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 Operating Instructions 

   

 

Pump ZPU 08 ATEX 

 

810-53711-1

   

 

 

Page 5 / 57

 

Rev.: 003 
31/07/2017 

 
 
5.

 

Technical data of the capacitive sensor ........................................................ 36 

 
6.

 

Technical data of the motor ............................................................................ 37 

 
7.

 

Brief description of the pump ........................................................................ 38 

 
8.

 

Installation and commissioning ..................................................................... 40

 

8.1.

 

Filling of the reservoir .................................................................................. 40

 

8.2.

 

Inadvertent filling with incorrect lubricant ..................................................... 41

 

8.3.

 

Inspections prior to initial start-up ................................................................ 41

 

8.4.

 

Activation of the pump ................................................................................. 42 

 
9.

 

Standard operation .......................................................................................... 43

 

9.1.

 

Daily start-up ............................................................................................... 43

 

9.2.

 

Inspections .................................................................................................. 43

 

9.3.

 

Filling of the reservoir during operation ....................................................... 43

 

9.4.

 

Cleaning ...................................................................................................... 43 

 
10.

 

Maintenance ..................................................................................................... 44

 

10.1.

 

Maintenance of pump ............................................................................... 44

 

10.2.

 

Maintenance of lubricant filter .................................................................. 45

 

10.3.

 

Maintenance of gear unit .......................................................................... 45

 

10.4.

 

SEW motor maintenance ......................................................................... 46

 

10.5.

 

Measurement of the insulation resistance ................................................ 46

 

10.6.

 

Maintenance of gear unit .......................................................................... 46 

 
11.

 

Troubleshooting .............................................................................................. 47 

 
12.

 

Declarations of conformity of the purchase parts ........................................ 51

 

 

 

 

 

Содержание ZPU 08

Страница 1: ...Operating Instructions Pump ZPU 08 ATEX 810 53711 1 Page 1 57 Rev 003 31 07 2017 ZPU 08 ...

Страница 2: ... 1 1 7 1 1 7 3 1 7 4 Furthermore the following directives and harmonized standards were applied in the respective applicable areas The special technical documents were prepared following ATEX directive 2014 34 EU annex VIII 3 and stored at the named institute CE 0123 Machinery directive 2006 42 EC annex VII part B was prepared We undertake to send this in electronic form to the respective authorit...

Страница 3: ...ties 9 2 8 Conversions or modifications 9 2 9 Inspections 9 2 10 Labels on the pump 10 2 11 Other applicable documents 11 2 12 Sources of hazard 12 2 13 Moving rotating parts 12 2 14 Energies 12 2 15 Lubricants 12 2 16 Explosive substances at the location of use 12 2 17 Existing residual risks 13 2 18 Persons authorized to operate the pump 16 2 19 Operator 16 2 20 Specialist for maintenance and re...

Страница 4: ...1 Selection of lubricants 26 3 2 Ageing of lubricants 26 3 3 Specification 27 4 Technical data 28 4 1 Ambient temperatures 28 4 2 Explosion protection marking 28 4 3 Operating pressure 28 4 4 Installation position 28 4 5 Sound pressure level 28 4 6 Maximum set up height 28 4 7 Maximum dust thickness 28 4 8 Weight 28 4 9 Gear ratio 28 4 10 Reservoir 29 4 11 Space requirements 30 4 12 Electrical con...

Страница 5: ...1 8 3 Inspections prior to initial start up 41 8 4 Activation of the pump 42 9 Standard operation 43 9 1 Daily start up 43 9 2 Inspections 43 9 3 Filling of the reservoir during operation 43 9 4 Cleaning 43 10 Maintenance 44 10 1 Maintenance of pump 44 10 2 Maintenance of lubricant filter 45 10 3 Maintenance of gear unit 45 10 4 SEW motor maintenance 46 10 5 Measurement of the insulation resistanc...

Страница 6: ... o List 2 Marks lists parenthesis Item numbers Instructions Instructions to personnel These always appear in chronological order 1 1 Warnings Activities which generate actual hazards to life and limb or possible damage to the material are marked by warnings Definitely observe the instructions given in the warnings The following warnings are possible Warning level Consequence Probability DANGER Dea...

Страница 7: ...pressure level greater than less than plus minus SW width across flats ESD electrostatic discharge N A not applicable MTTF mean time to failure 1 4 Manufacturer and Service addresses Manufacturer Customer Service SKF Lubrication Systems Germany GmbH Heinrich Hertz Str 2 8 DE 69190 Walldorf Central Customer Service Dept P O Box 1263 DE 69183 Walldorf 1 5 Warranty The instructions do not contain any...

Страница 8: ...stated explosion protection class The pump may be used within commercial machines or systems exclusively 2 3 Explosion protection class Explosion protection marking See declaration of conformity or type identification plate of the pump 2 4 Expiry of the ATEX certification The ATEX certificate for this product expires through Use not in accordance with the intended purpose Unauthorized modification...

Страница 9: ...LP regulation EC 1272 2008 and marked with GHS01 GHS06 and GHS08 hazard pictograms For the supply transport stockpiling of gases liquefied gases dissolved gases vapours and fluids whose vapour pressure exceeds normal atmospheric pressure 1013 mbar by more than 0 5 bar at the maximum admissible operating temperature 2 7 Prohibition of certain activities The following activities may be carried out b...

Страница 10: ...ve the lid and reach into the reservoir Risk of trapping or shearing off hands and fingers Behind the protective fitting marked with this symbol there is the lubricant filter Behind the protective fitting marked with this symbol there is the check valve Marks the equipotential bonding connection of the pump Provides instructions on how to clean the lubricant filter ...

Страница 11: ...or the SM type series Motor SEW Explosion protected three phase motors EDR 71 225 documentation no 19402007 Where appropriate Any documents of other components required to set up the centralized lubrication system Project planning documents Other relevant documents for the integration of the pump into the machine or system The owner must supplement these documents by the respective valid national ...

Страница 12: ...ngent safety and reliability tests Like for all complex machines also for this pump there may still be involved potential sources of hazard For example 2 13 Moving rotating parts Drive stirring paddles 2 14 Energies Electricity Temperature hot cold surfaces Position energy raised components Parts subject to operating pressure Parts subject to spring tension 2 15 Lubricants Greases 2 16 Explosive s...

Страница 13: ...cool down eliminate cause Replace the motor circuit breaker or adjust it correctly Loosening of plug in connections under voltage Secure plug in connections against inadvertent loosening by means of safety clips Prior to loosening the plug in connections de energise the pump Generation of electrostatic charges or sparks through unsuitable clothing or tools Within potentially explosive areas use ES...

Страница 14: ...ction of the pump de energize all affected electrical components If necessary please observe discharge times The electrical connection may be carried out by commissioned and qualified electricians only and in accordance with the connection diagram People falling due to contamination of floors with spilled lubricant Take care when filling Bind and remove leaked or spilled lubricant immediately with...

Страница 15: ...ervoir Electric shock through reduced insulation resistance Check the formation of condensation water in the motor regularly If applicable drain off condensation water at the drain plug Check the insulation resistance regularly Electric shock when connecting the pump Prior to connection of the pump de energize all affected electrical components If necessary please observe discharge times The elect...

Страница 16: ...ponents in potentially explosive areas and to initiate suitable measures to prevent such risks The specialist has knowledge of the different ignition protection types installation procedures and zone divisions He is familiar with the rules and regulations relevant for his activities and explosion protection in particular with ATEX directive 94 9 EG 2 21 Protection of special groups of persons The ...

Страница 17: ...s away from the machine Precautionary operational measures and instructions for the respective work must be observed Responsibilities for different activities must be clearly defined and observed Uncertainty seriously endangers safety Safety related protective and emergency devices must not be removed modified or affected otherwise in their function and are to be checked at regular intervals for c...

Страница 18: ...ature of the lubricant must lie at least 50 K over the maximum admissible surface temperature of the components Only use tools and clothing which are permitted for use in potentially explosive areas ESD Transport installation repairs and work on electrical components may only be carried out if it has been ensured that the atmosphere is not potentially explosive Repairs or modifications to machines...

Страница 19: ...rough heat up of bearing points on the machine in the area of ignition temperature If this cannot be ascertained provide a low level signal or suitable organisational measures for monitoring of the bearing point temperature Avoid dust accumulation and remove dust immediately Dust accumulations have a thermally insulating effect and if whirled up generate the formation of a potentially explosive at...

Страница 20: ...cing system of the motor With a direct coupling ensure that the parts align precisely observe the manufacturer s guidelines Assemble the product only outside of the operating range of moving parts at an adequate distance from sources of heat or cold Dry wet slippery surfaces Cover hot or cold surfaces accordingly Prior to performing work de energize and depressurize the pump and secure it against ...

Страница 21: ...tallation of the centralized lubrication system All components used must be designed for o maximum operating pressure o maximum minimum ambient temperature o lubricant to be supplied o required ATEX zone o operating ambient conditions at the location of use Parts of the centralized lubrication system must never be subjected to torsion shearing or bending Check all parts prior to use for contaminat...

Страница 22: ...ot use any aggressive cleaning agents Do not use sharp edged or spark generating tools for cleaning e g cooling fins of the motor Do not use steam jet or high pressure cleaners Electrical components may be damaged Observe the IP protection class Cleaning work on energized components may be carried out by electrical specialists only Do not touch cables or electrical components with wet or damp hand...

Страница 23: ...perating instructions selects suitable employees Provides these employees with sufficient and appropriate instructions with reference to explosion protection applies an approval system for hazardous activities and for those which may become hazardous in interaction with other work carries out the necessary inspections and monitoring ensures that only original spare parts are used 2 31 Provision of...

Страница 24: ...tions are to be documented and repeated at regular intervals New personnel may operate the machine under supervision and instruction by experienced personnel only Maintenance and repair work may be carried out by qualified personnel only 2 33 Briefing of external technicians Prior to commencing the activities external technicians must be informed by the operator of the company safety provisions th...

Страница 25: ... Keep the packaging material until any discrepancies are resolved 2 38 Returns Clean all parts and pack them properly before returning them Mark returns on the packaging as follows Do not burden this side up Protect against moisture Handle with care Fragile do not throw 2 39 Disposal At the end of its service life the pump must be dismantled correctly and disposed of according to the respective va...

Страница 26: ...or the planning of a centralized lubrication system The selection is made by the manufacturer operator of the machine preferably together with the lubricant supplier based on the requirement profile defined by the specific application Should you have little or no experience with the selection of lubricants for centralized lubrication systems please contact SKF You will avoid possible costly downti...

Страница 27: ...his may have unforeseeable effects on the usability and therefore on the function of the centralized lubrication system Due to the multitude of possible additives it is possible that individual lubricants which according to the manufacturer s data sheets fulfil the necessary specification are not in fact suitable for use in centralized lubrication systems e g incompatibility between synthetic lubr...

Страница 28: ... T4 Gb II 2D c IIIC T120 C Db Part no 605 41759 8 II 2G c IIC T4 Gb II 2D c IIIC T120 C Db 4 3 Operating pressure Operating pressure is limited to max 410 bar 10 by a pressure control valve All system parts must be designed for the maximum operating pressure 4 4 Installation position Vertical i e reservoir at top Maximum deviation 5 4 5 Sound pressure level 70 dB A 4 6 Maximum set up height 1000 m...

Страница 29: ...Operating Instructions Pump ZPU 08 ATEX 810 53711 1 Page 29 57 Rev 003 31 07 2017 4 10 Reservoir 40 XB 40 XL Used with pump 605 41759 8 605 40759 6 Used with pump 605 46554 7 ...

Страница 30: ...onal free space of 100 mm is provided in each direction for maintenance and inspections works The distance between the motor air intake and any obstacle must total to at least 40 mm Ensure that the air can flow into the motor without hindrance Outflowing air must not be sucked in again directly When planning consider an additional free space of 350 mm above the reservoir to remove the reservoir li...

Страница 31: ...on is carried out in accordance with the applicable national ATEX regulations for example ElexV DIN EN 60079 14 2014 VDE 0165 1 2014 Electrical systems in explosive areas DIN EN 60079 17 2014 Electrical equipment for use in areas with combustible dust DIN VDE 0100 Tolerance voltage 5 Tolerance frequency 2 The waveform and mains symmetry must be maintained so that the motor heat up remains within t...

Страница 32: ... Protective fitting AF 19 80 8 Nm Filter element AF 11 20 2 Nm T3 Check valve Protective fitting AF 19 80 8 Nm Check valve flat bladed screwdriver 20 2 Nm T4 Pressure gauge AF 22 45 4 5 Nm T6 Grounding connection lid reservoir AF 6 8 1 Nm T7 Pump to foundation 18 2 Nm If no tightening torques are stated the tightening torques are to be applied to the screw size for 8 8 screws T1 T2 T4 T3 T5 T6 ...

Страница 33: ...needed 4 18 Admissible speed of the eccentric shaft Minimum speed Maximum speed 10 rpm 85 rpm When supplying the pump without motor and gear speeds must be maintained by selecting a suitable motor and gear 4 19 Output approx 11 2 dm3 h This information applies for grease of NLGI class 2 at 20 C and 100 bar counterpressure Deviating conditions such as different NLGI class temperature or counterpres...

Страница 34: ...on Model Type designation of the pump MADE IN GERMANY Country of origin Part no Order number Part number Manufacturer CE EX marking Electrical information Ta Min max ambient temperature Voltage Voltage V AC Series Year of construction Order no batch 4 figures 6 figures 3 figures Frequency Hz Observe associated instructions Control voltage Control Voltage V DC WW YY Calendar week year of constructi...

Страница 35: ...lative 90 maximum Storage time 24 months max Special storage conditions of the motor Do not store the motor on the fan cover After a longer period of storage make sure to check the insulation resistance In case of storage 1 year Make sure to observe the grease service life of the ball bearings which is reduced by 10 per year NOTICE Risk of damage to the machine or system Prior to initial use or af...

Страница 36: ...ted 2 1 mA Switching frequency 0 1 kHz Output function 2 wire NAMUR Internal capacity Ci 150 nF Inductivity Li 150 µH Design Threaded tube M 18 x 1 Dimensions 74 mm Housing material Plastic PA12 GF30 Material of active surface Plastic PA12 GF30 yellow Admissible pressure onto front closing cap 6 bar Max tightening torque Housing nut 2 Nm Connection Cable Cable quality Ø 5 2 LiYY PVC 10 m Cable cro...

Страница 37: ...5 rpm Design B14 Rated voltage 254 440 V DC Size 80 Circuit D Y Shaft 19x40 Nominal current 2 15 1 24 A Performance factor 0 81 cos φ Insulation class F Part no Type of motor ATEX no Manufacturer 245 13984 7 EDRS80S4 PTB 10 ATEX 3026 01 SEW Rated power 0 55 kW Code Operating mode S 1 Flange Ø 120 Rated frequency 50 Hz IP 55 Rated speed 1415 rpm Design B14 Rated voltage 219 241 380 440 V DC Size 80...

Страница 38: ...for filling level monitoring and grounding 2 Pressure gauge 3 Motor 4 Gear 5 Pressure control valve 6 Pump housing 7 Lubricant filter 8 Check valve Connections A Pressure line B Relief line C Filling line DANGER Risk of explosion Carry out work on electrical parts only if the atmosphere is not potentially explosive Electric shock Disconnect the pump from the mains prior to all work on electrical p...

Страница 39: ...istons This type of drive allows to select or change the rotational direction of the pump shaft as needed The lubricant supplied by the pump element is dispensed to the pressure line connection via a check valve and a lubricant filter One respectively two sensors determine the reservoir filling level low level respectively high and low level indication Upper end position Start of the piston moveme...

Страница 40: ...tion Manual filling Filling procedure must be supervised by a second person Switch the filling pump on Fill the reservoir Switch off the filler pump Filling port C Filling via the reservoir lid Switch the pump off Open the reservoir lid 1 1 Ensure that no dirt enters the reservoir or the inner side of the reservoir lid In case of reservoirs equipped with a sensor the sensor must not be damaged or ...

Страница 41: ...he operator must inspect certain areas of the central lubrication system prior to initial commissioning Report any detected deficiencies immediately to your superior and remedy them Deficiencies may be remedied by an authorized and qualified specialist only Check the following points prior to initial commissioning NOTICE Risk of damage to the machine Fill the feed lines with lubricant and fill the...

Страница 42: ...ll parts such as lines cables metering devices etc have been correctly installed and are undamaged Mechanics No dust accumulations present in particular on the air intake of the motor Loose or missing parts remaining e g pressure relief valves feed lines Damages deformations or cracks Smoke or smouldering spots Discolorations contaminations and or corrosion Unusual humidity Unusual odours vibratio...

Страница 43: ...during operation Fill the reservoir as described in the chapter Installation and commissioning 9 4 Cleaning DANGER Danger to life Risk of fire and explosion when using inflammable cleaning agents Do not use steam jet or high pressure cleaners Electrical components may be damaged Do not touch cables or electrical components with wet or damp hands Cleaning work on energized components may be carried...

Страница 44: ... and qualified personnel only is allowed to carry out such works Works then have to be reviewed by a qualified and officially recognised person Carry out work on electrical parts only if the atmosphere is not potentially explosive Electric shock Make sure to disconnect the pump from the power supply before carrying out works on electrical parts 10 1 Maintenance of pump Any maintenance works may be...

Страница 45: ...Leakages Damages to the surface protection corrosion protection Every 3 000 hours but at least once a year Depending on the type of application and ambient conditions Switch the pump off Unscrew protective fitting 9 1 from lubricant filter AF 19 Unscrew lubricant fitting 9 SW 11 Clean lubricant filter with non flammable cleaning agents Blow lubricant filter with compressed air from inside two outs...

Страница 46: ...ate of the motor Main inspection After about 10 000 operating hours at the latest however after 1 year 10 5 Measurement of the insulation resistance Before the first start up and after longer downtimes measure the insulation resistance following the standards e g VDE 0100 DIN EN 61557 1 2007 valid in the country of use If the insulation resistance falls below the required minimum value determine a...

Страница 47: ...ctions on the pressure gauge fluttering Check and clean filter and replace if necessary Suction bore of pump element is clogged After disassembling the pump element Disassemble and clean the pump element Defective or dirty check valve After disassembling the pump element Replace check valve Eccentric shaft or driving parts of the swivelling lever and the stirring device defective Visual check Repl...

Страница 48: ...of the gear manufacturer Consult the manufacturer Oil grease leaking from shaft seal Defective seal Consult the manufacturer Oil leaking from vent valve Too much oil in the gear vent valve dirty frequent cold starts foaming oil Consult the manufacturer Output shaft does not rotate although motor is on Defective shaft hub joint Sent gear to manufacturer for repair For further relevant information o...

Страница 49: ...sufficient Provided the delta starting current is not too high immediately switch the motor on Otherwise use larger motor or special version after consultation Contact fault on star respectively delta connection Remedy the fault Wrong direction of motor rotation Motor connected wrongly Reverse two phases Motor hums and has a high power consumption Defective winding Consult the manufacturer Motor m...

Страница 50: ...age Higher voltage is very unfavourable in case of high pole motors as in case of a normal voltage their no load current is already close to the rated current Adapt the motor to the mains voltage Nominal operating mode S1 to S10 exceeded e g because of too high switching frequency Adapt the nominal operating mode of the motor to the required operating conditions if necessary consult an expert to d...

Страница 51: ...Operating Instructions Pump ZPU 08 ATEX 810 53711 1 Page 51 57 Rev 003 31 07 2017 12 Declarations of conformity of the purchase parts ...

Страница 52: ...Operating Instructions Pump ZPU 08 ATEX 810 53711 1 Page 52 57 Rev 003 31 07 2017 ...

Страница 53: ...Operating Instructions Pump ZPU 08 ATEX 810 53711 1 Page 53 57 Rev 003 31 07 2017 ...

Страница 54: ...Operating Instructions Pump ZPU 08 ATEX 810 53711 1 Page 54 57 Rev 003 31 07 2017 ...

Страница 55: ...Operating Instructions Pump ZPU 08 ATEX 810 53711 1 Page 55 57 Rev 003 31 07 2017 ...

Страница 56: ...Operating Instructions Pump ZPU 08 ATEX 810 53711 1 Page 56 57 Rev 003 31 07 2017 ...

Страница 57: ...Operating Instructions Pump ZPU 08 ATEX 810 53711 1 Page 57 57 Rev 003 31 07 2017 ...

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