Krautzberger MP-520 User manual

Article No. ■ 200-0216 ■ 200-0330
Original operating instructions
T-Dok-397-EN-Rev.0-
web
GB Diaphragm pump MP-520
Operating instructions

[email protected], www.krautzberger.com GB–2
Thank you for selecting a Krautzberger product.
This product has been manufactured according to the latest manufacturing procedures and with
extensive quality assurance measures. We promise you a product of the highest quality
If you have questions, desires or suggestions, please contact us; we are always glad to assist you.
Information about the topic of Ex protection
Many of our competitors have been identifying their products with the Ex symbol for a while now.
Krautzberger does not do this.
We construct and manufacture our products according the currently-valid guidelines.
If the marking on the product is required, then it is affixed on the product as the result of the neces-
sary analysis of ignition sources. If no marking is affixed, then the required analysis of ignition
sources as well as previous experience with the assessment of the applicability of the products in
the Ex area showed that the product described in these operating instructions provides no potential
source of ignition with the exception of the electrostatic charge.
Taking into account the potential equalisation (due to proper earthing), use in the Ex area is admis-
sible according to the currently-valid guidelines.

Table of contents
1 Safety................................................................................................................................... 4
1.1 Proper use................................................................................................................... 5
1.2 Personnel requirements............................................................................................... 5
1.3 Personal safety equipment and clothing...................................................................... 6
1.4 Disposal....................................................................................................................... 6
2 Technical data..................................................................................................................... 7
2.1 Dimensions.................................................................................................................. 7
2.2 General specifications................................................................................................. 8
2.3 Material delivery properties.......................................................................................... 8
3 Structure and function..................................................................................................... 10
3.1 Overview.................................................................................................................... 10
3.2 Functional description................................................................................................ 10
4 Installation and connection............................................................................................. 11
4.1 Installing the diaphragm pump................................................................................... 11
4.2 Connection example.................................................................................................. 12
4.3 Connecting the diaphragm pump............................................................................... 13
5 Operation........................................................................................................................... 14
5.1 Commissioning.......................................................................................................... 15
5.2 Stopping operation..................................................................................................... 15
6 Maintenance...................................................................................................................... 16
6.1 Maintenance schedule............................................................................................... 16
6.2 Maintenance work...................................................................................................... 17
7 Faults................................................................................................................................. 20
7.1 Fault table.................................................................................................................. 20
7.2 Replace the pressure controller/control valve............................................................ 22
8 Spare parts/accessories.................................................................................................. 26
8.1 Diaphragm pump spare parts.................................................................................... 26
8.2 Accessories............................................................................................................... 28
9 EU declaration of conformity.......................................................................................... 29
Diaphragm pump MP-520 ENGLISH
Article No. ■ 200-0216 ■ 200-0330
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1 Safety
Safety instructions
DANGER!
This combination of symbol and signal word indicates an immediately dangerous situation
which causes death or severe injuries if it is not avoided.
WARNING!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause death or severe injuries if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause slight injuries if it is not avoided.
NOTICE!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause property and environmental damage if it is not avoided.
This symbol highlights useful tips and recommendations as well as information for efficient
and fault-free operation.
Symbol Explanation
Indicates step-by-step instructions.
ðIndicates a condition or an automatic sequence as the result of an action.
Indicates references to sections of these instructions and other applicable
documents.
Indicates enumerations and list entries without a specified sequence.
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1.1 Proper use
The MP-520 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.
It is mainly used for painting and coating operations.
Proper use also includes observance of all details in these instructions.
Any use beyond the proper use or any other use counts as misuse.
WARNING!
Danger due to misuse!
Misuse of the diaphragm pump can cause dangerous situations.
–Always observe the valid safety, accident prevention, occupational safety and environ-
mental protection regulations valid for the area of application of the diaphragm pump.
–Only use sharply abrasive, chemically-aggressive, very hot or very cold spray media in
consultation with Krautzberger GmbH.
–Only use the manufacturer's original spare parts.
–Only operate the diaphragm pump while adhering the values specified in the Ä Chapter
2 ‘Technical data’ on page 7.
–Only operate the diaphragm pump after proper fastening on a suitable carrier construc-
tion.
–Do not hold the diaphragm pump in your hand during operation.
–Adhere to the spray media manufacturer's safety data sheets.
–Do not use the diaphragm pump in the food or pharmaceutical sectors.
No claims of any type can be asserted due to damage resulting from misuse.
1.2 Personnel requirements
Ensure the use of the device by skilled employees! Only skilled employees can independently
detect and avoid possible dangers during use based on their professional training, experience and
knowledge of the relevant regulations.
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1.3 Personal safety equipment and clothing
When using the device, always wear breathing, eye and ear protection.
Only wear approved protective gloves during cleaning work with solvents.
1.4 Disposal
When the useful life of the device has been exhausted, dispose of it in commercial waste. In order
to prevent damage to the environment, dispose of any remains of spray fluid properly separately
from the device.
Operating instructions T-Dok-397-EN-Rev.0-
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2 Technical data
2.1 Dimensions
Fig. 1: Dimensions in mm
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2.2 General specifications
Data Value Unit
Delivery rate (with respect to water, free flow) 15 l/min
Material connection (outlet) 3/4" external thread Inches
Max. temperature of the coating material used 0 ... +50 °C
Max. pressure 8 bar
Max. permitted operating pressure 8 bar
Compressed air connection (hose sleeve) 8/9 mm
Min. air intake pressure 4 bar
Max. air intake pressure 8 bar
Max. stroke (double strokes) 120 DS/min
Recommended number of strokes (double strokes) 100 DS/min
Weight 9.0 kg
Noise pressure level (at 8 bar and100 DS) 80 dB(A)
Transformation ratio 1:1
Compressed air supply oil-free, filtered
2.3 Material delivery properties
Material Suitability
Paint (with solvent) good
Water-based paint, dispersions, wood preservatives good
Water good
Oils, heating oils, diesel fuel good
Emulsions, soap, detergents good
Alcohol, glazes, latex limited
Lime sludge limited
Cell and fibre materials unsuitable
Sludge, mash, pastes unsuitable
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In case of doubt about suitability of materials not listed, please enquire. In special cases we
will determine the suitability in an experiment.
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3 Structure and function
3.1 Overview
Fig. 2: Overview
1 Material intake connection (material entry)
2 Compressed air connection
3 Pressure gauge
4 Material pressure connection (material outlet)
5 Surge tank connection
6 Material pressure connection 2 (material outlet)
7 Compressed air controller
8 Barrel cover mount (optional)
3.2 Functional description
The pressure required at the extraction point can be adjusted continuously variably using the com-
pressed air controller (Fig. 2/7). As soon as the set material pressure has been reached, the dia-
phragm pump switches off automatically. The material pressure is maintained until material is
extracted at the extraction point. The diaphragm pump switches on automatically and keeps the
set material pressure constant.
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4 Installation and connection
4.1 Installing the diaphragm pump
Fig. 3: Installation
1. Install the pump directly on a wall or supporting structure using the elongated holes
(Fig. 3/3) with suitable fastening screws. In the process, make sure that the material suction
connection (Fig. 3/1) points vertically downwards after installation.
The diaphragm pump can be fitted directly to a barrel cover using the optional barrel cover
mount (Fig. 3/4).
2. Connect the earthing with the earthing screw (Fig. 3/2).
WARNING!
Risk of fatal injury from electrostatic charge.
Electrostatic charges can cause shocks and sparks and thus explosions.
–Ensure proper earthing.
–Use conductive hose line (< 1 MW).
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4.2 Connection example
Fig. 4: Connection example
1 Air controller unit with filter
2 MP-520 diaphragm pump
3 Surge tank
4 Ball cock
5 Screw connection
6 Material filter
7 Reducer
8 Material controller
9 Low-pressure material hose with fittings
10 Spray gun
11 Intake hose with suction cage
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4.3 Connecting the diaphragm pump
Fig. 5: Connection
1. Connect the material intake hose to the material intake connection (Fig. 5/1).
2. Connect the compressed air supply to the compressed air port (Fig. 5/2).
The compressed air supply must be dry, free of oil and secured by a pressure relief
valve.
3. Connect the material pressure hose to the material pressure connection (material outlet)
(Fig. 5/3 or 5).
4. If necessary, connect the surge tank to the connection (Fig. 5/4).
5. Check that all connections are firmly in place.
Diaphragm pump MP-520 ENGLISH
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5 Operation
WARNING!
Risk of injury due to improper operation!
–Only perform operation in accordance with the steps shown in these operating instruc-
tions.
–Never point the compressed air at people.
–Check the material and compressed air hose lines before each use for damage and tight
fit.
–Make sure that the hose lines used fulfil the requirements with respect to pressure,
chemical and mechanical loads.
–Make sure that the connected compressed air is oil-free and free of solid matter.
–Adhere to the spray media manufacturer's specifications in the safety data sheet.
Operating instructions T-Dok-397-EN-Rev.0-
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5.1 Commissioning
Adhere to the operating instructions for the respective components.
1. Check the material and compressed air lines to make sure they are whole and fit tightly.
2. Switch on the compressed air supply.
3. Make sure that there is air pressure of 4 to 8 bar.
4. Make sure that the material intake hose is dipped into the material.
Fig. 6: Compressed air controller
5.
NOTICE!
Risk of increased wear if run in idle.
During initial commissioning there is still air in the diaphragm pump and the supply
lines. In idle mode the diaphragm pump is subject to particularly high levels of wear.
To bleed the pressure controller (Fig. 6/1), first set a low air pressure.
6. Activate the extraction point (e.g. manual spray gun) until material escapes.
7. After successful bleeding, set the desired material pressure with the pressure controller.
5.2 Stopping operation
See Ä Chapter 6.2.1 ‘Cleaning the diaphragm pump’ on page 17.
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6 Maintenance
Hose and pipelines
The service life of hose and pipelines is limited even with proper use by environmental influ-
ences. For the sake of prevention, all hose and pipelines should be replaced regularly
according to their load.
6.1 Maintenance schedule
The following sections describe the maintenance work that is required for optimal and fault-free
operation of the device.
Check wearing parts such as seals at regular intervals. The level of wear depends on the abrasive-
ness of the spray fluid used. Escaping air and spray fluid are signs that parts are worn. In case of
questions about maintenance work and intervals, contact the manufacturer; see contact data on
the last page.
Interval Maintenance work Personnel
After each use Clean diaphragm pump (
Ä Chapter 6.2.1 ‘Cleaning the
diaphragm pump’ on page 17)
Qualified personnel
When required Replace valve parts (
Ä Chapter 6.2.2 ‘Replacing valve
parts’ on page 18)
Qualified personnel
Replace diaphragms ( Ä Chapter 6.2.3 ‘Replacing dia-
phragms’ on page 19)
Qualified personnel
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6.2 Maintenance work
6.2.1 Cleaning the diaphragm pump
WARNING!
Danger of injury due to improper cleaning!
–Observe the safety data sheets of the detergent manufacturer.
–Do not use any halogenated detergents.
1. Interrupt the compressed air supply in a suitable location (e.g. shut-off device).
2. Dip the material intake hose into a suitable detergent.
3. Switch on the compressed air supply.
4. Rinse out the diaphragm pump by activating the extraction point until only detergent liquid
escapes.
5. Disconnect the compressed air supply.
6. If necessary, activate the extraction point again and depressurise the pump.
7. Leave detergent liquid in the pump.
8. Clean the outside of the device with a cloth dipped in detergent.
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6.2.2 Replacing valve parts
1. Clean diaphragm pump (
Ä Chapter 6.2.1 ‘Cleaning the diaphragm pump’ on page 17).
2. Make sure that the compressed air supply is switched off.
3. If necessary, depressurise the material by activating the extraction point.
Fig. 7: Valve parts
4. Unscrew the hexagon screws (Fig. 7/1).
5. Remove the bridge (Fig. 7/2).
6. Remove the flat seals (Fig. 7/3), ball cages (Fig. 7/4), valve balls (Fig. 7/5) and the valve
seat (Fig. 7/6).
7. Check all parts for damage and wear and replace them as necessary.
8. Replace diaphragms (
Ä Chapter 6.2.3 ‘Replacing diaphragms’ on page 19).
9. Clean the valve housing.
10. Install all valve parts (Fig. 7/3 to 6) in the sequence shown.
11. Attach the bridge (Fig. 7/2).
12. Screw the hexagon screws (Fig. 7/1) tight.
13. Clean the diaphragm pump (
Ä Chapter 6.2.1 ‘Cleaning the diaphragm pump’ on page 17)
and perform a test run ( Ä Chapter 5.1 ‘Commissioning’ on page 15).
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6.2.3 Replacing diaphragms
The following is a description of how to replace the diaphragm using the example of the left-
hand side of the diaphragm pump.
1. Clean diaphragm pump (
Ä Chapter 6.2.1 ‘Cleaning the diaphragm pump’ on page 17).
2. Make sure that the compressed air supply is switched off.
3. If necessary, depressurise the material by activating the extraction point.
4. Remove the bridges and valve parts (
Ä Chapter 6.2.2 ‘Replacing valve parts’ on page 18).
Fig. 8: Unscrew the cover
5. Unfasten all 4 screws (Fig. 8/1) and remove the diaphragm cover (Fig. 8/2).
6. Unscrew the diaphragm (Fig. 8/3) from the control pin (Fig. 8/4).
7. Clean contact surfaces of the diaphragm cover.
8. Screw the new diaphragm (Fig. 8/3) firmly into the control pin (Fig. 8/4).
9. Attach the diaphragm cover (Fig. 8/2).
10. Lightly grease all 4 screws (Fig. 8/1) and screw tight to 20 Nm.
11. Install the bridges and valve parts (
Ä Chapter 6.2.2 ‘Replacing valve parts’ on page 18).
12. Perform test run (
Ä Chapter 5.1 ‘Commissioning’ on page 15).
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7 Faults
7.1 Fault table
If the fault is not included in the following tables or if it cannot be eliminated with the measures
described, contact the manufacturer (for contact data, see last page).
Fault Cause Remedy
Air in the pressure line Suction line loose/leaking Check suction line, tighten if
necessary
Seals faulty/worn Replace seal (
Ä Chapter 6.2.2
‘Replacing valve parts’
on page 18)
Diaphragm faulty Replace diaphragm
( Ä Chapter 6.2.3 ‘Replacing
diaphragms’ on page 19)
Diaphragm pump runs
unevenly
Foreign bodies sucked in Remove the valve parts and
check for damage, replace any
parts as necessary ( Ä Chapter
6.2.2 ‘Replacing valve parts’
on page 18)
Air is sucked in Check suction direction
Suction line blocked Check suction line and clean it
as necessary
Valve balls/valve seat soiled/
leaking
Clean/replace valve balls/valve
seat ( Ä Chapter 6.2.2
‘Replacing valve parts’
on page 18)
The diaphragm pump runs
unevenly after removing the
control valve
The control valve has been
installed positioned slightly to
the side after removal /
replacement.
Check the position of the con-
trol valve and adjust it as
necessary ( Ä Chapter 7.2
‘Replace the pressure con-
troller/control valve’
on page 22)
The diaphragm pump does not
start up
No compressed air available Switch on and check com-
pressed air supply
Pressure controller/control
valve faulty
Replace the pressure con-
troller/control valve ( Ä Chapter
7.2 ‘Replace the pressure con-
troller/control valve’
on page 22)
Pump works but no pressure
builds up or no suction
Intake screen soiled Clean intake screen
Suction hose is kinked/leaking Check suction hose
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