Sample gas pumps Installation and Operation Instructions P2.x, P2.8x Original instructions

Sample gas pumps
P2.x, P2.8x
Installation and Operation Instructions
Original instructions
BE420001 ◦ 10/2013
Bühler Technologies GmbH, Harkortstr. 29, D­40880 Ratingen
Tel. +49 (0) 21 02 / 49 89­0, Fax: +49 (0) 21 02 / 49 89­20
Internet: www.buehler­technologies.com
E­Mail: analyse@buehler­technologies.com
All rights reserved., Bühler Technologies GmbH 2014
Document information
Document No......................................BE420001
Version ...................................................10/2013
Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Contents
Contents
1 Introduction .......................................................................................................................................................... 2
1.1 Intended use .................................................................................................................................................. 2
1.2 Product key .................................................................................................................................................... 2
1.3 Product description ........................................................................................................................................ 4
1.4 Scope of delivery ........................................................................................................................................... 4
2 Safety instructions............................................................................................................................................... 4
2.1 Important advice ............................................................................................................................................ 4
2.2 General indication of risk ............................................................................................................................... 6
3 Transport and storage......................................................................................................................................... 7
4 Installation and connection ................................................................................................................................ 7
4.1 Requirements to the installation site .............................................................................................................. 7
4.2 Mounting ........................................................................................................................................................ 8
4.3 Special condition moist sample gas............................................................................................................... 8
4.3.1 Conversion to pump body pointing down ........................................................................................... 8
4.4 Connecting the sample gas line..................................................................................................................... 9
4.5 Electrical connections .................................................................................................................................. 10
5 Operation and control ....................................................................................................................................... 10
5.1 Switching the sample gas pump on ............................................................................................................. 11
5.2 Operating the sample gas pump.................................................................................................................. 11
6 Maintenance ....................................................................................................................................................... 12
6.1 Replacing the inlet and outlet valves ........................................................................................................... 13
6.2 Replacing bellow and connecting rod­eccentric­combination ...................................................................... 14
6.3 Replacement of the O­ring of the bypass valve (optional) ........................................................................... 16
6.4 Replacement of the coupler (P2.4 & P2.84­pump) ...................................................................................... 16
7 Service und repair.............................................................................................................................................. 16
7.1 Troubleshooting ........................................................................................................................................... 16
7.2 Spare parts and accessories ....................................................................................................................... 18
8 Disposal .............................................................................................................................................................. 18
9 Attached documents ......................................................................................................................................... 18
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Introduction
1 Introduction
1.1 Intended use
The sample gas pumps are designed for installation in gas analyser systems in industrial applica­
tions.
The sample gas pump is designed to transport only gaseous media. It is not suitable for liquids.
Please regard information given in the data sheets with respect to specific use, available material
combinations and pressure and temperature limits.
DANGER
Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially ex­
plosive atmospheres.
Do not expose the device to combustible or explosive gas mixtures.
1.2 Product key
The device is delivered with different configurations. The part number given on the type plate in­
forms you about the specific configuration of your device.
On the type plate you will find the order number as well as the 13­digit product key. This number is
a code where each digit (x) describes a certain feature:
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Introduction
42
xx
x
x
x
x
x
9
56
57
63
64
1
2
5
1
2
1
2
3
1
2
9
1
2
3
4
9
1
2
3
5
9
0
00 Feature
Basic type
P2.3 400 l/h
P2.4 400 l/h
P2.83 800 l/h
P2.84 800 l/h
Motor supply
230 V 50/60 Hz. 0,85/0,8 A
115 V 50/60 Hz. 1,7/1,6 A
400 V 50/60 Hz. 0,5/0,43 A
Pump head position
Normal position vertical
Pointing downwards *
Pump head material
PTFE
SS 1.4571
PTFE with bypass valve *
Valve material
to 100 °C; PTFE / PVDF **
to 160 °C; PTFE / PEEK
Male stud couplings (for voltages 230 V and
400 V)
PTFE pump body
Stainless steel pump
body
DN 4/6 (standard)
6 mm (standard)
DN 6/8
8 mm
3/8“­1/4“
3/8“
1/4“­1/8“
1/4"­1/6”
1/4“
Male stud couplings (for voltage 115 V)
PTFE pump body
Stainless steel pump
body
1/4“­1/6“ (standard)
1/4“ (standard)
DN 6/8
8 mm
3/8“­1/4“
3/8“
1/4“­1/8“
DN 4/6
6 mm
Mounting accessories
including mounting console and buffer *
* not possible for P2.4 & P2.84
** not possible for P2.4, P2.83 & P2.84
If there are special instructions for a pump type, they are marked in the manual.
Take care of the limits of the pump (see data sheet). When ordering spare parts chose for the type
matching part numbers (e.g. valves).
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Safety instructions
1.3 Product description
This operating­ and installation manual describes the sample gas pumps P2.x.
The sample gas pump is designed to transport only gaseous media not liquids.
Please regard the information given in the data sheets concerning specific use, available materials,
pressure and temperature ranges. Regard in particular the information and type of protection given
on the type plate.
Pump head and drive are separated at the P2.4 / P2.84 pump installation of the pump head in hot
applications. The flange is subdivided so that the head can be mounted inside the heated housing
and the other flange part carries the motor mounted outside. The wall thickness may be up to 30
mm (1.2“).
Sample gases, which still contain humidity, tend to form condensate in the tubes and in the pump
body. In such cases the pump head must be mounted with the head pointing down (see chapter
Conversion to pump body pointing down [_ 8]).
NOTICE
Never use sample gas pumps outdoors!
1.4 Scope of delivery
P2.3 & P2.83
– 1 x sample gas pump with motor
– 4 x rubber­metal­buffer
– 1 x console made of 1.4301
– 1 x product documentation
P2.4 & P2.84
– 1 x pump body with flange
– 1 x motor
– 1 x coupling flange
– 1 x coupling
– 6 x screws M6x16
– 1 x mounting ring
– 1 x product documentation
2 Safety instructions
2.1 Important advice
Operation of the device is only valid if:
– the product is used under the conditions described in the installation­ and operation instruction,
the intended application according to the type plate and the intended use. In case of unauthor­
ized modifications done by the user Bühler Technologies GmbH can not be held responsible for
any damage,
– when complying with the specifications and markings on the nameplates.
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Safety instructions
– the performance limits given in the datasheets and in the installation­ and operation instruction
are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications
without advanced notice. Keep this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or
death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in
severe injuries or death if not avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the
device or the property or minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Tab. 1: Signal words for warnings
Warning signs
In this manual, the following warning signs are used:
Warning against hazardous situ­
ations
General notice
Warning against electrical voltage
Disconnect from mains
Warning against respiration of toxic
gases
Wear respirator
Warning against acid and corrosive
substances
Wear eye/face protection
Warning against potentially explos­
ive atmospheres
Wear protection gloves
Warning against hot surface
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Safety instructions
2.2 General indication of risk
Installation of the device shall be performed by trained staff only, familiar with the safety require­
ments and risks.
Check all relevant safety regulations and technical indications for the specific installation place.
Prevent failures and protect persons against injuries and the device against damage.
The operator of the system must secure that:
– safety and operation instructions are accessible and followed,
– local safety regulations and standards are obeyed,
– performance data and installation specifications are regarded,
– safety devices are installed and recommended maintenance is performed,
– national regulations for disposal of electrical equipment are obeyed.
Maintenance, repair:
– Repairs on the device must be carried out by Bühler authorized persons only.
– Only perform modifications, maintenance or mounting described in this manual.
– Only use original spare parts.
During maintenance regard all safety regulations and internal operation instructions.
DANGER
Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintention­
ally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER
Toxic and corrosive gases
Sample gas can be hazardous.
a) Take care that the gas is exhausted in a place where no persons are in
danger.
b) Before maintenance turn off the gas supply and make sure that it cannot be
turned on unintentionally.
c) Protect yourself during maintenance against toxic / corrosive gases. Use
gloves, respirator and face protector under certain circumstances.
DANGER
Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially ex­
plosive atmospheres.
Do not expose the device to combustible or explosive gas mixtures.
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Transport and storage
CAUTION
Tilting risk
Damage of the device
Secure the device against any sudden translocation during maintenance.
CAUTION
Hot surface
Burning hazard
According to the product type and operation conditions, the temperature of the
housing may exceed 50 °C during operation.
Depending on the conditions at the installation site it may be necessary to
provide these areas with appropriate warning signs.
3 Transport and storage
The products should be transported only in its original packaging or a suitable replacement.
When not in use, protect the equipment against moisture and heat. Keep it in a covered, dry and
dust­free room at a temperature of ­20 °C to +40 °C.
Outdoor storage is forbidden. As a matter of principle, the operator must regard all applicable
standards according prevention of damage due to lightning, which may otherwise damage the
sample gas pump.
The storage room must not be equipped with any ozone­producing devices like fluorescent light
sources, mercury arc lamps, electric high voltage devices.
4 Installation and connection
4.1 Requirements to the installation site
CAUTION
Damage to the device
Protect the equipment against dust, falling objects and external impacts.
Stroke of lightning
Outdoor installation is forbidden. As a matter of principle, the operator must re­
gard all applicable standards according prevention of damage due to lightning,
which may otherwise damage the sample gas pump.
Air ventilation must not be obstructed and exhausted air ­ including air from adjacent units ­ must
not be sucked in directly.
The motor is suitable for ambient temperatures between ­20 °C to +60 °C and altitude of height ≤
1000 m above sea level.
Please leave enough space between the motor and the rear panel by mounting without the con­
sole. Please refer to the data sheet attached to this manual for further information about ambient
parameters at the installation site.
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Installation and connection
d = air inlet
4.2 Mounting
P2.3 / P2.83
For mounting the sample gas pump to mounting plates only use the included brackets and rubber­
metal buffers. Use these buffers as well if the pump is installed on an existing substructure.
P2.4 / P2.84
Please refer to the attached drawings 42/011­14­3 for P2.4 and 42/014­Z05­03­3 for P2.84 for
mounting instructions. Here you also find the dimensions for the wall cut­out.
Install the pump always and only with the flange to the housing, cabinet or wall. Fixing the motor in
addition is neither required nor admissible because then the system is mechanically over­determ­
ined.
4.3 Special condition moist sample gas
Applications where the sample gas is still moist may result in condensate forming in line and the
pump body. In these events the pump head must be suspended (pump body facing down).
If the pump was not ordered this way, it can easily be converted on site.
Install the line between the gas output and condensate drain with a grade so the condensate can
drain and does not collect inside the pump or the lines.
4.3.1 Conversion to pump body pointing down
CAUTION
Damage to the device
Especially with pump head pointing down, make sure that no dust or small parts
can intrude the pump through the ventilations slot. Nevertheless, the slot must
not be covered directly. If this is not possible, the pump must not be mounted with
pump head pointing downward.
To do this, unscrew the three cross­head screws of the housing cover and remove the cover (see
fig. 3, fig. 4) (see components drawing in the appendix). The crankshaft and the motor flange are
now visible. The pump housing is fixed with four hexagon head screws (wrench size 8) to the motor
flange . Remove them completely (fig. 5). Hold the housing when screwing out the last screw. Now
turn the housing carefully by 180° on the flange centering, re­fix it with the screws (fig. 6, fig. 7) and
re­mount the cover (tightening torque of the hexagon head screws 3 Nm). mounting the pump head
with angle 45° is forbidden!
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Installation and connection
Fig. 3
Fig. 4
Fig. 6
Fig. 5
Fig. 7
4.4 Connecting the sample gas line
The pumps are delivered with customized gas connections. Please compare the part­no. on the
type plate with the part­no. explained in chapter "Introduction".
Avoid mixed installations, that is connecting metal tubes to plastic bodies. If this is unavoidable for
sporadic applications, screw the metal fitting with utmost care and without any use of force to the
PTFE pump body.
Install the tubes in a way that the line at the inlet and outlet is flexible over a sufficient distance
(pump vibrates).
The pumps are marked with “In” for inlet (input) and “Out” for outlet (output). Make sure that the
connections to the tubes are tight.
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Operation and control
4.5 Electrical connections
WARNING
Hazardous electrical voltage
The device must be installed by trained staff only.
CAUTION
Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
A switch or power switch (according to IEC 60947­1 and IEC 60947­3) must be installed for the
sample gas pump. It must be easily accessible by the user. The switch must be marked as circuit
breaker for the device. It must not be installed in the mains power cord and must not interrupt the
protective earth conductor. Furthermore, it must disconnect the device from all poles.
The sample gas pump must be protected against overheating by a suitable overload protection.
Regard the rated current for the settings of the circuit breaker (see motor type plate).
Connect the pump according to the circuit diagram inside the terminal cover plate and provide suffi­
cient strain relief of the mains cable. Make sure that mains voltage and frequency meet the spe­
cifications of the pump's motor (voltage tolerance ± 5 % and frequency tolerance ± 2 %.).
Select mains and PE cross section according to the rated current.
The cross section must be at least 1.5 mm2.
Connect the protective earth conductor of the motor to the local earth conductor.
It is essential to connect the protective earth conductor to the marked PE terminal. Regard national
directives, in Germany DIN VDE 0100.
Make sure that no foreign bodies, dirt and moisture are left inside the terminal box. Seal non­used
cable ducts and the terminal box itself against dirt and water. Use the original gasket when closing
the terminal box.
Seal non­used holes with approved plugs.
Obey differing specifications on the type plate. The conditions at the installation site must meet all
specifications on the type plate,
5 Operation and control
NOTICE
The device must not be operated beyond its specifications.
CAUTION
Hot surface
Burning hazard
According to the product type and operation conditions, the temperature of the
housing may exceed 50 °C during operation.
Depending on the conditions at the installation site it may be necessary to
provide these areas with appropriate warning signs.
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Operation and control
5.1 Switching the sample gas pump on
Before switching the sample gas pump on make sure that
– gas fittings and electric connections are correctly mounted an not damaged.
– no parts of the sample gas pump are dismantled (e. g. cover).
– gas inlets and outlet of the sample gas pump are not closed.
– the system pressure ranges below 0.5 bar.
– the limits of ambient conditions are observed.
– all specifications as given on the type plate are observed.
– motor voltage and frequency meet the mains values.
– the electrical connections are fixed tightly and that monitoring devices are installed and set ac­
cording to directions!
– air vents and cooling surfaces are clean.
– protection measures are installed; Grounding!
– the motor is fixed properly.
– the terminal box is closed and the cable ducts are sealed properly.
– the elastomer gear ring of the coupling (P2.4 / P2.84 only) is installed correctly and is not dam­
aged.
NOTICE
Never use sample gas pumps outdoors!
When switching the sample gas pump on make sure that
– no abnormal sounds or vibrations occur.
– the flow rate is neither too low nor too high. This would indicate a cracked bellow.
5.2 Operating the sample gas pump
The sample gas pump is suitable for delivering gases only. It is not suitable for liquids.
The sample gas pump should be operated without pressure. A system pressure above 0.5 bar is
not allowed. The gas outlet must not be closed. The flow through the pump has to be 50 l/h min­
imum with the P2.x and a minimum of 200 l/h with the P2.8x types. If the flow shall be reduced to
less than 150 l/h with the P2.x or 400l/h with the P2.8x permanently, the flow has to be regulated
with an external bypass valve. In this case, pump type "PTFE with bypass valve“ should be used.
NOTICE
Extreme throttling reduces the life time of the bellow.
If the pump is equipped with a bypass valve, the flow rate can be adjusted. Do not apply force
when turning the valve, because the valve may be damaged otherwise! The turning range of the
valve is about 7 turns.
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Maintenance
6 Maintenance
Wait until the surface has cooled down before beginning maintenance.
– Maintenance of the device shall be performed by trained staff only, familiar with the safety re­
quirements and risks.
– Only perform maintenance work described in this manual.
– Regard all relevant safety regulations and internal operating instructions during maintenance.
NOTICE
Please refer to the spare parts drawings attached when performing maintenance.
DANGER
Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintention­
ally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER
Toxic, corrosive gas
Sample gas may be harmful.
a) Before maintenance turn off the gas supply and surge with air if necessary.
b) Exhaust sample gas to a safe place.
c) Protect yourself against toxic / corrosive gas during maintenance. Wear ap­
propriate personal protective equipment.
CAUTION
Tilting risk
Damage of the device
Secure the device against any sudden translocation during maintenance.
CAUTION
Gas leakage
The sample gas pump should not be dismantled under pressure.
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Maintenance
CAUTION
Hot surface
Burning hazard
According to the product type and operation conditions, the temperature of the
housing may exceed 50 °C during operation.
Depending on the conditions at the installation site it may be necessary to
provide these areas with appropriate warning signs.
Depending on the composition of the sample gas, it may be necessary to replace the in­ and out­let
valves from time to time.
If the valves are heavily contaminated, especially after a short time, consider installing a particle fil­
ter upstream the pump. This increases the service life significantly.
The screws of the fastening ring should be re­tightened after 500 hours of operation with torque 3
Nm.
6.1 Replacing the inlet and outlet valves
1. Screw out the fittings (a/f 17mm) (Fig. I / Fig. II).
2. Screw out the valves with a wide screw driver (Fig. III, Fig. IV, Fig. V) (Do not damage the
screw thread!). Please note that the stainless steel pump head includes PTFE displacers. They
are placed below the valves are used for a reduction of the clearance volume.
3. Screw in new valves with max. 1 Nm (Fig. V, Fig. IV, Fig. III). Regard the right direction (red or
orange: inlet – black or grey: outlet).
4. Screw in the fittings (a/f 17mm) (Fig. VI, Fig. VII). Check tightness. Damaged seals from stain­
less steel fittings should be replaced.
10/2013
Fig. I
Fig. II
Fig. III
Fig. V
Fig. VI
Fig. VII
BE420001
Fig. IV
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Maintenance
6.2 Replacing bellow and connecting rod­eccentric­combination
NOTICE
Restrictions for connecting rod­eccentric replacement
The individual replacement of the eccentric, connecting rod or bearings is not al­
lowed. Only the factory pre­assembled connecting rod­eccentric combination is
suitable for replacement by the operator.
1. Remove the 3 fillister­head screws on the housing cover and demount the housing cover. (Fig.
A)
2. Clean the sample gas pump from dust and other contamination.
3. Mop up stuck dirt with a wet and clean cloth (do not use detergents containing organic
solvents).
4. Remove the four hexagon bolts a/f 7mm on the top of pump body. If the pump body is made of
PTFE, please remove also the retainer. (Fig. B)
5. Pull the pump head carefully out of the pump console. Make sure that the bellow won’t be ex­
panded. If the pump body is clamped to the bellow, try to loose it with rotary action.
6. Hold the bellow bottom which is the upside of the connecting rod and unscrew it counter clock­
wise (Fig. C). Draw the bellow out of the pump console upwardly. If you only need to replace
the bellow, continue with point 13.
7. Remove the six hexagon bolts a/f 8mm on the pump console (Fig. D) and lift the pump console
above the connecting rod (Fig. E)
8. Remove the grub screw a/f 2 mm on the eccentric. (Fig. F)
9. Prise the eccentric carefully out of the engine/intermediate shaft.
10. Cleanse the engine/intermediate shaft and check damage. Check tolerance of dimension 11G6
(11,006 to 11,017). (Fig. G) Lubricate the engine/intermediate shaft with resin­free oil.
11. Press the new connecting rod and eccentric combination evenly on the engine / intermediate
shaft (Fig. H). (Don’t hammer the components). Adjust the bore holes with the grub screw. (Fig.
I)
12. Insert grub screw with Loctite 243 (medium strength) and tighten the screw with 1.5 Nm.
Please make sure that the grub screw locates also in the engine/intermediate shaft.
13. Insert pump console through the connecting rod, adjust it perpendicular to the motor and fasten
it with hexagon bolts. Tighten the screws with 3 Nm.
14. Check the sealing surface and folding of the bellow whether there is damage or contamination.
If there is any contamination, please remove them first.
15. Insert the bellow (Fig. J) from top through the pump console and screw it tight to the connecting
rod by hand. Hold the bellow above the connecting rod. (Fig. C)
16. Clean the pump body and check for damage.
17. Insert the pump body on the bellow. Regard the position of in­ and outlet.
18. Fasten the pump body with retainer (with PTFE pump head only) and hexagon bolts DIN 933
M4 x 45 V2A. Tighten the screws with 3 Nm.
19. Fasten the housing cover with three fillister­head screws DIN 966 M3 x 8.
20. Connect the pump as described in chapter „Mounting and installation“ and carry out a test run.
The following values must be reached at least. Overpressure: P2.3/P2.4 = 1,7 bar; P2.83/P2.84 = 3,5 bar Negative pressure: P2.3/P2.4 = ­0,65 bar; P2.83/P2.84 = ­0,75 bar Flow rate: P2.3/P2.4 = 400 l/h; P2.83/P2.84 = 800 l/h
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Maintenance
Fig. A
Fig. B
Fig. C
Fig. D
Fig. E
Fig. F
Fig. G
Fig. H
Fig. I
Fig. J
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Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Service und repair
6.3 Replacement of the O­ring of the bypass valve (optional)
– Loosen the screws left and right of the knob and remove valve carefully.
– Replace the O­ring and reassemble the valve.
6.4 Replacement of the coupler (P2.4 & P2.84­pump)
In case of a broken coupler the reason for that should be examined! If the reason would be e.g. a
jamming bearing, the whole pump head should be exchanged.
– Dismount pump head and motor with coupling flange (see mounting drawing of the pump).
– Disassemble coupling flange from motor.
– Loosen the setscrews of the coupler and disassemble the parts of the coupler from the shafts.
Assemble new coupler and fix the setscrews.
– Mount the coupling flange to the motor and mount the pump again as described on the mount­
ing drawing.
7 Service und repair
If the device shows irregularities see this chapter for troubleshooting.
Repairs on the device must be carried out by Bühler authorized persons only.
If you need help or more information
call: +49­(0)2102­498955 or your local agent
If the device doesn’t work correctly after elimination of failures and turning power on, the device
must be checked by the manufacturer. Please ship the device with suitable packing to
Bühler Technologies GmbH
­ Reparatur/Service ­
Harkortstraße 29
40880 Ratingen
Deutschland
In Addition, attach the filled in and signed Declaration of Decontamination status to the packing.
Otherwise, your repair order cannot be processed!
The form can be requested by e­mail to service@buehler­technologies.com.
7.1 Troubleshooting
CAUTION
Risk due to defective device
Personal injury or damage to property
a) Switch off the device and disconnect it from the mains.
b) Repair the fault immediately. The device should not be turned on again be­
fore elimination of the failure.
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Service und repair
CAUTION
Hot surface
Burning hazard
According to the product type and operation conditions, the temperature of the
housing may exceed 50 °C during operation.
Depending on the conditions at the installation site it may be necessary to
provide these areas with appropriate warning signs.
Problem / Failure
Pump does not start
Pump does not trans­
port
Possible cause
– Mains disrupted or not correctly
mounted
– Motor defective
– Valves damaged or spoiled
– Bypass valve open
– O­ring of bypass valve dam­
aged
– Bellow cracked
– Spider cracked / worn­out
Pump noisy
– Crank gear worn­out
– Spider worn­out
– Loose coupling hub
Premature spider worn­
out
Tripping by protective
device
10/2013
– Motor bearing failure
– E. g. caused by Ozone contact
or similar, effecting a physical
change of the spider
– Coil­ and terminal short circuit
– Start­up time exceeded
BE420001
Solution
– Check fitting, fuse and switches
– Replace motor
– Blow out valves carefully or re­
place them or refer to chapter
Replacing the inlet and outlet
valves [_ 13].
– Close bypass valve
– Should be repaired by Bühler
service or refer to "Replacing the
O­ring of bypass valve"
– Should be repaired by Bühler
service or refer to Replacing bel­
low and connecting rod­eccent­
ric­combination.
– Should be repaired by Bühler
service or Inspecting and repla­
cing the flexible spider.
– Should be repaired by Bühler
service or Replacing bellow and
connecting rod­eccentric­com­
bination.
– Should be repaired by Bühler
service or Inspecting and repla­
cing the flexible spider.
– Should be repaired by Bühler
service or fix stud screw of coup­
ling hub with 1.34 Nm
– Replace motor
– Make sure that physical changes
of the spider do not occur
– Measure insulation resistance
– Check start­up conditions
17
Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Disposal
Problem / Failure
Possible cause
Insufficient delivery rate – Leakage
– Bellow cracked
– Valves damaged or spoiled
Solution
– Re­tighten the head screws, re­
gard allowed torque (see chapter
Maintenance).
– Should be repaired by Bühler
service or Inspecting and repla­
cing the flexible spider.
– Blow out valves carefully or re­
place them or refer to chapter
Replacing the inlet and outlet
valves [_ 13].
Tab. 2: Trouble shooting
7.2 Spare parts and accessories
To order spare parts, please specify device type and serial number.
For accessories and enhancement see data sheets and/or catalogue.
The following parts are recommended for stocking:
Spare part
P2.3 / P2.4
P2.83 / P2.84
Bellow
Connecting rod / eccentric com­
bination
Flexible spider for coupling
Set of 100 °C valves
Set of 160 °C valves
O­ring bypass
Bellow
Connecting rod / eccentric com­
bination
Flexible spider for coupling
Set of 100 °C valves
Set of 160 °C valves
O­ring bypass
Part no.
4200015
4200075
4220011
4201002
4202002
9009115
4200071
4200034
4220011
4201002
4202002
9009115
Tab. 3: Spare parts and accessories
8 Disposal
Dispose of parts so as not to endanger the health or environment. Follow the laws in the country of
use for disposing of electronic components and devices during disposal.
9 Attached documents
–
–
–
–
18
Spare part drawing P2.3:
Spare part drawing P2.83:
Mounting and spare part drawing P2.4:
Mounting and spare part drawing P2.84:
BE420001
42/008­17­3
42/014­01­3
42/011­14­3
42/014­Z05­03­3
10/2013
Installation and Operation Instructions
Sample gas pumps P2.x, P2.8x
Attached documents
– Data sheet:
– Declaration of Conformity:
– Declaration of Contamination status
10/2013
BE420001
DE/DA 42 0008
KX 42 0001
19
®
Sample Gas Pump
P 2.3; P 2.83; P 2.4; P 2.84
The transportation of sample gas in sample conditioning
systems requires reliable sample pumps. The corrosive
nature of the gas and the potential of condensate formation
are the real challenges for any pump.
§
Robust and reliable design
§
Easy to replace valves
These sample pumps are equipped with a bellows made
from solid PTFE . This design has demonstrated the highest
reliability and long lifetime in numerous applications.
Designed specifically for harsh gas applications that have
entrained liquids present or where condensate is expected
to form, it is recommended that the pump head be pointed
downwards to accommodate draining of these liquids
§
Bellow made of one solid piece
§
Pumps gases with entrained liquid
§
Long life
§
Explosion-proof version available
§
Low noise
§
115 V - models with FM C-US
approval
A special flange design makes the P2.4 and P2.84 designs
suitable for hot applications. The flange is designed in two
parts one -carrying the pump head- is installed in a heated
cabinet and the other -carrying the electrical motor- is
flanged to the outside of the cabinet keeping the motor in
ambient conditions.
DE 42 0008
05/2014
Page 1/4
Bühler Technologies GmbH
D - 40880 Ratingen, Harkortstr. 29
Tel.: + 49 (0) 2102 / 49 89-0 Fax: + 49 (0) 2102 / 49 89-20
Internet: www.buehler-technologies.com
e-mail: [email protected]
Pump Models P2.3 and P2.83
For easy installation of the P2.3 and P2.83 pumps, a support console with vibration dampers is included.
The pump head can be ordered with an internal bypass valve.
The difference between the P2.3 and P2.83 pump is in the flow provided. The P2.3 pump has a capacity of 400 l/h free flow and the
P2.83 has a capacity of 800 l/h free flow.
The P2.3 and P2.83 pumps must not be used in explosive areas. The corresponding type for ex areas would be the P2.2 ATEX,
P2.2 AMEX and P2.82 AMEX, data sheet 420009, or the US-P2.6Ex, data sheet 420005.
Technical Data
Nominal voltage
Nominal current
Protection class
See order number
See order number
Electrical
IP55
Mechanical IP20
6.5 kg
8.5 ml
Weight
Dead space
Media temperature
100 °C
Valves: PTFE / PVDF
160 °C
Valves: PTFE / PEEK
max. 60 °C
FM File No. 3038101 / 3038101C
Ambient temperature
FM C-US (115V only)
Flow Curve P2.83
Flow Curve P2.3
vacuum bar(atm.)
vacuum
Nl/h
bar (atm.)
bar(g.)
Nl/h
800
bar (g)
450
700
400
flow curve
600
flow curve
300
output
250
200
500
400
300
150
A000013D
100
50
-0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0
0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6
200
A000124D
output
350
100
bar
0
at 60Hz + 10% flow
-0,6 -0,4 -0,2 0
0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
bar
at 60Hz + 10% flow
Pump Models P2.4 and P2.84
A cabinet wall thickness of up to 30mm (1.2”) can be used without other modifications.
The difference between the P2.4 and P2.84 pump is in the flow provided. The P2.4 pump has a capacity of 400 l/h free flow and the
P2.84 has a capacity of 800 l/h free flow.
The P2.4 and P2.84 Pumps must not be used in explosive areas. The corresponding type for ex areas would be the P2.4 ATEX,
P2.4 AMEX and P2.84 AMEX, data sheet 420009.
Technical Data
Nominal voltage
Nominal current
Protection class
See order number
See order number
Electrical
IP55
Mechanical IP20
7.5 kg
8.5 ml
Weight (approx.)
Dead space
Media temperature
Ambient temp.
Motor
Pump head
FM C-US (115V only)
160 °C
max. 60 °C
max. 100 °C
FM File No. 3038101 / 3038101C
Flow Curve P2.84
Flow Curve P2.4
vacuum bar(atm.)
vacuum
450
700
400
600
output
flow curve
350
output
bar (g)
bar (atm.)
300
250
200
flow curve
500
400
300
150
200
A000013D
100
DE 42 0008
05/2014
Page 2/4
bar(g.)
Nl/h
800
50
-0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0
0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6
at 60Hz + 10% flow
bar
A000124D
Nl/h
Valve: PTFE / PEEK
100
0
-0,6 -0,4 -0,2 0
0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
at 60Hz + 10% flow
bar
Ordering hints:
Part-no.
42 XX X X X X X 9
56
57
63
64
1
2
5
1
2
1
2
3
1
2
9
1
2
3
4
9
1
2
3
5
9
0 00
Feature
Basic type
P2.3 400 l/h
P2.4 400 l/h
P2.83 800 l/h
P2.84 800 l/h
Motor supply
230 V 50/60 Hz. 0,85/0,8 A
115 V 50/60 Hz. 1,7/1,6 A
400 V 50/60 Hz. 0,5/0,43 A
Pump head position
Normal pos. vertical
Pointing downwards *
Pump head material
PTFE
SS 1.4571
PTFE with bypass valve *
Valve material
to 100 °C PTFE/PVDF **
to 160 °C PTFE/PEEK
Male stud couplings (for voltages 230 V and 400 V)
PTFE pump head
Stainless steel pump head
6 mm (standard)
DN 4/6 (standard)
8 mm
DN 6/8
3/8”
3/8"-1/4”
1/4"-1/8"
1/4"-1/6”
1/4”
Male stud couplings (for voltage 115 V)
PTFE pump head
Stainless steel pump head
1/4" (standard)
1/4"-1/6" (standard)
8 mm
DN 6/8
3/8”
3/8"-1/4”
1/4"-1/8"
6 mm
DN 4/6
Mounting accessories
including mounting console and buffer *
*not possible for P2.4 and P2.84
**not possible for P2.4, P2.83 and P2.84
Note:
x stands for number below.
Ordering example:
part no. 42 631112 99
63 for 800 Liter pump P2.83
1 for 230 V 50/60 Hz Motor
1 for pump head pointing up
1 pump head PTFE
2 for 160 °C valves
9 for DN4/6 screw in screw connection
9 including mounting console and buffer
DE 42 0008
05/2014
Page 3/4
Dimensions P2.3 and P2.83 Pumps
Gas connections at buyer's option
M20x1,5
24
Console
63
8
A
130
262
186
207
BÜHLER
81
100
125
M6
104
80
247,5
302
View: A
130
100
Ø7
Adjustable bypass valve optional
18
BÜHLER
100
130
Dimensions P2.4 and P2.84 Pumps
24
Gas connections at buyer's option
M20x1,5
wall
148
max.30
M6
211
BÜHLER
8
63
181
`
85
`
116
80
229
`
ø7
27
345
100
125
°
60
ø94
ø110
30°
A00000125X
1) Direction of the inlet/outlet connections can
be chosen while mounting
2) If the gas carries condensate, the inlet/outlet
connections must point downwards
DE 42 0008
05/2014
Page 4/4
ø7
Mounting hints
Cabinet cut-out
we reserve the right to amend specification
Sample Gas Pump
P 2.3; P 2.83; P 2.4; P 2.84
The transportation of sample gas in sample conditioning
systems requires reliable sample pumps. The corrosive
nature of the gas and the potential of condensate formation
are the real challenges for any pump.
§
Robust and reliable design
§
Easy to replace valves
These sample pumps are equipped with a bellows made
from solid PTFE . This design has demonstrated the highest
reliability and long lifetime in numerous applications.
Designed specifically for harsh gas applications that have
entrained liquids present or where condensate is expected
to form, it is recommended that the pump head be pointed
downwards to accommodate draining of these liquids.
§
Bellow made of one solid piece
§
Pumps gases with entrained liquid
§
Long life
§
Explosion-proof version available
§
Low noise
§
115 V - models with FM C-US
approval
A special flange design makes the P2.4 and P2.84 designs
suitable for hot applications. The flange is designed in two
parts one -carrying the pump head- is installed in a heated
cabinet and the other -carrying the electrical motor- is
flanged to the outside of the cabinet keeping the motor in
ambient conditions.
DA 42 0008
05/2014
Page 1/4
Buhler Technologies LLC
1030 West Hamlin Road, Rochester Hills, MI 48309
Phone: 248.652.1546
Fax: 248.652.1598
Internet: www.buhlertech.com
E-mail: [email protected]
Pump Models P2.3 and P2.83
For easy installation of the P2.3 and P2.83 pumps, a support console with vibration dampers is included.
The pump head can be ordered with an internal bypass valve.
The difference between the P2.3 and P2.83 pump is in the flow provided. The P2.3 pump has a capacity of 400 l/h (6.7 lpm) free
flow and the P2.83 has a capacity of 800 l/h (13.3 lpm) free flow.
The P2.3 and P2.83 pumps must not be used in explosive areas. The corresponding type for ex areas would be the P2.2 ATEX,
P2.2 AMEX and P2.82 AMEX, data sheet 420009, or the US-P2.6Ex, data sheet 420005.
Technical Data
Nominal voltage
Nominal current
Protection class
See order number
See order number
Electrical
IP55
Mechanical IP20
14 lb
0.52 cu. in.
Weight (approx.)
Dead space
Media temp.
210 °F
Valves: PTFE / PVDF
320 °F
Valves: PTFE / PEEK
max. 140 °F
FM File No. 3038101 / 3038101C
Ambient temp.
FM C-US (115V only)
Flow Curve P2.83
Flow Curve P2.3
vacuum
vacuum
bar (g)
bar (atm.)
Nl/h (lpm)
450 (7.5)
700 (11.7)
400 (6.7)
350 (5.8)
flow curve
600 (10.0)
flow curve
300 (5.0)
500 (8.3)
250 (4.2)
output
200 (3.3)
150 (2.5)
A000013D
100 (1.7)
50 (0.8)
-0,6 -0,5 -0,4 -0,3 -0,2 -0,1 0
-8.7 -7.3 -5.8 -4.4 -2.9 -1.5
0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6
0
2.9 5.8
8.7 11.6 14.5 17.4 20.3 23.2
400 (6.7)
300 (5.0)
200 (3.3)
A000124D
output
bar (g)
bar (atm.)
Nl/h (lpm)
800 (13.3)
100 (1.7)
bar
0 (0)
psig
-0,6 -0,4 -0,2 0
0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
bar
-8.7 -5.8 -2.9
2.9
psig
at 60Hz + 10% flow
5.8 8.7 11.6 14.5 17.4 20.3 23.2 26.1 29.0
at 60Hz + 10% flow
Pump Models P2.4 and P2.84
A cabinet wall thickness of up to 30mm (1.2”) can be used without other modifications.
The difference between the P2.4 and P2.84 pump is in the flow provided. The P2.4 pump has a capacity of 400 l/h (6.7 lpm) free
flow and the P2.84 has a capacity of 800 l/h (13.3 lpm) free flow.
The P2.4 and P2.84 Pumps must not be used in explosive areas. The corresponding type for ex areas would be the
P2.4 ATEX, P2.4 AMEX and P2.84 AMEX, data sheet 420009.
Technical Data
Nominal voltage
Nominal current
Protection class
See order number
See order number
Electrical
IP55
Mechanical IP20
16.5 lb
0.52 cu. in.
Weight (approx.)
Dead space
Media temperature
Ambient temperature
Motor
Pump head
FM C-US (115V only)
320 °F Valve: PTFE / PEEK
max. 140 °F
max. 212 °F
FM File No. 3038101 / 3038101C
Flow Curve P2.84
Flow Curve P2.4
vacuum bar(atm.)
bar (g)
bar (atm.)
Nl/h (lpm)
450 (7.5)
700 (11.7)
400 (6.7)
output
output
350 (5.8)
300 (5.0)
250 (4.2)
200 (3.3)
500 (8.3)
400 (6.7)
300 (5.0)
150 (2.5)
200 (3.3)
A000013E
100 (1.7)
50 (0.8)
DA 42 0008
05/2014
Page 2/4
flow curve
600 (10.0)
flow curve
A000124D
vacuum
bar(g.)
Nl/h (lpm)
800 (13.3)
100 (1.7)
0 (0)
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0
0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
bar
-0.6 -0.4 -0.2 0
0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
-8.7 -7.3 -5.8 -4.4 -2.9 -1.5
2.9 5.8
8.7 11.6 14.5 17.4 20.3 23.2
psig
-8.7 -5.8 -2.9
2.9
0
at 60Hz + 10% flow
0
5.8 8.7 11.6 14.5 17.4 20.3 23.2 26.1 29.0
at 60Hz + 10% flow
bar
psig
Ordering hints:
Part-no.
42 XX X X X X X 9
56
57
63
64
1
2
5
1
2
1
2
3
1
2
9
1
2
3
4
9
1
2
3
5
9
0 00
Feature
Basic type
P2.3 400 l/h
P2.4 400 l/h
P2.83 800 l/h
P2.84 800 l/h
Motor supply
230 V 50/60 Hz. 0,85/0,8 A
115 V 50/60 Hz. 1,7/1,6 A
400 V 50/60 Hz. 0,5/0,43 A
Pump head position
Normal pos. vertical
Pointing downwards *
Pump head material
PTFE
SS 1.4571
PTFE with bypass valve *
Valve material
to 212 °F PTFE/PVDF **
to 320 °F PTFE/PEEK
Male stud couplings (for voltages 230 V and 400 V)
PTFE pump head
Stainless steel pump head
6 mm (standard)
DN 4/6 (standard)
8 mm
DN 6/8
3/8”
3/8"-1/4”
1/4"-1/8"
1/4”
1/4"-1/6”
Male stud couplings (for voltage 115 V)
PTFE pump head
Stainless steel pump head
1/4" (standard)
1/4"-1/6" (standard)
8 mm
DN 6/8
3/8”
3/8"-1/4”
1/4"-1/8"
6 mm
DN 4/6
Mounting accessories
including mounting console and buffer *
*not possible for P2.4 and P2.84
**not possible for P2.4, P2.83 and P2.84
Note:
x stands for number below.
Ordering example:
Part no.. 42 631112 99
63 for 800 l/h pump P2.83
1 for 230 V 50/60 Hz motor
1 for pump head pointing up
1 pump head PTFE
2 for 320 °F valves
9 for DN4/6 screw in screw connection
9 including mounting console and buffer
DA 42 0008
05/2014
Page 3/4
Dimensions P2.3 and P2.83 Pumps
Gas connections at buyer's option
0.94”
M20x1,5
Console
3.19”
7.32”
8.15”
2.48”
0.31”
A
5.12”
10.31”
BÜHLER
3.94”
4.92”
M6
3.15”
9.74”
11.89”
view: A
3.94”
0.28”
5.12”
4.09”
0,71”
Adjustable bypass valve optional
3.94”
BÜHLER
5.12”
Dimensions P2.4 and P2.84 Pumps
Gas connections at buyer's option
0,94”
M20x1,5
5,83”
wall
max.1,18”
M6
7,13”
8,31”
BÜHLER
0,31”
2,48”
3,35”
`
4,57”
3,15”
9,02”
`
`
ø0,28”
3,94”
4,92”
13,58”
°
60
ø3,70”
ø4,33”
Mounting hints
30°
A00000125X
ø0,28”
1) Direction of the inlet/outlet connections can
be chosen while mounting
2) If the gas carries condensate, the inlet/outlet
connections must point downwards
DA 42 0008
05/2014
Page 4/4
Cabinet cut-out
we reserve the right to amend specification
Dekontaminierungserklärung
Declaration of Contamination status
Gültig ab / valid since: 2011/05/01
Revision 0
ersetzt Rev. / replaces Rev ---
Die gesetzlichen Vorschriften schreiben vor, dass Sie uns die Dekontaminierungserklärung ausgefüllt und unterschrieben
zurück zu senden haben. Die Angaben dienen zum Schutz unserer Mitarbeiter. Bringen Sie die Bescheinigung an der
Verpackung an. Ansonsten ist eine Bearbeitung Ihres Reparaturauftrages nicht möglich!
Legal regulations prescribe that you have to fill in and sign the Declaration of Contamination status and send it back. This
information is used to protect our employees. Please attach the declaration to the packing. Otherwise, your repair
order cannot be processed.
Gerät /
Device:
Serien-Nr. /
Serial no. :
Rücksendegrund /
Reason for return:
[
]
Ich bestätige hiermit, dass das oben spezifizierte Gerät ordnungsgemäß gereinigt und dekontaminiert wurde
und keinerlei Gefahren im Umgang mit dem Produkt bestehen.
I herewith declare that the device as specified above has been properly cleaned and decontaminated and that
there are no risks present when dealing with the device.
Ansonsten ist die mögliche Gefährdung genauer zu beschreiben / In other cases, please describe the hazards in
detail:
Aggregatzustand (bitte ankreuzen) / Condition of aggregation (please check):
Flüssig / Liquid
Fest / Solid
Pulvrig / Powdery
Gasförmig / Gaseous
Folgende Warnhinweise sind zu beachten (bitte ankreuzen) / The following safety advices must be obeyed (please
check):
Explosiv
Explosives
Giftig / Tödlich
Acute toxicity
Entzündliche Stoffe
Flammable
Brandfördernd
Oxidizing
Komprimierte Gase
Gas under pressure
Gesundheitsgefährdend
Irritant toxicity
Gesundheitsschädlich
Health hazard
Umweltgefährdend
Environmental hazard
Bitte legen Sie ein aktuelles Datenblatt des Gefahrenstoffes bei / Please include the current material safety data sheet
of the hazardous material!
Angaben zum Absender / Information about the dispatcher:
Firma / Company:
Anschrift / Address:
Ansprechpartner /
Contact person:
Abteilung / Division:
E-Mail:
Tel. / Phone:
Fax:
Ort, Datum /
Location, date:
Unterschrift /
Stempel
Signature / Stamp:
Bühler Technologies GmbH
D - 40880 Ratingen, Harkortstr. 29
Tel.: + 49 (0) 2102 / 4989-0 Fax: + 49 (0) 2102 / 4989-20
e-mail: [email protected]
Internet: www.buehler-technologies.com