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Instruction Manual 

 

 

Page 3 of 40 

Issue: 2.1

 

N:\Engineering\Manuals\Pump Unit E2-30 & 40 R2.1.doc 

 

Index 

Section 

 

1.1 

General Description 

1.2 

Operating Principle 

1.3 

Specifications 

1.4 

Dimensions and Mounting Details 

 

 

2.1 

Important Safety Information 

 

 

3.1 

Installation - General 

3.2 

Installation – Electrical / Grounding 

3.3 

Installation – Mechanical 

 

 

4.1 

Operation 

 

 

5.1 

Parts List – Main Assembly 

5.2 

Parts Lists – Mechanical Assembly 

5.3 

Parts Lists – Fluid Section Assembly 

 

 

6.1 

Maintenance - Assembly Procedure 

6.2 

Maintenance – General 

6.3 

Maintenance - Motor / Gearbox 

6.4 

Maintenance - Fault Finding 

6.5 

Maintenance – Testing / Lubrication / Draining 

 

 

7.1 

Spare Parts Lists 

 

 

8.1 

Accessories 

 

 

 

 

 

 

 

Summary of Contents for E2-30

Page 1: ...tion Manual For E2 30 Electric Drive Pump Model 107071 EU Model Model 107074 USA Model Model 107075 Japan Model E2 40 Electric Drive Pump Model 107093 EU Model Model 107094 USA Model Model 107095 Japa...

Page 2: ...ctive 94 9 EC by complying with the following statutory documents and harmonized standards Machinery Safety Standards EN ISO 12100 EN ISO 4413 EN ISO 4414 EN12621 Explosion Prevention Potentially Expl...

Page 3: ...ety Information 3 1 Installation General 3 2 Installation Electrical Grounding 3 3 Installation Mechanical 4 1 Operation 5 1 Parts List Main Assembly 5 2 Parts Lists Mechanical Assembly 5 3 Parts List...

Page 4: ...mance at a lower cost Running costs are much lower than compressed air driven models The Model E2 30 Electric Pump achieves a reciprocating drive by using a cam and cam followers combined with a slidi...

Page 5: ...adjustment is made by control of the Inverter Frequency Output through manual operation or from a PLC analogue output The motor frequency is directly proportional to the Fluid Output see specificatio...

Page 6: ...to save on space The outlet ball check is spring assisted to minimise pressure drop at change over A bellows provides the fluid seal on the connecting rod within the inlet chamber whilst a piston lip...

Page 7: ...min E2 30 Fluid Output 80 HZ 40 cycles min E2 40 Fluid Output 80 HZ 40 cycles min 30 0 Litres min 8 0 US Gall min 40 0 Litres min 10 6 US Gall min Fluid Inlet Outlet Connections 1 1 2 Sanitary Gearbo...

Page 8: ...Instruction Manual Page 8 of 40 Issue 2 1 N Engineering Manuals Pump Unit E2 30 40 R2 1 doc Dimensions and Mounting Details Section 1 4...

Page 9: ...ns are ignored Installation and maintenance should only be carried out by suitably qualified personnel 1 Before attempting any work on a high pressure system ensure material pump hydraulics compressed...

Page 10: ...engine in the spray dispense area Hot Surface Hazard The electric motor becomes hot during operation and the heat may be transferred to other connected equipment To reduce the risk of burning yoursel...

Page 11: ...uired pressure The maximum Pressure setting the pressure switch should be set to is 19 bar 275 psi and 14 bar 203 psi respectively The pressure switch must be fitted and functioning correctly before t...

Page 12: ...eeded by the operator as this will invalidate the certification and use of the electric motor Required European Inverter Settings Value Maximum Hz output 80 Hz Minimum Hz output 20 Hz Acceleration Ram...

Page 13: ...the pump The control card has in built software to control the paint flow rate and system pressure within given set parameters so that the paint system can be used in the most efficient way at all ti...

Page 14: ...anics from overload and subsequent damage It is recommended that the relief valve setting is set to 1 bar 14 5 psi above the maximum required pressure The maximum Pressure setting the relief valve sho...

Page 15: ...gulator to achieve the desired system fluid pressure Refer to Fluid Output Table for comparison of fluid output relative to Inverter frequency and Pump cycle rate The return line back pressure regulat...

Page 16: ...1 107075 95PUMP 121 192666 1 5 KW ATEX ELECTRIC MOTOR EU 1 107071 93 PUMP 121 192667 2 HP ELECTRIC MOTOR USA PUMP 1 107074 94 PUMP 121 192664 1 5 KW ELECTRIC MOTOR JAPAN 1 107075 95PUMP 122 164470 M1...

Page 17: ...Instruction Manual Page 17 of 40 Issue 2 1 N Engineering Manuals Pump Unit E2 30 40 R2 1 doc Parts List Section 5 1...

Page 18: ...G CAP 1 24 192645 O RING 100 x 2 5 1 25 192650 1 8 x 45 GREASE NIPPLE 3 26 192617 TOP BEARING CAP 1 27 192639 110 BALL BEARING 1 28 192594 TOP SHAFT 1 29 192600 CV CAM 1 30 192606 BASE SHAFT 1 31 1926...

Page 19: ...Instruction Manual Page 19 of 40 Issue 2 1 N Engineering Manuals Pump Unit E2 30 40 R2 1 doc...

Page 20: ...rts List Mechanical Assembly Carriage 192682 ITEM PART No DESCRIPTION QTY REMARKS 60 192608 LH CARRIAGE END 1 61 192607 CARRIAGE MIDDLE 1 62 192609 RH CARRIAGE END 1 63 192618 CARRIAGE ADAPTOR 1 64 19...

Page 21: ...bly Carriage 192682 ITEM PART No DESCRIPTION QTY REMARKS 68 192642 LINEAR BEARING 4 69 192615 LINEAR BEARING SPACER 2 70 192652 47 INTERNAL CIRCLIP 4 71 165086 M8 SPRING WASHER 6 72 165553 M8 x 25 CAP...

Page 22: ...8 192648 O RING 41 0 x 1 78 PTFE 1 89 192505 O RING 12 42 x 1 78 PTFE 1 90 165960 M12 x 40 CAP HD SCREW ST ST 4 91 165108 M8 SPRING WASHER ST ST 4 92 164472 M8 x 25 CAP HD SCREW ST ST 4 93 165044 M12...

Page 23: ...Instruction Manual Page 23 of 40 Issue 2 1 N Engineering Manuals Pump Unit E2 30 40 R2 1 doc Parts List Section 5 3...

Page 24: ...p 26 with M6 x 20 cap head screws 18 and spring washers 19 tighten to 20 Nm apply loctite 222 to thread Bottom Plate Assembly 1 Lightly grease seal 21 and push seal into base plate housing 10 Note ori...

Page 25: ...ring The shaft should be a firm press fit to ensure inner race of bearing contacts with the 58 shoulder 5 Pick up the bottom plate assembly and remove the inner race from the bearing Fully grease the...

Page 26: ...ate bearing making sure that the greasing port is at the back of the pump assy Fit the 6 off M6 x 20 cap screws 18 and washers 19 using Loctite 222 on the threads and tighten in a diagonal pattern unt...

Page 27: ...will be on the outside the edge of the block Orientate bearing so that the wide black section along its body is aligned to the block s side 4 Insert white bearing spacer 69 with cross holes aligned th...

Page 28: ...lace this loose assembly over the pin so that the two cross holes line up Place nut washer 66 and lightly greased nut 74 onto the pin Hold in position and tighten the nut to 80 Nm 4 Place the carriage...

Page 29: ...electing one carriage at a time slide the carriage assembly back to the side plate pushing via the cam follower bearing this will align the carriage parts Finally tighten the cap heads M8 x 25 72 cap...

Page 30: ...ns 4 Smear a film of loctite 572 over the nose of the bellows then thread the nut 107 onto the bellows using tool 502377 to push against the nut ensuring the thread starts squarely Grip the bellows an...

Page 31: ...en the cylinders 5 Lightly grease the thread of 4off M12x40 caphead screws 90 and assemble with 4off 12 washers 93 to hold the cylinders together Tighten evenly the caphead screws in a criss cross fas...

Page 32: ...to 22Nm Fit the green spider into the coupling half 5 Brush copperlite grease onto the gearbox shaft and key Slide the other coupling half over the gearbox shaft and key until flush with the end of th...

Page 33: ...are stocked as spare parts in addition to the recommended spare parts kits It is also a requirement of the E U ATEX directive Use of Equipment in Potentially Explosive Atmospheres that any Bearings s...

Page 34: ...ers for excessive wear replace if excessive wear can be seen Annually Inspect Piston and Replace Piston Seals Bellows Springs Inspect Piston Outlet Ball Checks replace as necessary Inspect Linear Guid...

Page 35: ...s must be correctly locked to avoid resistance increases with consequent contact overheating The insulation air distance and the surface distance between conductors required by the standards must be r...

Page 36: ...contact with cam a Spring tension insufficient b Fluid seal friction or piston movement prevented Check and replace springs Check fluid section Noisy Changeover Coupling spider worn Replace green spi...

Page 37: ...orrectly vented Check for any leaks and mechanical noises 9 While running at a slow speed apply 502375 grease to cam follower bearings 10 While running apply 502375 grease to main shaft bearing 40 str...

Page 38: ...Pump 250609 Bellows Replacement Kit 250610 Wet section overhaul Kit E2 30 Pump 250622 Wet section overhaul Kit E2 40 Pump 250611 Cam Follower Bearing Kit 250612 Linear Guide and Rod Kit 250599 Main B...

Page 39: ...am Follower Main Bearings 502376 Grease for Linear Bearings 502144 Pressure Switch 192720 Sensor Manifold 192547 Pressure Sensor 4 20 mA 0 25 Bar Pressure feedback 192008 1 5 Sanitary Gasket 192009 1...

Page 40: ...488 General e mail info finishingbrands eu 163 171 Av des Aur ats 26014 Valence cedex FR T l phone 33 0 4 75 75 27 53 T l copie 33 0 4 75 75 27 79 General e mail info finishingbrands eu USA Canada Cus...

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