Bijur Delimon FZ-A Operation Manual Download Page 1

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BIJUR DELIMON INTERNATIONAL

BA_2020_01_GB_FAX_FBX

Operation manual

in accordance with ATEX Directive 2014/34/EU

Pump FZ-A / FZ-B
ATEX version

BA_2020_D1_FAX_FBX (Rev. B)
December 2020

Summary of Contents for FZ-A

Page 1: ...1 BIJUR DELIMON INTERNATIONAL BA_2020_01_GB_FAX_FBX Operation manual in accordance with ATEX Directive 2014 34 EU Pump FZ A FZ B ATEX version BA_2020_D1_FAX_FBX Rev B December 2020 ...

Page 2: ...tions 10 2 13 The obligations of the operating company 11 2 13 1 Determining hazards 11 2 13 2 Personnel qualification and training 11 2 13 3 Providing personal protective equipment 11 2 13 4 Instructing external assembly fitters 11 2 13 5 Testing and ensuring proper use 11 2 13 6 How to behave in emergency situations 12 2 14 Dangers if the safety instructions are not observed 12 2 15 Residual ris...

Page 3: ... 5 7 3 Measures during commissioning 30 5 8 Determining running and break times 30 5 9 Examples of the systems 30 5 9 1 Multi line system 30 5 9 2 Progressive system 30 6 Operation 31 6 1 Operating safety 31 6 2 Operating modes 31 6 3 The pump s or lubrication system s control unit 31 6 4 Topping up the lubricant 31 6 5 Shutting down the pump 32 7 Inspection testing and maintenance 33 7 1 Pressure...

Page 4: ...who can recognise and prevent the hazards that can be caused by electricity Operator A trained person who based on their knowledge and experience is capable of commissioning and operating the product This also includes preventing potential hazards that may arise during operation Specialist for maintenance and servicing in potentially explosive atmospheres Trained staff member who is able to recogn...

Page 5: ... 2 Safety This section describes general and product specific safety instructions that must be observed and followed Further safety instructions can be found at appropriate points in other sections of this operating manual Please read this section carefully to understand the safety instructions throughout this document and on the product itself 2 1 Intended use The pump described below is intended...

Page 6: ...ability Death or serious injury Imminent Severe injury Possible Slight injury Possible Property damage Possible Pictograms General warning signs General mandatory signs General prohibition signs General warning General mandatory sign No unauthorised access Warning electric voltage Observe instructions Other signs Warning slipping hazard Wear safety goggles Warning tripping hazard Wear hearing prot...

Page 7: ...individuals away from the pump o Observe internal company instructions and relevant safety regulations o Wear personal protective equipment PPE o Check protective and safety equipment e g pressure limitation valves regularly They may not be removed or tampered with in any way o If safety equipment is replaced it must be immediately reinstalled and tested to ensure that it is working o Never use pa...

Page 8: ...lectrical work may only be carried out if no explosive atmosphere is present o The cleaning of the pump must only be carried out if there is no explosive atmosphere In any event it must be ensured that the cleaning aids used cannot lead to electrostatic charging during the cleaning process o Before commissioning check for any damage to the pump caused by transportation e g damage to the paint as t...

Page 9: ...All labels on the pump must be legible at all times 2 9 Type plate The type plate contains important specifications for identifying the pump This must always be legible Example FZ pump with approval for ATEX Zone 1 Example FZ pump with approval for ATEX Zone 2 and 22 2 10 General safety instructions for handling lubricants Lubricants perform different tasks and are selected specifically for the ap...

Page 10: ...nomena may occur e g separated lubricant components Before putting the machine system back into operation check whether the lubricant is still suitable for use If necessary the lubricant must be replaced before the machine system is put back into operation 2 11 Foreseeable misuse Misuse is considered to be unintended use especially in the following cases o Operation outside the specified operating...

Page 11: ... people authorised to use the pump have the necessary knowledge and qualifications before they use it for the first time The operator must instruct authorised personnel on explosion protection This includes at least o the allocation of zones o Scope and limits of the activities or responsibilities o Use of the PPE o Importance of warnings o Emergency behaviour The operator must ensure that this op...

Page 12: ...ential hazard If necessary suitable remedial measures must be taken Use in a potentially explosive atmosphere without testing the potential equalisation for electrical continuity The potential equalisation must be checked for continuity at regular intervals The operator defines the intervals In any case the test must be carried out prior to commissioning and after repairs maintenance Generation of...

Page 13: ...roups IIA and IIB Zone 22 Dust Ex category 3D EPL Dc in explosion groups IIIA and IIIB ATEX Temperature category The qualification with respect to surface temperature is T4 for all gases vapours mists with an ignition temperature 135 C the BMs are not a source of ignition In the Dust Ex area 125 C is the reference temperature for additional safety considerations with regard to the glow temperature...

Page 14: ...c nickel coating DIN 50979 Fe ZnNi8 An T0 Motor Grey cast iron RAL 5010 Gentian blue Weight not including lubricant 8 l reservoir 15 l reservoir 30 l reservoir approx 32 kg approx 34 kg approx 36 kg Optional accessories o Pressure limitation valve s 200 bar standard 160 bar o Level switch MIN MAX 3 4 Dimensions Pump s basic dimensions in mm A 8 L 580 15 L 600 30 L 670 B 8 L 238 15 L 240 30 L 306 D...

Page 15: ...in the section below 3 6 1 Pump body variants Depending on the number of outlets the FZ pump versions differ in the pump body with the following features Lubricant reservoir available in different sizes Flange motor Reduction gear Filling valve Pump body Outlets protected when delivered with a red closing cap Pump foot Flange and coupling Setting spindle s FZ A 1 6 outlets one row FZ A 7 12 outlet...

Page 16: ...uency may have a negative effect on the lubricating and feeding properties The available installation space is also a selection criterion For 15 and 30 litre reservoirs we advise using a reservoir support if the pump is exposed to vibrations or acceleration 3 6 4 Accessories The FZ pump can be equipped with a level monitoring system with 2 switching points for the use in zones 2 and 22 on request ...

Page 17: ...e lubricant flows from the suction chamber S into the piston s vertical grooves and from there into the ring channels R During the pressure stroke the lubricant is fed from the ring channel and into the pressure channel D and then into the outlet openings via a vertical groove 3 7 2 Outlet location and labelling The FZ A pump can be configured with up to 12 outlets Depending on the number one pump...

Page 18: ...1 cm3 piston stroke Total 0 1 cm3 piston stroke 2 outlets 2x 0 1 cm3 piston stroke Total 0 2 cm3 piston stroke 3 outlets 3x 0 1 cm3 piston stroke Total 0 3 cm3 piston stroke 12 outlets 12x 0 1 cm3 piston stroke Total 1 2 cm3 piston stroke The effective delivery volume time is determined by the choice of drive More detailed information and calculations are provided in the sections below for the rel...

Page 19: ...re assembled drive Not intended for ATEX version of FZ pump Flange motor 3 7 6 Drive with a flange motor and reduction gear For the pump configuration with its own flanged drive a reduction gear is always required to reduce the motor s rotation speed to the feed piston s permissible rotation speed A 4 pole asynchronous motor whose shaft speed is slightly below that of the electric drive rotating f...

Page 20: ...N MAX can be installed in the reservoir top see the section entitled Accessories Note When using in ATEX Zone 1 a fill level switch is mandatory A feed insert with scraper which rotates while the pump is running is installed in the reservoir base The rotation speed corresponds to the piston speed max 10 rpm The scraper ensures regular mixing of the lubricant and prevents deposits when grease is us...

Page 21: ...e below Both sensors are supplied factory wired in a connection box mounted on the reservoir top The interface to the power supply is provided by an isolation amplifier installed outside the ATEX area Further details can be found on the following page Important For the use in ATEX zone 1 Gas Ex the fill level monitoring is compulsory In the Dust Ex area Zone 2 and 22 the fill level monitoring is o...

Page 22: ...DC Ui 15 V DC Output current active area free typ 1 5 mA Output current active area occupied typ 2 5 mA Dimensions and connection diagram Intrinsic inductance L 0 2 mH Intrinsic capacity C 250 nF Protective circuit protection class Installed IP67 LED display yellow Connection cable 2m PUR 2x0 34 mm2 Permissible ambient temperature 20 C 70 C Approvals CE RoHS UL CSA ATEX Connection box with termina...

Page 23: ...ected against damage and any resulting hazards are avoided The standard limitation of 160 bar ensures compatibility with all progressive distributors e g ZP A The pump can also optionally be configured with a 200 bar pressure limitation As a result the pumping range is increased which can be an advantage especially in cold ambient temperatures However a prerequisite for this is that all other syst...

Page 24: ...ion line for example An inspection option must still be guaranteed Note If the FZ pump is used for a progressive system overpressure can be detected early on by exceeding a programmed monitoring time using a downstream monitored lubricant distributor ATTENTION Pump and system component damage possible The maximum operating pressure for the FZ pump is 200 bar When selecting or setting the pressure ...

Page 25: ...x 450 mm E 15 l reservoir support with base plate 450 x 450 mm F Accessories Without accessories 00 Fill level switch MIN MAX for Zone 1 compatibility 01 Increased pressure limit 200 bar instead of 160 bar 20 Fill level switch MIN MAX increased pressure limit 200 bar instead of 160 bar for Zone 1 compatibility 21 4 Transport handling and storage 4 1 Checking the delivery Before installation check ...

Page 26: ...lation locations o Keep a sufficient distance from moving parts and sources of heat or cold o If necessary take precautions according to the pump s and the attached components IP protection class and permissible ambient temperature Note On request the FZ pump can be supplied as a pump unit with protective housing o Comply with legal regulations specifications and safety distances o Choose a solid ...

Page 27: ...s operating manuals must be observed o The recommended tightening torques for the pipe fittings used must be observed ATTENTION Damage or blockages in the lubrication system possible It is essential to check and clean e g by blowing out pipelines for dirt and chips before assembly and after each sawing or cutting operation Protect stored pipe lengths from contamination with closing caps 5 5 Electr...

Page 28: ...itable filling pump ready and ensure cleanliness of all parts used and the lubricant It is important that the filling pump is approved for the given ATEX zone or that it is operated outside the explosive atmosphere Connect the potential equalisation between the filling pump and the FZ pump The connection fitting e g coupling by means of which the filling conduit is connected to the FZ pump must al...

Page 29: ...n has been carried out in full with pre filled lines and a filled pump controlled system commissioning can take place 5 7 1 Manufacturer s settings The pump is delivered with the following settings o Maximum delivery volume all setting spindles in position 4 o Pre set pressure limitation valves according to the order 160 or 200 bar 5 7 2 Checks before commissioning for the first time Checklist bef...

Page 30: ... lubrication points at short intervals Accordingly the pump running and break times can be regulated using a higher level control unit in case there is no mechanical drive regulating the running times After commissioning there may be deviations from calculated lubricant volumes and running times This is due to many influencing factors such as lubricant system size pipe dimensions and ambient condi...

Page 31: ...cessary 6 3 The pump s or lubrication system s control unit The pump s control unit depends on the drive variant o For electric drive a power supply is required to start the pump In the simplest case this can be implemented with a switch and suitable motor protection Usually an electrical control system provided by the client is employed for the purpose of automating and processing monitoring elec...

Page 32: ...he pump In the event of temporary shutdown the following measures are to be implemented Disconnect the pump from the power supply Release the residual pressure in the downstream lubrication system see section 7 2 Open and empty the reservoir when it is outside the potentially explosive atmosphere and dispose of the lubricant properly Clean the pump WARNING Hand injury due to the rotating scraper N...

Page 33: ...w seconds of operation Lubricant must then slowly escape from the downstream pressure limitation valve at the outlet If the pump does not reach the pressure you will find potential causes in section 9 Troubleshooting below Once the pressure test has been completed successfully reconnect the pump to the system and allow it to run normally ATTENTION Pump damage possible Carry out this test only unde...

Page 34: ...ion possible Avoid contact between the skin and lubricants at all costs Wear PPE Following contact with the skin wash lubricant off immediately Observe the lubricant manufacturer s safety data sheet ATTENTION Loss of warranty claims possible Do not independently disassemble the pump within the warranty period Always contact Delimon s Customer Service first if malfunctions occur 7 3 Gear oil The ge...

Page 35: ...fied tightening torques DANGER Risk of explosion The potential equalisation must be tested by a qualified electrician after assembly and prior to recommissioning 7 5 Check and renew filter The filter cartridge is replaced as required The replacement interval largely depends on the ambient conditions The initial control interval is recommended to be 4 weeks The filter is disassembled to access the ...

Page 36: ... it against being switched back on again before starting cleaning Electrical and live parts may only be cleaned by a qualified electrician Do not touch electrical or live parts with wet hands or cloths Wear PPE WARNING Fire hazard Do not use flammable substances for cleaning CAUTION Skin irritation possible Avoid contact between the skin and lubricants Wear PPE Following contact with the skin wash...

Page 37: ...essure that may be further below the pump s operating pressure is built up Leakage in the system Check the entire lubrication system for leaks and eliminate them if necessary Setting spindle s or feed piston s worn Contact Customer Service send the pump in Level switch malfunction Connection error Check wiring The pressure limitation valve opens The system pressure is too high e g due to blockages...

Page 38: ... followed for decommissioning Have a collection basin for escaping lubricant ready Ensure that there is no explosive atmosphere Disconnect the pump from the power supply and secure it against being switched back on again Disconnect the electrical connection cables If necessary relieve residual pressure in the system see section 5 2 Disassemble the connecting lines at the outlets and secure them ag...

Page 39: ...ating instructions If required documents are not available please get in touch with your contact or our Customer Service Otherwise the pump documentation is considered to be incomplete 12 Annexes 12 1 Declaration of CE conformity 12 2 Declaration of ATEX conformity 12 3 Motor data sheet 12 4 Motor Declaration of ATEX conformity 12 5 Level sensor ATEX Declaration of Conformity ...

Page 40: ...ogy Seamless and welded precision steel tubes dimensions and nominal pressures Safety of machinery Electrical equipment of machinery Part 1 General requirements DIN EN ISO 14123 1 2015 EN 809 I998 A1 2009 TBRS1151 We further declare that the specific technical documentation on request to be transmitted to the market surveillance authorities Authorized representative for the technical documentation...

Page 41: ...ecision steel tubes dimensions and nominal pressures Safety of machinery Electrical equipment of machinery Part I General requirements DIN EN ISO 14123 1 2015 EN 809 1 998 A1 2009 TBRS1151 We further declare that the specific technical documentation on request to be transmitted to the market surveillance authorities Authorized representative for the technical document tion Head of quality departme...

Page 42: ...tz durch konstruktive Sicherheit c Zündquellenüber wachung b FIüssigkeitskapselung k Ebenfalls mitfolgenden Europäischen und Nationalen Normen und tech nischen Vorschriften übereinstimmt Technische Regeln für Gefahrstoffe TRGS 727 2016 Vermeidung von Zündgefahren infolge elektrostatischerAufladungen Ausgefertigt in Düsseldorf am 23 Juni 2020 Name des Unterzeichners John Pearce Geschäftsführer Mana...

Page 43: ... gr 13 Temperaturerhöhung Temperature rise 80K Mechanische Daten Mechanical specification 14 Kühlart Cooling type IC411 51 Gewicht Mass kg 16 15 Service Faktor Service factor 1 52 Trägheitsmoment Moment of inertia kgm2 0 0002 16 53 Leerlaufgeräusch Noise at no load 1 m Lp dB A 44 17 54 Schwingstufe Vibration level IEC 34 14 A Elektrische Daten Electrical performances 55 Schwingungsobergrenze Vibra...

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Page 45: ...sential Health and Safety Requirements has been assured by compliance with EN60079 0 2012 A11 2013 EN60079 1 2007 EN60079 7 2007 EN60079 31 2014 10 If the sign X is placed after the certificate number it indicates that the equipment or protective system is subject to special conditions for safe use specified in the schedule to this certificate 11 This EU TYPE EXAMINATION CERTIFICATE relates only t...

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