dkc-dmc_en

Catalog

KRAL Pump Stations.DKC/DMC Series.

DKC/DMCEdition 10/2010

2 DKC/DMC Edition 10/2010 Catalog

Table of contents

KR

AL

Pum

p S

tatio

ns –

DK

C/D

MC

Ser

ies

Description

□ Structure 5

□ Function description 6▪ Functional principle 6▪ Reversing valve 6▪ Expansion valve 6▪ Pressure measurement 6▪ Protection against soiling 7

□ Type code 8

Technical data

□ Operational limits 9

□ Materials 9

□ Required NPSH values 10▪ Internal pressure loss of the pump

station 11

□ Weight tables 12▪ Weight tables pump 12▪ Weight table pump station 12▪ Filling volume 13

□ Noise levels 13

Dimensions

□ Dimensions DKC 15

□ Dimensional drawings DKC 15▪ Pump station DKC Standard 15▪ Pump station DKC with two-way valve 17▪ Pump station DKC with base frame with

oil pan 18▪ Pump station DKC with two-way valve

and base frame with oil pan 20

□ Dimensions DMC 21

□ Dimensional drawings DMC 21▪ Pump station DMC Standard 21▪ Pump station DMC with two-way valve 22▪ Pump station DMC with base frame with

oil pan 23▪ Pump station DMC with two-way valve

and base frame with oil pan 24

Options

□ Overview 25

□ Two-way valve 26▪ Limit switch 26▪ Actuators 27

□ Pressure maintaining valve 28

□ Pressure switch 29▪ Specifications of the pressure switch 29

□ Differential pressure monitoring at the strainer 30▪ Specifications of the differential pressure

indication 30

□ Temperature monitoring 31

□ Strainer cover protection 31

□ Oil leakage monitoring 32

□ Pump change-over device 33

□ Mounting 34

□ Built-on Volumeter OMA 34

□ Heating system 35▪ Electric heating system 35▪ Fluid heating system 37▪ Special heating system 37

General drawings

□ General drawings 39

□ Spare parts 44

Catalog DKC/DMC Edition 10/2010 3

Structure

Des

crip

tion

Description Structure

Fig. 1 Station structure

1 Station block

2 Hoisting eye3 Suction-side pressure gauge4 Strainer cover

5 Pressure-side pressure gauge

6 Reversing valve lever7 Vent valve

8 Pump

9 Pressure connection10 Suction connection

Station block sizes Terms used

Station with pump sizes K 5–42 / M 5–54 Small pump station

Station with pump sizes K 55–118 Large pump station

Fig. 2 Hydraulic scheme

1

2

3

4

5

6

3

7

8

2

9

10

PIPI

PIPI

PIPI

M

M

LFOLFO

HFOHFO

Suction SideSuction Side

Pressure SidePressure Side

TITI

TITI


Function description

Des

crip

tion


Functional principle

The pump stations of the DKC/DMC series are suitable for the parallel operation of two KRAL pumps of the M or K series.The station is connected to the piping system by means of the suction connection 10 at the front of the

station. Depending on the position of the reversing valve 6, the left-hand, the right-hand or both strainers are connected to the suction connection. The pumped liquid flows through the strainer from top to bot-tom and thus reaches the suction connection of the attached pumps. There the pressure of the pumped

liquid is increased which finally returns to the station through the pressure connection of the pump. The liquid flows through a return valve in an integral duct into the lower part of the station and via the rever-sing valve to the pressure connection 9, through which the liquid leaves the station again.

Reversing valve

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.

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 respec-

tively active line of the station.

Pressure measurement

A pressure gauge 5 is 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 6. In order to monitor the pressure on the suction sides of the two pumps,

two further pressure gauges 3 are mounted. These pressure gauges show only the respective pressure at one of the two strainers and can be used to monitor the degree of soiling of the strainers. The pres-sure gauge in the blocked line shows only the inner pressure of the blocked strainer. The stopcocks at

the pressure gauges may only be opened to read the pressure values.

If the reverseing valve lever 6 is in one of the two

side positions, the respectively other line of the station is separated from the liquid circuit so that the strainer of this line can be opened and clea-

ned. If the lever is in the center position, both lines are connected to the liquid circuit. The deli-very 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 pressure

drops at the active line.Fig. 3 Positions of the reversing valve



Des

crip

tion

Protection against soiling

The station is equipped by default with strainers. These strainers are designed to separate soiling that is normally not contained in the pumped liquid. Due to their small size the strainers cannot separate larger amounts of soiling occurring regularly, nor abrasive fine particles. If such operating conditions occur, the

station has to be protected additionally by a correspondingly dimensioned operating filter. Very fine abrasive particles cannot be held back by the operating filter and result in increased wear to the pumps.As an alternative the strainer can be replaced during commissioning by a fine-meshed commissioning

strainer. The commissioning strainer can be ordered at KRAL. A further possibility is the use of an exter-nal commissioning filter.The strainer inserts 2 are metallic and can be removed, cleaned and re-used after the strainer cover 1

has been opened.

Tab. 1 Strainer/filter and mesh widths

1 Strainer cover

2 Strainer insert

Options Usage Viscosity

[mm2/s]

Mesh width

[mm]

□ Strainer Separation of coarse soiling during operation

< 20 0.25

> 20 0.50

□ Commissioning strainer

Protection of the station during commissioning — 0.02

□ Commissioning filter

Protection of the station during commissioning — 0.02

□ Operating filter Protection of the station during operation depending on pumped liquid

1

2


Type code

Des

crip

tion

Type code

Tab. 2 Type code

1 Model

2 Size3 Seal type4 Pressure stage

5 Two-way valve6 Heating system7 Version index

Item Designation Type

1 Model DKC: Pressure build-up up to 16 bars

DMC: Pressure build-up up to 40 bars

2 Size Corresponds to flow rate in [l/h] at motor speed

3 Seal type 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 model

X: Special seal

4 Pressure

maintaining valve

A: Without pressure maintaining valve

B: Internal pressure maintaining valve, pressure stage 2–9 bars

C: Internal pressure maintaining valve, pressure stage 6–25 bars

D: Internal pressure maintaining valve, pressure stage 15–40 bars

E: External pressure maintaining valve, pressure stage 2–9 bars

F: External pressure maintaining valve, pressure stage 6–25 bars

G: External pressure maintaining valve, pressure stage 15–40 bars

5 Two-way valve A: Without suction-side two-way valve

B: Suction-side two-way valve, manually operated

C: Suction-side two-way valve, manually operated and limit switch

D: Suction-side two-way valve, electrically operated and limit switch

E: Suction-side two-way valve, pneumatically operated and limit switch

6 Heating 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

7 Version index For internal administration

DKC- 2400.BBBA.00002

1

2

3

4

5

6

7


Operational limits

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Technical data Operational limits

Materials

DKC DMC

Operating pressure max. [bar] 16 40

Temperature max. [°C] 180 180

Temperature min. [°C] for pump materials –20 –20

Viscosity [mm2/s]min.–max. 2–10000 2–10000

Feed pressure max. [bar] 6 6

DKC DMC

Material name Material no. Material name Material no.

Station block

Housing EN-GJS-400-15 EN-JS1030 EN-GJS-400-15 EN-JS1030

Strainer cover S235JR 1.0037 S235JR 1.0037

Pump

Housing

□ Standard EN-GJS-400-15 EN-JS1030 ENAC-AlSi10Mg —

□ Marine design — EN-GJS-400-15 EN-JS1030

Screw set 16MnCrS5 1.7139 16MnCrS5 1.7139

Flange cover

□ Standard EN-GJS-400-15 EN-JS1030 ENAC-AlSi10Mg —

□ Marine design — EN-GJS-400-15 EN-JS1030

Bearing cover — EN-GJS-400-15 EN-JS1030

End cover EN-GJS-400-15 EN-JS1030 EN-GJS-400-15 EN-JS1030


Required NPSH values

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The following table shows the required NPSH values to ensure that the various pump sizes can be ope-

rated without cavitation. These values are derived from the pump kinematics during operation with a low-volatility pumped liquid such as lubricating oil or hydraulic fluid. The following examples indicate that when pumped liquids have a readily volatile component content

the required NPSH values notably increase:

□ Fuel oil requires an NPSH value of at least 6 mWC.□ When the pumped liquid contains water (e.g. heavy fuel oil), the values in the table have to be incre-

ased by the vapor pressure of the water at the specified operating temperature.

The required NPSH value also needs to be increased if there are gas contents, regardless of whether it is dissolved or not. If in doubt, please contact KRAL.

Tab. 1 Required NPSH values for K-pump

Pump size Viscosity Rotation [min-1] Pump size Viscosity Rotation [min-1]

[mm2/s] 1450 1750 2900 3500 [mm2/s] 1450 1750 2900 3500

NPSH value [mWC] NPSH value [mWC]

K 5 6 2 K 42 6 2 2.3

37 2 37 2 2.1 2.6

152 2 152 2 2.8 3.5

380 2 380 2.5 2.7 4 4.8

K 7.5 6 2 K 55 6 2

37 2 37 2 2.7

152 2 152 2.1 2.8 3.3

380 2 2.3 2.6 380 2.5 2.7 3.5 4.0

K 10 6 2 74 6 2 2.6 3.0

37 2 37 2 2.9 3.4

152 2 2.3 152 2.3 2.5 3.3 4.1

380 2 2.6 3.1 380 2.7 3.0 4.4 5.0

K 15 6 2 K 85 6 2 2.8 3.4

37 2 37 2 3.1 3.8

152 2 2.2 152 2.4 2.6 3.8 4.6

380 2 2.7 3 380 2.8 3.1 4.6 5.8

K 20 6 2 K 105 6 2 2.7 3.2

37 2 37 2 2.2 3 3.6

152 2 2.4 2.7 152 2.4 2.6 3.6 4.4

380 2.2 2.4 3.2 3.8 380 2.8 3.1 4.4 5.4

K 32 6 2 K 118 6 2 3.1 3.9

37 2 37 2.2 3.5 4.4

152 2 2.3 2.6 152 2.5 2.8 4.3 5.4

380 2.2 2.4 3.1 3.7 380 3 3.3 5.3 6.8



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Tab. 2 Required NPSH values for M-pump

Internal pressure loss of the pump station

When determining the NPSH value of the pump station also take into account the internal pressure losses in the ducts of the station, in the reversing valve and particular in the strainer. The following dia-gram shows as an example the overall pressure loss from the suction connection of the station up to the

suction flange of the pump at operation with a clean strainer.

Pump size Viscosity Rotation [min-1] Pump size Viscosity Rotation [min-1]

[mm2/s] 1450 1750 2900 3500 [mm2/s] 1450 1750 2900 3500

NPSH value [mWC] NPSH value [mWC]

M 5 6 2 M 26 6 2 2.2 2.7

37 2 37 2 2.2 2.7

152 2 152 2 2.9 3.5

380 2 380 2.3 2.6 3.9 4.8

M 7.5 6 2 M 32 6 2

37 2 37 2

152 2 152 2 2.3 2.7

380 2 2.3 2.5 380 2,1 2.2 3 3.5

M 10 6 2 M 42 6 2 2.2 2.7

37 2 37 2 2.2 2.7

152 2 2.3 152 2 2.9 3.5

380 2 2.1 2.3 2.5 380 2,3 2.6 3.9 4.8

M 15 6 2 M 54 6 2 2.1 3 3.7

37 2 37 2.1 2.3 3.4 4.2

152 2 2.2 152 2.5 2.7 4.1 5.1

380 2 2.6 2.9 380 3 3.3 5 6.3

M 20 6 2 2.1

37 2 2.1

152 2 2.4 2.8

380 2.1 2.3 3.1 3.7

∆p Pressure lossQ Delivery rate

0,00

0,02

0,04

0,06

0,08

0,10

0,12

0 20 40 60 80 100 120

∆p [b

ar]

ν ≈ 14 mm²/s

Q [l/min]


Weight tables

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Weight tables

Weight tables pump

Tab. 3 Weights K- and M-Pumps and motors

Weight table pump station

Tab. 4 Weights for pump station

Mot

or s

ize

Mot

or w

eigh

t

[kg

]

K 5K 7.5K 10

K 15K 20

K 32K 42

K 55K 74K 85

K 105K 118

M 5M 7.5M 10

M 15M 20M 26

M 32M 42M 54

Weight of pump with free shaft end [kg]

Steel Alu Steel Alu Steel

8 10,5 21,5 4,5 5 9,5 11 15

Weight of pump bracket with coupling and screws [kg]

71 8 — 3,5 —

80 10 3,5 5 7 9

90S 12 3,5 6 7 7

90L 14 3,5 6 7 7

100L 21 4,5 3 — 10 10

112M 28 — 3 — 10 10

132S 39 — 4 — 12 12

132M 45 — 4 — 12 12

160M 110 — 5,5 —

160L 120 — 5,5 —

Part Weight [kg] for pump station with pump sizes

K 5–42 / M 5–54 K 55–118

Station block with strainer and reversing valve 58 90

Internal pressure maintaining valve 1.3 1.9

External pressure maintaining valve 13 16.5

Two-way valve, manually operated 8.1 14

Actuator, electrical 7.3 7.3

Actuator, pneumatic 5.8 5.8

Differential pressure indication 2.2 2.3

Base frame with oil pan 21 26

Counter flanges, 2 pc. 2.3 2.6

Pump with coupling and motor See weight tables pump


Noise levels

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Filling volume

Tab. 5 Filling volume of the station block

Noise levels

Tab. 6 Noise levels

Pump station with pump sizes

K 5–42 / M 5–54 K 55–118

Filling volume of the station block [l] 8 13

Noise level max. ±3 [dB(A)]

1 Pump 2 Pumps Motor 1 Pump + 1 Motor 2 Pumps + 2 Motors

K 5 – 42 56 59 57 60 63

K 55 – 118 61 64 65 67 70

M 5 – 54 59 62 69 70 73


Dimensions DKC

Dim

ensi

ons

Dimensions Dimensions DKC

Dimensional drawings DKC

Pump station DKC Standard

Tab. 1 Pump sizes K 5 – 42

Station size

DKC

Pump size Motor

size

DNs /

DNd

H1 H2 B1 B2 B3 B4

[mm] [mm] [mm] [mm] [mm] [mm]

240 – 2400 K 5 – 20 71

SA

E 1

1/2

"

3000

PS

I

590 682 561 382 437 534

80 645 737 604 398 453 541

90 688 780 618 405 460 558

1600 – 5000 K 32 – 42 80 651 743 637 410 465 562

90 694 786 651 417 472 569

100/112 755 847 707 438 493 590

3000 – 13000 K 55 – 118 90

SA

E 2

"

3000

PS

I 756 848 715 473 548 627

100/112 817 909 771 494 569 648

132 940 1032 807 508 583 662

100M16

117

132

B1

B2

281

DNs

DNd45 125 20

5

244

H1



Dim

ensi

ons


305

H1

DNs

DNd

148

45

248

5010

8

140

85M16

347

B1B

2



Dim

ensi

ons

Pump station DKC with two-way valve



DNd55 125 20

5

DNsDNs

336

B1

50

250

B3

DNd

148

15

248

DNsDNs

B1

422

280

B3

60



Dim

ensi

ons

Pump station DKC with base frame with oil pan


DNs

DNd

90

217 29

7

18

270500

H2

336

600

130

B1

550500

B4



Dim

ensi

ons


397

H2

DNs

DNd

340

240 34

0

10018

600

600660

132

700

B4

B1



Dim

ensi

ons

Pump station DKC with two-way valve and base frame with oil pan



DNsDNs

600

250

B1

550

500B

412

5 DNd

50090

18

297

270

2175

DNd 340

100600

18

340

240

15DNsDNs

660

B1

600

700

B4

117


Dimensions DMC

Dim

ensi

ons

Dimensions DMC

Dimensional drawings DMC

Pump station DMC Standard

Tab. 9 Pump sizes M 5 – 54

Station size

DMC

Pump size Motor

size

DNs /

DNd

H1 H2 B1 B2 B3 B4

[mm] [mm] [mm] [mm] [mm] [mm]

240 – 1200 M 5 – 10 71

SA

E 1

1/2

"30

00 P

SI

578 670 592 393 448 545

80 635 727 635 410 465 562

90 678 770 649 417 472 569

800 – 2600 M 15 – 26 80 694 786 637 410 465 562

90 737 829 651 417 472 569

100/112 781 873 707 436 493 590

1600 – 6500 M 32 – 54 80 694 786 637 410 465 562

90 737 829 651 417 472 569

100/112 781 873 707 436 493 590

132 908 1000 744 451 506 604

B1

B2

281

100M16

117

132

244

H1

DNs

DNd45 125 20

5



Dim

ensi

ons

Pump station DMC with two-way valve


DNd55 125 20

5

DNsDNs

336

50

B1

250

B3

100M16

117

13224

4H

1



Dim

ensi

ons

Pump station DMC with base frame with oil pan


H2

336

DNs

DNd

217

90

297

18

270500

500

600

130

B1

550

B4



Dim

ensi

ons

Pump station DMC with two-way valve and base frame with oil pan


DNd

90500

27018

217 29

75DNsDNs

500

600

B1

550

250

B4

125


Overview

Opt

ions

Options Overview

Option Option

Two-way valvepage 26

Temperature monitoringpage 31

Limit switchpage 26

Strainer cover protection page 31

Electrical actuatorpage 27

Oil leakage monitoringpage 32

Pneumatic actuatorpage 27

Pump change-over devicepage 33

Internal pressure maintaining valve

page 28

Mountingpage 34

External pressure maintaining valvepage 28

Built-on volumeter OMApage 34

Pressure switchpage 29

Electric heating systempage 35

Differential pressure monitoringpage 30

Fluid heating systempage 37

Betrieb

ausein

Prüfen

Alarm

Alarmton

Entriegeln

Pumpe 1 Pumpe 2

Alarm

Betrieb Störung Betrieb Störung

Pumpen - Steuerung

Entriegelung Entriegelung

Aus

Pumpe 1 Pumpe 1 Pumpe 2 Pumpe 2

Pumpe 1 Pumpe 2


Two-way valve

Opt

ions

Two-way valve

A two-way valve 2 is available at the suction-side SAE connection as an option. This allows the station

to be connected to two piping systems with different pumped liquids. When the lever 1 is moved by 90°, the system switches over between the two suction-side connections of the two-way valve.

Limit switch

As an additional option, a limit switch 3 that is used to monitor the lever position at the two-way valve

remotely is available.

Positions of the two-way valve

1 Two-way valve lever2 Two-way valve

Connection assignment

1 Two-way valve lever2 Two-way valve3 Two-way valve limit switch

1

2

3

2

1

PNP Gnd

B+U 10 - 30V DC

Signal

braun / brown

schwarz / black

blau / blue


Two-way valve

Opt

ions

Actuators

In order to operate the valve automatically, an electrical or pneumatic actuator can be installed.

Electrical actuator

Pneumatic actuator

Connection assignment

2 Compressed-air connection

202225

101112

123

4

5

Kondensator

Temperaturwächter

Auf

Wegschalter

Zu

Heizwiderstand

Zus. Wegschalter

Zu

Condenser

Temperature control

Open

Way switch

Close

Heating resistor

Add. Way switch

Close

6

Auf / Open

AufOpen

ZuClose

Zu / Close 1-ph AC

4

2


Pressure maintaining valve

Opt

ions

Pressure maintaining valve

An internal pressure maintaining valve 1 can be installed optionally in order to ensure a constant supply pressure even when the liquid requirement of the system varies. The valve is mounted in a vertical duct between the suction and the pressure connection of the station. A spring-loaded cylinder opens a

bypass between the pressure and suction sides when the setpoint pressure is exceeded. In this manner the free cross-section and thus the overflowing volume flow is controlled so that the delivery pressure remains constant to a great degree.

A further option is an external pressure maintaining valve 2 for mounting to the pressure connection of the station block. At this valve the overflowing flow rate is not supplied directly to the suction end as at an internal valve, but rather directed outwards via an additional flange connection. We recommend this

constellation if overheating of the station block would be caused by large overflow amounts or if highly volatile liquid components could arise through the pressure reduction during overflowing of outgassing or evaporation. Usually in these cases the overflowing amount is directed to a degassing vessel or

reservoir and then returned from there to the suction line or the feeder reservoir.

Pressure peaksAs a mechanical regulating valve the pressure maintaining valve has a certain sluggishness. Brief pres-sure peaks can therefore arise at rapid flow rate changes (such as the use of quick-acting valves, star-ting of the pump without soft start) and stiff piping systems. If this may result in operating problems or

damage to the system components, a pulsation damper can be installed into the piping system. As an alternative such a pulsation damper can also be mounted directly on the pump station. This pulsation damper is available from KRAL.

1 Internal pressure maintaining valve 2 External pressure maintaining valve

12


Pressure switch

Opt

ions

Pressure switch

Specifications of the pressure switch

It is optionally possible to install a pressure

switch 1 on the bottom of the station as an additional pressure monitoring device.

1 Pressure switch

Figure Criterion Data

Dimensions Sensor:

Measuring range:Output:

Differential gap:Repeatability:Operating temperature:

Fluid temperature:Storage temperature:Degree of protection:

FKM-Membrane

1 – 16 barFloating change-over contact

big; not adjustable±0,5...±2,0 % FS typ.0...+80 °C

0...+80 °C-40...+80 °CIP65*

A Pressure connection * only if female connector is mounted according to instructions

Pressure connection Differential gap approx.*:

Operating pressure max.:Pressure connection:Tightening torque:

0.4 – 1.7

200 barG1/4"; female32 – 40 Nm

A Pressure connection * depending on the preset value

Electrical connection Male plug:

Female connector: - Cable-ø: - Terminal screws:

MicroswitchRating AC:

Rating DC:

Resistance of insulation:Electric strength:

Mechanical lifetime:

DIN43650-A

6...13 mm4 x 0.5...1.5 mm2

250 V 10 (3) A

250 V 0.1 (0.05) A220 V 0.25 (0.2) A110 V 0.5 (0.3) A

24 V 2 (1) A> 2 MW2 kV terminal ground

1 Mio. cycles

1

A

A


Differential pressure monitoring at the strainer

Opt

ions

Differential pressure monitoring at the strainer

Specifications of the differential pressure indication

In order to monitor the differential pressure at the strainers, a differential pressure indication can be established. Monitoring on the

corresponding site can be activated or deactivated by opening or closing the ball valves 2 on one side of the pump station. An

optical display 1 or also electrical contacts can be used as monitoring organs. Electrical contact:By means of the movement of the piston stroke the red segment of the indicator disc is visible over a pressure range equal to 20–100 % of the

differential pressure. The first reed contact is actuated at 75 %, and the second at 100 % of the differential pressure.

Visual indicator:The red colour of the indicator disc becomes more intense with growing contamination of the

strainer as the differential pressure increases. Detailed documents available on request.

1 Differential pressure indication 2 Ball valve

Data Contact

Electrical data

□ Contacts 1 x NO 1 x NC

□ Load voltage max. [V ] 250 220

□ Frequency max. [Hz] 0...60

□ Switching current max. [A] 1.0 0.8

□ Load capacity max. [W/VA] 60/60 40/60

Operating data

□ Operating pressure max. [bar] 100

□ Operating temperature max. [°C] 150

Differential pressure Δp [bar] 0,5

Material GD-AL

Degree of protection IP 65

Wire connection 1 x Pg 13.5

2

2

1

M20x1,5G1/4

G1/

4

- +

2512

7

G1/

4

- +

1225

7

G1/4


Temperature monitoring

Opt

ions

Temperature monitoring

Strainer cover protection

The standard strainer cover can optionally be replaced by special strainer covers with securing unit. When the vent screw 1 is opened, the strainer chamber is vented. This avoids accidents through squir-ting pumped liquid.

In order to monitor the temperature of the pum-

ped liquid, two thermometers 1 that are moun-ted at the station block near the two strainer chambers are available.

1 Thermometer

Detailed view

1 Vent screw

1

1


Oil leakage monitoring

Opt

ions

Oil leakage monitoring

The leak oil monitoring device consists of the indi-

cation device and a PTC resistor sensor. The indication device contains the components for optical and acoustical alarm indication as well a

potential-free change-over switch for controlling additional signal equipment. When the PTC resis-tor that is heated up in its operating state is

immersed into oil, it cools down, thus triggering an alarm.The leak oil monitoring device is unsuitable for

heavy fuel oil applications.We recommend using the leak oil monitoring device with an elevated oil pan.

1 Operation2 Unlock

3 Alarm4 Check5 Signal

6 Off7 On8 Cable

Technical data

Power supply 230 V AC, 50 Hz, 10 VA

Output □ 1 visual alarm (red light)

□ 1 acoustic alarm, can be switched off (buzzer)

□ 1 potential free change-over switch for external signal max. 230 V AC, 3 A

Operating temperature -5...+40 °C

Housing dimensions 163 x 97 x 62 mm

Protection class II

Degree of protection IP41

Mounting Wall mounting

ϑ

Betrieb

3 m

ausein

Prüfen

Alarm

230 VAC50 Hz

Alarmton

Entriegeln

12345

8

67


Pump change-over device

Opt

ions

Pump change-over device

The pump change-over device provides several

functions to control double station pump units. It is unsuitable for heavy fuel oil applications.

Functions:□ Selectable control switch On-Off-P1-P2-

automatic□ Time clock for automatic switch□ Protective motor relay

□ Monitor lamps P1 and P2□ Fault indication□ Fault alarm output for external fault report

□ Automatic switch-over in case of breakdown of pump

□ Connection for pressure control

□ Connection for leak oil monitoring device

Technical data

Supply voltage 220/380 V AC, 50 Hz

Control voltage 220 V AC, 50 Hz

Protective motor range 0.7 – 17 A

Housing material Plastics

Housing dimensions 300 x 250 x 120 mm

Degree of protection IP 54

Mounting Wall mounting

Pumpe 1 Pumpe 2

Alarm

Betrieb Störung Betrieb Störung

Pumpen - Steuerung

Entriegelung Entriegelung

Aus

Pumpe 1 Pumpe 1 Pumpe 2 Pumpe 2

Pumpe 1 Pumpe 2


Mounting

Opt

ions

Mounting

Mounting types

□ Mounting on base frame with oil pan□ Bracket mounting

Built-on Volumeter OMA

To measure the flow A KRAL Volumeter of the OMA series can be built on the pump station.

Fig. 1 Base frame with oil pan Fig. 2 Bracket mounting

Fig. 3 KRAL Volumeter OMA Series Fig. 4 Pump station with built-on OMA


Heating system

Opt

ions

Heating system

The pump stations can be equipped with an optional heating system. We recommend heaters for high-

viscosity liquids that do not flow sufficiently if not heated. This can result in excessive power consump-tion or lead to problems arising through cavitation or sealing.

Method of heating:□ Electric heating system

□ Fluid heating system□ Special heating system

Electric heating system

Operating data:□ Voltage: 230 V

□ Power:▪ Small pump station with pump sizes K 5–42/M 5–54: 800 W▪ Large pump station with pump sizes K 55–118: 2 x 800 W

□ Frequency: 50/60 Hz□ Wire cross-section: 2 x 1 mm²□ Filling volume:

▪ Small pump station with pump sizes K 5–42/M 5–54: 0.40 l

▪ Large pump station with pump sizes K 55–118: 0.12 l per heating duct

Scope of delivery

1 Connecting cable2 Heating element3 Seal ring

4 Screw plug heating element5 Seal ring

Small pump station with pump sizes K 5–42/M 5–54

Large pump stations with pump sizesK 55–118

□ 1 Heating element□ 1 Screw plug

□ 2 Seal rings□ 0.5 l Thermal oil Caldo ISO 32

□ 2 Heating elements□ 2 Screw plugs

□ 4 Seal rings□ 0.25 l Thermal oil Caldo ISO 32

1

2

3

4

5


Heating system

Opt

ions

In the case of a small pump station the electric heating is installed in a heating duct within the station block. The electric heating for the large pump station consists of two heating elements that are integra-

ted in two heating ducts of the station block.

* Figure 3 shows the large pump station. The small pump station disposes of only one heating duct with

one upper and one lower screw plug each.

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.Heating up of the station block of the small pump station after the steady-state condition has been

reached:

□ Station rear: approx. 60 K□ Station front: approx. 40 K

Fig. 5 Heating duct* Fig. 6 Heating element installation

1 Connecting cable

2 Heating element3 Seal ring4 Screw plug heating element

5 Seal ring

6 Heating duct7 Upper screw plug heating duct*8 Lower screw plug heating duct*

∆t Heating-up time∆T Temperature riseA Station rear

B Station front

Fig. 7 Temperature rise after the heating has been switched on

7

86 6

1

35

2

4

76

0

10

20

30

40

50

60

0 10 20 30 40 50 60Δt [min]

ΔT [K

]

A

B


Heating system

Opt

ions

Fluid heating system

In the case of the fluid heating system the heating fluid passes through one or two heating ducts in the

station block. The screw connections required are available from KRAL. When setting the supplied liquid and its temperature observe the respective operating limit values of the station and the attached pumps.

Operating data:□ Maximum pressure: 16 bar

□ Maximum fluid temperature: 180 °C□ Connection:

▪ Small pump station with pump sizes K 5–42/M 5–54:

straight screw connection, outer diameter 28 mm

▪ Large pump station with pump sizes K 55–118: swiveling screw connection, outer diameter 22 mm and

straight screw connection, outer diameter 22 mm

Scope of delivery

Special heating system

If special heating systems are installed, please contact KRAL.

Fig. 8 Fluid heating system for small pump station

Fig. 9 Fluid heating system for large pump station

1 Piping2 Straight screw connection

3 Swiveling screw connection

Small pump station with pump sizes K 5–42/M 5–54

Large pump station with pump sizesK 55–118

□ 2 Straight screw connections

□ 1 Seal ring□ 1 Adapter sleeve

□ 2 Swiveling screw connections

□ 2 Straight screw connections

12 12

3


General drawings

Gen

eral

dra

win

gs

General drawings General drawings

Fig. 1 Station block for pump sizes K 5–42/M 5–54 with pressure maintaining valve closure

300

472

739.3

304

606.3

893

076

739.1

502

405

893

076

739.1

502

405164.1

739.4

739.5165.1

914.1

914.1

611.1606.1

914.1228.1

423 165.2

901.1901.2

611.2611.4

611.3165.2423

228.1

914.1

606.2

901.2

116

165.4165.3165.1

165.2

165.1

164.2

739.4

739.2

739.2

705

705

165.3

165.4

914

228.2


General drawings

Gen

eral

dra

win

gs

Fig. 2 Station block for pump sizes K 55–118 with pressure maintaining valve closure

300

472

739.3

304

606.3

893

076

739.1

502

405

914.1

228.2164.1

739.4739.5739.5

164.2

739.4

739.2

739.2

705

705

914

165.3165.3165.3

165.4

165.3165.3606.1

611.1

611.2

611.4611.3

165.2

423

606.2

228.1

914.1

116


General drawings

Gen

eral

dra

win

gs

Fig. 3 Internal pressure maintaining valve Fig. 4 External pressure maintaining valve

Small pump station

Large pump station

Fig. 5 Electric heating system Fig. 6 Screw connection fluid heating system

424

914.2

629

629

739.6

424

482

493

481

483

483


General drawings

Gen

eral

dra

win

gs

Fig. 7 Two-way valve / Limit switch two-way valve / Actuators

Fig. 8 Leak oil monitoring / Thermometer / Strainer cover protection /

Differential pressure monitoring / Base frame with oil pan

310

307

308

300

309.1309.1

425.1

425.2

425.3425.4

425.5

739.2 705

914914

705 739.2

425.6

309.2

075

605

717

621225


General drawings

Gen

eral

dra

win

gs

Fig. 9 Pressure switch

Fig. 10 Pump station with mounted pumps

607

729.2

729.1

225

901.2

894.2

180

529

001


Spare parts

Gen

eral

dra

win

gs

Spare parts

Tab. 1 Spare part numbers

Spare part No.

Part Spare part No.

Part

001 Pump 482 Electric heating system

075 Strainer cover protection 483 Screw connection

076 Strainer cover 493 Screw plug

116 Station block 502 Conical spring

164.1 Locking bolt 529 Motor

164.2 Screw plug 605 Differential pressure indication

165.1 Screw plug 606.1 Suction-side pressure gauge

165.2 Screw plug 606.2 Suction-side pressure gauge

165.3 Screw plug 606.3 Pressure-side pressure gauge

165.4 Screw plug 607 Pressure switch

180 Pump bracket 611 Non-return valve

225 Base frame with oil pan 611.1 Supporting ring

228.1 Hoisting eye 611.2 O-ring

228.2 Hoisting eye 611.3 Sealing washer

300 Two-way/reversing valve lever 611.4 Spring

304 Control plug 621 Leak oil monitoring

307 Actuator, electrical 629 Valve housing

308 Actuator, pneumatic 705 Counter flange

309 Two-way valve limit switch 717 Thermometer

309.1 Proximity switch 729.1 Flat gasket

309.2 Bracket 729.2 Flat gasket

310 Mounting bracket actuator 739.1 O-ring

405 Strainer insert 739.2 O-ring

423 Vent valve 739.3 O-ring

424 Pressure maintaining valve 739.4 O-ring

425 Two-way valve 739.5 O-ring

425.1 Circlip 739.6 O-ring

425.2 O-ring 893 Cap nut

425.3 Control plug 894.2 Hexagon nut

425.4 O-ring 901.1 Stud screw

425.5 Valve housing 901.2 Stud screw

425.6 Socket screw 914 Socket screw

472 Circlip 914.1 Socket screw

481 Heating element 914.2 Socket screw


KRAL AG, Bildgasse 40, Industrie Nord, 6890 Lustenau, Austria,Tel.: +43 / 55 77 / 8 66 44 - 0Fax: +43 / 55 77 / 8 84 33, www.kral.at, E-Mail: [email protected]

dkc-dmc_en

Documents

dkcdmc edition

straight screw

swiveling

fluid heating

dimensional

pump size

switch zu

differential