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OPERATING INSTRUCTIONS OID 01en

Edition 11/2016
Original operating instructions

KRAL Pump Stations


Series DL/DS
Operating Instructions
Edition: 11/2016
OID 01en

T AB L E OF C ONT E NT S

AB OUT T HIS DOC UME NT ....................................................................................................................................................... 3


GENERAL INFORMATION ............................................................................................................................................................. 3
TARGET GROUPS ...................................................................................................................................................................... 3
SYMBOLS ................................................................................................................................................................................. 3
DANGER LEVELS ....................................................................................................................................................................... 3
ASSOCIATED DOCUMENTS .......................................................................................................................................................... 4
S AF E T Y .................................................................................................................................................................................... 4
PROPER USE ............................................................................................................................................................................ 4
SAFETY INFORMATION ................................................................................................................................................................ 4
L AB E L ING ................................................................................................................................................................................ 5
TYPE CODE .............................................................................................................................................................................. 5
RATING PLATE .......................................................................................................................................................................... 5
T E C HNIC AL DAT A ................................................................................................................................................................... 6
OPERATING LIMITS ..................................................................................................................................................................... 6
REQUIRED NPSH VALUES ............................................................................................................................................................ 6
HE AT ING S Y S T E M .................................................................................................................................................................. 7
ELECTRIC HEATING SYSTEM........................................................................................................................................................ 7
FLUID HEATING SYSTEM ............................................................................................................................................................. 7
F UNC T ION DE S C R IP T ION ...................................................................................................................................................... 9
STRUCTURE ............................................................................................................................................................................. 9
HYDRAULIC SCHEME .................................................................................................................................................................. 9
ASSIGNMENT CARTRIDGE PUMPS – STATIONS ............................................................................................................................... 9
FEED PRESSURE/SUCTION BEHAVIOR......................................................................................................................................... 10
OVERFLOW VALVE ................................................................................................................................................................... 10
PROTECTION AGAINST CONTAMINATION...................................................................................................................................... 10
T R ANS P OR T AT ION, S T OR AG E AND DIS P OS AL ............................................................................................................... 11
UNPACKING AND CHECKING THE STATE OF DELIVERY ................................................................................................................... 11
LIFTING THE PUMP STATION ...................................................................................................................................................... 11
STORAGE ............................................................................................................................................................................... 11
PRESERVATION ....................................................................................................................................................................... 11
DISPOSING OF THE STATION ..................................................................................................................................................... 12
INS T AL L AT ION, R E MOV AL AND C ONNE C T ION ................................................................................................................ 13
INSTALLATION ......................................................................................................................................................................... 13
CONNECTING THE STATION TO THE PIPE SYSTEM ......................................................................................................................... 13
FOOT-ACTUATED VALVE ........................................................................................................................................................... 13
CONNECTING THE MOTORS ....................................................................................................................................................... 13
OP E R AT ION ........................................................................................................................................................................... 14
COMMISSIONING ...................................................................................................................................................................... 14
DURING OPERATION................................................................................................................................................................. 15
MAINT E NANC E ...................................................................................................................................................................... 17
SAFETY INSTRUCTIONS ON MAINTENANCE AND REPAIRS ............................................................................................................... 17
REQUIRED MAINTENANCE ......................................................................................................................................................... 17
CLEANING THE STRAINER ......................................................................................................................................................... 18
INSTALLING/REMOVING THE CARTRIDGE PUMP ............................................................................................................................ 19
T R OUB L E S HOOT ING ............................................................................................................................................................ 20
POSSIBLE FAULTS ................................................................................................................................................................... 20
TROUBLESHOOTING ................................................................................................................................................................. 20
AP P E NDIX .............................................................................................................................................................................. 21
EXPLODED VIEWS ................................................................................................................................................................... 21
SECTIONAL VIEWS/SPARE PARTS .............................................................................................................................................. 23
TABLE OF TIGHTENING TORQUES .............................................................................................................................................. 27
CONTENTS OF THE EC DECLARATION OF CONFORMITY............................................................................................................... 27
Operating Instructions
Edition: 11/2016
OID 01en

ABOUT THIS DOCUMENT

GENERAL INFORMATION
The operating instructions form part of the pump/pump station and must be kept for future reference. Furthermore please
observe the associated documents.

TARGET GROUPS
Target group Tasks
Operator-owner □ Keep these instructions available at the installation site for future reference.

□ Ensure that employees read and observe these instructions and the associated documents, in
particular the safety instructions and warnings.

□ Observe additional system-specific directives and regulations.

Specialist personnel, □ Read, observe and follow these instructions and the associated documents, in particular the
fitters safety instructions and warnings.

SYMBOLS

Symbol Meaning

Warning personal injury

Notice

Procedures mechanical installation

Procedures electrical installation

Check or fault table

► Request for action

DANGER LEVELS

Warning Danger level Consequences of non-observances

DANGER Immediate threat of danger Serious personal injury, death

WARNING Possible threat of danger Serious personal injury, invalidity

CAUTION Potentially dangerous situation Slight personal injury

CAUTION Potentially dangerous situation Material damage

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Operating Instructions
Edition: 11/2016
OID 01en

ASSOCIATED DOCUMENTS
□ ATEX supplementary instructions for operation in potentially explosive areas
□ Declaration of conformity according to EU-Directive 2006/42/EC
□ Declaration of conformity according to EU Directive 2014/34/EU
□ Manufacturer's declaration as per EU Directive 2014/68/EU
□ Corresponding pump operating instructions
□ Technical documentation for supplied components

SAFETY

PROPER USE
□ Use the pump/pump station only for transporting lubricating liquids that are chemically neutral and that contain no gas
or solid components.
□ Use the pump/pump station only within the performance limitations specified on the rating plate and in the "Technical
data" section. In the case of operating data that does not agree with the specifications on the rating plate, please
contact the manufacturer.
□ The pump/pump station is specifically configured for the operating pressure stated by the customer. In the case of a
significant difference between actual and configured operating pressure damages can occur even within the stated
performance limitations. This applies both to notably higher as well as to notably lower operating pressures. Under no
circumstances should the operating pressure fall below the minimum pressure of 2 bars. In case of any doubt, please
contact the manufacturer.

SAFETY INFORMATION

The following general safety instructions must be observed:

□ No liability is accepted for damage arising through non-observance of the operating instructions.
 Read the operating instructions carefully and observe them.
 The operator-owner is responsible for the observance of the operating instructions.
 Installation, removal and installation work may only be carried out by specialist personnel.
□ In order for the warranty to remain valid, corrective maintenance carried out during the warranty period
requires the express permission of the manufacturer.
□ Observe the general regulations for the prevention of accidents as well as the local safety and operating
instructions.
□ Observe the valid national and international standards and specifications of the installation location.
□ In case of systems with an increased potential of danger to humans and/or machines the failure of a pump
may not lead to injuries or damage to property.
 Always equip systems with an increased potential of danger with alarm equipment.
 Maintain and check the protective/alarm equipment regularly.
□ The pumped liquid may be dangerous (for example hot, poisonous, combustible). Observe the safety
regulations for handling dangerous materials.
□ Pumped liquid can be subject to high pressure and can cause damage and/or personal injury should leaks
occur.

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Operating Instructions
Edition: 11/2016
OID 01en

LABELING

TYPE CODE

1 Model
2 Size
3 Shaft seal
4 Bearing
5 Heating system
6 Version index

Item Designation Type


1 Model DS1 Delivery of heavy fuel oil up to a max. of 1 300 l/h, ∆pmax = 6 bar
DL2 Delivery of light fuel oil up to a max. of 1 300 l/h, ∆pmax = 6 bar
DL3 / DS3 Delivery of light/heavy fuel oil up to a max. of 2 900 l/h, ∆pmax = 6 bar
DL4 / DS4 Delivery of light/heavy fuel oil up to a max. of 6 000 l/h, ∆pmax = 6 bar
2 Size Corresponds to flow rate in [l/h] at motor speed
3 Shaft seal A Radial shaft seal
B Standard mechanical seal
C Mechanical seal of hard material
4 Bearing A Inside bearing
B External bearing
5 Heating A Without heating system
system B With heating system
6 Version index For internal administration

RATING PLATE

4
1 Year of construction
3 6 2 Differential pressure/operating pressure max.
3 Temperature range
2 7 4 Serial number
5 Type
1 8 6 Nominal delivery rate
7 Rotation speed
8 Nominal viscosity

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Operating Instructions
Edition: 11/2016
OID 01en

TECHNICAL DATA

OPERATING LIMITS

Light fuel oil Heavy fuel oil


DL2 DL2 DL3 DL4 DS1 DS3 DS4
Pump stations
150 to
240 1300
Operating pressure max. [bar] 6 6 6 6 6 6 6
Temperature min. [°C] -10 -10 -10 -10 -10 -10 -10
Temperature max. [°C] 80 80 80 80 150 150 180
2
Viscosity [mm /s]
min. 2 2 2 2 10 10 10
max. 37 37 37 37 1000 1000 1000
Suction head refer to NPSH characteristics
Feed pressure [bar]
- Radial shaft seal 0.5
- Mechanical seal 5

REQUIRED NPSH VALUES


The following table lists the required NPSH values during operation with a low-volatile liquid such as lubricating oil or
hydraulic liquid. When liquids have readily volatile component content, the required NPSH values increase notably:

□ When the pumped liquid contains water (e. g. heavy fuel oil), the values in the table have to be increased by the
vapor pressure of the water at the specific operating temperature.

The required NPSH values also need to be increased if there are gas contents, regardless of whether it is dissolved or not.
In case of any doubt, please contact the manufacturer.
2
Viscosity [mm /s]
Cartridge 6* 37 152 380
-1
pump Rotation speed [min ]
1450 1750 2900 3500 1450 1750 2900 3500 1450 1750 2900 3500 1450 1750 2900 3500
NPSH required [mWC]
FE 5 / NE 5 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3.1
NE 7,5 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3.3 3.5
NE 10 3 3 3 3 3 3 3 3 3 3 3 3.3 3 3.1 3.6 4
NE 13 3 3 3 3.3 3 3 3 3.3 3 3 3.6 4.1 3.2 3.4 4.4 5.1
NE 15 3 3 3 3 3 3 3 3 3 3 3 3.2 3 3 3.6 3.9
NE 20 3 3 3 3.1 3 3 3 3.1 3 3 3.4 3.8 3.1 3.3 4.1 4.7
NE 26 3 3 3.2 3.7 3 3 3.2 3.7 3 3 3.9 4.5 3.3 3.6 4.9 5.8
NE 32 3 3 3 3 3 3 3 3 3 3 3.3 3.7 3 3.2 4 4.5
NE 42 3 3 3.2 3.7 3 3 3.2 3.7 3 3 3.9 4.5 3.3 3.6 4.9 5.8
NE 54 3 3 3.5 4.2 3 3 4 4.9 3.1 3.4 5 6.2 3.8 4.2 6.4 —
* For heating oil EL we recommend a maximal suction head of 4 mWC, measured at the station suction flange.

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Operating Instructions
Edition: 11/2016
OID 01en

HEATING SYSTEM
The pump stations can be equipped optionally with a heating system. We recommend heating systems for high-viscosity
liquids that do not flow sufficiently if not heated. This can result in excessive power consumption or to problems arising
through cavitation or sealing.

ELECTRIC HEATING SYSTEM


The output of the heating elements corresponds to the radiation and convection losses of the station in the required
temperature range so that overheating is not possible.
Operating data:
□ Voltage: 230 V
□ Frequency: 50/60 Hz
□ Wire cross-section: 2x1 mm
2

□ Heating output:
 DS 1: 180 W
 DS3/DS4: 250 W

WARNING
Danger of the station block bursting through heat expansion of the pumped liquid.

► Do not shut off the station from the pipe system during the heating process.

FLUID HEATING SYSTEM


Observe the heating-up temperatures in the pump and sealing chamber:
a) Radial shaft seal: max. 80 °C
b) Mechanical seal: max. 100 °C

Steam heating:
a) Temperature: max. 180 °C
b) Pressure: max. DS 1: 18 bar
Pressure max DS3, DS4: 6 bar
The maximum heating temperature of 100 °C must not be exceeded.

Heating-up times:

Electric a) Steam b) a) c) a)
heating ∆t [min] heating p t Steam amount ∆t (min)
system 20 °C 50 °C system [bar] [° C] [kg/h] 20 °C 50 °C
DS1 (180 W) 60 180 DS1 15 180 5 30 100
DS4 (250 W) 120 240 DS4 15 180 5 40 120

WARNING
Danger of the station block bursting through heat expansion of the pumped liquid.

► Do not shut off the station from the pipe system during the heating process.

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Operating Instructions
Edition: 11/2016
OID 01en

DS1 DS3, DS4

Electric heating system

Fluid heating system

070.1 End cover 730.2 Flat gasket


161 Heat conducting plate 908.2 Screw plug
242 Heating block 914.1 Socket screw
481 Heating element 915.4 Socket screw
484 Terminal strip
493 Screwed gland

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Operating Instructions
Edition: 11/2016
OID 01en

FUNCTION DESCRIPTION

STRUCTURE
Flow direction and direction of rotation of the pump

1 Oil pan
2 Suction chamber
3 Pump
4 Pressure chamber
5 Coupling
6 Pump bracket
7 Non-return valve
8 Motor
9 Pressure gauge
10 Overflow valve
11 Strainer cover
12 Switching lever
13 Reversing valve
14 Vacuum gauge
15 Strainer

HYDRAULIC SCHEME

DL2 series DL3, DL4, DS1, DS3, DS4 series

2 Reversing valve each A/B + C/D 6 Overflow valve


3 Shut-off pressure and vacuum gauge 7 Non-return valve
4 Strainer 8 Pressure gauge
5 Pump unit

ASSIGNMENT CARTRIDGE PUMPS – STATIONS


Cartridge Station Cartridge Station
pump pump
FE 5 DL2/ 150 NE 20 DL3/2300 DS3/1100
DL2/ 240 DS3/2300
NE 5 DS1/ 150 NE 26 DL3/2900 DS3/1500
DS1/ 240 DL3/1500 DS3/2900
NE 7,5 DL2/ 400 DS1/ 400 DL3/2900
DL2/ 750 DS1/ 750 NE 32 DL4/3200 DS4/1600
NE 10 DL2/ 320 DS1/ 320 DS4/3200
DL2/ 500 DS1/ 500 NE 42 DL4/4000 DS4/2000
DL2/ 1000 DS1/ 1000 DS4/4000
NE 13 DL2/ 1300 DS1/ 1300 NE 54 DL4/6000 DS4/6000
NE 15 DL3/1800 DS3/900
DS3/1800

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Operating Instructions
Edition: 11/2016
OID 01en

FEED PRESSURE/SUCTION BEHAVIOR


The water contained in the "S" heating oil evaporates at high temperatures and feed pressure that is too low. The diagram
shows the minimum feed pressure at the suction connection of the pump. These values are to be observed in order to
ensure trouble-free operation (max. temperature 150 °C).
Feed pressure [bar]

Temperature °C

Water evaporation temperature


Recommended feed pressure

OVERFLOW VALVE
The overflow valve is used to protect the pump/pump station against impermissible overpressure, a result of which can be
leaking or even bursting of the pump parts under pressure. If the valve is kept open for too long under adverse operating
conditions (high differential pressures and/or low viscosities), this can result in damage to the valve or to the pump / pump
station. The overflow valve may not be used as a control or regulating valve.

Factory setting:
■ 110 % of the nominal pressure (however not under 3 bars).

PROTECTION AGAINST CONTAMINATION


The station is equipped by default with strainers. Due to their small size the strainers are not able to separate larger
quantities of particle contamination occurring regularly, nor abrasive fine particles. If such operating conditions occur, the
station has to be additionally protected by a suitably dimensioned operating filter, refer to "Cleaning the pipe system", page
13.

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Operating Instructions
Edition: 11/2016
OID 01en

TRANSPORTATION, STORAGE AND DISPOSAL

UNPACKING AND CHECKING THE STATE OF DELIVERY

1. Upon delivery unpack the pump/pump unit and check for transportation damage.
2. Report any transportation damage immediately to the manufacturer.
3. Dispose of packing materials in accordance with the locally applicable regulations.

LIFTING THE PUMP STATION

DANGER
Risk of injury and/or damage to equipment should the pump station fall.
► Use intact and correctly dimensioned hoisting equipment suitable for the weight to be lifted.
► Choose the attachment points of the hoisting equipment according to the center of gravity and weight
distribution.
► Always use at least two slings.
► Secure motors additionally against tilting.
► Do not stand under raised loads.

STORAGE
During the test run, the internal components of the station are wetted with test oil, which has a preservative effect. The pipe
connections are fitted with protective covers. Unless otherwise specified, the external components of the station are
preserved with a single-coat PU-based two-component paint. The preservative applied at the factory will protect the station
for about six weeks, if it is stored in a dry and clean location. KRAL offers a long-term preservation for storage times up to
60 months. With long-term preservation the station is additionally packed in hermetically sealing anti-corrosion paper.

PRESERVATION

Preserving the internal surfaces of the station


1. Close the pipe connections with cover flanges.
2. Open the strainer cover.
3. Fill the station block with non-corrosive, resin-free oil. Do not fill the station block completely but rather
leave an empty space of approx. 2 cm.
4. Close the strainer cover.
5. After about six months storage check the oil level in the station and top up if necessary.

Preserving the external surfaces of the station


Aids:
■ Preservative (e. g. Castrol Rustilo DWX 33)

1. Paint or spray the preservative onto all plain and unpainted parts.
2. At intervals of about six months, check the preservative effect and if necessary repeat preservation.

Notice: Store the preserved station in a dry and cool place and do not expose it to direct sunlight.

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Operating Instructions
Edition: 11/2016
OID 01en

Removing the preservative


Aids:
■ Solvents
■ Steam-jet cleaning device with wax-dissolving additives

1. Clean the outside of the station with solvents, if necessary using a steam-jet cleaning device.
2. Open the strainer cover.
3. Drain the station, collecting the preservative oil in a suitable vessel.
4. To remove the residual oil, rinse the station with the pumped liquid.

DISPOSING OF THE STATION


WARNING
Danger of poisoning and damage to the environment through pumped liquid or oil.
► Wear protective clothing during all the work.
► Collect the discharging pumped liquid and oil and dispose of in accordance with the locally applicable
regulations.
► Neutralize any residues of the pumped liquid.

1. Disassemble the station.


2. Clean residues of the pumped liquid from the individual parts.
3. Separate sealing elements made of elastomers and ceramics from the station and dispose of them in the
residual waste.
4. Recycle metal parts.

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Operating Instructions
Edition: 11/2016
OID 01en

INSTALLATION, REMOVAL AND CONNECTION

INSTALLATION

Observe the following instructions:

□ When selecting the location take the operating limits, NPSH values and ambient conditions into account,
see "TECHNICAL DATA".
□ The function, safety and service life may not be impaired by humidity, temperature influences or explosive
atmospheres.
□ During the installation ensure that all the parts of the station can be accessed easily and that the
maintenance work can be carried out easily.
Installing the station

Motor circuit diagram for


DL2/150, DL2/240

ON
OFF

CONNECTING THE STATION TO THE PIPE SYSTEM


Avoid pipe tensions.
The stations must not be used as the fastening point of the connected piping. Any forces and moments (such as
stresses, expansion of the piping through temperature influences, reaction and bearing forces) are to be avoided.

It is advisable to install expansion joints if heat expansion of the piping is possible.


.
The suction line is to be dimensioned so that the speed of flow lies between 0.5 to a max. of 1.3 m/sec. and the pressure
line between 2 and 3 m/sec. The suction line has to be laid airtight and rising. The pipe system and pump have to be free of
impurities, refer to "Cleaning the piping system", page 13. Observe the maximum permissible feed pressure of the shaft
seal ring when checking the pipe system for leaks.

FOOT-ACTUATED VALVE
A foot-actuated valve with suction strainer is to be installed in case of suction operation. The suction process is facilitated,
coarse soiling is kept away and emptying of the suction line is prevented.

CONNECTING THE MOTORS

DANGER
Risk of death resulting from electric shock.
► The motor may only be connected by an authorized electrician.
► Ensure that the power supply is disconnected.
► Earth the station carefully.

1. Ensure that the operating data on the rating plate of the motor agree with the operating data of the pumps
and with the local power supply.
2. Connect the motors in accordance with the circuit diagram in the motor terminal block.

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Operating Instructions
Edition: 11/2016
OID 01en

OPERATION

COMMISSIONING

Filling and venting the station


Pumps must not run dry since pump parts can be destroyed.
Fill the pumps and suction line with liquid and vent.

WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous or caustic.
► Wear protective clothing during all the work. Ensure face protection.
► Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner.

Filling process: DL3, DL4, DS1, DS3, DS4


DL2

► Remove the screw plug 908.2. ► Remove both strainer covers 074.
► Lever to the left – fill in oil. ► Fill the station with oil.
► Lever to the right – fill in oil.

► Venting: Open the screw plug of the vent hole 165 by a max. of 2 rotations, refer to "Section views / Spare parts",
page 24/25.
► Turn the pump by hand in the direction of the arrow for the direction of rotation and check whether it runs easily and
smoothly.

Cleaning the pipe system


The complete pipe system has to be cleaned before commissioning in order to protect the station.
If this is to be done by means of the station, an additional commissioning filter has to be installed before the station. The
strainer supplied by KRAL by default is not able to separate large amounts of particle contamination and abrasive fine
particles.

Recommended filter mesh widths of the additional commissioning filter:


Pump size up to 275 Light fuel oil  Mesh width 0.020 mm
Heavy fuel oil  Mesh width 0.050 mm
above 370 Light fuel oil  Mesh width 0.035 mm
Heavy fuel oil  Mesh width 0.070 mm

Recommended operating duration for rinsing with commissioning filter: 50 – 100 hours
The pump intake of the screw pump may not be overstrained by the additional pressure loss in the commissioning filter.
► Calculate the flow resistance and determine the remaining suction capacity.
► Check and clean the commissioning filter regularly.

A commissioning strainer to be purchased from KRAL can also be used as an alternative to the commissioning filter.

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Operating Instructions
Edition: 11/2016
OID 01en

Checking the direction of rotation


The direction of rotation of the motor has to agree with the arrow for the direction of rotation of the pump. In order to check
the direction of rotation the motor can be switched on briefly with the suction and pressure valves opened. If the direction of
rotation is incorrect, the pump does not suck - thus causing damage to the pump. Longer checks of the direction of rotation
have to be carried out without the pump.

Start
Before starting up, open the valves on the suction and pressure sides. Vent the pump/station during the starting up process.
Extreme temperature shocks can destroy the pump/pump station. Take into account the lever position at the block units and
the position of the non-return valves at the single and dual stations.

DURING OPERATION

Activating the reversing valve

DL2

DL3, DL4,
DS1, DS3, DS4

Lever right: Lever left: Lever in center position:


Only right pump Only left pump is Both pumps are
is ready to ready to operate ready to operate

Adjusting the overflow valve


The overflow valve is used to protect the pump/pump station against impermissible overpressure, a result of which can be
leaking or even bursting of the pump parts under pressure. Longer overflowing can result in damage to the valve or to the
pump / pump station. The overflow valve may not be used as a control or regulating valve.

Factory setting:
□ 110 % of the nominal pressure (however not under 3 bars).

Checking the set bypass pressure:


Close the pressure-side shut-off valve slowly. The pressure gauge indicates the bypass pressure.

Notice: Excessive duration of the liquid circulation within the pump can cause heating up, resulting in
mechanical damage.

Valve adjustment:
Increase the opening pressure: turn clockwise
Reduce the opening pressure: turn anticlockwise

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Operating Instructions
Edition: 11/2016
OID 01en

DL2 DL3, DL4, DS1, DS3, DS4

Checking the operating pressure


Pressure gauge stopcocks must always be closed. Only open for checking purposes!

open closed

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Operating Instructions
Edition: 11/2016
OID 01en

MAINTENANCE

SAFETY INSTRUCTIONS ON MAINTENANCE AND REPAIRS

The following safety instructions must be observed during all the work:
► All the work may only be carried out by authorized qualified personnel.
► Wear protective clothing during all the work.
► Switch off the motor and secure it against being switched back on.
► Before carrying out any work let the pump station cool down to the ambient temperature.
► Ensure that the station is depressurized.
► Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner.

REQUIRED MAINTENANCE
The service life of the station depends to a great extent on the operating conditions. If the operating limits are observed, see
"Technical data", the station has a service life of many years.

Signs of progressive wear of individual station elements:

Finding Cause Elimination


Increased pressure drop at the Strainer contaminated Clean the strainer
strainer
Increased running noises Incipient damage to bearing Replace the bearing.
Increased leaking Incipient damage to seal Replace the shaft seal.
Deposits on the seal Non-volatile liquids Clean the seal.
Increased play in the shaft coupling Advanced wear of the coupling Replace the coupling
intermediate ring intermediate ring.
Reduction in the flow rate or Advanced wear of screws and Replace the pump.
pressure under constant operating housing
conditions

1. Check the station visually and acoustically every four weeks.


2. Check for signs of wear as listed in the table above and eliminate the cause.
3. Observe the corresponding pump operating instructions additionally.

Checking the spare pump


The spare pump should be checked once a week. We furthermore recommend that you check whether the switching lever
moves easily. Contamination can cause the non-return valves to leak. Particle contamination can be removed by switching
several times between Pump 1 and Pump 2 as well as to mutual pump operation. If this is not successful, contact the
manufacturer.

Strainer
The frequency of cleaning the strainers depends on the degree of impurity of the pumped liquid. In case of strongly
contaminated strainers cavitation and strong noise generation arise. The suction-side pressure gauge is used to indicate
the degree of contamination. If the displayed pressure drops notably, the strainers have to be cleaned, see "CLEANING THE
STRAINER", page 18.

Maximum permissible vacuum for


Fuel oil EL max. 0.5 bar
Heavy fuel oil max. 0.7 bar

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Operating Instructions
Edition: 11/2016
OID 01en

CLEANING THE STRAINER

Model DS1/DL3/DL4/DS3/DS4

018 Strainer
074 Strainer cover
165 Screw plug of the vent
hole
300 Switching lever
501 Conical spring
739.1 O-ring

Fig. 1: DS1/DL3/DL4/DS3/DS4 Fig. 2: Vent valves on the rear side of the station

Aids:
□ Solvent

WARNING
Risk of injury by opening the strainer cover without reducing the pressure beforehand.

► Open the screw plug of the vent hole 165 by a max. of 2 rotations in order to reduce the inner
pressure in the housing.

WARNING
Risk of injury through emitted hot, poisonous or corrosive pumped liquid when removing the strainer.
► Observe the safety regulations for handling dangerous liquids.
► If work on the shut-off part of the station takes longer, monitor the filling level of the strainer chamber
and collect any leakage liquid.

1. Switch over the lever 300 of the reversing valve in order to shut off the respective side, see "Activating the
reversing valve", page 15.
2. To reduce the inner pressure in the housing open the screw plug of the vent hole 165 by a max. of 2
rotations.
3. Remove the strainer cover 074 and o-ring 739.1.
4. Remove the conical spring 501 and strainer 018 from the strainer chamber.
5. Clean the strainer, for example by washing it in a solvent.
6. Reinsert the strainer and conical spring and fill the station.
7. Remount the o-ring and strainer cover, tighten the screw plug of the vent hole 165 again and place the
reversing valve lever in the desired position.
8. Before recommissioning vent the station.

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Operating Instructions
Edition: 11/2016
OID 01en

INSTALLING/REMOVING THE CARTRIDGE PUMP


Removing the pump
► Disconnect the station from the power supply.
► Close the switching lever or the suction and pressure valves.
► Drain the pumps (via draining plug)
► Before installing again, check the flat gaskets and o-rings for damage.

A cartridge pump can be removed without interrupting operation. Carry out the switching process as described under
"Cleaning the strainers". Remove the motor and pump bracket. Loosen the cartridge pump carefully using two screwdrivers
and check whether any oil leaks through leaky non-return valves. Then lift the cartridge pump.
Installing the pump
Before carrying out installation, ensure that the maximum level of the oil in the station housing amounts to 5 cm, since oil
displacement otherwise makes the installation more difficult. Check the o-rings of the cartridge pump for damage and
grease them slightly. Push the insert pump into the station housing with slight pressure, mount the pump bracket and motor
and set the switching lever to the center position.

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Operating Instructions
Edition: 11/2016
OID 01en

TROUBLESHOOTING

POSSIBLE FAULTS

Fault Cause/Remedy

 No pump suction 1, 2, 3, 4, 5, 12
 Delivery rate too low 3, 4, 5, 8, 9, 10, 11, 17, 18
 Pump runs noisily 3, 4, 5, 6, 7, 10, 11, 13, 17
 Motor overload 9, 10, 13
 Uneven delivery rate 3, 5, 8, 10, 11, 18
 Leaking shaft seal 7, 10, 14, 15, 16, 18

TROUBLESHOOTING

No. Cause Remedy

1 Pump is dry ► Fill pump with liquid.


2 Incorrect pump direction of rotation ► Set direction of rotation direction in accordance with
the arrow for direction of rotation.
3 Strainer, suction valve or pipe obstructed ► Check and clean parts.
4 Suction pipe or shaft seal leaks ► Check the suction line (connecting points, valves).
► Check the shaft seal.
5 Suction head too high ► Reduce the suction head (level difference).
► Reduce pipe length.
► Increase pipe diameter.
► Reduce viscosity of the liquid (heat up).
► Install a larger suction filter.
6 Axis fault pump – coupling – motor ► Align the shaft end more exactly.
► Balance the coupling.
7 Vibrations and pulsation in the system ► Provide a flexible bearing arrangement for the unit.
► Make the connections with hoses.
8 Overpressure valve jammed or set too low ► Check or adjust the valve.
9 Incorrect voltage or frequency ► Check the speed and power consumption of the
motor.
► Compare the voltage and frequency with the rating
plate.
10 Liquid viscous ► Increase the liquid temperature.
► Reduce the rotation speed.
11 Airlock or gas in the liquid ► Remove the airlocks.
► Reduce the suction head or increase the feed
pressure.
12 Pump does not vent ► Vent the pressure pipe at the highest point.
13 Motor bearing damaged ► Redo the motor bearing.
14 Shaft seal damaged ► Replace the shaft seal.
15 Feed pressure too high or too low ► Reduce the feed pressure at the installation.
► Install a non-return valve at the pressure end.
16 Cold start when pumping heavy fuel oil ► Install a pump heating.
17 Overflow valve flutters ► Increase the opening pressure by turning the adjusting
screw clockwise.
18 Leaking non-return valves ► Clean the non-return valves.

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Operating Instructions
Edition: 11/2016
OID 01en

APPENDIX

EXPLODED VIEWS
Cartridge pump FE 5

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Operating Instructions
Edition: 11/2016
OID 01en

Cartridge pump NE 5 – 13

Cartridge pump NE 15 – 57

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Operating Instructions
Edition: 11/2016
OID 01en

SECTIONAL VIEWS/SPARE PARTS


Station DL2 / 150 – 240

Station DL2 / 320 – 1300

001 Cartridge pump 304 Control plug 859 Dowel pin


040 Sleeve 501 Spring 870.1 Circlip
052 Coupling 529 Motor 885 Set screw
055.1 Seal ring 606.1 Shut-off pressure gauge 894.1 Hexagonal nut
060 Washer 606.2 Shut-off pressure gauge 894.2 Hexagonal nut
119 Pressure housing 704.1 Flange 900.1 Hexagon screw
137 Valve housing 704.2 Flange 900.2 Hexagon screw
155.1 Pipe 730.3* Flat gasket 901 Stud screw
166 Adjusting screw 735.1* Copper seal 908.1* Screw plug
180 Pump bracket 739.1* O-ring 908.2* Screw plug
222.1* Flat gasket 739.2* O-ring 915.1 Socket screw
222.2* Flat gasket 739.3* O-ring 915.2 Socket screw
241 Oil pan 751.1 Spring 915.3 Socket screw
300 Switching lever 809.1 Ball 915.4 Socket screw
915.5 Socket screw
* Part of gasket set

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Operating Instructions
Edition: 11/2016
OID 01en

Station DS1

Detail: Z

Section: A-B

001 Cartridge pump 222* Flat gasket 894.2 Hexagonal nut


018 Strainer 241 Oil pan 900.3 Hexagon screw
052 Coupling 501 Conical spring 901.1 Stud screw
055.1 Seal ring 529 Motor 901.2 Stud screw
074 Strainer cover 606.1 Shut-off vacuum gauge 901.3 Stud screw
116.1 Main housing left 675 Control block 904.1 Washer
116.2 Main housing right 735.1* Copper seal 904.2 Washer
155.1 Pipe 739.1* O-ring 908.1* Screw plug
160 Angle 739.2* O-ring 915.1 Socket screw
165 Screw plug of the vent hole 893 Cap nut 915.2 Socket screw
180 Pump bracket 894.1 Hexagonal nut
Control block

055.1* Seal ring


137 Valve housing
165.1* Screw plug
165.2 Screw plug
165.3* Screw plug
166 Adjusting screw
298 Valve insert
299 Valve insert
300 Switching lever
304.1 Valve cone
304.2 Valve cone
312 Adjusting spindle
407 Control ball
456* Molded gasket
606.2 Shut-off pressure gauge
704 Flange
739.3* O-ring
739.4* O-ring
739.5* O-ring
739.8* O-ring
751.1 Spring
751.2 Spring
751.3 Spring
765 Disk spring
809.1 Ball
868 Support ring
869.1 Circlip
886 Set screw
915.4 Socket screw

* Part of gasket set

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Operating Instructions
Edition: 11/2016
OID 01en

Station DL3/DL4/DS3/DS4

Detail: Z

001 Insert pump 423 Vent valve 894.2 Hexagonal nut


018 Strainer 501 Conical spring 900.3 Hexagon screw
052 Coupling 529 Motor 901.1 Stud screw
074 Strainer cover 606.1 Shut-off vacuum gauge 901.2 Stud screw
116.1 Main housing left 675 Control block 901.3 Stud screw
116.2 Main housing right 735.1* Copper seal 904.1 Washer
155.1 Pipe 739.1* O-ring 904.2 Washer
160 Angle 739.2* O-ring 908.1* Screw plug
165 Screw plug of the vent hole 893 Cap nut 915.1 Socket screw
180 Pump bracket 894.1 Hexagonal nut 915.2 Socket screw
241 Oil pan
Control block

055.2* Seal ring


111.1 Welding neck flange
111.2 Welding neck flange
137 Valve housing
166 Adjusting screw
222 Flat gasket
298 Valve insert
299 Valve insert
300 Switching lever
304.1 Valve cone
304.2 Valve cone
312 Adjusting spindle
407 Control ball
456* Molded gasket
606.2 Shut-off pressure gauge
729.1* Flat gasket
729.2* Flat gasket
739.3* O-ring
739.4* O-ring
739.5* O-ring
751.1 Spring
751.2 Spring
751.3 Spring
765 Disk spring
809.1 Ball
868 Support ring
869.1 Circlip
886 Set screw
900.4 Hexagon screw
908.2 Screw plug

* Part of gasket set

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Operating Instructions
Edition: 11/2016
OID 01en

Cartridge pumps
FE 5 NE 5 – 13 NEG 5 – 13

NE 15 – 57 NEG 15 – 57 NEGA 15 – 57

039 Distance sleeve 127 Bearing housing 751 Spring


042 Balancing cylinder 131 Housing 809 Ball
052 Coupling 155 Pipe 817 Ball bearing
056 Spacer ring 417 Cylinder strainer 861 Straight grooved pin
058 Mounting ring 457* Mechanical seal 866 Key
059 Mounting ring 669 Screw set 869 Circlip
062 Spacer 735* Copper seal 870 Circlip
063* Support ring 739.1* O-ring 879 Straight pin
070 End cover 739.2* O-ring 915.1 Socket screw
074 Flange cover 739.3* O-ring 915.2 Socket screw
080 Bearing cover 745* Radial seal ring

* Part of gasket set

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Operating Instructions
Edition: 11/2016
OID 01en

TABLE OF TIGHTENING TORQUES

Tightening torque [Nm] for screws with metric threads + head contact surfaces Thread measured in inches
+ wedge lock Stainless steel screws Screw plugs with
Thread

washers A2 + A4 elastomer seal


5.6 8.8 10.9 8.8 + 8.8 Rust-proof Property Property Thread Galvanized +
Alu* A4-70 class 70 class 80 stainless steel
M3 0.6 1.5 — 1.2 1.5 1,1 — — G 1/8" 13
M4 1.4 2.9 4.1 2.3 3 2 — — G 1/4" 30
M5 2.7 6.0 8.0 4.8 6.0 3.9 3.5 4.7 G 3/8" 60
M6 4.7 9.5 14 7.6 10.3 6.9 6 8 G 1/2" 80
M8 11.3 23.1 34 18.4 25 17 16 22 G 3/4" 120
M 10 23 46 68 36.8 47 33 32 43 G 1" 200
M 12 39 80 117 64 84 56 56 75 G 1 1/4" 400
M 14 62 127 186 101 133 89 — — G 1 1/2" 450
M 16 96 194 285 155 204 136 135 180
M 18 133 280 390 224 284 191 — —
M 20 187 392 558 313 399 267 280 370
* reduced tightening torque
M 24 322 675 960 540 687 460 455 605 when screwing into aluminum

CONTENTS OF THE EC DECLARATION OF CONFORMITY


The screw pumps described in these operating 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 fulfills all the relevant provisions of the following directives:

Number Name Remark


2006/42/EC Machinery Directive –
2014/68/EU Pressure Equipment Directive –
2014/30/EU Directive on Electromagnetic Compatibility Only for machinery with electrical
components
2014/35/EU Low Voltage Directive Only for machinery with electrical
components
2014/34/EU Directive on Use in Potentially Explosive Areas Only for machinery in ATEX version
(ATEX)

- 27 -
KRAL AG, Bildgasse 40, Industrie Nord, 6890 Lustenau, Austria,
Tel.: +43 / 55 77 / 8 66 44-0, www.kral.at, E-Mail: kral@kral.at