WK12 - 15 - 159 User Manual
Contents
1. 6 9113504 TZ S Old OAILISOdSIG OTXS VNIdS Old 1 1 TIVYILVI 402 _ Old d 05 3 LLIWOD ONZE TV no s8ro 6 Do P0z 86 DO SEED OZ SOIZT 00 876 06 GE ETZU OT SETAC OT SES OTIT EL OO 20EF 66 007458776 1 0 40 01 5t enz0 0T 5t 80 0 0T D E658 T6 DEBOLE Z 00 9 66 D0 0r65 6 00257946 DO DO T 06 TE DOST IL DO0 OD05 T6 Dno z98T 66 D ZPTS 66 00 8 96 007 8946 SE ZOCOTE 00700417706 44011878 v102208 05 0 vTI3I8 1531 V102208IW3S 5 52 0 11318 VISIL v102208IW3S diis VISIL vTOJOOSIM3S ANI 05 0 vTI3I8 1531 v102208IMH3S 52 0 vTI3IS 91531 v1022081W3S AMI VTI3IS 1531 91052091935 H314V2 OddV L YILUVI OID2nddV2 OddV L OLNIWVAITIOS V44V1S 2NIZ 8 8 GELS STXZTW ALIA VILITAWOI V t099 INN OZX8X6UZT 00 0005 16 2 12 8 8 TEGS BTX9OW ALIA 00 298T 66 Old VIMVITISAV d d TZED 6 ZI TEGS OSXBOW ALIA 00 9bTE 66 2 3VS LOW VISNYT4 OZ OS 0 OI OF OFIWIZNVISIG 0Z 9vZ0 0T SZ TEXOF 0215119 OLNNID 0826470 OSLISV1d Zt ZbZ0 OT S OT H SETE 0 JIWIZNVISIO O0 SE 0 DT BINLI ST OHO4 H3d 1 00 0907 86 divini OITINVAGI SHOLOW VIONYIA 0277907072. FAIYO L93HIO 3NOIZIN253G 321002 NOLLIdIN253G 3405 TZES 6 ZI LEGS 5 ALIA 00860666 ECKE PE 3MOIZVHIdSV YIOATYA OddNdi VIVONVIW YIOATYA OddiiH9 S TXPSXS 6t O 15311 VIVONVH dSV VIOATVA 3035 VLAId OD vV2IH3JdS VIOATVA VNH31INI VIOATVA gexe sz 0 vTIOM VIVONVMW zvHIdSV V1OATVA VOIND EGTE 50 YON C9 CX68 8b 0 HO S TXSSX6 0S ISJLINV OTIJNV VIVONVMW ZwHuIdSV 310ATVA OddV L J310A1VA OIH2H3dO02 W VTZES 6 TEGS ALIA W VTZES GTI TEGS OSTXETW ALIA OF 0 3 015184 33d WIVISIL OF 3401513 834 WIWISIL SE 3401514 Yad VIVISIL 9 0 3401514 43d VIWISIL 0 3401514 Wad VIVISIL 0 3401919 339 1 1531 B 3401514 Yad 9191534 Ob VISIL Id OTI3NV 9 VISIL IO OTI3NV ZE V1531 IO OTI3NV 2 1531 IO OMINY dH lt 6 66 0 17 N31 OTTINV dH S E OXBPX9E 0 17 N31 S E gXppXzE O LOW NAL OTINV dH 5 p s zxSpxDE 071197831 OTI3NY S e 8XSSX0p 401534 OTIJNV oxspxoE 401533 E S SxbPbXZE 401534 OTI3NY S e 8xSpXDE B 401533 OTIJNV J3NOIZIN253G _ amp 0 3401519 834 VIVISIL O0 0TI6 06 DO Tez6 06 DO OrZE 06 00562606 D FEE 06 0 06 IS ESTE TE IS ESTE TE 522 2 0 997t 56 IO ZOEQ IZ 00 0FSZ F6 10 9
3. TO LETL OE 00092506 94 SE 090 SE 157980296 00 0552 6 IS SPOZ IE 00 688 06 007047406 OZ TTIETZ 14715478 00756266 00 08tt 66 STAGET T STATT ST S6eT TZ ST rect STEGET TZ STEET T SU TEET TE STOGZT TE TS EDOT TZ ES COUT TZ TS OOUT c POOT OE OO TERT 06 00 0282 06 pogar 06 00702206 5 007318206 OO rae OG D re 06 90ZE 50 29 2 0 25 0 HO OF 0 INOIZINYWNS 01303915 B INOIZINHWNS OL4OddNs 0 INOIZINYWNS OLYOddNs d1 OXSbXOb LIV NAL OTTINV d9XbbXOE TW NAL 91 S SXDbXZE LIV N31 OTTANY 41 S SX8EX0E 0 LIV Nal OTTINY OF 2 VLNNAL 43d 9E VINNIL 334 ZE VINNAL Yad OTTANY DE 934 OTIJNY KONI 25 OW33J OTI3NV ANOLSIJA 0199 5513 ILIA H506 YaN O0 ZXOQ TT HO 56 0 0 3401514 SEYZE 0 INOLVIA S6X9E 3401513 S6 0 3401519 TXOSXOT 0 VLLASOU S 8 LXTSX8E 0 OTISNV 0 OLLONIdS INOLSId vaino INN 07 0 839335 8X59X05 0 awa OTI3NV Old OLYI 371933471 2 v t099 INN OZX8X6UZT VLLINDNIT 052 LLIWOD V 381 9 Y11318 DIDOYHHIS ALIA BTNLL ST 0903 Oddvi HSO OO EXDO STZ YO HILYYI 504 OIH2H3dO02 TEXS TT 0 VISY NOD OddV L TANDIN ET Z TS 04491 890 50 HAN Z9 TXET ZT HO JIN
4. INTERPUMP 2 GROUP Pralissuli WK12 WK159 WK15 KF30G KF32G KF36G KF40G Use and Maintenance manual fa INTERPUMP 232 GROUP Pratissoli 1 INTRODUCTION 4 2 DESCRIPTION OF SYMBOLS 4 3 SAFETY 5 5 ______ 6 _ __ 5 3 2 Essential safety in the high pressure system 5 SS OI gt __6_____ 5 3 4 Rules of conduct for the use of 5 3 5 Safety d ring system Maintenance ini 6 4 PUMP IDENTIFICATION 6 5 TECHNICAL CHARACTERISTICS 7 6 DIMENSIONS AND WEIGHT 7 7 OPERATING INSTRUCTIONS 8 Tak NY dle Ce Te a 8 Ta Makma pe 8 gt mUEE 8 TA SOUBHE a 8 8 7 6 Brands and types of oils 9 8 PORTS AND CONNECTIONS 11 9 PUMP INSTALLATION 12 CRUSCA RR E A 12 9 2 Rotation _ ___ _ 13 13 9 4 Hydraulic connections 14 Pump power SUP OLY ___ ____________ 14 SUNCOM IMAM ________ _ NM MM NUMEN MN SM NEMPE 14 I 15 LEVE E E IAA 16 9 9 Calculation of the internal diameter of the duct pipes 00000 17 WAG Ie MAS 18 D II Tronsmission EMMI ON sce sen 18 9 12 D
5. x6 INTERPUMP Pralissuli 17 DECLARATION OF INCORPORATION DECLARATION OF INCORPORATION In accordance with Annex Il of European Directive 2006 42 CE The manufacturer INTERPUMP GROUP S p A Via E Fermi 25 42049 S ILARIO D ENZA RE Italy DECLARES that the product identified and described as follows Name Pump Type Reciprocating plunger pump for high pressure water Trademark INTERPUMP GROUP Model 71 KE series Is found to comply with the requirements of the directives listed below and subsequent updates e Machinery Directive 2006 42 CE e Directive on the restriction of certain hazardous substances 2002 95 CE e Directive on manufacturer responsibility 85 374 UNI EN ISO 12100 1 2005 UNI EN ISO 12100 2 2005 UNI EN 809 2000 The pump identified above meets all the essential safety and health protection requirements as listed in section 1 of Annex of the Machinery Directive and the relevant technical documentation has been compiled in accordance with Annex VII B In addition the manufacturer undertakes to make available following a reasoned request a copy of the relevant technical pump documentation in the manner and terms to be defined The pump should not be put into service until the plant to which the pump is to be incorporated has been declared in accordance with the provisions of the relevant directives and or standards Person authorised to compile the technical file Name Mauriz
6. 3 Unite the hydraulic part to the mechanical part as indicated in chapter 2 section 2 2 5 of the repair manual 13 ne INTERPUMP Zaz GROUP D dr G vo E 9 4 Hydraulic connections In order to isolate the system from vibrations produced by the pump it is advisable to make the first section of the duct adjacent to the pump both suction and outlet with flexible piping The consistency of the suction section must be such as to prevent deformations caused by vacuums produced by the pump 9 5 Pump power supply A positive head of at least 0 20 metres is required for the best volumetric efficiency N For negative prevalence contact our Technical or Customer Service Departments 9 6 Suction line For a smooth operation of the pump the suction line should have the following characteristics 1 Minimum internal diameter as indicated in the graph at point 9 9 and equal to or exceeding that of the pump head in cavitation Avoid 90 elbow bends with other piping constrictions counterslopes inverted U curves and T connections With a layout that is set in such a way to prevent cavitation Completely airtight and constructed to ensure sealing over time Prevents that pump stopping causes emptying even partial Do not use 3 or 4 way hydraulic fittings adapters swivel joints etc as they could jeopardise pump performance Do not install Venturi tubes or injectors for detergent suction Avoid
7. 1 The Operator must always place his safety and security first as well as that of others that may be directly affected by his her actions or any other assessments or interests The Operator s work must be dictated by common sense and responsibility 2 The Operator must always wear a helmet with a protective visor waterproof gear and wear boots that are appropriate for use and can ensure a good grip on wet floors Note appropriate clothing will protect against sprays of water but not from direct impact with jets of water or very close sprays Additional protections may therefore be necessary in certain circumstances Ult Pralissuli 3 Iti is generally best to organise personnel into teams of at least two people capable of giving mutual and immediate assistance in case of necessity and of taking turns during long and demanding operations 4 The work area jet range must be absolutely prohibited to and free from objects that inadvertently under a pressure jet can be damaged and or create dangerous situations 5 The water jet must always and only be pointed in the direction of the work area including during preliminary tests or checks 6 The Operator must always pay attention to the trajectory of debris removed by the water jet Where necessary suitable guards must be provided by the Operator to protect anything that could become accidentally exposed 7 The operator should not be distracted for any reason during work Workers
8. NO N O NI N co gt K K 282 381 Minimum pulley diameter must be respected Do not use laminated v belts fig 9 b Use high performance belts for example XPB instead of SPB as a lower quantity of belts for the same transmitted power may be necessary and a consequent shorter resulting distance compared to the shaft shoulder P T O a of fig 10 19 INTERPUMP GROUP Pratissoli Spallamento albero CHOY AD TS idl is AS fig 10 Pull the belts according to manufacturer instructions Excessive pulling can cause reduced bearing life and wear out the pulley prematurely Pulling depends on different variables as indicated in point 9 12 Belt length has a natural tolerance 2 0 75 For this reason the 4 belts must be purchased as a pair Follow the direction of the belt pull as shown in fig 9 for other needs contact our Technical or Customer Service Departments Take care of the alignment of the driving pulley and driven pulley grooves 9 12 Definition of static pull to apply on belts Static pull depends on The wheelbase between the two pulleys belt length The load due to static pull of the belt The number of belts The winding angle of the smallest pulley Average speed Etc Values of the static pull to be applied can be obtained from the diagr
9. 750 rpm 7 4 Cv to 800 rpm 8 3 Cv to 900 rpm 9 3 Cv to 1000 rpm 11 1 Cv to 1200 rpm By means of the joint withdrawable Max Torque is 130 Nm which corresponds to 14 Cv to 750 rpm 14 8 Cv to 800 rpm 16 6 Cv to 900 rpm 18 6 Cvto 1000 rpm 22 2 Cv to 1200 rpm AN By means of the V belt the transmission is considered suitable if belt pull is applied at a max distance of 22 mm with from the bend shaft shoulder fig 13 min diameter of pulley to be used 100 mm With transmission by means of the joint pay particular attention to perfect alignment so that no transverse forces are generated on the pump shaft AN For applications differing from those specified above contact our Technical or Customer Service Departments 22 INTERPUMP Zaz GROUP 10 START UP AND OPERATION 10 1 Preliminary checks Before start up ensure that Pratissoli AN The suction line is connected and pressurised see Point 9 4 9 5 9 6 the pump must never run dry 1 The suction line ensures a hermetic seal over time 2 Any shut off valves between the supply source and the pump are fully open The outlet line during is free discharge to permit air present in the pump head to come out quickly and therefore favour fast priming 3 All suction and outlet fittings and connections are properly tightened 4 The coupling tolerances on the pump transmission axis half joint misalignment Cardan joint tilt belt pulling etc remai
10. pump in relation to the quality of water used and actual clogging conditions 15 Oo INTERPUMP Pralissoli GROUP 9 8 Outlet line For the correct laying of the outlet line the following installation rules must be followed 1 2 DI Re The internal diameter of the pipe must be sufficient to ensure correct fluid velocity see graph at point 9 9 The first section of the line connected to the pump outlet must be a flexible hose in order to isolate the vibrations produced by the pump of the rest of the system Use high pressure pipes and fittings to ensure high safety margins in all operating conditions The outlet line must always be provided with a Max pressure valve Use pressure gauges suitable to withstand pulsating loads typical of the plunger pumps During the design stage keep in mind the line load losses which result in a drop in pressure during use with respect to the pressure measured on the pump For those applications where pulses produced by the pump on the outlet line may prove harmful or unwanted install a pulsation dampener of sufficient size 16 INTERPUMP de Pralissoli 9 9 Calculation of the internal diameter of the duct pipes To determine the internal diameter of the duct refer to the following diagram Suction duct With a flow rate of 170 L min and a water velocity of 0 5 m sec The graph line joining the two scales meets the central scale showing t
11. IZ TEGS VIdS OLV131vH31V1 DIHIHIdHOI 95 50 HAN Z9 CXPE 6 E 0 OMO OTI3AT Vids secz St 0 435335 OTI3NY WW 570 OLN3HWYSYH IO 34055345 T O OLN3HVSYH IO 33055345 _SLEE 50 UAN TI TXZ6 P6 NOD IT1NY OLLINIISNI DO0 T68 06 05512 T Of TZ ra ci rara OLESTZ TL OO Ose 06 007008206 00 08 22 06 0 09 2 OL EBTE TL L ORTE TE OL SOTT EL 00 2620 06 99 5612 4 00749 06 60 SOPD TZ e ooro eZ Gl EOFO TE 60 coro TZ 00 0 96 00 8 9 06 DO DEPZ ZG ST OOSO T 00 9090 06 00004106 zC O0ST TZ 00 0005 6 5E DOZO TZ 00 8ETE 66 Do o307 86 00 000 06 O008T TZ DO DETT 86 O0 EBTT B6 00 06 00 2981 66 44571878 004485706 TO 8TTT 0 00795 20 06 IR EOLE TZ 008 6 06 00066876 4 HILUYI ZZ 00T0 T 3NOIZIN253G NOLIdIN253G 28 po4uo ajjaiq eurzuo4q UM yy sjeas 23219105 aynuay PA 5 Ip PY 5 uonoans SUOIZEJI yy bupped quedwod 05 0 55 52 0 STZ 015 SETZ 2102 o ED oo 8102 LIDI 9907 9102 STHM STAM DOFIM DEEHM LIM 39745 LI 2 Qu
12. PUMP GROUP Pralissuli 5 TECHNICAL CHARACTERISTICS 6 DIMENSIONS AND WEIGHT For Standard Version pump dimensions and weight refer to fig 2 For type A Flange Version pump dimensions and weight refer to fig 2 a fig 2 INTERPUMP GROUP Praliszali ES a 4 1 LA DAO 19 018 Dry weight 71 Kg fig 2 a 7 OPERATING INSTRUCTIONS Pumps KFG and WK were designed to operate in environments with atmospheres that are not potentially explosive with filtered water see point 9 7 and at a maximum temperature of 40 C A N Other liquids can be used only upon formal approval by the Technical or Customer Service Departments 7 1 Water temperature 1 maximum permissible water temperature is 40 C However the pump be used with water up to a temperature of 60 but only for short periods In this case it is best to contact our Technical or Customer Service Departments 7 2 Maximum pressure and flow rate The rated specifications stated in our catalogue are the Max that can be obtained the pump Independently of the power used the maximum pressure and rpm indicated in the specification label can never be exceeded unless upon prior formal authorisation by our Technical or Customer Service Departments 7 3 Minimum rotating speed Any rotating speed other than that indicated in the performance table see chapter 5 must be express
13. R 300 R T 7 UNDER UNA Rec S UR NU I UM UR pp ix ae eS immissioni et Ma 200 pe hh ee A ie ammo STRA va seer V He I 150 ESSERI SSF REESE n san Ho SEE A a RA ED p p cs ee CCS MI SS 100 CR CUM L C ee _ E ZE LS aD ME ode ct RE TET SQ i Li LL NE Viscosity v SS DS PS CESS GS GE EY MEO 4 ae gt SSE RED USI SS RE CY RE VINES RIONE ENE TSE WES CRO SE SS GD CE 40 SE EE Sea a SSD GE GEA 8 SESS Ge ene veni 30 aA ES Ue 25 SS AT ST SRS A SER REN EN RS es ET TER Y A AMEN ___ml _______A cjei b 7 UT SD 20 I ttt 10 3 5 10 15 20 25 30 40 50 60 70 80 90 100 Room Temp The oil must be placed a suitable container and disposed of special centres It absolutely should not be discarded into the environment 10 f INTERPUMP GROUP Que Pralissuli 8 PORTS AND CONNECTIONS The KFG and WK series pumps see figure 4 are equipped with D 2 IN inlet ports 1 1 2 Gas Line connection to any of the two ports i
14. Technical or Customer Service Departments XPZ XPC LALA 27 gt Aid WT AT iil d Speed of small pulley ny min 2A d MILI LE 60 70 80 90 power transmission capacity per V belt 9 11 Transmission definition To prevent irregular radial loads on the shaft and the relative bearing follow these directions a Use pulleys with v belts with the size of the groove required recommended by the manufacturer of belt used In the absence of directions follow fig 8 and the table in fig 9 Fx Ll Pralissuli Single groove Multiple fig 8 Dimensions in mm Belt section as per DIN symbol XPB SPB XPC SPC DIN 7753 part 1 and B S 3790 symbol B S ISO SPB SPC Belt section as per DIN symbol 17 22 DIN 2215 and B S 3790 symbol B S ISO B C Pitch width bw n 34 E Oo p A9 23 0 4 14 5 0 8 Increased grooving depth 22 5 by primitive diameter from 140 to 190 narrow section v belts gt 190 DIN 7753 part 1 by primitive diameter dw from 112 to 190 from 180 to 315 olo Distance between grooving m h 3 5 Tolerance for 34 38 1 Pulleys for b2 by grooving number z 62 z 1 e 2f 71 O17 N NI
15. am in fig 11 for belts with a XPB profile in relation to the wheelbase 20 je INTERPUMP Z GROUP Pralissoli L LL LLL bL Lal ea B e s LA Ll lol Il T si C pet Lap T fet ol 200 300 400 500 600 700 800 900 1000 1100 1200 1300 Lf Wheelbase mm fig 11 Conclusion With a wheelbase of 600 mm and with a dynamometer loading the belt branch with 75 N as indicated in fig 12 a te bend of approximately 10 8 mm is obtained Lf Wheelbase te Belt bend Fe 75 Dynamometer load Note Unless otherwise stated by the supplier of the belts control of proper pull and its relative re tensioning should be performed after no less than 30 minutes of motion necessary for the normal adjustment of the belts Best performance and durability will be achieved with proper tensioning 21 INTERPUMP i GROUP Pralissoli Note In case of necessity or for routine maintenance never replace a single belt but the complete set 9 13 Transmission of power from the second PTO Upon request the KFG and WK series pumps can be supplied with auxiliary PTO on the side opposite of the drive Transmission of power from the second PTO Transmission can be carried out e By means of the V belts e By means of the joint By means of the V Belt withdrawable Max Torque is 65 Nm which corresponds to 7 to
16. e oil level is made with the pump not running at room temperature The oil change must be made with the pump at working temperature removing the pos and then the drain plug pos fig 3 The oil check and change must be carried out as indicated in the table in chapter 11 The quantity required is 3 8 litres Hersteller Manufacturer Producteur Schmierol Lubricant Lubrifiant ELF POLYTELIS 220 REDUCTELF SP 220 NUTO 220 TERESSO 220 CIRKAN 220 RENOLIN 212 RENOUN DTA 220 Mobil DTE Oil BB oil dipstick Pratissoli Hersteller Manvfacturer Producteur Schmier l Lubricant Lubrifiant Shell Tellus OI C 220 Wintershall Ersolon 220 Wintershall Wiolon CN 220 RANDO HD 220 TOTAL Cortis 220 INTERPUMP GROUP Pralissoli AN In any case the oil must be changed at least once a year as it is degraded by oxidation For a room temperature other than between 0 C 30 C follow the instructions in the following diagram considering that oil must have a minimum viscosity of 180 cSt Viscosity Room temperature Diagram mm s cSt 2x10 an mum ae 600 ESTETISTA Te a SS SE SS SS SS SS SS SS SS ES a1 ip 400 EEEEXEE E E EAE E
17. e pump for any reason until the circuit has not been fully defrosted in order to avoid serious damage to the pump The guarantee period and conditions are contained in the purchase agreement The guarantee will in any case be invalidated if The pump is used for purposes other than for those agreed upon The pump is fitted with an electric or combustion motor with performance exceeding those indicated in the table Safety devices are decalibrated or disconnected The pump is used with accessories or parts not supplied by Interpump Group Damage has been caused by a b d e improper use failure to follow maintenance instructions any use different from that described in the operating instructions lack of sufficient flow rate defective installation improper positioning or sizing of pipes unauthorised plan modifications cavitation 222 25 Pralissuli 15 OPERATING FAULTS AND THEIR POSSIBLE CAUSES The pump does not produce any noise upon start up pump is not primed and is running dry suction water Valves are blocked The outlet line during is closed and does not allow air present in the pump head to come out The pump pulsates irregularly A Air suction Insufficient supply Bends elbow bends fittings along the suction line are choking the passage of liquid The suction filter is dirty or too small The booster pump where installed is supplying insufficie
18. efinition of static pull to apply on belts 20 9 13 Transmission of power from the second PTO Li 22 10 START UP AND OPERATION 23 23 IN rm 23 11 PREVENTIVE MAINTENANCE 24 12 PUMP STORAGE 25 12 1 Long term 25 12 2 Method for filling pump with anti corrosion emulsion or anti freeze solution 25 13 PRECAUTIONS AGAINST FROST 25 INTERPUMP GROUP 14 GUARANTEE CONDITIONS Pralissuli 15 OPERATING FAULTS AND THEIR POSSIBLE CAUSES 26 16 EXPLODED DRAWING AND PARTS LIST 27 17 DECLARATION OF INCORPORATION 29 jc INTERPUMP 2 GROUP Pralissoli 1 INTRODUCTION This manual describes the instructions for use and maintenance of KFG WK pumps and should be carefully read and understood before using the pump Proper pump operation and duration depend on the correct use and maintenance Interpump Group disclaims any responsibility for damage caused by negligence or failure to observe with the standards described in this manual Upon receipt verify that the pump is intact and complete Report any faults before installing and starting the pump 2 DESCRIPTION OF SYMBOLS Warning Sign Read the contents of this manual carefully before each operation Danger sign Danger of
19. electrocution Danger sign Wear a protective mask Danger sign Wear protective goggles Danger sign Put on protective gloves before each operation Danger sign Wear appropriate footwear 2 Gnawa Pralissuli 3 SAFETY 3 1 General safety warnings Improper use of pumps and high pressure systems as well as non compliance with installation and maintenance standards can cause serious damage to people and or property Anyone assembling or using high pressure systems must possess the necessary competence to do so knowing the characteristics of the components that will assemble use and take all precautions necessary to ensure maximum safety in all operating conditions In the interest of safety both for the Installer and the Operator no reasonably applicable precaution should be omitted 3 2 Essential safety in the high pressure system 1 The pressure line must always be provided with a safety valve 2 High pressure system components particularly for systems that operate primarily outside must be adequately protected from rain frost and heat 3 The electrical control system must be adequately protected against sprays of water and must meet specific regulations in force 4 The high pressure pipes must be properly sized for maximum operating pressure of the system and always and only used within the operating pressure range specified by the Manufacturer of the pipe itself The same rules should be observed fo
20. he date of shipment before operation check the oil level inspect the valves as specified in chapter 10 then follow described start up procedures 12 2 Method for filling pump with anti corrosion emulsion or anti freeze solution using an external diaphragm pump based on the layout shown in paragraph 9 7 in fig 6 and fig 6 a In place of the service tank use a Suitable container containing the solution to be pumped Close the filter drainage if open Make sure that the hoses to be used are clean inside and spread grease on their connections Connect the high pressure exhaust pipe to the pump Connect the suction pipe to the diaphragm pump Connect the suction pipe between the pump head and the diaphragm pump Fill the service container with solution emulsion Insert the free ends of the suction pipes and the high pressure exhaust pipe inside the container Switch on the diaphragm pump Pump the emulsion until it exits from the high pressure exhaust pipe Continue pumping for at least another minute Stop the pump and remove the previously connected pipes Clean grease and plug the connections on the pump head The characteristics of the emulsion can be strengthened if necessary by adding for example Shell Donax 13 PRECAUTIONS AGAINST FROST A 14 GUARANTEE CONDITIONS Follow the instructions in Chapter 12 in areas and times of the year at risk of frost see point 12 2 In the presence of ice do not run th
21. he diameters corresponding to a value of 80 mm Outlet duct With a flow rate of 170 L min and a water velocity of 5 5 m sec The graph line joining the two scales meets the central scale showing the diameters corresponding to a value of 30 mm Optimal speed Suction lt 0 5 m sec Outlet lt 5 5 m sec i d mm DN Cm P4 d A e e E di mandata The graph does not take into account pipe resistance valves load loss produced by the length of the ducts the viscosity of the liquid pumped or the temperature of the same AN If necessary contact our Technical or Customer Service Departments 17 fg INTERPUMP GROUP j l Pralissoli 9 10 V belt transmission The pump can be controlled by a v belt system For this pump model we recommend use of 4 XPB belts 16 5x13 serrated Use an XPC profile only for long durations Both the characteristics and transmissible power of each belt can be verified in the diagram in fig 7 in relation to the number of rpm normally declared by the manufacturer Minimum duct pulley diameter on pump shaft 2 250 mm The radial load on the shaft must not exceed 7500 N value necessary for Layout definition The transmission is considered adequate if the load is applied to a maximum distance a 40 mm from the shaft shoulder P T O as shown in fig 10 N For dimensions differing from those specified above contact our
22. io Novelli Address INTERPUMP GROUP S p A Via E Fermi 25 42049 S ILARIO D ENZA RE Italy Person authorized to draw up the declaration CEO Mr Paolo M meer Reggio Emilia January 2010 Signattire 29 jc INTERPUMP 2 GROUP Pralissoli Copyright Copyright of these operating instructions is property of Interpump Group The instructions contain technical descriptions and illustrations which may not be entirely or in part copied or reproduced electronically or passed to third parties in any form and in any case without written permission from the owner Violators will be prosecuted according to law with appropriate legal action Data contained in this document may change without notice T N N e e LO rT e CN LU O I e rT N O PRATISSOLI a brand of INTERPUMP GROUP SPA 42049 S ILARIO REGGIO EMILIA ITALY Tel 39 0522 904311 Fax 39 0522 904444 E mail info pratissolipompe com http www pratissolipompe com 30
23. lfunction Non uniformity in the transmission motion 26 00 1S6 LZ QOO 510 3VS Ijueureiddoooe ojunic a Pralissuli INTERPUMP GROUP nep nueureuorze Jad ody 4 16 ojueuieuoize ojsoddo O 8 ns EZIO ip esaJg 0029005 POD nig 810 09 a207 002 BIESSIJ SJOYNPU uoo EZIO Ip S8Jd 00 900217 02 nig 210 09 31207 uoo v8 98 2298 28188 6806 WNOILdO LE euotznijsi 00910021 POD 052 SITIDO auos osseJB uoo 7 27 25 INOIZINUVNO 5429 92 8TX8 VNIdS TAHIIN 9 OddWi 50 YAN SZ TXZ8 OT O YO YIOLVOS 24 2 HSOL YAN Z9 7XC7 607 0 AWANI 0 8 Tu OFZ YNOYOD wacana 00514 LEZ JWOIOINA 052 TY FEZ 01995514 YITIONOB JNIZ 978 GELS 0 ILIA 6059 38345 OLLINIISNI ANAIONA Q 8 TH 222 JWGIOJIT3 005 TH 522 INONDId FWAIOI OSZ TY 222 INONDId OTES 34345 OLLINTISNI YIOLYIS OIH233d02 W VIZEO CT TE6S OSXBOW ALIA lt VIdS VNIdS NOLIA 8X59x05 0 OTI3NV Old O1V131v531Y1 OIH233d02 V t099 INN OZX8X6UZT VLLINONIT INIZ 8 8 TEGS 9 ILIA XO9YV39 JUOLLNGIY TEES GT TEGS SPXITH ILIA
24. ly formally authorised by our Technical or Customer Service Departments 7 4 Sound emission The sound pressure detection test was performed according to Directive 2000 14 of the European Parliament and Council Machinery Directive and EN ISO 3744 1995 with class instrumentation 1 A final detection of sound pressure must be performed on the machine complete system Should the operator be located at a distance of less than 1 metre he will have to use appropriate hearing protection according to current regulations 7 5 Vibrations The detection of this value shall be carried out only with the pump set up on the plant and at the performance declared by the customer Values must be in accordance with regulations ne INTERPUMP 237 GROUP 7 6 Brands and types of oils recommended The pump is supplied with oil suitable for room temperatures from O C to 30 C some types of recommended oil are indicated in the table below these oils have additives to increase corrosion resistance and fatigue resistance DIN 51517 part 2 Alternatively you can also use Automotive Gear SAE 85W 90 oil for gearing lubrication Hersteller Manufacturer Producteur Schmieral Lubricant Lubrifiant Agip AGIP ACER 220 ee Aral Dego BG 220 BP Energol HLP 220 CASTROL HYSPIN VG 220 CASTROL MAGNA 220 Falcon Ck 220 Check the oil level refill if necessary From the oil dipstick pos CD fig 3 The correct checking of th
25. n within limits required by the transmission manufacturer 5 Oil in the pump casing is at level verified with a dipstick fig 14 pos 1 and exceptionally with a level indicator fig 14 pos 2 In case of prolonged storage or long term inactivity check proper functioning of the suction and outlet valves 10 2 Start up At first start up verify that the rotation direction and the supply pressure are correct Start up the pump without any load Check that the supply pressure is correct Check that the rotation rom during operation does not exceed the nominal rom of the pump Let the pump run for a period of no less than 3 minutes before putting it under pressure Before each pump stop reset pressure by means of the control valve or with any relieving devices and reduce to a minimum rpm activation with combustion motors 23 fe INTERPUMP Be A GROUP Pralissuli 11 PREVENTIVE MAINTENANCE For pump reliability and efficiency comply with maintenance intervals as shown in the table MANUTENZIONE PREVENTIVA Ogni 500 ore Ogni 1000 ore Verifica livello olio Cambio olio Verifica Sostituzione Tenute di H P Tenute di L P Verifica Sostituzione Valvole Sedi valvole Molle valvole Guide valvole 24 GROUP Pralissuli 12 PUMP STORAGE 12 1 Long term inactivity If the pump is started for the first time after a long period from t
26. needing to access the operating area must wait for the Operator to stop work on his her own initiative after which they should immediately make their presence known 8 It is important for safety that all team members are always fully aware of each other s intentions in order to avoid dangerous misunderstandings 9 The high pressure system must not be started up and run under pressure without all team members in position and without the Operator having already directed his her lance toward the work area 3 5 Safety during system maintenance 1 High pressure system maintenance must be carried out in the time intervals set by the manufacturer who is responsible for the whole group according to law 2 Maintenance should always be performed by trained and authorised personnel 3 Assembly and disassembly of the pump and the various components must only be carried out authorised personnel using appropriate equipment in order to prevent damage to components in particular to connections 4 Always only use original spare parts to ensure total reliability and safety 4 PUMP IDENTIFICATION Each pump has its own serial number XX XXX XXX see point and a specification label see point of fig 1 which shows Pump model and version Max revs Absorbed power Hp kW Flow rate l min Gpm Pressure bar P S I 1 N Model version and serial number must always be indicated when ordering spare parts Hc INTER
27. nt pressure or flow rate The pump is not primed for insufficient head or the outlet is closed during priming The pump is not primed for the fixing of some valves Worn valves Worn pressure seals Imperfect functioning of the pressure control valve Problems on the transmission The pump does supply the nominal flow rate excessive noise Insufficient supply See various causes as above The number of rpms is less than the nominal rate Excessive leakage of the pressure control valve Worn valves Excessive leakage of the pressure seals Cavitation due to 1 Improper sizing of suction ducts undersized diameters 2 Insufficient flow rate 3 Elevated water temperature The pressure supplied by the pump is insufficient Use nozzle is or has become higher than the capacity of the pump The number of rpms is insufficient Excessive leakage of the pressure seals Imperfect functioning of the pressure control valve Worn valves The pump is overheated The pump is working in pressure excess or the number of rpms is higher than the nominal rate Oil in the pump casing is not at level or not the recommended type as detailed in chapter 7 see point 7 4 Excess belt tension or joint or pulley alignment is incorrect Excessive pump tilt during operation Vibrations and shock to pipes A Air suction Imperfect functioning of the pressure control valve Valve ma
28. r all other auxiliary systems affected by high pressure 5 The ends of high pressure pipes must be sheathed and secured in a solid structure to prevent dangerous whiplash in case of bursting or broken connections 6 Appropriate protective casing must be provided in pump transmission systems couplings pulleys and belts auxiliary power outlets A 3 3 Safety during work The room or area within which the high pressure system operates must be clearly marked and prohibited to unauthorised personnel and wherever possible restricted or fenced Personnel authorised to access this area should first be instructed how to operate within this area and informed of the risks arising from high pressure system defects or malfunctions Before starting the system the Operator is required to verify that 1 The high pressure system is properly powered see chapter 9 section 9 5 2 The pump suction filters are perfectly clean it is appropriate to include a device indicating the clogging level on all devices 3 Electrical parts are adequately protected and in perfect condition 4 The high pressure pipes do not show signs of abrasion and the fittings are in perfect order Any fault or reasonable doubt that may arise before or during operation should be promptly reported and verified by qualified personnel In these cases pressure should be immediately cleared and the high pressure system stopped 3 4 Rules of conduct for the use of lances
29. s indifferent for proper pump functioning The unused ports must be hermetically closed 2 2 outlet ports 1 Gas 3 service ports 1 2 Gas usually used for the pressure gauge 11 fe INTERPUMP 54 GROUP Pratissoli 9 PUMP INSTALLATION 9 1 Installation The pump must be fixed horizontally using the M 16x1 5 threaded support feet Tighten the screws with a torque of 210 Nm The base must be perfectly flat and rigid enough as not to allow bending or misalignment on the pump coupling axis transmission due to torque transmitted during operation The unit cannot be fixed rigidly to the floor but must interposed with vibration dampers For special applications contact the Technical or Customer Service Departments A lifting bracket is mounted on the pump for easy installation as per the figure below Should it be necessary to disassemble it to avoid the entrance of dirt in the front part of the casing close the threaded hole with the cap provided the correct quantity with the oil dipstick Replace the oil filling hole closing service plug red positioned on the rear casing cover Check The oil dipstick must always be reachable even when the unit is assembled N The pump shaft PTO should not be rigidly connected to the propulsor unit The following types of transmission are recommended Hydraulics by flange for proper application consult with our Technical or Customer Service Departmen
30. ts V belt Cardan shaft comply with manufacturer s Max recommended working angles Flexible joint 12 ug INTERPUMP Z4 GROUP Quu I LASSO ea 9 2 Rotation direction The rotation direction is indicated by an arrow located on the casing near the drive shaft From a position facing the pump head the rotation direction will be as in fig 5 antiorario fig 5 9 3 Version change The pump version is defined as right when Observing the pump facing the head side the pump shaft must have a PTO shank on the right side The pump version is defined as left when Observing the pump facing the head side the pump shaft must have a PTO shank on the left side Note The version shown in fig 5 is right amp The version can only be modified by trained and authorised personnel and carefully following the instructions below 1 Separate the hydraulic part from the mechanical part as indicated in chapter 2 section 2 2 1 of the repair manual 2 the mechanical part 180 and reposition the rear casing cover in such a way that the oil dipstick is turned upward Reposition the lifting bracket and relative hole closing plugs in the upper part of the casing Finally properly reposition the specification label in its housing on the casing Make sure that the lower casing draining holes in correspondence with the pistons are open and not closed from the plastic plugs provided for the previous version
31. use of base valves or other types of unidirectional valves Do not recirculate by pass valve discharge directly into suction Provide for proper guards inside the tank to prevent that water flow the bypass and the tank supply line can create vortexes or turbulence near the pump supply pipe port Localised restrictions should be avoided along the run of the duct as these can cause load losses resulting CON 10 Make sure the suction line is thoroughly clean inside before connecting it to the pump 14 fa INTERPUMP 257 GROUP Pralissuli 9 7 Filtration 1 filter must be installed on the pump suction line positioned as indicated in fig 6 and fig 6 a With a manually activated control valve 1 Filter 1 Prefilter 5 Manual control valve 2 Plunger pump Prefilter 3 Pressure 4 Safety valve With a pneumatically activated control valve 1 Filter 1 Prefilter 5 Pneumatic control valve Prefilter 2 Plunger pump 3 Pressure 4 Safety valve The filter must be installed as close as possible to the pump it must be easily inspected and must have the following characteristics 1 Minimum flow rate at least 3 times the nominal flow rate of the pump 2 Inlet outlet port diameters no smaller than the inlet port diameter of the pump 3 Filtration grade between 200 and 360 um a smooth pump operation regular filter cleaning is necessary planned according to the actual use of the
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