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Related Manuals for KRAL DL2 Series
Summary of Contents for KRAL DL2 Series
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Page 1: Operating Instructions
Operating instructions KRAL pump stations. Series DL2 Mechanical seal/Radial shaft seal OID 05en-GB Edition 2019-11 Original instructions www.kral.at... -
Page 2: Table Of Contents
Table of contents 1 About this document ............. 4 10.2.3 Checking the direction of rotation .... 19 10.2.4 Commissioning the pump station .... 20 General information ............ 4 10.3 During operation ............ 20 Associated documents .......... 4 10.3.1 Checking the operating pressure..... 20 Target groups .............. 4 10.3.2 Activating the reversing valve...... 22 Symbols................. 4 10.3.3 Adjusting the overflow valve ...... 22... - Page 3 Table of contents 16.2.4 Maintenance kit sealing kit radial shaft seal (DL2 as of 320/DS1) .......... 40 16.3 Repair kits.............. 40 16.3.1 Repair kit, overflow valve ........ 40 16.3.2 Repair kit non-return valve...... 41 17 Appendix............... 42 17.1 Tightening torques for screws with metric screw threads with and without wedge lock washers ...... 42 17.2 Tightening torques for screw plugs with thread meas- ured in inches and elastomer seal....... 42...
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Page 4: About This Document
1 About this document 1.1 General information 1 About this document 1.1 General information These instructions form part of the product and must be kept for future reference. Furthermore please observe the associated documents. 1.2 Associated documents o Declaration of conformity according to EU Directive 2006/42/EC o Manufacturer's declaration according to EU Directive 2014/68/EU o Corresponding operating instructions of the pump o Technical documentation of the supplied components... -
Page 5: Danger Signs
1 About this document 1.4 Symbols 1.4.2 Danger signs Meaning Source and possible consequences of non-observance Electrical voltage Electrical voltage causes serious physical injury or death. Raised load Falling objects can result in serious physical injury or death. Heavy load Heavy loads can result in serious back problems. -
Page 6: Symbols For Personal Protective Equipment
2 Safety 2.1 Proper use 1.4.4 Symbols for personal protective equipment Additional dangers arise for personnel without personal protective equipment. It is imperative that the personal protective equipment be worn. Information on the personal protective equipment is provided separately at the beginning of the indi- vidual chapters in these instructions. -
Page 7: Safety Instructions
3 Identification 2.4 Safety instructions 2.4 Safety instructions 2.4.1 Fundamental safety instructions The following safety instructions must be observed strictly: o Read these operating instructions carefully and observe them. o Read the operating instructions of the components carefully and observe them. o Have work only carried out by qualified personnel/trained personnel. -
Page 8: Rating Plate
ºC ¹ Serial number max. / p max. mm²/s Type Jahr | Year Gewicht | Weight KRAL GmbH, 6890 Lustenau, Austria KRAL GmbH, 6890 Lustenau, Austria www.kral.at www.kral.at Article number Fig. 2: Rating plate Differential pressure Nominal delivery rate Rated speed... -
Page 9: Weights
Fig. 4: Hydraulic scheme 5.2 Functional principle Pump stations of the DL2 series with two KRAL screw pumps of the series FE or NE are suitable for pumping light oil. Screw pumps are rotating pumps. Their displacement effect results from three rotating screws 9 and 11 and the enclosing cartridge housing 10. -
Page 10: Overflow Valve
6 Transportation, storage 5.3 Overflow valve The pump station is connected with the pipe system via the connections 4 and 5. Depending on the po- sition of the reversing valve 6 the pumped liquid flows through the left, right or both pumps. The oil pan collects leaks from the pump station. -
Page 11: Dangers During Storage
6 Transportation, storage 6.2 Dangers during storage 6.2 Dangers during storage The following safety instructions must be observed: o Observe the storage conditions. 6.3 Unpacking and checking the state of delivery Upon delivery unpack the pump station and check it for damage during transportation. Report damage during transportation immediately to the manufacturer. -
Page 12: Storing The Pump Station
7 Preservation 6.5 Storing the pump station 6.5 Storing the pump station During the test run, the internal components of the pump station are wetted with test oil, which has a preservative effect. The pipe connections are fitted with protective covers. Unless otherwise specified, the outer parts of the pump station are preserved with a single-coat PU-based two-component paint. -
Page 13: Preserving The Outer Surfaces
7 Preservation 7.3 Preserving the outer surfaces Open the screw plug 1. Pour the preservative into the station block until it reaches approx. 2 cm under the rim, while slowly turning the fan impeller of the motor in the direction of rotation at the pumps. Close the screw plug. -
Page 14: Installation, Removal
8 Installation, removal 8.1 Dangers during installation Drain the pump station, collecting the preservative in a collection tank. To remove the residual preservative, flush the pump station with the pumped liquid. 8 Installation, removal 8.1 Dangers during installation The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. -
Page 15: Removing The Pump Station
8 Installation, removal 8.4 Removing the pump station Suction-side connection Pressure-side connection Fastening element Fig. 8: Mounting the pump station Requirement: ü Pump station connections protected against soiling, for example by using the protective cover mounted in the factory Bring the pump station into the installation position. Take the flow direction into consideration. Fasten the pump station with fastening elements 3 securely on the underground. -
Page 16: Connection
9 Connection 9.1 Dangers during connection work Ensure that the pump station is depressurized. Close the pressure-side and suction-side shut-off devices. Loosen the connecting screws of the suction connection and the pressure connection. Collect any discharging pumped liquid. After the pumped liquid has been drained completely, dismantle the pressure-side and suction- side connecting flange. -
Page 17: Connecting The Pump Station To The Power Supply
9 Connection 9.3 Connecting the pump station to the power supply ATTENTION Damage to device through impurity in the pipe system. ► During welding work attach protective covers in front of the connecting flanges. ► Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and the pump station. -
Page 18: Operation
10 Operation 10.1 Dangers during operation 10 Operation 10.1 Dangers during operation The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before commissioning ensure that a safety valve has been installed in the pressure-side pipe sys- tem to protect the pump station. -
Page 19: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. ► Wear personal protective clothing during all the work. Ensure face protection. ► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations. -
Page 20: Commissioning The Pump Station
10 Operation 10.3 During operation 10.2.4 Commissioning the pump station Personnel qualification: o Fitter o Electrician o Work clothing Personal protective equipment: o Protective helmet o Protective gloves o Safety boots o Face protection o Collection tank Aids: WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. - Page 21 10 Operation 10.3 During operation ATTENTION Leak in the pressure gauge through permanently opened pressure gauge shut-off valve. ► Close the pressure gauge shut-off valve immediately after completing reading. Open the pressure gauge shut-off valve. Read the operating pressure and close the pressure gauge shut-off valve. Operating instructions OID 05en-GB Edition 2019-11...
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Page 22: Activating The Reversing Valve
10 Operation 10.3 During operation 10.3.2 Activating the reversing valve Personnel qualification: o Trained personnel Fig. 11: Reversing valve lever Fig. 12: Positions of the reversing valve Notice The reversing valve can be operated during operation. Turn the lever 1 to the left. ð... -
Page 23: Switching Off The Pump Station
10 Operation 10.4 Decommissioning Requirement: ü Pressure-side pressure gauge installed Switch on the pump and remove the screw plug 1 of the overflow valve. Increase the supply pressure step-by-step to check the opening pressure of the overflow valve. Keep an eye on the pressure gauge and make sure that the operating limits are observed. ð... -
Page 24: Recommissioning
11 Maintenance 10.5 Recommissioning Behaviour of the pumped Duration of the operation interruption liquid Short Long o Solids sediment Flush the pump station. Flush the pump station. o Congealed/frozen Heat or drain the pump station. Drain the pump station. o No corrosive burden o Congealed/frozen Heat or drain the pump station. -
Page 25: Maintaining The Pump Station
12 Servicing 11.4 Maintaining the pump station 11.4 Maintaining the pump station o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Safety boots Check the pump station visually and acoustically every four weeks. If there are signs of wear, eliminate the cause Ä Servicing, Page 25. Observe the additional operating instructions of optional components. -
Page 26: Replacing The Coupling
12 Servicing 12.3 Replacing the coupling 12.3 Replacing the coupling 12.3.1 Removing the coupling As of size 320 couplings are installed in the pump stations of the series DL2. o Fitter Personnel qualification: Personal protective equipment: o Work clothing o Protective gloves o Safety boots o Extractor Aids:... -
Page 27: Replacing The Pump (Dl2 To 240)
12 Servicing 12.4 Replacing the pump (DL2 to 240) Slide the pump-side coupling half 9 onto the shaft until it stops. Place the pump bracket 6 via stud screws 10 on the housing 11 and tighten the hexagon nuts 8 with torque. Measure and write down the distance X between the face of the coupling claws and the connect- ing surface of the pump bracket. -
Page 28: Replacing The Pump (Dl2 From 320)
12 Servicing 12.5 Replacing the pump (DL2 from 320) WARNING Risk of injury through emitted pumped liquid when working on the pump station without previ- ous pressure relief. ► Open the screw plug of the vent hole by a max. of 2 rotations in order to reduce the internal pres- sure in the housing. -
Page 29: Replacing The Mechanical Seal
12 Servicing 12.6 Replacing the mechanical seal WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. ► Wear personal protective clothing during all the work. Ensure face protection. ► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations. -
Page 30: Installing The Mechanical Seal (Dl2 From 320/Ds1)
12 Servicing 12.6 Replacing the mechanical seal Remove the feather key 1 from the main screw 6. Remove the socket screws 2 and pump flange 3. Press the stationary seal ring 4 together with the O-ring out of the pump flange. Standard mechanical seal: Remove rotary seal ring with spring 5 from the main screw. Mechanical seal of hard material (without figure): Loosen the threaded pins. -
Page 31: Replacing The Radial Shaft Seal
12 Servicing 12.7 Replacing the radial shaft seal 12.7 Replacing the radial shaft seal 12.7.1 Removing the radial shaft seal (DL2 to 240) Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Extractor Aids: Requirement: ü... -
Page 32: Removing The Radial Shaft Seal (Dl2 As Of 320/Ds1)
12 Servicing 12.7 Replacing the radial shaft seal 12.7.3 Removing the radial shaft seal (DL2 as of 320/DS1) Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Extractor Aids: Requirement: ü Cartridge pump removed Remove the feather key 1 from the main screw 8. -
Page 33: Replacing Seals
12 Servicing 12.8 Replacing seals 12.8 Replacing seals Notice The maintenance kit contains only the parts marked with * and is only supplied complete. o Fitter Personnel qualification: Personal protective equipment: o Work clothing o Protective gloves o Safety boots o Solvent Aids: o Silicone grease... -
Page 34: Disposal
13 Disposal 13.1 Dismantling and disposing of the pump station Pressure gauge: Replace the copper seal 14* Remove the pressure gauge 13. Replace the copper seal 14* and mount the pressure gauge. Reversing valve: Replace the O-ring 9* and screw plug 10* Remove the reversing valve lever 7, circlip 8, O-ring 9* and screw plug 10* Lightly grease the new O-ring and insert it. -
Page 35: Troubleshooting
14 Troubleshooting 14.1 Possible faults 14 Troubleshooting 14.1 Possible faults Faults can have different causes. The following tables list the symptoms of a fault, the possible causes and measures for troubleshooting. Identifica- Fault tion No pump suction Delivery rate too low Pump too loud Motor overload Uneven delivery rate... - Page 36 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – 2 – 4 – – – Speed/frequency/voltage of the motor false Ensure that the motor frequency and voltage match the operating voltage. Ensure that the speed of the motor matches the rating plate of the pump. If necessary ad- just the speed.
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Page 37: Accessories
15 Accessories 15.1 Pump station accessories Fault identification Cause Remedy 1 2 3 4 – – 7 Pump damaged through dry running Contact the manufacturer. 1 – – – – – – Pump does not vent Vent the pressure line at the highest point. 1 2 3 –... -
Page 38: Maintenance Kits
16 Spare parts 16.2 Maintenance kits 16.2 Maintenance kits 16.2.1 Maintenance kit sealing kit pump station Notice The maintenance kit contains only the numbered parts and is only supplied complete. 739.1 735.1 055.1 908.2 222.1 908.1 730.3 222.1 730.3 735.1 908.2 739.2 739.3... -
Page 39: Maintenance Kit Sealing Kit Pump (Dl2 To 240)
16 Spare parts 16.2 Maintenance kits 16.2.2 Maintenance kit sealing kit pump (DL2 to 240) Notice The maintenance kit contains only the numbered parts and is only supplied complete. 739.3 739.2 Qty. Item No. Part Support ring 739.2 O-ring 739.3 O-ring Radial shaft seal ring Tab. 15: Maintenance kit sealing kit pump (DL2 to 240) 16.2.3 Maintenance kit sealing kit mechanical seal (DL2 as of 320/DS1) -
Page 40: Maintenance Kit Sealing Kit Radial Shaft Seal (Dl2 As Of 320/Ds1)
16 Spare parts 16.3 Repair kits 16.2.4 Maintenance kit sealing kit radial shaft seal (DL2 as of 320/DS1) Notice The maintenance kit contains only the numbered parts and is only supplied complete. 739.3 739.2 Qty. Item No. Part Support ring Copper seal 739.2 O-ring 739.3... -
Page 41: Repair Kit Non-Return Valve
16 Spare parts 16.3 Repair kits 16.3.2 Repair kit non-return valve Notice The repair kit contains only the numbered parts and is only supplied complete. 730.3 730.3 222.1 222.1 Qty. Item No. Part Washer 222.1 Flat gasket Pressure spring 730.3 Flat gasket Tab. 19: Repair kit non-return valve Operating instructions... -
Page 42: Appendix
17 Appendix 17.1 Tightening torques for screws with metric screw threads with and without wedge lock washers 17 Appendix 17.1 Tightening torques for screws with metric screw threads with and without wedge lock washers Notice In the case of galvanised screw plugs and screw plugs made of stainless steel the inner thread and outer thread have to be greased thorough before mounting in order to prevent threads from seizing. -
Page 43: Contents Of The Declaration Of Conformity
17 Appendix 17.3 Contents of the Declaration of Conformity 17.3 Contents of the Declaration of Conformity The products described in these instructions are machinery in the sense of the Directive 2006/42/EC. The original of the EC Declaration of Conformity is enclosed with the machinery at delivery. The machinery fulfils all the relevant provisions of the following directives: Number Name... - Page 44 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...
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