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
4OID 05en-GB Edition 2019-11 Operating instructions

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.
6OID 05en-GB Edition 2019-11 Operating instructions

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.
10 OID 05en-GB Edition 2019-11 Operating instructions