Pump BS-B according to Atex

Transcription

1 Operating instructions Pump BS-B according to Atex with explosion protection 94/9/EG for applications in category 2 GD and 3 GD zone 1, 2, 21 and 22 INDEX Page 1. General Safety A. Pump type... 5 B. Number of outlets... 5 C. Revision... 5 D. Kinds of drive... 5 E. Position of drive... 6 F. Reservoir... 6 G. Accessories Application Design Principle of operation Specification Start-up, installation Maintenance Modules and measures Plates Page 1 of 14

2 1. GENERAL Prior to start up, we recommend to read these operating instructions carefully as we do not assume any liability for damages and operating troubles which result from the nonobservance of these operating instructions! Any use beyond the applications described in these operating instructions is considered to be not in accordance with the product s intended purposes. The manufacturer is not to be held responsilbe for any damages resulting from this: the user alone bears the corresponding risk. As to figures and indications in these operating instructions we reserve the right to make technical changes which might become necessary for improvements. The copyright on these operating instructions is kept reserved to the company DELIMON. These operating instructions are intended for the erecting, the operating and supervising personnel. They contain regulations and drawings a technical nature which must not completely or partially - be distributed nor used nor communicated to others without authorization for competition purposes. Company address, spare parts and service address DELIMON GmbH Branch office Arminstraße 15 Am Bockwald 4 D Düsseldorf D Grünhain-Beierfeld Phone : kontakt@bijurdelimon.com Fax : SAFETY These operating instructions contain fundamental instructions which are to be observed during erection, operation and maintenance. Therefore it is absolutely necessary for the fitter and the competent qualified staff/user to read these operating instructions before installation and start-up. The operating instructions must be available at all times at the place of use of the machine/system. Not only the general safety instructions stated under this main point safety are to be observed, but also the other specific safety instructions stated under the other main points. 2.1 Identification of safety warnings in the operating instructions The safety warnings contained in these operating instructions which, if not observed, may cause dangers to people, are specially marked with general danger symbols safety sign according to DIN 4844-W9, warning about a danger spot, in case of warning about electric voltage with safety sign according to DIN 4844-W8, warning about dangerous electric voltage. In case of safety instructions which, if not observed, may cause damage to the machine and its function, the word ATTENTION is inserted. Instructions that are directly attached to the machine, as for example rotational direction arrow identifications for fluid connections must be observed at all events and maintained in a fully legible condition. Note: There is an increased skid risk in case of spilled/leaked out lubricants. They are to be removed at once properly. Safety sign according to DIN , W28, warning about skid risk. Page 2 of 14

3 2. SAFETY (continuation) 2.2 Personnel qualification and training The operating, maintaining, inspecting and erecting personnel must have the appropriate qualification for such work. Area of responsibility, competence and supervision of the personnel have to be regulated by the user. If the personnel do not have the necessary knowledge, they have to be trained and given instructions. This can be effected, if necessary, by the manufacturer/supplier on behalf of the user of the machine. Furthermore, the user has to make sure that the contents of the operating instructions are fully understood by the personnel. 2.3 Dangers in case of nonobservance of the safety instructions The nonobservance of the safety instructions may result in hazards to persons, to the environment and to the machine. The nonobservance of the safety instructions may lead to the loss of any claims for damages. In detail, the nonobservance may for instance lead to the following hazards: Failure of important functions of the machine/system Failure of prescribed methods for maintenance and repair Hazard to persons by electrical, mechanical and chemical influences Hazard to the environment by the leakage of dangerous substances 2.4 Safety conscious working The safety instructions stated in these operating instructions, the existing national regulations as to the accident prevention as well as possible internal working, operating and safety rules of the user are to be observed. 2.5 Safety instructions for the user/operator If hot or cold machine parts lead to dangers, these parts have to be protected against touch. Protection against touch for moving parts (e. g. coupling) must not be removed when the machine is in operation. Leakages (e. g. from the shaft seal) of hazardous goods to be delivered (e. g. explosive, toxic, hot) are to be removed in such a way that there is no danger to persons and environment. Legal rules are to be observed. Hazards caused by electrical power are to be excluded (for details please refer for instance to the rules of the VDE and the local power supply companies). 2.6 Safety instructions for maintenance, inspection and installation work The user has to take care that all the maintenance, inspection and installation work is executed by authorized and qualified skilled personnel who have informed themselves adequately by thoroughly studying the operating instructions. Basically, work on the machine is only to be carried out during shut-down. It is obligatory to observe the shut-down procedure described in the operating instructions. Pumps or pump aggregates that deliver media being hazardous to health have to be decontaminated. Immediately after completion of the work, all safety and protective equipments have to be reinstalled and/or reactivated. Advice: When working with compressed air, do wear glasses. (DIN 4844-G1 Use breathing mask) Advice: Observe EC-Safety Data Sheet for consumable materials and additives used and use personal protective equipment. (DIN 4844-G4 Use breathing mask) Before recommissioning, observe the points stated in section initial start-up. 2.7 Unauthorized conversion and manufacture of spare parts Conversion or modifications to the machine are only permitted when agreed with the manufacturer. Original spare parts and accessories authorized by the manufacturer serve to ensure safety. The use of other parts may render the liability for consequential losses null and void. Page 3 of 14

4 2. SAFETY (continuation) 2.8 Unacceptable modes of operation The operational reliability of the machine supplied is only guaranteed if the machine is used in accordance with its intended purposes as per section 1 - General - of the operating instructions. The limiting values specified in the data sheet must on no account be exceeded. 2.9 Guidelines & standards 1., 2., 3. and 4. guideline (see data sheet: R&N_2009_X_GB) 3.0 Notes on environmental protection and waste disposal In correct operation with lubricants, the components are subject to the special requirements set by environmental legislation. The general requirements for lubricants are specified in the respective safety data sheets. Used lubricants are hazardous forms of waste and therefore require special supervision in the sense of 41 paragraph 1 sentence 1 and paragraph 3 no. 1 of KrW-/AbfG (Closed-Loop Waste Management Act). Used oils must be handled in compliance with AltölV (Waste Oil Ordinance). The devices or components contaminated with lubricant must be disposed of by a certified waste management company. Records of proper waste management must be filed in conformance to NachwV (Ordinance on Waste Recovery and Disposal Records). Page 4 of 14

5 GENERAL PRODUCT CHARACTERISTICS Possible versions: Guide line 94/9/EG-Atex category 2 GD and 3 GD for zone 1/2 and 21/22 Discharge pressure up to max. 400 bar High reliability due to forced control Discharge: 7,14 and 22 litres/h, depends on driving speed Geared motors Pressure gauge for pressure monitoring Compact and rugged design Lubricant grease, liquid grease Surface signal grey RAL 7004 A. PUMP TYPE BSX B. NUMBER OF OUTLETS 1 outlet C. REVISION Status A D. KINDS OF DRIVE Flange-mounted geared motor / / 50 Hz, 0.75 kw, 80 min -1 ; dimension A = 715 mm Flange-mounted geared motor / / 50 Hz, 0.75 kw, 80 min -1 ; dimension A = 715 mm Flange-mounted geared motor / / 50 Hz, 1.5 kw, 160 min -1 ; dimension A = 682 mm Flange-mounted geared motor / / 50 Hz, 1.5 kw, 250 min -1 ; dimension A = 682 mm Page 5 of 14

6 E. POSITION OF DRIVE without F. RESERVOIR 60 litre G. ACCESSORIES without Level switch A level switch is available for the indication of the filling level in the reservoir. As sensor serves an capacitive sensor. As soon as the min. or max. level allowed has been obtained, a signal is released. This signal can be used for the visual warning or for the control of an automatic filling facility. In case of receiving the order, we will attach particular operating instructions to the level switch with the following code: BA_2009_1_GB_65124F002. Page 6 of 14

7 3. APPLICATION The pump BS-B is used in cases where a lot of lubrication points shall centrally and reliably be supplied with lubricant. In connection with ZV-B distributors, the pump is predominantly used in dual-line lubrication systems. The pump BS-B is also suitable for filling and lubrication systems. 4. DESIGN The pump consists of the housing with the pump insert, and a lubricant reservoir mounted on top. An integral pressure relief valve is incorporated in the pump insert. In dual-line systems lubricant is being delivered under pressure by means of electric or pneumatic control valves into a main feed line and towards the metering blocks distributing it uniformly and preciselymetered to the points. Varying lubricant quantities can be coped with by selecting different blocks. Page 7 of 14

8 4. DESIGN (continuation) Page 8 of 14

9 5. PRINCIPLE OF OPERATION Reservoir with wedge plate assy. and scraper A ratched mechanism (39-43) (section G-H) converts the oscillating motion of the rocker arm (77) (section E-F) into rotary motion of the feed worm (4) and the scraper (34) attached to it. Irrespective of the direction of drive of the motor the two parts always rotate clockwise causing the grease to be scraped off the wall of the reservoir (1) and forced into the housing (17), thus eliminating cavitation and ensuring positive priming of the pump unit. Pump insert The pump insert is secured in the housing (17) by 8 cap screws. It comprises a flange (52) (section A-B) with an eccentric (74) (section I-K) running on a ball bearing, and the pump element (section I-K) bolted to the flange. The eccentric (74) causes a reciprocating motion in the rocker arm (77).(section E-F). The two feeding pistons (84) are connected to the rocker arm. The double acting pump operates with two pairs of pistons simultaneously such that, as one pair of pistons is on the suction stroke, the other pair forces the lubricant to the outlet ports, through the pressure connection. Each of the two feed pistons fitted in the housing (82) comprises two control pistons (80, 83) in a common bore. Suction stroke At the start of the suction stroke, the pistons (80, 83,84) are moving together towards the suction channel until the spring-loaded control piston (83) is pressed against the stop thus reaching its final position. As the delivery plunger (84) continues to move, a vacuum is created between the feed plunger (84) and the control plunger (83). As soon as the feed plunger (84) uncovers the suction port, the vacuum, in conjunction with the slight overpressure of the lubricant in the pump housing (17), causes lubricant to be sucked into the cylinder. If the force of the spring (81) is not sufficient enough to enable to move the control piston (83) to the stop into the final position in the housing (82), the control piston (83) is bound to be positively controlled at the end of the stroke, by the rocker arm (77) and displaced into its final position mechanically, thanks to a second control plunger (80) being provided. Pressure stroke Now the feed piston (84) moves towards the pressure connection closing the suction channel. The lubricant enclosed by the feed piston (84) and control piston (83) is moved axially, against the force of the spring (81). At the moment the annular groove in the control piston (83) is reaching the pressure channel, the axial movement of the control plunger stops. The lubricant is forded by the feed plunger (84) rotating in axial direction into the pressure channel. As soon as the two plungers (83, 84) make contact, the stroke of the feed plunger is terminated. 6. SPECIFICATIONS Discharge pressure adjustable, max. : bar Discharge rate at : min -1 : cm 3 /min ( 7 l/h ) 160 min -1 : cm 3 /min ( 14 l/h ) 250 min -1 : cm 3 /min ( 22 l/h ) Max. rpm : with geared motor : min -1 Rotational direction of drive :... right or left Reservoir capacity : litre Operating temperature according to design : o C to 50 o C Compatible lubricants :... up to NLGI class 3, DIN Integral strainer :... strainer area 40 cm 2, wire mesh size 0,4 x 0,18 DIN 4189 Integral pressure relief valve :... adjustable from 0 up to 450 bar, adjusted to 400 bar Depending on the kind of their electrical equipment/sensor technique, they can be used as follows: a. In zone 2 (gas-ex, category 3G)) in the explosion groups IIA and IIB b. In zone 22 (dust-ex, category 3D) for dusts with a minimum ignition power > 3 mj c. In zone 1 (gas-ex, category 2G)) in the explosion groups IIA and IIB d. In zone 21 (dust-ex, category 2D) for dusts with a minimum ignition power > 3 mj Die qualification with regard to the surface temperature is T4; for all gases, steams and mists with an ignition temperature > 135 C the appliances are no ignition source. In the dust ex-range, 125 C is the reference temperature for the further considerations regarding the safe distance from the glow temperature etc. (can only be decided by the user. Page 9 of 14

10 7. START-UP & INSTALLATION Install the pumps into a higher-ranking machine. Fix the time for the cleaning of the equipments (dust deposits) depending on the IP degree of protection. Be absolutely sure that the types of appliance protection installed are appropriate to the zones! Further important facts: a. The pump is allowed to be put into service in zone 2 or 22 (category 3GD) or zone 1 and 21 (category 2GD) by specialists. b. Seals have to be reattached after opening and closing. c. The appliances are only approved fort he operation with the greases specified in the operating instructions. Typical characteristics of high-performance multi-purpose greases Shell Alvania (LF) Greases EP (LF) 1 EP (LF) 2 Thickening agent DIN marking Service temperature range o C DIN Lithium -12- Hydroxystearate KP1G to +110 Lithium -12- Hydroxystearate KP1G to +130 Worked penetration Units DIN ISO NLGI class DIN Dropping point o C DIN ISO Corrosion prevention properties (Emcor test) Water resistance at 90 o C evaluation Oil separation 18 h at 40 o C %m 7 d at 40 o C %m Base oil, kinematic viscosity at 40 o C mm 2 /s at 100 o C mm 2 /s degree of corrosion stage of DIN and 0 0 and 0 DIN DIN DIN Caution! Care must be taken to use only greases whose service temperature does not exceed or drop below the pump s operating temperature. a. The operation of the appliance is only allowed in completely closed and undamaged housings. b. The equipotential bonding is connected via own screw. It has the be treated according to the erection regulations being valid in the country of the user. c. During the erection make sure that the installation fukfills the EMC. d. It is prohibited to operate the appliance when the housing is damaged. e. Equipment IP67 is sufficient; if necessary, portect the machine against the penetration of liquids and/or dirt. f. When the machine is in operation, see that it is exposed to low vibrations only. In case of doubt contact the manufacturer. 7.1 Use, operation The appliances are only approved for a proper use in accordance with their intended purposes. In case of contravention, any warranty and responsibility of the manufacturer will become invalid! a. Use only such accessory parts in hazardous areas which fulfill all the requirements of the European guidelines and national regulations. b. In case of non-conductive dusts, the use in the dust-ex zone is allowed with a minimum ignition power > 3 mj as far as the electric motor, too, comes up to the requirements. c. The ambient conditions specified in the operating instructions are to be observed at all events. d. When the systems are provided with an electrical protection against corrosion, they must not be operated without consultation with the manufacturer and, if necessary, execution of additional measurements. e. Measures as to lightning protection are to be ensured by the user. f. The pump is to be protected against impacts from outside. g. WARNING! After having refilled the grease, reattach the cotter pin in a professional way to secure the lid Page 10 of 14

11 7. START-UP & INSTALLATION (continuation) 7.2 Pump installation Set up the pump 90 ±5 and fasten it in place. Then connect the motor to the switchbox in accordance with the circuit diagram. The motor s rotational direction can be decided at will but a clockwise direction is recommended in view of the gearing teeth in the gear. 7.3 Filling the reservoir and pipe lines To open the reservoir: Release and unlock the snap fits. Unclose the lock which is used for closing the lid and remove it from the bolt. Swing the reservoir cover to the right or left side. Efficient operation demands the use of only clean lubricant! Contamination of the lubricant can lead to operation trouble and damage. To shorten the time of the initial start-up it is advisable to fill the grease using a barrel pump or a press via the R-outlet. Containers should only be re-charged via the filler plug provided, preferably by use of a filling pump or grease gun, or from the works bulk supply system. The container must always be kept closed and care taken in ensuring that the lubricant is kept free from dirt and other contamination. Recharging of the container at the correct time is most important, otherwise there is a risk of air finding its ways into the pump and main lines. In contrast to other pumps, no oil is required to be charged for initial start-up. To ensure trouble-free functioning the pump itself should be deaerated by running it for a period without back pressure. As soon as the lubricant is discharged free of air from pressure connection (P), the feed lines can be connected. Run the pump then and continue to bleed all main lines, then make the connection to the metering elements. 7.4 Connecting the pressure and relief lines The pressure outlet port at the flange (52) (section A-B) has a pipe connection of G 3/8" BSP female thread. When using the pump in a dual-line system, this branch is used to connect the 4/2-way reversing valve (or 3/2-way valve respectively). On the pump housing (17) there is the pressure relief port of G 3/8" BSP to connect the 4/2-way valve. In filling or greasing systems without a change-over valve, this port should be shut by a plug. WARNING! Make sure to fill tube (44) (section A-B) correctly otherwise, and in the event of failing to provide it at all, there is a danger to life and limb to everybody involved. 7.5 Position of the potential compensation screw Potentialausgleichschraube Page 11 of 14

12 8. MAINTENANCE Definition of terms according to IEC 60079: Maintenance and repair: A combination of all activities being effected in order to maintain an object in a condition or to bring it back into this condition, so that the object in question comes up to the requirements of the specification concerned and ensures the execution of the functions required. Inspection: An activity that consists in a thorough check of an object with the aim to make a reliable statement about the condition of this object. It is carried out without disassembly or, if necessary, with partial disassembly, completed by measures as for example measurements. Visual check: A visual check is a check on the occasion of which visible faults (e. g. missing screws) are found without the use of any access facilities or tools. Close-range check: A check on the occasion of which those faults (e. g. loose screws) are found - in addition to the aspects of a visual check - which can only be identified by the use of access facilities, e. g. steps (if necessary), and tools. For close-range-checks, it is usually not necessary to open a housing or to switch the equipment voltage-free. Detailed check: A check on the occasion of which those faults (e. g. loose connections) are found - in addition to the aspects of the close-range check - which can only be identified by the opening of housings and/or, if necessary, the use of tools and test facilities. a. Maintenance work is to be executed by the staff of DELIMON only or by persons having been specially trained by DELIMON. b. For the replacement of component parts use only original spare parts which are also approved for the use in the ex-zone. This also applies to the lubricants and process materials used. c. Regularly maintain and clean the appliances in the ex-zone. The intervals are locally fixed by the user according to the environmental stresses, e. g. in case of an approx mm dust deposit. d. After having carried out the maintenance/repair work, reattach all barriers and notes, which have been removed on this occasion, in their original position. Table 1 Activity 1 Visual check of the machine, eliminate dust deposits 2 Refill the store tank with grease. (without level switch monitoring) Visual check weekly Visual check monthly Close-range check every 6 months or 2,000 h 3 Check for grease leakage. 4 Check for a smooth running and a heating of the bearings. 5 Check of the electrical system for intactness 1 Detailed check every 12 months or 4,000 h 1 Refilling is necessary within a short time depending on the grease consumption and there must be at least 10% of the maximum filling in the storage container (without filling level monitoring) Special measures: Replacement of the compression spring (81) after 20,000 working hours or 5 years. Replacement of the bearings after 12,000 working hours or 3 years, continued operation for a duration of up to 3 times of the nominal indication if the check intervals are halved. Observe the operating instructions relating to the electric motor as well as the instructions of the manufacturer. In category 3 the maintenance intervals can be doubled. Note! In the model with level switch the level or topping up in the storage tank is monitored by means of a corresponding signal sent to the customer s control system. Page 12 of 14

13 8. MAINTENANCE (continuation) 8.1 Strainer The strainer (51) (section A-B) should retain any contamination, which, by carelessness, has been allowed to get into the lubricant. Therefore, check and clean with petrol or spirit the strainer at regular intervals. Any dirt therefore is retained inside the strainer (51). When disassembling the impurities are removed. ATTENTION A blinding filter due to pollution is leading to the bursting of the strainer. 8.2 Pressure relief valve The integral pressure relief valve (54-62) (section A-B) is adjustable from 0 up to 400 bar. Turning the square spindle (62) clockwise the pressure is increased, and turning it anti-clockwise it is decreased. The pressure relief valve is set by the manufacturer s to a pressure of 400 bar. ATTENTION The pressure rating adjusted at relief valve must not be higher than max. admissible operating pressure of the elements installed downflow. 8.3 Bursting discs The respond of the burst plates protects the components of the system (e. g. pipes, fittings etc.) for overpressure. Two burstings discs (47) are fitted in the stud (48) (section A-B) below the bush (46) which will rupture in the event of failure, or excessive pressure beyond 500 bar building up in the pressure channel in flange (52), e.g. if the relief valve (54-62) is clogged. When these discs burst, the lubricant issues out of the tube (44). In this case, first remedy the cause of failure and replace two new burst discs. Under the plug (53) in the flange (52) there are ten spare discs. When replacing new bursting discs take care that the curved face shows towards the bushing (46). If incorrectly fitted, the burst pressure is apt to be increased to such an extent causing the pump drive to be damaged. 8.4 Geared motor or gear When being delivered, the geared motor or the gear is ready for operation and filled with synthetic oil, which is suitable for an ambient temperature range from -20 C to 50 C. The oil level has to be controlled every 12 month or after operating hours. A complete oil amount has to be changed after each operating hours. The following oil type can be used for a temperature range from -20 C up to 50 C: Aral : Degol GS 220 or Degol PAS 220 BP : Energol SG-XP 220 Castrol : Alphasyn PG 220 DEA : Polydea CLP 220 Esso : Glycollube 220 Mobil : Glygoyle 30 oder Mobil SHC 630 Shell : Tivela Oil WB oder Omala 220 HD elf / Total : Carter SY 220 The quantity to be recharge is 0.3 litre for gear for 0.75 or 1.5 kw power ratings respectively. Please note the additional information within the manufacturer s data sheet: BA_ATEX-Getriebe_D-GB. 8.5 Fault clearance It is not permitted to make modifications to appliances being operated in connection with potentially explosive zones. Repairs of the appliance are to be carried out by authorized and qualified staff only having undergone a special training. 8.6 Disposal The disposal of the packaging and the worn out parts is to be effected according to the regulations of the country in which the appliance is installed. Page 13 of 14

14 9. MODULES AND MEASURES Table 2 Measures Zone 2/22 Zone 1/21 Electrical utilities, except simple apparatus for intrinsically safe devices Description from the manufacturer Simple apparatus for for intrinsically safe devices BS-B lubrication pump Pressure gauge EU model test certificate must be available The application of intrinsically safe switch amplifiers and/or zener barriers produces a distinct alleviation of the sensors as long as it concerns simple electrical apparatuses. The contacts normally only withstand a voltage of 500 V AC to ground. If the power Po of the supply apparatus does not exceed 750 mw then, in the normal ambient temperature range, even a simple electrical apparatus can be used according to EN 60079/14 and/or EN (e.g. an industrial end switch) subject to the temperature class with additional protection mode test (min. IP 20) in a gas and dust explosive area. Po can be increased up to 1.3 W in the gas explosive area. A temperature class is to be indicated. Evaluation of reliability of the assembly is contained in the DELIMON delivery package Evaluation of reliability of the assembly is contained in the DELIMON delivery package Pressure gauges used in double conductor devices are regarded as a utility without any potential source of ignition and does not therefore require its own certification. The danger posed by the interconnection of the individual modules has been evaluated by DELIMON. A new TFR number is not necessary. 10. PLATES Name plates 110 x 60 mm Page 14 of 14