Krautzberger MP-400 User manual

Article No. 200-0102
Translation of the original operating instructions
T-Dok-236-GB-Rev.1
GB Diaphragm pump MP-400
Operating instructions

Thank you for selecting a Krautzberger product.
This product has been manufactured following state-of-the-art manufacturing procedures and
extensive quality assurance measures. We promise you a product of the highest quality.
If you have questions, requests or suggestions, please contact us. We are always glad to assist
you.
Information about the operating manual
This manual provides important information on how to work with the device safely and efficiently.
The manual is part of the device and must always be kept in the immediate proximity of the device
so that it is accessible to the personnel at all times.
The personnel must have read and understood this manual before starting any work. Compliance
with all specified safety information and instructions is a basic requirement for safe working condi-
tions.
In addition, the local occupational safety regulations and general safety rules apply for the area of
application of the device.
Due to optional finishing variants, it is possible that the figures shown in this operating manual
deviate from your device.
Information about explosion protection
Many of our competitors have been marking their products with the Ex symbol as a matter of prin-
ciple for some time now.
At Krautzberger we do not do that.
We engineer and manufacture our products in line with currently applicable directives.
If the labelling on the product is required, it is affixed to the product as the result of the necessary
analysis of ignition sources. If no labelling is affixed, the analysis of ignition sources and previous
experience with the assessment of the suitability of products for use in a potentially explosive area
have shown that the product described in this operating manual does not represent a potential
source of ignition, with the exception of an electrostatic charge.
Taking into account the potential equalisation (provided by proper earth connection), the use in an
area at risk for explosions is permitted in accordance with the currently valid directives.
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GB–2

Table of contents
1 Information about the operating manual.......................................................................... 5
2 Function and identification................................................................................................ 6
2.1 Function....................................................................................................................... 6
2.2 Identification................................................................................................................. 6
3 Safety and responsibility................................................................................................... 8
3.1 Symbols in this manual................................................................................................ 8
3.2 Personnel requirements............................................................................................... 9
3.3 Personal safety equipment and clothing.................................................................... 10
3.4 Responsibility of the owner........................................................................................ 11
3.5 Intended use.............................................................................................................. 12
3.6 General safety instructions........................................................................................ 14
3.7 Residual risks............................................................................................................ 15
3.8 Course of action in an emergency............................................................................. 15
4 Transport, delivery condition, storage, and packaging................................................ 16
4.1 Transport................................................................................................................... 16
4.2 Delivery condition...................................................................................................... 16
4.3 Storage...................................................................................................................... 16
4.4 Packaging.................................................................................................................. 16
5 Overview and dimensions............................................................................................... 17
5.1 Menu.......................................................................................................................... 17
5.2 Dimensions................................................................................................................ 18
6 Installation and disassembly........................................................................................... 19
6.1 Safety......................................................................................................................... 19
6.2 General installation information................................................................................. 19
6.3 Installing the diaphragm pump................................................................................... 20
6.4 Connecting the diaphragm pump............................................................................... 22
6.5 Dismantling the diaphragm pump.............................................................................. 24
7 Start-up.............................................................................................................................. 27
7.1 Safety instructions..................................................................................................... 27
7.2 General information about the start-up...................................................................... 28
7.3 Start-up...................................................................................................................... 29
7.4 Shut-down.................................................................................................................. 29
7.4.1 Temporary shut-down............................................................................................. 29
7.4.2 Long-term shut-down.............................................................................................. 30
8 Maintenance...................................................................................................................... 31
8.1 Safety......................................................................................................................... 31
8.2 General maintenance information.............................................................................. 32
Diaphragm pump MP-400 ENGLISH
Article No. 200-0102 GB–3

8.3 Maintenance schedule............................................................................................... 32
8.4 Clean the diaphragm pump....................................................................................... 33
8.5 Replace valve parts................................................................................................... 34
8.6 Replace the diaphragm.............................................................................................. 36
9 Troubleshooting............................................................................................................... 38
9.1 Safety......................................................................................................................... 38
9.2 Customer Care.......................................................................................................... 38
9.3 Troubleshooting table................................................................................................ 39
9.4 Work for clearing faults.............................................................................................. 40
9.4.1 Moving the control piston into the end position....................................................... 40
9.5 Replacing the pressure controller.............................................................................. 41
10 Spare parts and accessories........................................................................................... 44
10.1 Safety....................................................................................................................... 44
10.2 General information................................................................................................. 44
10.3 Spare parts.............................................................................................................. 45
10.3.1 Diaphragm pump.................................................................................................. 45
10.3.2 Control unit........................................................................................................... 47
10.4 Accessories............................................................................................................. 48
11 Disassembly and disposal............................................................................................... 50
11.1 Safety....................................................................................................................... 50
11.2 Disassembly............................................................................................................ 50
11.3 Disposal................................................................................................................... 50
12 Technical data................................................................................................................... 52
13 Declaration of conformity................................................................................................ 53
14 Index.................................................................................................................................. 54
Operating instructions T-Dok-236-GB-Rev.1
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1 Information about the operating manual
This manual provides important information on how to work with the device safely and efficiently.
The manual is part of the device, must always be kept in the device's direct proximity and should
be available to the personnel at all times.
The personnel must have read and understood this manual before starting any work. Compliance
with all specified safety information and instructions is a basic requirement for safe working condi-
tions.
In addition, the local occupational safety regulations and general safety rules apply for the area of
application of the device.
Due to optional finishing variants, it is possible that the figures shown in this operating manual
deviate from your device.
Diaphragm pump MP-400 ENGLISH
Article No. 200-0102 GB–5

2 Function and identification
2.1 Function
The MP-400 is an air-operated diaphragm pump.
By changing the pressure in the air supply, the conveying capacity of the diaphragm pump can be
seamlessly regulated.
As soon as the set fluid pressure has been reached, the diaphragm pump switches off automati-
cally. The fluid pressure is maintained until material is extracted at the extraction point. The dia-
phragm pump switches on automatically and keeps the set fluid pressure constant.
It is optimally suited for conveying paints, oils, etc.
2.2 Identification
Scope of delivery Model Product number
Diaphragm pump MP-400 200-0102
Operating instructions T-Dok-236
Serial number
Fig. 1: Serial number
The serial number ( Fig. 1) of the diaphragm pump is located on the underside. It serves as a
unique identifier.
Operating instructions T-Dok-236-GB-Rev.1
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Additional information can be found in ( Ä Chapter 12 ‘Technical data’ on page 52).
Diaphragm pump MP-400 ENGLISH
Article No. 200-0102 GB–7

3 Safety and responsibility
3.1 Symbols in this manual
Safety information
This manual uses symbols to identify safety information. The safety information is preceded by
signal words that indicate the severity of the hazard.
DANGER!
This combination of symbol and signal word indicates an immediate dangerous situation,
which will cause death or severe injuries if it is not averted.
WARNING!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause death or severe injuries if it is not averted.
CAUTION!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause slight injuries if it is not averted.
NOTICE!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause property and environmental damage if it is not averted.
ENVIRONMENT!
This combination of symbol and signal word indicates potential environmental hazards.
Safety information in operating instructions
Safety information can refer to specific, individual operating instructions. Such safety information is
embedded in the operating instructions so that it does not disrupt the reading flow during the exe-
cution of the action. The signal words described above are used.
Operating instructions T-Dok-236-GB-Rev.1
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Example:
1. Loosen screw.
2.
CAUTION!
Pinching hazard at the cover!
Carefully close cover.
3. Tighten screw.
Special safety instructions
The following symbols are used in safety instructions to draw the attention to special hazards:
Warning signs Type of danger
Warning – hot surface.
Warning – danger zone.
Tips and recommendations
This symbol highlights useful tips and recommendations as well as information for efficient
and fault-free operation.
Additional identifications
The following symbols are used in this manual to highlight operating instructions, results, lists, ref-
erences, and other elements:
Identification Explanation
Step-by-step operating instructions
ðResults of procedural steps
References to sections in this manual and other applicable docu-
ments
Lists without specified sequence
[Pushbutton] Operating elements (e.g. buttons, switches), display elements
(e.g. signal lights)
‘Display’ Screen elements (e.g. buttons, assignment of function keys)
3.2 Personnel requirements
Diaphragm pump MP-400 ENGLISH
Article No. 200-0102 GB–9

This manual identifies the qualifications of the personnel for the different scopes of work as listed
below:
Qualified personnel
Due to their specialised professional training, knowledge, and experience as well as knowledge of
the industry-specific standards and regulations, qualified personnel are in a position to perform
assigned tasks and to identify and avert potential risks on their own.
User
The user is familiar with the basic regulations on occupational safety and accident prevention.
3.3 Personal safety equipment and clothing
Personal safety equipment is used to protect persons from impacts on safety and health at work.
The personnel must wear personal safety equipment while carrying out the various tasks and while
working with the device. The individual sections of this manual will indicate the personal safety
equipment separately.
The selection of the personal safety equipment depends on the coating material that is used.
To ensure the proper selection of personal safety equipment, the information provided by the
spray material manufacturer indicated on the safety data sheet must be adhered to.
Description of the personal safety equipment recommended by Krautzberger
The personal safety equipment and clothing is described below:
Ear protection
Ear protection provides protection against hearing damage.
Light respiratory protection
The light respiratory protection is used as a protection against hazardous dusts.
Operating instructions T-Dok-236-GB-Rev.1
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Protective clothing
Protective clothing are tight fitting work clothes with low tear resistance, with tight sleeves, and
without any protruding parts.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as
well as from contact with hot surfaces.
Safety goggles
Safety goggles are used to protect the eyes from flying components and splashes of liquid.
Safety shoes
Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.
3.4 Responsibility of the owner
Owner
The owner is the person, who directly operates the machine for commercial or economical pur-
poses or who allows a third-party to use/apply it and who is responsible for the legal product stew-
ardship for the protection of the user, the personnel or third parties.
Owner responsibilities
The machine is used in an industrial environment. The owner of the machine is therefore subject to
the obligations as stipulated by the Occupational Health and Safety Act.
Diaphragm pump MP-400 ENGLISH
Article No. 200-0102 GB–11

In addition to the safety information in this manual, the country-specific safety, accident prevention
guidelines and environmental protection regulations, applicable at the site of implementation of the
machine must be adhered to.
Furthermore, the owner is responsible for making sure that the machine is always in perfect tech-
nical condition. Therefore, the following applies:
nThe owner must ensure that the maintenance intervals described in this operating manual are
adhered to.
nThe owner must have all safety equipment checked regularly for functionality and complete-
ness.
3.5 Intended use
The MP-400 diaphragm pump is a pump operated with compressed air and is used exclusively:
nfor the conveying of liquid and low-viscosity coatings from non-pressurised storage con-
tainers.
nfor the supply of material to spray guns. automatic spray guns, metering devices and similar.
The intended use also includes the compliance with all the information in this manual.
Any use beyond the intended use or any other use constitutes misuse.
Operating instructions T-Dok-236-GB-Rev.1
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WARNING!
Danger due to misuse!
Improper of the diaphragm pump can lead to hazardous situations.
– Only carry out the installation, start-up, and use in accordance with the steps described
in this operating manual.
– Ensure that the utilised hose lines fulfil the requirements with respect to pressure, chem-
ical, and mechanical loads.
– Always observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations for the area of use for the diaphragm
pump.
– The chemical consistency of the materials used by us cannot always be reliably
assessed due to the large variety of utilised fluids, concentrations, temperatures, and
impurities. For this reason, please test the suitability because we cannot extend any
respective guarantees.
– Adhere to the spray media manufacturer's safety data sheets.
– Only use the manufacturer's OEM parts.
– Only operate the diaphragm pump in compliance with the values specified in ( Ä Chapter
12 ‘Technical data’ on page 52).
– Only operate the diaphragm pump after fastening it properly to a suitable supporting
structure.
– Do not hold the diaphragm pump in your hand during operation.
– Make sure that the connected compressed air is oil-free and free of solid matter.
– Operate the diaphragm pump with processed, dried compressed air (air quality pursuant
to DIN ISO 8573-1: quality class 4).
– Never point the compressed air at living beings.
– It is mandatory to adhere to the maintenance and cleaning intervals.
– The conformity of the product is voided in case of structural modifications of the dia-
phragm pump.
– Do not use the diaphragm pump in the food or pharmaceutical sectors.
No claims of any kind can be asserted due to damage resulting from misuse.
Diaphragm pump MP-400 ENGLISH
Article No. 200-0102 GB–13

3.6 General safety instructions
WARNING!
Risk of death, risk of injury or property damage due to hazardous media!
Potential consequences: The application of hazardous media can lead to death, severe inju-
ries or property damage.
When handling hazardous substances, ensure that the current safety data sheets of the haz-
ardous substance manufacturer are available. The necessary measures can be derived from
the content of the safety data sheet. Since the hazardous potential of a material can be reas-
sessed at any time due to new lessons learned, the safety data sheet must be checked regu-
larly and replaced if necessary.
The system owner is responsible for the presence and the up-to-date status of the safety data
sheet and the associated generation of the risk assessment of the effected workstations.
WARNING!
Hazardous media / contamination of persons and equipment
Possible consequences: Fatality or serious injuries, property damage
– Ensure the resistance of the device against the medium that is to be conveyed
– Always adhere to the safety data sheet of the medium that is to be conveyed The system
owner is responsible that the safety data sheet is present and up-to-date
– The safety data sheet of the conveyed medium is always authoritative for the initiation of
countermeasures in case of a leak of the conveyed medium
– Adhere to the general limitations with respect to viscosity limits, chemical stability and
density
WARNING!
Risk of injury due to hot surfaces!
The surfaces of components can become very hot during operation. Direct contact with hot
surfaces causes severe skin burns.
Note:
– Always wear protective clothing and protective gloves for all work in the vicinity of hot
parts.
– Ensure that all surfaces have sufficiently cooled down prior to starting any work.
Operating instructions T-Dok-236-GB-Rev.1
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CAUTION!
Risk of injury caused by compressed air!
Uncontrolled leaks of compressed air can lead to serious injuries.
Note:
– Prior to any work on the device/machine, all compressed-air lines must be closed and
disconnected.
– Never point compressed air at living beings.
3.7 Residual risks
Devices, machines or systems made by Krautzberger GmbH have been manufactured based on
state-of-the-art technology and in compliance with technical safety regulations.
Nonetheless, their use may pose a threat to the life or health of users or third parties, or harm the
device, the machine, the system or other material assets.
nMechanical hazards (crushing, shearing, cutting, jamming, burning, etc.) are possible at any
time during the installation, during operation as well as during maintenance work and serv-
icing.
3.8 Course of action in an emergency
In principle, the applicable national, regional and internal company regulations concerning the
course of action in case of an emergency must be adhered to and if necessary respective
safety measures must be taken on the system owner's side.
Diaphragm pump MP-400 ENGLISH
Article No. 200-0102 GB–15

4 Transport, delivery condition, storage, and packaging
4.1 Transport
nThe diaphragm pump is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
4.2 Delivery condition
Immediately upon receipt check the delivery for completeness and damage from transport.
In the event of visible exterior transport damage, proceed as follows:
nDo not accept delivery or only do so with reservations.
nRecord scope of damage on the transport documents or on the bill of delivery of the shipping
company.
nInitiate complaint.
4.3 Storage
Store the device/machine under the following conditions:
nIf possible, store the device/machine in the original packaging.
nDo not store outside.
nStore in a dry and dust-free environment.
nKeep away from any aggressive media.
nProtect from UV radiation.
nAvoid mechanical shocks.
nStorage temperature: 15 to 40 °C.
nRelative atmospheric humidity: max. 60%.
nFor storage for longer than 3 months, check the general condition of all parts and the pack-
aging on a regular basis.
It is possible that there are notes on the packaged units concerning the storage that extend
beyond the requirements listed here. Follow those accordingly.
4.4 Packaging
The device is packaged in accordance with the anticipated transport conditions and the packaging
needs to protect the device against transport damage, corrosion, and other damage.
nRemove packaging material.
nRemove potentially present transport safety restraints.
Disposal of packaging
Dispose of the packaging material in accordance with the respectively applicable legal regulations
and ordinances.
Operating instructions T-Dok-236-GB-Rev.1
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5 Overview and dimensions
5.1 Menu
Fig. 2: Menu
1 Screw plug
2 Surge tank connection
3 Screw plug
4 Screw plug
5 Compressed air controller
6 Screw plug
7 Fluid intake connection (fluid inlet)
8 Auxiliary actuator
9 Screw plug
10 Compressed-air connection
11 Fluid pressure connection (fluid outlet)
Diaphragm pump MP-400 ENGLISH
Article No. 200-0102 GB–17

5.2 Dimensions
Fig. 3: Dimensions
Operating instructions T-Dok-236-GB-Rev.1
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6 Installation and disassembly
6.1 Safety
Personnel:
nQualified personnel
Protective equipment:
nProtective clothing
nProtective gloves
nSafety goggles
nSafety shoes
WARNING!
Risk of injury due to improper installation!
Improper installation may cause serious personal injury or material damage.
Note:
– Ensure ample of space for the installation prior to starting any work.
– Carefully handle open, sharp-edged components.
– Maintain order and cleanliness at the installation site. Components that are loosely
stacked or are scattered around can cause accidents.
– Assemble components properly. Adhere to specified screw tightening torque.
– Secure components against tipping or falling.
– Ensure that the utilised hose lines meet the requirements for pressure, chemical and
mechanical loads. At the same time, adhere to the spray media manufacturer's specifica-
tions in the safety data sheet.
6.2 General installation information
Adhere to the following general information for the installation:
nOnly carry out the installation and start-up in accordance with the steps described in these
operating instructions.
nEnsure that the utilised hose lines meet the requirements for pressure, chemical and mechan-
ical loads.
nOnly operate the diaphragm pump after fastening it properly to a suitable supporting structure.
nInstall the diaphragm pump vertically and with the fluid intake connection pointing down.
nVibrations may occur on the diaphragm pump during operation. Ensure sufficient fastening.
nMake sure that the connected compressed air is oil-free and free of solid matter.
nOperate the diaphragm pump with processed, dried compressed air (air quality pursuant to
DIN ISO 8573-1: quality class 4).
nNever point the compressed air at living beings.
Diaphragm pump MP-400 ENGLISH
Article No. 200-0102 GB–19

6.3 Installing the diaphragm pump
Fig. 4: Installation
1. Attach the bracket ( Fig. 4/1) to a wall or supporting construction with the appropriate
screws so that the fluid intake connection ( Fig. 4/2) faces vertically downwards after
assembly.
Fig. 5: Installation
2. Lightly grease three screws ( Fig. 5/3).
3. Attach the diaphragm pump ( Fig. 5/4) to the bracket ( Fig. 5/2) with the screws ( Fig. 5/3).
4. Screw the earth connection to the earth connection screw ( Fig. 5/1).
Operating instructions T-Dok-236-GB-Rev.1
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