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Edition 11/2016
Original operating instructions
T AB L E OF C ONT E NT S
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.
Specialist personnel, □ Read, observe and follow these instructions and the associated documents, in particular the
fitters safety instructions and warnings.
SYMBOLS
Symbol Meaning
Notice
DANGER LEVELS
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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
□ 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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LABELING
TYPE CODE
1 Model
2 Size
3 Shaft seal
4 Bearing
5 Heating system
6 Version index
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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TECHNICAL DATA
OPERATING LIMITS
□ 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
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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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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.
□ 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.
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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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
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Temperature °C
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).
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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.
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
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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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.
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INSTALLATION
□ 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
ON
OFF
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.
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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OPERATION
COMMISSIONING
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.
► 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.
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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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
DL2
DL3, DL4,
DS1, DS3, DS4
Factory setting:
□ 110 % of the nominal pressure (however not under 3 bars).
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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open closed
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MAINTENANCE
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.
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.
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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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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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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
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APPENDIX
EXPLODED VIEWS
Cartridge pump FE 5
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Cartridge pump NE 5 – 13
Cartridge pump NE 15 – 57
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Station DS1
Detail: Z
Section: A-B
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Station DL3/DL4/DS3/DS4
Detail: Z
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Cartridge pumps
FE 5 NE 5 – 13 NEG 5 – 13
NE 15 – 57 NEG 15 – 57 NEGA 15 – 57
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Tightening torque [Nm] for screws with metric threads + head contact surfaces Thread measured in inches
+ wedge lock Stainless steel screws Screw plugs with
Thread
The machinery fulfills all the relevant provisions of the following directives:
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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