Bieri SRK701-ATEX User manual

1
Operating Instructions
for
Explosion-Proof Radial Piston Pump
Type: SRK and MRK
Ex-Designation according to RL 2014/34/EU: CE II 2Gc -20°C ≤Ta ≤40°C
Ex-Designation according to EN 80079-37: EX h IIC T4 Gb -20°C ≤Ta ≤40°C
Further applicable documents:
- none
(English translation of original German operating instructions -E-)
Manufacturer:
Bieri Hydraulik AG
Könizstrasse 274
3097 Liebefeld
Schweiz
Tel.: [phone]
Fax [phone]
Email [email protected]
Operating Manual Part no.: 4414418
Date: Created by: Checked by: Index: Change number:
2019-10-17 Grossenbacher E. Aebischer N. 09 995421

2
Table of Contents
1 Operating instruction ................................................................................................... 4
2 Symbols used in the manual ....................................................................................... 5
3 Proper use................................................................................................................... 6
4 General safety instructions.......................................................................................... 7
4.1 Staff qualification and training............................................................................. 7
4.2 Safe working practice ......................................................................................... 7
4.3 Improper use....................................................................................................... 8
4.4 Unauthorized reconstruction and spare parts ..................................................... 9
5 Designation of the system components .................................................................... 10
5.1 Data plate ......................................................................................................... 11
6 Scope of delivery....................................................................................................... 12
7 Transport and installation notices.............................................................................. 12
7.1 Delivery............................................................................................................. 12
7.2 Transport .......................................................................................................... 12
7.3 Unpacking......................................................................................................... 13
7.4 Set up ............................................................................................................... 13
7.5 Recommended installation ............................................................................... 14
7.6 Connections...................................................................................................... 15
7.6.1 Pipes (under pressure)......................................................................... 16
7.6.2 Pumping medium ................................................................................. 16
7.6.3 Cavitation ............................................................................................. 17
7.6.4 Drive motor .......................................................................................... 17
7.6.5 Main switch / emergency-off from the drive motor ............................... 18
7.7 Start up ............................................................................................................. 19
7.7.1 Trial run................................................................................................ 20
7.8 Storage and conservation................................................................................. 21
7.8.1 Deactivation ......................................................................................... 21
7.8.2 Deactivation when still installed ........................................................... 22
7.8.3 Restarting the pump............................................................................. 22
7.9 Claims............................................................................................................... 23
8 Functional principle ................................................................................................... 24
8.1 Calculating the drive power .............................................................................. 25
9 Operation .................................................................................................................. 26
9.1 Preparations and general notices ..................................................................... 26
9.2 Starting the pump ............................................................................................. 27
10 System care .............................................................................................................. 28
10.1 Changing location............................................................................................. 28
10.2 Cleaning the System......................................................................................... 28
10.3 Electrical / electronic equipment ....................................................................... 29
11 Maintenance.............................................................................................................. 30

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11.1 Safety notices ................................................................................................... 30
11.2 Maintenance plan ............................................................................................. 31
11.3 Restoration ....................................................................................................... 32
11.4 Log book........................................................................................................... 32
12 Troubleshooting ........................................................................................................ 33
12.1 Emergencies and accidents.............................................................................. 34
12.2 Service and information .................................................................................... 34
13 Spare parts................................................................................................................ 35
13.1 Recycling .......................................................................................................... 35
14 Technical data........................................................................................................... 36
14.1 Perfomance data / Dimension drawings ........................................................... 37
14.1.1 SRK701-ATEX ..................................................................................... 37
14.1.2 SRK702-ATEX ..................................................................................... 38
14.1.3 MRK701-ATEX .................................................................................... 39
14.1.4 MRK702-ATEX .................................................................................... 40
14.2 Type code......................................................................................................... 41
14.3 Standards and guidelines ................................................................................. 42
14.4 ATEX edition..................................................................................................... 43
14.4.1 Intended use ........................................................................................ 43
14.5 Declaration of conformity .................................................................................. 44
15 Warranty ................................................................................................................... 45
16 Glossary.................................................................................................................... 46

4
General
1 Operating instruction
By choosing the special radial piston pump ATEX (SRK-ATEX, MRK-ATEX), henceforth
referred to as "pump", you have selected a leadingedge system for the transportation of
liquids.
The valvecontrolled, modular radial piston pump can be equipped with 3 till 9 pistons on
one level. The pump is suited for the roughest of applications and for high nominal
operating pressures of up to 108MPa (1000 bar). The pumps meet the requirements of the
device group II category 2G of the ATEX-guideline.
This manual contains notices for your personal safety, as well as for the prevention of
damage to property. Read this operating instruction carefully before starting any work on
or with this device. It contains regulations and instructions for installation, startup,
operation, inspection and maintenance of the device.
The manufacturer accepts no liability for damage or faults arising from failure to follow the
instructions. In case of doubt, the enclosed German version of the operating instructions
shall apply. In case of any queries or problems, please contact the manufacturer directly.
This operating instruction must be retained for the full service life of the device in complete
and legible condition and kept accessible to the necessary persons.
Copyright © Bieri Hydraulik AG 2010 All rights reserved disclaimer
The distribution or reproduction of this document or the use or passing on of its contents is
not permitted unless permission has been expressly granted. Non-compliance shall incur
an obligation to pay damages. All rights reserved.
Bieri Hydraulik AG Könizstrasse 274 CH-3097 Liebefeld
We have checked the contents of this publication for agreement with the described
hardware and software. However, deviations cannot be excluded and therefore we do not
guarantee full agreement. The information in this publication is regularly checked and any
corrections found necessary are contained in subsequent editions.
We are grateful to receive suggestions for improvement.
© Bieri Hydraulik AG 2010

5
2 Symbols used in the manual
Danger
Means not applying the relevant measures will cause death, serious physi-
cal injuries or significant property damage.
Caution
Means not applying the relevant caution may cause slight physical injuries or
light property damage.
N
otice
Is important product information, information on product handling or may
highlight a particular part of the documentation requiring your special at-
tention.
Only qualified personnel may start up and operate the equipment. Qualified
personnel are those who know the safety requirements and are fully trained
and worked in on the system.
The manufacturer cannot be held liable for damages caused by not adhering
to safety instructions, by unprofessional procedures or for using the
equipment for purposes it was not designed for.
W
arning
The equipment may only be used as specified in the technical datasheet and
for the applications described and only in connection with equipment and
third- party equipment and components recommended and approved by
Bieri Hydraulik AG.
Trouble-free operation of the equipment requires professional transportation,
storage, installation, operation and maintenance.
Explosion-related
Explosion-related situations or dangers are highlighted.

6
3 Proper use
The special radial piston pump ATEX is intended to be directly driven by commercially
available electric or combustion motors, belt drives, gears etc. and is only meant to
transport liquids and to increase the pressure of liquids with different chemical and
physical characteristics in a defined atmosphere.
The pump meets the requirements in accordance with the European guidelines
2014/34/EU “Intended use of devices and protective systems in an explosion hazard area”,
for device category 2G.
I.e. the pumps themselves are not the source of any ignition. They can be used to
transport flammable liquids. They are built to withstand harsh applications such as those in
industrial plants and ma- chine workshops
D
anger
The special-radial piston pump ATEX may only be set up with in explosion
hazard areas of zones 1 and 2 or in other safe areas!
The danger of an explosion must be determined by the operator of the entire
system.
N
otice
The manufacturer is not liable for any damages in regard to operational and
personal safety caused by disregarding safety instructions, wrong
procedures or by using the equipment as not intended.

7
4 General safety instructions
4.1 Staff qualification and training
The installation, start-up, operating, inspection and maintenance staff who work on the
valve and solenoid coil must have the appropriate qualification for these types of work.
Specialised knowledge in the fields of hydraulics and electrics is required.
The operator is obliged to operate the device only in perfect condition. Any hazards arising
between Bieri Hydraulik AG systems and customer equipment must be secured by the
operator.
Area of responsibility, responsibility and supervision of personnel must be precisely
regulated by the operator. If the personnel do not have the necessary knowledge and
skills, they must be adequately trained and instructed.
Furthermore, the operator must ensure that the contents of the operating instructions are
fully understood by the personnel.
The integrator is obliged to ensure the continuous traceability of the product back to the
manufacturer.
4.2 Safe working practice
The organisational and general safety conditions must always be observed when working
in potentially explosive areas.
Explosion
-
related
Each member of staff must be familiar with the required conduct in explosive
atmospheres.
The safety information given in these operating instructions and the existing
national and international regulations on explosion protection and accident
prevention must be complied with, in addition to any internal works
regulations, operating and safety regulations specific to the owner.
Caution
In environments containing hydraulic oil, small leaks can form films of oil on
the ground.
Caution
Appropriate protective measures must be taken and information provided
when using toxic fluids.

8
4.3 Improper use
The radial piston pumps may only be operated in their intended use and within the
described technical data. The specified limit values must not be exceeded under any
circumstances.
The operator is obliged to report any changes immediately.
The owner must ensure that no safety devices are removed or disabled.
Explosion
-
related
The device may only be operated in a clean and undamaged condition.
Any type of damage may bypass the explosion protection.
As soon as there is any suspicion that device safety is impaired, the device
must be taken out of operation immediately. Ensure that the device is not
restarted inadvertently.
See the "Inspection" chapter for more details.
The other instructions, information and specifications in these operating instructions must
be followed and complied with.

9
4.4 Unauthorized reconstruction and spare parts
Reconstruction and alterations to the device are not permitted (e.g. painting). Original
spare parts and accessories authorized by the manufacturer ensure safety.
Use of other parts may void the liability for any consequential damage or loss.
Explosion
-
related
Signs of wear, like increased noise, altered sound or increased vibrations,
may indicate that the pumps service life is coming to an end, or that the
valve has not been installed correctly In such cases, the pump must be
replaced or sent to the manufacturer for repair.
If the pump has been installed incorrectly, the manufacturer must be
contacted for further advice.
Make particularly sure that the selected materials of those parts of the pump
as well as the system (sealing materials, pipes, fittings e.g.) which carry the
media are suitable for the media in use.
Media incompatibility of the materials can lead to serious consequential
damage due to detached particles.
Caution
Prior to installing/removing the pump, the pressure must be completely
released in order to reduce the risk to the fitter. Fluid must not be allowed to
escape unchecked from the pipe.

10
5 Designation of the system components
This illustration shows the system components of the pump. The drawings are for general
understanding only and are not intended as detailed scale drawings for construction
purposes.
Pos. Description
1 Suction stroke piston
2 Workspace
3 Suction valve
4 Pressure valve
5 Pressure flange
6 Collector pipe
7 Pressure connection

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5.1 Data plate
Ex-designation acc. to RL 2014/34/EU Manufacturer
Address
Type designation Production number + consecutive number
within an order
Order number Max. operating pressure
Type code Max. flow rate
Part no. + Index Max. speed
N
otice
If the pump is to be used in explosion hazardous areas as defined by ATEX
then this sign is attached beside the manufacturer’s plate and the CE
sign. The declaration of conformity is in the appendix of this manual.

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6 Scope of delivery
Before starting to use the pump, make sure that the delivery is complete:
• Special radial piston pump ATEX
• Operating instruction with EC declaration of conformity
7 Transport and installation notices
7.1 Delivery
Normal freight: The pump is packed in a parcel and protected by a plastic foil.
Sea freight: For sea freight, the parcel is placed in a wooden box.
Air freight: For air freight, the parcel is placed in the plywood box
7.2 Transport
Please observe the danger warnings before transporting the pump:
Caution
Heavy object may cause sprained muscles or back ache. Use appropriate
tools and the correct technique to lift the pump.
Heavy loads may fall down and cause serious injuries!
The personnel must wear protective shoes.
N
otice
Always transport the pumps with care and make sure they are not scratched
during transportation.
Use a suitable hoist to lift the pump.

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7.3 Unpacking
•Carefully remove the pump from the package and from any other bindings
•Check the pump for visible damage
7.4 Set up
From the factory the pump is delivered with its ducts blocked. Keep the ducts blocked until
connecting the pump to the pipes.
The pump is delivered ready-to-use and you can connect it to the drive motor and operate
it on your own. However, please read the operating instruction carefully first.
N
otice
Check the shipment against the delivery note (should the delivery be
incomplete, please contact our customer service).
Visible damages due to poor packaging or due to the means of
transportation must be reported immediately to our customer services, to the
shipping company, and to the insurance company.
N
otice
Heavy object may cause sprained muscles or back ache. Use appropriate
tools and the correct technique to lift the pump.
Until it is assembled or after disassembly, always store the pump on its
largest surface area.

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7.5 Recommended installation
The pump is stable within itself; it can be installed horizontally or vertically. On unleveled
foundations, the pump must be leveled.
For a smooth run, we recommend using a pump support base with dampening or a foot
with damping flanges and an elastic shaft coupling.
N
otice
Should the pumps be deactivated and uninstalled, then the opening ducts
must be blocked again to prevent hydraulic fluid from leaking out.
Should the pump be used in a stationary installation, then it must be
mounted on a leveled foundation that will compensate possible movements
caused by external influences such as vibrations or expansions.
Use foundation screws to connect the pumping station to the foundation. The
operator must ensure a safe anchoring.
Should the pump be intended to be mobile (mounted on a vehicle) then the
operator must make sure that the pump does not deviate from the horizontal
by more then 5°.
If the pump is operated at the larger slant, air bubbles could get caught in the
system.
If the pump is to be used outdoors, then it requires at least a covering roof.

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7.6 Connections
Install the compressed air pipes as straight as possible and with a minimum of pipe
connectors to prevent losses due to friction. Lay the pipes out without tension, because
rigidly installed suction and pressure pipes generate tension and significant forces that
affect the pump and can damage it.
The permissible suction height of the pumping medium is maximum 500 mm. The suction
pipe must be immersed at least 50mm in the medium and must have a minimum distance
of 50 mm to the bottom of the tank.
N
otice
The suction connections may be tightened with a maximum of 25 Nm torque.
The pressure connections must be connected in accordance with the
manufacturer’s recommendations and the permissible operating pressure
may not be exceeded.
The connections to the pump must be elastic (hoses or compensators).
Because of differing temperatures of the pumping medium, expansions may
occur in the pipes and continue as tension to the pump, the frame and all the
way down to the foundation.
Before assembly, the entire hydraulic system and the pipes must be carefully
cleaned to prevent any loose particles from reaching the pump.
Depending on the characteristics of the pumping medium, the operator must
take measures to catch any medium that would leak through the pump
connections.
C
aution
The pipes and fittings used must correspond to the pressure class for which
the system was designed. Always use pipes with the same nominal widths.
The sizes of pipes should meet the requirements of the guidelines on
hydraulics.
Make sure that the connections between the pump housings, and the pipes
are suited for the pressure rating and that they can not be deformed or come
loose during operation.
Check the drop in pressure in the pipes in consideration of the viscosity. It
may not exceed the performance envelope of the pump.

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7.6.1 Pipes (under pressure)
The pump feeds by volume independent of the pressure generated. Blocking a pipe under
pressure causes serious damage to the pump.
7.6.2 Pumping medium
As pumping medium HLP-oils acc. DIN 51524 part 2 can be used (other mediums upon
request). The recommended oil purity class, according to ISO standard 4406, is at least
17/15/12.
Any particles in the pumping medium subject the pumps to significantly higher loads which
may cause serious damage to the pump and to the entire hydraulic system, particles
should be eliminated by using filters in the pressurized and the backflow sides.
Caution
If a shut-off valve is installed in the pressurized side of a pipe, then the
safety valve must be located immediately after the outlet of the pump.
Warning
Mechanical friction may cause the pumping medium to absorb heat. Heat
dissipating from the pumping medium may heat up the pump.
With the housing temperature expected to rise above 65°C and without
isolation, the warning sign for hot surfaces (side length 5 cm) must be
attached to the pump.
(Warning sign for hot surfaces see pictogram on the left!)
Additionally, the operator has to install a cooling system for the circulating
medium to prevent the pump from reaching a surface temperature in excess
of 65°C. Otherwise, there is danger of the personnel sustaining burns on the
hands and arms on touching the pump!
Caution
Should there be a danger of the medium freezing, then the operator has to
take measures that will prevent the pump from starting if the medium is
frozen.
If there is any danger of the medium freezing, it has to be completely drained
from the pump. Frozen medium will damage the pump.
If the pumping medium is frozen, do not turn the pump shaft. Always make
sure that the pumping medium has thawed.
Notice
Create enough free space around the pump for maintenance work.
Make sure there is easy access to change filter cartridges and to fill /drain
the pumping medium.

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7.6.3 Cavitation
It should be noted that in bypass circuits a backflow from the high pressure side to the inlet
side is possible. This circuit can cause cavitation problems and thus damage the pump.
The same consequence can occur if the inlet pressure falls below the value stated in
chapter 14, if the inlet shut-off valve is not fully open or closed, if the inlet line is too small
or too long, or if the inlet filter is blocked.
It should also be noted that cavitation problems may occur if the outlet / inlet is below the
inlet.
7.6.4 Drive motor
Couplings may not transmit any axial and radial forces to the pump shaft. Use an elastic
coupling. A fixed coupling will lead to damaged bearings.
Caution
No control valve for the pump may be installed on the suction side.
The suction side must remain completely open during operation.
Notice
The drive motor may only be installed by authorized specialists in
consideration of the local regulations on the installation of pumps.
Let the specialists confirm that the installation was performed and checked in
accordance with the regulations and that the installation is complete and
function tested (or simulated).
To prevent the pump from running dry, we recommend the installation of a
pressure sensor that stops the drive motor when there is no pressure and
prevents it from starting when there is no pressure.
Explosion
-
related
To connect the motor for an ex-protected layout, follow the notices in the EU
type certificate of the motor.

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7.6.5 Main switch / emergency-off from the drive motor
In order to work safely on the pump, a padlockable main switch must be fitted as close as
possible to the pump. This switch is called a "pump switch". It only switches the drive
motor of the pump ON and OFF!
Notice
To interrupt the mains power, we recommend the installation of an
emergency-off switch by the operator. To be most useful, the switch should
be mounted in danger zones or along the escape path.
The EMERGENCY-OFF switch may not be used to start/stop the pump.

19
7.7 Start up
• Please read the safety notices carefully before starting up the pump and pay
attention to the signs and markings on the pump. Keep the signs legible at all times
and replace missing or damaged signs.
• Separate pressure and suction pipes from the system and check their condition.
• Fill the pump with pumping medium by letting the pumping medium flow into the
suction pipe. This can significantly shorten the bleeding time of the pump. Also
switching the drive motor on and off several times accelerates bleeding the pump.
• As long as the medium flows unevenly (possibly with small air bubbles) all pumps
have not yet been bled. If after 30 seconds no medium has been pumped, then the
drive motor has to be stopped at once!
• If after approx. 3 minutes the pump could not be fully bled then check the
connections and pipes for leaks.
• The entire hydraulic system has to be properly rinsed.
• Connect the pressure and suction pipes to the system.
• Check if the desired operating pressure can be attained.
Danger
The pump may not be modified, redesigned or rebuilt in a way that impairs
its safe- ty or function, or the CE-conformity becomes void.
C
aution
Do not switch the power on or off without warning persons in the working
area. Power must be switched on and off synchronized with other system
functions.
N
otice
Only qualified personnel may start up and operate the pump. Personnel
trained and worked in on the system and who are instructed on the safety
aspects of the system are regarded as qualified personnel.
Before starting work, the personnel must have read and understood the
operating manual and the valid regulations regarding «Safety measures».
The pumping medium (or the cleaning agents) can change the composition
of materials, seals and lubricants through mechanical, chemical or physical
influence. The operator must evaluate the risks involved and take
appropriate countermeasures.

20
7.7.1 Trial run
Take note of the following notices for the start up or trial run!
1. Make sure no unauthorized persons are in the vicinity of the hydraulic system.
2. Start the drive motor of the pump and let the pump run for 5 minutes without
pressure. If there is any noise, stop the drive motor of the pump and locate the cause
of the noise (refer to section 12).
3. Observe the starting and running characteristics of the pump over an entire cycle.
4. If no errors occur and the desired pressure can be attained and maintained, then the
pump that has just been started up is ready for operation.
N
otice
Make sure that…
• the operating personnel is familiar with the instructions, settings and
controls,
• the safety and monitoring devices have been tested,
• the person whos responsible for safety has checked that the safety
devices are installed.
• the electrical connections are made and tested and that the pump
rotates in the direction specified.
• there is a lockable main switch connected to the pump.
• all parts are clean and free of foreign particles.
• the pump is assembled to run without vibrations and is mechanically
fused.
• the pump and suction connections are correctly and functionally
connected.
• pressure and suction connections are without tension,
• current (power) is supplied,
• sufficient pumping medium to prevent the pump from running empty,
• the pumping medium is free of particles or that filters are used in the
suction and backflow pipe,
• a safety valve is installed and set to an operating pressure of + approx.
10% above the value,
• no warning and notice signs have been removed.
Caution
Trial runs with water or degreased fluids are not permitted.