Bühler technologies P2.x AMEX User manual

Analysentechnik
Installation and Operation Instructions
Original instructions
Sample gas pumps
P2.x AMEX
BE420003
04/2017
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2017
Document information
Document No......................................................... BE420003
Version......................................................................... 04/2017

P2.x AMEX
Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended use .........................................................................................................................................................................................................2
1.2 Product key............................................................................................................................................................................................................ 2
1.3 Type plate .............................................................................................................................................................................................................. 3
1.4 Scope of delivery.................................................................................................................................................................................................. 3
1.5 Product description ............................................................................................................................................................................................ 3
1.5.1 Construction ......................................................................................................................................................................................... 4
2 Safety instructions......................................................................................................................................................................................................... 5
2.1 Important advice ................................................................................................................................................................................................. 5
2.2 General hazard warnings ................................................................................................................................................................................. 5
3 Transport and storage ..................................................................................................................................................................................................8
4 Installation and connection ........................................................................................................................................................................................9
4.1 Requirements to the installation site............................................................................................................................................................9
4.1.1 Outdoor installation..........................................................................................................................................................................10
4.2 Installation ..........................................................................................................................................................................................................10
4.3 Special condition moist sample gas ............................................................................................................................................................10
4.3.1 Alteration of hanging pump bodies ..............................................................................................................................................11
4.4 Connecting the gas tubes ............................................................................................................................................................................... 12
4.4.1 Monitoring the sample gas pump................................................................................................................................................. 12
4.5 Electrical connections .......................................................................................................................................................................................13
5 Operation and control .................................................................................................................................................................................................15
5.1 Switching on the sample gas pump ............................................................................................................................................................ 16
5.2 Operating the sample gas pump.................................................................................................................................................................. 16
6 Maintenance...................................................................................................................................................................................................................17
6.1 Maintenance schedule..................................................................................................................................................................................... 19
6.2 Inspecting the bellow....................................................................................................................................................................................... 19
6.3 Replacing bellow and connecting rod-eccentric-combination........................................................................................................... 20
6.4 Replacement of the O-ring of the bypass valve (optional).................................................................................................................... 21
6.5 Replacing the inlet and outlet valves ..........................................................................................................................................................22
6.6 Cleaning ...............................................................................................................................................................................................................22
6.6.1 Cleaning the pump console............................................................................................................................................................ 22
6.6.2 Cleaning the motor............................................................................................................................................................................23
6.7 Inspecting and replacing the flexible spider.............................................................................................................................................23
7 Service and repair.........................................................................................................................................................................................................24
7.1 Troubleshooting ................................................................................................................................................................................................24
7.2 Spare parts and accessories ...........................................................................................................................................................................25
8 Disposal...........................................................................................................................................................................................................................26
9 Appendices..................................................................................................................................................................................................................... 27
9.1 Technical data ....................................................................................................................................................................................................27
9.2 Temperature classes.........................................................................................................................................................................................28
9.3 Dimensions P2.2 AMEX, P2.82 AMEX - Drawing 1.....................................................................................................................................29
9.4 Dimensions P2.4 AMEX, P2.84 AMEX - Drawing 2....................................................................................................................................29
9.5 List of chemical resistance ..............................................................................................................................................................................30
9.6 User book (Please make copies) .....................................................................................................................................................................31
10 Attached documents................................................................................................................................................................................................... 32
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1 Introduction
1.1 Intended use
Sample gas pumps are intended for installation in gas analysis systems for industrial applications.
The AMEX versions are suitable for use in Class I, Div. 2, Groups B, C, D.
The sample gas pump is only intended to convey gaseous media. It is not suitable for liquids.
Please note the additional information in chapters "Product Description" and "Operation and Control" along with the informa-
tion on specific intended use, existing material combinations, as well as pressure and temperature limits in the data sheets.
When installed outdoors, ensure adequate protection from the weather, see chapter Requirements to the installation site [>
page9]
1.2 Product key
The device is delivered with different configurations. The part number given on the type plate informs you about the specific
configuration of your device.
On the type plate you will find the order number as well as the 13-digit product key. This number is a code where each digit (x)
describes a certain feature:
42 xx x x x x x 9 0 00 Product characteristic
Base model
71 P2.2 Amex 400 L/h
72 P2.4 Amex 400 L/h
73 P2.82 Amex 800 L/h
74 P2.84 Amex 800 L/h
Motor voltage
1 230 V 50 Hz 0.88 A
2 230 V 60 Hz 0.89 A
3 115 V 50 Hz 1.76 A
4 115 V 60 Hz 1.78 A
Pump head position
1 Normal position vertical
2 turned by 180° *
Pump head material
1 PTFE
2 Stainless steel 1.4571
3 PTFE with bypass valve *
4 Stainless steel 1.4571 with bypass valve *
Valve material
1 up to 100°C; PTFE / PVDF **
2 up to 140 °C; PTFE / PEEK
Screw-in connections (depending on pump body)
PTFE Pump body Stainless steel pump body
9 1/4"-1/6" (Standard) 1/4" (Standard)
1 DN 6/8 8 mm
2 3/8"-1/4" 3/8"
3 1/4"-1/8"
5 DN 4/6 6 mm
Mounting accessories
9 incl. mounting bracket and bumper *
* not on P2.4 & P2.84
** not on P2.82 & P2.84
If there are special instructions for a pump type, they are marked in the manual.
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Take care of the limits of the pump. When ordering spare parts chose for the type matching part numbers (e.g. valves).
1.3 Type plate
Example:
Sample gas pump P2.2 Amex
100030047 4256111199000 001
CI.I, Div. 2, Gps. B, C, D. T3/T4
FM certificate C/US: 3038101C / 3038101
Voltage: 230 V 50 Hz
Material: PTFE/PEEK/1.4571/1.4401/Viton
Medium max: see manual; Tamb: see manual
Year: 2013
Manufacturer including address
Model designation
Order no.+Item no.+Metre
Blast protection marking
Voltage/Materials
in contact with media
Temperature specifications
Year of manufacture
FM C-US Certificate
1.4 Scope of delivery
P2.2 / P2.82 AMEX P2.4 / P2.84 AMEX
1 x Sample gas pump with motor 1 x Pump body with intermediate flange
4 x Rubber-metal bumpers 1 x Motor
1 x Mounting bracket made of 1.4301 1 x Coupling flange
Product documentation 1 x Coupling
1 x Mounting ring
Product documentation
1.5 Product description
The sample gas pumps are intended exclusively for the pumping of gaseous media. They are not suitable for liquids.
Please observe the information at the end of these instructions in relation to specific intended use, available material combina-
tions, and pressure and temperature limits. In addition, please observe the information and labelling on the identification
plates.
The maximum surface temperature depends on the ambient temperature and the temperature of the medium. The connection
between the temperature of the medium, the ambient temperature and the temperature class of the pump is specified in the
technical data.
NOTICE Restriction for AMEX pumps
The P2.8x AMEX pumps can pump exclusively non-flammable gaseous media and flam-
mable gaseous media that are clearly above the upper explosive limit or clearly below
the lower explosive limit.
The P2.2-, P2.4- AMEX pumps can pump non-flammable gaseous media and flammable
gaseous media that could occasionally be explosive in normal operation (Sampling zone
1). Sampling gas from zone 1 is generally forbidden if the gas flow leads to a dangerous
electro-static charge in the bellow / pump body (also see the “Operation” section).
The AMEX versions are intended for use in Class I, Div. 2, Groups B, C, D.
For use in hot applications, in the P2.4 AMEX / P2.84 AMEX sample gas pumps the pump head and the drive motor are separ-
ated. The sample gas pump has a divided reducing flange, one half of which can be mounted in the interior of a heated cabinet
and the other half of which, mounted on the outer side, carries the drive motor. As a result, wall thicknesses of up to 30 mm can
be bridged with no additional adjustments.
For applications in which the sample gas is still damp, condensate can form in the pipelines and in the pump body. In such
cases, the pump body must be mounted in a hanging position (see point “Alteration of hanging pump bodies”).
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1.5.1 Construction
P2.2 / P2.82 AMEX
Screw-in connection
Motor
Bypass valve (option)
ON OFF
M20x1.5
Pump head Assembly bracket with
rubber-metal bumpers
Pump
console
Pump body
P2.4 / P2.84 AMEX
Screw-in connection
Coupling flange
Motor
Connecting screws
M6x16
Ø7 mm for M6 screws
(not included)
Mounting ring
Intermediate flange
Pump head
Cabinet cut-out
Pump console
Pump body
Further overview and single-part drawings which describe the construction of the pumps in greater detail can be found in the
appendix to these operating instructions.
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2 Safety instructions
2.1 Important advice
This unit may only be used if:
– the product is being used under the conditions described in the operating- and system instructions, used according to the
nameplate and for applications for which it is intended. Any unauthorized modifications of the device will void the warranty
provided by Bühler Technologies GmbH,
– complying with the specifications and markings in the type plate,
– complying with the threshold values specified in the data sheet and the instructions,
– monitoring equipment / protection devices are connected correctly,
– service and repair work not described in these instructions are performed by Bühler Technologies GmbH,
– genuine spare parts are used.
These operating instructions are a part of the equipment. The manufacturer reserves the right to change performance-, specific-
ation- or technical data without prior notice. Please keep these instructions for future reference.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard Warns of limbs being crushed
Warns of voltage General notice
Warns not to inhale toxic gasses Unplug from mains
Warns of corrosive liquids Wear respiratory equipment
Warns of explosive areas Wear a safety mask
Warns of hot surfaces Wear gloves
2.2 General hazard warnings
This product has no dangerous ignition sources when observing regulations and operating parameters in these operating in-
structions. Installation into a complete system can pose new hazards the manufacturer of this sample gas pump has no control
over. If necessary, perform a risk assessment of the complete system this product will be installed into.
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Observe the relevant national safety regulations for the installation site and the generally applicable state of the art when con-
figuring and building the complete system. These can be determined through applicable harmonised standards, e.g. EN
60079-14 among others. Additional national regulations pertaining to initial operation, operation, maintenance, repairs, and
disposal must be observed.
Avoid any exothermic reactions in your system, do not use materials with a catalytic effect in the conveyor lines. Dangerous rises
in temperature may otherwise occur. Sample gas pump materials in contact with mediums are specified in this operating
manual to facilitate the safety assessment.
Adiabatic compression is part of the physical operating principle of bellows pumps. Dangerous rises in temperature cannot be
ruled out when exceeding the operating parameters.
Avoid these dangerous conditions. If necessary, protect the entire system against flashback. Follow these notes and the applic-
able national regulations and prevent malfunctions to avoid personal injury and property damage.
The operator of the system must ensure:
– The equipment is installed by a professional familiar with the safety requirements and risks,
– Safety notes and operating instructions are available and observed,
– The permissible data and operating conditions are observed,
– Protective devices are used and the required maintenance is performed,
– The unit is disposed according to the law.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Danger of explosions, danger of poisoning from poisonous corrosive gases
During maintenance work, depending on the medium used, explosive and/or poisonous
corrosive gases could escape, and this could lead to a danger of explosion or could be
hazardous to health.
a) Inspect the leak tightness of your sampling system before putting the device into op-
eration.
b) Ensure that gases that are hazardous to health are discharged safely.
c) Turn off the gas supply before beginning any maintenance or repair work and flush
the gas lines with inert gas or air. Secure the gas supply so that it cannot be turned on
unintentionally.
d) Protect yourself during maintenance from poisonous / corrosive gases. Wear appro-
priate protective equipment.
DANGER Explosion hazard
Life and explosion risk may result from gas leakage due to improper use.
a) Use the devices only as described in this manual.
b) Regard the process conditions.
c) Check tubes and hoses for leakage.
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DANGER Adiabatic compression (explosion hazard)!
In case of adiabatic compression, high gas temperatures may occur. The operator is re-
sponsible to consider this situation.
Make sure to obey the allowed technical specifications and ambient conditions (see data
sheet), take special attention to the media temperature with respect to temperature
class T3 or T4. These vary in addition to gas composition and ambient conditions. Where
necessary, the operator must install temperature sensors for monitoring and must auto-
matically shut down the sample gas pump should the temperature exceed the limits.
CAUTION Tilting risk
Damage of the device
Secure the device against any sudden translocation during maintenance.
DANGER DANGER - Explosion danger in case of high temperatures
Temperature of the device depends on the medium temperature. Correlation between
medium temperature and temperature classes is given in the data sheets.
Observe maximum temperature classes T3 or T4 for the pumps and the allowed ambient
temperatures and medium temperatures.
CAUTION Hot surface
Burning hazard
According to the product type and operation conditions, the temperature of the housing
may exceed 50 °C during operation.
Depending on the conditions at the installation site it may be necessary to provide these
areas with appropriate warning signs.
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3 Transport and storage
The products should be transported only in its original packaging or a suitable replacement.
When not in use, protect the equipment against moisture and heat. Keep it in a covered, dry and dust-free room at a temperat-
ure of -20 °C to +40 °C.
Outdoor storage is forbidden. As a matter of principle, the operator must regard all applicable standards according prevention
of damage due to lightning, which may otherwise damage the sample gas pump.
The storage room must not be equipped with any ozone-producing devices like fluorescent light sources, mercury arc lamps,
electric high voltage devices.
Before restarting the pump after long-term storage or an extended standstill period, the insulation resistance of the winding
phase-to-phase and phase-to-ground must be measured. Moist windings could cause leakage current and flash-over. The insu-
lation resistance of the stator windings must be at least 1.5 MΩ with motors for 220 to 1000 V, measured at a winding temperat-
ure of 20 °C. For lower values, drying the winding is required.
The motor shaft should be rotated in regular intervals to ensure sufficient lubrication of the bearings in long term.
To do this, unscrew the three cross-head screws of the housing cover and remove the cover (see fig. 1, fig. 2). The crankshaft is
now visible.
CAUTION Contusion hazard
Contusion of the fingers
Don’t have your fingers caught between eccenter and slide.
Fig. 1 Fig. 2
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4 Installation and connection
Check the equipment for damage before installation. Among other things, this could be a damaged housing, supply cables, etc..
Never use equipment with obvious damage.
CAUTION Use appropriate tools
According to DIN EN 1127-1, the operator is responsible to select and use appropriate
tools.
4.1 Requirements to the installation site
CAUTION Equipment damage
Protect the equipment, particularly gas connections and gas lines, from dust, falling ob-
jects, as well as external blows.
Lightning
On principle, the operator must meet all applicable standards with respect to preventing
damage to the equipmentdue to lightning, which could result in equipment damage.
CAUTION Avoid vibrations and resonances
The operator is responsible to mount the pump in a way that vibrations and resonance
do not cause premature failure resulting in creating an effective ignition source.
Mounting, installation and demounting the pump must be carried out in non-hazardous area and with pump cooled down.
Air ventilation must not be obstructed and exhausted air - including air from adjacent units - must not be sucked in directly.
Motors with mains voltage 110 - 120 V or 220 - 240 V are suitable for ambient temperatures from -20 °C to +50 °C and altitude of
height ≤ 1000 m above sea level. Motors with mains voltage from 380 – 420 V must be operated only in ambient temperature
range between -20 °C to +40 °C.
When mounting the pump without brackets, leave enough space between motor and rear wall. Please refer to the data sheet at-
tached to this manual for further information about ambient parameters at the installation site.
d = air inlet
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4.1.1 Outdoor installation
The sample gas pumps were not specifically designed for outdoor setup. The operating and environmental conditions are cru-
cial for the required types of protection and any additional measures required, such as:
– adequate protection from the weather
– Adjusting the maintenance intervals (e.g. cleaning and replacing wear parts)
Use suitable measures and regular inspections to prevent damage to the equipment from e.g.:
– Corrosion
– Sunlight (temperature peaks and damage from
UV rays)
– Moisture from condensation (e.g. due to rapid temperature changes or downtimes)
– Icing
– Insects and microbes
– other animals, e.g. martens, etc.
Please remember that all technical operating parameters of the equipment must also be met with outdoor installation. Specific-
ally:
– Maximum or minimum operating temperatures
– Degree of protection
4.2 Installation
CAUTION Damage to the device
Protect the device, especially the gas inlets and tubes, against dust, falling parts and ex-
ternal impact.
P2.2 AMEX / P2.82 AMEX
During the installation of the P2.2 AMEX / P2.82 AMEX sample gas pump onto mounting plates, use the supplied mounting
bracket and exclusively the supplied rubber-metal buffer. Operation without the rubber-metal buffer is forbidden. They must
also be used if the pump is installed on an existing supporting structure. The hole pattern of the mounting bracket and the mo-
tor base can be found in the data sheets at the end of the operating and installation instructions.
P2.4 AMEX / P2.84 AMEX
During the installation of the P2.4 AMEX / P2.84 AMEX sample gas pump, please observe the assembly drawing 42/011-Z01-03-3.
The sample gas pump should be checked for its completeness before beginning installation. 6xM6 screws with nuts of the ap-
propriate length are also required for the installation.
For all pump types, the pump head can be oriented exclusively at an angle of 0° or of 180°.
4.3 Special condition moist sample gas
Applications where the sample gas is still moist may result in condensate forming in line and the pump body. In these events
the pump head must be suspended (pump body facing down).
If the pump was not ordered this way, it can easily be converted on site.
Install the line between the gas output and condensate drain with a grade so the condensate can drain and does not collect in-
side the pump or the lines.
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4.3.1 Alteration of hanging pump bodies
CAUTION Damage to the device
Especially with pump head pointing down, make sure that no dust or small parts can in-
trude the pump through the ventilations slot. Nevertheless, the slot must not be covered
directly. If this is not possible, the pump must not be mounted with pump head pointing
downward.
To perform this, unscrew the three Phillips head screws of the casing cover (Figure 3, Figure 4) and remove the cover (also see the
spare parts drawing at the end of the operating instructions). The crankshaft drive and the engine flange will now be visible. The
pump housing is fixed to the engine flange and/or the intermediate flange (depending on the pump type) with four hexagon
bolts (SW8). Unscrew these completely (Figure 5). When unscrewing the last screw, hold the housing tight. Now carefully rotate
the housing on the centring of the flange by 180°, screw it tight again (Figure 6, Figure 7) and then re-install the cover (tighten-
ing torque of the hexagonal bolts 3Nm). Offsetting the installation of the pump head by 45° is not permitted!
Figure 3 Figure 4 Figure 5
Figure 6 Figure 7
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4.4 Connecting the gas tubes
The pumps are delivered with customized gas connections. Please compare the part-no. on the type plate with the part-no. ex-
plained in chapter "Introduction".
Avoid mixed installations, that is connecting metal tubes to plastic bodies. If this is unavoidable for sporadic applications, screw
the metal fitting with utmost care and without any use of force to the PTFE pump body.
Install the tubes in a way that the line at the inlet and outlet is flexible over a sufficient distance (pump vibrates).
The pumps are marked with “In” for inlet (input) and “Out” for outlet (output). Make sure that the connections to the tubes are
tight.
4.4.1 Monitoring the sample gas pump
NOTICE
When following preventive maintenance according to the maintenance plan, a crack in
the bellows is a rare malfunction, but cannot be completely eliminated.
NOTICE
If the bellow cracked, turn the pump off immediately!
NOTICE
If flammable gases (even above upper explosion limit (UEL)) or toxic gases are supplied,
continuous monitoring of the pump is mandatory.
DANGER Explosion hazard, danger of poisoning!
A crack in the bellows when conveying flammable or poisonous gasses may allow explos-
ive or poisonous gas mixtures to leak or develop.
Monitor the pump with a flow- and/or vacuum monitoring system (see flow diagram).
If a pump defect occurs, shut it off immediately.
4.4.1.1 General monitoring measures
Since a crack in the bellow allows the ambient atmosphere to be sucked in and the sample gas pump continues to generate
pressure, the bellows of the sample gas pumps must be inspected regularly.
In addition, the flow rate of the pump (to the sample gas outlet) must be monitored with a suitable flow meter.
For more information or Inspecting the bellow the maintenance schedule, please refer to the chapter Maintenance at the end of
the operating and installation instructions.
4.4.1.2 Monitoring measures when conveying flammable and/or toxic gasses
Conveying flammable and/or toxic gasses further requires continuous monitoring of the sample gas pump during operation.
This can be done as follows (1) or (2).
1. Flow rate monitor before the pump’s gas inlet or after the gas outlet. A sudden reduction of the suction volume / flow
volume ahead of the pump and consistent or suddenly increased flow volume after the pump indicates a defective bellow
(the pump can convey ambient air suctioned in due to the tear).
2. Vacuum monitoring before the pump’s gas inlet and flow monitoring after the gas outlet (see illustration). A sudden drop
in the vacuum before the gas inlet indicates a defective bellow.
When conveying flammable gasses above the upper explosive limit (UEL) we further recommend monitoring the lower explosive
limit (LEL) in the installation location.
When conveying toxic gasses we recommend MAC monitoring (MAC: Maximum Workplace Concentration) at the installation
site.
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underpressure
manometer
sample gas pump
manometer
flowmeter
shut-off valve
Fig.1: Sample flow diagram of suitable monitoring
4.5 Electrical connections
WARNING Hazardous electrical voltage
The device must be installed by trained staff only.
WARNING
Inverter operation is forbidden!
WARNING
Regard National directives concerning installation and operation of electrical devices in
hazardous areas when installing and commissioning the motor (e. g. EN 60079-14).
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
According to the certification, a switch or power switch must be installed for the motor. It must be easily accessible by the user.
The switch must be marked as circuit breaker for the device. It must not be installed in the mains power cord and must not in-
terrupt the protective earth conductor. Furthermore, it must disconnect the device from all poles.
The device must be operated with the factory-installed motor. The operator must not replace the device or the motor with a dif-
ferent model.
The sample gas pump must be protected against overheating by a suitable overload protection (motor protection switch accord-
ing to the certification).
Regard rated current and settings of the motor protection switch (see type plate of the motor).
In contrast to protection class "Ex nA II", failure mode is monitored in protection class "increased protection". Therefore, the mo-
tor protection switch must switch off within the specified time tE for the respective temperature class if the motor is blocked.
The requirement will be satisfied if the tripping time (it can be picked from the tripping characteristics (initial temperature 20
°C) for the ratio IA/IN) is lower than the specified time tE. (See data sheet 03 and 04 and CE-Type Examination Certificate PTB 02
ATEX 3147.)
Connect the pump according to the circuit diagram inside the terminal cover plate and provide sufficient strain relief of the
mains cable. Make sure that mains voltage and frequency meet the specifications of the motor (voltage tolerance ±5 % and fre-
quency tolerance ±2 % based on 220-240 V respectively 110-120 V).
Select mains and PE cross section according to the rated current.
The cross section must be at least 1.5 mm2.
Connect the protective earth conductor of the motor to the local earth conductor.
Connect the mounting plate of the pump with means of the press-fitted PE bolt to the local earth conductor. As an alternative, it
is allowed to connect the PE bolt at the mounting plate to the external PE bolt with a cable.
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Stray electric currents may not flow through this connection.
It is essential to connect the protective earth conductor to the marked PE terminal. Regard national directives, in Germany
DIN VDE 0100.
Make sure that no foreign bodies, dirt and moisture are left inside the terminal box. Seal non-used cable ducts and the dermal
box itself against dirt and water. Use the original gasket when closing the terminal box.
Seal non-used holes with ATEX-approved plugs.
Obey differing specifications on the type plate. The conditions at the installation site must meet all specifications on the type
plate.
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5 Operation and control
NOTICE
The device must not be operated beyond its specifications.
DANGER Danger of explosions, danger of poisoning from poisonous corrosive gases
During maintenance work, depending on the medium used, explosive and/or poisonous
corrosive gases could escape, and this could lead to a danger of explosion or could be
hazardous to health.
a) Inspect the leak tightness of your sampling system before putting the device into op-
eration.
b) Ensure that gases that are hazardous to health are discharged safely.
c) Turn off the gas supply before beginning any maintenance or repair work and flush
the gas lines with inert gas or air. Secure the gas supply so that it cannot be turned on
unintentionally.
d) Protect yourself during maintenance from poisonous / corrosive gases. Wear appro-
priate protective equipment.
DANGER Adiabatic compression (explosion hazard)!
In case of adiabatic compression, high gas temperatures may occur. The operator is re-
sponsible to consider this situation.
Make sure to obey the allowed technical specifications and ambient conditions (see data
sheet), take special attention to the media temperature with respect to temperature
class T3 or T4. These vary in addition to gas composition and ambient conditions. Where
necessary, the operator must install temperature sensors for monitoring and must auto-
matically shut down the sample gas pump should the temperature exceed the limits.
DANGER Dangerous electrostatic charging (explosion hazard)
Conveying e.g. very dry and particle-laden gasses may result in incendive electrostatic
charges inside the bellow / pump body.
Please install a particle-filter with suitable grade of filtration before the gas input of the
pump.
Removing explosive gaseous mediums (max. from zone 1) with pump P2.2.-P2.4-AMEX is
prohibited if the gas flow results in an incendive electrostatic charge in the bellow /
pump body (projected surface inside the bellow / pump body ~ 15 cm2).
Pumps 2.8x-AMEX are suitable only to deliver non-explosive gases.
CAUTION Hot surface
Burning hazard
According to the product type and operation conditions, the temperature of the housing
may exceed 50 °C during operation.
Depending on the conditions at the installation site it may be necessary to provide these
areas with appropriate warning signs.
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5.1 Switching on the sample gas pump
Before switching on the device, ensure that:
– the hose and electrical connections are undamaged and correctly installed,
– no parts of the sample gas pump have been dismantled (e.g. cover),
– the gas inlet and outlet of the sample gas pump is not shut,
– the preliminary pressure is under 0.5 bar,
– in the event of throttling under 150 l/h (P2.x Amex) or under 400 l/h (P2.8x Amex) in continuous operation, a bypass is avail-
able,
– the ambient parameters are complied with,
– information on rating plates is observed,
– the voltage and frequency of the motor correspond to those of the network,
– the electrical connections are tightly fastened and the monitoring devices have been connected and configured correctly!
– air inlet openings and cooling surfaces are clean,
– protective measures have been carried out; earthing!
– the motor is secured correctly,
– the terminal box cover is closed and the cable entry points have been properly sealed,
– the elastomer sprocket of the coupling is correctly installed and undamaged,
– depending on the operating mode, the necessary protective and monitoring devices are present and functional (depending
on the type of pump, e.g. motor circuit breaker, manometer, flame arrestor, temperature monitoring).
When switching the sample gas pump on make sure that
– no abnormal sounds or vibrations occur.
– the flow rate is neither too low nor too high. This would indicate a cracked bellow.
5.2 Operating the sample gas pump
The sample gas pump is intended exclusively for the pumping of gaseous media. It is not suitable for liquids.
The sample gas pump should be operated without pre-compression. A preliminary pressure of more than 0.5 bar is not permit-
ted. The gas outlet must not be shut. The flow rate must be at least 50 l/h for the P2.x AMEX and at least 200 l/h for the P2.8x
Amex pumps. In the event of throttling under 150 l/h for the P2.x AMEX and under 400 l/h for the P2.8x Amex pumps in continu-
ous operation, the flow rate must be regulated via a bypass. In this case you should choose a version with bypass valve.
NOTICE
Extreme throttling reduces the life time of the bellow.
For pumps with an integrated bypass valve, the output power can be adjusted. Do not expend a great amount of power when
turning the valve as otherwise the valve could be damaged! The turning range of the valve is around seven rotations.
NOTE: Read and observe the maintenance plan!
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6 Maintenance
Maintenance work on the device must be carried out in a non-hazardous area (ex-free zone) and in a cooled down condition. In
particular, cleaning work with pressurised air must only be carried out in a non-hazardous area.
During maintenance, remember:
– The equipment must be maintained by a professional familiar with the safety requirements and risks.
– Only perform maintenance work described in these operating and installation instructions.
– When performing maintenance of any type, observe the respective safety and operation regulations.
NOTICE
Please refer to the spare parts drawings attached when performing maintenance.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Danger of explosions, danger of poisoning from poisonous corrosive gases
During maintenance work, depending on the medium used, explosive and/or poisonous
corrosive gases could escape, and this could lead to a danger of explosion or could be
hazardous to health.
a) Inspect the leak tightness of your sampling system before putting the device into op-
eration.
b) Ensure that gases that are hazardous to health are discharged safely.
c) Turn off the gas supply before beginning any maintenance or repair work and flush
the gas lines with inert gas or air. Secure the gas supply so that it cannot be turned on
unintentionally.
d) Protect yourself during maintenance from poisonous / corrosive gases. Wear appro-
priate protective equipment.
CAUTION Tilting risk
Damage of the device
Secure the device against any sudden translocation during maintenance.
CAUTION Gas leakage
The sample gas pump should not be dismantled under pressure.
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DANGER Use appropriate tools
According to DIN EN 1127-1, the operator is responsible to select and use appropriate
tools.
Application in explosive atmosphere
Combustible gases and dust may inflame or explode. Avoid the following hazardous
situations:
Electrostatic charge (spark formation)
Clean plastic parts and labels with damp cloth only.
Spark formation
Protect the equipment against external impact.
Install a flame arrester in case of a flashback hazard.
Inflame of dust
If the device is used in dust ambiance, remove the layer from the components regularly.
Also remove the dust layer in areas difficult to access (see chapter "Cleaning").
Conserve the protective effect of the coating
To avoid potential ignition hazard, the protective effect of the coating must not be
derogated by abrasion or corrosive media and must be conserved in any case.
Refinishing or repainting is not allowed!
Do not use sharp or pointed tools.
DANGER Explosion hazard due to incorrect replacement of components
The replacement of the components requires carefulness. Inexpert operation could lead
to explosion.
If you feel uncertain about any details of the operation, please bear in mind that the re-
placement should be done by the manufacturer only.
CAUTION Hot surface
Burning hazard
According to the product type and operation conditions, the temperature of the housing
may exceed 50 °C during operation.
Depending on the conditions at the installation site it may be necessary to provide these
areas with appropriate warning signs.
Depending on the quality of the sample gas to be pumped, the valves in the inlet and the outlet may have to be changed from
time to time. A description of the replacement of parts can be found in the “Replacing inlet and outlet valves” section.
If the valves are heavily contaminated, in particular after just a short period of operation, then you should provide for particle
filtration before the pump. This will increase the service life considerably.
Depending on the operating conditions, the following must be performed at suitable intervals (see “Maintenance plan”)
– Inspect the terminal compartments and terminals for cleanliness and clean them if necessary.
– Inspect whether the electrical connections are firmly in place.
– The cooling air channels of the motor are cleaned.
– Carry out an inspection of the radial clearance and a visual check of the elastomer sprocket.
The exhaust ports and the cooling surfaces of the motor must be protected from blocking and impurities.
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