Krautzberger MP-400 User manual

T-Dok-236-GB-Rev.3
GB Diaphragm pump MP-400
Operating instructions
Item number: 200-0102
Translation of the original 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.
[email protected], www.krautzberger.com
GB–2

Table of contents
1 Function and identification................................................................................................ 5
1.1 Function....................................................................................................................... 5
1.2 Identification................................................................................................................. 5
2 Using this operating manual............................................................................................. 6
2.1 Information about the operating manual...................................................................... 6
2.2 Symbols in this operating manual................................................................................ 6
2.3 Personnel requirements............................................................................................... 8
2.4 Personal protective equipment.................................................................................... 8
3 Safety and responsibility................................................................................................. 11
3.1 Responsibility of the owner........................................................................................ 11
3.2 Intended use.............................................................................................................. 11
3.3 Predictable misuse.................................................................................................... 11
3.4 General safety instructions........................................................................................ 12
3.5 Residual risks............................................................................................................ 13
3.6 Course of action in an emergency............................................................................. 14
4 Transport, storage, and packaging................................................................................. 15
4.1 Transport................................................................................................................... 15
4.2 Storage...................................................................................................................... 15
4.3 Packaging.................................................................................................................. 15
5 Menu.................................................................................................................................. 16
6 Installation......................................................................................................................... 17
6.1 Safety......................................................................................................................... 17
6.2 General installation information................................................................................. 18
6.3 Installing the diaphragm pump................................................................................... 19
6.4 Connecting the diaphragm pump............................................................................... 21
7 Operation........................................................................................................................... 23
7.1 Safety......................................................................................................................... 23
7.2 General information about the start-up...................................................................... 25
7.3 Shut-down.................................................................................................................. 25
7.3.1 Temporary shut-down............................................................................................. 25
7.3.2 Long-term shut-down.............................................................................................. 25
7.4 Start-up...................................................................................................................... 26
8 Maintenance...................................................................................................................... 27
8.1 Safety......................................................................................................................... 27
8.2 General maintenance information.............................................................................. 28
8.3 Maintenance schedule............................................................................................... 28
8.4 Clean the diaphragm pump....................................................................................... 29
Diaphragm pump MP-400 ENGLISH
Item number: 200-0102 GB–3

8.5 Replace valve parts................................................................................................... 30
8.6 Replace the diaphragm.............................................................................................. 32
9 Faults................................................................................................................................. 34
9.1 Safety......................................................................................................................... 34
9.2 Customer Care.......................................................................................................... 34
9.3 Fault table.................................................................................................................. 35
9.4 Fault rectification work............................................................................................... 36
9.4.1 Moving the control piston into the end position....................................................... 36
9.5 Replacing the pressure controller.............................................................................. 37
10 Spare parts........................................................................................................................ 40
11 Accessories...................................................................................................................... 41
12 Disassembly and disposal............................................................................................... 42
12.1 Safety....................................................................................................................... 42
12.2 Disassembly............................................................................................................ 42
12.2.1 Dismantling the diaphragm pump......................................................................... 43
12.3 Disposal................................................................................................................... 45
13 Technical data................................................................................................................... 46
13.1 Dimensions.............................................................................................................. 47
14 Declaration of conformity................................................................................................ 48
15 Notes.................................................................................................................................. 49
16 Index.................................................................................................................................. 50
Operating instructions T-Dok-236-GB-Rev.3
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1 Function and identification
1.1 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.
1.2 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.
Diaphragm pump MP-400 ENGLISH
Item number: 200-0102 GB–5

2 Using this operating manual
2.1 Information about the operating manual
nKnowledge of the fundamental safety instructions and safety regulations is a basic require-
ment for safe handling and defect-free operation of the product.
nThis operating manual contains the most important information about enabling safe operation
of the product.
nThis operating manual and, in particular, the safety instructions are to be observed by all per-
sons who work on or with the product.
nFurthermore, the rules and regulations for accident prevention in force at the respective oper-
ating site are to be observed.
2.2 Symbols in this operating manual
Safety instructions
This operating manual uses symbols to identify safety instructions. The safety instructions are pre-
ceded 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 potentially dangerous situation which
can cause death or severe injuries if it is not averted.
CAUTION!
This combination of symbol and signal word indicates a potentially dangerous situation which
can cause slight injuries if it is not averted.
NOTICE!
This combination of symbol and signal word indicates a potentially dangerous situation which
can cause property and environmental damage if it is not averted.
Operating instructions T-Dok-236-GB-Rev.3
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ENVIRONMENT!
This combination of symbol and signal word indicates potential dangers to the environment.
Tips and recommendations
This symbol highlights useful tips and recommendations as well as information for efficient
and defect-free operation.
Example for safety instructions in operating instructions
Safety instructions can refer to specific, individual operating instructions. Such safety instructions
are embedded in the operating instructions so that they do not disrupt the reading flow when per-
forming the action. The signal words described above are used.
1. Loosen the screw.
2.
CAUTION!
Pinching hazard at the lid!
Carefully close the lid.
3. Tighten the screw.
Special safety instructions
The following symbols are used in safety instructions to draw attention to specific hazards:
Warning signs Type of danger
Warning – hot surface.
Warning – danger zone.
Additional markings
The following markings are used in this manual to highlight operating instructions, outcomes, lists,
references, and other elements:
Diaphragm pump MP-400 ENGLISH
Item number: 200-0102 GB–7

Identification Explanation
Step-by-step instructions
ðResults of procedural steps
References to sections in this manual and other applicable docu-
ments
Lists without specified order
[Button] Operating elements (e.g. buttons, switches), display elements
(e.g. signal lights)
‘Display’ Screen elements (e.g. pushbuttons, assignment of function keys)
2.3 Personnel requirements
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.
Specialised 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 hazards on their own.
Trained electrician
Due to specialised professional training, knowledge and experience as well as knowledge of the
industry specific standards and regulations, a trained electrician is able to carry out work on the
electrical systems and to identified and avert potential risks on his/her own.
The trained electrician has completed specialised training for the specific work environment where
he/she works and knows the relevant standards and regulations.
User
The user is familiar with the basic regulations on occupational safety and accident prevention.
2.4 Personal protective equipment
Personal protective equipment is used to protect persons against adverse effects on their health
and safety when working.
Personnel must wear personal protective equipment while carrying out the different tasks on and
with the machine.
In the course of regular, recurring trainings, the owner should inform operating personnel that
working without protective equipment can be detrimental to their health.
Operating instructions T-Dok-236-GB-Rev.3
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Protective equipment is selected according to the ambient conditions at the owner’s premises
and the raw materials that are used. The information provided by the material manufacturer
on the safety data sheet must be adhered to in order to ensure the proper selection of protec-
tive equipment.
The recommended personal protective equipment is described below:
Light respiratory protection
Light respiratory protection is used as protection against hazardous dusts.
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 airborne components and splashes of liquid.
Diaphragm pump MP-400 ENGLISH
Item number: 200-0102 GB–9

Protective clothing
Protective clothing are tight fitting work clothes with low tear resistance, with tight sleeves, and
without any protruding parts.
Safety shoes
Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.
Safety helmet
The helmet protects the head from falling parts and oscillating loads on the one hand, and it can
protect it from injuries in cramped situations on the other.
Operating instructions T-Dok-236-GB-Rev.3
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3 Safety and responsibility
3.1 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.
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.
3.2 Intended use
The MP-400 diaphragm pump is a pump operated with compressed air and is used exclusively:
nfor conveying liquid and low-viscosity coating material from depressurised storage con-
tainers.
nfor supplying material to automatic spray guns, metering devices and such like.
The intended use also includes compliance with all of the specifications in this operating manual.
3.3 Predictable misuse
Any use beyond the intended use or any other use constitutes misuse.
nAlways carry out installation, commissioning, and use in accordance with the steps described
in this operating manual.
nEnsure that the hose lines used meet the requirements with regard to pressure, chemical, and
mechanical loads.
nAlways observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations etc. for the area of use for the diaphragm
pump.
nThe chemical resistance of the materials which we use cannot always be assessed with
authority due to the large number of fluids used, concentrations, temperatures and impurities.
For this reason, please check the suitability as we cannot offer any guarantees in this regard.
nAdhere to the safety data sheets of the spray medium manufacturer.
nOnly use the manufacturer's OEM parts.
nOnly operate the diaphragm pump in compliance with the values specified in (
Ä Chapter 13
‘Technical data’ on page 46).
nOnly operate the diaphragm pump after fastening it properly to a suitable supporting structure.
nDo not hold the diaphragm pump in your hand during operation.
Diaphragm pump MP-400 ENGLISH
Item number: 200-0102 GB–11

nMake sure that the connected compressed air is oil-free and free from 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.
nIt is imperative to adhere to maintenance and cleaning intervals.
nThe conformity of the product is voided in case of structural modifications of the diaphragm
pump.
nDo not use the diaphragm pump in the food or pharmaceutical industries.
WARNING!
Improper use of the diaphragm pump can lead to hazardous situations.
No claims of any kind can be asserted due to damage resulting from misuse.
3.4 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
Operating instructions T-Dok-236-GB-Rev.3
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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.
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.
Operation in indoor and outdoor areas!
During operation in indoor and outdoor areas, use suitable measures to protect the device
against ambient conditions such as:
–Moisture
–UV radiation
–Frost, etc.
3.5 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.
Diaphragm pump MP-400 ENGLISH
Item number: 200-0102 GB–13

3.6 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.
Operating instructions T-Dok-236-GB-Rev.3
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4 Transport, storage, and packaging
4.1 Transport
nThe diaphragm pump is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
4.2 Storage
Store packaged units subject to following conditions:
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%.
4.3 Packaging
The diaphragm pump is packaged in accordance with the anticipated transport conditions and the
packaging needs to protect it against transport damage, corrosion, and other damage.
nRemove packaging material.
nRemove potentially present transport safety restraints.
Diaphragm pump MP-400 ENGLISH
Item number: 200-0102 GB–15

5 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)
Operating instructions T-Dok-236-GB-Rev.3
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6 Installation
6.1 Safety
Personnel:
nSpecialised personnel
nTrained electrician
Protective equipment:
The selection of the protective equipment depends on the installation conditions on site. Always
observe the applicable country-specific safety, accident prevention, occupational safety, and envi-
ronmental protection regulations for the proper selection of the protective equipment.
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.
CAUTION!
Risk of injury through compressed air!
Uncontrolled leaks of compressed air can lead to serious injuries!
– Prior to any work on the device, all compressed-air lines must be closed and bleed if nec-
essary.
Diaphragm pump MP-400 ENGLISH
Item number: 200-0102 GB–17

CAUTION!
Risk of injury due to sharp edges!
Sharp edges and pointed corners can cause abrasions and cuts on the skin.
Note:
– Proceed cautiously when working on or near sharp edges and pointed corners.
– Wear protective gloves, if in doubt.
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.
Operating instructions T-Dok-236-GB-Rev.3
[email protected], www.krautzberger.com GB–18

6.3 Installing the diaphragm pump
Fig. 3: Installation
1. Attach the bracket ( Fig. 3/1) to a wall or supporting construction with the appropriate
screws so that the fluid intake connection ( Fig. 3/2) faces vertically downwards after
assembly.
Fig. 4: Installation
2. Lightly grease three screws ( Fig. 4/3).
3. Attach the diaphragm pump ( Fig. 4/4) to the bracket ( Fig. 4/2) with the screws ( Fig. 4/3).
4. Screw the earth connection to the earth connection screw ( Fig. 4/1).
Diaphragm pump MP-400 ENGLISH
Item number: 200-0102 GB–19

WARNING!
Risk of fatal injury from electrostatic charge!
Electrostatic charges can cause shocks and sparks and thus lead to explosions.
– Ensure proper earth connection.
– Use conductive hose line (< 1 MW).
Operating instructions T-Dok-236-GB-Rev.3
[email protected], www.krautzberger.com GB–20