KRAL DL3 Series Operating Instructions Manual Download Page 1

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Operating instructions

KRAL pump stations.

Series DL3 / DL4 / DS1 / DS3 / DS4

Mechanical seal/Radial shaft seal

OID 06en-GB
Edition 2019-11
Original instructions

www.kral.at

Summary of Contents for DL3 Series

Page 1: ...Operating instructions KRAL pump stations Series DL3 DL4 DS1 DS3 DS4 Mechanical seal Radial shaft seal OID 06en GB Edition 2019 11 Original instructions www kral at ...

Page 2: ...20 10 2 2 Filling and venting the pump station 20 10 2 3 Checking the direction of rotation 21 10 2 4 Commissioning the pump station 22 10 3 During operation 22 10 3 1 Checking the operating pressure 22 10 3 2 Activating the reversing valve 23 10 3 3 Adjusting the overflow valve 23 10 3 4 Switching off the pump station 24 10 4 Decommissioning 24 10 4 1 Taking the pump station out of operation 24 1...

Page 3: ...tation DL3 DL4 DS3 DS4 50 16 2 2 Maintenance kit sealing kit pump station DS1 51 16 2 3 Maintenance kit sealing kit mechanical seal DL3 DL4 DS3 DS4 52 16 2 4 Maintenance kit sealing kit mechanical seal DL2 as of 320 DS1 52 16 2 5 Maintenance kit sealing kit radial shaft seal DL3 DL4 DS3 DS4 53 16 2 6 Maintenance kit sealing kit radial shaft seal DL2 as of 320 DS1 53 16 3 Repair kits 54 16 3 1 Repa...

Page 4: ...uired qualification of the personnel is provided separately at the beginning of the individual chapters in these instructions The following table provides an overview Target group Activity Qualification Transport personnel Transporting unloading setting up Qualified personnel for transport mobile crane operators crane operators forklift operators Fitter Mounting connection Qualified personnel for ...

Page 5: ...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 The following table provides an overview Meaning Possible consequences of non observance Protective...

Page 6: ...plications The operator owner is therefore subject to the statutory obligations concerning occupational health and safety In addition to the safety instructions in these instructions the regulations on safety accident prevention and environmental protection respectively valid for the range of application of the product are to be ob served 2 4 Safety instructions 2 4 1 Fundamental safety instructio...

Page 7: ...in 1 3 Shaft seal A Standard radial shaft seal B Standard mechanical seal C Mechanical seal of hard material 4 Storage A Inner bearing B Outer bearing 5 Heating A Without heating B With heating system 6 Version index For internal administration Tab 2 Type code 3 2 Rating plate KRAL GmbH 6890 Lustenau Austria www kral at KRAL GmbH 6890 Lustenau Austria www kral at pS max pD max Typ Type SN Serial n...

Page 8: ... temperatures and inlet pressure that is too low The diagram shows the minimum inlet pressure to be complied with at the suction side connection depending on the temperature in operation The maximum temperature amounts to 150 C 70 80 90 100 110 120 130 140 150 1 0 1 2 3 4 5 6 7 T C p bar Fig 3 Inlet pressure for heavy fuel oil p Inlet pressure Recommended inlet pressure T Temperature O Evaporating...

Page 9: ... 0 59 0 46 0 46 0 60 0 60 0 60 0 1 pump unit 51 1 52 2 53 3 57 1 57 8 60 8 53 7 55 1 61 5 62 1 63 1 2 pump units 53 7 54 9 56 1 58 5 59 5 62 1 56 3 57 8 62 6 63 5 63 8 Tab 7 Sound pressure level DS3 and DS4 4 5 Mesh width strainer filter Options Usage Series Viscosity mm2 s Mesh width mm Strainer Separation of coarse soiling during operation DL3 DL4 20 0 25 DS1 DS3 DS4 20 0 50 Commissioning strain...

Page 10: ...crew pumps are rotating pumps Their displacement effect results from three rotating screws 12 and 14 and the enclosing cartridge housing 15 Radial support of the screw set is effected through the sliding contact in the cartridge housing that depends on lubrication by the pumped liquid Screw pumps are therefore not suitable for dry running and can only be used up to specific pressure limits and vis...

Page 11: ...alve 1 Screw plug 2 Adjusting screw 3 Pressure spring 4 Seal ring 5 Reversing valve lever 6 Suction side connection 7 Valve ball 8 Control block 9 Pressure side connection The overflow valve is integrated in the control block and ensures that very high pressures that could result in housing parts bursting do not arise The overflow valve is purely there as a safety element for the pumps and should ...

Page 12: ...ped with two strainers as standard These strainers serve to separate soiling that is normally not contained in the pumped liquid Due to their small size the strainers cannot separ ate larger amounts of soiling occurring regularly nor abrasive fine particles In the case of such operat ing conditions the pump station has to be protected additionally by a correspondingly dimensioned op erating filter...

Page 13: ...pment o Work clothing o Protective helmet o Protective gloves o Safety boots Aids o Mobile crane forklift hoisting equipment WARNING Risk of injury and damage to equipment through 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 accordance with the centre of ...

Page 14: ...rve measures for storing and preservation 1 Store cool and dry and protect against sunlight 2 Ensure that the anti corrosion paper is not damaged 3 Observe the intervals for preservation Ä Preservation Page 14 7 Preservation 7 1 Preservation table Preservation has to be carried out additionally under the following conditions Type of delivery Condition Standard delivery o Storage time exceeding six...

Page 15: ...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 device with wax dissolving additives o Collection tank CAUTION Risk of injury through emitted preservative Wear personal protective clothing during all the work Collect any discharging preservative s...

Page 16: ... in 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 an additional commissioning filter has to be in stalled temporarily before the pump station Alternatively the strainers supplied as standard can be re placed during commissioning by fine meshed com...

Page 17: ...thing o Protective helmet o Protective gloves o Safety boots Aids o Mobile crane forklift hoisting equipment o Collection tank 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 through emitted pumped liquid Pumpe...

Page 18: ...o Have all work on the pump station and pipe system only carried out by authorized qualified per sonnel o Ensure that impurities cannot get into the pump station and pipe system o Ensure that mechanical connections are mounted free of stress o Observe the tightening torques o Have all the work on the electrical equipment only carried out by electricians o Before commissioning ensure correct earthi...

Page 19: ...f temperature related material expansion is possible 5 Check the linear height and angular offset and correct if necessary ð If the screws tighten easily this is a sure sign that the installation is stress free 6 Tighten the connecting screws with torque Ä Appendix Page 57 7 Lay the suction line hermetically sealed with a slight ascending slope 9 3 Connecting the pump station to the power supply P...

Page 20: ...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 Alternatively the strainers supplied as standard can be re placed during commissioning by fine meshed commissioning strainers Personnel qualification o Fitte...

Page 21: ... the motor 4 Place on the strainer cover and cap nuts 5 Tighten the screw plug of the vent hole with torque Ä Appendix Page 57 6 Repeat the filling procedure for the second pump 10 2 3 Checking the direction of rotation The direction of rotation of the pumps is indicated by an arrow on the pump The direction of rotation of the motor specifies the direction of rotation of the pump The fan impeller ...

Page 22: ...Pipe system is free of impurities ü Pump station filled ü Shut off devices in the suction line and pressure line opened ü All connections connected sealingly 1 Switch on the pump station ð The pump station delivers when the pressure on the pressure side of the pump station rises 2 If the pump station does not deliver after 10 15 seconds of operation abort commissioning elim inate the cause of the ...

Page 23: ...the lever 1 to the left ð The left hand strainer and the left hand pump are connected with the pipe system 2 Turn the lever 1 to the right ð The right hand strainer and the right hand pump are connected with the pipe system 3 Turn the lever 1 into the middle position ð Both strainers and both pumps are connected with the pipe system Notice The reversing valve seals mechanically and therefore has a...

Page 24: ...ter clockwise Reduce the opening pressure 4 Repeat Steps 2 and 3 until the desired opening pressure is reached 5 Tighten the screw plug 1 again 10 3 4 Switching off the pump station Personnel qualification o Trained personnel ATTENTION Damage to seal through pressurizing during standstill Ensure that the maximum permissible system pressure is not exceeded 1 Switch off the motors 2 Close the pressu...

Page 25: ...burden o Remains liquid o Corrosive burden 1 Drain the pump station 2 Preserve the pump station Tab 12 Measures depending on the behaviour of the pumped liquid Drain the pump station via the pressure line suction line vent screws and screw plugs 10 5 Recommissioning 10 5 1 Recommissioning the pump station Carry out all the steps as for the commissioning process Ä Commissioning Page 20 11 Maintenan...

Page 26: ...re not required The manufacturer recommends renewing the ball bearings every 20 000 operating hours When using the pump in lubrication oil applications a bearings replacement at the latest after 5 years 40000 h is suffi cient 11 5 Maintaining the pump station Personnel qualification o Fitter o Electrician Personal protective equipment o Work clothing o Protective gloves o Safety boots o Face prote...

Page 27: ...ble lists signs of progressive wear of individual station elements Finding Cause Elimination Increased running noises Incipient damage to bearing Replace the pump Increased leaking Incipient damage to seal Replace the shaft seal Deposits at the shaft seal Low volatile liquids Clean the shaft seal Increased play in the coupling Advanced wear of the coupling intermediate ring Replace the coupling in...

Page 28: ...rdance 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 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...

Page 29: ...ured against being switched back on 1 2 3 4 5 6 7 1 Switch over the lever of the reversing valve 1 in order to shut off the respective side Ä During op eration Page 22 2 Remove the hexagon nuts 2 and socket screws 7 and lift the motor 3 from the pump bracket 6 3 Remove the coupling intermediate ring 5 and pull off the motor side coupling half 4 using an ex tractor 11 6 8 9 10 4 Remove the hexagon ...

Page 30: ...ket 6 via stud screws 10 on the housing 11 and tighten the hexagon nuts 8 with torque 4 Measure and write down the distance X between the face of the coupling claws and the connect ing surface of the pump bracket 1 2 3 4 5 6 7 5 Insert the coupling intermediate ring 5 in the pump side coupling half 6 Tighten the motor side coupling half 4 on the shaft end of the motor 3 7 Check the distance betwee...

Page 31: ...ever of the reversing valve 1 in order to shut off the respective side Ä During op eration Page 22 2 Remove the hexagon nuts 2 and socket screws 7 and lift the motor 3 from the pump bracket 6 3 Remove the coupling intermediate ring 5 and pull off the motor side coupling half 4 using an ex tractor 11 6 8 9 10 12 4 Remove the hexagon nuts 8 between the pump bracket and housing 11 and remove the pump...

Page 32: ...e 4 Place the pump bracket 6 via stud screws 10 on the housing 11 and tighten the hexagon nuts 8 with torque 5 Measure and write down the distance X between the face of the coupling claws and the connect ing surface of the pump bracket 1 2 3 4 5 6 7 6 Insert the coupling intermediate ring 5 in the pump side coupling half 7 Tighten the motor side coupling half 4 on the shaft end of the motor 3 8 Ch...

Page 33: ...quid safely and dispose of it in an environmentally compatible manner in accordance 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 through emitted pumped liquid when working on the pump station without previ ous pressure relief Open the screw plug of th...

Page 34: ...eal DL2 from 320 DS1 Personnel qualification o Fitter Personal protective equipment o Work clothing o Protective gloves o Safety boots Aids o Silicone grease 5 4 3 2 1 6 1 Clean the fitting surfaces grease the O ring of the stationary seal ring 4 2 Press the stationary seal ring with O ring into the pump flange 3 Take the position of the recess for the dowel pin anti rotation screw 3 Clean the mai...

Page 35: ...l DL3 DL4 DS3 DS4 Personnel qualification o Fitter Personal protective equipment o Work clothing o Protective gloves o Safety boots Aids o Silicone grease 1 2 3 4 5 8 7 6 1 Clean the fitting surfaces grease the O ring of the stationary seal ring 5 2 Press the stationary seal ring with O ring into the mounting ring 3 Take the position of the recess for the dowel pin anti rotation screw 3 Clean the ...

Page 36: ... Safety boots Aids o Molybdenum disulphide paste for example Fenkart T4 8 7 5 3 2 1 4 6 1 Clean the contact surface of the radial shaft seal ring 4 and 6 in the pump flange 7 carefully 2 Carefully press the radial shaft seal ring 6 into the cartridge housing Take the mounting direction into account In the case of excessive resistance apply additional thread sealant 3 Fill the radial shaft seal rin...

Page 37: ... boots Aids o Molybdenum disulphide paste for example Fenkart T4 Notice The thread sealant serves during installation of the radial shaft seal as a lubricant and after it has cured as an anti rotation measure 1 2 3 4 5 10 9 6 8 7 1 Clean the contact surface of the radial shaft seal ring 5 and 7 in the mounting ring 3 carefully 2 Carefully press the radial shaft seal ring 5 into the mounting ring T...

Page 38: ...ove the socket screws 2 and pull out the bearing housing 5 2 Remove the circlip 3 and ball bearing 4 with the extractor from the bearing housing 3 Remove the feather key 1 from the main screw 10 4 Remove the mounting ring 6 and press the stationary seal ring 7 from the mounting ring 5 Remove the distance sleeve 8 from the main screw and remove the rotary seal ring 9 6 Carefully clean all the seali...

Page 39: ...30 9 34 35 Dismantling the housing and control block 1 Remove the socket screws 35 hexagon nuts 6 washer 7 and O ring 8 and remove the pump station from the oil pan 34 2 Remove the socket screws 1 and copper seals 2 and remove the housing 9 from the control block 15 3 Remove the flat gasket 11 Strainer Remove the O ring 5 1 Remove the cap nuts 3 strainer cover 4 and O ring 5 from the housing 2 Lig...

Page 40: ...ntrol block with the fin gers 3 Rotate lever of the reversing valve to the middle position and remove the valve ball 4 Remove the reversing valve lever circlip 31 and supporting ring 32 5 Press the tappet 16 towards the bottom 6 Remove the O ring 33 from the control block 7 Insert the tappet 16 from the bottom and rotate in such a way that the valve ball can be inserted via the nut 8 Insert the va...

Page 41: ...11 17 16 18 20 21 22 23 24 25 26 26 25 4 3 28 30 31 32 38 38 38 9 9 13 12 11 15 Dismantling the housing and control block 1 Remove the socket screws 35 hexagon nut 6 washer 7 and O ring 8 and remove the pump sta tion from the oil pan 34 2 Remove the socket screws 1 and copper seals 2 and remove the housing 9 from the control block 15 3 Remove the flat gasket 11 Strainer Remove the O ring 5 1 Remov...

Page 42: ... block with the fin gers 3 Rotate lever of the reversing valve to the middle position and remove the valve ball 4 Remove the reversing valve lever circlip 31 and supporting ring 32 5 Press the tappet 16 towards the bottom 6 Remove the O ring 33 from the control block 7 Insert the tappet 16 from the bottom and rotate in such a way that the valve ball can be inserted via the nut 8 Insert the valve b...

Page 43: ...ct 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 Pump station at a location suitable for dismantling 1 Dismantle the pump station and disassemble it into its individual parts 2 Clean residues of the pumped liquid from the individual p...

Page 44: ...3 4 5 Viscosity of the pumped liquid too high Increase the temperature of the pumped liquid or Decrease the speed 2 Viscosity of the pumped liquid too low Reduce the temperature of the pumped liquid or Increase the speed 2 3 5 Airlock gas in the pumped liquid 1 Test the pipe system for air admission replace leaking parts 2 Reduce the suction head or Increase the inlet pressure 2 4 Speed frequency ...

Page 45: ... pump 7 Inlet pressure too low Install a non return valve at the pressure side 7 Shaft seal is overloaded through thermal chemical influences 1 Check the maximum operating temperature 2 Check the suitability and resistance of the elastomers with regard to the pumped liquid or Contact the manufacturer 7 Overload of the shaft seal by pressure build up during the heating process Open the pressure sid...

Page 46: ...f the strainer chamber Differential pressure monitoring o Monitoring of the differential pressure at the strainer o Optical display or electrical contacts Fluid heating system electrical heating system o At high viscosity pumped liquids that do not flow sufficiently if not heated Tab 16 Pump station accessories 15 2 Heating 15 2 1 Possible types of heating Pump stations of the DS series can be equ...

Page 47: ...trol block 1 The heating takes place optionally with a heat ing element 481 and or heating liquid that follows through the heating duct 2 The heat transfer takes place via the heat conducting plates 161 The output of the heating element corresponds to the radi ation losses and convection losses of the pump in the required temperature range so that overheating is not possible 15 2 3 Operating data ...

Page 48: ... electrical heating system 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 1 Switch on the electric heating system 2 Take the required heating up periods into account Ä Accessories Page 46 15 2 7 Commissioning the fluid heating system DANGER Risk of injury through emitted pumpe...

Page 49: ... 48 DL2 320 1300 DS1 Maintenance kit Mechanical seal sealing kit UED 04 DL3 DS3 DL4 DS4 Maintenance kit Mechanical seal sealing kit UED 06 UED 08 DL3 DS3 DL4 DS4 Maintenance kit Radial shaft seal sealing kit UED 49 UED 50 DS1 Repair kit Overflow valve BVU211 DL3 DL4 DS3 DS4 Repair kit Overflow valve BVU209 DS1 Repair kit Return valve BVU212 DL3 DL4 DS3 DS4 Repair kit Return valve BVU210 Tab 20 Ove...

Page 50: ...35 1 739 5 739 1 739 2 739 4 739 3 729 1 729 2 739 2 908 1 908 1 735 1 739 1 456 222 Qty Item No Part 1 055 2 Seal ring 2 222 Flat gasket 2 456 Molded gasket 1 729 1 Flat gasket 1 729 2 Flat gasket 6 735 1 Copper seal 2 739 1 O ring 4 739 2 O ring 2 739 3 O ring 1 739 4 O ring 1 739 5 O ring 4 908 1 Screw plug Tab 21 Maintenance kit sealing kit pump station DL3 DL4 DS3 DS4 50 OID 06en GB Edition 2...

Page 51: ...9 3 739 4 055 1 055 1 456 739 8 739 1 739 2 908 1 055 1 735 1 739 5 Qty Item No Part 1 055 1 Seal ring 1 165 1 Screw plug 1 165 2 Screw plug 1 165 3 Screw plug 2 222 Flat gasket 2 456 Molded gasket 6 735 1 Copper seal 2 739 1 O ring 4 739 2 O ring 2 739 3 O ring 1 739 4 O ring 1 739 5 O ring 2 739 8 O ring 2 908 1 Screw plug Tab 22 Maintenance kit sealing kit pump station DS1 Operating instruction...

Page 52: ... O ring 1 739 3 O ring Tab 23 Maintenance kit sealing kit mechanical seal DL3 DL4 DS3 DS4 16 2 4 Maintenance kit sealing kit mechanical seal DL2 as of 320 DS1 Notice The maintenance kit contains only the numbered parts and is only supplied complete 457 735 739 3 739 2 Qty Item No Part 1 457 Mechanical seal 4 735 Copper seal 1 739 2 O ring 1 739 3 O ring Tab 24 Maintenance kit sealing kit mechanica...

Page 53: ...al shaft seal ring Tab 25 Maintenance kit sealing kit radial shaft seal DL3 DL4 DS3 DS4 16 2 6 Maintenance kit sealing kit radial shaft seal DL2 as of 320 DS1 Notice The maintenance kit contains only the numbered parts and is only supplied complete 739 3 739 2 735 745 745 063 Qty Item No Part 1 063 Support ring 4 735 Copper seal 1 739 2 O ring 1 739 3 O ring 2 745 Radial shaft seal ring Tab 26 Mai...

Page 54: ...air kit contains only the numbered parts and is only supplied complete 809 1 751 1 166 055 2 908 2 Qty Item No Part 1 055 2 Seal ring 1 166 Adjusting screw 1 751 1 Pressure spring 1 809 1 Ball 1 908 2 Screw plug Tab 27 Repair kit overflow valve 54 OID 06en GB Edition 2019 11 Operating instructions ...

Page 55: ...ly supplied complete 304 1 739 3 751 2 751 3 739 3 304 2 739 4 298 222 222 Qty Item No Part 2 222 Flat gasket 1 298 Valve insert 1 304 1 Valve cone 1 304 2 Valve cone 2 739 3 O ring 1 739 4 O ring 1 751 2 Pressure spring 1 751 3 Pressure spring Tab 28 Repair kit non return valve Operating instructions OID 06en GB Edition 2019 11 55 ...

Page 56: ...1 Outer bearing overview DS3 DS4 127 817 870 915 1 457 457 Qty Item No Part 1 127 Bearing housing 1 131 Housing 1 457 Mechanical seal 1 817 Ball bearing 1 870 Circlip 1 915 1 Socket screw Tab 29 Spare parts DS3 DS4 56 OID 06en GB Edition 2019 11 Operating instructions ...

Page 57: ...3 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 0 204 285 155 135 180 100 M 18 133 284 390 224 M 20 187 3999 558 313 280 370 135 M 24 322 687 960 540 455 605 360 Tab 30 Tightening torques metric screw thread When screwing into aluminium the tightening torque re...

Page 58: ... 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 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 ATEX On...

Page 59: ...Notes Operating instructions OID 06en GB Edition 2019 11 59 ...

Page 60: ...KRAL GmbH 6890 Lustenau Austria Tel 43 5577 86644 0 E Mail kral kral at www kral at ...

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KRAL DL3 Series, Operating Instructions Manual

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