Buhler P2.3C Owner's manual

Analysentechnik
Installation and Operation Instructions
Original instructions
Sample gas pumps
P2.3C P2.4C
BE420022
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..........................................................BE420022
Version......................................................................... 04/2017

P2.3C P2.4C
Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended use .........................................................................................................................................................................................................2
1.2 Item number structure...................................................................................................................................................................................... 3
1.3 Type plate ..............................................................................................................................................................................................................4
1.4 Scope of delivery..................................................................................................................................................................................................4
1.5 Product description ............................................................................................................................................................................................4
1.5.1 Construction ..........................................................................................................................................................................................5
2 Safety instructions.........................................................................................................................................................................................................6
2.1 Important advice .................................................................................................................................................................................................6
2.2 General hazard warnings ................................................................................................................................................................................. 7
3 Transport and storage ..................................................................................................................................................................................................9
4 Installation and connection ...................................................................................................................................................................................... 10
4.1 Requirements for the set-up location......................................................................................................................................................... 10
4.1.1 Outdoor installation...........................................................................................................................................................................11
4.2 Installation ........................................................................................................................................................................................................... 11
4.3 Special condition moist sample gas .............................................................................................................................................................11
4.3.1 Alteration of hanging pump bodies ............................................................................................................................................. 12
4.4 Connecting the gas tubes ................................................................................................................................................................................13
4.4.1 Monitoring the sample gas pump................................................................................................................................................. 13
4.5 Electrical connections ...................................................................................................................................................................................... 14
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 plan............................................................................................................................................................................................. 18
6.2 Inspecting the bellow....................................................................................................................................................................................... 18
6.3 Replacing bellow and connecting rod-eccentric-combination............................................................................................................ 19
6.4 Replacement of the O-ring of the bypass valve (optional)................................................................................................................... 20
6.5 Replacing the inlet and outlet valves .......................................................................................................................................................... 21
6.6 Cleaning the pump console ........................................................................................................................................................................... 21
6.7 Changing the Coupling....................................................................................................................................................................................22
7 Service and repair......................................................................................................................................................................................................... 23
7.1 Troubleshooting and fault rectification.....................................................................................................................................................23
7.2 Spare parts and accessories ...........................................................................................................................................................................24
8 Disposal........................................................................................................................................................................................................................... 25
9 Appendices.....................................................................................................................................................................................................................26
9.1 General specifications for all pumps...........................................................................................................................................................26
9.2 Technical data for P2.3C and P2.4C ..............................................................................................................................................................26
9.3 Temperature classes for P2.3C and P2.4C...................................................................................................................................................26
9.4 Dimensions P2.3C .............................................................................................................................................................................................. 27
9.5 Dimensions P2.4C.............................................................................................................................................................................................. 27
9.6 List of chemical resistance..............................................................................................................................................................................28
9.7 User book (Please make copies) ....................................................................................................................................................................29
10 Attached documents...................................................................................................................................................................................................30
iBühler Technologies GmbHBE420022 ◦ 04/2017

P2.3C P2.4C
1 Introduction
1.1 Intended use
Sample gas pumps are intended for installation in gas analysis systems for industrial applications.
DANGER Danger of explosion if used in a potentially explosive atmosphere
Sample gas pumps of types P2.3C and P2.4C are not suitable for use in potentially explos-
ive atmospheres and must not be placed in them.
The complete designation of the P2.3C and P2.4C sample gas pumps is:
II 3G/- c IIB T4 X
The P2.3 C and P2.4C sample gas pumps may only be used to convey explosion class IIA and IIB flammable gaseous media which
are not explosive during normal operation, as well as non-flammable gaseous media.
The maximum surface temperature varies by the medium and ambient temperatures. Please refer to the data sheets for the
correlation between media temperature, ambient temperature and the pump’s temperature class. Flammable mediums must
not be heated beyond these values. Please note, flammable gas must only be heated up to 80 % of its ignition temperature. The
lower of the two values is the maximum medium temperature.
Gas sampling is generally prohibited if the gas flow results in a dangerous electrostatic charge in the bellow / pump body (also
see chapter "Operation and Control").
The sample gas pumps are only intended to convey gaseous media. They are not suitable for liquids.
Please note the additional information in chapter "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 for the set-up location [>
page10]
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1.2 Item number structure
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
52 P2.3C 400 L/h (II 3G/- c IIB T4 X)
53 P2.4C 400 L/h (II 3G/- c IIB T4 X)
Motor voltage
1 230 V 50/60 Hz. 0.85/0.8 A
2 115 V 50/60 Hz. 1.7/1.6 A
5 400 V 50/60 Hz. 0.5/0.43 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 160°C; PTFE / PEEK
Screw-in connections (for 230 V and 400 V voltage)
PTFE Pump body Stainless steel pump body
9 DN 4/6 (Standard) 6 mm (Standard)
1 DN 6/8 8 mm
2 3/8"-1/4" 3/8"
3 1/4"-1/8"
4 1/4"-1/6” 1/4"
Screw-in connections (for 115 V voltage)
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 applicable to 2.4C
If there are special instructions for a pump type, they are marked in the manual.
Take care of the limits of the pump. When ordering spare parts chose for the type matching part numbers (e.g. valves).
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1.3 Type plate
Example:
Sample gas pump P2.3C
1000300216 4252111199000 001
II 3G/- c IIB T4 X File Ref.: 4694
Voltage: 230 V 50/60 Hz
Material: PTFE/PEEK/1.4571/1.4401/Viton
Medium max: see manual; Tamb: see manual
Year: 2015
Manufacturer's address
Type description
Order-no., position and part-no.
Type of protection
Power supply / tech. file ref.
Temperature
Year of construction
1.4 Scope of delivery
P2.3C P2.4C
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
The P2.xC pumps can pump non-flammable gaseous media and flammable gaseous me-
dia that are probably not explosive in normal operation (sampling from zone 2).
Sampling gas from zone 2 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 P2.xC pumps must not be operated in dusty areas.
The operating material is not suitable for use in a potentially explosive atmosphere!
In the P2.4C sample gas pumps, the pump head and the drive motor are separated from each other for use in hot applications.
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.
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1.5.1 Construction
P2.3C
Screw-in connection
Motor
Bypass valve (option)
ON OFF
M20x1.5
Pump head Assembly bracket with
rubber-metal bumpers
Pump
console
Pump body
P2.4C
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
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2.2 General hazard warnings
Installation into a complete system can pose new hazards on which the manufacturer of this sample gas pump has no bearing.
If necessary, perform a risk assessment of the complete system this product will be installed into.
When configuring and building the complete system the relevant national safety regulations for the installation site and the
generally applicable state of the art must be observed. These can be determined through applicable harmonised standards,
among other things, e.g. IEC 60079-14. Additional national regulations pertaining to initial operation, operation, maintenance,
repairs and disposal must be observed.
When conveying flammable gasses, avoid potential exothermic reactions in your system, do not use materials with a catalytic
effect in the conveyor lines. Dangerous rises in temperature could result. Sample gas pump materials in contact with media are
listed 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 with improper exceeding of the operating parameters. Conveying flammable gasses then pose an explosion hazard.
Avoid these dangerous circumstances. If necessary, the complete system should be secured against flashback. Follow these no-
tices and the applicable national regulations, prevent malfunctions to avoid personal injury and property damage.
The operator of the system must ensure:
– The equipment is only installed by a professional familiar with the safety requirements and risks,
– Safety notices and operating instructions are available and observed,
– The permissible data and operating conditions are observed,
– Protective devices are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal.
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.
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DANGER Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive at-
mospheres.
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.
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, take spe-
cial attention to the media temperature with respect to temperature class T4. These vary
in addition to gas composition and ambient conditions. Where necessary, the operator
must install temperature sensors for monitoring and must automatically shut down the
sample gas pump should the temperature exceed the limits.
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 chapter “Technical data”.
Observe maximum temperature classes T4 for the pumps and the allowed ambient tem-
peratures and medium temperatures.
DANGER Danger of explosion due to exothermic reactions
Avoid catalytic materials in the conveyor pipelines and other materials, e.g. male stud
couplers, connecting to the sample gas pump.
Depending on the particular medium conveyed (e.g. ethylene oxide), a polymerisation of
the medium may occur. Heat build-ups are possible and constitute an ignition source. If
necessary, for clarification consult a technical department that possesses sufficient
chemical expertise.
DANGER Explosion hazard
Flammable media fed into the pump may only be heated to a maximum of 80 % of their
respective ignition temperature.
CAUTION Tilting risk
Damage of the device
Secure the device against any sudden translocation during maintenance.
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.
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 for the set-up location
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.
The ventilation must be unobstructed and the exhaust air – and from the adjacent units as well – must not be directly re-
siphoned.
The motor is rated for ambient temperatures between -20°C and +50°C and for installation altitudes ≤ 1000 m above sea level.
If installed without the mounting bracket, there must be sufficient spacing between the motor and the rear wall. The further en-
vironmental parameters for the set-up location can be found in the data sheet at the end of the operating and installation in-
structions.
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.
P2.3C
During the installation of the P2.3C 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 motor base can be found in
the data sheets at the end of the operating and installation instructions.
P2.4C
For the installation of the P2.4C sample gas pump, please consult the 42/011-14-3 assembly drawing. The sample gas pump
should be checked for its completeness before beginning installation. 6xM6 screws with nuts of the appropriate 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.
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
For the sample gas pump, a switch and a circuit breaker (in accordance with the authorisation) is to be provided. This must be
organised to be easily accessible for the operator. The switch must be labelled as an isolating device for the unit. It must not be
inserted into a mains power line or interrupt the protective conductor. Furthermore, the switch must separate the sample gas
pump from the live parts for all the poles.
The sample gas pump must be secured against unacceptable excessive warming by using a suitable overload protection (motor
protection circuit breaker).
Observe the rated current for the setting of the circuit breaker (see the motor identification plate).
Attach the pump in accordance with the circuit diagram on the terminal box housing cover and ensure that the strain relief for
the connection line is sufficient. When doing this, ensure that the pump motor has the correct voltage and frequency (voltage
tolerance ± 5 % and frequency tolerance ±2%).
The supply line and earthing cross sections must be adapted to the rated current.
Use at least a wire cross-section of 1.5mm2.
Connect the circuit breaker of the motor to the local protective conductor.
Connect the protective conductor in accordance with DIN VDE 0100 without fail to the marked protective conductor terminal.
There must be no foreign objects, dirt or humidity in the terminal box. Close unneeded cable inlet openings and seal the box it-
self against water and dust. Use the original seal when closing the terminal box.
Unused openings must be closed with approved stoppers.
Observe without fail any different information on the identification plate. The conditions at the operation site must correspond
to all the ratings plate information.
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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, take spe-
cial attention to the media temperature with respect to temperature class T4. These vary
in addition to gas composition and ambient conditions. Where necessary, the operator
must install temperature sensors for monitoring and must automatically shut down the
sample gas pump should the temperature exceed the limits.
DANGER Dangerous electro-static charge (danger of explosion)
During the pumping of, for instance, very dry gases or gases contaminated with particu-
late matter, potentially incendiary electro-static charges could build up in the bellow /
pump body.
Provide the pump with a particle filtration with a suitable filter unit placed before the
pump gas inlet.
The extraction of explosive gaseous media (max. zone 2) with the pumps is not permit-
ted if the gas flow leads to a potentially incendiary electro-static charge in the bellow /
pump body (projected surface area in bellow / pump body ~ 15 cm2).
DANGER Explosion hazard
Flammable media fed into the pump may only be heated to a maximum of 80 % of their
respective ignition temperature.
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 in continuous operation, a bypass is available,
– 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 (P2.4C only) 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 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. In the event of throttling under 150 l/h in continuous
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 cooled state.
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.
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.
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 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.
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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.
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.
6.1 Maintenance plan
Component Interval Work to be carried out To be carried out by
Screws of the pump body After 500 h Tighten the screws to 3 Nm Customer
Entire pump Every 500 h Inspect hose connections, protective and control
devices, for correct functioning, contamination,
leakages.
In the event of any damage, replace and/or have
it repaired by Bühler Technologies.
Customer
Entire pump Every 8,000 h or in the event of
heavy soiling
Cleaning of the entire pump,
see “Cleaning the pump console”.
Customer
Valves Every 8,000 h or in the event of
pressure drop
Inspect the valves, replace if necessary,
see “Replacing the inlet and outlet valves”.
Customer
Bellow Every 4,000 h or six months Inspect by shutting off the suction line. Repair
any damage;
see “Inspecting the bellow”.
Customer
Replace the bellow after two years;
see “Inspecting the bellow”.
Customer
Wear parts that come
into contact with media
After 43,800 hours or five years
from the date of manufacture
Replace all parts subject to wear that come into
contact with media such as valves, the bellow,
the O-ring of the bypass valve
Customer
6.2 Inspecting the bellow
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.
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