KRAL DL2 Series User manual

Operating instructions
KRAL pump stations.
Series DL2
Mechanical seal/Radial shaft seal
OID 05en-GB
Edition 2019-11
Original instructions
www.kral.at

Table of contents
1 About this document ..................................................... 4
1.1 General information .......................................................4
1.2 Associated documents ..................................................4
1.3 Target groups ................................................................4
1.4 Symbols.........................................................................4
1.4.1 Danger levels ....................................................4
1.4.2 Danger signs.....................................................5
1.4.3 Symbols in this document .................................5
1.4.4 Symbols for personal protective equipment......6
2 Safety .............................................................................. 6
2.1 Proper use .....................................................................6
2.2 Foreseeable misuse ......................................................6
2.3 Obligations of the operator-owner .................................6
2.4 Safety instructions .........................................................7
2.4.1 Fundamental safety instructions .......................7
3 Identification................................................................... 7
3.1 Type code......................................................................7
3.2 Rating plate ...................................................................8
4 Technical data ................................................................ 8
4.1 Operating limits..............................................................8
4.2 Filling volume.................................................................8
4.3 Sound pressure level.....................................................8
4.4 Weights..........................................................................9
5 Function description...................................................... 9
5.1 Structure ........................................................................9
5.2 Functional principle........................................................9
5.3 Overflow valve .............................................................10
5.4 Pressure measurement ...............................................10
6 Transportation, storage............................................... 10
6.1 Dangers during transportation .....................................10
6.2 Dangers during storage ...............................................11
6.3 Unpacking and checking the state of delivery .............11
6.4 Transporting the pump station.....................................11
6.5 Storing the pump station..............................................12
7 Preservation ................................................................. 12
7.1 Preservation table........................................................12
7.2 Preserving the inner surfaces......................................12
7.3 Preserving the outer surfaces......................................13
7.4 Removing the preservation..........................................13
8 Installation, removal .................................................... 14
8.1 Dangers during installation ..........................................14
8.2 Dangers during removal ..............................................14
8.3 Mounting the pump station ..........................................14
8.4 Removing the pump station.........................................15
9 Connection ................................................................... 16
9.1 Dangers during connection work .................................16
9.2 Connecting the pump station to the pipe system.........16
9.3 Connecting the pump station to the power supply.......17
10 Operation ...................................................................... 18
10.1 Dangers during operation ............................................18
10.2 Commissioning ............................................................18
10.2.1 Cleaning the pipe system................................18
10.2.2 Filling and venting the pump ...........................18
10.2.3 Checking the direction of rotation ....................19
10.2.4 Commissioning the pump station ....................20
10.3 During operation ..........................................................20
10.3.1 Checking the operating pressure.....................20
10.3.2 Activating the reversing valve..........................22
10.3.3 Adjusting the overflow valve ............................22
10.3.4 Switching off the pump station.........................23
10.4 Decommissioning.........................................................23
10.4.1 Taking the pump station out of operation ........23
10.5 Recommissioning.........................................................24
10.5.1 Recommissioning the pump station.................24
11 Maintenance...................................................................24
11.1 Dangers during maintenance.......................................24
11.2 Required maintenance.................................................24
11.3 Ball bearing (inner bearing)..........................................24
11.4 Maintaining the pump station .......................................25
12 Servicing ........................................................................25
12.1 Dangers during servicing .............................................25
12.2 Wear ............................................................................25
12.2.1 Signs of wear...................................................25
12.2.2 Mechanical seal...............................................25
12.2.3 Radial shaft seal ..............................................25
12.3 Replacing the coupling.................................................26
12.3.1 Removing the coupling ....................................26
12.3.2 Installing the coupling ......................................26
12.4 Replacing the pump (DL2 to240) ................................27
12.5 Replacing the pump (DL2 from320)............................28
12.6 Replacing the mechanical seal ....................................29
12.6.1 Removing the mechanical seal (DL2 from320/
DS1) ................................................................29
12.6.2 Installing the mechanical seal (DL2 from320/
DS1) ...............................................................30
12.7 Replacing the radial shaft seal.....................................31
12.7.1 Removing the radial shaft seal (DL2 to240) ...31
12.7.2 Installing the radial shaft seal (DL2 to240) .....31
12.7.3 Removing the radial shaft seal (DL2 as of320/
DS1) ................................................................32
12.7.4 Installing the radial shaft seal (DL2 as of320/
DS1) ................................................................32
12.8 Replacing seals............................................................33
13 Disposal..........................................................................34
13.1 Dismantling and disposing of the pump station ...........34
14 Troubleshooting ............................................................35
14.1 Possible faults..............................................................35
14.2 Troubleshooting ...........................................................35
15 Accessories ...................................................................37
15.1 Pump station accessories ............................................37
16 Spare parts.....................................................................37
16.1 Overview ......................................................................37
16.2 Maintenance kits ..........................................................38
16.2.1 Maintenance kit sealing kit pump station.........38
16.2.2 Maintenance kit sealing kit pump (DL2 to240)
.........................................................................39
16.2.3 Maintenance kit sealing kit mechanical seal
(DL2 as of320/DS1)........................................39
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Table of contents
16.2.4 Maintenance kit sealing kit radial shaft seal (DL2
as of320/DS1) ................................................40
16.3 Repair kits....................................................................40
16.3.1 Repair kit, overflow valve ................................40
16.3.2 Repair kit non-return valve..............................41
17 Appendix....................................................................... 42
17.1 Tightening torques for screws with metric screw threads
with and without wedge lock washers .........................42
17.2 Tightening torques for screw plugs with thread meas-
ured in inches and elastomer seal...............................42
17.3 Contents of the Declaration of Conformity...................43
Operating instructions OID 05en-GB Edition 2019-11 3

1 About this document
1.1 General information
1 About this document
1.1 General information
These instructions form part of the product and must be kept for future reference. Furthermore please
observe the associated documents.
1.2 Associated documents
oDeclaration of conformity according to EU Directive 2006/42/EC
oManufacturer's declaration according to EU Directive 2014/68/EU
oCorresponding operating instructions of the pump
oTechnical documentation of the supplied components
1.3 Target groups
The instructions are intended for the following persons:
oPersons who work with the product
oOperator-owners who are responsible for the use of the product
Persons who work with the product 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 carry out the work properly due to their training, knowledge and experience
and on the basis of the relevant provisions.
Information on the required 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 mounting
Electrician Electrical connection Qualified personnel for electric installation
Trained personnel Delegated task Personnel trained by the operator-owner who know
the task delegated to them and the possible dangers
arising through improper behaviour.
Tab.1: Target groups
1.4 Symbols
1.4.1 Danger levels
Signal word Danger level Consequences of non-observance
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
ATTENTION Potentially dangerous situation Material damage
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1 About this document
1.4 Symbols
1.4.2 Danger signs
Meaning Source and possible consequences of non-observance
Electrical voltage Electrical voltage causes serious physical injury or death.
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 Discharging pumped liquid and oils on the foundation or tread
surfaces can cause falls with serious physical injury or death.
Flammable substances Discharging pumped liquid and oils can be easily inflammable and
can result in serious burns.
Hot surface Hot surfaces can cause burns.
1.4.3 Symbols in this document
Meaning
Warning personal injury
Safety instruction
Request for action
1.
2.
3.
Multi-step instructions for actions

Action result

Cross-reference
Operating instructions OID 05en-GB Edition 2019-11 5

2 Safety
2.1 Proper use
1.4.4 Symbols for personal 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 helmet Serious head injury through falling or toppling parts
Protective goggles Eye injury through hot, poisonous or corrosive liquids
Hearing protection Damage to hearing through loud noises
Heat-resistant protective gloves
with arm protection
Serious burns or cuts
Close fitting work clothing Serious physical injury through clothes being drawn in
Slip resistant safety boots Serious foot injury through falling or toppling parts and
serious physical injury through falling
2 Safety
2.1 Proper use
oUse the pump station solely for transporting lubricating liquids that are chemically neutral and that
do not contain gas or solid components.
oUse the pump station only within the operating limits specified on the rating plate and in the chapter
"Technical data". In the case of operating data that do not agree with the specifications on the rat-
ing plate, please contact the manufacturer.
oThe pump station is designed specially for the operating pressure named by the customer. If the ac-
tual operating pressure deviates notably from this design pressure, damage to the pump station can
also arise within the specified operating limits. This applies both to notably higher as well as to not-
ably lower operating pressures. Under no circumstances may the minimum pressure lie below
2bar. In case of any doubt, please contact the manufacturer.
2.2 Foreseeable misuse
oAny use that extends beyond the proper use or any other use is misuse.
oThe product is not suitable for pumping liquids outside the operational limits.
oAny bypassing or deactivation of safety equipment during operation is prohibited.
2.3 Obligations of the operator-owner
The operator-owner is the person who operates the product commercially or permits a third party to
use it and who bears the legal responsibility for the product, the protection of the personnel and third
parties during its operation.
The product is used in industrial applications. 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.
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3 Identification
2.4 Safety instructions
2.4 Safety instructions
2.4.1 Fundamental safety instructions
The following safety instructions must be observed strictly:
oRead these operating instructions carefully and observe them.
oRead the operating instructions of the components carefully and observe them.
oHave work only carried out by qualified personnel/trained personnel.
oWear personal protective equipment and work carefully.
oPumped liquids can be subject to high pressure and can result in personal injury and damage to
property in case of incorrect operation or damaged components.
oPumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
oObserve the associated data sheets and safety regulations when handling dangerous materials.
oAvoid skin contact with system parts carrying liquids at operating temperatures exceeding 60°C.
oCollect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations. Neutralize residues.
oKeep the mounting surfaces, scaffolding, ladders, lifting platforms and tools clean in order to pre-
vent slipping or stumbling.
oIf pressurized or energized components are damaged, shut down the pump station immediately.
Replace the components.
3 Identification
3.1 Type code
DL2- 240.AAA.0001
1
2
3
4
5
6
Fig.1: Type code
1Type
2Size
3Shaft seal
4Storage
5Heating
6Version index
Item Classification Description
1Type DL2 oStation with pumps of the FEseries
oStation with pumps of the NE series
2Size Corresponds to delivery rate in[l/h] at 1450min-1
3Shaft seal A Standard radial shaft seal
B Standard mechanical seal
C Mechanical seal of hard material
4 Storage A Inner bearing
5 Heating A Without heating
6 Version index For internal administration
Tab.2: Type code
Operating instructions OID 05en-GB Edition 2019-11 7

4 Technical data
3.2 Rating plate
3.2 Rating plate
KRAL GmbH, 6890 Lustenau, Austria www.kral.at KRAL GmbH, 6890 Lustenau, Austria www.kral.at
pSmax. / pDmax.
Ty p |Type
SN | Serial no.
Tmin. / Tmax. ºC
l/min
mm²/s
kg
min-¹
bar
bar
∆p
Jahr |Year Gewicht | Weight
n
Q
Art.-Nr. | Item no.
1
2
3
5
4
10
7
9
8
6
11
Fig.2: Rating plate
1Construction year
2Max. operating overpressure
suction-side / Max. operating
overpressure pressure-side
3Temperature range
4Serial number
5Type
6Article number
7Differential pressure
8Nominal delivery rate
9Rated speed
10 Nominal viscosity
11 Weight
4 Technical data
4.1 Operating limits
In addition to the operating limits of the pump station, the operating limits of the attached pumps must
also be observed.
Parameter Unit Size
150 240 320 400 500 750 1000 1300
Max. operating pressure [bar] 6.0
Max. inlet pressure
oMechanical seal [bar] 5.0
oRadial shaft seal [bar] 0.5
Max. temperature of
pumped liquid
[°C] 80
Viscosity min.–max. [mm2/s] 2–37
Min.–max. ambient
temperature
[°C] -10 ... 50
Tab.3: Pump station operating limits
4.2 Filling volume
Parameter Unit Size
150 240 320 400 500 750 1000 1300
Filling volume of station block [l] Approx. 1.0
Tab.4: Filling volume of station block
4.3 Sound pressure level
Guide value at 1m distance, rated speed of the station, 50Hz operation
Size
150 240 320 400 500 750 1000 1300
Max. sound pressure level±3[dB(A)]
Pump 44.8 46.1 47.7 47.8 49.0 50.4 51.8 53.6
Motor 45.0 45.0 45.0 44.0 44.0 54.0 54.0 54.0
1 pump unit (lever position left/
right)
47.9 48.6 49.6 49.3 50.2 55.6 56.0 56.8
2 pump units (middle position) 49.6 50.5 51.7 51.6 52.6 56.7 57.4 58.5
Tab.5: Sound pressure level
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5 Function description
4.4 Weights
4.4 Weights
The weight is specified on the rating plate.
5 Function description
5.1 Structure
1
2
3
5
4
6
7
10
8
9
11
12
Fig.3: Structure of pump station
1Pressure-side pressure gauge 7Oil pan
2Motor 8Shaft seal (radial shaft seal)
3Station block 9Shaft end pump (main screw)
4Pressure-side connection 10 Cartridge housing
5Suction-side connection 11 Idle screw
6Reversing valve with integrated over-
flow valve
12 Strainer
M
M
Fig.4: Hydraulic scheme
5.2 Functional principle
Pump stations of the DL2 series with two KRAL screw pumps of the series FE or NE are suitable for
pumping light oil.
Screw pumps are rotating pumps. Their displacement effect results from three rotating screws9 and11
and the enclosing cartridge housing10. 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 viscosity
limits. Due to the narrow tolerances pumping of suspended solids is not possible. The shaft seal8
seals the main screw at the outlet of the housing. The sealing chamber is connected with the suction
chamber via a relief line.
Operating instructions OID 05en-GB Edition 2019-11 9

6 Transportation, storage
5.3 Overflow valve
The pump station is connected with the pipe system via the connections4 and5. Depending on the po-
sition of the reversing valve 6 the pumped liquid flows through the left, right or both pumps.
The oil pan collects leaks from the pump station.
5.3 Overflow valve
1 2 4 5
8
76
3
Fig.5: Overflow valve
1Valve ball
2Pressure spring
3Adjusting screw
4Reversing valve
5Screw plug
6Reversing valve lever
7Suction-side connection
8Pressure-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 not be used for control
or regulation purposes such as maintaining pressure. If the valve is kept open for too long under ad-
verse operating conditions (high differential pressures and/or low viscosities) it will only take a few
minutes for the overflow valve and the valve seating to become damaged. As a result, the overflow
valve will leak permanently and there will be a corresponding reduction in the delivery rate. In addition
to this, circulation through the overflow valve for too long results in excess heating of the pump. This
reduces viscosity and can ultimately lead to pump failure.
It therefore has to be ensured at the system by a safety valve that the maximum operating overpres-
sure always lies under the opening pressure of the overflow valve.
Notice The opening pressure of the overflow valve is set to 110% of the differential pressure in the factory.
The overflow valve is accessible through a screw plug5 and can be adjusted from the outside Ä Dur-
ing operation,Page20.
Notice oA function test of the overflow valve at least every 5 years is essential for the safe operation Ä Dur-
ing operation,Page20.
oScope and if necessary shorter test intervals must be specified by the operator-owner in accord-
ance with the requirements and national provisions (for example Austrian Ordinance of Safety and
Health (BetrSichV)).
oThe first function test must take place directly after the commissioning.
oAfter longer downtimes (> 4 weeks) the function of the overflow valve must be tested again.
5.4 Pressure measurement
A pressure gauge5 is mounted in the centre of the station in order to monitor the supply pressure. The
pressure gauge is always connected to the pressure side of the station and is thus independent of the
position of the reversing valve6.
The shut-off valves at the pressure gauges may only be opened to read the pressure values, Ä During
operation,Page20.
6 Transportation, storage
6.1 Dangers during transportation
The following safety instructions must be observed:
oHave all work only carried out by authorized transport personnel.
oUse intact and correctly dimensioned hoisting equipment.
oEnsure that the means of transport is in a flawless state.
oEnsure that the centre of gravity of the load is taken into consideration.
oDo not stand under raised loads.
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6 Transportation, storage
6.2 Dangers during storage
6.2 Dangers during storage
The following safety instructions must be observed:
oObserve the storage conditions.
6.3 Unpacking and checking the state of delivery
1. Upon delivery unpack the pump station and check it for damage during transportation.
2. Report damage during transportation immediately to the manufacturer.
3. Dispose of packaging material in accordance with the locally applicable regulations.
6.4 Transporting the pump station
Personnel qualification: oTransport personnel
Personal protective equipment: oWork clothing
oProtective helmet
oProtective gloves
oSafety boots
Aids: oMobile 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 gravity and the
weight distribution.
► Use at least two load ropes.
► Do not stand under raised loads.
1
1
Fig.6: Fastening of hoisting equipment
1. Screw in eye bolt1 at both motors. Position see figure.
2. Secure the hoisting equipment to the eye bolts of the pump station and lift the pump station using
the crane.
Operating instructions OID 05en-GB Edition 2019-11 11

7 Preservation
6.5 Storing the pump station
6.5 Storing the pump station
During the test run, the internal components of the pump station are wetted with test oil, which has a
preservative effect. The pipe connections are fitted with protective covers. Unless otherwise specified,
the outer parts of the pump station are preserved with a single-coat PU-based two-component paint.
The preservative applied at the factory will protect the pump station for about six weeks, if it is stored in
a dry and clean location.
The manufacturer offers a long-term preservation for storage times of up to 60months. The pump sta-
tion is additionally packed in hermetically sealing anti-corrosion paper.
Personnel qualification: oTransport personnel
Aids: oMobile crane, forklift, hoisting equipment
ATTENTION
Damage to equipment and corrosion if stored improperly and during longer standstills.
► Protect the pump station against damage, heat, sunlight, dust, moisture and magnetic fields.
► Protect against corrosion during longer standstill.
► Observe measures for storing and preservation.
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12.
7 Preservation
7.1 Preservation table
Preservation has to be carried out additionally under the following conditions:
Type of delivery Condition
Standard delivery oStorage time exceeding six weeks
oUnfavourable storage conditions such as high humidity,
salty air, etc.
Delivery with long-term preservation oOpened or damaged packaging
Tab.6: Conditions for additional preservation
7.2 Preserving the inner surfaces
Personnel qualification: oTrained personnel
Personal protective equipment: oWork clothing
oProtective gloves
oSafety boots
Aids: oCastrol Rustilo DWX 33 or other preservative offering compar-
able protection
1
Fig.7: Preserving the inner surface
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7 Preservation
7.3 Preserving the outer surfaces
1. Open the screw plug1.
2. Pour the preservative into the station block until it reaches approx.2cm under the rim, while
slowly turning the fan impeller of the motor in the direction of rotation at the pumps.
3. Close the screw plug.
4. After about six months storage check the filling level of the oil and if necessary top up.
7.3 Preserving the outer surfaces
Personnel qualification: oTrained personnel
Personal protective equipment: oWork clothing
oFace protection
oProtective gloves
oSafety boots
Aids: oCalcium complex grease (for example TEVI-
ER®GREASEWAWE100 with adhesive additive)
oCastrol Rustilo DWX 33 or other preservative offering compar-
able protection
1. Brush calcium complex grease corrosion protection (for example TEVIER® FETT WAWE 100
with adhesive additive) to the mounting surfaces.
2. Brush or spray preservative (for example Castrol Rustilo DWX 33) onto the process connections
and remaining plain and unpainted parts.
3. At intervals of about six months check the preservation and if necessary repeat.
7.4 Removing the preservation
Personnel qualification: oTrained personnel
Personal protective equipment: oWork clothing
oProtective gloves
oSafety boots
Aids: oSolvent
oSteam-jet cleaning device with wax-dissolving additives
oCollection tank
CAUTION
Risk of injury through emitted preservative.
► Wear personal protective clothing during all the work.
► Collect any discharging preservative safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
1
1
1. Clean the outside of the pump station with solvents, if necessary using a steam-jet cleaning
device.
2. Remove the screw plug1 carefully in order to reduce any pressure that may exist in the pump
station.
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8 Installation, removal
8.1 Dangers during installation
3. Drain the pump station, collecting the preservative in a collection tank.
4. To remove the residual preservative, flush the pump station with the pumped liquid.
8 Installation, removal
8.1 Dangers during installation
The following safety instructions must be observed strictly:
oHave all work carried out only by authorized qualified personnel.
oBefore installation ensure that the operating limits, NPSH values and ambient conditions are ob-
served.
oObserve the tightening torques Ä Appendix,Page42.
oEnsure that all the components can be accessed and that maintenance work can be carried out
easily.
8.2 Dangers during removal
The following safety instructions must be observed strictly:
oHave all work carried out only by authorized qualified personnel.
oBefore beginning work, let the pump unit cool down to the ambient temperature.
oCollect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
oEnsure that the collection tank for discharging pumped liquids is sufficiently large.
8.3 Mounting the pump station
The pump station is operated 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 commissioning strainers.
Personnel qualification: oTransport personnel
oFitter
Personal protective equipment: oWork clothing
oProtective gloves
oSafety boots
Aids: oMobile crane, forklift, hoisting equipment
WARNING
Risk of injury and damage to equipment through falling and toppling parts.
► Only fasten the pump station on a stable bearing underground.
► Ensure that fastening elements and pipings are fastened sufficiently.
ATTENTION
Damage to device through impurity in the pipe system.
► During welding work attach protective covers in front of the connecting flanges.
► Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and
the pump station.
► Ensure that a commissioning filter is installed when the pipe system is flushed and cleaned using
the pump.
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8 Installation, removal
8.4 Removing the pump station
IN
OUT
2
1
3
Fig.8: Mounting the pump station
1Suction-side connection
2Pressure-side connection
3Fastening element
Requirement:
üPump 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. Take the flow direction into consideration.
2. Fasten the pump station with fastening elements 3 securely on the underground.
3. After the connecting work clean the pipe system thoroughly Ä Commissioning,Page18.
8.4 Removing the pump station
Personnel qualification: oTransport personnel
oFitter
oElectrician
Personal protective equipment: oWork clothing
oProtective helmet
oProtective gloves
oSafety boots
Aids: oMobile crane, forklift, hoisting equipment
oCollection 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.
Pumped liquids can be hot, poisonous, combustible and caustic and can spray out under high pres-
sure.
► Wear personal protective clothing during all the work. Ensure face protection.
► Before beginning work, let the pump station cool down to the ambient temperature.
► 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 regulations.
Requirement:
üPump station and pumped liquid cooled down to the ambient temperature
1. Ensure that the pump station is deenergized and is secured against being switched back on.
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9 Connection
9.1 Dangers during connection work
2. Ensure that the pump station is depressurized.
3. Close the pressure-side and suction-side shut-off devices.
4. Loosen the connecting screws of the suction connection and the pressure connection. Collect
any discharging pumped liquid.
5. After the pumped liquid has been drained completely, dismantle the pressure-side and suction-
side connecting flange.
1
1
6. Open the screw plugs1, collect any discharging pumped liquid.
7. Remove the pump station.
9 Connection
9.1 Dangers during connection work
The following safety instructions must be observed:
oHave all work on the pump station and pipe system only carried out by authorized qualified per-
sonnel.
oEnsure that impurities cannot get into the pump station and pipe system.
oEnsure that mechanical connections are mounted free of stress.
oObserve the tightening torques.
oHave all the work on the electrical equipment only carried out by electricians.
oBefore commissioning ensure correct earthing and equipotential bonding.
oBefore beginning work on the pump station ensure that the electrical power supply is deenergized
and is secured against being switched back on.
oIf the insulation of the electrical cables or wires is damaged, disconnect the power supply immedi-
ately.
9.2 Connecting the pump station to the pipe system
Fig.9: Connecting the pipe system
Personnel qualification: oFitter
Personal protective equipment: oWork clothing
oProtective gloves
oProtective helmet
oSafety boots
Aids: oMobile crane, forklift, hoisting equipment
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9 Connection
9.3 Connecting the pump station to the power supply
ATTENTION
Damage to device through impurity in the pipe system.
► During welding work attach protective covers in front of the connecting flanges.
► Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and
the pump station.
► Ensure that a commissioning filter is installed when the pipe system is flushed and cleaned using
the pump.
ATTENTION
Damage to device through mechanical stress.
► Ensure that the pump station is mounted free of mechanical stresses in the pipe system.
► Observe the tightening torques.
1. Attach protective covers in front of the connecting flanges before welding work.
2. Avoid mechanical tensions in the pipe system when carrying out connecting.
3. Place the piping in position and support the weight of the piping. Do not use the pump station as
a support for connected piping.
4. Install compensating elements if temperature-related material expansion is possible.
5. Check the linear, height and angular offset and correct if necessary.
ðIf 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42.
7. Lay the suction line hermetically sealed with a slight ascending slope.
9.3 Connecting the pump station to the power supply
Personnel qualification: oElectrician
Personal protective equipment: oWork clothing
oProtective gloves
oSafety boots
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.
► Before commissioning ensure correct grounding and equipotential bonding.
► Observe the operating instructions of the electrical components.
1. Carefully earth the base frames with the screwing.
2. Connect the electrical components of the pump station in accordance with the corresponding op-
erating instructions.
3. When connecting the pump station to the complete system continue equipotential bonding.
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10 Operation
10.1 Dangers during operation
10 Operation
10.1 Dangers during operation
The following safety instructions must be observed strictly:
oHave all work carried out only by authorized qualified personnel.
oBefore commissioning ensure that a safety valve has been installed in the pressure-side pipe sys-
tem to protect the pump station.
oBefore commissioning, make sure that the suction line and pump station are filled.
oPumped liquids can be hot, poisonous, combustible and caustic. Use corresponding protective
equipment.
oObserve the operating instructions of the pump and the further components.
oEnsure that the pump station is only operated within the operating limits.
oEnsure that during cooling down or heating up the pump station is only subjected to slow temper-
ature changes.
oEnsure that existing safety equipment is not bypassed or activated during operation.
oBefore decommissioning ensure that the electrical power supply is deenergized and is secured
against being switched back on.
10.2 Commissioning
10.2.1 Cleaning the pipe system
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 commissioning strainers.
Personnel qualification: oFitter
Personal protective equipment: oWork clothing
oProtective gloves
oProtective helmet
oSafety boots
ATTENTION
Damage to equipment through additional pressure loss in the commissioning filter/commis-
sioning strainer.
► Calculate the flow resistance and determine the remaining pump intake.
► Monitor the suction-side pressure.
► Check the commissioning filter/commissioning strainer regularly.
Requirement:
üIf required, commissioning filter/commissioning strainer installed (mesh width0.02 mm)
1. Clean the complete pipe system before commissioning in order to protect the pump station.
2. Flush the pipe system at least 50 – 100hours.
10.2.2 Filling and venting the pump
Personnel qualification: oFitter
Personal protective equipment: oWork clothing
oProtective helmet
oFace protection
oProtective gloves
oSafety boots
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10 Operation
10.2 Commissioning
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic.
► Wear personal protective clothing during all the work. Ensure face protection.
► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
1
2
Requirement:
üShut-off devices of the suction line and pressure line closed
üLever of the reversing valve to middle position
1. Remove the screw plug1.
2. Open the screwing of the pressure gauge2 by a max. of two rotations so that air can escape dur-
ing the filling process.
3. Fill the pump via the hole1 until pumped liquid is emitted at the pressure gauge, rotate the fan
impeller of the motor in the process.
4. Tighten the screw plug and screwing of the pressure gauge again with torque, Ä Ap-
pendix,Page42.
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 of the motor must rotate in
the same direction in which the arrow for the direction of rotation on the pump points.
Notice Standard direction of rotation: clockwise (viewed from the motor)
Personnel qualification: oFitter
1. Switch on the power supply and then turn it off again immediately.
1
2. Compare the direction of rotation of the fan impeller with the arrow indicating the direction of rota-
tion1.
3. If the directions do not match, swap the two electrical connection phases. Repeat Steps1 and2.
4. Repeat Steps1 to 3 for the second pump.
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10 Operation
10.3 During operation
10.2.4 Commissioning the pump station
Personnel qualification: oFitter
oElectrician
Personal protective equipment: oWork clothing
oProtective helmet
oProtective gloves
oSafety boots
oFace protection
Aids: oCollection tank
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous, combustible and caustic.
► Wear personal protective clothing during all the work. Ensure face protection.
► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible
manner in accordance with the applicable local regulations.
ATTENTION
Dry running can damage pump equipment.
► Ensure that the pump and the connected pipe system are filled properly.
► If the pump does not deliver after10–15 seconds, abort commissioning.
Requirement:
üPump station set up and connected correctly
üMotors connected correctly
üPipe system is free of impurities
üPump station filled
üShut-off devices in the suction line and pressure line opened
üAll connections connected sealingly
1. Switch on the pump station.
ðThe 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 fault and only then continue the commissioning procedure. Take the in-
formation from the fault table into account, Ä Troubleshooting,Page35.
3. Run the pump station for a few minutes to allow the pipe system to vent fully.
ðThe pipe system is fully vented when there is a smooth operating noise and a pressure gauge
on the pressure side of the pump shows no more fluctuations.
4. Checking overflow valve functions Ä During operation,Page20.
10.3 During operation
10.3.1 Checking the operating pressure
Personnel qualification: oTrained personnel
barbar
Fig.10: Pressure gauge shut-off valves closed / open - principle diagram
20 OID 05en-GB Edition 2019-11 Operating instructions