DÖRR EcoPump AD Bedienungsanleitung
MPU00013EN, V05
Translation of the original operation manual
© Dürr Systems AG 2015
Dürr Systems AG
Application Technology
Carl-Benz-Str. 34
74321 Bietigheim-Bissingen
Germany
Phone: +49 (0)7142 78-0
Internet: www.durr.com
The reproduction and distribution of this document, use and communication of its contents are not permitted
without express written approval. Offenders will be liable for damages. All rights reserved in the event of the
grant of a patent or utility model.
01/2020EcoPump AD - MPU00013EN
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Information about the document
This document describes the correct handling of
the product.
Read the document prior to every activity.
Prepare the document for the application.
Pass on the product only together with the com-
plete documentation.
Always follow safety instructions, handling
instructions and specifications of every kind.
Illustrations can deviate from the technical con-
struction.
Validity range of the document
The scope of the document is as follows:
N24140011
EcoPump AD 2420 8 SST 1 1/2"
Hotline and Contact
If you have queries or would like technical informa-
tion, please contact your dealer or sales partner.
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TABLE OF CONTENTS
1 Product overview...................................... 5
1.1 Overview............................................. 5
1.2 Short description................................. 5
2 Safety.......................................................... 5
2.1 Presentation of Notes.......................... 5
2.2 Intended Use....................................... 5
2.3 Residual risks...................................... 6
2.4 Conduct in the event of a hazardous
situation............................................... 6
2.5 Staff qualification................................. 6
2.6 Personal protective equipment............ 7
3 Design and Function................................. 7
3.1 Design................................................. 7
3.2 Operation............................................. 8
4 Transport, scope of supply and
storage....................................................... 9
4.1 Transport............................................. 9
4.2 Unpacking........................................... 9
4.3 Scope of delivery................................. 9
4.4 Storage................................................ 9
5 Assembly................................................... 9
5.1 Requirements for the
Installation point.................................. 9
5.2 Assembly........................................... 10
5.3 Assembling ground conductor........... 10
5.4 Connecting........................................ 11
6 Commissioning....................................... 12
6.1 Safety recommendations................... 12
6.2 Preparing for commissioning............. 13
6.3 Setting operating parameters ........... 13
7Operation................................................. 13
7.1 Safety recommendations................... 13
7.2 General notes.................................... 14
7.3 Starting Operations........................... 14
7.4 Rinsing.............................................. 14
7.4.1 Safety recommendations................ 14
7.4.2 Flush the pump............................... 14
8 Cleaning................................................... 15
8.1 Safety recommendations .................. 15
8.2 Cleaning............................................ 15
9 Maintenance............................................. 15
9.1 Safety recommendations................... 15
9.2 Maintenance schedule...................... 16
9.3 Dismantle and assemble................... 16
9.3.1 General notes................................. 16
9.3.2 Dismantle inlet and outlet mani-
fold.................................................. 17
9.3.3 Dismantle material assembly.......... 17
9.3.4 Dismantle pneumatic assembly...... 18
9.3.5 Assemble pneumatic assembly...... 19
9.3.6 Assemble material assembly.......... 21
9.3.7 Assemble inlet and outlet mani-
folds................................................ 21
10 Faults........................................................ 23
10.1 Defects table................................... 23
11 Disassembly and Disposal..................... 26
11.1 Disassembly.................................... 26
11.2 Disposal .......................................... 28
12 Technical data.......................................... 28
12.1 Dimensions and weight................... 28
12.2 Connections.................................... 28
12.3 Operating conditions....................... 28
12.4 Operating values............................. 28
12.5 Compressed air quality.................... 29
12.6 Type plate........................................ 29
12.7 Operating and auxiliary materials.... 29
12.8 Materials used................................. 29
12.9 Tightening torques........................... 30
12.10 Characteristic curve of the outflow
rate.................................................. 30
13 Replacement parts, tools and accesso-
ries............................................................ 30
13.1 Replacement parts.......................... 30
13.2 Tools................................................ 31
13.3 Accessories..................................... 31
13.4 Order............................................... 31
14 Index......................................................... 32
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1 Product overview
1.1 Overview
Fig. 1: Overview
1 Type plate
2 Pressure side connection for material supply
3 Material assembly
4 Pneumatic assembly
5 Compressed air connection
6 Suction side connection for material supply
7 Mounting feet
1.2 Short description
The double diaphragm pump with pneumatic
actuator (from here on “pump") is an air operated
positive displacement pump. The pump is used to
pump low- to medium-viscosity liquids (flammable
and non-flammable coating materials) in industrial
coating of surfaces.
2 Safety
2.1 Presentation of Notes
The following notes can appear in this instruction:
DANGER!
High risk situation that can lead to serious inju-
ries or death.
WARNING!
Medium risk situation that can lead to serious
injuries or death.
CAUTION!
Low risk situations that can lead to minor injuries.
NOTICE!
Situations that can lead to material damage.
ENVIRONMENT!
Situations that can lead to environmental
damage.
Additional information and recommenda-
tions.
2.2 Intended Use
Use
The EcoPump AD is solely intended for pumping
low- to medium-viscosity fluids of the fluid group 1
according to the Pressure Devices Directive.
The EcoPump AD is intended for use in industry
and trade only.
The EcoPump AD may be used under the fol-
lowing conditions:
in explosive areas of Ex zones 1 and 2
in non-explosive areas
with flammable fluid coating materials of the
Explosion group IIA
with non-flammable fluid coating materials
Only use the pump within the approved operating
conditions Ä 12 “Technical data”.
Misuse
If used improperly, it can cause serious injuries.
Examples of wrong use are:
Use in areas with Ex zone 0
Use of unapproved materials, see safety data
sheets
Making conversions or changes on your own
Use of pumps as a support for the pipe system
Ex labeling
II 2G Ex h IIA T4 Gb X
Product overview
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II - Device group II: all areas except mining
2G - Device category 2 for gaseous ex-atmos-
phere
Ex h - Ignition protection category for non-elec-
trical devices
IIA - Explosion group
T4 - Temperature class
Gb - Device protection level: Zone 1
X - Restriction: The device is configured for
operation in an ambient temperature of
15°C to 40°C.
2.3 Residual risks
Explosion danger
Pumps with conductive Acetal parts in contact with
media may not be used with acids and lyes. Reac-
tion and explosion of these materials can cause
serious injury or death. Reaction and explosion of
these materials can cause serious injury or death.
Pump motor section
Fluid caps
Distributor
Parts in contact with material
Sparks due to electrostatic discharge
If the pump is not properly grounded or the poten-
tial equalization fails, components may get
charged electrostatically. Electrostatic discharge
can cause sparks that in explosive atmosphere
can cause a fire or an explosion. Serious injury
and death could be the consequence.
Ground Pump as specified.
Check connection of grounding cable during
operation.
Measure volume resistivity.
Media
Material escaping under pressure can cause
serious injuries.
Before working on the product:
Disconnect the system, in which the product is
installed, from compressed air and material
supply.
Depressurize the lines.
Secure the system against being switched on
again.
Observe approved operating pressures Ä 12.4
“Operating values”.
2.4 Conduct in the event of a hazardous
situation
Conduct in case of danger depends on the opera-
tor’s installation situation.
Perform the following activities:
Close lines.
Secure against reconnection.
Depressurize lines.
2.5 Staff qualification
WARNING!
Inadequate qualification
Wrong estimation of dangers can cause serious
injury or death.
– Only sufficiently qualified persons may exe-
cute all work.
– Some work requires additional qualification.
Additional qualifications of specialized per-
sonnel are marked with a “+”.
This document is intended for qualified personnel
in industry and craftmanship.
Cleaning staff
The cleaning staff receives regular instructions
from the operator about the following contents:
Using the product
Handling cleaning tools
Handling cleaning agents
Technical Measures for occupational safety and
health
Electrician
Electricians assemble, install, service and repair
electrical systems in a professional manner.
Furthermore, electrical engineers have the fol-
lowing knowledge:
Guidelines, Standards and Rules of Engi-
neering
Local conditions
Electrical Systems and Their Loading Limits
Technical Measures for occupational safety and
health
Mechanic
The mechanic is trained specifically for the field of
work in which he works.
Furthermore, he has the following knowledge:
Guidelines, Standards and Rules of Engi-
neering
Local conditions
Technical Measures for occupational safety and
health
Safety
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The mechanic is responsible for the following activ-
ities on equipment and components:
Assembly
Waiting
Maintenance
Disassembly
+ additional qualification explosion protection
In addition to the knowledge of the various spe-
cialist fields, the mechanic has knowledge of regu-
lations and safety measures when working in
potentially explosive areas.
Dürr Systems offers special product training for
Ä “Hotline and Contact”.
2.6 Personal protective equipment
When working in explosive areas, the protective
clothing, including gloves, must meet the require-
ments of DIN EN 1149-5. Footwear must meet the
requirements of EN ISO 20344 and EN IEC
61340-4-3. The volume resistivity must not exceed
100MΩ.
Wear the specified personal protective equipment
when working. Provide the following personal pro-
tective equipment:
Anti-Static Safety Boots
Protect feet from crushing, falling items
and slipping on slippery ground.
Moreover, anti-static safety boots reduce
electrostatic charge by discharging the
electrostatic charges.
Eye protection
Protects eyes from dust, paint drops and
particles.
Protective gloves
Protect the hands from:
mechanical forces
Thermal forces
Chemical effects
Protective workwear
Tight fitting workwear with low tear
strength, tight sleeves and no hanging
parts.
Respirator mask
Protects from hazardous gases, vapors,
dust and similar materials and media.
Use ear protection
Protects from auditory damage due to
noise.
3 Design and Function
3.1 Design
EcoPump AD main assemblies:
Pneumatic assembly (compressed air)
Material assembly
Inlet and outlet manifold
Pneumatic assembly (compressed air)
Fig. 2: Pneumatic assembly - Front view
Design and Function
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Fig. 3: Pneumatic assembly - Rear view
Material assembly
Fig. 4: Material assembly
Inlet and outlet manifold
Fig. 5: Inlet and outlet manifold
1 Outlet manifold for material supply on pressure
side
2 Inlet manifold for material supply on suction
side
3.2 Operation
The pump has an air-driven dual diaphragm that
sends a differential pressure to the air chambers.
In this way the material chambers can be suc-
tioned up and emptied alternately. Ball valves pre-
vent a return flow of the medium.
The pump starts as soon as compressed air is sup-
plied. The pumping process adjusts to the respec-
tive demand. This builds up pressure and keeps it
steady. The flow is stopped when the maximum
tube pressure is reached. After this, the pumping
process is restarted as necessary.
Design and Function
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4 Transport, scope of supply and
storage
4.1 Transport
WARNING!
Raising heavy loads
Raising heavy loads without suitable hoist and
stopper material can cause major injuries.
– Transport heavy loads only by using suitable
hoists and stoppers.
WARNING!
Hovering load
Hovering loads can fall down and cause serious
injuries or death.
– Do not enter the area below hovering loads.
– Wear specified protective equipment.
– Only use approved hoists and stoppers.
– Ensure that the hoists and stoppers have
adequate bearing capacity.
NOTICE!
Incorrect Transport
Improper transportation of the pump may cause
the agitator the pumpto fall and suffer damage.
– Protect Pump from moisture.
– Protect Pump from vibrations.
– Use transport locks (e. g. against slipping).
Permissible ambient temperature during the
transportation for a few hours:
-40°C to 60°C
4.2 Unpacking
DANGER!
Electrostatically charged plastic films and
foils in potentially explosive areas
The foil can charge electrostatically at the time of
unpacking. Electrostatic discharge can cause
sparks that in explosive atmosphere can cause a
fire or an explosion. Serious injury and death
could be the consequence.
– Unpack product outside Ex zones.
1. Check the pump packaging for damage. If there
is any damage, notify the customer service
immediately Ä “Hotline and Contact”.
2. Remove packing film.
3. Dispose of the packaging professionally.
4. Check pump for damage.
5. Transport pump and muffler to the assembly
location without packaging film.
4.3 Scope of delivery
The scope of supply only includes the pump.
Personnel:
Mechanic
Protective equipment:
Protective gloves
Protective workwear
Anti-Static Safety Boots
1. Check the pump for integrity on receiving it.
2. Report defects immediately Ä “Hotline and
Contact”.
4.4 Storage
Ambient Conditions
NOTICE!
Damage from improper storage
High load stresses o the packaging can damage
the product.
– Do not stack the packaging.
Observe the following environmental conditions for
the storage of the pump:
Temperature: 10-40°C
Humidity: 35 % – 90 %
Protection from direct sunlight
Protection from cold
Protection from vibration
Protection from dust and dirt
Do not store outdoors.
Store in a dry and dust-free place.
Do not expose to aggressive media.
Storage of Replacement Parts
The same storage provision as for the pump apply
to the replacement parts.
5 Assembly
5.1 Requirements for the Installation point.
Protect pump from vibration damage:
Erect mounting feet for the pump on horizontal
ground.
Transport, scope of supply and storage
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5.2 Assembly
If air containing a lubricant is present in the
equipment, the air must be compatible with
O-rings and seals in the compressed air part
of the pump .
Ä 12.5 “Compressed air quality”
Personnel:
Mechanic
Protective equipment:
Protective gloves
Anti-Static Safety Boots
NOTICE!
Material damage due to improper assembly
Installing the pump in an incorrect installation
position will damage the pump.
– Store the pump in an upright position only.
Fig. 6: Assemble the sound muffler
Assemble the sound muffler (2) on the pneumatic
assembly, using the elbow piece (1).
Fig. 7: Assemble pump
Mount the pump on the mounting feet (1) using 4
screws. The recesses (2) for the screws are on the
front and back of the pump.
5.3 Assembling ground conductor
WARNING!
Sparks due to electrostatic discharge
If the pump is not grounded, there can be an
electrostatic charge on the the pump. Electro-
static discharge can cause sparks that in explo-
sive atmosphere can cause a fire or an explo-
sion. Serious injury and death could be the
consequence.
– Ground Pump as specified.
– Before carrying out any work, make sure that
there is no explosive atmosphere.
Assembly
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