Carlisle Smart Pumps EV2-30 Owner's manual

Brand: Carlisle

Model: Smart Pumps EV2-30

Type: Owner's manual

Carlisle Smart Pumps EV2-30 are great for use with solvent and water-based materials in hazardous areas such as Zone 1, with a protection level of Ex h IIB T4 Gb X (pump), II 2 G Exd/Exde IIB T4 IP55 (motor), and II 2 GD ck T4 (gearbox). They have a nominal pump stroke of 50mm, a maximum fluid pressure of 20bar, and a nominal flow volume per cycle of 0.75 l/m. Fluid output at 20 Hz is 7.5 l/m, and at 80 Hz is 30 l/m.

READ ALL INSTRUCTIONS BEFORE OPERATING THIS PRODUCT

Service Manual

EV2-30

IMPORTANT! DO NOT DESTROY

It is the Customer's responsibility to have all operators and service personnel read and understand this

manual.

Contact your local Carlisle Fluid Technologies representative for additional copies of this manual.

• 104226 - EU Model

• 104222 - Japan Model

77-3319 R1.4 (11/2021) www.carlisleft.com

This Declaration of conformity / incorporation is issued

under the sole responsibility of the manufacturer:

Carlisle Fluid Technologies UK Ltd,

Ringwood Road,

Bournemouth, BH11 9LH. UK

Representative authorised to compile the technical file

Sales and Marketing Director. CFT UK Ltd

1 Avenue de Lattre de Tassigny

94736 Nogent, Cedex. France

Signed for and on behalf of Carlisle Fluid

Technologies UK Ltd:

R. Peterson

Vice President: Engineering and

Operations, Scottsdale, AZ, 85254.

USA

5/5/21

Notified body details and role:

Electric Pump E2-7, E2-15 XXX, E2-20, E2-30, E2-40, E2-60, EV2-

15, EV2-30, E4-60, E4-100

This Product is designed for use with:

Solvent and Water based materials

Suitable for use in hazardous area:

Zone 1

Protection Level:

Ex h IIB T4 Gb X (Pump)

II 2 G Exd/Exde IIB T4 IP55 (Motor) CE0722

II 2 GD ck T4 (Gearbox)

Product Description / Object of Declaration:

This Declaration of conformity / incorporation is issued under the sole responsibility of the

manufacturer:

Machinery Directive 2006/42/EC

ATEX Directive 2014/34/EU

EMC Directive 2014/30/EU

by complying with the following statutory documents and harmonized standards:

EN ISO 12100:2010 Safety of Machinery - General Principles for Design

EN 12621:+A1:2010 Machinery for the supply and circulation of coating materials under pressure - Safety

requirements

EN 1127-1:2019 Explosive atmospheres - Explosion prevention - Basic concepts

EN ISO 80079-36:2016 Explosive Atmospheres- Part 36: Non Electrical equipment for explosive atmospheres-

Basic methods and requirements.

EN ISO 80079-37:2016 Explosive Atmospheres- Part 37: Non Electrical equipment for explosive atmospheres -

protection by methods "c", "b" and "k".

EN 60079-0:+A11:2013 Explosive atmospheres - Equipment. General requirements

EN 60079-1:2014 Explosive atmospheres - Equipment protection by flameproof enclosures "d"

EN 60079-7:2015 Explosive atmospheres. Equipment protection by increased safety "e"

EN 60034-1: 2010 Rotating electrical machines

EU Declaration of Conformity

Element Materials Technology (0891)

Lodging of Technical file

Providing all conditions of safe use / installation stated within the product manuals have been complied with and

also installed in accordance with any applicable local codes of practice.

77-3319 R1.4 2 www.carlisleft.com

Providing all conditions of safe use/installation stated within the product manuals have been complied with and

also installed in accordance with any applicable local codes of practice.

R. Peterson

5/5/21

This Declaration of conformity/incorporation

is issued under the sole responsibility of the

manufacturer:

Carlisle Fluid Technologies UK Ltd,

Ringwood Road,

Bournemouth, BH11 9LH. UK

Vice President: Engineering and

Operations, Scottsdale, AZ, 85254. USA

UKCA Declaration of Conformity

This Declaration of conformity/incorporation is issued under the sole responsibility of the

manufacturer:

Supply of Machinery (Safety) Regulations 2008

Equipment and Protective Systems Intended for use in Potentially Explosive Atmospheres Regulations 2016

Electromagnetic Compatibility Regulations 2016

by complying with the following statutory documents and harmonised standards:

BS EN ISO 12100:2010 Safety of Machinery - General Principles for Design

BS EN 12621:+A1:2010 Machinery for the supply and circulation of coating materials under pressure - Safety

requirements

BS EN 1127-1:2019 Explosive atmospheres - Explosion prevention - Basic concepts

BS EN ISO 80079-36:2016 Explosive Atmospheres- Part 36: Non Electrical equipment for explosive atmospheres-

Basic methods and requirements.

BS EN ISO 80079-37:2016 Explosive Atmospheres- Part 37: Non Electrical equipment for explosive atmospheres -

protection by methods "c", "b" and "k".

BS EN 60079-0:+A11:2013 Explosive atmospheres - Equipment. General requirements

BS EN 60079-1:2014 Explosive atmospheres - Equipment protection by flameproof enclosures "d"

BS EN 60079-7:2015 Explosive atmospheres. Equipment protection by increased safety "e"

BS EN 60034-1: 2010 Rotating electrical machines

Signed for and on behalf of

Carlisle Fluid Technologies UK

Ltd:

Product Description / Object of Declaration:

Electric Pumps E2-7, E2-15 XXX, E2-20, E2-30, E2-40, E2-

60, EV2-15, EV2-30, E4-60, E4-100

This Product is designed for use with:

Solvent and Water based materials

Suitable for use in hazardous area:

Protection Level:

Ex h IIB T4 Gb X (Pump)

II 2 G Exd/Exde IIB T4 IP55 (Motor) CE0722

II 2 GD ck T4 (Gearbox)

Notified body details and role:

Element Materials Technology (0891)

Lodging of Technical file

Zone 1

77-3319 R1.4 3 www.carlisleft.com

AUTOMATIC EQUIPMENT. Automatic

equipment may start suddenly without

warning.

WEAR SAFETY GLASSES. Failure to wear safety glasses with side

shields could result in serious eye injury or blindness.

PROJECTILE HAZARD. You may be

injured by venting liquids or gases that

are released under pressure, or flying

debris.

NOISE LEVELS. The A-weighted sound level of pumping and spray

equipment may exceed 85 dB(A) depending on equipment settings.

Actual noise levels are available on request. It is recommended that

ear protection is worn at all times while equipment is in use.

KNOW WHERE AND HOW TO SHUT

OFF THE EQUIPMENT IN CASE OF AN

EMERGENCY.

PACEMAKER WARNING. You are in the

presence of magnetic fields which may

interfere with the operation of certain

pacemakers.

HIGH PRESSURE CONSIDERATION. High pressure can cause serious

injury. Relieve all pressure before servicing. Spray from the gun,

hose leaks or ruptured components can inject fluid into your body

and cause extremely serious injury.

NEVER MODIFY THE EQUIPMENT. Do

not modify the equipment unless the

manufacturer provides written

approval.

PROP 65 WARNING. WARNING: This product contains chemicals

known to the state of California to cause cancer and birth defects or

other reproductive harm.

PINCH POINT HAZARD. Moving parts

can crush and cut. Pinch points are

any areas where ther are moving

parts.

Read the following warnings before using this equipment.

INSPECT THE EQUIPMENT DAILY. Inspect the equipment for worn or

broken parts on a daily basis. Do not operate the equipment if you

are uncertain about its condition.

OPERATOR TRAINING. All personnel

must be trained before operating

finishing equipment.

EQUIPMENT MISUSE HAZARD. Equipment misuse can cause the

equipment to rupture, malfunction or start unexpectedly and result in

serious injury.

KEEP EQUIPMENT GUARDS IN PLACE.

Do not operate the equipment if the

safety devices have been removed.

STATIC CHARGE. Fluid may develop a static charge that must be

dissipated through proper grounding of the equipment, objects to be

sprayed and alll other electrically conductive objects in the dispensing

area. Improper grounding or sparks can cause a hazardous condition

and result in fire, explosion or electric shock and other serious injury.

DE-ENERGIZE, DE-PRESSURISE, DISCONNECT AND LOCK OUT ALL

POWER SOURCES DURING MAINTENANCE. Failure to de-energize,

disconnect and lock out all power supplies before performing

equipment maintenance could cause serious injury or death.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE

OPERATOR OF THE EQUIPMENT.

In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as

follows:

WARNING

CAUTION

NOTE

Hazards or unsafe practices which could result in

severe personal injury, death or substantial property

damage.

Hazards or unsafe practices which could result in

minor personal injury, product or property

damage

Important installation, operation or maintenance

information.

WARNING

READ THE MANUAL. Before operating finishing equipment, read and

understand all safety, operation and maintenance information

provided in the operation manual.

PRESSURE RELIEF PROCEDURE.

Always follow the pressure relief

procedure in the equipment instruction

manual.

77-3319 R1.4 4 www.carlisleft.com

'B'

Synthetic 220 (typically Agip Blasia S)

400V 3PH 1.5 Kw @ 50HZ

Fluid inlet connection:

0.75 l/m [0.20 US gal/m]

SPECIFICATION

Nominal pump stroke:

50mm [1.97 ins]

20bar [290psi]

NOTE

Gearbox Ratio:

58.25:1

EV2-30 Maximum fluid pressure:

EV2-30 Nominal flow volume / cycle:

2 bar [29 psi]

Reduce Maximum working pressure by 2 bar [29 psi] when using in Open Loop Flow Mode

e.g. EV2-30 Maximum Set Pressure of 18 bar to operate Pump on a 24/7 basis

30 l/m [8.0 US gal/m]

Fluid outlet connection:

'A'

4Pole 1390 RPM @50Hz

Gearbox Oil (EU Model)

Max. Inlet Pressure

Fluid Output @ 80 HZ [40 cycles/min]

AC Induction Electric Motor- EU Model

Total Weight of Pump (inc electric motor)

256 kg [564 lbs]

1½'' Sanitary

Fluid Output @ 20 HZ [10 cycles/min]

7.5 l/m [2.0 US gal/m]

Pressure when used in 'Smart Mode' (Closed Loop Pressure Mode)

Rated 20 to 80 Hz (c/w thermisters)

77-3319 R1.4 5 www.carlisleft.com

DIMENSIONS AND MOUNTING DETAILS

the Pump Frame must be wired to a suitable earth

ground to ensure that there is no possibility of static

build up.

Head screw for pump earth grounding;

SECTION A-A

M6 HEX.

77-3319 R1.4 6 www.carlisleft.com

•

Ensure the gearbox is filled with oil. (The gearbox is filled with the correct amount of oil at the factory)

If the gearbox has been in long term storage, it is particularly important to check it is filled with the

correct oil to the correct level. Depending on length of storage, it may be necessary to change the oil

before use. Some gearbox variants use a special oil dip-stick delivered loose with the gearbox for

checking oil level.

INSTALLATION

•

Fit over temperature warning sticker delivered loose with gearbox in location specified in gearbox

operating and assembly instructions.

•

Check that the rubber pin in the vent plug on top of Gearbox has been removed to allow venting. For

locations of vent, oil fill and oil drain please see gearbox operation and assembly instructions.

It is recommended that the switch setting is set to 1 bar [14.5 psi] above the maximum required

pressure. The maximum pressure setting the Pressure Switch should be set to is 20 bar [305 psi].

The Pressure Switch is classified as simple apparatus and as such should be electrically connected as part

of an intrinsically safe electrical circuit. The Pressure Switch should be wired as a Normally Closed

contact (fail safe) and be hard wired to stop the motor on operation, to minimise response time.

•

Outlet - Ø32 - Ø38 I.D. [20 bar working pressure]

Ensure adequate air space around the Pump for maintenance and electric motor cooling requirements.

•

It is recommended that a Local Control Box is positioned in close proximity to the pump, as a convenient

local Start / Stop facility and Junction box.

Attach suitable flexible hoses to the inlet and outlet connections. e.g.,

Suction - Ø38 - Ø50 I.D. [-1 to 10 bar working pressure]

The main Pump Control Panel must be positioned within an Electrically Safe Area.

A Pressure switch (and/or Pressure relief valve) must be connected to the outlet manifold port and set to

stop the pump (or relieve the fluid pressure) in the event of the system overpressure e.g. blocked paint

filter, otherwise Pump warranty may be invalidated. This is necessary to protect the Pump mechanics

from overload. An adapter to mount a pressure switch and pressure sensor is available, see accessories.

If the unit is inactive for over nine months, the gearbox must be prepared to avoid internal corrosion and

early failure - see page Gearbox Long Term Storage towards the end of this manual.

•

The Pump Units are designed for location in Zone 1 Hazardous areas, ATEX Category 2.

Electrical connections must be in accordance with Local Regulations for installation in Hazardous Areas.

•

77-3319 R1.4 7 www.carlisleft.com

50 Hz

Rated Motor Voltage

Once operating temperature is reached, this device quickly changes the resistance;

INSTALLATION

Electric Motor

The motor must be wired to provide a clockwise direction of the cam, looking from the direction of the gearbox.

Electric Motors for hazardous areas are specially designed to comply with official regulations concerning the risk

of explosion.

If improperly used, badly connected, or altered no matter how minor, their reliability could be in doubt.

Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into

consideration.

Only trained personnel familiar with these standards should handle this type of apparatus.

3.73A

Rated Motor Speed

Value

80 Hz

0.73

79.3%

400 V

1390 RPM

1.5 kW

20 Hz

Rated Motor Power Factor

Rated Motor Efficiency

Rated Motor Frequency

Deceleration Ramp

Rated Motor Power

Rated Motor Current

Mininmum Hz Output

Acceleration Ramp

5 Seconds

0.1 Seconds

Inverter

Required Inverter Settings

Maximum Hz Output

it must be connected to a suitable releasing device mounted within the control panel and wired to stop the motor

if an over temperature occurs.

The motor is fitted with PTC temperature sensors (Thermistors).

77-3319 R1.4 8 www.carlisleft.com



SYSTEM OPERATION

Set the pump speed to the minimum frequency 20 Hz and start the pump to remove any air from the circuit.

Before starting:-

Inspect for any system leaks.

Set the pump cycle rate to achieve the required paint volume and then adjust the system back pressure regulator

to achieve the desired system fluid pressure.

Smart Mode:

The return line ‘back pressure’ regulator responds to the changes in system fluid flow demand, (due to variable

paint usage) by dynamically adjusting the paint flow rate returning to the system paint tank, thus maintaining the

set pressure.

Confirm gearbox oil level is correct within an oil temperature range of +20°C to +40°C. For oil level limits

and location of level plug see gearbox operating and assembly instructions.

Ensure all electrical and mechanical connections are correctly made.

All required interlocks are tested and operational.

Suitable material for pumping is available at the suction hose.

The outlet connection is not blocked or isolated by any valves.

77-3319 R1.4 9 www.carlisleft.com

177126

195490

PRV & EV2-30 MANIFOLD KIT

DESCRIPTION

QTY

REMARKS

PARTS LIST - Pump Assembly

PART NUMBER

ITEM

104218

195500

WASHER

TORQUE ARM

SPACER

177049

195488

EU Model

ATEX GEARBOX & MOTOR

ATEX GEARBOX

195542

177125

195514

195492

EV2-30 MECHANICAL ASSY

M20 WASHER

M8 x 25 HEX HEAD CAP SCREW

M20 x 45 HEX HEAD CAP SCREW

Japan Model

77-3319 R1.4 10 www.carlisleft.com

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

77-3319 R1.4 11 www.carlisleft.com

PART NUMBER

PARTS LIST - Mechanical Assembly

104217

TORQUE ARM PIN

104216

COVER C/W CAP FIXINGS

DESCRIPTION

QTY

REMARKS

195512

DRIVE UNIT

195489

ITEM

162726

32.92 x 3.53 O-RING

FLUID SECTION

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

77-3319 R1.4 12 www.carlisleft.com

Tighten bolts holding carriage ends once pump is fully assembled.

Ensure linear rods have been fully tightened and secured first!

Tighten on final assembly to give correct orientation for hose

connection to grease nipple.

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

77-3319 R1.4 13 www.carlisleft.com

PARTS LIST - Drive Unit

PART NUMBER

DESCRIPTION

QTY

192441

165552

BEARING CLAMP

177020

177006

M16 SPRING WASHER (ST ST)

165108

BEARING CAP

(CARBON STEEL)

165077



M8 x 30 GRUBSCREW - STST

M8 x 20 CAP HEAD SCREW (ST ST)

M16 EYE BOLT

Ø50 x Ø110 x 44.4 BALL BEARING

Ø45 x Ø110 x 36 ROLLER BEARING

192639

192616

ITEM

(STAINLESS STEEL)

DVX-364

192400

SPRING RETAINING WASHER

0114-014179

165978



192640

192617

165660

M14 x 40 CAP HEAD SCREW (ST ST)

M10 SPRING WASHER (ST ST)

M8 MUD GUARD WASHER

165663

165592

165100

M8 x 16 GRUB SCREW

M5 x 12 SOCKET HEAD CAP SCREW

S.S.

M8 LOCKNUT ST ST

M6 x 20 CAP HEAD SCREW (ST ST)

M10 x 20 CAP HEAD SCREW

M14 SPRING WASHER

M6 SPRING WASHER (ST ST)

165087

REMARKS

163161

163952

164471

M8 SPRING WASHER (ST ST)

M8 x 20 CAP HEAD SCREW

M16 x 50 CAP HEAD SCREW

77-3319 R1.4 14 www.carlisleft.com

BRACE

DRIVE PLATE - MACHINED

195501

BASE PLATE

PARTS LIST - Drive Unit

TOP PLATE

195493

KEY

CARRIAGE SPRING ROD

195494

CARRIAGE SPRING

195497

195496

LEFT HAND LEG

GREASE NIPPLE

194820

195503

M45 BEARING LOCKNUT

195499

192661

192662

CLAMP ASSY

1/8'' / 6mm PUSH IN ELBOW

SPRING KEEP ASSEMBLY

193105

195491

192651

ITEM

PART NUMBER

DESCRIPTION

QTY

REMARKS

192643

1/4 / 10mm ELBOW

LEAK DETECTION HOSE

LINEAR BEARING ROD

RIGHT HAND LEG

192644

192655

192653

Ø6 GREASE HOSE



Ø100 x Ø2.5 O-RING

1/8'' PLUG

Ø12 x 30 DOWEL PIN



192645





GREASE NIPPLE

192650

195486

192668

193102

193104



194540

SPACER

192752

Ø58 x Ø80 x 8 SEAL

CAM SHAFT ASSY

77-3319 R1.4 15 www.carlisleft.com

165553

195511

165959

CARRIAGE ASSEMBLY

165552

PARTS LIST - Carriage Assembly

165108





192642

PARTS LIST - Drive Unit

MIDDLE CARRIAGE MACHINED

M6 WASHER (BRASS)

192652

192649

192641

192618

LH CARRIAGE END

RH CARRIAGE END

Ø72 x Ø30 x 29 CAM FOLLOWER

1/8'' GREASE NIPPLE - SLIP ON

192615

ITEM

PART NUMBER

DESCRIPTION

QTY

REMARKS



M16 NYLOC NUT (PLATED)

M8 SPRING WASHER (ST ST)

M8 x 20 SOCKET HEAD CAP SCREW

M8 x 25 SOCKET HEAD CAP SCREW

163152

192607

192609

192608

LINEAR BEARING

ITEM

PART NUMBER

DESCRIPTION

CAM FOLLOWER PIN

QTY

REMARKS

Ø47 x 1.75 INTERNAL CIRCLIP



192612

192611

192610



195507

SIDE PLATE MACHINED

FOLLOWER GUARD WASHER

FOLLOWER NUT WASHER

LINEAR BEARING SPACER

CARRIAGE ADAPTOR

M6 x 20 SET SCREW (BRASS)

165958

77-3319 R1.4 16 www.carlisleft.com

When fitting new bearings: Ensure seals have been

removed from inside of bearing to ensure a correct

grease supply path via centre spacer.

Bolts remain loose, tightened when

mechanical assembly is complete.

Orientate bearing so black section along the

body is aligned to the block's side.

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

77-3319 R1.4 17 www.carlisleft.com

165571

MIDDLE SHAFT

PARTS LIST - Shaft Assembly

REMARKS

192606

BASE SHAFT

195487

DRIVE SHAFT

ITEM

192604

QTY

PART NUMBER

DESCRIPTION

CONSTANT VELOCITY CAM

192600

M10 x 70 CAP HEAD SCREW

(PLATED)

Position first cam 180 degrees out

of phase with second cam.

KEY

(Reverse for assembly)

LOCTITE

TORQUE

MAINTENANCE ORDER

GREASE INTERNAL

(AGMD-010)

GREASE

77-3319 R1.4 18 www.carlisleft.com

1 2 3

Place CAM onto middle shaft (with 'TOP' engraving facing down towards the assembly tool).

PROCEDURE - Shaft Assembly

Place the base shaft on top of the CAM, align the holes and screw in the M10 x 70 cap head screws using

Loctite 243 and tighten to 65Nm.

Lift the assembly off of the assembly tool, rotate assembly and place back onto tool to complete

assembly.

Shaft Assembly

195486

Hold assembly tool (502512) in a vice (flats provided) and install middle shaft.

Assembly Tool

502512

Place the second CAM (with 'TOP' engraving facing up), ensure the CAM is 5 holes radially out of pitch

from the first CAM. (180 degrees offset), add drive shaft on top then align the holes and screw in the

M10 x 70 long cap head screws using Loctite 243 and tighten to 65Nm.

77-3319 R1.4 19 www.carlisleft.com



195845

192632



192620

INLET CYLINDER

192626







192647



OUTLET SPRING KEEP

192630

PISTON SEAL

OUTLET CYLINDER

192648

SHAFT/BELLOWS ASSY

192624

OUTLET BLOCK

192625

OUTLET CAP

PART NUMBER

QTY

REMARKS

PARTS LIST - Fluid Section

171788

165960

165108

195502

DESCRIPTION

165087

ITEM

192551



BALL CHECK SPRING

160539

194237

OUTLET CAGE

SEAT



192505

Ø41.0 x 1.78 O-RING

Ø100 PISTON ASSEMBLY



192679

M12 x 40 CAP HEAD SCREW (ST ST)

Ø1 3/8'' ST ST BALL

Ø12.42 x 1.78 O-RING

1/4'' BSP HEXAGON PLUG (ST ST)

Ø50.5 x 2.62 O-RING

163921

165957

165044

M6 x 25 CAP HEAD SCREW (ST ST)

M12 SPRING WASHER (ST ST)

M6 SPRING WASHER (ST ST)

M8 SPRING WASHER (ST ST)

M8 x 90 CAP HEAD SCREW (ST ST)

77-3319 R1.4 20 www.carlisleft.com

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Carlisle Smart Pumps EV2-30 Owner's manual

Carlisle Smart Pumps EV2-30 Owner's manual

Carlisle Smart Pumps EV2-30 Owner's manual

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