DÖRR EcoPump VP User manual
MPU00003EN, V06
Translation of the original operation manual
© Dürr Systems AG 2015
Dürr Systems AG
Application Technology
Carl-Benz-Str. 34
74321 Bietigheim-Bissingen
Germany
Phone +49 7142 78-0
Internet: www.durr.com
Transmission and duplication of this document, as well as use and sharing 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.
02/2020EcoPump VP - MPU00003EN2/52
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:
N24170012
EcoPump VP 1000 135 SST PU
N24170013
EcoPump VP 1000 90 SST PU
N24170014
EcoPump VP 250 360 SST PU
N24170024
EcoPump VP 250 360 SST PK
Applicable documents
If you use accessories, follow the operating
instructions for the accessories.
MCU00002 - EcoPUC A
Hotline and Contact
If you have queries or would like technical informa-
tion, please contact your dealer or sales partner.
02/2020 EcoPump VP - MPU00003EN 3/52
TABLE OF CONTENTS
1 Product overview...................................... 6
1.1 Overview............................................. 6
1.2 Short description................................. 6
2 Safety.......................................................... 6
2.1 Presentation of Notes.......................... 6
2.2 Intended Use....................................... 6
2.3 Residual risks...................................... 7
2.4 Conduct in the event of a hazardous
situation............................................... 7
2.5 Staff qualification................................. 8
2.6 Personal protective equipment............ 8
3 Design and Function................................. 9
3.1 Control Unit......................................... 9
3.2 Motor................................................... 9
3.3 Fluid part............................................. 9
4 Transport, scope of supply and
storage..................................................... 10
4.1 Unpacking......................................... 10
4.2 Transport........................................... 10
4.3 Scope of delivery............................... 10
4.4 Handling of packaging material......... 11
4.5 Storage.............................................. 11
5 Assembly.................................................. 11
5.1 Safety recommendations................... 11
5.2 Requirements for the
Installation point................................. 11
5.3 Assembly........................................... 11
5.4 Connecting........................................ 13
6 Commissioning....................................... 14
6.1 Safety recommendations................... 14
6.2 Commissioning.................................. 15
6.3 Setting operating parameters ........... 15
7 Operation................................................. 15
7.1 Safety recommendations................... 15
7.2 General notes.................................... 16
7.3 Rinsing.............................................. 16
7.3.1 Safety recommendations................ 16
7.3.2 Flush the pump............................... 16
8 Cleaning................................................... 16
8.1 Safety recommendations .................. 16
8.2 Cleaning............................................ 18
9 Maintenance............................................. 18
9.1 Safety notes...................................... 18
9.2 Maintenance schedule...................... 19
9.3 Dismantle and assemble................... 20
9.3.1 Disassemble control unit................ 20
9.3.2 Dismantle control unit..................... 20
9.3.3 Assemble control unit..................... 21
9.3.4 Assemble control unit..................... 22
9.3.5 Disassemble fluid part and con-
necting rods.................................... 23
9.3.6 Dismantle motor............................. 24
9.3.7 Assemble motor.............................. 26
9.3.8 Dismantle fluid part......................... 26
9.3.9 Assemble fluid part......................... 29
9.3.10 Assemble fluid part and connecting
rods................................................ 29
10 Faults........................................................ 30
10.1 Defects table................................... 30
10.2 Troubleshooting............................... 32
10.2.1 Replace switchover valve............. 32
10.2.2 Bring diaphragm in the control
unit in the home position.............. 33
10.2.3 Assembling ice reduction............. 33
11 Disassembly and Disposal..................... 35
11.1 Safety recommendations................. 35
11.2 Disassembly.................................... 36
11.3 Disposal .......................................... 37
12 Technical data.......................................... 37
12.1 Dimensions and weight................... 37
12.2 Connections.................................... 38
12.3 Operating conditions....................... 38
12.4 Emissions........................................ 38
12.5 Operating values............................. 38
12.6 Compressed air............................... 39
12.7 Type plate........................................ 39
12.8 Materials used................................. 40
12.9 Operating and auxiliary materials.... 40
12.10 Characteristic curve of the outflow
rate.................................................. 41
12.11 Material specification....................... 41
13 Replacement parts, tools and accesso-
ries............................................................ 42
13.1 Replacement parts.......................... 42
13.1.1 Control Unit.................................. 42
13.1.2 Fluid part...................................... 43
13.1.3 Motor............................................ 45
13.1.4 Repair kits.................................... 46
13.1.5 Seal sets....................................... 47
13.2 Tools................................................ 48
13.3 Accessories..................................... 48
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1 Product overview
1.1 Overview
Fig. 1: Assemblies
1 Motor
2 Compressed air connection
3 Control unit
4 Switchover valve
5 Material outlet
6 Material inlet
7 Fluid part
8 Sound muffler
1.2 Short description
The vertical piston pump (hereafter called "pump")
is a pneumatically operated pump. The pump con-
veys low viscosity to high viscosity coating mate-
rials. The pump is suitable for medium pressure
application and high pressure application.
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
EcoPump VP is a pneumatically operated vertical
piston pump.
EcoPump VP may only be used for pumping low
viscosity to high viscosity coating materials and
their detergents. The pump is used for the fol-
lowing applications:
Airless applications with (ignitable and non-
ignitable) water-based and solvent -based
coating materials
PVC applications with (flammable and non-
flammable) solvent-free coating materials
The selection of sealing material depends on the
coating material.
The pump is approved for use in explosive areas
of Ex zones 1 and 2.
Operate the pump only in the industrial area and
within the approved technical data Ä 12 “Technical
data”.
By using appropriate safety valves or safety
switches (PLr = b), the operator must ensure that
the technical data are observed, in particular the
maximum connection air pressure P1 and the max-
imum output pressure.
The maintenance unit for supplying the pump must
be equipped with an overpressure valve that trig-
gers at 6bar connection air pressure.
Product overview
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Tighten housing parts on block. O-rings are used
for sealing. Maintain the specified tightening tor-
ques.
Misuse
Not using as intended entails danger to life.
Examples of wrong use are:
Use outdoors
Installation without mechanical ventilation
Use of unapproved materials, see safety data
sheets
Use in explosive areas Ex zone 0
Operating an ungrounded pump
Making conversions or changes on your own
Use of non-conductive lines
Use of unsuitable components
Use of components unapproved by
Dürr Systems
Ex labeling
II 2G Ex h IIA T6 Gb X
II - Device group II: all areas except mining
2G - Device category 2 for gaseous atmosphere
Ex h - Mechanical explosion protection
IIA - Explosion group IIA
T6 - Temperature class
Gb - Device protection level Gb
X - The pump is configured for operation in an
ambient temperature of 15°C to 40°C.
2.3 Residual risks
Danger of explosion due to sources of ignition
in an explosive atmosphere.
Sparks, open flames and hot surfaces can cause
explosions in explosive atmospheres. Serious
injury and death could be the consequence.
Before carrying out any work, make sure that
there is no explosive atmosphere.
Do not use any sources of ignition and no open
light in the work area.
Do not smoke.
Do not unpack Pump in Ex zone.
Dispose of packaging according to regulation
outside of Ex zone or store it.
Use tools with Ex approval.
Ground Pump.
Wear suitable protective equipment.
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.
Escaping material
Material leaking under high pressure can penetrate
the body. Even if the injury looks like a harmless
cut wound, the penetrating material leads to ampu-
tation, serious injuries can cause death.
Do not try to seal leakages using body parts,
gloves or towels.
If there are injuries, seek medical attention
immediately.
Install appropriate pressure release device (e.g.
valve or ball valve).
Before working on the product:
Purge the system, in which the product is
installed.
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.
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 operational.
Ensure that the pump is integrated in a closed
process.
Follow the safety data sheet.
Wear specified protective equipment.
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.
Safety
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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
The mechanic is responsible for the following activ-
ities on equipment and components:
Assembly
Waiting
Maintenance
Disassembly
+ Additional qualification high pressure
In addition, the mechanic has knowledge of regula-
tions and safety measures for high pressure sys-
tems > 20 bar.
+ 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.
Face protection
Protect the face from dust, paint drops
and particles flying around, such as ships
and slivers.
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.
Safety
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3 Design and Function
3.1 Control Unit
Fig. 2: Control Unit operation
Air reaches into the distributor block (2) of the con-
trol unit via the compressed air connection (3). The
valve (4) in the distributor block (2) controls the air
intake to the motor. The air outlet is through the
two sound mufflers (1).
3.2 Motor
Fig. 3: Motor operation
The pneumatically operated motor drives the
pump. The piston (4) of the motor divides the cyl-
inder (3) into two air chambers. Compressed air
moves the piston (4) to and fro in the cylinder (3).
When the piston reaches one end of the cylinder,
the piston switches the switchover valve (2). The
switchover valve (2) causes the control unit (1) to
change the supply of motor air from one side of the
piston to the other. The piston moves in the oppo-
site direction.
3.3 Fluid part
Fig. 4: Fluid part operation
At the time of the upward stroke, the non-return
valve in the piston (3) closes and pumps the mate-
rial in the top piston chamber (2) into the pressure
line through the material outlet (1). At the same
time, the non-return valve on the material inlet (5)
opens and sucks materials into the lower piston
chamber (4). The initial material pressure in the
material input (6) supports the suction process.
At the time of the downward stroke, the non-return
valve in the piston (3) opens and the non-return
valve (5) at the material intake closes. The material
in the lower piston chamber (4) is pumped into the
pressure line by the piston to the material outlet
(1).
Design and Function
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4 Transport, scope of supply and
storage
4.1 Unpacking
DANGER!
Electrostatically charged plastic films and
foils in potentially explosive areas
The foil and the product can charge electrostati-
cally at the time of the unpacking. Electrostatic
discharge can cause sparks that in explosive
atmosphere can cause a fire or an explosion.
Serious injury and death could be the conse-
quence.
– Unpack product outside Ex zones.
– Discharge the product.
– Dispose packaging outside of the Ex zone in
accordance with the regulation or store prop-
erly for a later return.
4.2 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
Personnel:
Mechanic
Protective equipment:
Protective workwear
Protective gloves
Anti-Static Safety Boots
Requirements:
Pump has been disassembled Ä 11.2 “Disas-
sembly”.
Fig. 5: Transport ring bolt
1. Fix stoppers on the eye bolts (1).
2. Transport pump using a hoist.
4.3 Scope of delivery
The scope of supply only includes the pump.
Sound muffler and compressed air connection are
included and must be assembled before commis-
sioning Ä 5.3 “Assembly”
Personnel:
Mechanic
Protective equipment:
Protective workwear
Protective gloves
Anti-Static Safety Boots
1. Check the pump for integrity on receiving it.
2. Report defects immediately Ä “Hotline and
Contact”.
Transport, scope of supply and storage
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4.4 Handling of packaging material
ENVIRONMENT!
Incorrect disposal
Incorrectly disposed packaging material can
damage environment.
– Dispose of material no longer required in an
environment-friendly manner.
– Observe local disposal specifications.
4.5 Storage
Requirements for the warehouse:
Do not store outdoors.
Store in a dry and dust-free place.
Do not expose to aggressive media.
Protect from solar radiation.
Avoid mechanical vibrations.
Close all openings when storing after disas-
sembly.
Temperature: 10°C to 40°C
Relative humidity: 35% to 90%
5 Assembly
5.1 Safety recommendations
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.
5.2 Requirements for the Installation point.
Control air supply and the material feed can be
paused and secured against reconnection.
Lines, seals and screw connections must be
designed to conform to the pump requirements
Ä 12.5 “Operating values”.
The pump must be protected from atmospheric
influences at the installation point.
Ensure by using appropriate safety valves or
safety switches (PLr = b) that the technical data
are observed, in particular the maximum con-
nection air pressure and the maximum output
material pressure.
5.3 Assembly
Assembling the pump
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Protective gloves
Anti-Static Safety Boots
Fig. 6: Assembling the Pump
1. Mount pump on a suitable stand.
ðUse bores (1) for fastening.
Assemble sound mufflers and compressed air
connection
The pump is supplied with sound mufflers and
compressed air connection, both disassembled.
Assembly
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Fig. 7: Assembling Sound Mufflers and Com-
pressed Air Connection
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Protective gloves
Anti-Static Safety Boots
1. Screw-in and hand-tighten sound mufflers (1) in
the control unit.
2. Screw-in and hand-tighten compressed air con-
nection (2) in the control unit.
Assemble EcoPUC A (optional)
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Protective gloves
Anti-Static Safety Boots
Protective workwear
Fig. 8: Assemble EcoPUC A (optional)
1 Sensor connection
2 Screws
3 Opening for sensor
1. Screw EcoPUC A with four screws (2) below on
the control unit of the pump and tighten.
2. Connect sensor to EcoPUC A.
Fig. 9: Disassembling Connection Block and Com-
pressed Air Connection.
3. Thread off two screws (4).
4. Unscrew compressed air connection (5).
5. Remove connection block (6).
Assembly
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Fig. 10: Assemble sensor
6. Push sensor with insertion nipple (8) from
below fully into the opening (3) on the control
unit.
7. Secure insertion nipple (8) using the threaded
pin (7).
The threaded pin is included in the scope
of supply of EcoPUC A.
8. Assemble connection block (6) and com-
pressed air connection (5).
9. Insert two screws (4) and tighten.
5.4 Connecting
Fig. 11: Connecting the Pump
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Face protection
Protective workwear
Protective gloves
Anti-Static Safety Boots
1. Grease all O-rings and threads of the pipelines.
2. Assemble material inlet (4).
3. Screw-in high pressure hose into the material
outlet (3).
4. Connect control air hose to the compressed air
connection (1).
Assembly
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Grounding the Pump
Movement of the piston and of the flowing material
create the charge. The charge can only flow if the
piston pump is grounded with all components.
Connection of the suction pipe and pressure pipe
are not sufficient for grounding.
Personnel:
Electrician
+ Additional qualification high pressure
Protective equipment:
Anti-Static Safety Boots
1. Connect the grounding cable to the grounding
hole (2).
2. Connect the other end of the grounding cable to
a secure current conductor.
3. Measure volume resistivity.
6 Commissioning
6.1 Safety recommendations
WARNING!
Risk of injury due to noise
The sound pressure level during commissioning
may cause severe hearing damage.
– Wear ear protection.
– Put the pump only with assembled sound
muffler into operation.
WARNING!
Danger from harmful or irritant substances
Serious injuries or death can result if you come
into contact with dangerous fluids or steam.
– Check pump regularly for leakage. Observe
local regulations and maintenance schedule.
– Ensure that the forced ventilation is opera-
tional.
– Ensure that the pump is integrated in a closed
process.
– Follow the safety data sheet.
– Wear specified protective clothing.
WARNING!
Risk of injury from whipping hoses
If hoses under pressure come off loose, the
hoses can lash around and cause injuries.
– Check that the hose connections are seated
tightly.
– Check hoses for damage.
WARNING!
Danger due to escaping compressed air
Compressed air escaping from the sound muffler
can contain solid or liquid particles. Particles
under pressure can injure the eyes or the skin.
– Wear specified protective equipment.
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!
Danger due to freezing
The noise mufflers on the motor can cool down
drastically. Contact with it can result in frostbite.
– Before working on the motor, ensure that the
noise muffler is at room temperature.
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.
The operator must ensure that connected
pipelines or hose lines are tested according
to the specifications in force (e.g. pressure
test).
Commissioning
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6.2 Commissioning
Checks before commissioning:
Pump is grounded.
Pump is properly assembled Ä 5 “Assembly”.
Screw connections are tightened as specified.
Sound muffler and compressed air connection
are assembled Ä “Assemble sound mufflers
and compressed air connection”.
Appropriate safety valves and safety switches
(PLr = b) are used to ensure that the technical
data are observed, in particular the maximum
connection air pressure and the maximum
output material pressure.
The maintenance unit for supplying the pump
with air is equipped with an overpressure valve
that triggers at 6bar connection air pressure.
Ensure that the housing parts on the block are
tightened and sealed with O-rings.
Put pump into operation
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Protective workwear
Face protection
Use ear protection
Protective gloves
Anti-Static Safety Boots
1. Purge pump before the initial commissioning
Ä 7.3 “Rinsing”.
Residues of the testing media might still
be in the pump.
2. Ensure that there is no air in the pump.
Let the pump run with the minimum cycle
rate.
3. During this time, check the tightness of the
pump, connections and lines.
4. Watch out for unusual noises. Carry out checks
if there are unusual noises Ä 7.2 “General
notes”.
6.3 Setting operating parameters
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Protective workwear
Use ear protection
Protective gloves
Anti-Static Safety Boots
1. Set the operating parameters on the higher
level control.
2. Check operating parameters Ä 12.5 “Operating
values”.
7 Operation
7.1 Safety recommendations
WARNING!
Risk of injury due to noise
The sound pressure level during normal opera-
tion may cause severe hearing damage.
– Wear ear protection.
– Put the pump only with assembled sound
muffler into operation.
WARNING!
Danger due to freezing
The noise mufflers on the motor can cool down
drastically. Contact with it can result in frostbite.
– Wear protective hand gloves.
WARNING!
Danger from harmful or irritant substances
Serious injuries or death can result if you come
into contact with dangerous fluids or steam.
– Check pump regularly for leakage. Observe
local regulations and maintenance schedule.
– Ensure that the forced ventilation is opera-
tional.
– Ensure that the pump is integrated in a closed
process.
– Follow the safety data sheet.
– Wear specified protective clothing.
Operation
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7.2 General notes
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Respirator mask
Face protection
Use ear protection
Protective gloves
Protective workwear
Anti-Static Safety Boots
Check for unusual noises during operation. Per-
form visual inspections:
Check tightness of the connections.
If there are conspicuous noises, carry out fur-
ther checks during down times.
Check for steady delivery pressure.
Appropriate safety valves and safety switches
(PLr = b) are used to ensure that the technical
data are observed, in particular the maximum
connection air pressure and the maximum
output material pressure.
The maintenance unit for supplying the pump
with air is equipped with an overpressure valve
that triggers at 6bar connection air pressure.
If the pump is not in operating mode, the
number of cycle of the pump can drop down
to the minimum flow velocity of the medium.
– Pump wear and operating expenses are
reduced.
7.3 Rinsing
7.3.1 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.
7.3.2 Flush the pump.
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Face protection
Protective gloves
Protective workwear
Anti-Static Safety Boots
Use ear protection
Complete the following steps if the pump is not in
operation for a longish period:
Purge pump with a suitable detergent Ä 12.9
“Operating and auxiliary materials”.
Disconnect compressed air supply to pump.
8 Cleaning
8.1 Safety recommendations
WARNING!
Risk of injury due to residual pressure
After switching off the pump, there may be
residual pressure inside of the pipes and the
pump. Serious injuries due to escaping com-
pressed air and material can be the conse-
quence.
Before working on the pump:
– Disconnect the system, in which the product
is installed, from compressed air and material
supply.
– Secure the system against being switched on
again.
– Depressurize the lines.
– Ensure that the pump is unpressurized.
– Install appropriate pressure release device,
e.g. valve or ball valve, to ensure safe
depressurization.
Cleaning
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WARNING!
Unexpected motor start
If the pump is connected to the compressed air
supply, the motor may start unexpectedly. This
may cause a crushing hazard an injuries due to
parts flying around.
Before working on the product:
– Disconnect the system, in which the product
is installed, from compressed air and material
supply.
– Secure the system against being switched on
again.
– Depressurize the lines.
– Ensure that the pump is unpressurized.
– Install appropriate pressure release device,
e.g. valve or ball valve, to ensure safe
depressurization.
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.
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 due to freezing
The noise mufflers on the motor can cool down
drastically. Contact with it can result in frostbite.
– Before working on the motor, ensure that the
noise muffler is at room temperature.
WARNING!
Danger from harmful or irritant substances
Serious injuries or death can result if you come
into contact with dangerous fluids or steam.
– Check pump regularly for leakage. Observe
local regulations and maintenance schedule.
– Ensure that the forced ventilation is opera-
tional.
– Ensure that the pump is integrated in a closed
process.
– Follow the safety data sheet.
– Wear specified protective clothing.
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.
Cleaning
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8.2 Cleaning
ENVIRONMENT!
Environmental damage due to wrong dis-
posal
Improper waste disposal threatens the environ-
ment and prevents re-use and recycling.
– Collect leaked out operating and auxiliary
materials completely.
– Dispose of operating and auxiliary materials
according to the disposal provisions in force.
– In case of doubt, refer to the local disposal
authorities.
Make sure that the Pump is completely free of
media residues and other contamination.
Personnel:
Cleaning staff
Protective equipment:
Protective gloves
Anti-Static Safety Boots
Face protection
Protective workwear
Respirator mask
1. Clean pump carefully using a moist cloth.
9 Maintenance
9.1 Safety notes
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!
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.
WARNING!
Danger due to freezing
The noise mufflers on the motor can cool down
drastically. Contact with it can result in frostbite.
– Before working on the motor, ensure that the
noise muffler is at room temperature.
WARNING!
Risk of injury due to residual pressure
After switching off the pump, there may be
residual pressure inside of the pipes and the
pump. Serious injuries due to escaping com-
pressed air and material can be the conse-
quence.
Before working on the pump:
– Disconnect the system, in which the product
is installed, from compressed air and material
supply.
– Secure the system against being switched on
again.
– Depressurize the lines.
– Ensure that the pump is unpressurized.
– Install appropriate pressure release device,
e.g. valve or ball valve, to ensure safe
depressurization.
WARNING!
Unexpected motor start
If the pump is connected to the compressed air
supply, the motor may start unexpectedly. This
may cause a crushing hazard an injuries due to
parts flying around.
Before working on the product:
– Disconnect the system, in which the product
is installed, from compressed air and material
supply.
– Secure the system against being switched on
again.
– Depressurize the lines.
– Ensure that the pump is unpressurized.
– Install appropriate pressure release device,
e.g. valve or ball valve, to ensure safe
depressurization.
Maintenance
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9.2 Maintenance schedule
If a maintenance assistant is used in the system visualizer, the maintenance intervals of the mainte-
nance assistant are valid.
The life cycle and the associated maintenance intervals depend heavily on the abrasiveness and tem-
perature of the material to be pumped as well as the pumping pressure and twice the number of
strokes of the pump. The present details are guide values and must be suitably adjusted according to
the application.
Interval Maintenance work
weekly Check cleanliness of the pump.
Test the tightness and condition of the connections, hoses
and lines.
Check tightness and state of the pump.
Check noise generation in the pump.
Check for steady delivery pressure.
after about 1 million cycles (corresponding
to 10 dual strokes /min. in a single shift
operation for 6 months)
Replace rod seal of the fluid part.
Ä 9.3.8.1 “Dismantle non-return valve in the piston”
Replace piston seal of the fluid part.
Ä 9.3.8.1 “Dismantle non-return valve in the piston”
after about 10 million cycles (corre-
sponding to 10 dual strokes /min. in a
single shift operation for 5 years)
Replace worn out parts:
Replace piston seals of the air motor Ä 9.3.6.3 “Disassemble
piston seal.”.
Replace rod seal of the air motor Ä 9.3.8.3 “Dismantle seal
set.”.
Replace rod seal of the air motor.
Replace non-return valves,.
Ä 9.3.8.1 “Dismantle non-return valve in the piston”
Ä 9.3.8.2 “Dismantle non-return valve in the material inlet”
Replace changeover valve Ä 10.2.1 “Replace switchover
valve”.
Replace valve in the control unit Ä 9.3.2.2 “Removing the
valve”.
Maintenance
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9.3 Dismantle and assemble
9.3.1 Disassemble control unit
Fig. 12: Disassemble control unit
Molykote TP-42 Paste
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Protective workwear
Respirator mask
Face protection
Protective gloves
Anti-Static Safety Boots
1. Thread off four screws (1).
2. Remove control unit (2) from the motor.
3. Remove O-rings between control unit and
motor.
9.3.2 Dismantle control unit
9.3.2.1 Remove membrane
Fig. 13: Remove membrane
Klüber Syntheso GLEP 1
Molykote TP-42 Paste
Personnel:
Mechanic
+ additional qualification explosion protection
+ Additional qualification high pressure
Protective equipment:
Protective workwear
Respirator mask
Eye protection
Protective gloves
Anti-Static Safety Boots
1. Unscrew sound muffler (4).
2. Thread off two screws (3).
3. Pull out adapter (5) together with O-ring from
the housing (1).
4. Pull out two membranes (2) from the housing
(1) using a long nose pliers.
Maintenance
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Table of contents
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