North Ridge Pumps KRAL DKB Series User manual

Product Specification Sheet
X-Cel House, Chrysalis Way, Langley Bridge, Eastwood, Nottinghamshire NG16 3RY
Tel: [phone] | Email: [email protected] | Website: www.northridgepumps.com
Operating Instructions
KRAL Pump Stations.
DKB Series.
OID 04en
Edition 08/2014
Original operating instructions

2 OID 04en Edition 08/2014 Operating Instructions
Table of contents
KRAL Pump Stations – DKB Series
About this document
□General information 3
□Target groups 3
□Symbols 3
□Danger levels 4
□Associated documents 4
Safety
□Proper use 5
□Safety information 5
Labeling
□Type code 6
□Rating plate 6
Technical data
□Operating limits 7
□Required NPSH values 7
□Weights 7
□Filling volume 7
□Sound pressure levels 7
Heating system
□General 8
□Electric heating system 8
▪Mounting the electric heating system 8
▪Connecting and commissioning the
electric heating system 10
□Fluid heating system 11
▪Mounting the fluid heating system 11
▪Commissioning the fluid heating system 11
Function description
□Structure 12
□Function description 13
▪Functional principle 13
▪Reversing valve 13
▪Expansion valve 13
▪Pressure measurement 13
□Options 14
▪Suction-side pressure monitoring 14
▪Temperature monitoring 14
▪Leak oil monitoring 15
▪Pressure switch 15
Transportation, storage and disposal
□Unpacking and checking the state of
delivery 16
□Lifting the station 16
□Storage 17
□Preservation 17
▪Preserving the internal surfaces of the
station 17
▪Preserving the external surfaces of the
station 17
▪Removing the preservative 17
□Disposing of the station 18
Installation, removal and connection
□Installation 19
▪Setting up the station 19
▪Protecting the station against
contamination 20
▪Connecting the station to the pipe
system 20
□Removing the station 21
Operation
□Commissioning 22
▪Cleaning the pipe system 22
▪Filling the station 22
▪Checking the direction of rotation 23
▪Commissioning the station 23
□During operation 24
▪Activating the reversing valve 24
▪Reading the pressure values 25
▪Switching off the station 25
□Taking the station out of operation 26
□Recommissioning the station 26
Maintenance
□Safety instructions 27
□Required maintenance 27
□Replacing the pump 28
□Replacing the seal ring of the control plug 30
Troubleshooting
□Possible faults 31
□Troubleshooting 31
Appendix
□General drawings 34
□Spare parts 37
□Tightening torques 37
□Contents of the EC Declaration of
Conformity 38
□Notes 39

Operating Instructions OID 04en Edition 08/2014 3
General information
About this document
About this document General information
The operating instructions form part of the pump/pump station and must be kept for future reference.
Furthermore please observe the associated documents.
Target groups
Symbols
Target group Tasks
Operator-owner □Keep these instructions available at the installation site for future
reference.
□Ensure that employees read and observe these instructions and
the associated documents, in particular the safety instructions
and warnings.
□Observe additional system-specific directives and regulations.
Specialist personnel, fitters □Read, observe and follow these instructions and the associated
documents, in particular the safety instructions and warnings.
Symbol Meaning
Warning personal injury
Notice
Procedures mechanical installation
Procedures electrical installation
Check or fault table
Request for action

4 OID 04en Edition 08/2014 Operating Instructions
Danger levels
About this document
Danger levels
Associated documents
Warning Danger level Consequences of non-observances
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
CAUTION potentially dangerous situation material damage
Declaration of conformity according to EU Directive 2006/42/EC
Manufacturer’s declaration as per EU Directive 97/23/EG
Corresponding pump operating instructions
Technical documentation for supplied components

Operating Instructions OID 04en Edition 08/2014 5
Proper use
Safety
Safety Proper use
□Use the pump/pump station only for transporting lubricating liquids that are chemically neutral and
that contain no gas or solid components.
□Use the pump/pump station only within the performance limitations specified on the rating plate and
in the "Technical data" section. In the case of operating data that does not agree with these specifi-
cations, please contact the manufacturer.
□The pump/pump station is specifically configured for the operating pressure stated by the customer.
In the case of a significant difference between actual and configured operating pressure damages
can occur even within the stated performance limitations. This applies both to notably higher as well
as to notably lower operating pressures. Under no circumstances should the operating pressure fall
below the minimum pressure of 2 bar. In case of any doubt, please contact the manufacturer.
Safety information
The following general safety instructions must be observed:
□No liability is accepted for damage arising through non-observance of the operating instruc-
tions.
▪Read the operating instructions carefully and observe them.
▪The operator-owner is responsible for the observance of the operating instructions.
▪Installation, removal and installation work may only be carried out by specialist personnel.
□In order for the warranty to remain valid, corrective maintenance carried out during the war-
ranty period requires the express permission of the manufacturer.
□Observe the general regulations for the prevention of accidents as well as the local safety
and operating instructions.
□Observe the valid national and international standards and specifications of the installation
location.
□In case of systems with an increased potential of danger to humans and/or machines the fai-
lure of a pump must not lead to injuries or damage to property.
▪Always equip systems with an increased potential of danger with alarm equipment.
▪Maintain and check the protective/alarm equipment regularly.
□The pumped liquids can be dangerous (e.g. hot, dangerous to health, poisonous, combus-
tible). Observe the safety regulations for handling dangerous materials.
□Pumped liquid can be subject to high pressure and can cause damage and/or personal injury
should leaks occur.

6 OID 04en Edition 08/2014 Operating Instructions
Type code
Labeling
Labeling Type code
Rating plate
1Model
2Size
3Shaft seal
4Heating system
5Version index
Item Designation Type
1Model DKB: pressure build-up up to 16 bars
2Size corresponds to flow rate in [l/h] at motor speed
3Shaft seal A: standard mechanical seal
B: mechanical seal of hard material
C: standard radial shaft seal
D: magnetic coupling
E: mechanical seal with quench
F: radial shaft seal, high-temperature
X: special seal
4Heating system A: without heating system
B: electric heating system in the block
C: fluid heating system in the block
D: electric heating system in the block and at the pumps
E: fluid heating system in the block and at the pumps
5Version index for internal administration
1Nominal delivery rate
2Differential pressure/
Operating pressure max.
3Temperature range
4Serial number
5Type
6Year of construction
7Rotation speed
8Nominal viscosity
DKB- 3000.BA.00001
1
2
3
4
5
DKB- 3000.BA.00001DKB- 3000.BA.00001
196148196148 20102010
-10-10 6060
5/165/16
7575
8282
14501450
1
2
3
4
56
7
8

Operating Instructions OID 04en Edition 08/2014 7
Operating limits
Technical data
Technicaldata Operating limits
In addition to the operating limits of the pump station, the operating limits of the attached pumps must
also be observed.
Tab. 1 Pump station operating limits
Required NPSH values
See corresponding pump operating instructions.
Weights
Tab. 2 Weights
Filling volume
Tab. 3 Filling volume
Sound pressure levels
Guide values at 1 m distance, 1450 min-1, 10 bar
Tab. 4 Sound pressure levels
DKB
Operating pressure max. [bar] 16
Temperature of the pumped liquid max. [°C] 180
Ambient temperature [°C] -10...50
Viscosity [mm2/s]
min. – max. 2 – 10000
Feed pressure max. [bar] 6
Part Weight [kg]
Station block with reversing valve 37.5
Counter flanges, 2 pieces 2.4
Base frame with oil pan 21.0
Pump with coupling and motor see corresponding pump operating instructions
Filling volume of the station block [l] 1.8
Sound pressure level ± 3 [dB(A)]
pump motor 1 pump + 1 motor 2 pumps + 2 motors
K 55 – 118 60.0 62.0 64.0 67.0

8 OID 04en Edition 08/2014 Operating Instructions
General
Heating system
Heating system General
The pump stations can be equipped with an optional heating system. We recommend heating systems
for high-viscosity liquids that do not flow sufficiently if not heated. This can result in excessive power
consumption or lead to problems arising through cavitation or sealing.
Method of heating:
□Electric heating system
□Fluid heating system
Electric heating system
Operating data:
□Voltage: 230 V
□Wattage: 220 W
□Frequency: 50/60 Hz
□Wire cross-section: 2 x 1 mm²
□Filling volume: 0.22 l
The output of the heating element corresponds to the radiation and convection losses of the station in
the required temperature range so that overheating is not possible.
Mounting the electric heating system
The electric heating is installed in a heating duct within the station block, see Fig. 4, page 9.
Scope of delivery:
□Heating element
□Screw plug
□2 seal rings
□0.25 l thermal oil Caldo ISO 32
1Connecting cable
2Heating element
3Seal ring
4Screw plug heating element
5Seal ring
Fig. 1 Electric heating system
1
2
3
4
5

Operating Instructions OID 04en Edition 08/2014 9
Electric heating system
Heating system
Pay attention to the following when installing the heating element:
□Protect the area of the connecting head against liquid and pasty media (anti-friction agent,
oil, plastics, etc.) as well as their vapors, because leakage currents or flashovers can other-
wise occur at the emersion point of the supply line.
□Protect the supply lines against mechanical vibrations in the area of the emersion from the
heating element.
□Store the heating element in an absolutely dry room or in hermetically sealed plastic bags. If
the heating element has absorbed humidity, dry it for 8 hours in a drying furnace at 180 °C.
1Connecting cable
2Heating element
3Seal ring
4Screw plug heating element
5Seal ring
6Station block
7Heating duct
8Upper screw plugs heating duct
9Lower screw plug heating duct
Fig. 2 Sectional view heating duct
Fig. 3 Position of the heating element Fig. 4 Heating element installation
9
7
88
6
6
4
5
2
1
3
9

10 OID 04en Edition 08/2014 Operating Instructions
Electric heating system
Heating system
1. Slide the seal ring 3, screw plug of the heating element 4and seal ring 5 onto the heating element 2,
see Fig. 1, page 8. Tighten the screw plug.
2. Remove the lower screw plug of the heating duct 9 at the station block, see Fig. 2, page 9.
3. Insert the heating element from below into the heating duct 7 and tighten the screw plug of the hea-
ting element 4.
4. Remove one of the upper screw plugs of the heating duct 8 at the station block.
5. Fill the heating duct with thermal oil up to a maximum of 45 mm under the sealing surface of the
screw plug.
6. Close the heating duct again with the upper screw plug 8.
Connecting and commissioning the electric heating system
1. Connect the connecting cable of the heating element.
2. Switch on the electric heating system.
Heating up of the station block after the steady-state condition has been reached:
□Station rear: approx. 80 K
□Station front: approx. 40 K
WARNING
Danger of the station block bursting if the heating duct is filled completely and risk of injury through
emitted thermal oil.
►Fill the heating duct with thermal oil up to a maximum of 45 mm under the sealing surface of the
screw plug.
DANGER
Risk of death resulting from electric shock.
►Ensure that the power supply is disconnected during the connecting work.
►The electric heating system may only be connected by an authorized electrician.
WARNING
Danger of the station block bursting through heat expansion of the liquid and risk of injury through
emitted liquid.
►Do not shut off the station from the pipe system during the heating process.
∆tHeating-up time
∆tTemperature rise
AStation rear
BStation front
Fig. 5 Temperature rise after the heating has been switched on
0
10
20
30
40
50
60
70
80
90
0 4 8 1216202428323640444852566080
∆t [min]
B
A
∆T [K]

Operating Instructions OID 04en Edition 08/2014 11
Fluid heating system
Heating system
Fluid heating system
In the case of the fluid heating system the heating fluid passes through a heating duct 3in the station
block, see Fig. 7, page 11. The screw connections 2 required to this purpose are available from KRAL,
see "Spare parts", page 37. Observe the respective operating limits of the station and the attached
pumps when setting the supplied fluid and its temperature, see Tab. 1, page 7, and the associated
pump operating instructions.
Operating data:
□Maximum pressure: 16 bar
□Maximum fluid temperature: 180 °C
□Connection: Inserted screw connection straight, outer diameter 22 mm
Mounting the fluid heating system
Scope of delivery:
□2 screw connections
1. Remove the upper screw plugs of the heating duct at the station block, see Fig. 2, page 9.
2. Mount the piping 1 using the screw connections 2, see Fig. 7, page 11.
Commissioning the fluid heating system
►Observe the respective operating limits of the station and the attached pumps when setting the sup-
plied fluid and its temperature, see Tab. 1, page 7, and the associated pump operating instructions.
Fig. 6 Installation position of the fluid heating
system
Fig. 7 Sectional view of fluid heating system
1Piping
2Screw connection for fluid heating system
3Heating duct
3
2
1
3
2
1
WARNING
Danger of the station block bursting through heat expansion of the liquid and risk of injury through
emitted liquid.
►Do not shut off the station from the pipe system during the heating process.

12 OID 04en Edition 08/2014 Operating Instructions
Structure
Function description
Function de scription Structure
Fig. 1 Station structure
1Pumps
2Reversing valve lever
3Pressure-side pressure
gauge
4Suction connection
5Pressure connection
Fig. 2 Hydraulic scheme
1
3
2
5
4
1
PI
PI
PI
M
M
Pressure Side
TI
TI
Suction Side

Operating Instructions OID 04en Edition 08/2014 13
Function description
Function description
Function description
Functional principle
The pump stations of the DKB series are suitable for the parallel operation of two KRAL pumps of the K
or L series. The functional description of the pumps is contained in the associated pump operating inst-
ructions.
The station is connected to the pipe system by means of the suction connection 4at the front of the sta-
tion. Depending on the position of the reversing valve 2, the left-hand, the right-hand or both pumps are
connected to the suction connection. There the pressure of the pumped liquid is increased which finally
returns to the station through the pressure connection of the pump. Via a return valve the liquid flows
through the reversing valve finally to the pressure connection 5, through which the liquid leaves the sta-
tion again.
Reversing valve
If the lever of the reversing valve 2is in one of the two side positions, the respectively other line of the
station is separated from the liquid circuit so that the pump of this line can be dismantled. If the lever is
in the center position, both lines are connected to the liquid circuit, see "Activating the reversing valve",
page 24. The delivery rate can thus be increased through parallel operation 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 pres-
sure drops at the active line. In order to ensure a uniform distribution of the operating hours, an interval-
controlled automatic switch-over between the two pumps is also possible in this valve position. The
return valves ensure that the respective pump that is stopped does not begin to rotate backwards.
Due to its metal sealing the reversing valve has a low amount of leakage.
Expansion valve
The liquid volume in the respectively blocked line of the station could result in an impermissibly high
inner pressure due to heating up through thermal expansion. In order to prevent this, the cylinder of the
reversing valve contains two small spring expansion valves that vent any overpressure in the respecti-
vely active line of the station.
Pressure measurement
A pressure gauge 3is located in the center of the station in order to monitor the delivery 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 2. In order to monitor the pressure on the suction sides of the two pumps,
two further pressure gauges can be mounted optionally, see "Suction-side pressure monitoring",
page 14.

14 OID 04en Edition 08/2014 Operating Instructions
Options
Function description
Options
Suction-side pressure monitoring
Temperature monitoring
In order to monitor the pressure on the suction
sides of the two pumps, two further pressure
gauges 1can be mounted optionally.
The stopcocks at the pressure gauges may
only be opened to read the pressure values,
see "Reading the pressure values", page 25.
1Suction-side pressure gauge
Fig. 3 Pressure monitoring
In order to monitor the temperature of the
pumped liquid, two thermometers 1that are
mounted at the station block near the two suc-
tion connections are available optionally.
1Thermometer
Fig. 4 Temperature monitoring
1
1
1
1

Operating Instructions OID 04en Edition 08/2014 15
Options
Function description
Leak oil monitoring
The leak oil monitoring device consists of the indication device and a PTC resistor sensor. The indica-
tion device contains the components for optical and acoustical alarm indication as well as a potential-
free change-over switch for controlling additional signal equipment. When the PTC resistor that is hea-
ted up in its operating state is immersed into oil, it cools down, thus triggering an alarm.
We recommend using the leak oil monitoring device with an elevated oil pan.
Pressure switch
1Operation
2Unlock
3Alarm
4Test
5Alarm sound
6Off
7On
8Cable
9Indication device
10 PTC resistor sensor
Fig. 5 Leak oil monitoring
It is optionally possible to install pressure
switches 1on the rear of the pumps as an
additional pressure monitoring device.
1Pressure switch
Fig. 6 Pressure switch
ϑ
Betrieb
3 m
aus
ein
Prüfen
Alarm
230 V AC
50 Hz
Alarmton
Entriegeln
1
2
3
4
5
8
6
7
9
10
1

16 OID 04en Edition 08/2014 Operating Instructions
Unpacking and checking the state of delivery
Transportation, storage and disposal
Transporta tion, storage and d isposal Unpacking and checking the state of delivery
1. Upon delivery unpack the station and check for transport damage.
2. Report any transport damage immediately to the manufacturer.
3. Dispose of packing material in accordance with the locally applicable regulations.
Lifting the station
►Attach the hoisting equipment to the pump station, see Fig. 1, and lift the pump station with a crane.
Fig. 1 Attachment of hoisting equipment - schematic diagrams
DANGER
Risk of injury and/or damage to equipment should the pump station fall.
►Use intact and correctly dimensioned hoisting equipment suitable for the weight to be lifted.
►Choose the attachment points of the hoisting equipment according to the center of gravity and
weight distribution.
►Always use at least two slings.
►Secure motors additionally against tilting.
►Do not stand under raised loads.

Operating Instructions OID 04en Edition 08/2014 17
Storage
Transportation, storage and disposal
Storage
During the test run, the internal components of the station are wetted with test oil, which has a preserva-
tive effect. The pipe connections are fitted with protective caps. Unless otherwise specified, the external
components of the station are preserved with a single-coat PU-based two-component paint. The preser-
vative applied at the factory will protect the station for about six weeks, if it is stored in a dry and clean
location. KRAL offers a long-term preservation for storage times of up to 60 months. The station is addi-
tionally packed in hermetically sealing anti-corrosion paper.
Preservation
Preservation has to be carried out in the following cases:
□Standard delivery: for storage periods exceeding six weeks and in case of adverse storage condi-
tions such as high humidity, salty air, etc.
□Delivery with long-term preservation: if the packaging has been opened or damaged
Preserving the internal surfaces of the station
1. Tilt the station so that the connections are facing upwards.
2. Fill the station block via the suction connection with non-corrosive, resin-free oil, while turning the
pump slowly at the fan impeller of the motor in accordance with the arrow for the direction of rota-
tion. Do not fill the block completely in the process, but rather leave an empty space of approx. 2 cm.
3. Attach the protective cover on the suction and pressure connection.
After about 6 months storage check the oil level in the station and top up oil if necessary.
Preserving the external surfaces of the station
Aids:
□Preservative (e.g. Castrol Rustilo DWX 33)
►Paint or spray the preservative onto all plain and unpainted parts.
At intervals of about 6 months, check the preservative effect and if necessary repeat preservation.
Notice: Store the preserved station in a dry and cool place and do not expose it to direct sunlight.
Removing the preservative
Aids:
□Solvents
□Steam-jet cleaning device with wax-dissolving additives
1. Clean the outside of the station with solvents, if necessary using a steam-jet cleaning device.
2. Remove the protective cover.
3. Drain the station, collecting the preservative oil in a suitable vessel.
4. To remove the residual oil, rinse the station with the pumped liquid.
WARNING
Risk of injury through emitted preservative oil.
►Wear protective clothing during all the work.
►Collect the emitted oil safely and dispose of it in an environmentally compatible manner.

18 OID 04en Edition 08/2014 Operating Instructions
Disposing of the station
Transportation, storage and disposal
Disposing of the station
Aids:
□Solvents or industrial cleaners suitable for the pumped liquid
1. Disassemble the station.
2. Clean residues of the pumped liquid from the individual parts.
3. Separate sealing elements made of elastomers from the station and dispose of them in the residual
waste.
4. Recycle metal parts.
WARNING
Danger of poisoning and damage to the environment through pumped liquid or oil.
►Wear protective clothing during during all the work.
►Collect the discharging pumped liquid and oil and dispose of it in accordance with the locally
applicable regulations.
►Before disposing of the station, neutralize any residues of the pumped liquid.

Operating Instructions OID 04en Edition 08/2014 19
Installation
Installation, removal and connection
Installation, removal and connection Installation
Setting up the station
The station is operated in a vertical mounting position.
Prerequisite:
□The station connections are to be protected against contamination, for example by using the protec-
tive covers mounted at the factory
►Place the station in position and fasten it with fastening elements securely to the mounting surface.
Observe the following instructions:
□When selecting the location take the operating limits, NPSH values and ambient conditions
into account, see "Technical data", page 7.
□The function, safety and service life may not be impaired by humidity, temperature influences
or explosive atmospheres.
□During the installation ensure that all the parts of the station can be accessed easily and that
the maintenance work can be carried out easily.
Mounting types:
Fig. 1 Mounting on base frame with oil pan Fig. 2 Bearer mounting
18
260
760
18
85
190
CAUTION
Damage to the station and piping through insufficient fastening.
►Only fasten the station on a stable load bearing surface.
►Ensure that the fastening elements are tightened sufficiently.

20 OID 04en Edition 08/2014 Operating Instructions
Installation
Installation, removal and connection
Protecting the station against contamination
►After the connecting work carefully clean the pipe system, see "Cleaning the pipe system", page 22.
Connecting the station to the pipe system
1. Check whether the reversing valve moves easily.
If the lever of the reversing valve cannot be turned by hand, remedy the fault before installing the
station.
2. Attach protective covers to the connecting flanges when welding.
3. Place the piping in position and support the weight of the piping.
4. Check the clearance and the angular, vertical and linear offset, adjusting where necessary.
If the screws tighten easily, this is a sure sign that the installation is stress-free.
5. Tighten the connecting screws in an alternating fashion using the tightening torque, see Tab. 2,
page 37.
CAUTION
Damage through impurities in the pipe system.
►During welding work attach protective covers to the connecting flanges.
►Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and
the station.
CAUTION
Danger of damage to the device or impaired functionality through mechanical stresses.
►Ensure that the station is connected to the pipe system free of mechanical stress.