Sample gas pumps Installation and Operation Instructions P2.x, P2.8x Original instructions
Sample gas pumps P2.x, P2.8x Installation and Operation Instructions Original instructions BE420001 ◦ 10/2013 Bühler Technologies GmbH, Harkortstr. 29, D40880 Ratingen Tel. +49 (0) 21 02 / 49 890, Fax: +49 (0) 21 02 / 49 8920 Internet: www.buehlertechnologies.com EMail: analyse@buehlertechnologies.com All rights reserved., Bühler Technologies GmbH 2014 Document information Document No......................................BE420001 Version ...................................................10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Contents Contents 1 Introduction .......................................................................................................................................................... 2 1.1 Intended use .................................................................................................................................................. 2 1.2 Product key .................................................................................................................................................... 2 1.3 Product description ........................................................................................................................................ 4 1.4 Scope of delivery ........................................................................................................................................... 4 2 Safety instructions............................................................................................................................................... 4 2.1 Important advice ............................................................................................................................................ 4 2.2 General indication of risk ............................................................................................................................... 6 3 Transport and storage......................................................................................................................................... 7 4 Installation and connection ................................................................................................................................ 7 4.1 Requirements to the installation site .............................................................................................................. 7 4.2 Mounting ........................................................................................................................................................ 8 4.3 Special condition moist sample gas............................................................................................................... 8 4.3.1 Conversion to pump body pointing down ........................................................................................... 8 4.4 Connecting the sample gas line..................................................................................................................... 9 4.5 Electrical connections .................................................................................................................................. 10 5 Operation and control ....................................................................................................................................... 10 5.1 Switching the sample gas pump on ............................................................................................................. 11 5.2 Operating the sample gas pump.................................................................................................................. 11 6 Maintenance ....................................................................................................................................................... 12 6.1 Replacing the inlet and outlet valves ........................................................................................................... 13 6.2 Replacing bellow and connecting rodeccentriccombination ...................................................................... 14 6.3 Replacement of the Oring of the bypass valve (optional) ........................................................................... 16 6.4 Replacement of the coupler (P2.4 & P2.84pump) ...................................................................................... 16 7 Service und repair.............................................................................................................................................. 16 7.1 Troubleshooting ........................................................................................................................................... 16 7.2 Spare parts and accessories ....................................................................................................................... 18 8 Disposal .............................................................................................................................................................. 18 9 Attached documents ......................................................................................................................................... 18 10/2013 BE420001 i Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Introduction 1 Introduction 1.1 Intended use The sample gas pumps are designed for installation in gas analyser systems in industrial applica tions. The sample gas pump is designed to transport only gaseous media. It is not suitable for liquids. Please regard information given in the data sheets with respect to specific use, available material combinations and pressure and temperature limits. DANGER Potentially explosive atmosphere Explosion hazard if used in hazardous areas. The device is not suitable for operation in hazardous areas with potentially ex plosive atmospheres. Do not expose the device to combustible or explosive gas mixtures. 1.2 Product key The device is delivered with different configurations. The part number given on the type plate in forms you about the specific configuration of your device. On the type plate you will find the order number as well as the 13digit product key. This number is a code where each digit (x) describes a certain feature: 2 BE420001 10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Introduction 42 xx x x x x x 9 56 57 63 64 1 2 5 1 2 1 2 3 1 2 9 1 2 3 4 9 1 2 3 5 9 0 00 Feature Basic type P2.3 400 l/h P2.4 400 l/h P2.83 800 l/h P2.84 800 l/h Motor supply 230 V 50/60 Hz. 0,85/0,8 A 115 V 50/60 Hz. 1,7/1,6 A 400 V 50/60 Hz. 0,5/0,43 A Pump head position Normal position vertical Pointing downwards * Pump head material PTFE SS 1.4571 PTFE with bypass valve * Valve material to 100 °C; PTFE / PVDF ** to 160 °C; PTFE / PEEK Male stud couplings (for voltages 230 V and 400 V) PTFE pump body Stainless steel pump body DN 4/6 (standard) 6 mm (standard) DN 6/8 8 mm 3/8“1/4“ 3/8“ 1/4“1/8“ 1/4"1/6” 1/4“ Male stud couplings (for voltage 115 V) PTFE pump body Stainless steel pump body 1/4“1/6“ (standard) 1/4“ (standard) DN 6/8 8 mm 3/8“1/4“ 3/8“ 1/4“1/8“ DN 4/6 6 mm Mounting accessories including mounting console and buffer * * not possible for P2.4 & P2.84 ** not possible for P2.4, P2.83 & P2.84 If there are special instructions for a pump type, they are marked in the manual. Take care of the limits of the pump (see data sheet). When ordering spare parts chose for the type matching part numbers (e.g. valves). 10/2013 BE420001 3 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Safety instructions 1.3 Product description This operating and installation manual describes the sample gas pumps P2.x. The sample gas pump is designed to transport only gaseous media not liquids. Please regard the information given in the data sheets concerning specific use, available materials, pressure and temperature ranges. Regard in particular the information and type of protection given on the type plate. Pump head and drive are separated at the P2.4 / P2.84 pump installation of the pump head in hot applications. The flange is subdivided so that the head can be mounted inside the heated housing and the other flange part carries the motor mounted outside. The wall thickness may be up to 30 mm (1.2“). Sample gases, which still contain humidity, tend to form condensate in the tubes and in the pump body. In such cases the pump head must be mounted with the head pointing down (see chapter Conversion to pump body pointing down [_ 8]). NOTICE Never use sample gas pumps outdoors! 1.4 Scope of delivery P2.3 & P2.83 – 1 x sample gas pump with motor – 4 x rubbermetalbuffer – 1 x console made of 1.4301 – 1 x product documentation P2.4 & P2.84 – 1 x pump body with flange – 1 x motor – 1 x coupling flange – 1 x coupling – 6 x screws M6x16 – 1 x mounting ring – 1 x product documentation 2 Safety instructions 2.1 Important advice Operation of the device is only valid if: – the product is used under the conditions described in the installation and operation instruction, the intended application according to the type plate and the intended use. In case of unauthor ized modifications done by the user Bühler Technologies GmbH can not be held responsible for any damage, – when complying with the specifications and markings on the nameplates. 4 BE420001 10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Safety instructions – the performance limits given in the datasheets and in the installation and operation instruction are obeyed, – monitoring devices and safety devices are installed properly, – service and repair is carried out by Bühler Technologies GmbH, – only original spare parts are used. This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep this manual for later use. Signal words for warnings DANGER Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided. WARNING Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not avoided. CAUTION Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or minor or medium injuries if not avoided. NOTICE Signal word for important information to the product. Tab. 1: Signal words for warnings Warning signs In this manual, the following warning signs are used: Warning against hazardous situ ations General notice Warning against electrical voltage Disconnect from mains Warning against respiration of toxic gases Wear respirator Warning against acid and corrosive substances Wear eye/face protection Warning against potentially explos ive atmospheres Wear protection gloves Warning against hot surface 10/2013 BE420001 5 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Safety instructions 2.2 General indication of risk Installation of the device shall be performed by trained staff only, familiar with the safety require ments and risks. Check all relevant safety regulations and technical indications for the specific installation place. Prevent failures and protect persons against injuries and the device against damage. The operator of the system must secure that: – safety and operation instructions are accessible and followed, – local safety regulations and standards are obeyed, – performance data and installation specifications are regarded, – safety devices are installed and recommended maintenance is performed, – national regulations for disposal of electrical equipment are obeyed. Maintenance, repair: – Repairs on the device must be carried out by Bühler authorized persons only. – Only perform modifications, maintenance or mounting described in this manual. – Only use original spare parts. During maintenance regard all safety regulations and internal operation instructions. DANGER Electrical voltage Electrocution hazard. a) Disconnect the device from power supply. b) Make sure that the equipment cannot be reconnected to mains unintention ally. c) The device must be opened by trained staff only. d) Regard correct mains voltage. DANGER Toxic and corrosive gases Sample gas can be hazardous. a) Take care that the gas is exhausted in a place where no persons are in danger. b) Before maintenance turn off the gas supply and make sure that it cannot be turned on unintentionally. c) Protect yourself during maintenance against toxic / corrosive gases. Use gloves, respirator and face protector under certain circumstances. DANGER Potentially explosive atmosphere Explosion hazard if used in hazardous areas. The device is not suitable for operation in hazardous areas with potentially ex plosive atmospheres. Do not expose the device to combustible or explosive gas mixtures. 6 BE420001 10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Transport and storage CAUTION Tilting risk Damage of the device Secure the device against any sudden translocation during maintenance. CAUTION Hot surface Burning hazard According to the product type and operation conditions, the temperature of the housing may exceed 50 °C during operation. Depending on the conditions at the installation site it may be necessary to provide these areas with appropriate warning signs. 3 Transport and storage The products should be transported only in its original packaging or a suitable replacement. When not in use, protect the equipment against moisture and heat. Keep it in a covered, dry and dustfree room at a temperature of 20 °C to +40 °C. Outdoor storage is forbidden. As a matter of principle, the operator must regard all applicable standards according prevention of damage due to lightning, which may otherwise damage the sample gas pump. The storage room must not be equipped with any ozoneproducing devices like fluorescent light sources, mercury arc lamps, electric high voltage devices. 4 Installation and connection 4.1 Requirements to the installation site CAUTION Damage to the device Protect the equipment against dust, falling objects and external impacts. Stroke of lightning Outdoor installation is forbidden. As a matter of principle, the operator must re gard all applicable standards according prevention of damage due to lightning, which may otherwise damage the sample gas pump. Air ventilation must not be obstructed and exhausted air including air from adjacent units must not be sucked in directly. The motor is suitable for ambient temperatures between 20 °C to +60 °C and altitude of height ≤ 1000 m above sea level. Please leave enough space between the motor and the rear panel by mounting without the con sole. Please refer to the data sheet attached to this manual for further information about ambient parameters at the installation site. 10/2013 BE420001 7 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Installation and connection d = air inlet 4.2 Mounting P2.3 / P2.83 For mounting the sample gas pump to mounting plates only use the included brackets and rubber metal buffers. Use these buffers as well if the pump is installed on an existing substructure. P2.4 / P2.84 Please refer to the attached drawings 42/011143 for P2.4 and 42/014Z05033 for P2.84 for mounting instructions. Here you also find the dimensions for the wall cutout. Install the pump always and only with the flange to the housing, cabinet or wall. Fixing the motor in addition is neither required nor admissible because then the system is mechanically overdeterm ined. 4.3 Special condition moist sample gas Applications where the sample gas is still moist may result in condensate forming in line and the pump body. In these events the pump head must be suspended (pump body facing down). If the pump was not ordered this way, it can easily be converted on site. Install the line between the gas output and condensate drain with a grade so the condensate can drain and does not collect inside the pump or the lines. 4.3.1 Conversion to pump body pointing down CAUTION Damage to the device Especially with pump head pointing down, make sure that no dust or small parts can intrude the pump through the ventilations slot. Nevertheless, the slot must not be covered directly. If this is not possible, the pump must not be mounted with pump head pointing downward. To do this, unscrew the three crosshead screws of the housing cover and remove the cover (see fig. 3, fig. 4) (see components drawing in the appendix). The crankshaft and the motor flange are now visible. The pump housing is fixed with four hexagon head screws (wrench size 8) to the motor flange . Remove them completely (fig. 5). Hold the housing when screwing out the last screw. Now turn the housing carefully by 180° on the flange centering, refix it with the screws (fig. 6, fig. 7) and remount the cover (tightening torque of the hexagon head screws 3 Nm). mounting the pump head with angle 45° is forbidden! 8 BE420001 10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Installation and connection Fig. 3 Fig. 4 Fig. 6 Fig. 5 Fig. 7 4.4 Connecting the sample gas line The pumps are delivered with customized gas connections. Please compare the partno. on the type plate with the partno. explained in chapter "Introduction". Avoid mixed installations, that is connecting metal tubes to plastic bodies. If this is unavoidable for sporadic applications, screw the metal fitting with utmost care and without any use of force to the PTFE pump body. Install the tubes in a way that the line at the inlet and outlet is flexible over a sufficient distance (pump vibrates). The pumps are marked with “In” for inlet (input) and “Out” for outlet (output). Make sure that the connections to the tubes are tight. 10/2013 BE420001 9 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Operation and control 4.5 Electrical connections WARNING Hazardous electrical voltage The device must be installed by trained staff only. CAUTION Wrong mains voltage Wrong mains voltage may damage the device. Regard the correct mains voltage as given on the type plate. A switch or power switch (according to IEC 609471 and IEC 609473) must be installed for the sample gas pump. It must be easily accessible by the user. The switch must be marked as circuit breaker for the device. It must not be installed in the mains power cord and must not interrupt the protective earth conductor. Furthermore, it must disconnect the device from all poles. The sample gas pump must be protected against overheating by a suitable overload protection. Regard the rated current for the settings of the circuit breaker (see motor type plate). Connect the pump according to the circuit diagram inside the terminal cover plate and provide suffi cient strain relief of the mains cable. Make sure that mains voltage and frequency meet the spe cifications of the pump's motor (voltage tolerance ± 5 % and frequency tolerance ± 2 %.). Select mains and PE cross section according to the rated current. The cross section must be at least 1.5 mm2. Connect the protective earth conductor of the motor to the local earth conductor. It is essential to connect the protective earth conductor to the marked PE terminal. Regard national directives, in Germany DIN VDE 0100. Make sure that no foreign bodies, dirt and moisture are left inside the terminal box. Seal nonused cable ducts and the terminal box itself against dirt and water. Use the original gasket when closing the terminal box. Seal nonused holes with approved plugs. Obey differing specifications on the type plate. The conditions at the installation site must meet all specifications on the type plate, 5 Operation and control NOTICE The device must not be operated beyond its specifications. CAUTION Hot surface Burning hazard According to the product type and operation conditions, the temperature of the housing may exceed 50 °C during operation. Depending on the conditions at the installation site it may be necessary to provide these areas with appropriate warning signs. 10 BE420001 10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Operation and control 5.1 Switching the sample gas pump on Before switching the sample gas pump on make sure that – gas fittings and electric connections are correctly mounted an not damaged. – no parts of the sample gas pump are dismantled (e. g. cover). – gas inlets and outlet of the sample gas pump are not closed. – the system pressure ranges below 0.5 bar. – the limits of ambient conditions are observed. – all specifications as given on the type plate are observed. – motor voltage and frequency meet the mains values. – the electrical connections are fixed tightly and that monitoring devices are installed and set ac cording to directions! – air vents and cooling surfaces are clean. – protection measures are installed; Grounding! – the motor is fixed properly. – the terminal box is closed and the cable ducts are sealed properly. – the elastomer gear ring of the coupling (P2.4 / P2.84 only) is installed correctly and is not dam aged. NOTICE Never use sample gas pumps outdoors! When switching the sample gas pump on make sure that – no abnormal sounds or vibrations occur. – the flow rate is neither too low nor too high. This would indicate a cracked bellow. 5.2 Operating the sample gas pump The sample gas pump is suitable for delivering gases only. It is not suitable for liquids. The sample gas pump should be operated without pressure. A system pressure above 0.5 bar is not allowed. The gas outlet must not be closed. The flow through the pump has to be 50 l/h min imum with the P2.x and a minimum of 200 l/h with the P2.8x types. If the flow shall be reduced to less than 150 l/h with the P2.x or 400l/h with the P2.8x permanently, the flow has to be regulated with an external bypass valve. In this case, pump type "PTFE with bypass valve“ should be used. NOTICE Extreme throttling reduces the life time of the bellow. If the pump is equipped with a bypass valve, the flow rate can be adjusted. Do not apply force when turning the valve, because the valve may be damaged otherwise! The turning range of the valve is about 7 turns. 10/2013 BE420001 11 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Maintenance 6 Maintenance Wait until the surface has cooled down before beginning maintenance. – Maintenance of the device shall be performed by trained staff only, familiar with the safety re quirements and risks. – Only perform maintenance work described in this manual. – Regard all relevant safety regulations and internal operating instructions during maintenance. NOTICE Please refer to the spare parts drawings attached when performing maintenance. DANGER Electrical voltage Electrocution hazard. a) Disconnect the device from power supply. b) Make sure that the equipment cannot be reconnected to mains unintention ally. c) The device must be opened by trained staff only. d) Regard correct mains voltage. DANGER Toxic, corrosive gas Sample gas may be harmful. a) Before maintenance turn off the gas supply and surge with air if necessary. b) Exhaust sample gas to a safe place. c) Protect yourself against toxic / corrosive gas during maintenance. Wear ap propriate personal protective equipment. CAUTION Tilting risk Damage of the device Secure the device against any sudden translocation during maintenance. CAUTION Gas leakage The sample gas pump should not be dismantled under pressure. 12 BE420001 10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Maintenance CAUTION Hot surface Burning hazard According to the product type and operation conditions, the temperature of the housing may exceed 50 °C during operation. Depending on the conditions at the installation site it may be necessary to provide these areas with appropriate warning signs. Depending on the composition of the sample gas, it may be necessary to replace the in and outlet valves from time to time. If the valves are heavily contaminated, especially after a short time, consider installing a particle fil ter upstream the pump. This increases the service life significantly. The screws of the fastening ring should be retightened after 500 hours of operation with torque 3 Nm. 6.1 Replacing the inlet and outlet valves 1. Screw out the fittings (a/f 17mm) (Fig. I / Fig. II). 2. Screw out the valves with a wide screw driver (Fig. III, Fig. IV, Fig. V) (Do not damage the screw thread!). Please note that the stainless steel pump head includes PTFE displacers. They are placed below the valves are used for a reduction of the clearance volume. 3. Screw in new valves with max. 1 Nm (Fig. V, Fig. IV, Fig. III). Regard the right direction (red or orange: inlet – black or grey: outlet). 4. Screw in the fittings (a/f 17mm) (Fig. VI, Fig. VII). Check tightness. Damaged seals from stain less steel fittings should be replaced. 10/2013 Fig. I Fig. II Fig. III Fig. V Fig. VI Fig. VII BE420001 Fig. IV 13 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Maintenance 6.2 Replacing bellow and connecting rodeccentriccombination NOTICE Restrictions for connecting rodeccentric replacement The individual replacement of the eccentric, connecting rod or bearings is not al lowed. Only the factory preassembled connecting rodeccentric combination is suitable for replacement by the operator. 1. Remove the 3 fillisterhead screws on the housing cover and demount the housing cover. (Fig. A) 2. Clean the sample gas pump from dust and other contamination. 3. Mop up stuck dirt with a wet and clean cloth (do not use detergents containing organic solvents). 4. Remove the four hexagon bolts a/f 7mm on the top of pump body. If the pump body is made of PTFE, please remove also the retainer. (Fig. B) 5. Pull the pump head carefully out of the pump console. Make sure that the bellow won’t be ex panded. If the pump body is clamped to the bellow, try to loose it with rotary action. 6. Hold the bellow bottom which is the upside of the connecting rod and unscrew it counter clock wise (Fig. C). Draw the bellow out of the pump console upwardly. If you only need to replace the bellow, continue with point 13. 7. Remove the six hexagon bolts a/f 8mm on the pump console (Fig. D) and lift the pump console above the connecting rod (Fig. E) 8. Remove the grub screw a/f 2 mm on the eccentric. (Fig. F) 9. Prise the eccentric carefully out of the engine/intermediate shaft. 10. Cleanse the engine/intermediate shaft and check damage. Check tolerance of dimension 11G6 (11,006 to 11,017). (Fig. G) Lubricate the engine/intermediate shaft with resinfree oil. 11. Press the new connecting rod and eccentric combination evenly on the engine / intermediate shaft (Fig. H). (Don’t hammer the components). Adjust the bore holes with the grub screw. (Fig. I) 12. Insert grub screw with Loctite 243 (medium strength) and tighten the screw with 1.5 Nm. Please make sure that the grub screw locates also in the engine/intermediate shaft. 13. Insert pump console through the connecting rod, adjust it perpendicular to the motor and fasten it with hexagon bolts. Tighten the screws with 3 Nm. 14. Check the sealing surface and folding of the bellow whether there is damage or contamination. If there is any contamination, please remove them first. 15. Insert the bellow (Fig. J) from top through the pump console and screw it tight to the connecting rod by hand. Hold the bellow above the connecting rod. (Fig. C) 16. Clean the pump body and check for damage. 17. Insert the pump body on the bellow. Regard the position of in and outlet. 18. Fasten the pump body with retainer (with PTFE pump head only) and hexagon bolts DIN 933 M4 x 45 V2A. Tighten the screws with 3 Nm. 19. Fasten the housing cover with three fillisterhead screws DIN 966 M3 x 8. 20. Connect the pump as described in chapter „Mounting and installation“ and carry out a test run. The following values must be reached at least. Overpressure: P2.3/P2.4 = 1,7 bar; P2.83/P2.84 = 3,5 bar Negative pressure: P2.3/P2.4 = 0,65 bar; P2.83/P2.84 = 0,75 bar Flow rate: P2.3/P2.4 = 400 l/h; P2.83/P2.84 = 800 l/h 14 BE420001 10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Maintenance Fig. A Fig. B Fig. C Fig. D Fig. E Fig. F Fig. G Fig. H Fig. I Fig. J 10/2013 BE420001 15 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Service und repair 6.3 Replacement of the Oring of the bypass valve (optional) – Loosen the screws left and right of the knob and remove valve carefully. – Replace the Oring and reassemble the valve. 6.4 Replacement of the coupler (P2.4 & P2.84pump) In case of a broken coupler the reason for that should be examined! If the reason would be e.g. a jamming bearing, the whole pump head should be exchanged. – Dismount pump head and motor with coupling flange (see mounting drawing of the pump). – Disassemble coupling flange from motor. – Loosen the setscrews of the coupler and disassemble the parts of the coupler from the shafts. Assemble new coupler and fix the setscrews. – Mount the coupling flange to the motor and mount the pump again as described on the mount ing drawing. 7 Service und repair If the device shows irregularities see this chapter for troubleshooting. Repairs on the device must be carried out by Bühler authorized persons only. If you need help or more information call: +49(0)2102498955 or your local agent If the device doesn’t work correctly after elimination of failures and turning power on, the device must be checked by the manufacturer. Please ship the device with suitable packing to Bühler Technologies GmbH Reparatur/Service Harkortstraße 29 40880 Ratingen Deutschland In Addition, attach the filled in and signed Declaration of Decontamination status to the packing. Otherwise, your repair order cannot be processed! The form can be requested by email to service@buehlertechnologies.com. 7.1 Troubleshooting CAUTION Risk due to defective device Personal injury or damage to property a) Switch off the device and disconnect it from the mains. b) Repair the fault immediately. The device should not be turned on again be fore elimination of the failure. 16 BE420001 10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Service und repair CAUTION Hot surface Burning hazard According to the product type and operation conditions, the temperature of the housing may exceed 50 °C during operation. Depending on the conditions at the installation site it may be necessary to provide these areas with appropriate warning signs. Problem / Failure Pump does not start Pump does not trans port Possible cause – Mains disrupted or not correctly mounted – Motor defective – Valves damaged or spoiled – Bypass valve open – Oring of bypass valve dam aged – Bellow cracked – Spider cracked / wornout Pump noisy – Crank gear wornout – Spider wornout – Loose coupling hub Premature spider worn out Tripping by protective device 10/2013 – Motor bearing failure – E. g. caused by Ozone contact or similar, effecting a physical change of the spider – Coil and terminal short circuit – Startup time exceeded BE420001 Solution – Check fitting, fuse and switches – Replace motor – Blow out valves carefully or re place them or refer to chapter Replacing the inlet and outlet valves [_ 13]. – Close bypass valve – Should be repaired by Bühler service or refer to "Replacing the Oring of bypass valve" – Should be repaired by Bühler service or refer to Replacing bel low and connecting rodeccent riccombination. – Should be repaired by Bühler service or Inspecting and repla cing the flexible spider. – Should be repaired by Bühler service or Replacing bellow and connecting rodeccentriccom bination. – Should be repaired by Bühler service or Inspecting and repla cing the flexible spider. – Should be repaired by Bühler service or fix stud screw of coup ling hub with 1.34 Nm – Replace motor – Make sure that physical changes of the spider do not occur – Measure insulation resistance – Check startup conditions 17 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Disposal Problem / Failure Possible cause Insufficient delivery rate – Leakage – Bellow cracked – Valves damaged or spoiled Solution – Retighten the head screws, re gard allowed torque (see chapter Maintenance). – Should be repaired by Bühler service or Inspecting and repla cing the flexible spider. – Blow out valves carefully or re place them or refer to chapter Replacing the inlet and outlet valves [_ 13]. Tab. 2: Trouble shooting 7.2 Spare parts and accessories To order spare parts, please specify device type and serial number. For accessories and enhancement see data sheets and/or catalogue. The following parts are recommended for stocking: Spare part P2.3 / P2.4 P2.83 / P2.84 Bellow Connecting rod / eccentric com bination Flexible spider for coupling Set of 100 °C valves Set of 160 °C valves Oring bypass Bellow Connecting rod / eccentric com bination Flexible spider for coupling Set of 100 °C valves Set of 160 °C valves Oring bypass Part no. 4200015 4200075 4220011 4201002 4202002 9009115 4200071 4200034 4220011 4201002 4202002 9009115 Tab. 3: Spare parts and accessories 8 Disposal Dispose of parts so as not to endanger the health or environment. Follow the laws in the country of use for disposing of electronic components and devices during disposal. 9 Attached documents – – – – 18 Spare part drawing P2.3: Spare part drawing P2.83: Mounting and spare part drawing P2.4: Mounting and spare part drawing P2.84: BE420001 42/008173 42/014013 42/011143 42/014Z05033 10/2013 Installation and Operation Instructions Sample gas pumps P2.x, P2.8x Attached documents – Data sheet: – Declaration of Conformity: – Declaration of Contamination status 10/2013 BE420001 DE/DA 42 0008 KX 42 0001 19 ® Sample Gas Pump P 2.3; P 2.83; P 2.4; P 2.84 The transportation of sample gas in sample conditioning systems requires reliable sample pumps. The corrosive nature of the gas and the potential of condensate formation are the real challenges for any pump. § Robust and reliable design § Easy to replace valves These sample pumps are equipped with a bellows made from solid PTFE . This design has demonstrated the highest reliability and long lifetime in numerous applications. Designed specifically for harsh gas applications that have entrained liquids present or where condensate is expected to form, it is recommended that the pump head be pointed downwards to accommodate draining of these liquids § Bellow made of one solid piece § Pumps gases with entrained liquid § Long life § Explosion-proof version available § Low noise § 115 V - models with FM C-US approval A special flange design makes the P2.4 and P2.84 designs suitable for hot applications. The flange is designed in two parts one -carrying the pump head- is installed in a heated cabinet and the other -carrying the electrical motor- is flanged to the outside of the cabinet keeping the motor in ambient conditions. DE 42 0008 05/2014 Page 1/4 Bühler Technologies GmbH D - 40880 Ratingen, Harkortstr. 29 Tel.: + 49 (0) 2102 / 49 89-0 Fax: + 49 (0) 2102 / 49 89-20 Internet: www.buehler-technologies.com e-mail: [email protected] Pump Models P2.3 and P2.83 For easy installation of the P2.3 and P2.83 pumps, a support console with vibration dampers is included. The pump head can be ordered with an internal bypass valve. The difference between the P2.3 and P2.83 pump is in the flow provided. The P2.3 pump has a capacity of 400 l/h free flow and the P2.83 has a capacity of 800 l/h free flow. The P2.3 and P2.83 pumps must not be used in explosive areas. The corresponding type for ex areas would be the P2.2 ATEX, P2.2 AMEX and P2.82 AMEX, data sheet 420009, or the US-P2.6Ex, data sheet 420005. Technical Data Nominal voltage Nominal current Protection class See order number See order number Electrical IP55 Mechanical IP20 6.5 kg 8.5 ml Weight Dead space Media temperature 100 °C Valves: PTFE / PVDF 160 °C Valves: PTFE / PEEK max. 60 °C FM File No. 3038101 / 3038101C Ambient temperature FM C-US (115V only) Flow Curve P2.83 Flow Curve P2.3 vacuum bar(atm.) vacuum Nl/h bar (atm.) bar(g.) Nl/h 800 bar (g) 450 700 400 flow curve 600 flow curve 300 output 250 200 500 400 300 150 A000013D 100 50 -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 200 A000124D output 350 100 bar 0 at 60Hz + 10% flow -0,6 -0,4 -0,2 0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 bar at 60Hz + 10% flow Pump Models P2.4 and P2.84 A cabinet wall thickness of up to 30mm (1.2”) can be used without other modifications. The difference between the P2.4 and P2.84 pump is in the flow provided. The P2.4 pump has a capacity of 400 l/h free flow and the P2.84 has a capacity of 800 l/h free flow. The P2.4 and P2.84 Pumps must not be used in explosive areas. The corresponding type for ex areas would be the P2.4 ATEX, P2.4 AMEX and P2.84 AMEX, data sheet 420009. Technical Data Nominal voltage Nominal current Protection class See order number See order number Electrical IP55 Mechanical IP20 7.5 kg 8.5 ml Weight (approx.) Dead space Media temperature Ambient temp. Motor Pump head FM C-US (115V only) 160 °C max. 60 °C max. 100 °C FM File No. 3038101 / 3038101C Flow Curve P2.84 Flow Curve P2.4 vacuum bar(atm.) vacuum 450 700 400 600 output flow curve 350 output bar (g) bar (atm.) 300 250 200 flow curve 500 400 300 150 200 A000013D 100 DE 42 0008 05/2014 Page 2/4 bar(g.) Nl/h 800 50 -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 at 60Hz + 10% flow bar A000124D Nl/h Valve: PTFE / PEEK 100 0 -0,6 -0,4 -0,2 0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 at 60Hz + 10% flow bar Ordering hints: Part-no. 42 XX X X X X X 9 56 57 63 64 1 2 5 1 2 1 2 3 1 2 9 1 2 3 4 9 1 2 3 5 9 0 00 Feature Basic type P2.3 400 l/h P2.4 400 l/h P2.83 800 l/h P2.84 800 l/h Motor supply 230 V 50/60 Hz. 0,85/0,8 A 115 V 50/60 Hz. 1,7/1,6 A 400 V 50/60 Hz. 0,5/0,43 A Pump head position Normal pos. vertical Pointing downwards * Pump head material PTFE SS 1.4571 PTFE with bypass valve * Valve material to 100 °C PTFE/PVDF ** to 160 °C PTFE/PEEK Male stud couplings (for voltages 230 V and 400 V) PTFE pump head Stainless steel pump head 6 mm (standard) DN 4/6 (standard) 8 mm DN 6/8 3/8” 3/8"-1/4” 1/4"-1/8" 1/4"-1/6” 1/4” Male stud couplings (for voltage 115 V) PTFE pump head Stainless steel pump head 1/4" (standard) 1/4"-1/6" (standard) 8 mm DN 6/8 3/8” 3/8"-1/4” 1/4"-1/8" 6 mm DN 4/6 Mounting accessories including mounting console and buffer * *not possible for P2.4 and P2.84 **not possible for P2.4, P2.83 and P2.84 Note: x stands for number below. Ordering example: part no. 42 631112 99 63 for 800 Liter pump P2.83 1 for 230 V 50/60 Hz Motor 1 for pump head pointing up 1 pump head PTFE 2 for 160 °C valves 9 for DN4/6 screw in screw connection 9 including mounting console and buffer DE 42 0008 05/2014 Page 3/4 Dimensions P2.3 and P2.83 Pumps Gas connections at buyer's option M20x1,5 24 Console 63 8 A 130 262 186 207 BÜHLER 81 100 125 M6 104 80 247,5 302 View: A 130 100 Ø7 Adjustable bypass valve optional 18 BÜHLER 100 130 Dimensions P2.4 and P2.84 Pumps 24 Gas connections at buyer's option M20x1,5 wall 148 max.30 M6 211 BÜHLER 8 63 181 ` 85 ` 116 80 229 ` ø7 27 345 100 125 ° 60 ø94 ø110 30° A00000125X 1) Direction of the inlet/outlet connections can be chosen while mounting 2) If the gas carries condensate, the inlet/outlet connections must point downwards DE 42 0008 05/2014 Page 4/4 ø7 Mounting hints Cabinet cut-out we reserve the right to amend specification Sample Gas Pump P 2.3; P 2.83; P 2.4; P 2.84 The transportation of sample gas in sample conditioning systems requires reliable sample pumps. The corrosive nature of the gas and the potential of condensate formation are the real challenges for any pump. § Robust and reliable design § Easy to replace valves These sample pumps are equipped with a bellows made from solid PTFE . This design has demonstrated the highest reliability and long lifetime in numerous applications. Designed specifically for harsh gas applications that have entrained liquids present or where condensate is expected to form, it is recommended that the pump head be pointed downwards to accommodate draining of these liquids. § Bellow made of one solid piece § Pumps gases with entrained liquid § Long life § Explosion-proof version available § Low noise § 115 V - models with FM C-US approval A special flange design makes the P2.4 and P2.84 designs suitable for hot applications. The flange is designed in two parts one -carrying the pump head- is installed in a heated cabinet and the other -carrying the electrical motor- is flanged to the outside of the cabinet keeping the motor in ambient conditions. DA 42 0008 05/2014 Page 1/4 Buhler Technologies LLC 1030 West Hamlin Road, Rochester Hills, MI 48309 Phone: 248.652.1546 Fax: 248.652.1598 Internet: www.buhlertech.com E-mail: [email protected] Pump Models P2.3 and P2.83 For easy installation of the P2.3 and P2.83 pumps, a support console with vibration dampers is included. The pump head can be ordered with an internal bypass valve. The difference between the P2.3 and P2.83 pump is in the flow provided. The P2.3 pump has a capacity of 400 l/h (6.7 lpm) free flow and the P2.83 has a capacity of 800 l/h (13.3 lpm) free flow. The P2.3 and P2.83 pumps must not be used in explosive areas. The corresponding type for ex areas would be the P2.2 ATEX, P2.2 AMEX and P2.82 AMEX, data sheet 420009, or the US-P2.6Ex, data sheet 420005. Technical Data Nominal voltage Nominal current Protection class See order number See order number Electrical IP55 Mechanical IP20 14 lb 0.52 cu. in. Weight (approx.) Dead space Media temp. 210 °F Valves: PTFE / PVDF 320 °F Valves: PTFE / PEEK max. 140 °F FM File No. 3038101 / 3038101C Ambient temp. FM C-US (115V only) Flow Curve P2.83 Flow Curve P2.3 vacuum vacuum bar (g) bar (atm.) Nl/h (lpm) 450 (7.5) 700 (11.7) 400 (6.7) 350 (5.8) flow curve 600 (10.0) flow curve 300 (5.0) 500 (8.3) 250 (4.2) output 200 (3.3) 150 (2.5) A000013D 100 (1.7) 50 (0.8) -0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0 -8.7 -7.3 -5.8 -4.4 -2.9 -1.5 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 0 2.9 5.8 8.7 11.6 14.5 17.4 20.3 23.2 400 (6.7) 300 (5.0) 200 (3.3) A000124D output bar (g) bar (atm.) Nl/h (lpm) 800 (13.3) 100 (1.7) bar 0 (0) psig -0,6 -0,4 -0,2 0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 bar -8.7 -5.8 -2.9 2.9 psig at 60Hz + 10% flow 5.8 8.7 11.6 14.5 17.4 20.3 23.2 26.1 29.0 at 60Hz + 10% flow Pump Models P2.4 and P2.84 A cabinet wall thickness of up to 30mm (1.2”) can be used without other modifications. The difference between the P2.4 and P2.84 pump is in the flow provided. The P2.4 pump has a capacity of 400 l/h (6.7 lpm) free flow and the P2.84 has a capacity of 800 l/h (13.3 lpm) free flow. The P2.4 and P2.84 Pumps must not be used in explosive areas. The corresponding type for ex areas would be the P2.4 ATEX, P2.4 AMEX and P2.84 AMEX, data sheet 420009. Technical Data Nominal voltage Nominal current Protection class See order number See order number Electrical IP55 Mechanical IP20 16.5 lb 0.52 cu. in. Weight (approx.) Dead space Media temperature Ambient temperature Motor Pump head FM C-US (115V only) 320 °F Valve: PTFE / PEEK max. 140 °F max. 212 °F FM File No. 3038101 / 3038101C Flow Curve P2.84 Flow Curve P2.4 vacuum bar(atm.) bar (g) bar (atm.) Nl/h (lpm) 450 (7.5) 700 (11.7) 400 (6.7) output output 350 (5.8) 300 (5.0) 250 (4.2) 200 (3.3) 500 (8.3) 400 (6.7) 300 (5.0) 150 (2.5) 200 (3.3) A000013E 100 (1.7) 50 (0.8) DA 42 0008 05/2014 Page 2/4 flow curve 600 (10.0) flow curve A000124D vacuum bar(g.) Nl/h (lpm) 800 (13.3) 100 (1.7) 0 (0) -0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 bar -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 -8.7 -7.3 -5.8 -4.4 -2.9 -1.5 2.9 5.8 8.7 11.6 14.5 17.4 20.3 23.2 psig -8.7 -5.8 -2.9 2.9 0 at 60Hz + 10% flow 0 5.8 8.7 11.6 14.5 17.4 20.3 23.2 26.1 29.0 at 60Hz + 10% flow bar psig Ordering hints: Part-no. 42 XX X X X X X 9 56 57 63 64 1 2 5 1 2 1 2 3 1 2 9 1 2 3 4 9 1 2 3 5 9 0 00 Feature Basic type P2.3 400 l/h P2.4 400 l/h P2.83 800 l/h P2.84 800 l/h Motor supply 230 V 50/60 Hz. 0,85/0,8 A 115 V 50/60 Hz. 1,7/1,6 A 400 V 50/60 Hz. 0,5/0,43 A Pump head position Normal pos. vertical Pointing downwards * Pump head material PTFE SS 1.4571 PTFE with bypass valve * Valve material to 212 °F PTFE/PVDF ** to 320 °F PTFE/PEEK Male stud couplings (for voltages 230 V and 400 V) PTFE pump head Stainless steel pump head 6 mm (standard) DN 4/6 (standard) 8 mm DN 6/8 3/8” 3/8"-1/4” 1/4"-1/8" 1/4” 1/4"-1/6” Male stud couplings (for voltage 115 V) PTFE pump head Stainless steel pump head 1/4" (standard) 1/4"-1/6" (standard) 8 mm DN 6/8 3/8” 3/8"-1/4” 1/4"-1/8" 6 mm DN 4/6 Mounting accessories including mounting console and buffer * *not possible for P2.4 and P2.84 **not possible for P2.4, P2.83 and P2.84 Note: x stands for number below. Ordering example: Part no.. 42 631112 99 63 for 800 l/h pump P2.83 1 for 230 V 50/60 Hz motor 1 for pump head pointing up 1 pump head PTFE 2 for 320 °F valves 9 for DN4/6 screw in screw connection 9 including mounting console and buffer DA 42 0008 05/2014 Page 3/4 Dimensions P2.3 and P2.83 Pumps Gas connections at buyer's option 0.94” M20x1,5 Console 3.19” 7.32” 8.15” 2.48” 0.31” A 5.12” 10.31” BÜHLER 3.94” 4.92” M6 3.15” 9.74” 11.89” view: A 3.94” 0.28” 5.12” 4.09” 0,71” Adjustable bypass valve optional 3.94” BÜHLER 5.12” Dimensions P2.4 and P2.84 Pumps Gas connections at buyer's option 0,94” M20x1,5 5,83” wall max.1,18” M6 7,13” 8,31” BÜHLER 0,31” 2,48” 3,35” ` 4,57” 3,15” 9,02” ` ` ø0,28” 3,94” 4,92” 13,58” ° 60 ø3,70” ø4,33” Mounting hints 30° A00000125X ø0,28” 1) Direction of the inlet/outlet connections can be chosen while mounting 2) If the gas carries condensate, the inlet/outlet connections must point downwards DA 42 0008 05/2014 Page 4/4 Cabinet cut-out we reserve the right to amend specification Dekontaminierungserklärung Declaration of Contamination status Gültig ab / valid since: 2011/05/01 Revision 0 ersetzt Rev. / replaces Rev --- Die gesetzlichen Vorschriften schreiben vor, dass Sie uns die Dekontaminierungserklärung ausgefüllt und unterschrieben zurück zu senden haben. Die Angaben dienen zum Schutz unserer Mitarbeiter. Bringen Sie die Bescheinigung an der Verpackung an. Ansonsten ist eine Bearbeitung Ihres Reparaturauftrages nicht möglich! Legal regulations prescribe that you have to fill in and sign the Declaration of Contamination status and send it back. This information is used to protect our employees. Please attach the declaration to the packing. Otherwise, your repair order cannot be processed. Gerät / Device: Serien-Nr. / Serial no. : Rücksendegrund / Reason for return: [ ] Ich bestätige hiermit, dass das oben spezifizierte Gerät ordnungsgemäß gereinigt und dekontaminiert wurde und keinerlei Gefahren im Umgang mit dem Produkt bestehen. I herewith declare that the device as specified above has been properly cleaned and decontaminated and that there are no risks present when dealing with the device. Ansonsten ist die mögliche Gefährdung genauer zu beschreiben / In other cases, please describe the hazards in detail: Aggregatzustand (bitte ankreuzen) / Condition of aggregation (please check): Flüssig / Liquid Fest / Solid Pulvrig / Powdery Gasförmig / Gaseous Folgende Warnhinweise sind zu beachten (bitte ankreuzen) / The following safety advices must be obeyed (please check): Explosiv Explosives Giftig / Tödlich Acute toxicity Entzündliche Stoffe Flammable Brandfördernd Oxidizing Komprimierte Gase Gas under pressure Gesundheitsgefährdend Irritant toxicity Gesundheitsschädlich Health hazard Umweltgefährdend Environmental hazard Bitte legen Sie ein aktuelles Datenblatt des Gefahrenstoffes bei / Please include the current material safety data sheet of the hazardous material! Angaben zum Absender / Information about the dispatcher: Firma / Company: Anschrift / Address: Ansprechpartner / Contact person: Abteilung / Division: E-Mail: Tel. / Phone: Fax: Ort, Datum / Location, date: Unterschrift / Stempel Signature / Stamp: Bühler Technologies GmbH D - 40880 Ratingen, Harkortstr. 29 Tel.: + 49 (0) 2102 / 4989-0 Fax: + 49 (0) 2102 / 4989-20 e-mail: [email protected] Internet: www.buehler-technologies.com
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