EcoPump HP Pneumatic Horizontal Piston Pump

Transcription

1 EcoPump HP Pneumatic Horizontal Piston Pump Operating instructions MPU00002EN, V04 N N N

2 Dürr Systems GmbH Application Technology Carl-Benz-Str. 34 D Bietigheim-Bissingen Telephone: Internet: Original operating instructions MPU00002EN, V04 Transmission and duplication of this document, as well as use and communication of its contents are not permitted without express written approval. Violations will be liable for compensation for damages. All rights in the event of a patent grant or design registration are reserved. Dürr Systems GmbH /44 EcoPump HP - MPU00002EN 03/2016

3 Information about the document This document facilitates safe handling of the product. Read the document before beginning any work. The document must be kept readily accessible and close to the place of use for use in the future. The document must be included if the product is transferred. Always follow specifications such as instructions for use and safety tips. Images are there to help general understanding and can differ from the actual product. Validity range of the document The scope of the document is as follows: N EcoPump HP N EcoPump HP N EcoPump HP Applicable documents If you use accessories, follow the operating instructions for the accessories. MCU EcoPUC A Hotline and Contact If you have queries or would like technical information, please contact your dealer or sales partner. 03/2016 EcoPump HP - MPU00002EN 3/44

4 TABLE OF CONTENTS 1 Product overview Overview Short description Safety Explanation of symbols Intended Use Residual risks Conduct in the event of a hazardous situation Staff qualification Personal protective equipment Installation and operation Control Unit Motor Fluid part Transport, packaging and storage Scope of delivery Handling of packaging material Storage Transport Assembly Requirements for the installation point Assembly Connecting Commissioning Safety recommendations Commissioning Setting operating parameters Operation Checks Rinsing Safety recommendations General notes Flush the pump Cleaning and maintenance Safety recommendations Cleaning Maintenance Maintenance schedule General notes Dismantle and assemble control unit Disassemble control unit Dismantle control unit Assemble control unit Assemble control unit Dismantling and assembling fluid parts Disassemble outlet cylinder Outlet cylinder assembly Dismantling non-return valve in the outlet cylinder Assembling non-return valve in the outlet cylinder Dismantle non-return valve in the piston Assemble non-return valve in the piston Dismantling inlet cylinder Inlet cylinder assembly Dismantle and assemble motor Dismantle motor Assemble motor Faults Defects table Troubleshooting Replace switchover valve Disassembly and Disposal Safety recommendations Disassembly Disposal Technical data Dimensions and weight Connections Operating conditions Emissions Operating values Compressed air Type plate Materials used Operating and auxiliary materials Material specification Replacement parts and accessories Replacement parts Control Unit /44 EcoPump HP - MPU00002EN 03/2016

5 Fluid part Motor Repair kits Seal sets Tools Accessories Order Index /2016 EcoPump HP - MPU00002EN 5/44

6 Product overview 1 Product overview 1.1 Overview CAUTION! Low risk situation that can lead to minor injuries. NOTICE! Situations that can lead to material damage. ENVIRONMENT! Situations that can lead to environmental damage. Contains additional information and recommendations. Fig. 1: Assemblies 1 Motor 2 Fluid parts 3 Sound muffler 4 Switchover valve 5 Compressed air connection 6 Hose leakage indicator 7 Control unit valve 8 Control Unit 1.2 Short description The horizontal piston pump (hereafter called Pump ) with pneumatic drive conveys waterbased and solvent-based paint e.g. in automated paint mixing rooms. 2 Safety 2.1 Explanation of symbols The following notes can appear in this instructions manual. DANGER! High risk situation that can lead to serious injuries or death. 2.2 Intended Use The EcoPump HP is an auto-suction pneumatic horizontal piston pump. The EcoPump HP may only be used for pumping water of solvent-based paints and the appropriate cleaning agents. The pump may only be operated within the approved technical specifications. Ä 11 Technical data The pump is approved for use in explosive areas of Ex zones 1 and 2. Wrong Use If the pump is improperly used, there is a risk of injury. Adhere to the following conditions: Only use pump in a closed process or a remote-controlled and automated process. Only install pump in an area with ventilation system. Only use approved materials. Observe the safety data sheets. Only use fluids with high conductivity Ä Material specification. Do not attempt to make conversions or changes on your own. Do not use the pump in Ex zone 0. EX labelling II 2G IIA T6 WARNING! Medium risk situation that can lead to serious injuries or death. 6/44 EcoPump HP - MPU00002EN 03/2016

7 Safety II - Device group II: all areas except mining 2G - Device category 2 for gaseous ex-atmosphere IIA - Explosion group IIA T6 - Temperature class 2.3 Residual risks Danger of explosion if there are sources of ignition in an explosive atmosphere. Sparks, open flames and hot surfaces can cause explosions in explosive atmospheres. Serious injuries and death can result. Perform all maintenance away from explosive atmospheres. Do not use any sources of ignition and no open light in the work area. Do not smoke. Ground the product. Electrostatic charging If the product is not grounded, there will be an electrostatic charge on the product. Electrostatic discharge can cause sparks. In an explosive atmosphere, these sparks can be ignition sources for an explosion. Serious injuries and death can be the consequence. Ensure the pump is properly grounded. Pressure Material can escape with high pressure and penetrate the body. Death or serious injuries may result. Before working on the product: Disconnect the system with the product from compressed air and material supply. Secure the system against being switched on again. Relieve the lines. Danger from harmful or irritant substances If you come in contact with hazardous liquids or vapors, serious injury or death can be the consequence. Ensure the ventilation system is operational. Observe the safety data sheets. Wear specified protective clothing. Moving parts: Serious injuries can result. Before carrying out any work: Disconnect the system with the product from compressed air and material supply and secure the system against being switched on again. 2.4 Conduct in the event of a hazardous situation The behavior in the event of a hazardous situation is dependent on assembly at the operator. Basically: Close media lines. Secure against being switched on again. Relieve the lines. 2.5 Staff qualification WARNING! Inadequate qualification If you do not assess risks properly, serious injury or death may result. All activities must be conducted exclusively by people who possess the proper qualifications. Cleaning staff The cleaning personnel is verifiably instructed on the following contents by the operator: Handling cleaning tools Handling cleaning agents Possible dangers at the place of work Mechanic The mechanic is trained specifically for the field of work in which he works. The mechanic has been instructed by the operator and receives regular training. The mechanic has knowledge of regulations and safety measures when working in potentially explosive areas. Furthermore, he has the following knowledge: National Health and Safety Regulations Guidelines and Rules of engineering Applicable accident prevention regulations 03/2016 EcoPump HP - MPU00002EN 7/44

8 Installation and operation The mechanic is responsible for the following activities on equipment and components: Assembly Commissioning Servicing Maintenance Disassemble 3 Installation and operation 3.1 Control Unit Dürr Systems GmbH offers special product training Ä Hotline and Contact. 2.6 Personal protective equipment Wear the required personal protective equipment when working. Provide the following personal protective equipment: Eye protection Protects eyes from dust, paint drops and particles. Protective gloves Protects your hands against: Mechanical attacks Cuts Grazing Puncture Thermal attacks Heat Cold Chemical attacks Irritation Caustic burns Protective workwear Tight fitting workwear with low tear strength, tight sleeves and no hanging parts. Fig. 2: Control Unit operation 1 Motor 2 Sound muffler 3 Compressed air connection 4 Valve 5 Distribution block Air reaches into the distributor block of the control unit (5) via the compressed air connection (3). The valve (4) in the distributor block (5) controls the air intake to the motor (1). The air outlet is through the two sound mufflers (2). Respirator mask Protects from hazardous gases, vapors, dust and similar materials and media. Safety boots Protect feet from crushing, falling items and slipping. 8/44 EcoPump HP - MPU00002EN 03/2016

9 Transport, packaging and storage 3.2 Motor 3.3 Fluid part Fig. 3: Motor operation 1 Switchover valve 2 Cylinder 3 Piston The pneumatically operated motor drives the pump. The piston (3) of the pneumatic motor divides the cylinder (2) into two air chambers. Compressed air moves the piston (3) to and fro in the cylinder (2). When the piston (3) reaches one end of the cylinder (2), the piston switches the switchover valve (1). The switchover valve (1) causes the control unit to change the supply of motor air from one side of the piston to the other. The piston moves in the opposite direction. Fig. 4: Fluid part operation 1 Suction line 2 Pressure line 3 Non-return valve in the outlet cylinder 4 Non-return valve in the piston 5 Piston rod The motor and the fluid parts are mutually linked through the piston rod (5). The movement of the piston rod causes suction of the material into a fluid part through the suction line (1). At the same time, material is pushed out through the pressure line (2) in the second Fluid part. Non-return valves (3) and (4) prevent material from flowing back. 4 Transport, packaging and storage 4.1 Scope of delivery The scope of supply only includes the pump/ Check the pump for integrity on receiving it. Report defects immediately. Ä Hotline and Contact 03/2016 EcoPump HP - MPU00002EN 9/44

10 Assembly 4.2 Handling of packaging material ENVIRONMENT! Environmental damage due to wrong disposal Wrongly disposed packaging material may not be re-used or recycled. It harms the environment. Dispose of material no longer required in an environment-friendly manner. Observe local disposal specifications. 4.3 Storage Requirements for the warehouse: Do not store outdoors. Store in a dry and dust-free place. Do not expose to aggressive media. Protect from solar radiation. Avoid mechanical vibrations. Close all opening when storing after disassembly. Temperature: 10 C to 40 C Relative humidity: 35% to 90 % Requirements: Pump has been disassembled Ä 10.2 Disassembly. 1. Place one round sling each around the fluid parts (1). ð See that the round slings cannot slip. 2. Transport pump using a crane. 5 Assembly 5.1 Requirements for the installation point It should be possible to disconnect the control air and material feed and prevent them from reconnecting. Lines, seals and screw connections must be designed to conform to the pump requirements Ä 11.5 Operating values. The workplace must have a ventilation system. The pump must be protected from atmospheric influences at the installation point. 5.2 Assembly Assembling the pump 4.4 Transport NOTICE! Property damage due to improper transport Improper transport of the pump may cause damage. Protect the pump from moisture. Protect the pump from vibration. Fig. 6: Assembling the pump Fig. 5: Attaching the round slings Molykote D paste Loctite Pressure line connection 2 Suction line connection 3 Pressure line 4 Support Bracket 5 Suction line 10/44 EcoPump HP - MPU00002EN 03/2016

11 Assembly Personnel: Mechanic Protective equipment: Safety boots 1. Mount pump using supports (4) on the wall or a fixture designed for the pump. 2. Mount pump such that connections (1) and (2) point upwards. Assemble EcoPUC (optional) Fig. 8: Assemble sensor. 3. Push sensor with insertion nipple (4) into the opening (3) on the control unit. 4. Secure insertion nipple (4) using the threaded pin (5). The threaded pin is included in the scope of supply of EcoPUC. Fig. 7: Assemble EcoPUC. 1 Sensor connection 2 Screws 3 Opening for sensor Personnel: Mechanic 1. Attach EcoPUC with four screws (2) below on the control unit of the pump and tighten. 2. Connect sensor to EcoPUC. 5.3 Connecting Connect the material feed. Personnel: Mechanic Protective equipment: Protective workwear Safety boots 1. Unscrew the protective caps from the manifolds. 2. Grease all O-rings and threads of the pipelines. 3. Screw the tube from material feed into the suction pipe manifold Ä 5.2 Assembly. 4. Screw the tube from material discharge into the pressure pipe manifold Ä 5.2 Assembly. 03/2016 EcoPump HP - MPU00002EN 11/44

12 Commissioning Connect compressed air 6 Commissioning 6.1 Safety recommendations WARNING! Electrostatic charging If the product is not grounded, there will be an electrostatic charge on the product. Electrostatic discharge can cause sparks. In an explosive atmosphere, these sparks can be ignition sources for an explosion. Serious injuries and death can result. Ground the product carefully. Fig. 9: Connect compressed air Personnel: Mechanic 1. Connect the compressed air hose to the connection (1). Connect the pump to ground. Movement of the piston and of the flowing material create the payload. The payload can only flow if the reciprocating piston pump is grounded with all components. Connection of the suction pipe and pressure pipe are not sufficient for grounding. The grounding holes are on both sides of the drive. The grounding holes are diagonally opposite. WARNING! Risk of injury due to escaping material and compressed air Material can escape with high pressure and penetrate the body. Death or serious injuries may result. Before working on the product: Disconnect the system with the product from compressed air and material supply. Secure the system against being switched on again. Relieve the lines. WARNING! Danger from harmful or irritant substances If you come in contact with hazardous liquids or vapors, serious injury or death can be the consequence. Ensure the technical ventilation is operational. Observe the safety data sheets. Wear specified protective clothing. NOTICE! Fig. 10: Connect the pump to ground. Personnel: Mechanic 1. Connect the grounding cable to one of the two grounding bores. Material damage on the pump. Operating the pump with the suction line closed can cause irreparable damage to the pump. Operate the pump only with the suction line open. 12/44 EcoPump HP - MPU00002EN 03/2016

13 Operation 6.2 Commissioning Checks before commissioning Pump is grounded. Personnel: Mechanic Protective equipment: Protective gloves Safety boots 1. Rinse pump prior to initial commissioning. Residues of the testing media might still be in the pump. 2. Ensure that there is no air in the pump. Let the pump run with the minimum cycle rate. 3. During this time, check the tightness of the pump, connections and lines. 4. Watch out for unusual noises. 6.3 Setting operating parameters Personnel: Mechanic Protective equipment: Protective gloves Safety boots Input pressures of the media supplied via the tube system are within the required ranges. Ä 11.5 Operating values 7 Operation 7.1 Checks Personnel: Mechanic Protective equipment: Eye protection Protective gloves Safety boots Check for unusual noises during the operation and perform regular visual inspections: Check tightness of the connections. If there are conspicuous noises, carry out further checks during down times. Check for steady delivery pressure. 7.2 Rinsing Safety recommendations NOTICE! Material damage due to unsuitable rinsing agent If the rinsing agent reacts chemically with the components or the material, components get damaged. Use only the rinsing agents that are compatible with the components and the material. Refer to safety data sheet of material manufacturer General notes When rinsing, use fluid to remove inner soiling from components Flush the pump. Personnel: Mechanic Protective equipment: Eye protection Protective gloves Protective workwear Complete the following steps if the pump is not operating for several hours: Rinse pump with suitable solvent. Ä 11.9 Operating and auxiliary materials Disconnect compressed air supply to pump. 03/2016 EcoPump HP - MPU00002EN 13/44

14 Cleaning and maintenance 8 Cleaning and maintenance 8.1 Safety recommendations WARNING! Danger of fire and explosion Flammable materials can cause a fire or an explosion. Ensure that the flashpoint of the cleaning agent is at least 5 K above the ambient temperature. Pay attention to the explosion group of the material, cleaning and rinsing agent. Ensure that technical ventilation and fire protection equipment are in operation. Do not use any sources of ignition and no open light. Do not smoke. Observe the safety data sheets. WARNING! Risk of injury from unsuitable replacement parts in potentially explosive atmospheres If you use replacement parts that do not comply with the provisions of the ATEX guidelines, the replacement parts can cause explosions in an explosion-prone atmosphere. Serious injuries and death can result. Only use original replacement parts. WARNING! Danger from harmful or irritant substances If you come in contact with hazardous liquids or vapors, serious injury or death can be the consequence. Ensure the technical ventilation is operational. Observe the safety data sheets. Wear specified protective clothing. WARNING! Risk of injury due to escaping material and compressed air Material can escape with high pressure and penetrate the body. Death or serious injuries may result. Before working on the product: Disconnect the system with the product from compressed air and material supply. Secure the system against being switched on again. Relieve the lines. NOTICE! Material damage due to unsuitable cleaning agent Unsuitable cleaning agents can damage the product. Only use suitable cleaning agents approved by the material manufacturer. Observe the safety data sheets. Use alcohol (isopropanol, n-butanol) for waterbased paint. Remove dried water-based paint residue using a manufacturer approved thinner. NOTICE! Damage due to unsuitable cleaning tools Unsuitable cleaning tools can damage the surface of the product. Only use cloths, soft brushes and paintbrushes. Do not use abrasive cleaning tools. Do not use compressed air for cleaning. Do not use any thinner spray guns. Do not use high pressure for cleaning agents. 8.2 Cleaning Make sure that the Pump is completely free of media residues and other contamination. 14/44 EcoPump HP - MPU00002EN 03/2016

15 Cleaning and maintenance Personnel: Cleaning staff Protective equipment: Protective gloves Protective workwear Eye protection Respirator mask 1. Clean the pump carefully and dry it with a soft cloth. 8.3 Maintenance Maintenance schedule Interval Maintenance work Personnel Daily Check cleanliness of the pump. Cleaning staff Check tightness and state of the pump. Test the seal tightness and condition of the connections and lines. Mechanic Mechanic weekly Check noise generation in the pump. Mechanic Annually Check for steady delivery pressure. Check the piston seals. Replace worn out parts Ä Dismantling inlet cylinder. In the case of maximum permissible continuous load: Replace piston seals Ä Dismantling inlet cylinder. In the case of maximum permissible continuous load: Replace rod seal Ä Dismantle motor.. In the case of maximum permissible continuous load: Replace O-rings on the front plate of the pneumatic drive Ä Dismantle motor.. Check bellows. Replace worn out parts. Ä Dismantling inlet cylinder In the case of maximum permissible continuous load: Replace bellows Ä Dismantling inlet cylinder. Check the non-return valves. Replace worn out parts Ä Dismantling non-return valve in the outlet cylinder, Ä Dismantle non-return valve in the piston. In the case of maximum permissible continuous load: Replace nonreturn valves Ä Dismantling non-return valve in the outlet cylinder, Ä Dismantle non-return valve in the piston. In the case of maximum permissible continuous load: Replace changeover valve Ä Replace switchover valve. Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic 03/2016 EcoPump HP - MPU00002EN 15/44

16 Cleaning and maintenance 8.4 General notes Maintenance work on the pump may only be carried out by personnel with the qualifications and protective equipment listed below. Personnel: Mechanic Protective equipment: Protective workwear Respirator mask Eye protection Protective gloves Safety boots 8.5 Dismantle and assemble control unit Disassemble control unit Dismantle control unit Remove membrane Fig. 12: Remove membrane Klüber Syntheso GLEP1 Molykote D paste 1. Unscrew sound mufflers (4). 2. Thread off two screws (3). 3. Pull out adapter (5) together with O-ring from the housing (1). 4. Pull out membrane (2) from the housing (1) using a long nose pliers. Removing the valve Fig. 11: Disassemble control unit Molykote D paste 1. Thread off four screws (1). 2. Remove control unit (2) from the motor. 3. Remove O-rings between control unit and motor. Fig. 13: Control unit valve Klüber Syntheso GLEP1 Loctite Thread-off sealing screw (1) with O-ring on both sides of the distributor block. 2. Remove spacers (2) on both sides of the distributor block. 16/44 EcoPump HP - MPU00002EN 03/2016

17 Cleaning and maintenance 3. Push out valve (3) from the distributor block using suitable tool. 4. Check whether the piston can easily move in the valve (3). ð If the piston works properly and the control unit is leaking, the O-rings on the valve could be damaged. 5. Check O-rings on the valve for damage. ð Replace damaged O-rings. Assembling valve Assemble control unit. Install membrane. Fig. 14: Install membrane. Klüber Syntheso GLEP1 Molykote D paste 1. Lightly grease bore for the membrane (2). 2. Push in membrane (2) into the housing (1) up to the stop with the closed side in front. 3. Push in adapter (5) with O-ring into the housing (1). 4. Grease screws (3). 5. Tighten adapter (5) with two screws (3). ð Observe tightening torques: 6. Screw-in and hand-tighten sound mufflers (4) in the adapter (5). Fig. 15: Control unit valve Klüber Syntheso GLEP1 Loctite Grease valve (3). 2. Push valve (3) into the distributor block using a suitable tool. 3. Place spacers (2) on both sides of the valve. 4. Apply Loctite on the threads of the sealing screw (1). 5. Thread-in sealing screw (1) on both sides of the valve in the distributor block Assemble control unit Fig. 16: Assemble control unit Molykote D paste 03/2016 EcoPump HP - MPU00002EN 17/44

18 Cleaning and maintenance 1. Grease O-rings. 2. Insert O-rings between control unit and motor. 3. Grease screws (1). 4. Firmly attach control unit (2) with four screws (1). ð Observe tightening torques: Dismantling non-return valve in the outlet cylinder 8.6 Dismantling and assembling fluid parts Disassemble outlet cylinder. Fig. 17: Outlet cylinder N : 35 Nm N , N : 50 Nm Molykote D paste 1. Remove four screws (1). 2. Pull out housing (2) carefully from the piston (3) Outlet cylinder assembly 1. Assemble outlet cylinder in reverse order.ä Disassemble outlet cylinder. ð Observe tightening torques: Fig. 18: Non-return valve in the outlet cylinder Klüber Syntheso GLEP1 Molykote D paste 1. Thread off screw-in socket (1). 2. Remove sealing ring (2). 3. Unscrew the valve ball guide (3) from outlet cylinder housing (7). 4. Remove ball (4), O-ring (5) and gasket (6) from outlet cylinder housing (7) Assembling non-return valve in the outlet cylinder. 1. Grease O-ring (5) and threads (1) and (3). 2. Insert seal washer (6), O-ring (5) in the outlet cylinder housing (7). 3. Place ball (4) in the seal cone of the seal washer (6). 4. Screw-in the valve ball guide (3) in outlet cylinder housing (7). 5. Insert sealing ring (2) in the outlet cylinder housing (7). 6. Thread-in the screw-in socket (1) in outlet cylinder housing (7). 18/44 EcoPump HP - MPU00002EN 03/2016

19 Cleaning and maintenance Dismantle non-return valve in the piston Dismantling inlet cylinder Fig. 19: Non-return valve in the piston Klüber Syntheso GLEP1 Loctite Remove three screws (8). 2. Pull out the valve ball guide (7) from piston (1). 3. Remove ball (4), compression spring bracket (5) and compression spring (6) from valve ball guide (7). 4. Remove gasket (3). 5. Remove O-Ring (2) Assemble non-return valve in the piston 1. Grease O-ring (2) and screws (8). 2. Slide O-ring (2) and seal washer (3) into piston (1). 3. Place ball (4) in the seal cone of the seal washer (3). 4. Insert compression spring (6) and compression spring bracket (5) in valve ball guide (7). 5. Screw in and tighten valve ball guide (7) with three screws (8). ð Observe tightening torques: Fig. 20: Dismantling inlet cylinder N : 35 Nm N , N : 1. Stage = 25 Nm, 2. Stage = 50 Nm Klüber Syntheso GLEP1 Molykote D paste Loctite 222 Requirements: Outlet cylinder has been disassembled Ä Disassemble outlet cylinder.. Non-return valve in the piston is dismantled Ä Dismantle non-return valve in the piston. 1. Pull piston seal (5) from the piston (6) and remove. 2. Remove three screws (7). 3. Remove piston (6). 4. Remove four screws (8) on the intake cylinder housing (4). 5. Remove intake cylinder housing (4). 6. Hold fast the bellows (2) and unscrew the nut (3). 7. Push down bellows (2) from piston rod (1) Inlet cylinder assembly 1. Push in new bellows (2) onto piston rod (1) until the bellows latch in. 2. Hold fast the bellows (2) and set the nut (3) on the bellows. 03/2016 EcoPump HP - MPU00002EN 19/44

20 Faults NOTICE! Property damage at the bellows assembly If you screw-on the nut on the bellows and twist the bellows, it can damage the bellows. If you screw-on the nut on the bellows, hold the bellows firmly on the side that is in contact with the nut. 3. Screw-in the nut (3) up to the stop at the end of the bellows (2). ð The nut will tap threads into the bellow. 4. Grease O-ring (5) and screws (8). 5. Carefully slide intake cylinder housing (4) over the bellows (2). 6. Secure intake cylinder housing (4) with four screws (8). 7. Slide piston (6) onto the piston rod (1). 8. Insert three screws (7) in the piston rod(1). ð Paint screws (7) to with Loctite. 9. Push piston deal (5) only on the piston (6). 10.Tighten screws (8) in a crosswise sequence. ð Observe tightening torques: 8.7 Dismantle and assemble motor Dismantle motor. Requirements: Control unit is disassembled Ä Disassemble control unit. Both fluid parts are disassembled Ä Disassemble outlet cylinder., Ä Dismantling inlet cylinder. The bellows were removed on both sides of the drive of the piston rod Ä Dismantling inlet cylinder. 1. Disassemble leakage indicator hose (9). 2. Pull out seal housing (2) with piston guide belt (1), O-ring (3) and rod seal (4) from the piston rod (5). 3. Loosen and remove four screws (6) on one side of the motor. 4. Remove front plate (7) from the tube (8). Fig. 22: Dismantle piston rod. Klüber Syntheso GLEP1 Lubricant for piston (included in the scope of supply) 5. Pull out piston with piston rod (2), sealing ring (3) and tube (4) from the seco0nd front plate (5). 6. Remove O-rings (1) from front plate rod (5) Assemble motor. 1. Grease all O-rings 2. Apply Loctite on the threads of the screws Ä Dismantle motor.. 3. Coat the tube of the piston inside with the supplied grease. Fig. 21: Dismantle motor. Klüber Syntheso GLEP1 Loctite Assemble motor in reverse sequence of dismantling Ä Dismantle motor.. 9 Faults 9.1 Defects table 20/44 EcoPump HP - MPU00002EN 03/2016

21 Faults Fault description Cause Remedy Pump does not run. No compressed air supply Changeover valve is defective. One or more ball valves on the suction side and/ or pressure side closed. Check compressed air supply: Replace changeover valve. Open all ball valves. Pump does not deliver. Air in intake pipe Check seals and pipe connections. Operating pressure is not reached. Paint on inside of piston drive Air leak from the leakage bore. Air leaks from the leakage bore. Piston seal defective Non-return valves in piston or outlet does not seal properly. No compressed air or media supply. Piston seal defective Changeover valve is defective. Non-return valves in piston or outlet does not seal properly. Bellows on piston rod is defective. Rod seal is defective. Bellows defective. Air enters the slurry circuit. Bellows defective. Replace piston seal Ä Dismantling inlet cylinder. Check non-return valve and repair if necessary. Ä Dismantling non-return valve in the outlet cylinder Ä Dismantle non-return valve in the piston Check valves and hoses for compressed air and media supply. Replace piston seal Ä Dismantling inlet cylinder. Replace changeover valve Ä Replace switchover valve. Clean, check balls and seal washers in the nonreturn valve and replace if necessary. Ä Dismantling non-return valve in the outlet cylinder Ä Dismantle non-return valve in the piston Replace bellows Ä Dismantling inlet cylinder. Replace rod seal Ä Dismantle motor.. Replace bellows Ä Dismantling inlet cylinder. Check the rod seal Ä Dismantle motor.. Replace bellows Ä Dismantling inlet cylinder. 03/2016 EcoPump HP - MPU00002EN 21/44

22 Disassembly and Disposal Fault description Cause Remedy Significant pressure fluctuations during normal operation Compressed air supply restricted. Non-return valves blocked. Seals defective. Air venting restricted. Check compressed air supply: Clean, check seal washers, balls and guideway of the valve ball and replace if necessary. Ä Dismantling non-return valve in the outlet cylinder Ä Dismantle non-return valve in the piston Check seals on the drive piston and on piston rod and replace if necessary Ä Dismantle motor.. Check membrane and valve in the control unit Ä Dismantle control unit. Check the exhaust outlet. Piston seal in the fluid part defective. Replace piston seal Ä Dismantling inlet cylinder. 9.2 Troubleshooting Replace switchover valve There is one switchover valve each on both sides of the motor. Assembly 1. Grease switchover valve (2) and O-rings on the switchover valve. 2. Push in switchover valve (2) with slight rotatory movements into the front plate of the drive. 3. Mount the retainer ring (1) on the switchover valve (2). 10 Disassembly and Disposal 10.1 Safety recommendations WARNING! Fig. 23: Switchover valve Detach Klüber Syntheso GLEP1 1. Remove retainer ring (1). 2. Pull out switchover valve (2) from front plate of the motor using tongs. Danger from harmful or irritant substances If you come in contact with hazardous liquids or vapors, serious injury or death can be the consequence. Ensure the technical ventilation is operational. Observe the safety data sheets. Wear specified protective clothing. 22/44 EcoPump HP - MPU00002EN 03/2016

23 Disassembly and Disposal WARNING! 1. Place a collector tray under the pipelines. Risk of injury due to escaping material and compressed air Material can escape with high pressure and penetrate the body. Death or serious injuries may result. Before working on the product: Disconnect the system with the product from compressed air and material supply. Secure the system against being switched on again. Relieve the lines. Even if the pump is flushed, medium can still come out on loosening the pipe connections. 1. Place suitable collecting trays below the pipe connections Disassembly Personnel: Mechanic Protective equipment: Protective workwear Respirator mask Eye protection Protective gloves Safety boots Requirements: Pump has been rinsed Ä 7.2 Rinsing. Ball valves in the pressure line are closed. Ball valves in the suction line are closed. Lines are depressurized. Collection trays are below the outlet openings. Fig. 24: Disassembling the pump 2. Open locking screw (2). ð Material in the pump flows out. 3. Loosen cap nuts (1) on the manifolds. 4. Separate pipelines from the pump. ð Material flows out from the pipelines. 5. Separate grounding cable from the grounding hole Ä 5.3 Connecting Disposal ENVIRONMENT! Environmental damage caused by improper disposal Improper waste disposal threatens the environment and prevents re-use and recycling. Always dispose of components in accordance with their characteristic. Ä 11.8 Materials used Collect leaked out operating and auxiliary materials completely. Dispose of operating and auxiliary materials according to the disposal provisions in force. In case of doubt, refer to the local disposal authorities. 03/2016 EcoPump HP - MPU00002EN 23/44

24 Technical data Requirements: Pump has been rinsed. Hoses, connections and valves of the pump are disassembled. Pump is disassembled and cleaned. Personnel: Mechanic Protective equipment: Eye protection Protective gloves Safety boots 1. Dispose of material residue from pump professionally. 2. Remove seals and dispose of them professionally. 3. Dispose of pump components professionally. 11 Technical data 11.1 Dimensions and weight Fig. 26: Dimensions N N Height Width Depth Weight Value mm mm 274 mm 64 kg Fig. 25: Dimensions N N Value Height Width mm mm Fig. 27: Dimensions N Depth 230 mm N Value Weight 45 kg Height 431 mm Width mm 24/44 EcoPump HP - MPU00002EN 03/2016

25 Technical data N Value N Value Depth Weight 390 mm 94 kg Recommended number of cycles for continuous running duty 20 cycles/ minute = 8 l/ min 11.2 Connections Connection Material outlet connection Material inlet connection Air supply Value EcoTube DN25 EcoTube DN25 G3/8" Number of cycles for short-time duty 40 cycles/ minute = 16 l/ min Transmission ratio 3.5:1 Displacement per cycle and flow rate N Displacement Value 800 cm 3 /cycle 11.3 Operating conditions Detail Min. operating temperature Value 10 C Recommended number of cycles for continuous running duty Number of cycles for short-time duty 20 cycles/ minute = 16 l/ min 40 cycles/ minute = 32 l/ min Operating temperature, max. Min. ambient temperature Max. ambient temperature 50 C 10 C 40 C Relative humidity, min. 35 % Relative humidity, max. 90 % Transmission ratio 3.5:1 Displacement per cycle and flow rate N Displacement Recommended number of cycles for continuous running duty Value 1600 cm3/ cycle 20 cycles/ minute = 32 l/ min 11.4 Emissions Detail Value Number of cycles for short-time duty 40 cycles/ minute = 64 l/ min Sound level 85 db Transmission ratio 3.5: Operating values Displacement per cycle and flow rate N Value Displacement 400 cm 3 /cycle 03/2016 EcoPump HP - MPU00002EN 25/44

26 Replacement parts and accessories Material pressure und air pressure 11.9 Operating and auxiliary materials Detail Value Material Specification Inlet material pressure, max. Outlet material pressure, max. Permissible air pressure, max Compressed air Quality of compressed air N , N N Type plate 0.5 bar 21 bar 6 bar ISO :2010 Class 1:4( -3 C):1 ISO :2010 Class 1:3( -20 C):1 The type plate is on the pump drive housing and features the following details: Product name Material number Year of manufacture Serial number Maximum air pressure Maximum material pressure CE labelling ATEX marking Manufacturer QR code Seal lubricant Screw lubricant Klüber Syntheso GLEP1 Molykote D paste Screw locking Loctite 222 Loctite 243 Loctite 572 Cleaning agent Use only approved detergents that: are suitable for use in explosion hazardous areas. are compatible with the materials used. Ä Material specification Rinsing agents Use only approved rinsing agents that: are suitable for use in explosion hazardous areas. are compatible with the pumped material. are compatible with the materials used. Ä Material specification Material specification Detail Viscosity min. Value 40 mpa s 11.8 Materials used Viscosity max. 250 mpa s Detail Material Solids diameter, max. 400 μm Wetted materials Stainless steel Conductivity, min. > 1000 ps/m Motor material Ball material Ball seat material Piston seal material Bellows material Aluminum Stainless steel Hard metal PE PTFE 12 Replacement parts and accessories 12.1 Replacement parts Control Unit 26/44 EcoPump HP - MPU00002EN 03/2016

27 Replacement parts and accessories Fig. 28: Control unit replacement parts N for N and N Position Description Quantity Material number 1 Distribution block 1 3 Sealing screw 2 4 Spacer 2 5 Adapter 2 6 5/2 Directional control valve 1 Included in Kit N Sound muffler 2 M Membrane DN35 2 Included in Kit N Sound muffler M5 with wire mesh 2 13 Screw-in plug connector D12 G3/8" 1 30 O-Ring 16x2 2 Included in Kit N O-Ring 32 x Included in Kit N /2016 EcoPump HP - MPU00002EN 27/44

28 Replacement parts and accessories Position Description Quantity Material number 32 O-Ring 6 x 2 4 Included in Kit N O-Ring 25 x Included in Kit N Cheese-head screw M6 x Sealing screw G3/8 1 N for N Position Description Quantity Material number 1 Distribution block 1 3 Sealing screw 2 4 Spacer 2 5 Adapter 2 6 5/2 Directional control valve 1 Included in N Sound muffler 2 M Membrane DN50 2 Included in N Sound muffler M5 with wire mesh 2 13 Screw-in plug connector D22 G3/4" 1 30 O-Ring 27 x 2 2 Included in N O-Ring 46 x 3 2 Included in N O-Ring 6 x 2 4 Included in N O-Ring 25 x Included in N Cheese-head screw M8x Sealing screw G1/ Fluid part 28/44 EcoPump HP - MPU00002EN 03/2016

29 Replacement parts and accessories Fig. 29: Replacement parts for Fluid Part N Position Description Quantity Repairs / Seal set 2 Intake cylinder housing 2 3 Outlet cylinder housing 2 4 Screw-in socket DN25 G1 2 5 Screw-in socket DN25 G1 2 7 Bellows D25 2 N Piston 2 9 Valve ball guide 2 10 Valve ball guide pressure side G Compression spring fix bracket 2 12 Piston seal DN65 2 N Seal washer D N Seal washer D N Sealing ring D30 2 N , N Hexagon nut M28 x Ball D N /2016 EcoPump HP - MPU00002EN 29/44

30 Replacement parts and accessories Position Description Quantity Repairs / Seal set 21 Ball D N Compression spring 2 23 Sealing screw G1/4'' 2 30 O-ring 35 x N , N O-Ring 25 x N , N Sealing ring D N Cheese-head screw M10 x 40 with Safety washer Cheese-head screw M4 x Cheese-head screw M6 x 25 6 N Position Description Quantity Repairs / Seal set 2 Intake cylinder housing 2 3 Outlet cylinder housing 2 4 Screw-in socket DN25 G1 2 5 Screw-in socket DN25 G1 1/2 2 7 Bellows D25 2 N Piston 2 9 Valve ball guide 2 10 Valve ball guide pressure side G1 1/2'' 2 11 Compression spring fix bracket 2 12 Piston seal DN95 2 N Seal washer D64 2 N Seal washer D N Sealing ring D N , N Hexagon nut M28 x Ball D44,45 2 N /44 EcoPump HP - MPU00002EN 03/2016

31 Replacement parts and accessories Position Description Quantity Repairs / Seal set 21 Ball D N Compression spring 2 23 Sealing screw G1/4'' 2 30 O-Ring 50 x N , N O-Ring 41 x N , N Sealing ring D N Cheese-head screw M12 x 40 with Safety washer Cheese-head screw M6 x Cheese-head screw M6 x 25 6 N Position Description Quantity Repairs / Seal set 2 Intake cylinder housing 2 3 Outlet cylinder housing 2 4 Screw-in socket DN25 G1 2 5 Screw-in socket DN25 G1 1/2 2 7 Bellows D25 2 N Piston 2 9 Valve ball guide 2 10 Valve ball guide pressure side G1 1/2'' 2 11 Compression spring fix bracket 2 12 Piston seal DN135 2 N Seal washer D64 2 N Seal washer D N Sealing ring D N , N Hexagon nut M28 x Ball D44,45 2 N /2016 EcoPump HP - MPU00002EN 31/44

32 Replacement parts and accessories Position Description Quantity Repairs / Seal set 21 Ball D N Compression spring 2 23 Sealing screw G1/4'' 2 30 O-Ring 50 x N , N O-Ring 41 x N , N Sealing ring D N Cheese-head screw M12 x 40 with Safety washer Cheese-head screw M6 x Cheese-head screw M6 x Motor Fig. 30: Replacement parts for drive N Position Description Quantity Repairs / Seal set 1 Piston seal D125 1 N Control Unit 1 3 Valve unit changeover valve. 2 N /44 EcoPump HP - MPU00002EN 03/2016

33 Replacement parts and accessories Position Description Quantity Repairs / Seal set 4 Front plate 2 6 Seal housing 2 7 Drawbar 4 9 Bracket for pump 2 20 Rod seal D25 2 N Piston guide belt 2 N , N O-ring 125 x 3 2 N O-Ring 42 x N Cheese-head screws M10x Cheese-head screw M10 x Safety washer 8 43 Sealing screw G1/8" 2 44 Elbow plug-in connection G1/8" 2 45 Retainer ring 2 46 Cheese-head screw M 6 x Hose leakage indicator 1 N Position Description Quantity Repairs / Seal set 1 Piston seal D180 1 N Control Unit 1 3 Valve unit changeover valve. 2 N Front plate 2 6 Seal housing 2 7 Drawbar 4 9 Bracket for pump 2 20 Rod seal D25 2 N Piston guide belt 2 N , N /2016 EcoPump HP - MPU00002EN 33/44

34 Replacement parts and accessories Position Description Quantity Repairs / Seal set 30 O-ring 180 x 3 2 N O-Ring 42 x N Cheese-head screw M12 x Cheese-head screws M12x Safety washer 8 43 Sealing screw G1/8" 2 44 Elbow plug-in connection G1/8" 2 45 Retainer ring 2 46 Cheese-head screw M 6 x Hose leakage indicator 1 N Position Description Quantity Repairs / Seal set 1 Piston seal D260 1 N Control Unit 1 3 Valve unit changeover valve. 2 N Front plate 2 6 Seal housing 2 7 Drawbar 4 9 Bracket for pump 2 20 Rod seal D25 2 N Piston guide belt 2 N , N O-Ring 260x3 2 N O-Ring 42 x N Cheese-head screw M12 x Cheese-head screws M12x Safety washer 8 43 Sealing screw G1/8" 2 34/44 EcoPump HP - MPU00002EN 03/2016

35 Replacement parts and accessories Position Description Quantity Repairs / Seal set 44 Elbow plug-in connection G1/8" 2 45 Retainer ring 2 46 Cheese-head screw M 6 x Hose leakage indicator Repair kits Fluid part N for N Seal washer D Seal washer D Sealing ring D30 2 Ball D Ball D O-ring 35 x O-Ring 25 x Piston guide belt 2 O-Ring DN25 6 N for N and N Seal washer D64 2 Seal washer D Sealing ring D Ball D Ball D O-Ring 50 x O-Ring 41 x Piston guide belt 2 Drive unit N Valve unit changeover valve. 2 Control Unit N for N and N /2 Directional control valve 1 O-Ring 16x2 2 O-Ring 6 x 2 4 O-Ring 25 x N for N /2 Directional control valve 1 O-Ring 27 x 2 2 O-Ring 6 x 2 4 O-Ring 25 x Seal sets Fluid part N for N Bellows D25 2 Piston seal DN65 2 Quantity Quantity Quantity Quantity Quantity Quantity O-Ring DN /2016 EcoPump HP - MPU00002EN 35/44

36 Replacement parts and accessories N for N Quantity N for N Quantity Sealing ring D30 2 Sealing ring D18 2 O-ring 35 x O-ring 125 x 3 2 O-Ring 42 x Piston seal D125 1 O-Ring 25 x O-Ring DN25 6 N for N N for N Rod seal D25 2 Piston guide belt 2 Bellows D25 2 Piston seal DN95 2 Sealing ring D O-ring 180 x 3 2 O-Ring 42 x Piston seal D180 1 Sealing ring D18 2 O-Ring 50 x N for N O-Ring 41 x O-Ring DN25 6 Rod seal D25 2 Piston guide belt 2 N for N O-Ring 260x3 2 O-Ring 42 x Bellows D25 2 Piston seal D260 1 Piston seal DN135 2 Sealing ring D Sealing ring D18 2 Control Unit N for N and N O-Ring 50 x O-Ring 41 x O-Ring DN25 6 Drive unit N for N Quantity Quantity Quantity Membrane DN35 2 O-Ring 32 x N for N Membrane DN50 2 O-Ring 46 x 3 2 Quantity Quantity Quantity Quantity Rod seal D25 2 Piston guide belt 2 36/44 EcoPump HP - MPU00002EN 03/2016

37 Replacement parts and accessories 12.2 Tools There are no special tools available for this product Accessories Manifolds Fig. 31: Replacement parts for manifolds Description Position Quantity N N N O-Ring DN25 6 Included in N N Included in N N Included in N N Manifold Material inflow with female union and cap nuts 71 Manifold Material outlet with female union and cap nuts 1 M M M M M M Monitoring units Description Material number Description EcoPUC A RA BUS Material number F EcoPUC A F EcoPUC A RA F /2016 EcoPump HP - MPU00002EN 37/44

38 Replacement parts and accessories 12.4 Order WARNING! Risk of injury from unsuitable replacement parts in potentially explosive atmospheres If you use replacement parts that do not comply with the provisions of the ATEX guidelines, the replacement parts can cause explosions in an explosion-prone atmosphere. Serious injuries and death can result. Only use original replacement parts. Ordering replacement parts, tools and accessories as well as information on product that are listed without order number Ä Hotline and Contact. 38/44 EcoPump HP - MPU00002EN 03/2016

39 13 INDEX A Advanced training...8 Ambient temperature...25 Assemblies...6 Assembly...10 Installation point...10 Motor...20 Non-return valve in the outlet cylinder...18 Non-return valve in the piston...19 ATEX...6 Auxiliary materials...26 C Cleaning...14 Cleaning agent...26 Safety recommendations...14 Commissioning...13 Connect Compressed air...12 Material feed...11 Pump...11 Connect compressed air...12 Connect the material feed Connections...25 Contact...3 Control Unit assembly...17 disassembly...16 Operation...8 D Depth...24 Dimensions...24 Disassembly Pump...23 Safety recommendations...22 Dismantling Motor...20 Non-return valve in the outlet cylinder...18 Displacement...25 Disposal...22 Handling packaging material...10 E Emissions...25 EX labelling...6 Explanation of symbols...6 F Faults Defects table...20 Flow rate...25 Fluid part Operation...9 G Grounding Pump...12 H Height...24 Hotline...3 I Information about the document...3 Inlet cylinder...19 Installation point...10 Intended use...6 L Labelling...6 Loctite...26 Lubricant...26 M Maintenance Maintenance schedule...15 Safety recommendations...14 Material number...3 Material pressure...25 Material specification...26 Materials...26 Motor assembly...20 dismantling...20 Operation...9 N Noise emissions...25 Non-return valve Outlet cylinder...18 O Operating materials...26 Operating parameters adjust...13 Operating pressure...25 Operating temperature...25 Operating values...25 Operation Fluid part...9 Order...38 Outlet cylinder assembly...18 disassembly /2016 EcoPump HP - MPU00002EN 39/44

40 Dismantle non-return valve...18 Non-return valve assembly...18 Overview...6 P Packaging Handling packaging material...10 Personal protective equipment...8 Piston Non-return valve assembly...19 Pressure...25 Protective equipment...8 Pump assembly...10 Commissioning...13 connection...11 Connections...25 disassembly...23 grounding...12 Q Qualification...7 R Relative humidity...25 Replace bellows...19 Rinsing...13 Rinsing agents...26 S Safety Explanation of symbols...6 Intended use...6 Safety recommendations Dismantling and Disposal...22 Scope of delivery...9 Scope of the document...3 Screws Lubricant...26 Screw locking...26 Seal Lubricant...26 Serial number...26 Service...3 Sound level...25 Staff qualification...7 Storage...10 T Temperature Operation...25 Surroundings...25 Tools...37 Training...8 Transport...10 Transport inspection...9 Type plate...26 U Use...6 V Viscosity...26 W Weight...24 Width...24 Wrong Use...6 Y Year of manufacture /44 EcoPump HP - MPU00002EN 03/2016