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KRAL ELL 11 Operating Instructions Manual
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KRAL ELL 11 Operating Instructions Manual

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Operating instructions
KRAL pump stations.
ELL/ELS 11/12/13/14
Magnetic coupling
The safety instructions for persons with cardiac pacemakers, metallic implants or
neurostimulators must be observed.
OIL 04en-GB
Edition 2024-11
Original instructions
www.kral.at

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Summary of Contents for KRAL ELL 11

  • Page 1 Operating instructions KRAL pump stations. ELL/ELS 11/12/13/14 Magnetic coupling The safety instructions for persons with cardiac pacemakers, metallic implants or neurostimulators must be observed. OIL 04en-GB Edition 2024-11 Original instructions www.kral.at...
  • Page 2 Table of contents 1 About this document........... 4 Mounting the pump station ......... 20 General information............ 4 Protecting the pump station against pressure peaks .. 21 Associated documents ..........4 Removing the pump station ........21 Target groups ............. 4 9 Connection..............
  • Page 3 Table of contents 16.4 Contents of the Declaration of Conformity ....45 Operating instructions OIL 04en-GB Edition 2024-11...
  • Page 4 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 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 2 Safety 2.1 Proper use Meaning Possible consequences of non-observance Heat-resistant protective gloves Serious burns or cuts with arm protection Close fitting work clothing Serious physical injury through clothes being drawn in Slip resistant safety boots Serious foot injury through falling or toppling parts and seri- ous physical injury through falling 2 Safety 2.1 Proper use...
  • Page 7 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 Serial number max. / p max. mm²/s Type Jahr | Year Gewicht | Weight Article number KRAL GmbH, 6890 Lustenau, Austria KRAL GmbH, 6890 Lustenau, Austria www.kral.at www.kral.at Fig. 2: Rating plate Differential pressure Nominal delivery rate Rated speed 10 Nominal viscosity...
  • Page 9 4 Technical data 4.1 Operating limits 4 Technical data 4.1 Operating limits Parameter Unit ELL 11 ELL 12/13 ELL 14 ELS 11 ELS 12/13 Max. operating pressure o Pump unit [bar] o Strainer + degasser [bar] o Shut-off devices o Suction side and re-...
  • Page 10 4 Technical data 4.4 Output tables 4.4 Output tables To determine the effective delivery rate the minimum return volume has to be deducted. In the case of the ELL 14 series the specified inlet pressure and a maximum burner capacity of 2400 l/h has to be taken into consideration.
  • Page 11 5 Function description 4.5 Mesh width strainer/filter 4.5 Mesh width strainer/filter Options Usage Viscosity Mesh width [mm] Strainer Separation of coarse soiling during oper- < 20 0.25 ation > 20 Commissioning strainer/ Protection of the station during commis- – 0.02 commissioning filter sioning Operating filter...
  • Page 12 Pump unit Pressure maintaining valve Strainer Base frame Deaerator with integrated strainer Venting KRAL flowmeter Suction-side pressure gauge KRAL Electronic Unit Pressure-side pressure gauge Ball valve Overflow valve 5.2 Structure of special design 3 19 Fig. 7: ELL 14 special design Pump unit...
  • Page 13 The flow measurement consists of a KRAL flowmeter 4 with integrated pick up and the corresponding KRAL electronic unit 5. Detailed information on the pump, flowmeter, pick up and electronic unit is available in the associated operating instructions.
  • Page 14 5 Function description 5.6 Expansion valve (optional) 5.6 Expansion valve (optional) Fig. 8: Structure of expansion valve Screw plug Valve body Adjusting screw Inflow from the station Pressure spring Overflow When the station is switched off, thermal expansion of the fluid volume which is caused by heating up can result in an impermissibly high inner pressure.
  • Page 15 5 Function description 5.8 Options for standard version 5.8 Options for standard version Electrical heating system strainer Pressure monitor for pressure line Venting with time control Override switch for ball valve Differential pressure indicator Ball valve with limit switch Expansion valve Non-return valve Drain valve strainer Leak oil monitoring...
  • Page 16 6 Transportation, storage 6.1 Dangers during transportation The heating element is inserted into the strainer chamber and fastened with a special cover. The oil heated up in the strainer also enters the pump and thus ensures reliable starting. Parameter Unit Value Voltage Heating output...
  • Page 17 6 Transportation, storage 6.5 Storing 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 18 7 Preservation 7.1 Preservation table ATTENTION Damage to equipment and corrosion if stored improperly and during longer standstills. ► Protect the pump station against damage, heat, sunlight, dust, moisture and magnetic fields. ► Protect against corrosion during longer standstill. ► Observe measures for storing and preservation. Store cool and dry and protect against sunlight.
  • Page 19 8 Installation, removal 7.4 Removing the preservation 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. ®...
  • Page 20 8 Installation, removal 8.2 Dangers during removal 8.2 Dangers during removal The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before beginning work, let the pump station cool down to the ambient temperature. o Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations.
  • Page 21 8 Installation, removal 8.4 Protecting the pump station against pressure peaks Fig. 11: Securing the oil pan After the connecting work clean the pipe system thoroughly Ä Commissioning, Page 26. 8.4 Protecting the pump station against pressure peaks DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►...
  • Page 22 9 Connection 9.1 Dangers during connection work DANGER Risk of death resulting from electric shock. ► Ensure that the electrical power supply is de-energized and is secured against being switched back on. ► Observe the operating instructions of the electrical components. DANGER Risk of death resulting from falling load.
  • Page 23 9 Connection 9.2 Connecting the pump station to the pipe system 9.2 Connecting the pump station to the pipe system 9.2.1 Setup of the suction line Fig. 12: Setup of the suction line Lay the suction line hermetically sealed. If preheated heating oils are pumped, install the tank above the station and lay the suction line without siphon or pipe elbow.
  • Page 24 9 Connection 9.2 Connecting the pump station to the pipe system Attach protective covers in front of the connecting flanges before welding work. Place the piping in position and support the weight of the piping. Do not use the pump station as a support for connected piping.
  • Page 25 10 Operation 9.3 Connecting the pump station to the power supply Screw the union nut lightly in by hand. While doing so, press the pipe against the stop in the in- ternal cone. Tighten the union nut. The pipe may not turn as well in the process. 9.3 Connecting the pump station to the power supply o Electrician Personnel qualification:...
  • Page 26 10 Operation 10.2 Commissioning 10.2 Commissioning 10.2.1 Cleaning the pipe system Note Soiling in the pipe system impairs the service life of the pump station. If the pipe system is flushed us- ing the pump station during the initial commissioning, an additional commissioning filter has to be in- stalled temporarily before the pump station.
  • Page 27 10 Operation 10.2 Commissioning Filling and venting the pump station via the suction connection or pressure connection Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Protective helmet o Safety boots o Face protection o Collection tank Aids: DANGER Magnetic field.
  • Page 28 10 Operation 10.2 Commissioning Dismantle the strainer cover. Fill the pumped liquid into the strainer until it is filled completely. Vent the pump and strainer. Observe the associated operating instructions while doing so. Fill the strainer chamber again with pumped liquid. Mount the strainer cover.
  • Page 29 10 Operation 10.2 Commissioning ATTENTION Dry running can damage pump equipment. ► Ensure that the pump and the connected pipe system are filled properly. ► If the pump does not deliver after 10 – 15 seconds, abort commissioning. Requirement: ü Filter/strainer with magnetic separator installed on suction side ü...
  • Page 30 10 Operation 10.3 During operation 10.3 During operation 10.3.1 Checking the operating pressure Personnel qualification: o Trained personnel Fig. 15: Pressure gauge shut-off valves closed/open - principle diagram DANGER Magnetic field. Risk of death for persons with cardiac pacemaker, metallic implant or neurostimulator. ►...
  • Page 31 10 Operation 10.4 Decommissioning Remove the screw plug A. Switch on the station and set the desired pressure by turning the setting screw C. If a pressure gauge does not exist on the system side, this can be connected to the pressure gauge connec- tion B.
  • Page 32 11 Maintenance 10.5 Recommissioning 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 33 11 Maintenance 11.2 Required maintenance 11.2 Required maintenance The service life depends on the observance of the operating conditions of the pump station and the re- quirements from the operating instructions of the components. Component Required maintenance Cycle o Visual inspection Pump station 4 weeks o Acoustic inspection...
  • Page 34 12 Servicing 11.5 Maintaining the magnetic coupling 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 strainers visually and acoustically every four weeks.
  • Page 35 12 Servicing 12.3 Servicing the pump station If iron particles accumulate and deposit on the inner rotor and containment can, regular inspection and cleaning of the magnetic coupling is required. In this case, the manufacturer recommends installing a filter/strainer with magnetic separator or a similar device to catch ferrous particles upstream of the pump.
  • Page 36 12 Servicing 12.4 Replacing the pump 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.
  • Page 37 12 Servicing 12.5 Cleaning the strainer 12.5 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 38 13 Disposal 13.1 Dismantling and disposing of the pump station Fig. 17: Strainer (left) / Deaerator with integrated strainer (right) Close the pressure-side and suction-side shut-off devices. Open the vent screw 6/vent cock 7 carefully in order to reduce the pressure in the strainer. Drain the strainer by means of the drain screw 6.
  • Page 39 14 Troubleshooting 14.1 Possible faults Requirement: ü Disconnect the pump station from the power supply and secure it against being switched back on ü Pump station cooled down to the ambient temperature and disconnected from the pipe system ü Pump station drained completely ü...
  • Page 40 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 41 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – – 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. -or- Set the flow speed in the suction line so that it does not exceed 1 m/s.
  • Page 42 15 Spare parts 15.1 Overview 15 Spare parts 15.1 Overview 407.2 407.1 606.2 729.2 729.1 729.1 606.1 180 526 Fig. 18: ELL/ELS 11 407.2 407.2 407.1 606.2 729.2 729.1 729.1 606.1 180 526 Fig. 19: ELL/ELS 12 407.2 407.1 407.2 606.2 729.2 729.1 729.1 606.1...
  • Page 43 15 Spare parts 15.1 Overview 424 407.2 729.1 407.2 407.1 729.1 606.2 606.1 729.2 729.1 180 526 Fig. 21: ELL 14 405.4 408.4 405.3 408.3 408.2 408.5 405.2 408.3 405.1 408.1 Fig. 22: Strainer (left) / Deaerator with integrated strainer (right) Item No. Part Item No.
  • Page 44 16 Appendix 16.1 Tightening torques for screws with metric screw threads with and without wedge lock washers 16 Appendix 16.1 Tightening torques for screws with metric screw threads with and without wedge lock washers Note 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 45 16 Appendix 16.3 Tightening torques for screws of tensioning elements 16.3 Tightening torques for screws of tensioning elements Tightening torque [Nm] Thread 12.9 17.4 42.2 M 10 83.0 M 12 Tab. 19: Tightening torques tensioning elements 16.4 Contents of the Declaration of Conformity The products described in these instructions are machinery in the sense of the Directive 2006/42/EC.
  • Page 46 Notes Operating instructions OIL 04en-GB Edition 2024-11...
  • Page 47 Notes Operating instructions OIL 04en-GB Edition 2024-11...
  • Page 48 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...

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