DÖRR EcoPump AD User manual

MPU00013EN, V05
N24140011
www.durr.com
EcoPump AD
Air Operated Diaphragm Pump
Operation manual

MPU00013EN, V05
Translation of the original operation manual
© Dürr Systems AG 2015
Dürr Systems AG
Application Technology
Carl-Benz-Str. 34
74321 Bietigheim-Bissingen
Germany
Phone: [phone]
Internet: www.durr.com
The reproduction and distribution of this document, use and communication of its contents are not permitted
without express written approval. Offenders will be liable for damages. All rights reserved in the event of the
grant of a patent or utility model.
01/2020EcoPump AD - MPU00013EN
2/36

Information about the document
This document describes the correct handling of
the product.
Read the document prior to every activity.
Prepare the document for the application.
Pass on the product only together with the com-
plete documentation.
Always follow safety instructions, handling
instructions and specifications of every kind.
Illustrations can deviate from the technical con-
struction.
Validity range of the document
The scope of the document is as follows:
N24140011
EcoPump AD 2420 8 SST 1 1/2"
Hotline and Contact
If you have queries or would like technical informa-
tion, please contact your dealer or sales partner.
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TABLE OF CONTENTS
1 Product overview...................................... 5
1.1 Overview............................................. 5
1.2 Short description................................. 5
2 Safety.......................................................... 5
2.1 Presentation of Notes.......................... 5
2.2 Intended Use....................................... 5
2.3 Residual risks...................................... 6
2.4 Conduct in the event of a hazardous
situation............................................... 6
2.5 Staff qualification................................. 6
2.6 Personal protective equipment............ 7
3 Design and Function................................. 7
3.1 Design................................................. 7
3.2 Operation............................................. 8
4 Transport, scope of supply and
storage....................................................... 9
4.1 Transport............................................. 9
4.2 Unpacking........................................... 9
4.3 Scope of delivery................................. 9
4.4 Storage................................................ 9
5 Assembly................................................... 9
5.1 Requirements for the
Installation point.................................. 9
5.2 Assembly........................................... 10
5.3 Assembling ground conductor........... 10
5.4 Connecting........................................ 11
6 Commissioning....................................... 12
6.1 Safety recommendations................... 12
6.2 Preparing for commissioning............. 13
6.3 Setting operating parameters ........... 13
7Operation................................................. 13
7.1 Safety recommendations................... 13
7.2 General notes.................................... 14
7.3 Starting Operations........................... 14
7.4 Rinsing.............................................. 14
7.4.1 Safety recommendations................ 14
7.4.2 Flush the pump............................... 14
8 Cleaning................................................... 15
8.1 Safety recommendations .................. 15
8.2 Cleaning............................................ 15
9 Maintenance............................................. 15
9.1 Safety recommendations................... 15
9.2 Maintenance schedule...................... 16
9.3 Dismantle and assemble................... 16
9.3.1 General notes................................. 16
9.3.2 Dismantle inlet and outlet mani-
fold.................................................. 17
9.3.3 Dismantle material assembly.......... 17
9.3.4 Dismantle pneumatic assembly...... 18
9.3.5 Assemble pneumatic assembly...... 19
9.3.6 Assemble material assembly.......... 21
9.3.7 Assemble inlet and outlet mani-
folds................................................ 21
10 Faults........................................................ 23
10.1 Defects table................................... 23
11 Disassembly and Disposal..................... 26
11.1 Disassembly.................................... 26
11.2 Disposal .......................................... 28
12 Technical data.......................................... 28
12.1 Dimensions and weight................... 28
12.2 Connections.................................... 28
12.3 Operating conditions....................... 28
12.4 Operating values............................. 28
12.5 Compressed air quality.................... 29
12.6 Type plate........................................ 29
12.7 Operating and auxiliary materials.... 29
12.8 Materials used................................. 29
12.9 Tightening torques........................... 30
12.10 Characteristic curve of the outflow
rate.................................................. 30
13 Replacement parts, tools and accesso-
ries............................................................ 30
13.1 Replacement parts.......................... 30
13.2 Tools................................................ 31
13.3 Accessories..................................... 31
13.4 Order............................................... 31
14 Index......................................................... 32
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1 Product overview
1.1 Overview
Fig. 1: Overview
1 Type plate
2 Pressure side connection for material supply
3 Material assembly
4 Pneumatic assembly
5 Compressed air connection
6 Suction side connection for material supply
7 Mounting feet
1.2 Short description
The double diaphragm pump with pneumatic
actuator (from here on “pump") is an air operated
positive displacement pump. The pump is used to
pump low- to medium-viscosity liquids (flammable
and non-flammable coating materials) in industrial
coating of surfaces.
2 Safety
2.1 Presentation of Notes
The following notes can appear in this instruction:
DANGER!
High risk situation that can lead to serious inju-
ries or death.
WARNING!
Medium risk situation that can lead to serious
injuries or death.
CAUTION!
Low risk situations that can lead to minor injuries.
NOTICE!
Situations that can lead to material damage.
ENVIRONMENT!
Situations that can lead to environmental
damage.
Additional information and recommenda-
tions.
2.2 Intended Use
Use
The EcoPump AD is solely intended for pumping
low- to medium-viscosity fluids of the fluid group 1
according to the Pressure Devices Directive.
The EcoPump AD is intended for use in industry
and trade only.
The EcoPump AD may be used under the fol-
lowing conditions:
in explosive areas of Ex zones 1 and 2
in non-explosive areas
with flammable fluid coating materials of the
Explosion group IIA
with non-flammable fluid coating materials
Only use the pump within the approved operating
conditions Ä 12 “Technical data”.
Misuse
If used improperly, it can cause serious injuries.
Examples of wrong use are:
Use in areas with Ex zone 0
Use of unapproved materials, see safety data
sheets
Making conversions or changes on your own
Use of pumps as a support for the pipe system
Ex labeling
II 2G Ex h IIA T4 Gb X
Product overview
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II - Device group II: all areas except mining
2G - Device category 2 for gaseous ex-atmos-
phere
Ex h - Ignition protection category for non-elec-
trical devices
IIA - Explosion group
T4 - Temperature class
Gb - Device protection level: Zone 1
X - Restriction: The device is configured for
operation in an ambient temperature of
15°C to 40°C.
2.3 Residual risks
Explosion danger
Pumps with conductive Acetal parts in contact with
media may not be used with acids and lyes. Reac-
tion and explosion of these materials can cause
serious injury or death. Reaction and explosion of
these materials can cause serious injury or death.
Pump motor section
Fluid caps
Distributor
Parts in contact with material
Sparks due to electrostatic discharge
If the pump is not properly grounded or the poten-
tial equalization fails, components may get
charged electrostatically. Electrostatic discharge
can cause sparks that in explosive atmosphere
can cause a fire or an explosion. Serious injury
and death could be the consequence.
Ground Pump as specified.
Check connection of grounding cable during
operation.
Measure volume resistivity.
Media
Material escaping under pressure can cause
serious injuries.
Before working on the product:
Disconnect the system, in which the product is
installed, from compressed air and material
supply.
Depressurize the lines.
Secure the system against being switched on
again.
Observe approved operating pressures Ä 12.4
“Operating values”.
2.4 Conduct in the event of a hazardous
situation
Conduct in case of danger depends on the opera-
tor’s installation situation.
Perform the following activities:
Close lines.
Secure against reconnection.
Depressurize lines.
2.5 Staff qualification
WARNING!
Inadequate qualification
Wrong estimation of dangers can cause serious
injury or death.
– Only sufficiently qualified persons may exe-
cute all work.
– Some work requires additional qualification.
Additional qualifications of specialized per-
sonnel are marked with a “+”.
This document is intended for qualified personnel
in industry and craftmanship.
Cleaning staff
The cleaning staff receives regular instructions
from the operator about the following contents:
Using the product
Handling cleaning tools
Handling cleaning agents
Technical Measures for occupational safety and
health
Electrician
Electricians assemble, install, service and repair
electrical systems in a professional manner.
Furthermore, electrical engineers have the fol-
lowing knowledge:
Guidelines, Standards and Rules of Engi-
neering
Local conditions
Electrical Systems and Their Loading Limits
Technical Measures for occupational safety and
health
Mechanic
The mechanic is trained specifically for the field of
work in which he works.
Furthermore, he has the following knowledge:
Guidelines, Standards and Rules of Engi-
neering
Local conditions
Technical Measures for occupational safety and
health
Safety
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The mechanic is responsible for the following activ-
ities on equipment and components:
Assembly
Waiting
Maintenance
Disassembly
+ additional qualification explosion protection
In addition to the knowledge of the various spe-
cialist fields, the mechanic has knowledge of regu-
lations and safety measures when working in
potentially explosive areas.
Dürr Systems offers special product training for
Ä “Hotline and Contact”.
2.6 Personal protective equipment
When working in explosive areas, the protective
clothing, including gloves, must meet the require-
ments of DIN EN 1149-5. Footwear must meet the
requirements of EN ISO 20344 and EN IEC
61340-4-3. The volume resistivity must not exceed
100MΩ.
Wear the specified personal protective equipment
when working. Provide the following personal pro-
tective equipment:
Anti-Static Safety Boots
Protect feet from crushing, falling items
and slipping on slippery ground.
Moreover, anti-static safety boots reduce
electrostatic charge by discharging the
electrostatic charges.
Eye protection
Protects eyes from dust, paint drops and
particles.
Protective gloves
Protect the hands from:
mechanical forces
Thermal forces
Chemical effects
Protective workwear
Tight fitting workwear with low tear
strength, tight sleeves and no hanging
parts.
Respirator mask
Protects from hazardous gases, vapors,
dust and similar materials and media.
Use ear protection
Protects from auditory damage due to
noise.
3 Design and Function
3.1 Design
EcoPump AD main assemblies:
Pneumatic assembly (compressed air)
Material assembly
Inlet and outlet manifold
Pneumatic assembly (compressed air)
Fig. 2: Pneumatic assembly - Front view
Design and Function
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Fig. 3: Pneumatic assembly - Rear view
Material assembly
Fig. 4: Material assembly
Inlet and outlet manifold
Fig. 5: Inlet and outlet manifold
1 Outlet manifold for material supply on pressure
side
2 Inlet manifold for material supply on suction
side
3.2 Operation
The pump has an air-driven dual diaphragm that
sends a differential pressure to the air chambers.
In this way the material chambers can be suc-
tioned up and emptied alternately. Ball valves pre-
vent a return flow of the medium.
The pump starts as soon as compressed air is sup-
plied. The pumping process adjusts to the respec-
tive demand. This builds up pressure and keeps it
steady. The flow is stopped when the maximum
tube pressure is reached. After this, the pumping
process is restarted as necessary.
Design and Function
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4 Transport, scope of supply and
storage
4.1 Transport
WARNING!
Raising heavy loads
Raising heavy loads without suitable hoist and
stopper material can cause major injuries.
– Transport heavy loads only by using suitable
hoists and stoppers.
WARNING!
Hovering load
Hovering loads can fall down and cause serious
injuries or death.
– Do not enter the area below hovering loads.
– Wear specified protective equipment.
– Only use approved hoists and stoppers.
– Ensure that the hoists and stoppers have
adequate bearing capacity.
NOTICE!
Incorrect Transport
Improper transportation of the pump may cause
the agitator the pumpto fall and suffer damage.
– Protect Pump from moisture.
– Protect Pump from vibrations.
– Use transport locks (e. g. against slipping).
Permissible ambient temperature during the
transportation for a few hours:
-40°C to 60°C
4.2 Unpacking
DANGER!
Electrostatically charged plastic films and
foils in potentially explosive areas
The foil can charge electrostatically at the time of
unpacking. Electrostatic discharge can cause
sparks that in explosive atmosphere can cause a
fire or an explosion. Serious injury and death
could be the consequence.
– Unpack product outside Ex zones.
1. Check the pump packaging for damage. If there
is any damage, notify the customer service
immediately Ä “Hotline and Contact”.
2. Remove packing film.
3. Dispose of the packaging professionally.
4. Check pump for damage.
5. Transport pump and muffler to the assembly
location without packaging film.
4.3 Scope of delivery
The scope of supply only includes the pump.
Personnel:
Mechanic
Protective equipment:
Protective gloves
Protective workwear
Anti-Static Safety Boots
1. Check the pump for integrity on receiving it.
2. Report defects immediately Ä “Hotline and
Contact”.
4.4 Storage
Ambient Conditions
NOTICE!
Damage from improper storage
High load stresses o the packaging can damage
the product.
– Do not stack the packaging.
Observe the following environmental conditions for
the storage of the pump:
Temperature: 10-40°C
Humidity: 35 % – 90 %
Protection from direct sunlight
Protection from cold
Protection from vibration
Protection from dust and dirt
Do not store outdoors.
Store in a dry and dust-free place.
Do not expose to aggressive media.
Storage of Replacement Parts
The same storage provision as for the pump apply
to the replacement parts.
5 Assembly
5.1 Requirements for the Installation point.
Protect pump from vibration damage:
Erect mounting feet for the pump on horizontal
ground.
Transport, scope of supply and storage
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5.2 Assembly
If air containing a lubricant is present in the
equipment, the air must be compatible with
O-rings and seals in the compressed air part
of the pump .
Ä 12.5 “Compressed air quality”
Personnel:
Mechanic
Protective equipment:
Protective gloves
Anti-Static Safety Boots
NOTICE!
Material damage due to improper assembly
Installing the pump in an incorrect installation
position will damage the pump.
– Store the pump in an upright position only.
Fig. 6: Assemble the sound muffler
Assemble the sound muffler (2) on the pneumatic
assembly, using the elbow piece (1).
Fig. 7: Assemble pump
Mount the pump on the mounting feet (1) using 4
screws. The recesses (2) for the screws are on the
front and back of the pump.
5.3 Assembling ground conductor
WARNING!
Sparks due to electrostatic discharge
If the pump is not grounded, there can be an
electrostatic charge on the the pump. Electro-
static discharge can cause sparks that in explo-
sive atmosphere can cause a fire or an explo-
sion. Serious injury and death could be the
consequence.
– Ground Pump as specified.
– Before carrying out any work, make sure that
there is no explosive atmosphere.
Assembly
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Fig. 8: Connecting Ground
Personnel:
Electrician
+ additional qualification explosion protection
Protective equipment:
Protective workwear
Protective gloves
Anti-Static Safety Boots
1. Assemble ground conductor on the ground con-
nection (1).
2. Measure grounding resistance.
5.4 Connecting
Connecting material supply
Fig. 9: Material supply connection
Personnel:
Mechanic
Protective equipment:
Eye protection
Protective gloves
Anti-Static Safety Boots
1. Connect the pressure side material supply
system (1).
2. Connect the suction side material supply
system (2).
Connect compressed air supply
WARNING!
Excessive control air pressure
Excessive control air pressure can damage the
pump. Serious injuries and death can be the con-
sequence.
– Do not exceed the control air pressure
Ä 12.4 “Operating values”.
Assembly
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Fig. 10: Compressed air connection
Personnel:
Mechanic
Protective equipment:
Eye protection
Protective gloves
Anti-Static Safety Boots
1. Install a filter in the air supply line.
ðThe filter must filter out particles above 50
µm.
2. Connect compressed air hose to the com-
pressed air connection (1).
6 Commissioning
6.1 Safety recommendations
WARNING!
Excessive input pressure
Charging the pump with excessive input pressure
will damage the pump. Serious injuries and death
can be the consequence.
– Charge the pump with low pressure at the
time of commissioning.
– Before increasing the pressure, check that
hoses and connections are seated tightly.
– Increase pressure gradually, until the max-
imum input pressure is reached.
– Do not exceed maximum input pressure.
Ä 12.4 “Operating values”.
WARNING!
Sparks due to electrostatic discharge
If the pump is not grounded, there can be an
electrostatic charge on the the pump. Electro-
static discharge can cause sparks that in explo-
sive atmosphere can cause a fire or an explo-
sion. Serious injury and death could be the
consequence.
– Ground Pump as specified.
– Before carrying out any work, make sure that
there is no explosive atmosphere.
WARNING!
Escaping material
Escaping compressed material can cause
serious injury.
Before commissioning:
– Check ball valve for functioning.
WARNING!
Danger from harmful or irritant substances
Serious injuries or death can result if you come
into contact with dangerous fluids or steam.
– Pump Check regularly for leakage. Observe
local regulations and maintenance schedule.
– Ensure that the forced ventilation is opera-
tional.
– Follow the safety data sheet.
– Wear specified protective clothing.
– Avoid contact (e.g. with eyes, skin).
Commissioning
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WARNING!
Unsuitable tools in explosive areas
Tools that do not have Ex approval can generate
sparks and cause a fire or an explosion in Ex
zones. It can cause serious injuries or death.
– If possible, carry out cleaning and mainte-
nance work outside the Ex zones.
– For work within the Ex zone, use tools with
the corresponding Ex labeling.
6.2 Preparing for commissioning
Personnel:
Mechanic
Protective equipment:
Protective gloves
Anti-Static Safety Boots
Carry out the following checks for the operation:
Check grounding connection of the pump.
Ambient temperature
Relative humidity
Compressed air connection is flexible and con-
ductive.
Connections of the suction and pressure line
are designed to be conductive.
The connection of the suction and pressure line
must be flexible to equalize vibrations of the
pump. Connections must not be made using
tubes and must be compatible with the material
to be pumped.
Connected media lines and connections are
sealed.
Check all screw connections with a torque
wrench.
Ä 12.9 “Tightening torques”
6.3 Setting operating parameters
Personnel:
Mechanic
Protective equipment:
Protective gloves
Anti-Static Safety Boots
Input pressures of the media supplied via the
tube system are within the required ranges
Ä 12.4 “Operating values”.
7 Operation
7.1 Safety recommendations
WARNING!
Hot surfaces
In operation, the surfaces of the product can heat
intensely. Contact can cause burn injuries.
– Wear protective hand gloves.
WARNING!
Danger from noise
Disconnecting pressurized pneumatic lines cre-
ates loud noises. This might damage the hearing.
Before carrying out any work:
– Depressurize pneumatic lines. Secure against
reconnection.
– Wear ear protection.
WARNING!
Danger of explosion due to sources of igni-
tion in an explosive atmosphere.
Sparks, open flames and hot surfaces can cause
explosions in explosive atmospheres. Serious
injury and death could be the consequence.
– Do not use any sources of ignition and no
open light in the work area.
– Ensure that the forced ventilation is opera-
tional.
– Do not smoke.
– Ground Pump.
– Wear suitable protective equipment.
WARNING!
Danger of fire and explosion
Flammable coating materials and their deter-
gents and cleaning agents can cause a fire or an
explosion.
– Ensure that the flashpoint of the fluid is at
least 15 K above the ambient temperature.
– Note explosion group of the fluid.
– Follow the safety data sheet.
– Ensure that forced ventilation and fire protec-
tion equipment are in operation.
– Do not use sources of ignition and open light.
– Do not smoke.
– Check grounding.
Operation
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WARNING!
Risk of injury due to escaping material and
compressed air
Escaping compressed material can cause
serious injury.
Before carrying out any work:
– Disconnect the system, in which the pump is
installed, from compressed air and material
supply.
– Secure the system against being switched on
again.
– Depressurize the lines.
7.2 General notes
Personnel:
Mechanic
Protective equipment:
Protective gloves
Anti-Static Safety Boots
Check state of the pump.
If pump temperature and vibrations are too
high:
Switch off pump.
Service and repair pump Ä 10 “Faults”.
Clean the pump surface to prevent dust deposi-
tion Ä 8.2 “Cleaning”.
Other checks Ä 6.3 “Setting operating parame-
ters ”.
7.3 Starting Operations
Personnel:
Mechanic
Protective equipment:
Protective gloves
1. Turn pressure regulator control knob until pump
motor starts.
2. Leave pump running slowly until material is
sucked in and air is expelled from hose and
outlet valve.
3. Close the outlet valve.
4. Stop the pump by putting on maximum load.
5. Check connections for leaks.
6. Adjust pressure regulator as required to ach-
ieve desired operating pressure and flow rate.
7.4 Rinsing
7.4.1 Safety recommendations
NOTICE!
Material damage due to unsuitable rinsing
agent
If the rinsing agent reacts chemically with the
components or the material, components get
damaged.
– Use only the rinsing agents that are compat-
ible with the components and the material.
– Refer to safety data sheet of material manu-
facturer.
7.4.2 Flush the pump.
Personnel:
Mechanic
+ additional qualification explosion protection
Protective equipment:
Eye protection
Protective gloves
Protective workwear
Respirator mask
Use ear protection
Anti-Static Safety Boots
Complete the following steps if the pump is not in
operation for a longish period:
Purge pump with a suitable detergent Ä 12.7
“Operating and auxiliary materials”.
Disconnect compressed air supply to pump.
Operation
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8 Cleaning
8.1 Safety recommendations
WARNING!
Danger of fire and explosion
Flammable coating materials and their deter-
gents and cleaning agents can cause a fire or an
explosion.
– Ensure that the flashpoint of the fluid is at
least 15K above the ambient temperature.
– Only electrically conductive containers may
be used for the cleaning fluid. Containers
must be grounded.
– Note explosion group of the fluid.
– Follow the safety data sheet.
– Ensure that forced ventilation and fire protec-
tion equipment are in operation.
– Do not use sources of ignition and open light.
– Do not smoke.
– Ground Pump.
WARNING!
Danger of fire and explosion
Sources of ignition in explosive atmosphere can
cause a fire or an explosion. Serious injuries and
death can be the consequence.
– Before carrying out any cleaning and mainte-
nance work, ensure there is no explosive
atmosphere.
WARNING!
Danger from harmful or irritant substances
Serious injuries or death can result if you come
into contact with dangerous fluids or steam.
– Pump Check regularly for leakage. Observe
local regulations and maintenance schedule.
– Ensure that the forced ventilation is opera-
tional.
– Follow the safety data sheet.
– Wear specified protective clothing.
– Avoid contact (e.g. with eyes, skin).
NOTICE!
Unsuitable cleaning agents
Unsuitable detergents can cause material
damage.
– Only use cleaning agents approved by the
material manufacturer.
– Follow safety data sheets.
NOTICE!
Unsuitable Cleaning Tools
Unsuitable cleaning tools can cause damage.
– Only use cloths, soft brushes and paint-
brushes.
– Do not use abrasive cleaning tools.
– Do not use compressed air for cleaning.
– Do not use any thinner spray guns.
– Do not use high pressure for cleaning agents.
8.2 Cleaning
Personnel:
Cleaning staff
Protective equipment:
Eye protection
Protective gloves
Protective workwear
Respirator mask
1. Purge the pump Ä 7.4 “Rinsing”.
2. Clean pump carefully Ä 12.7 “Operating and
auxiliary materials”.
9 Maintenance
9.1 Safety recommendations
WARNING!
Danger of fire and explosion
Sources of ignition in explosive atmosphere can
cause a fire or an explosion. Serious injuries and
death can be the consequence.
– Before carrying out any cleaning and mainte-
nance work, ensure there is no explosive
atmosphere.
Cleaning
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WARNING!
Unsuitable replacement parts in explosive
areas
Replacement parts not compliant with the speci-
fications of the ATEX guidelines can cause
explosions in an explosive atmosphere. Serious
injury and death could be the consequence.
– Use exclusively original replacement parts.
WARNING!
Danger from poisonous aerosols
When the diaphragm is defective, a mixture of
paint, solvent and air is leaking from the muffler.
– Wear respiratory protection when working on
the diaphragm.
– Carry out larger work on the pump at a suit-
able work station in the workshop.
WARNING!
Risk of injury due to escaping material and
compressed air
Escaping compressed material can cause
serious injury.
Before carrying out any work:
– Disconnect the system, in which the pump is
installed, from compressed air and material
supply.
– Secure the system against being switched on
again.
– Depressurize the lines.
9.2 Maintenance schedule
The maintenance intervals given below are based on experiential values. Adjust maintenance intervals.
If a maintenance assistant is used in the system visualizer, the maintenance intervals of the mainte-
nance assistant are valid.
Interval Maintenance work
Daily Check cleanliness.
Check tightness.
Ä 9.3.3 “Dismantle material assembly.”
Ä 9.3.4 “Dismantle pneumatic assembly”
Check connections on all hoses and lines.
Weekly Check noise generation.
Check for steady delivery pressure.
9.3 Dismantle and assemble
9.3.1 General notes
NOTICE!
Danger of leakages
Used or incorrectly installed seals can lead to
leakage at the valve.
– Use only new seals.
– Do not twist seals when inserting them.
NOTICE!
Installation of used wear parts
Used wear parts can no longer withstand the
loads during operation. Installing used wear parts
can cause irreparable damage to the product.
– Assemble only new parts.
Maintenance
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9.3.2 Dismantle inlet and outlet manifold
Removing the outlet manifold
Fig. 11: Central body with outlet manifold
Personnel:
Mechanic
Protective equipment:
Eye protection
Protective gloves
Anti-Static Safety Boots
Requirements:
Pump is properly disassembled. Ä 11.1 “Disas-
sembly”
1. Remove 4 screws (4) from outlet manifold (5).
2. Remove outlet manifold (5).
3. Remove 2 balls (3), 2 O-rings (2) and 2 ball
seats (1).
Installing the inlet manifold
Fig. 12: Central body with inlet manifold
Personnel:
Mechanic
Protective equipment:
Eye protection
Protective gloves
Anti-Static Safety Boots
Requirements:
Pump is properly disassembled. Ä 11.1 “Disas-
sembly”
1. Remove 4 screws (4) from outlet manifold (5).
2. Remove outlet manifold (5).
3. Remove 2 balls (1), 2 O-rings (2) and 2 ball
seats (3).
9.3.3 Dismantle material assembly.
Remove material cover and membrane.
Fig. 13: Material cover and membrane
Personnel:
Mechanic
Protective equipment:
Eye protection
Protective gloves
Anti-Static Safety Boots
Requirements:
Inlet and outlet manifold are dismantled.
1. Remove 10 screws (10) and 10 nuts (2) on
material cover (11).
2. Remove material cover (11).
3. Remove membrane screw (12).
Maintenance
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4. Remove washer (13) and O-ring (14).
5. Remove washer (9).
6. Remove membrane (8) (PTFE models only).
7. Remove membrane (7).
8. Remove washer (6).
Do not damage the surface of the dia-
phragm rod.
9. Remove O-ring (5) and membrane rod (3) from
central body (1).
10. Remove O-ring (4) from diaphragm rod (3).
11. Repeat all steps for the removal of the material
cover and membrane on the left side.
9.3.4 Dismantle pneumatic assembly
Dismantling the main valve
Fig. 14: Main valve with central body
Personnel:
Mechanic
Protective equipment:
Eye protection
Protective gloves
Anti-Static Safety Boots
Requirements:
Material assembly is dismantled.
1. Remove 4 screws (2), 4 washers (3) from cover
plates (4).
2. Remove 2 cover plates (4) and 2 seals (5).
3. Push piston (6) towards control piston (14).
4. Remove piston (6) and control piston (14) from
central body (15).
5. Remove U-cap (1) from piston (6).
6. Remove spacers (12, 13).
7. Remove O-rings (10, 11) and washers (9).
8. Remove 3 screws (7) and grounding lug (8).
9. Remove sound muffler (16) and elbow piece
(17).
10. Remove thread (18).
Maintenance
01/2020EcoPump AD - MPU00013EN18/36

Dismantle control valve
Fig. 15: Control valve with central body
Personnel:
Mechanic
Protective equipment:
Eye protection
Protective gloves
Anti-Static Safety Boots
Requirements:
Material assembly is dismantled.
1. Remove 2 clamping rings (3).
2. Remove 4 screws (2).
3. Remove piston rod (7), 2 tube bushings (1), 4
O-rings (9) and 3 spacers (10) from central
body (4).
4. Remove 2 O-rings (8) from piston rod (7).
5. Remove tube (6) and 2 O-rings (5).
6. Remove thread (11).
9.3.5 Assemble pneumatic assembly.
Assemble the control valve
Fig. 16: Control valve with central body
Personnel:
Mechanic
Protective equipment:
Eye protection
Protective gloves
Anti-Static Safety Boots
Requirements:
Clean work area
Components are cleaned.
Ä 12.7 “Operating and auxiliary materials”
Replace damaged components.
Ä 13.1 “Replacement parts”
Use suitable lubricant.
Ä 12.7 “Operating and auxiliary materials”
1. Lubricate O-rings.
2. Insert tube (6) and 2 O-rings (5).
3. Insert 2 O-rings (8) in piston rod (7).
4. Insert 3 spacers (10), 4 O-rings (9), 2 tube
bushings (1) and a piston rod (7) into the cen-
tral body.
Use Loctite262 for screws threads (1).
5. Tighten 2 screws (1) on tube bushing (1) using
4.5 - 5.6Nm.
Maintenance
01/2020 EcoPump AD - MPU00013EN 19/36

6. Insert 2 clamping rings (3).
Use Loctite 572 for threads (11).
7. Insert thread (11).
Assemble main valve
Fig. 17: Main valve with central body
Personnel:
Mechanic
Protective equipment:
Eye protection
Protective gloves
Anti-Static Safety Boots
Requirements:
Clean work area
Components are cleaned.
Ä 12.7 “Operating and auxiliary materials”
Replace damaged components.
Ä 13.1 “Replacement parts”
Use suitable lubricant.
Ä 12.7 “Operating and auxiliary materials”
1. Lubricate O-rings and U-caps.
2. Lubricate thread (18) with Loctite 262 and
insert.
3. Insert grounding lug (8) and screw (7). Tighten
using 4.5 - 5.6 Nm.
4. Tighten 2 screws (7) using 4.5 - 5.6 Nm.
Lips of U-caps (1) must point towards the
seal (5).
5. Lubricate U-cap (1). Insert into piston (6).
6. Install washers (8), O-rings (10, 11) and
spacers (12, 13) on control piston (14).
7. Insert control piston (14) into central body (15).
8. Insert 2 seals (5) and 2 cover plates (4).
9. Insert 4 washers (3) and 4 screws (2) each.
Tighten using 4.5 - 5.6 Nm.
Maintenance
01/2020EcoPump AD - MPU00013EN20/36