotary shaft lip seal 6 Gasket 20 Housing 7 Socket head cap screw 21 Plain bearing bush 8 Rod 22 Driving shaft 9 Piston 23 Driven shaft 10 Valve cone 24 O Ring 11 Compression spring 25 Cover 12 Valve housing 26 Valve 13 O Ring 2 Adjusting washer 14 Cover 28 Retaining ring See section section 3 3 Types of seals for further seal types BKFOOO4EN_D0024710002 06 2011 01 10 21 KRACHT 3 3 Types of seals Tab 3 10 Type of seals KF 4 112 Transfer Gear Pumps KF 4 112 Pump with single rotary shaft lip seal Mounting F W Sealing materials 1 NBR 2 FKM 3 PTFE 9 EPDM 23 31 FKM low tem perature Pump with triple rotary shaft lip seal for vac uum and normal oper ation with connection borehole G 1 8 for lig uid seal quench Mounting F W on request 22 Pump with single rotary shaft lip seal and out board bearing Mounting G X Sealing materials 1 NBR 2 FKM 3 PTFE SN 1 ANY un 1 A GZ 7 Pump with mechanical seal Mounting F W Sealing materials 5 FKM 6 PTFE 20 EPDM Pump with double rota ry shaft lip seal with connection borehole G 1 8 for liquid seal quench Mounting F W Sealing materials 4 PTFE 7 FKM 19 NBR 32 EPDM ES va Dix Pump with double rota ry shaft lip seal for vac uum operation with connec
38. ize in order not to obstruct the gear rim in its axial movability The permissible displacement values of the elastic clutches stated represent general guide values taking a clutch loading up the the clutch nominal torque and an operating speed n 1500 rpm as well as an occurring ambient tem perature of 30 C into account Consultation with the manufacturer is necessary for deviating operating conditions The displacement data may only be used individually in each case and in case of simultaneous appearance in proportion only Increasing the service life of the coupling e Careful and exact shaft alignment inreases clutch life 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 Fig 6 1 Displacements aligning the clutch KRACHT i Clutch clearance E Shaft with parallel key extends into the gear d Tab 6 9 Types of coupling 19 24 28 38 42 48 55 65 75 Type of coupling 19 24 24 28 28 38 38 45 42 55 48 60 55 70 65 75 75 90 Clutch clearance E 16 18 20 24 26 28 30 35 40 Dimension 2 2 2 5 3 3 3 5 4 4 5 5 Dimension di 18 27 30 38 46 51 60 68 80 Dimension dw 12 20 22 28 36 40 48 55 65 Max axial displace 1 2 1 4 1 5 1 8 2 0 2 1 2 2 2 6 3 0 ment Max radial displace AK 0 20 0 22 0 25 0 28 0 32 0 36 0 38 0 42 0 48 ment n 1500 1 min Max angular dis AK 1 2 0 9
39. lation when using unsuitable sealing materials foreign bodies can getinto the interior of the device or the plant due to a lack of cleanliness and cause malfunctions there e During installation do not use any hemp or filler as sealing material 6 5 1 Suction line Suction and pressure hoses Installation of suction and pressure hoses diminishes the noise level of hydraulic systems Some hose manufacturer offer special highly flexi ble suction hoses for this purpose e Lay pressure hoses in sufficiently large radii Malfunction due to incorrectly designed inlet line Due to excessive underpressure an incorrectly designed inlet line can lead to a reduction of the delivery rate increased noise emissions and cavitation Design the inlet line with extreme care since it will strongly influence the pump s performance BKFOOO4EN_D0024710002 06 2011 01 10 KRACHT 40 Transfer Gear Pumps 4 112 The suction line must be piped as short as possible and in a straight line Avoid large suction heights Additional line resistance such as formed parts fittings and closed meshed suction filters increase the pipe resistance of the suction line and must be avoided The negative pressure in the suction line is calculated from the sum of all suction side resistances and the suction height considering the media spe cific data Check the underpressure e negative pressure can be controlled by fitting a
40. lead to accidents with severe injuries or even lead to death e Use only connections and lines approved for the expected pressure range e Comply with each manufacturer s regulations eem Danger due to breakage or squirting fluids Using damaged connections and lines can cause parts to fly around un controlled or fluids to squirt out which can lead to accidents and severe injuries or even result in death e Immediately replace damaged connections pipes and hose lines 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT TE Hazard caused by incorrect direction of rotation Operating the device with the incorrect direction of rotation can lead to damage to the device and to the up or downstream plant elements Break age can lead to parts flying around uncontrolled or to fluids squirting out which can lead to accidents and severe injuries or even result in death e Always pay attention to the correct direction of rotation when installing the pumps e Always pay attention to the correct direction of rotation when connecting the motors e Secure the fitting keys against flying off when monitoring the direction of rotation DANGER Danger due to electric voltage Danger of death due to electric shock e Follow the special safety regulations during all work on electrical instal lations e Only allow electricians to work on electrical systems
41. lets on the motor to transport the pump devices They can only support the weight of the motor Tab 5 2 Examples for safe transport of pump units BKFOOO4EN_D0024710002 06 2011 01 10 31 KRACHT Transfer Gear Pumps KF 4 112 5 3 Corrosion protection 32 The device s function is tested in the plant with mineral hydraulic oil Then all connections are closed The remaining residual oil protects the interior parts for about 6 months Clean bare outer metal parts have also been protected by anti corrosive oil or protective metal paint for a period of 6 months against corrosion The device must not be exposed in the influence of the weather and major fluctuations in temperature during transport and storage and must be stored in a dry place If the device is stored over a longer period it must be treated on the inside and outside with a suitable corrosion protecting oil In addition it must be protected from humidity by a humidity absorbing agent If high air humidity or aggressive atmosphere is to be expected during trans port suitable corrosion prevention measures must be carried out Corrosion damage on units with EPDM seals The functionality of units with EPDM seals is not tested There is no pres ervation of the interior parts If the unit is not put into operation immediately corrosion damage can occur e Protect the unit by using suitable corrosion preventing measures NOTICE Chemical impact
42. nd cause malfunctions there e Payattention to cleanliness during all work 2011 01 10 33 KRACHT 6 2 Noise reduction Transfer Gear Pumps KF 4 112 Measures for sound optimizing In view of optimising noise protection it is advisable to mount a bell housing with vibration damper between pump and motor as well as vibration damper between motor and mounting surface Suction and pressure piping must be able to move freely or it needs to be elastically suspended Installation of suction and pressure hoses diminishes the noise level of hydraulic systems Some hose manufacturers offer special highly flex ible suciton hoses for this purpose Installation of the pump above the liquid level diminished the noise level of hydraulic systems The pressure p on the pump s intake should be approx 0 8 0 9 bar absolute 6 3 Definition of the direction of rotation and pumping flow 34 DANGER Hazard caused by incorrect direction of rotation Operating the device with the incorrect direction of rotation can lead to damage to the device and to the up or downstream plant elements Break age can lead to parts flying around uncontrolled or to fluids squirting out which can lead to accidents and severe injuries or even result in death Always pay attention to the correct direction of rotation when installing the pumps Always pay attention to the correct direction of rotation when connecting the motors Secure the fi
43. nhaling va pours from these liquids Comply with the safety data sheets and regulations on handling the hazardous liquids Collect and dispose leaks of hazardous materials so that no hazards arise for people or the environment Comply with national and international rules at the place of installation Wear suitable protective clothing Danger due to hot surfaces When operating the device with hot media there is a danger of being burned and scalded when touching the hot surfaces Let the device cool off first wnen the medium temperature is over 48 C Wear safety gloves Remove the depressurised pipelines from the pump Seal the pump connections and pipelines to prevent dirt penetration Disassemble the pump Pull off clutch hub resp the driving pinion from shaft end using an ex tractor Danger of malfunction due to curing liquids Curing liquids can engage the device mechanically and make it unusable Immediately clean the pump or store it in such a way that curing is def initely prevented in cases where the pump was operated with curing liquids BKFOOO4EN_D0024710002 06 2011 01 10 59 KRACHT Transfer Gear Pumps KF 4 112 9 Maintenance 9 1 General points NOTICE Danger of property damage due to insufficiently qualified personnel Improper work can lead to damages and malfunctions in the device and in the plant e Permit only expert and technically qualified per
44. no hazards arise for people or the environment e Comply with national and international rules at the place of installation e Wear suitable protective clothing Danger due to hot surfaces When operating the device with hot media there is a danger of being burned and scalded when touching the hot surfaces e Let the device cool off first when the medium temperature is over 48 C e Wear safety gloves 9 2 Unusual noises 62 Some damage is indicated by unusual noises If there is a change in the dec ive s operating noise a thorough examination of the cause must always take place 2011 01 10 BKFOOO4EN D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT 9 3 Cleaning The pump shaft as well as the associated hardware must not run in dust ac cumulations Regular cleaning of the pump and its environment is therefore necessary Cleaning the pump using a steam jet cleaner is not permissible 9 4 Static seals The static seals on the device s separation joints and the connection lines must be periodically checked for leakproofness If there are any visible leaks immediately stop plant operation If the leaks cannot be stopped by simply retightening the connection replace all affected seals 9 5 Confining fluid level Checking the confining fluid filling level is mandatory for safe pump operation Top up the confining fluid as required If there is no automatic monitoring the filling level must be ch
45. ns and must accordingly be carfully checked Too high admission pressure wrong rotational direction frequent start ups gas or air portions in the oil or con tamination lead to increased wear increased leckage and impermissible temperature rises Small amounts of leckages however are indispensable for mechanical seal function The permissible amount of leackage though is highly dependent on the operational conditions and cannot be quantified If there are excessive amounts of leakage stop pump operation immediately Replace the mechanical seal In so doing heed the assembly instructions of the mechanical seal manufacturer Increased wear on the mechanical seal should be taken into account in the case of vertical pump installation Clutches must be maintained according to the specifications of the respective manufacturer All the screw joints must be checked at regular intervals to make sure they are tight fit Loose screw joints must be tightened and if necessary secured against loosening by e g Loctite medium stregth Check the pump as well as its environment regularly for damage such as dents in the clutch guard 9 11 Surface temperature 64 For identifying premature wear or pump overload it is useful to check the temperatures on the pump surface at regular intervals 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT This temperatures should never be much higher max 10 C than the m
46. on the device and the sealing materials Incompatibility between the preservation agents and the materials and elastomers used in the device can lead to damage of the device and the seals being used e Check to make sure the preservation agent is compatible with the ma terials and elastomers used in the device e Check to make sure the preservation agent is compatible with the media to be pumped 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 6 Installation 6 1 General points BKFOOO4EN_D0024710002 06 KRACHT Hazard caused by rotating parts and fluid squirting out During all work on the device rotating parts and squirting fluids can lead to acciedents and severe injuries or even result in death e Depressurize all connection lines during all work on the device e Depressurize or disconnect the driving motor during all work on the de Vice e Securely prevent the motor and device from restarting during work e Wear suitable protective clothing Danger of property damage due to insufficiently qualified personnel Improper work can lead to damages and malfunctions in the device and in the plant e Permit only expert and technically qualified personnel to work on the device E Danger of property damage due to a lack of cleanliness During installation foreign bodies can get into the interior of the device or the plant due to a lack of cleanliness a
47. pumped N DANGER Danger due to breakage or squirting fluids Using unsuitable connections and lines can lead to breakage Parts flying around uncontrolled or squirting fluids can lead to accidents with severe injuries or even lead to death e Use only connections and lines approved for the expected pressure range e Comply with each manufacturer s regulations Danger of property damage due to distortion The load on the device due to impermissible external loads can lead to malfunctions or to breakage of the flange or housing e Pipelines must be fitted absolutely tension free to the device connec tions e Pipelines must be designed in such a way that no tension e g caused by changes in length due to fluctuations in temperature can be trans ferred to the device 2011 01 10 BKFOOO4EN_D0024710002 06 KRACHT Transfer Gear Pumps KF 4 112 Connect suction and pressure side according to the marking on the pump or the information on the type plate see section 6 3 Definition of the direction of rotation and pumping flow Connect the pipework to the suction and pressure piping Always heed the respective manufacturer s instructions Mount a suitable tank for the liquid seal See chapter 7 Operation start up if applicable when operating the pump with liquid seal quench a Danger due to breakage or squirting fluids Operating the device with impermissibly high pressures can lead to damage to
48. pumps with liquid seal quench fill the sealing cavity using an appropriate confining fluid see section 7 2 Pumps with liquid seal quenching connection Checking the direction of rotation See section Change of the direction of rotation in chapter 6 Installation for any change in rotational direc tion 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT 7 2 Pumps with liquid seal quenching connection 7 2 1 General points NOTICE Danger of the failure of the seal due to a lack of sealing fluid A lack of sealing fluid can lead to a failure of the shaft seal and to increased temperatures and increased wear e Fillthe pump s sealing cavity with a suitable sealing medium The seal ing fluid must be compatible with the seals and materials used as well as with the pumping medium e The confining fluid s minimum and maximum filling level must be en sured using appropriate technical and or organisational measures e The liquid seal in the quenching connection must not be subjected to pressure or vacuum If fluids are delivered that cure in air crystallise in contact with air humidity the leakage of which must not be released into the environment e under vacuum and their seal shall be gastight than the employment of a double seal with liquid seal is necessary e Atankforthe liquid seal is to be connected to the quenching connection Suitable tanks are availabl
49. r Pumps KF 4 112 KRACHT 4 Technical data 4 1 General characteristics Tab 4 1 General characteristics KF 4 112 General characteristics KF 4 112 Construction External gear pump Materials See section 4 4 Overview materials Fixing type Flange DIN ISO 3019 End of drive shaft ISO R 775 short cylindrical Pipe connection KF 4 12 Whitworth pipe thread G 3 4 KF 4 12 158 Flange connection SAE 3 4 KF 16 25 Whitworth pipe thread G 1 KF 16 25 158 Flange connection SAE 1 KF 32 80 Flange connection SAE 1 1 2 KF 50 80 232 Flange connection SAE 2 KF 100 112 KF 100 112 232 Flange connection SAE 2 1 2 Installation position KF R L B ohne Quench Arbitrary KF R L B mit Quench Horizontal quenching connec tion on top KF U Horizontal perssure connection on top Viscosity V min 12 mm s Vmax 20000 mm s Ambient tempera umn 20 C ture 00 C Speed n See section 4 2 Overview of nominal sizes Fluid temperature 3 Operating pressure p and See section 4 5 Operating pressure and fluid temperature Db Filtering Filter porosity lt 60 um Permissible media Fluids without abrasive components which are compatible with the pump materials used The fluids must guarantee minimum lubrica tion Media specific characteristics must be taken into account Petrols solvents etc are not permissible A reduced
50. s sembling or dismantling the cover or pressrue relief valve e g by bending out of line there could be malfunctions and a decrease of the service life Furthermore the seal faces on the cover or pressure relief valve could be damaged That can lead to leaks during operation e When mounting and dismantling the cover or pressure relief valve do not damage the bearings e g by bending out of line e When dismantling the cover or pressure relief valve do not lever in the joint with a screwdiver or similar tools BKFOOO4EN_D0024710002 06 2011 01 10 37 KRACHT Transfer Gear Pumps KF 4 112 Tab 6 4 Change of the direction of rotation KF R und KF L p Suction side Fastening screws p Pressure side aak oil hole In case of a pump s change of the direction of rotation the cover and or pres sure relief valve must be rotated through 180 e Loose fastening screws e Remove the cover or the pressure relief valve respectively from the pump housing and put it back on rotated by 180 e Tighten all fastening screws applying the below mentioned tightening torques see table 6 5 When checking pay attention to the following points e Pumps without pressure relief valve must have their leak oil hole on the interior cover side at the pump s suction side e Pumps with pressure relief valve must have their pressure relief valve adjusting screw point toward the pump s pressure side Tab 6 5 Tig
51. sert during the filling process BKFOOO4EN_D0024710002 06 2011 01 10 KRACHT Transfer Gear Pumps KF 4 112 e Filling the media tank with the prescribed fluid e Ensure sufficient filling of the media tank 6 8 Assembly with further components and devices Danger of property damage if installation is not correct Incorrect assembly with components or devices from other manufacturers can lead to breakdowns e Comply with each manufacturer s operating instructions when assem bling with additional components or devices 6 9 Electrical connection LN DANGER Danger due to electric voltage Danger of death due to electric shock e Follow the special safety regulations during all work on electrical instal lations e Only allow electricians to work on electrical systems A DANGER Hazard caused by incorrect direction of rotation Operating the device with the incorrect direction of rotation can lead to damage to the device and to the up or downstream plant elements Break age can lead to parts flying around uncontrolled or to fluids squirting out which can lead to accidents and severe injuries or even result in death e Always pay attention to the correct direction of rotation when installing the pumps e Always pay attention to the correct direction of rotation when connecting the motors e Secure the fitting keys against flying off when monitoring the direction of rotation All dat
52. service life must be expected for the shaft seal when vertically installed Lower viscosities only in connection with GJS housings and reduced pressures consult manu facturer BKFOOO4EN_D0024710002 06 2011 01 10 25 KRACHT Transfer Gear Pumps KF 4 112 4 2 Overview of nominal sizes Tab 4 2 Nominal sizes KF 4 112 Nominal Geom Speed Permissi Sound lev Weights size delivery ble radial el 5553 kg Lpa with with D with Vo rom rpm F radial db A valve univer cm N sal de 1500 vice rpm 4 4 03 5 5 05 6 6 38 PAS Qe 25 8 8 05 4 2 5 95979 10 10 11 200 3000 700 lt 67 12 12 58 16 16 09 3 peer 4 a 20 20 10 gett 5 ett 7 5 25 25 10 32 32 12 40 40 21 7 7 9 5 27 5 50 50 20 200 3000 1500 lt 68 63 63 18 9 4 11 2 29 5 80 80 50 100 101 5 200 3000 1500 lt 69 15 9 19 0 112 113 5 See type key and type designation at pump KF Radial forces only at version with outboard bearing on central shaft end Valid for pump KF 4 25 with Whitworth pipe thread Valid for pump KF 4 25 with flange connection SAE n 1500 rpm v 34 mm s p 5 25 bar 4 3 Permissible speed Tab 4 3 Permissible speed depending on the viscosity Kinematic viscosity v in mm s lt 300 300 500 1000 2000 3000 6000
53. sonnel to work on the device Danger of damages and malfunctions due to a lack of maintenance If the device is not regularly maintained damage that is not discovered or not repaired can lead to malfunctions and to the failure of the device e Maintain the device regularly e Check the device initially right after commissioning e Adapt the scope and time between maintenance intervals to the de mands posed by the location During visual inspections look purposefully for possible damages The device must not be used if visible damages are found Document the type and extent of the maintenance work That allows the fastest possible detection of a change in operating performance When designed to the conditions of use and fitted correctly the devices are able to be used for long and problem free operation They only require a little maintenance This is absolutely essential for problem free operation howev er Experience shows that a high percentage of the problems and damage that occur can be traced back to dirt and lack of maintenance The scope and time intervals for inspections and maintenance are generally specified by the operator in a respective plan T Barriers and instructions e All removed barrieres and warning signs must be put back to their orig inal position on completing maintenance and or repair sx Checking the operating data e Regular checking of all operating data such as pressure temperature current
54. sure line 42 6 6 Mounting the clutch 44 6 7 Mechanical installation 47 6 8 Assembly with further components and devices 50 6 9 Electrical connection 50 7 Operation start up 51 1 1 Preparation 51 7 2 Pumps with liquid seal quenching connection 53 7 2 1 General points 93 7 2 2 Seal variants with liquid seal 54 7 3 Setting the pressure relief valve 55 7 4 Further operation start up 57 8 Removal 58 8 1 General points 58 8 2 Disassembling the pump 58 9 Maintenance 60 9 1 General points 60 9 2 Unusual noises 62 9 3 Cleaning 63 9 4 Static seals 63 9 5 Confining fluid level 63 9 6 Rotary shaft lip seal 63 9 7 Mechanical seal 64 9 8 Clutch 64 9 9 Screw joints 64 9 10 Damage 64 9 11 Surface temperature 64 9 12 Bearing gear wheel chamber housing 65 10 Repairs 66 10 1 General points 66 10 2 Troubleshooting 66 10 3 Elimination of damage 66 10 4 Return 66 10 5 Disposal 67 10 6 Detecting and eliminating problems 67 Transfer Gear Pumps KF 4 112 KRACHT 1 General poi nts 1 1 About the documentation These operating instructions describe the installation operation and mainte nance of the transfer gear pumps KF 4 112 also referred to below as the device The device is manufactured in different versions Information about the ver sion concerned in the individual case can be found on the device s type plate The structure of the type designation and a more detailed description of the individual series and nominal sizes can
55. tion borehole G 1 8 for liquid seal quench Special number 74 Mounting F W Sealing materials 4 PTFE 7 FKM 19 NBR 32 EPDM Pump with mechanical seal and connection G 1 8 KF 4 25 or G 1 4 KF 32 80 for liquid seal quench Special number 198 Mounting F W Sealing material 5 FKM 2011 01 10 Pump without shaft seal Mounting F W oealing material 30 FKM O Ring BKFOOO4EN_D0024710002 06 KRACHT Transfer Gear Pumps KF 4 112 3 4 Type key Tab 3 11 Ordering example KF 4 112 KF 40 D 15 1 2 Tab 3 12 Explanation of type key KF 4 112 Explanation of type key KF 4 112 1 Product name 2 Nominal size Vg Size 1 4 5 6 8 10 12 16 20 25 cn Size 2 32 40 50 63 80 cm Size 3 100 112 cm 3 Direction of rotation R Right B Right and left L Left U Universal Direction of rotation right and left direction of discharge consistent 4 Mounting F DIN flange without outboard bear W Mounting angle without outboard bearing ing DIN flange with outboard bearing X Mounting angle with outboard bearing 5 Seal tyoe 1 Single rotary shaft lip seal BABSL 18 Single rotary shaft lip seal BAUMX7 FKM NBR 2 Single rotary shaft lip seal BABSL 19 Double rotary shaft lip seal BABSL NBR FKM 3 Single rotar
56. tting keys against flying off when monitoring the direction of rotation 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT 6 3 1 KF 4 112 with end cover or pressure relief valve Tab 6 1 Rotation and delivery direction KF 4 112 The following definition shall apply with respect to the rotation and delivery direction of external gear pumps in case of pump connections being posi tioned below the drive shaft Looking at the pump shaft end the Looking at the pump shaft end the pumping flow is from left to right pumping flow is from right to left when the shaft is moving clock when the shaft is moving anticlock wise wise Without pressure relief valve Suction side p Pressure side With pressure relief valve p Suction side p Pressure side BKFOOO4EN_D0024710002 06 2011 01 10 35 KRACHT Transfer Gear Pumps KF 4 112 6 3 2 KF 4 25 U with universal valve Tab 6 2 Rotating and delivery direction KF 4 25 U With regard to the direction of rotation and pumping flow of pumps with universal device KF 4 25 the following definition shall apply when looking at the pump shaft end Direction of rotation right Direction of discharge consistent and left p Suction side p Pressure side 6 3 3 KF 32 80 U with universal valve 36 Tab 6 3 Rotating and delivery direction KF 32 80 U With regard to the direction of rotation and pumping flow of
57. ure 7 1 e loosen the hexagon nut 1 e adjust set screw 2 clockwise response pressure higher anticlockwise response pressure lower secure the set screw 2 using hexagon nut 1 once the desired pressure has been adjusted BKFOOO4EN_D0024710002 06 2011 01 10 55 KRACHT Transfer Gear Pumps KF 4 112 INE Gefahr durch Bruch oder Herausspritzen von Fl ssigkeit When securing screw 3 is loose set screw 2 can be screwed into the valve until the valve is completely shut That can result in inadmissibly high pressures in the system if there is no other pressure relief device Breakage can lead to parts flying around uncontrolled or to fluids squirting out which can lead to accidents and severe injuries or even result in death Fluid can spurt out from the valve if set screw 2 is completely screwed out That can lead to accidents with severe injuries or result in death e Never operate the unit with securing screw 3 loosened e Never completely screw set screw 2 into the valve e Never completely unscrew set screw 2 out of the valve 56 2011 01 10 BKFOOO4EN_D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT 7 4 Further operation start up BKFOOO4EN_D0024710002 06 The pumps may only start without or with low pressure load For this purpose open the existing shut off elements and adjust the pressure relief valve incorporated in the pressure pipe to the lowest opening pres sure Start up takes
58. vacuum gauge to the pump suction line connector Ensure proper suction when piping the suction line and the distances to the floor and to the bulkhead partitions must be sufficiently large The inlet port must have a sufficient distance to the lowest fluid level Nominal width of the suction line e The nominal width of the suction line may actually be selected to be larger than the pump connection Expansion of the suction cross section e Funnel shaped formation of the suction port at the pump suction side or obliquely cutting the suction pipe end is recommended of enlargement of the suction cross section When hose lines are used on the pump suction side care must be taken to ensure that the hoses are sufficient stability so that they will not be constricted through the sucking action The media specific data need to be observed for example the device must be arranged below the fluid level in case of aqueous dispersions and solu tions Danger of property damage when pumping aqueous fluids When pumping aqueous dispersions or solvents low pressure on the inlet port can lead to cavitation damage on the pump e Comply with the media specific attributes e When designing the inlet line make sure the inlet port pressure on the pump inlet during operation is always higher than the steam pressure of the pumping fluid While doing so also take the altitude of the site of the device over mean sea level into consideration
59. ven result in death e Depressurize all connection lines during all work on the device e Depressurize or disconnect the driving motor during all work on the de vice e Securely prevent the motor and device from restarting during work e Wear suitable protective clothing BKFOOO4EN_D0024710002 06 2011 01 10 KRACHT Transfer Gear Pumps KF 4 112 TE Danger due to breakage or squirting fluids Operating the device with impermissibly high pressures can lead to damage to the device and to the up or downstream plant elements Breakage can lead to parts flying around uncontrolled or to fluids squirting out which can lead to accidents and severe injuries or even result in death e Never allow positive displacement pumps to pump against closed gates e pressure relief valve or other kind of over pressure safeguard must be installed as close as possible to the pump pressure connection The pressure relief device must be dimensioned so that the entire delivery volume can be conducted through it with the lowest possible pressure or must be depressurized e Do not put the device into operation without a pressure relief device Danger due to hazardous fluid Danger of death upon contact with hazardous fluids and when inhaling va pours from these liquids e Comply with the safety data sheets and regulations on handling the hazardous liquids e Collect and dispose leaks of hazardous materials so that
60. y shaft lip seal PTFE 20 Mechanical seal with EPDM secondary seal not resistant to mineral oil 4 Double rotary shaft lip seal PTFE 23 Singel rotary shaft lip seal MSS 1 FKM low temperature 5 Mechanical seal with FKM secon 30 Without shaft seal O Ring FKM dary seal external leak oil discharge 6 Mechanical seal with PTFE secon 31 Single rotary shaft lip seal BABSL FKM dary seal low temperature 7 Double rotary shaft lip seal BABSL 32 Double rotary shaft lip seal EPDM FKM not resistant to mineral oil 9 Single rotary shaft lip seal EPDM not resistant to mineral oil 6 Special number for specific types See section 3 5 Important special numbers BKFOOO4EN_D0024710002 06 2011 01 10 23 KRACHT Transfer Gear Pumps KF 4 112 Explanation of type key KF 4 112 7 Pressure relief valve only for direction of rotation R or L D 15 Adjustable from 0 15 bar D 25 Adjustable from 15 25 bar 8 Housing and cover material Not specified EN GJL 250 GG 25 GJS EN GJS 400 15 GGG 40 3 5 Important special numbers Tab 3 13 Important special numbers KF 4 112 Special Description num bers 74 Pump with double rotary shaft lip seal for vacuum operation and connection for liquid seal quench inner rotary shaft lip seal mounted with sealing lip towards shaft end 158 SAE 7
61. y tank too low Too little oil supply Return line to tank leaking Wrong tank dimensioning Shaft seal or seal on suction line leaking Return line end above the fluid level in the supply tank Insufficient venting Too strong foaming in the gear Mechani cal vibra tions Incorrectly aligned or loose clutch Magnetic coupling defective Faulty or insufficient line fastening Wobbling pressure relief valve No noise optimized design missing dampers Unfavourable place of pump installation Pump worn out tooth flanks worn out Disturbances in pump operation Pump does not suck Too high negative pressure Fluid level in supply tank too low Magnetic coupling torn off Wrong direction of rotation Throttled shut off element in the suction line Suction line too long Suction line leaking Suction resistance too high Foreign objects in suction line Volume of pressure pipe between pump and non return valve too little pump cannot compress the air contained in the suction line Non return valve not bled Too high start up pressure if suction line is filled with air Speed too low Place of installation too high 68 2011 01 10 BKF0004EN D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT Fault Potential causes Insufficient delivery Too high negative pressure Throttled shut off element in the suction line Fluid level in supply tank too low Suction filter plugged or too small Too high viscosity
62. ype description is required 66 2011 01 10 BKF0004EN D0024710002 06 Transfer Gear Pumps KF 4 112 KRACHT If harding or agglutinative media are involved the device must be cleaned befor it is returned Cleaning is also necessary if the device has been operated with hazardous fluids Any openings must be closed 10 5 Disposal Disposal of the packaging and used parts must be carried out according to the regualtions valid in the country where the device 1 installed 10 6 Detecting and eliminating problems The following table lists the possible causes of the most frequently occuring malfunctions and notes on possible remedies If the problems cannot be identified please request help from the manufac turer Tab 10 1 Transfer pumps Faults and causes Fault Potential causes Negative pressure too high causing pump short filling Suction height too high Suction filter plugged or too small Inner diameter of suction line too small Suction line too long Too many bends in the suction line Too many local constrictions in the suction line Suction line plugged or leaking Too high viscosity Temperature too low Wrong direction of rotation Place of installation too high Increased Pump noise cavitation BKFOOO4EN_D0024710002 06 2011 01 10 67 KRACHT Transfer Gear Pumps KF 4 112 Fault Potential causes Foaming or trap ped air in medium Suction line leaking Fluid level in suppl

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