KRAL DKC Series Operating Instructions Manual Download Page 1

Page: 1 / 56

Operating instructions

KRAL pump stations.

DKC/DLC Series.

OID 02en-GB
Edition 2019-11
Original instructions

www.kral.at

Summary of Contents for DKC Series

Page 1: ...Operating instructions KRAL pump stations DKC DLC Series OID 02en GB Edition 2019 11 Original instructions www kral at...

Page 2: ...uring removal 21 8 3 Mounting the pump station 21 8 4 Protecting the pump station against pressure peaks 23 8 5 Installing the heating system optional 23 8 5 1 Danger when installing the heating eleme...

Page 3: ...4 Maintenance kit electrical heating system 51 15 2 Repair kits 52 15 2 1 Repair kit non return valve 52 16 Appendix 53 16 1 Tightening torques for screws with metric screw threads with and without we...

Page 4: ...duct must be qualified The qualification ensures that possible dangers and damage to property that are connected to the activity are detected and avoided These persons are qualified personnel who carr...

Page 5: ...es serious physical injury or death Raised load Falling objects can result in serious physical injury or death kg Heavy load Heavy loads can result in serious back problems Risk of slipping Dischargin...

Page 6: ...station Station with pump sizes K 5 42 L 5 54 Large pump station Station with pump sizes K 55 118 L 55 85 2 Safety 2 1 Proper use o Use the pump station solely for transporting lubricating liquids th...

Page 7: ...tructions of the components carefully and observe them o Have work only carried out by qualified personnel trained personnel o Wear personal protective equipment and work carefully o Pumped liquids ca...

Page 8: ...pressure maintain ing valve 2 8 bar 3 7 bar C Internal pressure maintain ing valve 6 20 bar 7 16 bar D Internal pressure maintain ing valve 15 38 bar 16 34 bar E External pressure maintain ing valve 2...

Page 9: ...ax temperature of pumped liquid C 180 180 Viscosity min max mm2 s 2 10 000 2 10 000 Ambient temperature min max C 10 50 10 50 Tab 3 Pump station operating limits 4 2 Filling volume Parameter Unit Smal...

Page 10: ...4 6 Weights Part Unit Small pump station Large pump station Station block with strainer and revers ing valve kg 59 91 Internal pressure maintaining valve kg 1 3 1 9 External pressure maintaining valve...

Page 11: ...0 40 2 x 0 12 Tab 7 Operating data electrical heating system Operating data fluid heating system Parameter Unit Small pump station Large pump station Max pressure bar 16 Max liquid temperature C 180...

Page 12: ...ock 5 Reversing valve lever 8 Pump 2 Lifting lug 6 Pressure side pressure gauge 9 Pressure connection 3 Suction side pressure gauge 7 Loosen the screw plug of the vent hole 10 Suction connection 4 Str...

Page 13: ...eration of the two pumps If only one pump is being operated the second pump can be cut in automatically if the delivery rate or the pressure drops at the active line In order to ensure a uniform distr...

Page 14: ...rating filter and cause increased wear to the pumps Alternatively the strainers can be replaced during commissioning by fine meshed commissioning strain ers Commissioning Page 30 The commissioning str...

Page 15: ...the pump sta tion 1B1 P0 2B1 1P3 1P2 1P1 2P3 2P2 2P1 1S3 1S1 1S2 2S3 2S1 2S2 P1 P2 S3 S4 S2 S1 S01 S0 Pressure maintaining valve in ternal o Ensuring of a constant sup ply pressure even when the liqui...

Page 16: ...g system for the large pump station consists of two heating elements that are integrated in two heating ducts of the station block The output of the elements corresponds to the radiation losses and co...

Page 17: ...sportation The following safety instructions must be observed o Have all work only carried out by authorized qualified personnel o A crane operator and transport personnel are required for transportat...

Page 18: ...ugh falling and toppling parts Use intact and correctly dimensioned hoisting equipment in accordance with the total weight to be transported Select the lift points for the hoisting equipment in accord...

Page 19: ...aper is not damaged 3 Observe the intervals for preservation Preservation Page 19 6 6 Heating system optional 6 6 1 Storing heating elements 1 Store the heating element in an absolutely dry room or in...

Page 20: ...ry repeat 7 4 Removing the preservation Personnel qualification o Trained personnel Personal protective equipment o Work clothing o Protective gloves o Safety boots Aids o Solvent o Steam jet cleaning...

Page 21: ...n a vertical installation position Notice 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...

Page 22: ...pump station Requirement Pump station connections protected against soiling for example by using the protective cover mounted in the factory 1 Bring the pump station into the installation position 2 F...

Page 23: ...system The electrical heating system is installed in one heating duct within the station block in the case of the small pump station and in two heating ducts within the station block in the case of t...

Page 24: ...repare the second heating element in the same manner and insert it into the second heating duct 6 Remove the upper screw plug 7 of the heating duct at the station block 7 Small pump station Fill the h...

Page 25: ...rew connection 3 8 5 4 Installing the heating system special design When installing special designs contact the manufacturer 8 6 Removing the pump station Personnel qualification o Transport personnel...

Page 26: ...emperature Ensure that the pump station is depressurized Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local...

Page 27: ...e gloves o Protective helmet o Safety boots Aids o Mobile crane forklift hoisting equipment ATTENTION Damage to device through impurity in the pipe system During welding work attach protective covers...

Page 28: ...lly or equip them with suitable contact protection 9 4 Connecting the pipe station electrically pneumatically Personnel qualification o Electrician Personal protective equipment o Work clothing o Prot...

Page 29: ...ified personnel o Before commissioning ensure that a safety valve has been installed in the pressure side pipe sys tem to protect the pump station o Before commissioning make sure that the suction lin...

Page 30: ...is installed when the pipe system is flushed and cleaned using the pump ATTENTION Damage to equipment through additional pressure loss in the commissioning filter commis sioning strainer Calculate th...

Page 31: ...ure side shut off device and fill the pump station via the suction connection 1 or pressure connection 2 4 Vent the pumps Take the corresponding operating instructions of the pumps into consideration...

Page 32: ...to indicate direction of ro tation For information on checking the direction of rotation please refer to the pump operating instruc tions 10 2 4 Commissioning the pump station Personnel qualification...

Page 33: ...ng into operation optional Connecting and commissioning the electric heating system Personnel qualification o Electrician Personal protective equipment o Work clothing o Face protection o Protective g...

Page 34: ...lve immediately after completing reading 1 Open the pressure gauge shut off valve 2 Read the operating pressure and close the pressure gauge shut off valve 10 3 2 Setting the pressure maintaining valv...

Page 35: ...stem 2 Turn the lever 1 to the right The right hand strainer and the right hand pump are connected with the pipe system 3 Turn the lever 1 into the middle position Both strainers and both pumps are co...

Page 36: ...d 1 Switch off the motors 2 Close the pressure and suction side shut off devices 10 4 Decommissioning 10 4 1 Taking the pump station out of operation Personnel qualification o Fitter o Electrician Per...

Page 37: ...f the operation interruption Short Long o Solids sediment Flush the pump station Flush the pump station o Congealed frozen o No corrosive burden Heat or drain the pump sta tion Drain the pump station...

Page 38: ...weeks Strainer o Visual inspection o If required clean 4 weeks Overflow valve o Function test 5 years Tab 16 Required maintenance 11 3 Maintaining the pump station Personnel qualification o Fitter o E...

Page 39: ...in an environmentally compatible manner in accordance with the applicable local regulations o Ensure that the collection tank for discharging pumped liquids is sufficiently large o Observe the tighte...

Page 40: ...ction o Protective gloves Aids o Collection tank o Solvent DANGER Risk of death resulting from electric shock Ensure that the electrical power supply is de energized and is secured against being switc...

Page 41: ...ling surfaces place on new flat gaskets 7 Place the new pump on the stud screws 8 tighten the hexagon nuts 5 8 Tighten the screw plug 9 at the station block again 9 Fill and vent the strainer chamber...

Page 42: ...vent hole by a max of 2 rotations in order to reduce the internal pres sure in the housing 6 7 8 9 5 4 3 1 2 Fig 25 Cleaning the strainer 1 Switch over the lever of the reversing valve 8 in order to s...

Page 43: ...with the applicable local regulations If work on the blocked part of the pump station takes longer monitor the filling level of the strainer housing and catch the leakage WARNING Risk of injury throug...

Page 44: ...ARNING Danger of poisoning and environmental damage through residues Wear personal protective clothing during all the work Ensure face protection Before disposal collect any pumped liquid still presen...

Page 45: ...or Heat up the pumped liquid or Install a filter strainer with a larger mesh width Ensure that the permissible mesh width is not exceeded 1 3 Level in the intake container too low Fill the intake cont...

Page 46: ...s or Contact the manufacturer 3 4 7 Ball bearing damaged Replace the ball bearing see corresponding operating instructions of the pump 2 3 4 7 Superficial damage to pump parts coming into contact with...

Page 47: ...alve set incorrectly Set the pressure maintaining valve During operation Page 34 Tab 18 Fault table 15 Spare parts 15 1 Maintenance kits 15 1 1 Maintenance kit sealing kit small pump station Notice Th...

Page 48: ...y valve and external pressure maintaining valve For pump stations with two way valve or external pressure maintaining valve 3 pc or For pump stations with two way valve and external pressure maintaini...

Page 49: ...4 O ring 2 611 2 O ring 2 739 1 O ring 2 3 4 739 2 O ring 1 739 3 O ring 1 739 6 O ring 1 740 Seal ring For pump stations with two way valve or For pump stations with two way valve and external press...

Page 50: ...he maintenance kit contains only the numbered parts and is only supplied complete 739 1 739 1 405 Fig 28 Maintenance kit strainers Qty Item No Part 1 405 Strainer insert 1 739 1 O ring Tab 21 Parts ma...

Page 51: ...only supplied complete 481 1 481 Fig 29 Maintenance kit electrical heating system Qty Item No Part 1 2 481 Heating element 1 2 481 1 Seal ring 1 Thermal oil Only for large pump station For small pump...

Page 52: ...and is only supplied complete 611 4 611 1 611 2 611 3 729 1 729 2 Fig 30 Repair kit non return valve Qty Item No Part 2 611 1 Supporting ring 2 611 2 O ring 2 611 3 Sealing washer 2 611 4 Pressure spr...

Page 53: ...5 4 7 5 M 6 4 7 10 3 14 0 7 6 6 0 8 0 9 M 8 11 3 25 0 34 0 18 4 16 0 22 0 14 M 10 23 0 47 0 68 0 36 8 32 0 43 0 36 M 12 39 0 84 0 117 64 0 56 0 75 0 60 M 14 62 0 133 186 101 90 M 16 96 0 204 285 155...

Page 54: ...fulfils 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 Compat...

Page 55: ...Notes Operating instructions OID 02en GB Edition 2019 11 55...

Page 56: ...KRAL GmbH 6890 Lustenau Austria Tel 43 5577 86644 0 E Mail kral kral at www kral at...

Search results

Summary of Contents for DKC Series

Reviews:

Related manuals for DKC Series

Brands by name

Popular brands

KRAL DKC Series, Operating Instructions Manual

Search results

Summary of Contents for DKC Series

Reviews:

Related manuals for DKC Series

Brands by name

Popular brands