Bijur Delimon FZ-A Operating Instructions Manual

Operating instructions

Pump FZ-A according to

Atex

INDEX

Page

1. General

.................................................................................

2

2. Safety

..............................................................................

2 – 4

A. Pump type

............................................................................

5

B. Number of outlets

................................................................

5

C. Revision

................................................................................

5

D. Kinds of drive zone 2 and 22

........................................

6 – 8

E. Position of drive

..................................................................

8

F. Reservoir

..............................................................................

8

G. Accessories

.........................................................................

9

3. Application

.........................................................................

10

4. Principle of operation

........................................................

10

5. Rotational direction of drive

.............................................

10

6. Specification

......................................................................

11

7. Start-up & Installation

...............................................

11 – 12

8. Maintenance

...............................................................

13 – 14

9. Plates

..................................................................................

15

Page 1 of 15 BA_2005_2_GB_FAX

1. General

Before installing and operating this equipment, we highly recommend that you become thoroughly familiar with these instructions. DELIMON does not accept liability, expressed or implied, for any direct or inconsequential injuries to personnel or damage to equipment, including process interruption, arising from the misuse or misapplication of its products. Application and / or modification of product beyond its intended purpose is strictly prohibited.

DELIMON reserves the right to make modifications, changes and/or amendments to both products and to these instructions as may become necessary to assure ongoing technical clarity.

The content of this technical publication is the sole graphic and intellectual property of DELIMON and is protected by local and International Copyright Law. As such, it may not be copied, reproduced or used for any purpose other than that intended by the Company; i.e. as a guide to proper installation, maintenance and operation of its equipment by qualified personnel and their supervisors. Use of this information for any other purpose or intent requires the expressed written permission of DELIMON.

Contact Information: For assistance with product, replacement parts, service or training.

DELIMON GmbH; Main Offices

Arminstraße 15

D-40277 Düsseldorf

Phone : +49 211 77 74-0

Fax : +49 211 77 74-210

Branch Office

Am Bockwald 4

D-08344 Grünhain-Beierfeld

E-mail : [email protected] www.bijurdelimon.com

2. Safety

These instructions provide basic guidance which must be followed during installation, operation and maintenance. It is assumed that personnel performing required tasks are skilled in the areas of electrical and mechanical millwright trades plus all local and federal safety requirements. These instructions should be kept near the point of use and made available for reference at all times.

2.1 Identification of safety warnings in the operating instructions

To minimize risk to people working with this equipment, safety warnings included within these instructions must be observed. Potential safety issues are identified through use of the following general danger symbols:

Safety Sign, per DIN 4844, provides warning of potential general danger.

Safety Sign, per DIN 4844, provides warning of potential electrical danger.

ATTENTION

Caution designation utilized to signify that damage to machinery and function may result if guidance is not properly followed.

Instructions affixed directly to machines and equipment must always be observed and maintained to ensure that they are fully legible. Examples of such instructions would be:

• Rotational direction arrows for shafts and couplings.

• Identification of fluid connections, direction of flow and substance contained in pipes.

Important Note: There is always increased risk of slipping or falling whenever spilled or leaking lubricants are present. In all cases, they should be properly removed and disposed of.

Safety Sign, per DIN 4844, provides warning of an increased risk of slipping and falling due to the presence of water, oil, grease or other foreign substances on pavements,

floors

Page 2 of 15 BA_2005_2_GB_FAX

2. Safety

2.2 Personnel qualification and training

Personnel performing work required to install, operate, maintain or inspect this equipment must be adequately trained and qualified. In this regard, determination of competency, understanding and supervision levels required for individual assignment is left to the purchaser of the equipment. However, should assistance with on-site training be desired, please contact your local Bijur-Delimon office for assistance.

2.3 Dangers in case of nonobservance of the safety instructions

Failure to properly follow all safety instructions may result in hazard to personnel, the environment or to machinery and equipment. Failure to follow these instructions may also additionally void warranties and nullify claims for damages. Examples of such instances follow:

• Failure of machinery or operating systems to function properly

• Failure to observe proper methods of maintenance and repair

• Unnecessary creation of hazards to personnel by means of electrical shock, mechanical injury or exposure to potentially hazardous chemicals

• Unnecessary creation of environmental hazards through chemical leaks

2.4 Safety conscious working

All Safety Instructions resulting from National, Local or User mandated regulations, as well as those contained within this instruction, must be observed at all times.

2.5 Safety instructions for the user/operator

• Users should always take care that only authorized and skilled personnel are allowed to perform installation, maintenance and inspection work.

• Installation, maintenance and inspection of lubrication systems should only be performed while machinery and equipment being serviced is in “Shut-Down Mode”.

• Protective covers and guards, provided to ensure that contact with moving parts is eliminated during machine operation, (e.g. couplings, pulleys, gears, etc.), must be replaced following maintenance and repair.

• Use “Common Sense”! When hot or cold machine parts can lead to potential dangers, those parts must be handled in such manner so as to avoid human touch; i.e. shielding is required.

• Leaks from shaft seals, reservoirs, piping or fittings should be repaired so as to not cause potentially hazardous materials from escaping to the work area. In instances where such leaks have occurred, all local and National rules and regulations for their recovery and disposition must be followed.

• All potential hazards resulting from exposure to electrical sources must be eliminated. Please refer to

VDE and local power company rules and regulations for guidance.

• Before restarting system and equipment, refer to instruction in Section 7; Start-Up Procedure.

2.6 Safety instructions for maintenance, inspection and installation work

Before installing or servicing lubrication equipment and machinery, management should insure that only persons who are fully trained, skilled and authorized to perform such work are assigned to such tasks.

Major installation or modification work should only be performed during shut-downs. It is also imperative that shut-down procedures recommended by equipment manufacturers be followed. Pumps, lubricators and distribution systems which deliver potentially hazardous materials to the environment must be thoroughly cleaned. All safety devices and protective equipment, disabled or removed during cleaning, must be immediately reinstalled and reactivated prior to machine use.

Safety Sign, per DIN 4844, Use Safety Glasses or Goggles.

Advice: Whenever working with compressed air, wear safety glasses

Safety Sign, per DIN 4844, Use Breathing Mask.

Advice: Observe EC-Safety Data Sheet for materials of consumption and additives used and use personal protective equipment.

Page 3 of 15 BA_2005_2_GB_FAX

2. Safety

Additional Cautions for Pump Type FZ-A

• Potential ‘pinch-point’ whenever closing the reservoir lid! When filling the reservoir while pump is operational, DO NOT put your hand into the reservoir. Risk of personal injury may result from contact with scraper blade and agitator.

• Whenever handling lubricants, take measures to avoid environmental pollution.

• DO NOT use high-pressure cleaning devices on outside of pump. Always use solvent free cleansers.

2.7 Unauthorized conversion and manufacture of spare parts

The modification and/or manufacturing of parts for use as spare or replacement parts in Bijur-Delimon lubrication equipment, without the written consent and approval of Bijur-Delimon Engineering, is strictly prohibited. Any such modification and/or manufacture of component parts shall immediately render any and all warranties as null and void.

2.8 Unacceptable modes of operation

The operational integrity and reliability of all equipment supplied is warranted only when said equipment is utilized in strict accordance with parameters established in Section 1; Introduction. Maximum operating parameters outlined in Engineering Data Sheets must never be exceeded.

2.9 Guidelines & standards

1., 2., 3. and 4. guideline (see data sheet: R&N_2009_X_GB)

3.0 Notes on environmental protection and waste disposal

During proper operation, various component parts of lubricating systems are subject to special requirements as set forth by Environmental Legislation.

General requirements for handling lubricants are specified in their respective safety data sheets.

Used lubricants are hazardous forms of waste and therefore require special handling and supervision with regard to § 41 paragraph 1, sentence 1 and paragraph 3 no. 1 of KrW-/AbfG (Closed-Loop Waste

Management Act).

Used oils must be handled in compliance with AltölV (Waste Oil Ordinance).

Any devices or components which become contaminated with lubricant must be disposed of by a certified waste management company. Additionally, records indicating proper conformance to waste management practice and law must be filed according to NachwV (Ordinance on Waste Recovery and Disposal

Records).

Page 4 of 15 BA_2005_2_GB_FAX

PRODUCT CHARACTERISTICS

• possible versions: Guideline 94/9/EG – Atex category 2G and 3GD – for zone 1/2 and 22

• Central piston technique

• Insert for anticlockwise and clockwise rotation

• Feed volume per outlet up to 60cm 3

• Surface signal grey RAL 7004

/h

• Lubricants: oil, grease, liquid grease

A. PUMP TYPE FAX

B. NUMBER OF OUTLETS

6 outlets

12 outlets

Outlets 1 - 6 are arranged in the upper row. Outlets placed one above the other can only be combined in the order shown in the picture. Fusions begin at the outlets 1/7 and follow the direction of the arrow. Refer to graphic for order of outlets.

The pump body is comprised of a control sleeve which guides the piston, and a setting spindle which determines piston stroke; thus determining the delivery rate of each outlet (up to 6 outlets), or of two outlets when placed on above the other (7 to 12 outlets).

Designation and position of outlets when being combined.

Whenever dealing with 2 outlets having half the total volumetric output, one outlet in the upper and lower rows may be opened.

C. REVISION

Stage A

Page 5 of 15 BA_2005_2_GB_FAX

D. KINDS OF DRIVE ZONE 2 AND 22

Shaft end free, gear ratio, 3 : 1




Step-down gear, gear ratio 95 : 1



Kinds of drive zone 2

Step-down gear & motor 230-260V / 400-460V, 50/60Hz, gear ratio 215 : 1





Step-down gear & motor 500V, 50Hz, gear ratio 215 : 1





Kinds of drive zone 22











Page 6 of 15 BA_2005_2_GB_FAX


(continuation)

Drive with free shaft end

The drive assembly consists of a ball bearing supported drive shaft and worm gear. A filler plug is provided to facilitate filling of the housing with oil. The filler plug must be removed prior to removal of the shaft with a mandrel.

Rotary drive with free shaft end Drive with reduction gear

Drive with reduction gear or with reduction gear and motor

The assembly consists of the drive assembly with free shaft end, to which a second worm gear drive is added.

Page 7 of 15 BA_2005_2_GB_FAX


(continuation)

Drive with reduction gear and motor

E. POSITION OF DRIVE

Position 1 left

Position 5 right without

F. RESERVOIR

The reservoir lid is hinged for ease of access. It can be secured with a padlock to prevent unauthorized access or tampering. Reservoirs are equipped with a scraper and feed screw. The scraper removes grease from the sidewall of the tank, while the feed screw assures slight pressurization of grease being fed to the pump’s inlet chamber. A strainer is fitted in the bottom of the tank to protect the pump inlet chamber against contamination.

Page 8 of 15 BA_2005_2_GB_FAX

G. ACCESSORIES

without

Level switch

Filling valve

Level switch and filling valve

Pressure control

Level switch with connection box

A lubricant level switch is available for reservoir monitoring. When the minimum or maximum level is reached, an electrical signal is generated by capacitive means. The signal may be used for the purpose of providing visual indication of status, or to activate an automated filling device. When so equipped, operating instructions pertaining to P/N 65124-2200 BA1 are provided with the unit.

Pressure control

In case of receiving the order, we will attach particular operating instructions to the pressure control:

PB_2005_1_GB_38132.

Page 9 of 15 BA_2005_2_GB_FAX

3. Application

The pumps FZ-A are central piston-type pumps for the centralized lubricant supply to machines which are driven by an electric motor.

4. Principle of operation

(Fig. 1 and 2)

The top of the worm wheel (1) driven by a worm shaft is provided with 2 drivers with recesses in which a crosspiece (2) engages. In two other grooves of the crosspiece the drivers of the eccentric disk (3) engage and impart a rotary movement to the eccentric disk and the piston (4). The compression spring (5) located between the crosspiece and the eccentric disk presses the eccentric disk upwards. On its top surface the eccentric disk is provided with a cam which, due to its rotary movement, strikes the 6 setting spindles (6) arranged on the circumference of the pump and therefore forces the piston to perform one suction stroke each time.

The lubricant is supplied to the pump inlet chamber (S) by a feed unit.

The underside of the eccentric disk is provided with 6 cams. Due to the rotary movement the cams on the eccentric disk strike against a pressure cam (7), causing the piston to make a compression stroke each time. The piston has three vertical grooves (N), which terminate in an annular channel (R). On pumps with up to 12 (2 x 6) outlets the piston has two sets of three vertical grooves each terminating in an annular channel. During the suction stroke lubricant is drawn from the inlet chamber (S) into the vertical grooves of the piston and from there delivered into the annular channels (R). During the compression stroke the lubricant is delivered from the annular channel via a vertical groove into the pressure channel (D).

In continuous operation the pump can overcome a backpressure of 200 bar. Transient pressures of up to

250 bars are permitted. Safety valves can be installed in the discharge line as protection against overload.

Fig. 2 Principle of operation (FZ-A, 12 outlets) Fig. 1 Section through the pump FZ-A (6 outlets)

5. Rotational direction of drive

All pumps can be arranged for clockwise or anti-clockwise running, as required, with the same power and without modifications.

Page 10 of 15 BA_2005_2_GB_FAX

6. Specifications

Permissible back pressure: ............................................................................................................... 200 bar

for a short time: .............................................................................................................. 250 bar

Reservoir capacity : ............................................................................................................... 8, 15 and 30 ltr.

Permissible pump piston speed: with running drive: ................................................................................................................... max. 10 r.p.m.

In case that higher speed or less then < 1 is requested and also when distributors ZPA or E 4 are installed downstream, ask manufacturer.

Usable lubricants : greases based of mineral oils ......................................................... to NLGI-class 2, DIN 51818

Oils : ............................................................................................................................ on request

Synthetic greases : ...................................................................................................... on request

Operating temperature : ............................................................................................... - 20

Depending on the lubricant used, restrictions to the service temperature are possible. o

C up to + 50 o

C

Depending on the kind of their electrical equipment/sensor technique, they can be used as follows: a. In zone 2 (gas-ex, category 3G)) in the explosion groups IIA and IIB b. In zone 22 (dust-ex, category 3D) for dusts with a minimum ignition power > 3 mJ c. In zone 1 (gas-ex, category 2G)) in the explosion groups IIA and IIB

Die qualification with regard to the surface temperature is T4; for all gases, steams and mists with an ignition temperature > 135°C the appliances are no ignition source. In the dust ex-range, 125°C is the reference temperature for the further considerations regarding the safe distance from the glow temperature etc. (can only be decided by the user.


Install the pumps into a higher-ranking machine. Fix the time for the cleaning of the equipments (dust deposits) depending on the IP degree of protection. Be absolutely sure that the types of appliance protection installed are appropriate to the zones!

Further important facts:

• The pump is allowed to be put into service in zone 2 or 22 (category 3GD) or zone 1 (category 2G) by specialists.

• Seals have to be reattached after opening and closing.

• The appliances are only approved fort he operation with the greases specified in the operating instructions.

• The operation of the appliance is only allowed in completely closed and undamaged housings.

• The equipotential bonding is connected via own screw. It has the be treated according to the erection regulations being valid in the country of the user.

• During the erection make sure that the installation fukfills the EMC.

• It is prohibited to operate the appliance when the housing is damaged.

• Equipment IP54 is sufficient; if necessary, portect the machine against the penetration of liquids and/or dirt.

• When the machine is in operation, see that it is exposed to low vibrations only. In case of doubt contact the manufacturer.

Page 11 of 15 BA_2005_2_GB_FAX


(continuation)

Use, operation

The appliances are only approved for a proper use in accordance with their intended purposes. In case of contravention, any warranty and responsibility of the manufacturer will become invalid!

• Use only such accessory parts in hazardous areas which fulfill all the requirements of the European guidelines and national regulations.

• In case of non-conductive dusts, the use in the dust-ex zone is allowed with a minimum ignition power

> 3 mJ as far as the electric motor, too, comes up to the requirements.

• The ambient conditions specified in the operating instructions are to be observed at all events.

• When the systems are provided with an electrical protection against corrosion, they must not be operated without consultation with the manufacturer and, if necessary, execution of additional measurements.

• Measures as to lightning protection are to be ensured by the user.

• The pump is to be protected against impacts from outside.

• After having refilled the grease, reattach the cotter pin in a professional way to secure the lid.

Figure 3 Pump body FZ-A

*

In case that the outlet bores are closed by item no. 2.17, item nos. 2.18 and 2.19 are to be removed from the pertaining relieving bores.

Installing and connecting the lubricating pump

The pump should be installed and mounted vertically. Connection of the motor to be control box must be carried out in accordance with the circuit diagram (paragraph concerning the direction of drive rotation to be observed).

Filling the lubricant tank and piping

All piping must be carefully cleaned before descaling and blowing through and filled with clean grease using a grease gun. For initial start-up, the grease tank is first filled up to the strainer with oil and then with grease, because otherwise a longer start-up time is required to allow venting. Before connecting the piping the pump must operate long enough at full capacity to ensure that the grease emerges evenly and without air from each outlet. Next, the piping should be connected (use sealing washers), until air-free grease emerges at the ends of the piping.

Once the bearings to be lubricated are also filled with grease, the piping can be connected to the lubricating points. The system can be started after adjustment of the required lubricant quantity.

Setting the delivery rate (figure 3)

At full capacity, corresponding to 0.1 cm

3

lubricant per discharge and piston stroke, an arrow on the discharge identification points to the number 4 stamped on the head of the setting spindle (2.5). By turning the spindle clockwise the delivery is reduced. Reduction below 1/4 of the max. delivery (setting 1) should be avoided. In case of pumps having 7 to 12 outlets, the delivery rate of two vertically arranged outlets is adjusted by means of an adjusting spindle. The second arrow of the discharge identification points to the outlet bore relating to the setting spindle.

By changing the drive speed or the internal gear ratio of the pump the output volume of all outlets and thus the overall output volume is changed.

Page 12 of 15 BA_2005_2_GB_FAX

8. Maintenance

Definition of terms according to IEC 60079:

Maintenance and repair: A combination of all activities being effected in order to maintain an object in a condition or to bring it back into this condition, so that the object in question comes up to the requirements of the specification concerned and ensures the execution of the functions required.

Inspection: An activity that consists in a thorough check of an object with the aim to make a reliable statement about the condition of this object. It is carried out without disassembly or, if necessary, with partial disassembly, completed by measures as for example measurements.

Visual check: A visual check is a check on the occasion of which visible faults (e. g. missing screws) are found without the use of any access facilities or tools.

Close-range check: A check on the occasion of which those faults (e. g. loose screws) are found - in addition to the aspects of a visual check - which can only be identified by the use of access facilities, e. g. steps (if necessary), and tools. For close-range-checks, it is usually not necessary to open a housing or to switch the equipment voltage-free.

Detailed check: A check on the occasion of which those faults (e. g. loose connections) are found - in addition to the aspects of the close-range check - which can only be identified by the opening of housings and/or, if necessary, the use of tools and test facilities.

• Maintenance work is to be executed by the staff of DELIMON only or by persons having been specially trained by DELIMON.

• For the replacement of component parts use only original spare parts which are also approved for the use in the ex-zone. This also applies to the lubricants and process materials used.

• Regularly maintain and clean the appliances in the ex-zone. The intervals are locally fixed by the user according to the environmental stresses, e. g. in case of an approx. 0.5 ...1 mm dust deposit.

• After having carried out the maintenance/repair work, reattach all barriers and notes, which have been removed on this occasion, in their original position.

Activity

1 Visual check of the machine, eliminate dust deposits

2 Refill the store tank with grease.

3 Check for grease leakage.

4 Check for a smooth running and a heating of the bearings. monthly

●

●

Close-range check every 6 months or 4,000 h

●

Detailed check every 12 months or 8,000 h

●

5 Check of the electrical system for intactness ●

Special measures:

• Replacement of the compression spring after 40,000 working hours or 5 years.

• Replacement of the bearings after 40,000 working hours or 5 years, continued operation for a duration of up to 3 times of the nominal indication if the check intervals are halved.

• Observe the operating instructions relating to the electric motor as well as the instructions of the manufacturer.

• In category 3 the maintenance intervals can be doubled.

Fault clearance

It is not permitted to make modifications to appliances being operated in connection with potentially explosive zones. Repairs of the appliance are to be carried out by authorized and qualified staff only having undergone a special training.

Disposal

The disposal of the packaging and the worn out parts is to be effected according to the regulations of the country in which the appliance is installed.

Page 13 of 15 BA_2005_2_GB_FAX

8. Maintenance

Filling the grease tank

As soon as approximately 3/4 of the tank capacity are consumed, the grease tank should be refilled. The grease level should never drop to a level where the feed screw is visible, because air may otherwise penetrate into the piping. During filling, care should be taken to ensure that only clean grease is used and no dirt penetrates into the tank when the cover is opened, because this may result in malfunctioning. Filling via a filling valve and firmly installed pipelines is at all events to be preferred.

Changing the number of outlets (figure 3)

The pump is supplied with the required number of outlets in accordance with the order. If other operating conditions should arise, i.e. if outlets have to be blanked off or opened, the following procedure should be followed.

An outlet is blanked off by connecting the pressure channel to the pump inlet chamber. For this purpose the top discharge channels are joined to the pump inlet chamber by threaded connections. To blank off an upper outlet, the tank is removed and the cap screw M 4 x 6 (2.19) is removed from its threaded hole.

When opening a blanked-off outlet, the cap screw should be screwed in, taking care to ensure good tightness by means of the sealing A 4 x 8 (2.18). Generally the associated outlet is either closed by means of a screw plug (2.17) or opened by removing the plug.

If it deals with of pumps having two vertically arranged outlets, and the lower outlet shall also be shut down, you have to remove the setting spindle (2.5), the ball (2.6) and the compression spring (2.7). Before taking out the spindle, unscrew the shank screw (2.9). After this, insert the plug (2.20) in the bore of the setting spindle. For a later installation of the setting spindle, successively insert – after having unscrewed the shank screw (2.9) with sealing ring (2.8) – the ball and the compression spring. The locating screw brings spring and ball into the correct position as far as the shank meshes analogously with the spiral groove of the setting spindle on the occasion of the screwing-in process which now follows. Advantageously, you should use a new sealing ring and lubricate both ball and spring prior to inserting them.

When two outlets, which are arranged one upon the other, are shut down for a short time, the setting spindle is to be set to 0, and the outlets must not be closed. Use plastic plugs instead of screw plugs (2.17) to allow accidentally occurring delivery rates to escape and to thus avoid overpressure.

ATTENTION!

If the number of outlets is modified improperly, damage to the pump cannot be avoided.

Removal of the drive shaft (see figure)

After removing the spring washer (3.11) and the cap, the circlip (3.13) should be removed. After loosening the plug (3.20) the drive shaft (3.12) including the roller bearings (3.17) and the sleeve (3.16) can be driven out using a copper dowel and a hammer.

Gearboxes:

The gearboxes are filled with lubricant type grease, Gearmaster LX00 (Messrs. Lubritech) or something comparable by the manufacturer. The filling should only be renewed when the gearbox is dismantled and cleaned.

Filling plugs:

Main gearbox 3.9

Reduction gear 3.20

Page 14 of 15 BA_2005_2_GB_FAX

9. Plates

Name plate

Type plate 110 x 60 mm (75312-4121)

Zone 1

Zone 2 and 22

Page 15 of 15 BA_2005_2_GB_FAX

Bijur Delimon FZ-A Operating Instructions Manual

Operating instructions

Pump FZ-A according to

Atex

INDEX

Page

1. General

2

2. Safety

2 – 4

A. Pump type

5

B. Number of outlets

5

C. Revision

5

D. Kinds of drive zone 2 and 22

6 – 8

E. Position of drive

8

F. Reservoir

8

G. Accessories

9

3. Application

10

4. Principle of operation

10

5. Rotational direction of drive

10

6. Specification

11

7. Start-up & Installation

11 – 12

8. Maintenance

13 – 14

9. Plates

15

1. General

Contact Information: For assistance with product, replacement parts, service or training.

2. Safety

2. Safety

2. Safety

PRODUCT CHARACTERISTICS

A. PUMP TYPE FAX

B. NUMBER OF OUTLETS

C. REVISION

D. KINDS OF DRIVE ZONE 2 AND 22

D. KINDS OF DRIVE ZONE 2 AND 22

D. KINDS OF DRIVE ZONE 2 AND 22

E. POSITION OF DRIVE

F. RESERVOIR

G. ACCESSORIES

3. Application

4. Principle of operation

5. Rotational direction of drive

6. Specifications

7. Start-up & Installation

7. Start-up & Installation

*

8. Maintenance

8. Maintenance

9. Plates

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