Metering Technology

Original Operating Instructions

DRUM PUMP
P200 Standard
Customer: • XXXXXX Contents 1
Serial No.: • XXXXX
Index: •0
Key Word Index 2
General 3
Safety rules 4
Structure and Function 5
Commissioning 6
Operation 7
Maintenance 8
Disposal 9
Certificates 10
Spare parts lists 11
Connection diagram 12
Technical specification
sheets 13
DOPAG Customer Ser-
vice 14
Notes 15

©
DOPAG 1/2010
2/ PU200-N001/407-001
Contents

1 Contents
1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Key Word Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Objective of Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Keeping the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Note on changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Symbols and pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Margin column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Cross-references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 Safety advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.9 Prohibition signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.10 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.11 Mandatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.12 Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Hazardous zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3.1 Particular sources of danger . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3.2 Danger from electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3.3 Danger from toxic and combustible materials . . . . . . . . . . . 15
4.3.4 Danger from high pressure . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Responsibilities of the operating company . . . . . . . . . . . . . . . . . . . 16
4.5 Changes to the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Flushing and cleaning the system . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.8 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Structure and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Basic function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2.1 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.2 Chassis and drum holder . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.3 Lifting cylinder and pump elevator . . . . . . . . . . . . . . . . . . . . 21
5.2.4 Drive and transfer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.5 Level control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.6 Follower plate with Ventilation and De-aeration . . . . . . . . . 22
5.2.7 Ventilation rod (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2.8 Discharge system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.9 Compressed air preparation unit . . . . . . . . . . . . . . . . . . . . . 23
5.2.10 Silicagel air dehumidifier (optional) . . . . . . . . . . . . . . . . . . . 24
5.2.11 Connecting block with de-aeration valve (optional) . . . . . . . 25
5.2.12 Material pressure reducing valve . . . . . . . . . . . . . . . . . . . . . 26
5.2.13 Material filter (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.14 Packing box nut with lubricating cup (optional) . . . . . . . . . . 27
5.2.15 Drum roller device (optional) . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.16 Drum roller conveyor (optional) . . . . . . . . . . . . . . . . . . . . . . 27

PU200-N001/407-001 1/3
 Contents

5.3 Funktionen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3.1 Indicator and operating elements . . . . . . . . . . . . . . . . . . . . 29
5.3.2 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3.3 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3.4 Two hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.5 Pump elevator UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.6 Pump elevator UP - 0 - DOWN . . . . . . . . . . . . . . . . . . . . . . 30
5.3.7 Ventilation of follower plate . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.1 Operating cylinder pressure controller . . . . . . . . . . . . . . . . . 30
5.4.2 Pump elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4.3 Ready to operate indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5.2 Technical informations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.5.3 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3 Operating location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4 Removing packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.5 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.6 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.6.1 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.6.2 Compressed air connection . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.7 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.8 Setting level control (drum pump) . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.9 Filling (Delivery pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.10 De-aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.11 Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.2 Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.3 Container change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.6 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4/1 PU200-N001/407-001
Contents

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1.1 DOPAG-Customer Services . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1.2 DOPAG-Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1.3 Operating material and Lubricants . . . . . . . . . . . . . . . . . . . 50
8.1.4 Adjustable Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.2 Maintenance of the components . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.2.1 Maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.2.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2.4 Lamp Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2.5 Metering/delivery pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2.6 Outlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2.7 Compressed air preparation unit . . . . . . . . . . . . . . . . . . . . . 54
8.2.8 Silica gel air dehumidifier (Option) . . . . . . . . . . . . . . . . . . . . 55
8.2.9 Material pressure regulator (optional) . . . . . . . . . . . . . . . . . 55
8.2.10 Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.2.11 Material filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.2.12 Pneumatic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.1 Disposing of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.1.1 Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.1.2 Materials, packaging and system parts . . . . . . . . . . . . . . . . 59
9.2 Final system decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.1 EC Declaration of Conformity (as per directive 2006/42/EC) . . . . . 63
11 Spare parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
12 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
13 Technical specification sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
14 DOPAG Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

PU200-N001/407-001 1/5
 Contents

6/1 PU200-N001/407-001
Key Word Index
2 Key Word Index
A Lamp Function Test ......................... 55
Advice for the user ........................... 10
Ambient conditions ........................... 34
C
Cleaning ........................................... 55
Commissioning ................................. 37
Compressed air preparation unit ...... 56
Conformity ........................................ 19
Connection ....................................... 39
Compressed air connection .......... 39
Electrical connection ..................... 39
Cross-references .............................. 10
Customer Services ........................... 51
D
Danger from
Cleaning ........................................ 19
combustible materials ................... 17
flushing .......................................... 19
high pressure ................................ 17
toxic materials ............................... 17
Danger from electricity ..................... 17
De-aeration ...................................... 24
Dimensions ...................................... 33
Directions for action ......................... 10
Display ............................................. 31
Disposal ........................................... 61
E P
Environmental conditions ................. 15
EU
Low voltage ................................... 19
EU Directive
Electromagnetic Tolerance ........... 19
Machines ....................................... 19
EU Directive Pressure Equipment .... 19
F
Filling
Delivery pump ............................... 41
Follower plate ................................... 24
Functional check .............................. 40
G Pump elevator UP - 0 - DOWN ........ 32
Greases ............................................ 52
H Ready to operate indicator ............... 32
Hazardous zones ............................. 16
I
Intended use .................................... 15
L
Labelling ........................................... 13
PU200-N001/407-001
Leads
Maintenance .................................. 58
Level control ..................................... 23
set ................................................. 40
Links ................................................. 10
Lubricants ......................................... 52
M
Maintenance ..................................... 51
Maintenance plan ............................. 54
Mandatory signs ......................... 10, 13
Margin column .................................. 10
Material ............................................ 34
Material pressure reducing valve ..... 28
Metering/delivery pump
maintenance of the ........................ 55
O
Operating Instructions
Objective ......................................... 9
Operating instructions
changes ......................................... 10
store ................................................ 9
Operating location ............................ 38
Operating material ............................ 52
Outlet valve
Maintenance .................................. 55
Packaging ........................................ 39
Pictograms ....................................... 10
Pneumatic cylinder
maintenance .................................. 59
Pressure control
Ventilation of follower plate ........... 32
Pressure controller
Pump elevator ............................... 32
Pressure controller operating
cylinder ............................................. 32
Pressure release ........................ 47, 55
Product safety .................................. 16
Prohibition signs ......................... 10, 12
R
remarks ............................................ 10
Responsibilities of the operating
company ........................................... 18
Running in ........................................ 43
2/7
 Key Word Index

S Switching off .....................................47

Safety advice .................................... 11 Symbols ............................................10
Safety rules ...................................... 15
T
Sealing fluid ...................................... 52
Target audience .................................9
seals ................................................. 52
Technical data ..................................33
Set-up ............................................... 39
Temperature .....................................34
Signal word ....................................... 11
Tips ...................................................10
Caution .......................................... 11
Transportation ..................................38
Danger .......................................... 11
Troubleshooting ................................48
Information .................................... 11
Two hand control ..............................32
Warning ......................................... 11
Type plate .........................................13
Silica gel air dehumidifier
Maintenance .................................. 57 V
Sources of danger ............................ 16 ventilation .........................................24
Spare parts ....................................... 51
W
Start .................................................. 31
Warning signs .............................10, 12
Stop .................................................. 31
Warranty and liability ........................20
Structure ........................................... 22

8/2 PU200-N001/407-001
General

3 General
3.1 Objective of Operating Instructions
These operating instructions are to ensure the intended and efficient use of the
equipment. They contain the relevant information for the safety, construction, func-
tion, commissioning, operating, servicing and disposal. The required information
can be located in the operating instructions using the Contents Index, the Key Word
Index, Title and Further Information.
Ignoring the operating instructions and the safety information can lead to dangers
and restrictions for:
• life and limb of the operator;
• the machine and material assets of the operating company;
• efficient operation of the system.

NOTICE!
The company DOPAG (hereafter called the manufacturer of the equipment)
takes no responsibility for any damage resulting from not observing the op-
erating instructions.

3.2 Keeping the operating instructions

The operating instructions are a component of the equipment. They must be made
available to personnel at all times The equipment operator must ensure that both the
operating and service personnel have read and understand them.

3.3 Target audience

The equipment operator has the responsibility for ensuring that the operating and
service personnel have the appropriate qualifications. He must ensure that only
company authorized personnel operate the equipment.

Operators Persons working at the system and operating it possess sufficient training for the op-
erations concerned. It is essential for personnel to have read and understood the op-
erating instructions.

Service personnel Persons who service and repair the system must be skilled and:
• adequately trained to undertake the operations necessary;
• be familiar with and follow the relevant technical regulations and safety instruc-
tions;
• have read and understood the operating instructions.
Skilled persons mean those whose training and experience have provided them with
adequate knowledge in the fields of hydraulics, pneumatics, and material-handling
technology, in addition to being familiar with the regulations applicable to occupa-
tional safety and accident prevention, directives and generally recognized rules on
technology and standards, so that they can evaluate operational safety of the sys-
tem.

PU200-N001/407-001 3/9
 General

3.4 Note on changes

Text, illustrations and data are commensurate with the technical status of the ma-
chine at the time of these operating instructions going to print. The company re-
serves the right to make changes in the interests of ongoing development.

3.5 Symbols and pictograms

The operating instructions contain various symbols and pictograms. They convey to
the operating and maintenance personnel warnings, handling instructions, informa-
tion and directions.

Directions for action to be taken

D...  The triangle indicates actions that must be undertaken in sequence.
• The spot indicates the reaction to an action.
T...
Warning signs, prohibition signs and mandatory signs.
Safety information, prohibitions, instructions and warnings are indicated by the ap-
propriate ISO Safety Signs. They can be found in the operating instructions and on
the equipment and it is essential that they are obeyed.

Pictograms
Buttons, switches, pressure gauges and functions are designated by pictograms in
the operating instructions and on the machine itself. The letters A, B, C... picto-
grams identify the components.

Advice for the user

Operator advice and tips for efficient operation of the system are indicated by
lights and heavy print Follow these instructions!

3.6 Margin column

Further information contains additional advice (Pictograms, key words and descrip-
tions of illustrations) They point out dangers and ease the search.

3.7 Cross-references
Cross references are printed in italics. They point out information in other sections,
e.g. (<Nicht definierter Querverweis>).These points are to be found in the Contents
or the Key Word Index.

10/3 PU200-N001/407-001
General

3.8 Safety advice

There are four types of safety information: Danger, warning, caution, information
They contain: Type of danger, possible consequences and avoidance measures to
be taken.

Danger Signal word to indicate a danger with a high risk that could lead directly to death or
serious physical injury.

DANGER!
Type of danger
Potential consequences
Steps to avert danger

Warning Signal words indicate a danger with a high risk that could lead directly to death or
serious physical injury.

WARNING!
Type of danger
Potential consequences
Steps to avert danger

Caution Signal words indicate a danger with a low risk that could lead directly to death or se-
rious physical injury.

CAUTION!
Type of danger
Potential consequences
Steps to avert danger

Information Signal word for a possible damaging situation, were the system or anything in the
vicinity could be damaged.

NOTICE!
Text of notice

PU200-N001/407-001 3/11
 General

3.9 Prohibition signs

Attention Prohibition signs forbid types of behavior that pose danger. The consequence of ig-
noring a prohibitive signs could lead to a dangerous situation and serious injuries.

Attention - No fire, naked flames or smoking

This prohibitory sign is used when there is a danger of fire due to flammable mate-
rials.

Attention - Do not touch

This prohibitory sign is used when there is danger injury by coming into contact with
parts of the equipment.

3.10 Warning signs

Warning Warning signs warn of acute danger. The consequences of ignoring prohibitive signs
can lead to a dangerous situation and most serious injuries.

Warning - General
This general warning sign is always used in conjunction with safety information.
The safety notice must be observed without fail.

Warning - Caution, high voltage

Warning of a dangerous electrical voltage. If contact is made with components in
this danger area serious injury possibly leading to death may occur.

Warning - Flammable
Warning of flammable materials. These materials are easily combustible. If they
catch fire, serious burns could result possibly leading to death.

Warning - Danger of ignition

Warns of hot parts on the machine. Touching these parts when hot can cause seri-
ous burns.

12/3 PU200-N001/407-001
General

3.11 Mandatory signs

Mandate Mandatory signs prescribe specific courses of action. They must be followed, as
they help protect against injury.

Wear protective gloves

Wearing protective gloves prevents contact with poisonous substances. Caustic
burns and poisoning is avoided.

Wear protective goggles

Parts of the equipment operate under pressure and spraying substances can cause
damage to eyes. Wearing eye protection avoids damage to eyes.

3.12 Labelling
The type plate is located on the control cabinet and provides the following details:

1 Type description
2 Serial number
1
3 Month/Year of con-
struction 2 7
4 Voltage
3 8
5 Current
6 Mains air pressure 4 9
7 Diagram number
5 10
8 Weight
9 Voltage frequency 6
10 Power
11 Address of manufac- 11
turer
12 CE label 12

Fig. 3-1 Type plate

PU200-N001/407-001 3/13
 General

Notes

14/3 PU200-N001/407-001
Safety rules

4 Safety rules
4.1 Intended use
The equipment and its functions may only be used for the purposes of delivering,
measuring and mixing. The prescribed environmental conditions for operation
(5.5.3 Ambient conditions) must be observed. Only those materials confirmed in the
contract may be used.
• If the composition of materials change, then the use of these materials must be
declared to and be approved by DOPAG Customer Services.
• If a different type of material is to be used, this must be clarified and approved
by DOPAG Customer Service.

NOTICE!
The use of material unapproved by DOPAG Customer Services can damage
the equ ipment. If f or ex ample se als ca nnot with stand th e new compo und,
then they will be destroyed. Information on your telephone contact can be ob-
tained from DOPAG Customer Services (14 DOPAG Customer Service).

Explosive vapors Mixing and metering materials that form explosive vapors is prohibited. This ma-
chine has no protection against explosion.

DANGER!
Danger of explosion!
Operating the system using materials that form explosive vapors can cause serious
burns resulting from explosions.
Do not mix or meter explosive materials.

Foodstuffs Mixing and metering foodstuffs is prohibited. This system is not designed for pro-
cessing foodstuffs. Toxic substances would contaminate foodstuffs.

DANGER!
Danger of poisoning!
Operating the machine with foodstuffs can result in serious poisoning.
Do not mix or meter foodstuffs.

PU200-N001/407-001 4/15
 Safety rules

4.2 Product safety

The system conforms to acknowledged rules of engineering and technology and the
relevant safety regulations. The correct operation of the equipment is required to
avoid damage and accidents. Operating the machine incorrectly or subjecting it to
abuse may imperil:
• life and limb of the operator;
• the system and material assets of the operating company;
• efficient operation of the system.
The system may only be operated if it is in perfect condition and if the operating in-
structions are observed.

4.3 Hazardous zones

The hazardous zone denotes the area at a system and/or in its vicinity that poses a
danger to personal health or safety. There are various danger zones surrounding the
unit. All safety regulations given in the operating instructions and information signs
on the equipment must be observed. Observe the safety regulations in force where
the equipment is installed.

4.3.1 Particular sources of danger

Operating this system is safe. Even so, dangers can arise in various situations. Ad-
here to the following points.
• The oscillating pumps are powered by pneumatic- or hydraulic cylinders. Never
reach in between the drive and the pump. Otherwise injury from crushing can
result.
• Under all situations when working on the equipment, whether installation, re-
moval and re-installation, commissioning, operation, modification, adaptation,
maintenance and cleaning, the isolation procedure and safety information given
in the operating instructions is to be observed.
• All service maintenance on the system must be carried out while system is sta-
tionary.
• In all cases observe local regulations applicable to safety and accident preven-
tion.

16/4 PU200-N001/407-001
Safety rules

4.3.2 Danger from electricity

Electricity is dangerous in many ways. Adhere to the following points.

• Work on power supply systems may only be performed by qualified electricians.
• Check the system electrical equipment regularly. Loose connections and burnt
cables should be removed immediately or restored to their proper condition.
• The control cabinet must be kept closed at all times. Access to the control cab-
inet is permitted only to authorized staff with a key or tool.
• If work is necessary on live parts, a second person must be enlisted who can
turn off the main switch in an emergency.
• Otherwise the main switch should be turned off and locked against inadvertent
switching on.
• Remove mains plug.

4.3.3 Danger from toxic and combustible materials

The system may contain toxic and combustible materials.

• If using solvents or other corrosive chemicals special precautions must be taken,
e.g. Eye washing facilities.
• During flushing and cleaning processes, vaporisation of solvents can create an
explosive zone.

4.3.4 Danger from high pressure

Pneumatic and hydraulic component sections are pressurized. Adhere to the follow-
ing points:
• Only personnel with special knowledge and experience may work on hydraulic
systems.
• When dealing with the system, protective goggles and protective gloves must be
worn.
• De-aerate sections of the system and pressurized lines that are to be opened
before starting repair work.
• Change hydraulic hose lines at appropriate intervals, even if no safety related
defects are detected.
• Pumps operate at high pressure. All pumps and lines must be discharged before
opening or assembly work. No residual pressure may exist.
• Otherwise the main switch should be turned off and locked against inadvertent
switching on. The main switch (Device for isolation from electricity supply) iso-
lates the entire system. All electric functions are switched off and the outlet valve
closes. Parts of the system continue to be subject to pressure.
• Remove mains plug.

PU200-N001/407-001 4/17
 Safety rules

4.4 Responsibilities of the operating company

The following responsibilities are generally applicable to working with this system:
• Observe the generally recognized rules that apply to occupational safety. Over
and above this, observe the basic regulations and rules on occupational safety
and accident prevention applicable to the service location.
• The operating company is obliged to observe the provisions applicable to the
use of equipment, especially those specified in EC Directive 89/665/EEC.
• The system may only be operated in a perfect and clean condition.
• It is forbidden to remove, change, bypass or avoid any kind of systems in place
for protection, safety or monitoring.
• Converting or modifying this system is prohibited.
• For repairs, contact DOPAG Customer Service (<Nicht definierter Querver-
weis>). Only DOPAG spare parts may be used.
• Check system at least once per shift for visible signs of damage and for function-
ality.

4.5 Changes to the system

Changes to the system are not allowed as a matter of principle. If changes do be-
come necessary, please observe the following points:
• Do not undertake changes, add-ons or conversion to the system without express
approval by the manufacturer.
• Do not undertake changes to system software without express approval by the
manufacturer.
• All conversion measures require written approval by the manufacturer.
• Only original DOPAG spare parts may be used. Safe operation is not guaranteed
if parts sourced elsewhere are used.

18/4 PU200-N001/407-001
Safety rules

4.6 Flushing and cleaning the system

The safety data sheets on the substances and materials used are an important fac-
tor when selecting flushing and cleaning materials.

DANGER!
Danger of explosion when using solvents!
When using solvents based on halogenized hydrocarbons, such as trichlorethane
and methylene chloride (dichloromethane), chemical reactions can arise on alumin-
ium and on galvanized parts. The parts can oxidize and be destroyed as a result.
In extreme cases, the reaction can occur in an explosive manner.
Do not use any solvents based on halogenized hydrocarbons.

When selecting flushing and cleaning agents, please observe the following points:
• Note manufacturer's recommendations.
• System components must be capable of withstanding the recommended flush-
ing and cleaning agents. If you have any questions, please contact DOPAG Cus-
tomer Service (14 DOPAG Customer Service).
• Note the current safety data sheets of your suppliers.
At certain points in these instructions, reference is made to the use of cleaning
agents, oils and similar products (e.g. Mesamoll ®). Safety data sheets of the man-
ufacturers of these materials, as far as we are aware, quoted are in these instruc-
tions (13 Technical specification sheets). The current safety data sheets must be
available and the instructions contained therein must be followed.

4.7 Conformity
The equipment complies with the EU Directive Machines (2006/42/EU), Low voltage
(2006/95/EU), Pressure Equipment (97/23/EU) and EMV (2004/108/EU). You can
find details in the Declaration of Conformity (10 Certificates).

PU200-N001/407-001 4/19
 Safety rules

4.8 Warranty and liability

In principle, our general conditions of sale and supply are applicable. They will be
available to the operating company no later than the date on which the contract is
finalized. Claims under the warranty for personal and material damage are excluded
if they are traced back to one or several of the following causes:
• Improper use of the system.
• Improper assembly, commissioning, operation and maintenance.
• Operating the system with faulty safety systems or protective systems that have
been incorrectly fitted, or non-functional safety- and protection systems.
• Disregarding instructions on safety, transport, storage, assembly, commission-
ing, maintenance and disposal the machine.
• Unauthorized structural modification to the system.
• Unauthorized intervention in the system software.
• Unauthorized changing of drive-power levels (power, rotary speed, etc).
• Poor monitoring of system parts subject to wear.
• Improperly executed repairs.
• Disasters caused by extraneous influences and force majeure.
• Using spare parts other than those of DOPAG.
• Damage arising from normal wear and tear.

20/4 PU200-N001/407-001
Structure and Function

5 Structure and Function

5.1 Basic function
The drum pump is a pneumatically driven reciprocating pump for the conveyance of
highly viscous materials, such as rigid fats, jointing compounds and adhesives. The
materials for processing are conveyed directly from drums to the task location,
where they undergo further processing.
Drum pumps are used to supply single workstations and also as centralised systems
for supplying materials.

Components 7 5
1 Drum pump
2 Drum or container 1
3
3 Hose
4 Dispensing valve
5 Material pressure reg- 6
ulator
6 Volume counters
7 Air relief valve
4

Fig. 5-1 Diagram

The drum pump consists of a number of components. The material is supplied from
the drum via a hose to the dispensing valve. As optional extras, material pressure
regulators, volume counter cells and a separate air relief valve are built in. For a de-
tailed function diagram (12 Connection diagram).

PU200-N001/407-001 5/21
 Structure and Function

5.2 Structure

Components
15 2
1 Air prepare mainte-
nance unit
2 Control unit
3 Compressed air con-
nection
4 Pump elevator
9
5 Drive
6 Lifting cylinder
7 Level control 10
8 Chassis
9 Terminal block with air
relief valve and pres- 12
sure gage (optional)
11
10 Transfer pump
11 De-aeration of the fol-
lower plate
12 Ventilation of the fol- 13
lower plate (optional) 8
13 Drum holder
14 Follower plate 1 4
15 Material pressure re-
ducing valve (option)

3
5

14

Fig. 5-2 Construction of drum pump P200

22/5 PU200-N001/407-001
Structure and Function

5.2.1 Control unit

The control cabinet accommodates the various operation controls. It is equipped

with a lockable door. The system is equipped with a pneumatic two-hand safety con-
trol system, which helps prevent injury while the follower plate is being lowered.

5.2.2 Chassis and drum holder

The chassis of the system consists of a U-section. The system can be transported
using a lifting truck. The drum holder centres and secures the drum on the chassis.

5.2.3 Lifting cylinder and pump elevator

Two lifting cylinders raise and lower the pump elevator when drums are changed,
and subject the material to pressure via the follower plate.

5.2.4 Drive and transfer pump

The transfer pump is powered by a pneumatic cylinder. It is equipped with a rapid

reversing valve to reduce pulsation when material is dispended.

5.2.5 Level control

If the lower level limit is reached, the level control will output an acoustic alert, indi-
cating that the container will soon be empty. Additionally, it turns off the pump when
the min. level is reached and prevents that air is sucked in. The level limits are ad-
justable.
Systems with only one level control trigger an alarm wh en the min. level is
reached. The pump is turned off automatically.

1 Lower level limit (op-

tion)
2 Min. level limit

1
2

Fig. 5-3 Level control

PU200-N001/407-001 5/23
 Structure and Function

5.2.6 Follower plate with Ventilation and De-aeration

During the operation the follower plate applies pressure on the material in the con-
tainer. The follower plate may be equipped with several sealing options as well as
ventilation and de-aeration devices. The ventilation is either connected firmly to the
follower plate or is installed instead of the vent rod.

1 Transfer pump
2 Vent rod
3 De-aeration opening
4 Ventilation
1
5 Follower plate
6 Seal
2

Fig. 5-4 Follower plate

5.2.7 Ventilation rod (optional)

An ventilation rod is used for material that tends to form crusts and glues together.
It is screwed in place of the vent rod into the follower plate. The ventilation rod helps
overcome the vacuum below the follower plate.

1 Ventilation rod
2 Vent rod

Fig. 5-5 Ventilation rod

24/5 PU200-N001/407-001
Structure and Function

5.2.8 Discharge system

The system may be equipped with an outlet valve or may be linked to another sys-
tem. An outlet valve is used for material discharge. It closes at the end of the casting
operation to prevent any material from flowing out or dripping.

1 Outlet valve with han-

dle 1
2 Diaphragm outlet
valve
3 Needle metering valve
2

Fig. 5-6 Discharge system

5.2.9 Compressed air preparation unit

The compressed air preparation unit supplies the system with compressed air to cre-
ate optimum operating conditions. The inflow of air pressure is filtered and impreg-
nated with oil. A silica gel de-humidifier (Option) removes moisture from the air.

1 Main valve for air pres-

3 2
sure
2 Pressure control for 5
operating pressure
3 Pressure gauge for
operating pressure 1
4 Connection for oil
charging
5 Vacuum valve for oil
charging 6
6 Connection to com-
4
pressed air supply
7
7 Valve for water drain- 8
age
Fig. 5-7 Compressed air preparation unit
8 Silica gel air dehumid-
ifier (optional)

PU200-N001/407-001 5/25
 Structure and Function

5.2.10 Silicagel air dehumidifier (optional)

The Silicagel air dehumidifier removes moisture from the air pressure. It prevents air
pressure with too much moisture content reaching the material container.

1 Air dehumidifier
2 Viewing glass
1

Fig. 5-8 Silicagel air dehumidifier

5.2.11 Connecting block with de-aeration valve (optional)

The connecting block with de-aeration valve can be utilized when the system is to
be de-aerated after production is concluded. After container changeover or commis-
sioning of the transfer pump, the system can be de-aerated.

1 Pressure gauge for

material pressure
2 Connecting block 1
3 De-aeration valve

Fig. 5-9 Connecting block with de-aeration valve

26/5 PU200-N001/407-001
Structure and Function

5.2.12 Material pressure reducing valve

DOPAG Material pressure reducing valve reduces the pressure of the delivered ma-
terial to the required working pressure.
They compensate for pulsations (Changeover position in the pump) in the material
delivery due to the action of a piston pump.
The valves function with material viscosities of between 5.000 to 500.000 mPas.
Filter elements at material entry prevent the entry of contaminants. The spring hous-
ing is sealed using a slip-ring seal (13 Technical specification sheets).

1 with pistons
2 with membrane 1
3 for silicone

Fig. 5-10 Material pressure reducing valve

5.2.13 Material filter (optional)

DOPAG material filters prevent impurities reaching into the valves. Impurities
present in the material are harmful to valve seats.
For detailed information (13 Technical specification sheets).

1 Connection for pres-

sure gauge 1
2 Material outlet
3 Filter housing
4 Material input 2

Fig. 5-11 Material filter

PU200-N001/407-001 5/27
 Structure and Function

5.2.14 Packing box nut with lubricating cup (optional)

With material susceptible to air, a packing box nut with lubricating cup replaces the
standard packing box nut. The lubricating cup filled with oil or sealing liquid prevents
air from reaching the seal.

1 Piston
2 Lubricating cup
1
3 Transfer pump / Me-
tering pump

Fig. 5-12 Packing box nut with lubricating cup

5.2.15 Drum roller device (optional)

The drum roller device assists insertion of a heavy container below the follower plate
during container changeover.

1 Drum roller device

2 Drum holder
3 Chassis

3
Fig. 5-13 Drum roller device

28/5 PU200-N001/407-001
Structure and Function

5.2.16 Drum roller conveyor (optional)

The drum roller conveyor assists insertion and alignment of a heavy drum below the
follower plate during drum changeover.

1 Drum roller conveyor

2 Drum holder
3 Chassis

Fig. 5-14 Drum roller conveyor

PU200-N001/407-001 5/29
 Structure and Function

5.3 Funktionen

5.3.1 Indicator and operating elements

All the indicators and operating elements are detailed described on the following
chapters.

Functions
10
1 Pump elevator pres-
sure gauge
2 Pump elevator pres-
sure controller 1
3 Selection switch UP-
0-DOWN
4 Latch
5 Two-hand control 3 2
6 Ready to operate indi-
cator 11
4
7 Start Pump
8 Stop Pump
9 Pump elevator UP 6
5
10 Operating cylinder of
pressure controller
5
11 Ventilation valve for
follower plate
8
7

Fig. 5-15 Control unit of drum pump P200

5.3.2 Start

Button to start pre-selected functions

5.3.3 Stop

Button to stop pre-selected functions

30/5 PU200-N001/407-001
Structure and Function

5.3.4 Two hand control

Due to safety reasons, the follower plates are raised and lowered with the two hand
control. Positioning the follower plate in the container causes risks which are re-
duced by means of the two hand control.

5.3.5 Pump elevator UP

Button to raise the pump elevator

5.3.6 Pump elevator UP - 0 - DOWN

Rotary switch for pre-selection of pump elevator direction. In position DOWN the
automatic following of the follower plate is engaged.

5.3.7 Ventilation of follower plate

Pressure control to set the pressure for the ventilation of the follower plate. The
pressure gauge indicates how much pressure is created under the follower plate to
move it out of the container.

5.4 Pressure control

5.4.1 Operating cylinder pressure controller

Controls the pressure at the operating cylinder. The pressure gauge indicates the
operating pressure.. Increasing the operating pressure also increases the pump
pressure and the quantity of delivered material and vice-versa.

5.4.2 Pump elevator

Controls the pressure at the pump elevator. The pressure gage indicates the pump
elevator pressure. If the pressure is adjusted, the speed of raising and lowering
changes. This pressure operates on the follower plate during operation i.e. on the
material in the container.

5.4.3 Ready to operate indicator

The ready to operate indicator lights up when the pump is ready to operate. The
follower plate must lie in contact with the material and the pump elevator rotary
switch set at the position DOWN.

PU200-N001/407-001 5/31
 Structure and Function

5.5 Technical data

5.5.1 Dimensions

HA
H

Fig. 5-16 Dimensions

Dimensions
Height H 1650 mm
Extended Height HA 2570 mm
Width W 610 mm
Length/Depth T 1100 mm
Total empty weight 230 kg
Diameter of oil control ring 580 mm
Diameter of drum 560 mm
Diameter of material pressure plate 540 mm
Diameter of lifting cylinder 80 mm
Compressed air connection G 1/2 i
Material outlet G1i

32/5 PU200-N001/407-001
Structure and Function

5.5.2 Technical informations

Technical informations
Mains pressure 6 bar (min. 13 mm cross section)
Nominal pressure (transfer pump) 13 Technical specification sheets
Maximum material pressure (transfer 13 Technical specification sheets
pump)
Air consumption (air motor) 13 Technical specification sheets
Max. material viscosity 13 Technical specification sheets
Output rate depending on viscosity of 13 Technical specification sheets
material
Prepare ratio 13 Technical specification sheets
Emissions LpA 75 dB
Technical information depending on a component can be obtained from the
technical specifications sheets (13 Technical specification sheets).

5.5.3 Ambient conditions

System operation
System operation (without material)
Air temperature + 5 to + 40 °C
Relative air humidity 30 to 70%

Transport and storage

Transportation and storage (without material)
Air temperature - 25 to + 55 °C
Relative air humidity 30 to 60%

Operating Temperature For all operations the material must be brought to the correct processing tempera-
Material ture. This temperature is to be considered, if:
• the material is taken out of cold storage,
• heating is required to heat up the materials,
• cooling is required to cool down the materials.

NOTICE!
Observe the temperature information in the material data sheet.

PU200-N001/407-001 5/33
 Structure and Function

Notes

34/5 PU200-N001/407-001
Commissioning

6 Commissioning
6.1 Commissioning procedure
Before work can commence on the system, it must be commissioned by service
staff. Commissioning proceeds in 6-8 steps:

Start

Removing packaging
Setup Connection

Ceck the hoses and the

Checking
funktion of the system

Setting the level control

Setting
detector
Standard commissioning

Pressure vessel filling

Filling Prepare drums

Venting Machine venting

Parameter setting Data entry

Option

Mixing ratio Mixing ratio

setting defining und setting

Charging Charging the machine

End

Fig. 6-1 Commissioning procedure

PU200-N001/407-001 6/35
 Commissioning

6.2 Transportation
The machine is packaged and delivered by the manufacturer in a proper manner. It
is protected for transportation and against weather conditions, and provided with
suitable packaging materials.

DANGER!
Transporting the system incorrectly could result in personal injury!
Fatal injury could result if the system is transported incorrectly.
Enlist staff for transport who are forklift-trained and who are able to handle heavy
items.

Transport the system to final destination as packaged and only remove before
first use. The packaging protects the system.

6.3 Operating location

At the operating location the weight of the system and the local protection provisions
are to be observed. Easily combustible materials (e.g. solvents) require special care.
Observe the following points:
• Check ground's ability to withstand the load.
• Assess space conditions and accessibility.
• Note local regulations concerning safeguards and protection.
• Erect safety signs.
• Have protective clothing available.
• Check thermal conditions (where systems have heating systems).
• Ensure adequate ventilation when working with toxic fumes and vapors.
• Ensure that air conditioning keeps environment dry.
• Provide space for air supply and exhaust with aerated control cabinet.

36/6 PU200-N001/407-001
Commissioning

6.4 Removing packaging

Disposal All packaging must be disposed of with care. Packaging material must be disposed
of in the correct manner (9 Disposal).

Warranty conditions The system must be checked for damage that may have occurred in transit. If dam-
age is ascertained, then the conditions of guarantee must be observed. These are
described in the sales documents.

6.5 Set-up
The system must be set up and operated on a level floor. If the system of part of it
are fitted with rollers and are free to roll then a roller brake must be fitted to prevent
accidental movement. Additional securing is not necessary. All system parts must
be set up on a non-slip base. Note ergonomic principles applicable at local level.
The system has been constructed for operation in spaces that are protected from
weather conditions. Operation and storage in a hostile or too humid environment or
in the open air will result in corrosion damage, for which the manufacturer accepts
no responsibility.

6.6 Connection

6.6.1 Electrical connection

The system with electrical components such as control devices, agitator, heating
etc. require an appropriate connection to a power supply (12 Connection diagram).
The control cabinet should be earthed at the screw provided for this purpose.

DANGER!
Danger of electric shock!
Touching parts in this danger zone may result in serious or fatal injury from electric
shock.
Work on power supply systems may only be performed by qualified electricians.

6.6.2 Compressed air connection

The system must be connected to a compressed air supply. Therefore a com-

pressed air connection is (5.2 Structure). The delivery hose must have a bore diam-
eter corresponding to the technical data for a constant pressure delivery of 6 bar.

PU200-N001/407-001 6/37
 Commissioning

6.7 Functional check

Checking functions is necessary for initial commissioning and after repair work. This
is done without material (pressure container and lines empty).

Checking the system:  Carry out visual check.

 Fill air prepare maintenance unit with oil ().
 Compressed air - Open delivery.
 Check components and hoses for air leaks.

Checking the buttons and  Turn on main switch.

control unit:  Lamp function tests (for systems with electrical connection).
• After operating the main switch, all buttons and pilot lights light up and
horn sounds.

Checking seals:  Listen for leaks in pneumatic lines.

6.8 Setting level control (drum pump)

The system is fitted with one or two alarms.
• the low level limit informs the operator that the container will be empty, soon.
• the min. level limit turns off the pump automatically to prevent air from entering
the system.
The level control sensors are preset at the factory, but may be adapted to your
needs.

1 Sensor for low level

limit
1
2 Sensor for min. level
limit 2 2
3 Retaining bolt
4 Lifting cylinder 3
3

Fig. 6-2 Level control

Align level control sen-  Loosen retaining screws.

sor:  Move sensor vertically.
 Tighten retaining screws.

38/6 PU200-N001/407-001
Commissioning

6.9 Filling (Delivery pump)

In order to operate the system, the appropriate containers and materials must be
provided.

DANGER!
Danger of trapping limbs!
During raising and lowering of the follower plate/container plate situations can arise
in which limbs (hands and fingers) can become trapped.
Exercise care that when positioning a container to ensure that the hands are away
from the container rim. Two handed control protects your hands.

CAUTION!
Take care when working with open containers!
Contaminated material can result in faults occurring in the system.
Use only clean material and cover open container. Do not use containers with dents
or that have been damaged.

Setting pressure:  Open compressed air main valve.

 Set pump elevator pressure to approx. 2 bar.

 Set operating pressure to 0 bar.

Raising the pump eleva-  Turn selector switch to position .

tor (without drum):
 Press button .
• Pump elevator is raised.

Preparing the filling oper-  Lubricate seal of follower plate (silicone oil or Vaseline).
ation:  Release clamp lever of container holder and push outwards.
 Place empty container without lid under follower plate.

Lowering pump elevator:  Open vent rod by 6 turns.

 Turn selector switch to position .

 Press buttons of two-hand operation.

• Pump elevator is lowered.
• All-clear indicator lights green.
 Close vent rod.
 Align barrel support to the container and tighten.

PU200-N001/407-001 6/39
 Commissioning

6.10 De-aeration
The system must be de-aerated first. The de-aeration procedure differs according to
the material viscosity. The following procedure assumes a low viscosity. This situa-
tion requires the biggest effort for an air-free system.
The system must be de-aerated correctly before the commissioning. This en-
sures a smoot h op eration f or all app lications. In y our c ase, the proc edure
must be adapted to the procedure described below. In most cases, not all of
the steps are necessary to de-aerate your system.

Venting the follower  Open vent rod by 6 turns.

plate:
 Turn selector switch to position .

 Press buttons of two-hand operation.

• Pump elevator is lowered.
 Wait until material flows out of vent aperture.
 Close vent rod.

Venting the transfer  Press button .

pump: • Pump starts.
 Open air-relief valve at connecting block.
 Wait until material without bubbles flows out of vent aperture.
 Close air-relief valve at connecting block.

Venting the hose or dis- The dispensing aperture (hose or dispensing valve) must be raised as high as pos-
pensing valve: sible. Air can rise up and emerge. This can take some time, depending on material
viscosity.
 Wait until air can escape.

 Press button .
• Pump starts.
 Dispend material until it is free from bubbles.
• Repeat several times if necessary.

40/6 PU200-N001/407-001
Commissioning

6.11 Running in
The material outlet respectively the hose end must be equipped with an outlet sys-
tem prior to running in. The discharge system controls the discharge of material.

Running in system:  Turn selector switch in position .

 Press buttons of two-hand operation.

• Pump elevator is lowered.
• All-clear indicator lights green.
The pump will only start, if the follower plate is lying on the material and the
ready to operate indicator becomes green.

 Press the button.

• The pump starts.
• The automatic following of the follower plate starts to run.
The automatic following of the follower plate is turned on as along as the se-

lection switch is in position .

 Open outlet valve and discharge material until it is free of bubbles.

PU200-N001/407-001 6/41
 Commissioning

Notes

42/6 PU200-N001/407-001
Operation

7 Operation
7.1 Setup
Prior to starting production, the system must be prepared for operation.
The system must be checked visually every day before the beginning of the
work s hift. It should be shut down immediately, if t here is any dou bt ab out
trouble-free operation. Before further operations, the system must be checked
by the service staff.

Set up the system:  Connect compressed air supply.

 Open compressed air main valve.

 Set pump elevator pressure .

 Turn selector switch in position .

 Driving pressure .

 Press the keys of two-hand control.

• Pump elevator is lowered.
• All-clear indicator lights green.

 Press the key .

• The pump starts.
• The automatic following of the follower plate starts to run.
 Open outlet valve and discharge material until it is free of bubbles.
The pump will only start, if the follower plate is lying on the material and the
ready to operate indicator becomes green.

7.2 Discharge
The system must be ready for operation for material discharging.
 Activate discharge valve and discharge material.

The procedure during material discharging depends greatly on the discharge

system and the process. The processes must be defined and monitored. In so
doing, all safety-related points set down in these operating instructions must
be observed.

PU200-N001/407-001 7/43
 Operation

7.3 Container change

If the container is empty the delivery pump is turned off by the level control and the
horn sounds. The container must be changed now.

DANGER!
Danger of trapping limbs!
During raising and lowering of the follower plate/container plate situations can arise
in which limbs (hands and fingers) can become trapped.
Exercise care that when positioning a container to ensure that the hands are away
from the container rim. Two handed control protects your hands.

CAUTION!
Take care when working with open containers!
Contaminated material can result in faults occurring in the system.
Use only clean material and cover open container. Do not use containers with dents
or that have been damaged.

Raising the pump eleva-  Turn selector switch to position .

tor (out of drum):  Optional: fit ventilation rod instead of vent rod and connect air pressure.

 Open ventilation valve for follower plate .

• Pump elevator moves slowly out of drum.

 Close ventilation valve for follower plate .

 Press button and move pump elevator to top position.

 Optional: release air pressure connection and fit vent rod instead of ventilation
rod.
 Clean ventilation rod.

Changing drums:  Release clamp lever of drum holder and push outwards.
 Remove empty drum.
 Clean seal of follower plate and lubricate (silicone oil or Vaseline).
 Place empty drum without lid under follower plate.

44/7 PU200-N001/407-001
Operation

Lowering pump elevator:  Open vent rod by 6 turns.

 Turn selector switch to position .

 Press buttons of two-hand operation.

• Pump elevator is lowered.
• All-clear indicator lights green.
 Close vent rod.

Venting the system:  Align drum holder to drum and tighten.

 Venting the system (6.10 De-aeration).

7.4 Switching off

After work, the system must be switched off.

Switch off the pump:  Press the button.

• Pump stops.

Pressure release:  Open pressure release valve.

• Material flows until pressure equalizes.
 Close pressure release valves.

Cleaning the system:  Close compressed air main valve.

 Cleaning the system (8.2.3 Cleaning).

PU200-N001/407-001 7/45
 Operation

7.5 Troubleshooting
This list provides information on possible faults occurring in the system and rectify-
ing them.

System fails to displace

material upon start-up Causes What to do
Main switch OFF Main switch ON
Close the compressed air main valve Close air pressure main valve.
Drive pressure too low Increase drive pressure
Material pressure controller Adjust material pressure controller
Barrel empty Refill barrel
Material filter clogged Clean material filter

Air pockets in mixed ma-

terial Causes What to do
Drum empty Change drum
Pumps not vented correctly Vent pumps
Dispensing valve dripping Vent pumps and hose

Alarm sounds
Causes What to do
Drum empty Change drum

If fault cannot be rectified, contact DOPAG Customer Service (14 DOPAG Cus-
tomer Service).

46/7 PU200-N001/407-001
Operation

7.6 Shutting down

If the system needs to be shut down for any length of time, several precautionary
measures must be taken.
If the constituents processed in the system react to air humidity, the parts that con-
duct the material must be flush with solvent, sealing liquid or a similar agent. Those
parts that conduct material in the system include the pressure vessel, drums, supply
pumps, any heating systems fitted, metering pumps, hoses/tubes, the mixing block,
etc.
In order to flush the parts conducting material, the drums must be filled with the
flushing agent. The agent must circulate in the system. Please note that even these
agents may contain traces of water. It is therefore necessary to flush out the system
cleanly in order to remove any residues of hardening agents. Even a mixture of
flushing agent and hardener can produce an unwanted reaction and clog the sys-
tem.

Shutting down:  Move pump elevator to lowest position.

 Fill with sealing liquid (if necessary).
 Clean external surfaces of system.
 Provide protection against dust and humidity.
 Remove electrical connections.
 If possible, do not remove air pressure connections. Parts conducting the mate-
rial must be hermetically sealed.
 Regenerate silica gel.
 Note temperature range for interim storage (5.5 Technical data).

NOTICE!
Pay attention to the storage periods and storage temperatures of all materials
remaining in the system. If materials remain in the system and they set hard,
an inspection is necessary.

If the system is shut down for any length of time, then DOPAG recommends
an inspection. Further details can be obtained from DOPAG Customer Service
(14 DOPAG Customer Service).

PU200-N001/407-001 7/47
 Operation

Notes

48/7 PU200-N001/407-001
Maintenance

8 Maintenance
8.1 General
Maintenance work must be undertaken by properly trained service staff (3.3 Target
audience).

DANGER!
Danger arising from service work!
If you undertake service work without having received the necessary training, sys-
tem safety is no longer guaranteed The outcome could be serious physical injury
or fatality.
Observe all safety instructions and leave maintenance to trained staff.

8.1.1 DOPAG-Customer Services

Note the customer service center responsible for your area (14 DOPAG Customer
Service). For current addresses, go to www.dopag.com.

8.1.2 DOPAG-Spare parts

DOPAG spare parts can be found in the spare parts list (11 Spare parts lists). Parts
subject to wear that should be held in store are marked **. For further information,
see the spare parts drawing.

DANGER!
It is dangerous to use incorrect spare parts!
Using spare parts that have not been tested and approved by DOPAG means that
system safety is not guaranteed The outcome could be serious physical injury or
fatality.
Use only DOPAG spare parts.

In order that DOPAG Customer Service can deal with your order, please give the fol-
lowing order details:

Order details required if available

Job number x
Description x
Characteristics x
Order number x
Serial number x
Drawing number of spare part x
Spare part number x
Item number x
Number of items x

PU200-N001/407-001 8/49
 Maintenance

Storing the key spare parts and parts subject to wear at the setup site is an im-
portant prerequisite for ongoing operation and service-readiness of the sys-
tem or of the module supplied.

8.1.3 Operating material and Lubricants

DOPAG recommends the following operating materials and lubricants:

Oils for pneumatics and

hydraulics Manufacturer Oils for pneumatics Oils for hydraulics
Temperature range 0 – 30°C Temperature range 0 – 30°C
Viscosity 4-5E / 50°C ISO-VG46
BP Energol HLP-HM 22
ESSO Nuto H 22 Nuto H 46
MOBIL DTE 15M
SHELL Tellus 22 Tellus 46
TEXACO Rando HD 32 Rando HD 46

Sealing fluid For filling the seal chambers, DOPAG recommends Mesamoll® sealing liquid
(13 Technical specification sheets).

Greases DOPAG recommends commercially available Vaseline. Use the grease gun sup-
plied for greasing the grease fittings.

8.1.4 Adjustable Seals

During the first week of operation adjustable seals must be regularly tightened until
they are correctly run-in Finally the seals must be adjusted weekly. A few drops of
oil or sealing liquid added the seal chamber will prolong its service life. Seal leakage
can be greatly reduced by tightening the adjusting nuts, however, it cannot be re-
duced entirely. If after adjustment the leakage is still excessive, the seal must be re-
placed.

1 Piston rod
2 Adjusting nut
3 Seal packing
4 1 7
Seal holder 1
5 Pressure ring 8 8
8
6 V-Sleeve 2 2
2
7 Shaft 5
8 Hole for withdrawal 3 5
3
6
4
4

Fig. 8-1 Adjustable seals

50/8 PU200-N001/407-001
Maintenance

Adjustment  The seal must be tightened with the adjusting nuts.

 Use an appropriate tool (e.g. a punch) in the hole to withdraw.
 For the larger seals (e.g. the metering pumps) use two tools in order to apply
more force.

1 Punch
2 Special tool

Fig. 8-2 Tools

A certain un-tightness is allowable by design without the need to change the
seals Leakage past the seal occurs, adjusting will not achieve100% tightness.
Exercise care as over adjustment can adversely affect functional operation

PU200-N001/407-001 8/51
 Maintenance

8.2 Maintenance of the components

8.2.1 Maintenance plan

To ensure a trouble-free operation, the following service intervals are required for
various components:
DOPAG recommends an annual maintenance by an in-house specialist. Indi-
vidual training for your staff is of fered. Further details can be obtained from
DOPAG Customer Service (14 DOPAG Customer Service).

Maintenance task Interval

Visual check daily
Cleaning daily
Lamp function test (option) daily
Transfer pump daily/weekly
Outlet valve (option) weekly
Air prepare maintenance unit weekly
Material pressure reducing valve (option) monthly
Lines weekly
Material filter (option) weekly
Pneumatic cylinder monthly

8.2.2 Visual check

The following points should be checked:

• Are all safety systems available and fully functional?
• Are all system operating instructions available?
• Are all safety and danger warning information as well as signs available and
clearly legible?
• Are all the connecting couplings tight?
• Is the main switch (Mains isolation device) freely accessible?
• Does the system shut down immediately when the main switch is thrown?
• Are cable connections secure and undamaged?
• Is the control cabinet locked and the key secured against unauthorized use?

52/8 PU200-N001/407-001
Maintenance

8.2.3 Cleaning

The system should be cleaned daily and immediately if it is contaminated with ma-
terial. A dried material is very difficult to remove and requires a great effort. Observe
the safety information for cleaning (4.6 Flushing and cleaning the system).

Switching off:  Switch off the system. Procedure according to the instructions in chapter Switch-
ing off (7.4 Switching off).

Pressure release:  Open pressure release valve.

• Material flows until pressure equalizes.
 Close pressure release valves.

Cleaning the system:  Close compressed air main valve.

 Rub system down with cloth.

NOTICE!
Under no circumstances should the system be sprayed with water. Determine
which cleaning agent to use from the material used, and clean the system as
environmentally friendly and with as much care as possible.

8.2.4 Lamp Function Test

The lamp function test provides information about the state of the indicator lights and
the acoustic horn. Faulty lights must be replaced.

Procedure:  Hold down button for 5 seconds.

• All functioning indicator lights light up briefly.
• Horn sounds.
 Change faulty lights.

8.2.5 Metering/delivery pump

The metering/delivery pumps are fitted with an adjustable seal. During the first week
of operation, the seals must be re-adjusted by re-tightening the adjustment nut. Af-
terwards, the seal must be adjusted weekly. A few drops of oil or sealing liquid added
to the seal chamber will prolong the seal's service life. Seal leakage can be greatly
reduced by tightening the adjusting nut, however, it cannot be removed entirely. If
after adjustment the seal is still leaking excessively, the seal must be replaced.
For detailed information (13 Technical specification sheets).

8.2.6 Outlet valve

Discharge valves can come equipped with an adjustable seal. The adjustment nut
must be tightened. A few drops of oil can prolong the service life of the seal.
For detailed information (13 Technical specification sheets).

PU200-N001/407-001 8/53
 Maintenance

8.2.7 Compressed air preparation unit

The quality of the compressed air, which drives the system, depends on the prepa-
ration.

1 Main valve for com-

3 2
pressed air
2 Pressure control for 5
operating pressure
3 Pressure gauge for
operating pressure 1
4 Connection for oil fill-
ing
5 Vacuum valve for oil
filling 6
6 Connection to com-
4
pressed air supply
7
7 Valve for water drain- 8
age
Fig. 8-3 Compressed air preparation unit
8 Silica gel air dehumid-
ifier (Optional)

Drain water: The filter must be drained frequently. If there is too much water in the water separa-
tor it can adversely affect the equipment and its function.
 Open compressed air main valve.
 Press water drainage valve
• Water drains out.
 When all water has drained out release valve
• The valve closes automatically.

Clean air filter and water The air filter and water separator are to be inspected weekly for contamination and
separator. cleaned when necessary.
 Close compressed air main valve.
 Release pressure

NOTICE!
Clean air filter and filter holder with water only! Using chemicals could de-
stroy the transparent filter holder.

 Loosed screws and remove water separator downwards.

 Clean water separator and filter with water.
 Inspect seal and replace if necessary.
 Replace filter from below and tighten screws.
 Open compressed air main valve.

Refill oil: The oil level in the lubricator must be inspected. When necessary refill oil. A contain-
er with pneumatic oil and a length of tube is required.

54/8 PU200-N001/407-001
Maintenance

 Open compressed air main valve.

 Place one end of the hose on the connector for oil filling
 Place the other end of the hose in the container with the pneumatic oil.
 Keep vacuum valve for oil refilling process pressed.
• Air escapes and a vacuum occurs in the oil container.
• Pneumatic oil is drawn into the oil container.
 When the oil container is full, release vacuum valve for oil refilling.
 Remove container with pneumatic oil and hose.

NOTICE!
If the lubricator needs to be cleaned never use a solvent. The lubricator must
only be cleaned with water.

8.2.8 Silica gel air dehumidifier (Option)

The Silica gel air dehumidifier removes moisture from the flowing compressed air.
The dehumidifier prevents too moist compressed air being fed into the material con-
tainer. The silica gel can be reactivated by drying. Silica gel when saturated with
moisture changes colour. This is visible from the outside by looking into the viewing
glass.

1 Air dehumidifier
2 Viewing glass
1

Fig. 8-4 Silica gel air dehumidifier

 For reactivation, heat the silica gel for approx. 5 hours with hot, dry air at 120 °C
maximum.
 After cooling in dry air, the silica gel can be reused.
The frequency with which the silica gel must be reactivated depends on the
quality of the compressed air and on the throughput. This interval must be
specified by the user according to his own requirements, conditions and ob-
servations.

PU200-N001/407-001 8/55
 Maintenance

8.2.9 Material pressure regulator (optional)

If the material pressure reducing valve is equipped with a filter screen, it must be
checked and cleaned regularly. The regularity depends greatly on the cleanliness of
the material used.
The spare parts obtainable for the module can be seen in the service literature. If
you have any questions, please contact DOPAG Customer Service.
For detailed information (13 Technical specification sheets).

8.2.10 Leads

The leads and connections must be checked for damage. When a leak occurs de-
termine whether or not a component is defective or a connection must be re-sealed.
Replace defective parts immediately!

Check leads:  Switch off system at the main switch.

• The system is isolated.
 Close compressed air main valve.
 Remove compressed air connection on all material pressure vessels.
• The air in the material pressure vessels escapes.
 Begin visual inspection.
If the leads and connections are split, crushed or there is other damage they
must be replaced. After replacement the system must be depressurized.

8.2.11 Material filter

The material filter must be regularly maintained. Filter elements or filter core can be
removed and cleaned.
For detailed information (13 Technical specification sheets).

NOTICE!
Dirty material filters cause faulty operation of system. Check the filters regu-
larly. Depending on the material, the filter must be cleaned more often.

56/8 PU200-N001/407-001
Maintenance

8.2.12 Pneumatic cylinder

The pneumatic cylinder must be lubricated.. Grease nipples are fitted to the upper
and lower flange.
 Apply grease through the grease nipple with a single action of the grease gun.

1 Grease nipple

Fig. 8-5 Pneumatic cylinder

The grease gun is supplied with the system

PU200-N001/407-001 8/57
 Maintenance

Notes

58/8 PU200-N001/407-001
Disposal

9 Disposal
9.1 Disposing of the system

9.1.1 Principle

Exercise caution when handling raw materials present in this system. Check the re-
usability value of materials and system parts prior to disposing of them. Recycle as
much as possible.
Careless or incorrect disposal can result in unforeseen consequences. Be con-
cerned about yourself and us, our future generations, nature, the environment and
the economy. Materials and system parts should be disposed of in a manner that is
proven to be un-detrimental to humans, nature and the environment. Note the de-
tails provided by the manufacturer and legislation and regulations.

9.1.2 Materials, packaging and system parts

Dispose of elements and system parts separately according to type of material:

• Aluminium from scrap steel
• Copper and non-ferrous heavy metal in electrical parts and conductors
• Batteries
• Plastics
• Organic substances, such as timber
Recycle as much as possible.

9.2 Final system decommissioning

If the system decommissioning is final, first of all empty the parts that conduct ma-
terials. Those parts that conduct material in the system include the material contain-
er, supply pumps, metering pumps, hoses/tubes, the mixing block, volumetric flow
meters.
If the system is equipped with a heating system, the system must first of all be
warmed up. The system can only be emptied if the material is sufficiently fluid.

Emptying the system:  Switch on heating system and heat up material (if present).
 Draw off residual material in container.
 Switch off heating system (if present).

WARNING!
Danger of burning!
System components are heated. Touching these parts when hot can result in seri-
ous burns.
Only touch heated components when cool.

Flushing the system:  Fill material container with a suitable flushing agent (4.6 Flushing and cleaning
the system).

PU200-N001/407-001 9/59
 Disposal

NOTICE!
Dispose of the material residues correctly and in accordance with local reg-
ulations.

Isolating the system from  Isolate system from compressed air supply.
the mains.  Carefully discharge residual air pressure from all parts, from material container
by detaching air pressure connections, from lines by opening de-aeration
valves, from discharge valve or by careful release of line connections.
 If present, empty hydraulic lines, hydraulic tank and hydraulic cylinder.
 Make sure that no part is under pressure.
 Isolate system from power supply.
 Remove any batteries and rechargeable batteries fitted (auxiliary functions).
 Make sure no electrical connection whatsoever is present, and no voltage po-
tential is present at any point.
The system is now fully decommissioned and can be dismantled.

Dismantling parts:  Dismantle the system from top to bottom and by subassembly.
 If you are able to reuse individual components in other system, clean them care-
fully and check them for wear and defects. Have these parts overhauled by
DOPAG.
 Pack the reusable components before storing them.
Dismantle non-reusable components and separate them according to materi-
als. Dispose of the parts professionally and correctly.

60/9 PU200-N001/407-001
Certificates

10 Certificates
This chapter contains acceptance reports, declarations of conformity and cer-
tificates.

PU200-N001/407-001 10/61
 Certificates

Notes

62/10 PU200-N001/407-001
Certificates

10.1 EC Declaration of Conformity (as per directive 2006/42/EC)

We, the machine manufacturers, declare that the following machine is of conformity
with the directives and standards listed below.

Manufacturer: DOPAG Dosiertechnik und Pneumatik AG

Langackerstrasse 25
CH-6330 Cham

Authorized person for the DOPAG Dosiertechnik und Pneumatik AG, Heinz Gaisser
compilation of the techni- Langackerstrasse 25
cal documentation: CH-6330 Cham

Type description: P200 Standard

Serial number: 1XXXX

Year of construction: 01/2010

Directives:
Description Date
2006/42/EC 09.06.2006
2004/108/EC 15.12.2004
2006/95/EC 12.12.2006
97/23/EC 29.05.1997
2002/95/EC 27.01.2003

Standards:
Description Date
EN ISO 12100-1 11/2003
EN ISO 12100-2 11/2003
EN 60204-1 11/2006
EN ISO 14121-1 09/2007
DIN EN 983 06/2009

Place and date: Cham, 1/10

Technical Director: Heinz Gaisser

PU200-N001/407-001 10/63
 Certificates

Notes

64/10 PU200-N001/407-001
Spare parts lists

11 Spare parts lists

This chapter contains spare parts lists.

PU200-N001/407-001 11/65
 Spare parts lists

Notes

66/11 PU200-N001/407-001
Connection diagram

12 Connection diagram
This chapter contains diagrams for pneumatics, hydraulics and electrical con-
nections.

PU200-N001/407-001 12/67
 Connection diagram

Notes

68/12 PU200-N001/407-001
Technical specification sheets

13 Technical specification sheets

This chapter contains all documents related to parts of individual components
and t hird-party su ppliers. Complet e t hese do cuments a long wit h at tached
safety data sheets on material used.

PU200-N001/407-001 13/69
 Technical specification sheets

Notes

70/13 PU200-N001/407-001
DOPAG Customer Service

14 DOPAG Customer Service

This chapter contains important addresses and telephone numbers. You can
obtain up-to-date details by going to www.dopag.com.

PU200-N001/407-001 14/71
 DOPAG Customer Service

Notes

72/14 PU200-N001/407-001
DOPAG Customer Service

File label

Original Operating Instructions

Type: P200 Standard
Serial No.: 1XXXX

Original Operating Instructions

Type: P200 Standard
Serial No.: 1XXXX

PU200-N001/407-001 14/73