Table of Contents
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Table of Contents
Troubleshooting
Related Manuals for KRAL DL3 Series
Summary of Contents for KRAL DL3 Series
- Page 1 Operating instructions KRAL pump stations. Series DL3 / DL4 / DS1 / DS3 / DS4 Magnetic coupling Observe safety instructions for persons with cardiac pacemaker, metallic implant or neurostimulator. OID 07en-GB Edition 2020-03 Original instructions www.kral.at...
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Page 2: Table Of Contents
Table of contents 1 About this document ............. 4 Dangers during connection work ......... 20 General information ............ 4 Connecting the pump station to the pipe system .. 20 Associated documents .......... 4 Connecting the pump station to the power supply .. 21 Target groups .............. 4 10 Operation................ - Page 3 Table of contents 15.2.7 Commissioning the fluid heating system.. 44 16 Spare parts .............. 45 16.1 Overview.............. 45 16.2 Maintenance kits............ 45 16.2.1 Maintenance kit sealing kit pump station (DL3/ DL4/DS3/DS4) .......... 45 16.3 Repair kits.............. 46 16.3.1 Repair kit, overflow valve ........ 46 16.3.2 Repair kit non-return valve...... 47 16.4 Other spare parts............ 48 16.4.1 Overview pump and magnetic coupling .. 48 17 Appendix...............
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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. Magnetic field Magnetic field can cause 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
2 Safety 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: Identification
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: Technical Data
4 Technical data 4.1 Assignment of the sizes of pump station and pump 4 Technical data 4.1 Assignment of the sizes of pump station and pump 1800 3200 1600 2300 4000 1100 2000 2900 6000 1500 3200 1800 4000 2300 6000 2900 1000... -
Page 10: Sound Pressure Level
4 Technical data 4.5 Sound pressure level 4.5 Sound pressure level Guide value at 1 m distance, rated speed of the station, 50 Hz operation Size DL3 Size DL4 1800 2300 2900 3200 4000 6000 Max. sound pressure level ±3 [dB(A)] Pump 53.0 54.6 56.1 56.2 58.0... -
Page 11: Function Description
Pump stations of the DL3 and DL4 series are suitable for pumping light oil. Pump stations of the DS1, DS3 and DS4 series are suitable for pumping heavy fuel oil. The pump stations are equipped with two KRAL screw pumps of the NE series. Screw pumps are rotating displacement pumps. Their displacement effect results from three rotating screws 12 and 13 and the enclosing cartridge housing 14. -
Page 12: Magnetic Coupling
5 Function description 5.3 Magnetic coupling 5.3 Magnetic coupling The shaft end of the pump 12 is enclosed by a containment can 13, that is connected air-tight with the motor-side flange of the pump. Therefore, it is not necessary to seal a rotating free shaft end against a stationary seal housing. -
Page 13: Pressure Measurement
6 Transportation, storage 5.6 Pressure measurement 5.6 Pressure measurement A pressure gauge 8 is located in the centre of the station in order to monitor the supply pressure. The pressure gauge is always connected to the pressure side of the station and is thus independent of the position of the reversing valve 6. -
Page 14: Transporting The Pump Station
6 Transportation, storage 6.4 Transporting the pump station 6.4 Transporting the pump station o Transport personnel Personnel qualification: o Work clothing Personal protective equipment: o Protective helmet o Protective gloves o Safety boots Aids: o Mobile crane, forklift, hoisting equipment DANGER Magnetic field. -
Page 15: Preservation
7 Preservation 7.1 Preservation table The manufacturer offers a long-term preservation for storage times of up to 60 months. The pump sta- tion is additionally packed in hermetically sealing anti-corrosion paper. o Transport personnel Personnel qualification: o Mobile crane, forklift, hoisting equipment Aids: DANGER Magnetic field. -
Page 16: Preserving The Outer Surfaces
7 Preservation 7.3 Preserving the outer surfaces 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 strainer cover. After about six months storage check the filling level of the oil and if necessary top up. -
Page 17: Installation, Removal
8 Installation, removal 8.1 Dangers during installation Clean the outside of the pump station with solvents, if necessary using a steam-jet cleaning device. Remove the screw plug 1 carefully in order to reduce any pressure that may exist in the pump station. -
Page 18: Removing The Pump Station
8 Installation, removal 8.4 Removing the pump station DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu- lator perform work on the pump station. WARNING Risk of injury and damage to equipment through falling and toppling parts. - Page 19 8 Installation, removal 8.4 Removing the pump station DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu- lator perform work on the pump station. DANGER Risk of death resulting from electric shock.
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Page 20: Connection
9 Connection 9.1 Dangers during connection work Open the screw plugs 1, collect any discharging pumped liquid. Remove the pump station. 9 Connection 9.1 Dangers during connection work The following safety instructions must be observed: o Have all work on the pump station and pipe system only carried out by authorized qualified per- sonnel. -
Page 21: 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 22: 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 23: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning Requirement: ü Shut-off devices of the suction line and pressure line closed ü Lever of the reversing valve to middle position Open the screw plug of the vent hole 3 by a max. of two rotations so that air can escape during the filling process. -
Page 24: During Operation
10 Operation 10.3 During operation DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu- lator perform work on the pump station. WARNING Risk of injury through emitted pumped liquid. -
Page 25: Adjusting The Overflow Valve
10 Operation 10.3 During operation DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu- lator perform work on the pump station. ATTENTION Leak in the pressure gauge through permanently opened pressure gauge shut-off valve. -
Page 26: Activating The Reversing Valve
10 Operation 10.3 During operation Turn the adjusting screw 2 to set the opening pressure: Turning clockwise: Increase the opening pressure Turning counter-clockwise: Reduce the opening pressure Repeat Steps 2 and 3 until the desired opening pressure is reached. Tighten the screw plug 1 again. 10.3.3 Activating the reversing valve Personnel qualification: o Trained personnel... -
Page 27: Decommissioning
10 Operation 10.4 Decommissioning DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu- lator perform work on the pump station. ATTENTION Damage to seal through pressurizing during standstill. -
Page 28: 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 sta- Drain the pump station. o No corrosive burden tion. -
Page 29: Maintaining The Strainers
11 Maintenance 11.4 Maintaining the strainers DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ► Under no circumstances may persons with cardiac pacemakers, metallic implant or neurostimu- lator perform work on the pump station. Check the pump station visually and acoustically every four weeks. -
Page 30: Servicing
12 Servicing 12.1 Dangers during servicing Play of the ball bearing (bearing clearance) Radial bearing clearance Axial bearing clearance Fig. 15: Bearing clearance The ball bearing must be replaced when the limit values of the radial and axial play (bearing clearance) are exceeded. -
Page 31: Cleaning The Strainer
12 Servicing 12.3 Cleaning the strainer 12.3 Cleaning the strainer The frequency of cleaning the filter depends on the degree of soiling of the pumped liquid. In case of strongly soiled strainers cavitation and strong noise generation arise. The suction-side pressure gauge is used to indicate the degree of soiling. -
Page 32: Replacing The Magnetic Coupling
12 Servicing 12.4 Replacing the magnetic coupling Remove the conical spring 5 and the strainer insert 6 from the strainer chamber. Clean the strainer insert, for example by washing it in a solvent. Reinsert the strainer insert and conical spring. Place the strainer cover with O-ring and tighten with cap nuts. Place the reversing valve lever in the desired position. -
Page 33: Installing The Inner Rotor
12 Servicing 12.4 Replacing the magnetic coupling Remove the screws of the tensioning element. Turn the screws back into the existing threaded holes. ð This loosens the tensioning element from the inner rotor and from the pump shaft. 12.4.3 Installing the inner rotor Personnel qualification: o Fitter o Work clothing... -
Page 34: Replacing The Pump
12 Servicing 12.5 Replacing the pump WARNING Danger of crushing when assembling motor and pump. When the motor approaches the pump, high magnetic forces can produce sudden collisions and thus injuries to hands or fingers. ► Two persons are required for the assembly. ►... -
Page 35: Replacing The Ball Bearing
12 Servicing 12.6 Replacing the ball bearing 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 36: Replacing Seals
12 Servicing 12.7 Replacing seals 12.7 Replacing seals 12.7.1 Replacing seals (DL3/DL4/DS3/DS4) 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 Aids: o Solvent... - Page 37 12 Servicing 12.7 Replacing seals Control block: Replace the flat gasket 27* Take off the hexagon screws 25, welding neck flange 26 and flat gasket 27*. Clean the sealing surface and place on the new flat gasket. Mount the welding neck flange with hexagon screws with torque. Housing: Replacing the screw plug 10* Replace the screw plug 10*.
- Page 38 12 Servicing 12.7 Replacing seals 12.7.2 Replacing seals (DS1) Notice The maintenance kit contains only the parts marked with * and is only supplied complete. o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Safety boots Aids: o Solvent o Silicone grease...
- Page 39 12 Servicing 12.7 Replacing seals Replace the screw plug 10*. Overflow valve: Replacing the screw plug 28* Replace the screw plug 28*. Control block: Replace the screw plug 36* Replace the screw plug 36*. Control block: Remove the O-ring 27* Take off the hexagon screws 25, welding neck flange 26 and O-ring 27*. Lightly grease the new O-ring and insert it.
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Page 40: Disposal
13 Disposal 13.1 Dismantling and disposing of the pump station 13 Disposal 13.1 Dismantling and disposing of the pump station Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Face protection o Protective gloves o Safety boots o Solvents or industrial cleaners suitable for the pumped liquid Aids: o Collection tank DANGER... -
Page 41: Troubleshooting
14 Troubleshooting 14.2 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy 1 – – – – – – Pump suction line closed Check the shut-off devices. If required, open. 1 2 3 – 5 – – Parts soiled (filter, suction line, suction valve, strainer) Clean parts. -
Page 42: Accessories
15 Accessories 15.1 Pump station accessories Fault identification Cause Remedy – – 3 – – – – Vibrations/pulsations in the system Bear the pump station elastically. -or- Make the connections with hoses. – – 3 – – – – Flow speed in the pressure line or suction line too high Set the flow speed in the pressure line so that it does not exceed 3 m/s. -
Page 43: Heating
15 Accessories 15.2 Heating 15.2 Heating 15.2.1 Possible types of heating Pump stations of the DS series can be equipped optionally with a heating system. The manufacturer recommends a heating system at high-viscosity pumped liquids that do not flow sufficiently if not heated. -
Page 44: Heating-Up Period
15 Accessories 15.2 Heating 15.2.4 Heating-up period Electrical heating system Required heating-up period for temperature differences of 20 °C or 50 °C: Series Wattage Heating-up period [min] at a temperature difference of 20 °C 50 °C 1 x 180 DS3, DS4 1 x 250 Tab. 18: Heating-up period for electric heating system Fluid heating system Required heating-up period for temperature differences of 20 °C or 50 °C at liquid temperature of... -
Page 45: Spare Parts
16 Spare parts 16.1 Overview DANGER Risk of injury through emitted pumped liquid. The pump housing may burst through heat expansion of the pumped liquid. ► Open all the valves during the heating process. Take the required heating-up periods into account Ä Accessories, Page 42. When setting the pressure and temperature of the heating fluid take the permissible operating limits of the pump into account Ä... -
Page 46: Repair Kits
16 Spare parts 16.3 Repair kits Qty. Item No. Part 729.1 Flat gasket 729.2 Flat gasket 735.1 Copper seal 739.1 O-ring 739.2 O-ring 739.3 O-ring 739.4 O-ring 739.5 O-ring 908.1 Screw plug Tab. 21: Maintenance kit sealing kit pump station (DL3/DL4/DS3/DS4) 16.3 Repair kits 16.3.1 Repair kit, overflow valve Notice The repair kit contains only the numbered parts and is only supplied complete. -
Page 47: 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. 751.2 304.1 739.3 739.4 739.3 304.2 751.3 Qty. Item No. Part Flat gasket Valve insert 304.1 Valve cone 304.2... -
Page 48: Other Spare Parts
16 Spare parts 16.4 Other spare parts 16.4 Other spare parts 16.4.1 Overview pump and magnetic coupling 739.x 585 518 915.x 739.x 915.x Qty. Item No. Part Containment can Outer rotor support Flange cover Bearing cover Edge sealing ring Circlip Outer rotor Inner rotor Tensioning element... -
Page 49: 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 50: 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 51 Notes Operating instructions OID 07en-GB Edition 2020-03...
- Page 52 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...
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