Operating instructions Diaphragm Metering Pump Makro TZ, TZMb

Transcription

1 Operating instructions Diaphragm Metering Pump Makro TZ, TZMb P_MA_0022_SW Please carefully read these operating instructions before use! Do not discard! The operator shall be liable for any damage caused by installation or operating errors! Technical changes reserved. Part no Original operating instructions (2006/42/EC) BA MA /14 EN

2 Supplemental instructions Supplementary information Fig. 1: Please read! Read the following supplementary information in its entirety! Should you already know this information, you will benefit more from referring to the operating instructions. The following are highlighted separately in the document: Enumerated lists Operating guidelines ð Outcome of the operating guidelines - see (reference) Information This provides important information relating to the correct operation of the unit or is intended to make your work easier. Safety notes Safety notes are identified by pictograms - see Safety Chapter. Validity These operating instructions conform to current EU regulations applicable at the time of publication. State the identity code and serial number Please state identity code and serial number, which you can find on the nameplate when you contact us or order spare parts. This enables the device type and material versions to be clearly identified. EX pumps only The nameplate stuck on the cover page is identical with the pump supplied so that a clear assignment is given between the operating instructions and the pump. 2

3 Table of contents Table of contents 1 Identity code Safety chapter Storage, transport and unpacking Overview of equipment, control elements Functional description Assembly Installation Installation, hydraulic Basic installation notes Installation, electrical Start up During Operation Maintenance Repairs Replacing the diaphragm Repair the diaphragm rupture sensor V version EX Version Valve repair Double ball valves Single ball valves Plate valves Troubleshooting Decommissioning and Disposal Decommissioning Disposal Technical data Performance data Precision Reproducibility Metering precision Viscosity Wetted materials Ambient conditions Temperatures Air humidity Housing degree of protection Stroke sensor (optional), intrinsically safe Diaphragm rupture sensor Motor data Filling volumes Gear oil Sound pressure level Supplement for modified versions Spare parts Spare parts Other material Gear oil Dimensional drawings Motor data sheet

4 Table of contents 18 Diagrams for adjusting the capacity EC Declaration of Conformity

5 Identity code 1 Identity code TZMb Makro TZ diaphragm metering pump Power end type H D A B Main power end Main power end, doubled Add-on power end Add-on power end doubled Type _ Performance data at maximum back pressure and type: refer to nameplate on the pump housing Dosing head material PC PP TT SS PVC Polypropylene PTFE + 25 % carbon Stainless steel Material of seals / diaphragm T PTFE Displacement body material 1 Multi-layer safety diaphragm with rupture signalling Dosing head design 0 no valve spring 1 With valve spring Hydraulic connector 0 Standard connection 1 Union nut and PVC insert 2 Union nut and PP insert 3 Union nut and PVDF insert 4 Union nut and SS insert Design 0 With ProMinent logo, no frame 2 Without ProMinent logo A B C D With ProMinent logo, with single frame With ProMinent logo, with double frame With ProMinent logo, with triple frame With ProMinent logo, with quadruple frame M Modified* * order-related design, refer to order paperwork for pump features Electric power supply _ Connection data - refer to nameplate on motor 4 No motor, with flange 56 C 7 No motor, with flange 120/80 5

6 Identity code TZMb Makro TZ diaphragm metering pump 8 No motor, with flange 160/90 9 No motor, with flange 200/90 Motor version 0 IP 55 (Standard) ISO class F 1 Exe design ATEX-T3 2 Exd version ATEX-T4 A ATEX design of power end Stroke sensor 0 no stroke sensor 1 Stroke sensor (Namur), intrinsically safe Stroke length adjustment 0 Stroke length adjustment, manual 1 Actuator 230 V 2 Actuator 115 V 3 Control drive 230 V 0-20 ma 4 Control drive 230 V 4-20 ma 5 Control drive 115 V 0-20 ma 6 Control drive 115 V 4-20 ma Applications 0 standard 6

7 Safety chapter 2 Safety chapter Identification of safety notes The following signal words are used in these operating instructions to denote different severities of danger: Signal word WARNING CAUTION Meaning Denotes a possibly dangerous situation. If this is disregarded, you are in a life-threatening situation and this can result in serious injuries. Denotes a possibly dangerous situation. If this is disregarded, it could result in slight or minor injuries or material damage. Warning signs denoting different types of danger The following warning signs are used in these operating instructions to denote different types of danger: Warning signs Type of danger Warning hand injuries. Warning high-voltage. Warning hot surface. Warning danger zone. Intended use Only use the pump to meter liquid feed chemicals. In potentially explosive atmospheres in zone 1, device category II 2G, explosion group II C, only operate the pump with the appropriate nameplate (and the respective EC Declaration of Conformity) for pumps for use in areas at risk of explosion in compliance with Directive 94/9/EC in accordance with the European guidelines. The explosion group, category and degree of protection specified on the label should correspond to or be better than the conditions given in the intended field of application. Only start up the pump after it has been correctly installed and commissioned in accordance with the technical data and specifications contained in the operating instructions. Observe the general restrictions with regard to viscosity limits, chemical resistance and density - see also ProMinent Resistance List (in the Product Catalogue or at All other uses or modifications are prohibited. Never operate pumps without the relevant nameplate (and the respective EC Declaration of Conformity) for pumps for use in atmospheres at risk from explosion in atmospheres potentially at risk from explosion. The pump is not intended for the metering of gaseous media or solids. The pump is not intended to meter explosive substances and mixtures. 7

8 Safety chapter Only SS and TT pump designs with carbon and diaphragm rupture indicator are approved to meter flammable liquids, and if the operator takes appropriate safety measures. The pump is not intended for unprotected outside use. The pump is only intended for industrial use. The pump should only be operated by trained and authorised personnel, see the following table. Observe the information contained in the operating instructions at the different phases of the device's service life. Only the following combinations of identity codes are permitted in areas at risk from explosion: Combinations Identity code specification values 1 Electric power supply L, P Motor version Electric power supply 0, 4, 7, 8, 9 Motor version A 3 Electric power supply V Motor version 2 Qualification of personnel Action Storage, transport, unpacking Assembly Planning hydraulic installation Hydraulic installation Installation, electrical Operation Maintenance, repair Decommissioning, disposal Troubleshooting Qualification Instructed person Technical personnel, service Qualified personnel who have a thorough knowledge of metering pumps. Technical personnel, service Electrical technician Instructed person Technical personnel, service Technical personnel, service Technical personnel, electrical technician, instructed person, service Explanation of the terms: Technical personnel A qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognise possible dangers based on his/her technical training, knowledge and experience, as well as knowledge of pertinent regulations. Note: A qualification of equal validity to a technical qualification can also be gained by several years employment in the relevant work area. Electrical technician 8

9 Safety chapter Electrical technicians are deemed to be people, who are able to complete work on electrical systems and recognise and avoid possible dangers independently based on their technical training and experience, as well as knowledge of pertinent standards and regulations. Electrical technicians should be specifically trained for the working environment in which they are employed and know the relevant standards and regulations. Electrical technicians must comply with the provisions of the applicable statutory directives on accident prevention. Instructed person An instructed person is deemed to be a person who has been instructed and, if required, trained in the tasks assigned to him/her and possible dangers that could result from improper behaviour, as well as having been instructed in the required protective equipment and protective measures. Service Customer Service department refers to service technicians, who have received proven training and have been authorised by ProMinent or Pro Maqua to work on the system. Safety notes Safety notes These operating instructions include notes and quotes from German guidelines relating to the system operator's scope of responsibility. This information does not discharge the operator from his responsibility as an operator and is intended only to remind him or make him aware of specific problem areas. This information does not lay claim to being complete, nor applicable to every country and every type of application, nor to being unconditionally up-to-date. Observe the European Operator Directive 99/92/EC (ATEX 137), implemented in Germany by the Industrial Health and Safety Regulation and the German Ordinance on Hazardous Substances, for the installation and operation of equipment in areas at risk from explosion. Observe the European standards EN , EN , EN , EN and EN and EN for inherently safe electrical circuits. (In Germany these standards are partly implemented by VDE 0165 and VDE 0118). Adhere to the respective national regulations outside of the EU. Ensure that installations in areas at risk from explosion are checked by a "recognisably trained" skilled operative. This applies specifically to intrinsically safe electrical circuits. The following information relates essentially to the unique characteristics in areas at risk from explosion but does not replace the standard operating instructions. Only clean plastic parts carefully with a damp cloth to avoid electrostatic charges and sparks. 9

10 Safety chapter Warning of dangerous or unknown feed chemical Should a dangerous or unknown feed chemical be used: It may escape from the hydraulic components when working on the pump. Take appropriate protective measures before working on the pump (e.g. safety glasses, safety gloves,...). Observe the safety data sheet for the feed chemical. Drain and flush the liquid end before working on the pump. Danger from hazardous substances! Possible consequence: Fatal or very serious injuries. Please ensure when handling hazardous substances that you have read the latest safety data sheets provided by the manufacture of the hazardous substance. The actions required are described in the safety data sheet. Check the safety data sheet regularly and replace, if necessary, as the hazard potential of a substance can be re-evaluated at any time based on new findings. The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date, as well as for producing an associated hazard assessment for the workstations affected. Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system. Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthorised persons. Depressurise the system before commencing any work on hydraulic parts. Warning of feed chemical spraying around An unsuitable feed chemical can damage the parts of the pump that come into contact with the chemical. Take into account the resistance of the wetted materials when selecting the feed chemical - see the ProMinent product catalogue or visit Danger of personnel injury and material damage The use of untested third party parts can result in personnel injuries and material damage. Only fit parts to metering pumps, which have been tested and recommended by ProMinent. 10

11 Safety chapter Danger from incorrectly operated or inadequately maintained pumps Danger can arise from a poorly accessible pump due to incorrect operation and poor maintenance. Ensure that the pump is accessible at all times. Adhere to the maintenance intervals. Information in the event of an emergency In the event of an electrical accident, disconnect the mains cable from the mains or press the emergency cut-off switch fitted on the side of the system! If feed chemical escapes, also depressurise the hydraulic system around the pump as necessary. Adhere to the safety data sheet for the feed chemical. Safety information relating to the operating instructions Prior to commissioning the system or system component, the system operator is obliged to obtain the latest safety data sheet from the supplier for the chemicals / resources to be used with the system. The operator should create the legal framework for safe operation of the system or system component, such as for example the preparation of operating instructions (operator duties), based on the information provided in the data sheets concerning health and safety, water and environmental protection and taking into consideration the actual operating environment on site. Safety equipment Protective equipment P_MA_0042_SW Fig. 2: Isolating protective equipment Makro TZ with add-on power end (shown here for piston version) 1 Terminal box cover, motor 2 Protective cowling above the motor fan 3 Flange cover, side 4 Protective cover (only diaphragm and piston versions) 11

12 Safety chapter Ite m Protective equipment May only be removed by*: 1 Terminal box cover, motor Electrical technician, service 2 Protective cowling above the motor fan Service 3 Flange cover, side Service 4 Protective cover (only diaphragm and piston versions) - Only with protective devices: their corresponding parts Technical personnel, service Technical personnel, service * Only if the mains cable remains disconnected (no mains voltage). Other safety equipment Attach the following safety note to pumps that contain parts made of electrically non-conductive plastic: Ensure that the label is always fitted and legible. WARNING Electrostatic charge may cause an explosion! Clean plastic parts very carefully using a damp cloth! Fig. 3 Sound pressure level Sound pressure level LpA < 70 db according to EN ISO at maximum stroke length, maximum stroke rate, maximum back pressure (water) 12

13 Storage, transport and unpacking 3 Storage, transport and unpacking Safety notes The transporting of pumps which have been used with radioactive feed chemicals is forbidden! They will also not be accepted by ProMinent! Only return metering pumps for repair in a cleaned state and with a flushed liquid end - refer to "Decommissioning! Only return metering pumps with a completed Decontamination Declaration form. The Decontamination Declaration constitutes an integral part of an inspection / repair order. A unit can only be inspected or repaired when a Declaration of Decontamination Form is submitted that has been completed correctly and in full by an authorised and qualified person on behalf of the pump operator. You can find the "Decontamination Declaration" form under or on the CD. Danger of environmental and material damage The unit can be damaged or oil may escape due to incorrect or improper storage or transportation! The unit should only be stored or transported in a well packaged state - preferably in its original packaging. Only transport the unit with the locking screw - not the bleed plug - fitted to the oil filling opening. The packaged unit should also only be stored or transported in accordance with the stipulated storage conditions. The packaged unit should be protected from moisture and the ingress of chemicals. Storage Personnel: Technical personnel 1. Plug the caps on the valves. 2. Check whether the seal screw is screwed into oil filler opening instead of the vent screw. 3. Preferably place the pump standing vertically on a pallet and secure against falling over. 4. Cover the pump with a tarpaulin cover - allowing rear ventilation. Store the pump in a dry, sealed place in the following ambient conditions. 13

14 Overview of equipment, control elements 4 Overview of equipment, control elements Power end, single head P_MA_0023_SW 4 Fig. 4: Side view (here TZMb H) A Drive C Liquid end 1 Vent screw 2 Stroke length adjustment wheel 3 Oil inspection window 4 Motor 5 Oil drainage screw C A 5 Power end, double head P_MA_0024_SW 4 C A 5 C Fig. 5: Side view (here TZMb D) A Drive C Liquid end 1 Vent screw 2 Stroke length adjustment wheel 3 Oil inspection window 4 Motor 5 Oil drainage screw 14

15 Overview of equipment, control elements Liquid end P_MA_0025_SW Fig. 6: View of the liquid end 1 Discharge valve 2 Dosing head 3 Diaphragm rupture sensor 4 Suction valve 5 Tube nozzle for leakage 6 Protective cover

16 Functional description 5 Functional description Pump The metering pump is an oscillating diaphragm pump, the stroke length of which can be adjusted. An electric motor drives the pump. Functional description of the diaphragm liquid end The metering diaphragm (2) hermetically shuts off the pump volume of the dosing head (3) from the outside. The suction valve (4) closes as soon as the metering diaphragm (2) is moved in to the dosing head (3) and the feed chemical flows through the discharge valve (1) out of the dosing head. The discharge valve (1) closes as soon as the metering diaphragm (2) is moved in the opposite direction due to the vacuum pressure in the dosing head and fresh feed chemical flows through the suction valve (4) into the dosing head. One cycle is thus completed Fig. 7: Cross-section through the liquid end 1 Discharge valve 2 Diaphragm 3 Dosing head 4 Suction valve 5 Diaphragm rupture signaller P_MA_0029_SW Diaphragm rupture warning system functional description The diaphragm rupture warning system monitors the leak-tightness of the multi-layer diaphragm. Together with the diaphragm rupture sensor and downstream analysis electronics, the multi-layer diaphragm forms the diaphragm rupture warning system. The multi-layer diaphragm has an expandable point (4) on its hole circle. If an outer layer of the multi-layer diaphragm breaks, feed chemical penetrates into it under pressure and inflates this expandable point (4). Consequently the pin (2) of the safety piston (1) presses against the diaphragm (3) of the diaphragm rupture sensor signaller so that a contact signal switches off the pump or triggers an alarm signal (customer installed!). Moreover, the multi-layer diaphragm prevents feed chemicals escaping in the event of diaphragm rupture. 16

17 Functional description P_MA_0030_SW Fig. 8: Diaphragm rupture sensor: Cross-section view and multi-layer diaphragm 1 Safety piston 2 Pin 3 Diaphragm rupture signaller 4 Expandable point 17

18 Assembly 6 Assembly Compare the dimensions on the dimension sheet and pump. Supporting floor h Danger of electric shock If water or other electrically conducting liquids penetrate into the drive housing, in any other manner than via the pump's suction connection, an electric shock may occur. Position the pump so that it cannot be flooded. P_MOZ_0016_SW Fig. 9 The pump can break through the supporting floor or slide off it The supporting floor must be horizontal, smooth and permanently load-bearing. Capacity too low Vibrations can disturb the valves of the liquid end. The supporting floor must not vibrate. Space requirement A Danger from incorrectly operated or inadequately maintained pumps Danger can arise from a poorly accessible pump due to incorrect operation and poor maintenance. A Ensure that the pump is accessible at all times. Adhere to the maintenance intervals. Fig. 10 P_MOZ_0018_SW Position the pump so that control elements such as the stroke length adjustment knob, the indicating dial A or the oil inspection window are accessible. In so doing, ensure there is enough space to carry out an oil change (vent screws, oil drain plugs, oil trough...). f Discharge valve 2 Dosing head 3 Suction valve f P_MOZ_0017_SW f 3 Ensure there is sufficient free space (f) around the dosing head as well as the suction and discharge valve so that maintenance and repair work can be carried out on these components. Fig

19 Assembly Liquid end alignment Capacity too low If the valves of the liquid end do not stand upright, they cannot close correctly. The discharge valve must be upright. Fastening Capacity too low Vibrations can disturb the valves of the liquid end. Secure the metering pump so that no vibrations can occur. m DN Take the dimensions (m) for the fastening holes from the appropriate dimensional drawings or data sheets. Fasten the pump base to the supporting floor using suitable screws. Fig. 12 Instruction m P_MOZ_0015_SW Screw the pump to a support surface with 4 sufficiently strong screws through the 4 holes in the frame. Nothing more need be fitted to the pump itself: the pump is filled with gear oil and completely assembled on a frame. 19

20 Installation 7 Installation 7.1 Installation, hydraulic EX pumps in areas at risk from explosion It is essential that metering pumps to be used in areas at risk from explosion are fitted with an appropriate safety relief valve on the outlet side of the metering pump (to protect it from excessive heating up from overloading and from impact sparks resulting from overloading triggered by the breakage of power end components). In the event of different temperature classes with the various components, the possible uses of the complete pump are based on the component with the lowest temperature class. Diaphragm pump with mechanically actuated diaphragm, e.g. MTMa.., TZMa.., Sigmas S1Ba..., S2BaHM..., S3Ba: no additional action is required, but in principle use the design with Ex"i" diaphragm rupture indicator. Ensure that installations in areas at risk from explosion are checked by a "recognisably qualified and skilled" operative. Please observe the relevant national regulations and guidelines during installation! Danger of fire with flammable feed chemicals Combustible media may only be transported using stainless steel dosing heads. In exceptional cases where this is not possible, PTFE with carbon can be used, whereby our TT_ versions are manufactured from this conducting plastic. Here, the operator is urged to take special care due to the low mechanical strength. Only designs of metering pump with Ex"i" diaphragm rupture indicators are permitted in principle to meter flammable media. The following applies to all metering pumps for the metering of combustible media: During filling and draining of the liquid end, an expert must ensure that feed chemical does not come into contact with oxygen. Warning of feed chemical reactions to water Feed chemicals that should not come into contact with water may react to residual water in the liquid end that may originate from works testing. Blow the liquid end dry with compressed air through the suction connector. Then flush the liquid end with a suitable medium through the suction connector. 20

21 Installation The following measures are an advantage when working with highly aggressive or hazardous feed chemicals: Install a bleed valve with recirculation in the storage tank. Install an additional shut-off valve on the discharge or suction ends. Warning of backflow A back pressure valve or a spring-loaded injection valve do not represent absolutely leak-tight closing elements. For this purpose use a shut-off valve, a solenoid valve or a vacuum breaker. Suction problems possible The valves may no longer close properly with feed chemicals with a particle size of greater than 0.3 mm. Install a suitable filter in the suction line. Warning against the discharge line bursting With a closed discharge line (e.g. due to a clogged discharge line or by closing a valve), the pressure that the metering pump generates can reach several times the permissible pressure of the system or the metering pump. This could lead to lines bursting, resulting in dangerous consequences with aggressive or toxic feed chemicals. Install a relief valve that limits the pressure of the pump to the maximum permissible operating pressure of the system. Warning against the discharge line bursting Hose lines with insufficient pressure rating may burst. Only use hose lines with the required pressure rating. Uncontrolled flow of feed chemical Feed chemicals can leak through a stopped metering pump if there is back pressure. Use an injection valve or a vacuum breaker. 21

22 Installation Uncontrolled flow of feed chemical Feed chemical can leak through the metering pump in an uncontrolled manner in the event of excessive priming pressure on the suction side of the metering pump. Do not exceed the maximum permissible priming pressure for the metering pump. Arrange the installation properly. Warning against lines coming loose Suction, discharge and relief lines installed incorrectly can come loose from the pump connection. Only use original hoses with the specified tube diameter and wall thickness. Only use clamp rings and hose nozzles that correspond to the respective hose diameter. Always connect the lines without mechanical tension. Only connect steel piping via a flexible piping section to a plastic valve body - see the following figure P_MOZ_0021_SW Fig. 13: Connect the steel piping to the plastic pump body as shown 1 Steel pipe 2 Flexible pipe section 3 Plastic valve body Warning of feed chemical spraying around PTFE seals, which have already been used / compressed, can no longer reliably seal a hydraulic connection. New, unused PTFE seals must always be used. Warning of backflow Liquid ends, foot valves, back pressure valves, relief valves or spring-loaded injection valves do not constitute absolutely leak-tight sealing elements. Use a shut-off valve, a solenoid valve or a vacuum breaker for this purpose. 22

23 Installation Danger due to incorrect use of the safety relief valve The safety relief valve can only protect the motor and the gear, only against illegal positive pressure that is monitored by the metering pump itself. It cannot protect the system against positive pressure. Protect the motor and gear of the system against positive pressure using other mechanisms. Protect the system against illegal positive pressure using other mechanisms. Precise metering is only possible when the back pressure is maintained above 1 bar at all times. If metering at atmospheric pressure, a back pressure valve should be used to create a back pressure of approx. 1.5 bar. Route the leakage liquid drainage line The leaked liquid is drained off via the flushing collar and a hose nozzle, without other parts of the liquid end coming into contact with the medium. 1. Connect a hose to the lower hose nozzle. 2. Route the hose into a collection vessel for the leakage liquid Basic installation notes Safety notes Danger resulting from rupturing hydraulic components Hydraulic components can rupture if the maximum permissible operating pressure is exceeded. Never allow the metering pump to run against a closed shut-off device. With metering pumps without integral relief valve: Install a relief valve in the discharge line. Hazardous feed chemicals can escape With hazardous feed chemicals: Hazardous feed chemical can leak out when using conventional bleeding procedures with metering pumps. Install a bleed line with a return into the storage tank. Shorten the return line so that it does not dip into the feed chemical in the storage tank. 23

24 Installation 1 2 P_MAZ_0001_SW Fig. 14: Standard installation 1 Main line 2 Storage tank Legend for hydraulic diagram Symbol Explanation Symbol Explanation Metering pump Foot valve with filter meshes Injection valve Multifunctional valve Level switch Manometer 7.2 Installation, electrical EX pumps in areas at risk from explosion Potential-free switches can be evaluated as simple electrical devices (EN or EN 50020). Only connect potential-free as well as non-isolating low voltage switch accessories, such as diaphragm rupture indicators, stroke frequency instruments etc., to an intrinsically safe power circuit in areas at risk from explosion. If several electrical components are connected together, test and confirm the technical safety of the entire connected system. This can either be in the form of a declaration of conformity from the supplier (ProMinent) for the entire unit or, with the supply of individual components, with the operator's explosion protection document. Only motor protection switches, mains switches and fuses permitted for use in areas at risk from explosion in line with the manufacturer's information may be used as electrical components in areas at risk from explosion. Note the enclosed documentation for the individual electrical components. 24

25 Installation Danger of electric shock Unprofessional installation may lead to electric shocks. Provide all shortened cable cores with cable end sleeves. Only technically trained personnel are authorised to undertake the electrical installation of the device. Danger of electric shock In the event of an electrical accident, it must be possible to quickly disconnect the pump, and any electrical ancillaries which may possibly be present, from the mains. Install an emergency cut-off switch in the mains supply line to the pump and any electrical ancillaries which may be present or Integrate the pump and electrical ancillaries which may be present in the emergency cut-off management of the system and inform personnel of the isolating option. Danger of electric shock This pump is equipped with a protective earth conductor, to reduce the risk arising from an electric shock. Connect the PE conductor to "earth" with a clean and permanent electrical connection. Danger of electric shock A mains voltage may exist inside the motor or electrical ancillaries. If the housing of the motor or electrical ancillaries has been damaged, you must disconnect it from the mains immediately. The pump must only be returned to service after an authorised repair. What requires electrical installation? Motor External fan (optional) Stroke control drive (optional) Stroke adjusting drive (optional) Stroke sensor (optional) Frequency converter (optional) 25

26 Installation Motor P_SI_0012_SW Fig. 15: Direction of rotation of motor EX pumps in areas at risk from explosion Protect drive motors with appropriate motor protection switches. Only use motor protection permitted for this kind of application with Ex"e" motors. (Protection against heating from overloading) Ensure that motors are only installed and inspected by a "recognisably trained" skilled operative in areas at risk from explosion. Observe the enclosed operating instructions for the Ex motor. The motor can be damaged Provide appropriate motor protection devices (e.g. motor protection switch with thermal overcurrent trip) to protect the motor against overloading. Fuses do not provide motor protection. The pump can be damaged The pump can be damaged if the motor drives the pump in the wrong direction. When connecting the motor, pay attention to the correct direction of rotation indicated by the arrow on the fan cover, as shown in Fig. 15. Install an electrical isolating device in the mains supply cable, e.g. a mains switch, to be able to switch off the pump independently of the entire installation (e.g. for repair). 1. Install a motor protection switch, as the motors have no fuse. 2. Install an emergency cut-off switch or include the motor in the emergency cut-off management plan for the system. 3. Use a suitable cable between the motor terminal box and power supply. Key motor data can be found on the nameplate. The terminal wiring diagram is located in the terminal box. 26

27 Installation Motor data sheets, special motors, special motor flanges, external fan, temperature monitoring For further information for the motor with identity code specification "S", refer to the motor data sheet in the Appendix. Motor data sheets can be requested for all other motors. For motors other than those with identity code specifications "S", "M" or "N": Pay special attention to the operating instructions for the motors. Special motors or special motor flanges are possible on request. External fan Provide a separate power supply for the external fan with motors with external fans (identity code specification "R" or "Z"). Variable speed motors with frequency converter Connect up the motor as per the wiring diagram for the controller, if it is controlled by an electronic control unit (such as direct current motors by a frequency converter). Stroke length actuators / control drives Connect the motors as per the enclosed wiring diagram or the wiring diagram on the inside of the housing. Only operate stroke length actuators / control drives when the pump is running! Otherwise they will be damaged. Warning of unnoticed diaphragm rupture Only above approximately 2 bar system back pressure is a signal generated upon a diaphragm rupture. Only rely on the diaphragm rupture sensor at back pressures greater than 2 bar. When using combustible media: Danger of fire with flammable feed chemicals The electric diaphragm rupture sensor must switch off the pump immediately after a diaphragm rupture. Connect the pump and the diaphragm rupture sensor to a control so that the pump is stopped immediately in the event of a diaphragm rupture. 27

28 Installation Overpressure sensor Warning of damage by overpressure Electrically connect the overpressure sensor to a suitable monitoring device. Stroke sensor (optional) Connect the stroke sensor to a suitable monitoring device according to the technical data provided with the monitoring device and that of the stroke sensor - see chapter "Technical data". Other units Install the other units in line with their documentation. 28

29 Start up 8 Start up Safety notes EX pumps in areas at risk from explosion An appropriately skilled operative should check whether the appropriate installation information from the "Installation " chapter has been implemented correctly. Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen. During filling and draining of the liquid end, an expert must ensure that feed chemical does not come into contact with oxygen. Possible environmental and material damage The screw plug in the oil filler neck is factory-fitted and, during operation, prevents any pressure equalisation between the power end housing and the surroundings. This ensure that oil can be pushed from the power end housing. Replace the screw plug on the oil filler neck by the air vent plug supplied. Retain the sealing plug for subsequent transport of the unit. Single head version only: Oil may escape The screw plug in the oil filler neck is factory-fitted and, during operation, prevents any pressure equalisation between the drive housing and the surroundings. This ensure that oil can be pushed from the drive housing. Ensure that the hole in the metal cap on the drive flange is always clear - see "Overview of equipment, control elements". Feed chemical could escape Check suction and discharge lines and liquid end with valves for leak-tightness and tighten if necessary. Check whether the necessary flushing pipes or bleed lines have been connected. Prior to commissioning, check that the power end motor and corresponding ancillary equipment is connected in compliance with the regulations. 29

30 Start up When using pumps with speed control, observe the instructions in the frequency converter operating instructions. Installing a vent screw Replace the sealing screw on the oil filler neck with the vent screw supplied - see chapter "Overview of equipment and control elements". Checking the oil level When the pump is idle, check whether the pump oil level slightly covers the lower oil inspection window. This indicates that the pump has not lost oil and consequently been damaged. Checking the direction of rotation When commissioning the unit, check whether the drive motor is rotating correctly - check this against the arrow on the motor housing or the diagram in the chapter entitled "Electrical Installation." Eliminating suction problems (only for single ball valves with PTFE ball seat) For suction problems occurring during start up: Exclude the possibility that there are foreign bodies in the valve. Place the valve on a stable surface. Using a hammer (1) and a brass bar (2), gently tap the PTFE ball seat above the valve ball - see figure below. Then with the valve in a damp condition allow it to prime. Fig. 16: Tapping the valve set disc Adjusting the stroke length The stroke length can only be adjusted when the machine is stationary, provided the liquid ends are depressurised. 30

31 Start up P_MA_0032_SW Fig. 17: Stroke length adjustment wheel with scale 10 mm = 100 % stroke length (10 rotations) 6.3 mm = 63 % stroke length (6 rotations and 3 long scale markings) Stroke length adjustment wheel markings: 1 rotation = 10 % 1 long scale marking = 1 % 1 short scale marking = 0.5 % The pump can now be handed over for operation. 31

32 During Operation 9 During Operation Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen. During filling and draining of the liquid end, an expert must ensure that feed chemical does not come into contact with oxygen. Personnel injury and material damage may occur During use all units, protective equipment, additional devices must be fitted, operational and tightly closed. Sparking caused by dry running If the bearings in the power end run dry, sparks can be formed. Check for oil leaks. When the pump is idle, the pump oil level must slightly cover the lower oil inspection window. Observe the instructions in the "Start up" chapter and the operating instructions for the other machine components. 32

33 Maintenance 10 Maintenance Safety notes EX pumps in areas at risk from explosion Ensure correct operation in general, particularly of the power end and bearing, by regular monitoring (for leaks, noises, temperatures, smell...). Do not allow the pump to become hot due to a lack of oil. Regularly check lubricated metering pumps for the existence of lubricant, for example by checking the liquid level, visual leak control etc. If oil is leaking, examine the leakage point immediately and eliminate the cause. Check the correct operation of the relief valve downstream of the pump. In premises at risk from explosion, the relief valve should prevent the gear from becoming overloaded and becoming hot. When cleaning plastic components, ensure that no electrostatic charges are generated by excessive friction. - see warning label. Replace wear parts, such as bearings, as soon as unacceptable wear is detected. (The nominal service life cannot be calculated with lubricated bearings). Use genuine spare parts for replacement. Only perform tests and repairs in compliance with DIN EN IEC and only permit "experienced personnel who have the requisite knowledge" to perform the work. These measures constitute the minimum protective measurements stipulated by ProMinent. It is the duty of the operator to eliminate any other dangers identified by appropriate measures. Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen. During filling and draining of the liquid end, an expert must ensure that feed chemical does not come into contact with oxygen. It is mandatory that you read the safety information and specifications in the "Storage, Transport and Unpacking" chapter prior to shipping the pump. Warning of dangerous or unknown feed chemical Should a dangerous or unknown feed chemical be used: It may escape from the hydraulic components when working on the pump. Take appropriate protective measures before working on the pump (e.g. safety glasses, safety gloves,...). Observe the safety data sheet for the feed chemical. Drain and flush the liquid end before working on the pump. 33

34 Maintenance Danger of an electric shock When working on the motor or electrical auxiliary equipment, there is a danger of an electric shock. Before working on the motor, take note of the safety instructions in its operating instructions! Should external fans, servomotors or other auxiliary equipment be installed, these should also be disconnected and checked that they are voltage free. Risk of fingers being crushed Under unfavourable conditions, the stroke axle or displacement body can cause crushing of the fingers. Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthorised persons. Risk of injury from the fan impeller The fan impeller beneath motor's fan cowling can cause severe injuries while it is turning. The pump must only be connected to the mains voltage with the fan cowling closed. Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system. Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthorised persons. Depressurise the system before commencing any work on hydraulic parts. Maintenance work Under heavy loading (e.g. continuous operation) shorter maintenance intervals are recommended than those given. Third party spare parts for the pumps may lead to problems when pumping. Use only original spare parts. Use the correct spare parts kits. In case of doubt, refer to the exploded views and ordering information in the appendix. 34

35 Maintenance Interval Maintenance work quarterly* Check the tightening torques for the dosing head screws (1) (30 Nm) and the drive flange screws (2) (25 Nm). Check that the discharge valve and suction valve are correctly seated. Check the correct seating and state of the metering lines at both discharge and suction ends. Check for firm seating of the diaphragm rupture sensor. Check the tightness of the entire liquid end - particularly around the leakage hole! Check the oil level. Single head versions only: Check that the hole in the metal cap on the drive flange is clear - see the figure in the "Safety Chapter". Check that the electrical connections are intact. Check whether the pump is transporting media correctly - run briefly at high power. Observe the maximum permissible operating pressure! Check, whether moisture can be detected at the tube nozzle (3); if so a diaphragm rupture has probably occurred. 1 (30 Nm) 2 (25 Nm) P_MA_0034_SW Fig. 18: Liquid end tightening torques 1 Dosing head screws 2 Drive flange screws 3 Tube nozzle 3 Interval After approx. 5,000 operating hours * After approx. 10,000 operating hours ** Maintenance work Change the gear oil. Replace the diaphragm - refer to the "Repair" chapter - "Changing the diaphragm". * Under normal loading (approx. 30 % of continuous operation) Under heavy loading (e.g. continuous operation): Shorter intervals. ** under normal loading. With very unfavourable metering parameters: Shorter intervals. Changing the gear oil Risk of burns due to hot gear oil The gear oil may become very hot when the pump is heavily loaded When draining oil, avoid contact with the oil running out. 35

36 Maintenance Gear oil Gear oil Supplied quantity Part no. Mobilgear 634 VG l Gear oil filling volumes Types All Volume, approx. 3.2 l Draining the gear oil: 1. Remove the vent screw (1). 2. Place an oil trough under the oil drain plug (2). Expected oil quantity - see filling volumes, above. 3. Unscrew the oil drain plug (2) from the power end housing. 4. Allow the gear oil to run out of the power end. 5. Screw in the oil drain plug (2) with a new seal. 1 3 Fig. 19: Oil change 1 Vent screw 2 Oil drainage screw 3 Oil inspection window Filling with gear oil: 1. Start the pump. P_MA_0037_SW 2. Slowly pour gear oil through the vent screw (1) opening until the upper oil inspection window (3) is nearly covered. 3. Allow the pump to run for a further minutes. 4. Replace the vent screw (1). 2 36

37 Repairs 11 Repairs Safety notes EX pumps in areas at risk from explosion Generally check the proper operation of the system, particularly of the power end and bearings, by regular monitoring (for leaks, noises, temperatures, smell... ). Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen. During filling and draining of the liquid end, an expert must ensure that feed chemical does not come into contact with oxygen. It is mandatory that you read the safety information and specifications in the "Storage, Transport and Unpacking" chapter prior to shipping the pump. Warning of dangerous or unknown feed chemical Should a dangerous or unknown feed chemical be used: It may escape from the hydraulic components when working on the pump. Take appropriate protective measures before working on the pump (e.g. safety glasses, safety gloves,...). Observe the safety data sheet for the feed chemical. Drain and flush the liquid end before working on the pump. Risk of fingers being crushed Under unfavourable conditions, the stroke axle or displacement body can cause crushing of the fingers. Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthorised persons. Risk of injury from the fan impeller The fan impeller beneath motor's fan cowling can cause severe injuries while it is turning. The pump must only be connected to the mains voltage with the fan cowling closed. 37

38 Repairs Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system. Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthorised persons. Depressurise the system before commencing any work on hydraulic parts Replacing the diaphragm 1. Flush the suction line, discharge lines and liquid end (activate flushing equipment or immerse suction lance in a suitable medium and pump for a while (consider the effect of the medium on your system first!)) or proceed, as described below. 2. Set the stroke length to 0 % stroke with the pump running. 3. Switch off the pump. 4. Secure the pump to prevent it being switched back on. 5. If the liquid end has not been flushed according to the above processes, then protect yourself against the feed chemical - protective clothing, safety glasses,.... After dismantling immediately place parts that have been wetting with the medium in a trough with a suitable medium for flushing, in dangerous media were used flush and rinse thoroughly. 6. Unscrew the hydraulic connectors on the discharge and suction side. 38

39 Repairs P_MA_0038_SW 5 Fig. 20: Cross-section through the liquid end 1 Dosing head 2 Diaphragm 3 Reinforce plate 4 Screw 5 Leakage hole 6 Slide rod 7 Threaded connection 8 Turret 9 Backplate 2 1 P_MA_0039_SW 3 4 Fig. 21: Cross-section through the diaphragm rupture warning system 1 Safety piston 2 Spring 3 Bushing 4 O-ring 5 Expandable point multi-layer diaphragm 8. Undo the safety screw and remove the protective cover (5) from the backplate (6). 9. Unscrew the diaphragm rupture signaller from the dosing head. 10. Unscrew the bushing (3) from the dosing head. 11. Take the safety piston (1) with the spring (2) out of the dosing head. 12. Undo the screws (4) on the reinforce plate. 13. Remove the dosing head (1) with the screws from the turret (8). 39

40 Repairs 14. Unscrew the diaphragm (2) from the slide rod (6) and detach. 15. Clean the sealing surfaces. 16. Smear the thread of the threaded connection of the diaphragm slide rod with a little screw locking paste. 17. Screw the new diaphragm (2) up to the stop on the slide rod (8). ð This must be done correctly to ensure the pump meters accurately. 18. Place the dosing head (1), the reinforce plate (3) and the backplate (9) onto the turret(8). 19. Position the screws 20. Push the safety piston (1) with the spring (2) into the channel of the dosing head. 21. Screw the bushing into the dosing head (O-ring (4)!) and tighten by hand. 22. Screw the diaphragm rupture signaller into the dosing head. Failure of the diaphragm rupture signalling. Ensure the safety piston (1) and its pin can move freely. 23. Start the pump and tighten the screws crosswise at a 100% stroke. Tightening torque 30 Nm 24. Position the protective cover (5) on the turret (8) and screw in the safety screws. Check the tightening torque of the screws after 24-hours' operation. With PP dosing heads, recheck the tightening torque again after three months Repair the diaphragm rupture sensor V version 30 V version Check diaphragm rupture sensor 40

41 Repairs When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head. 2. Check for electrical continuity: 3. Using a blunt insulating probe (Ø mm, no sharp edges), press into the channel of the diaphragm rupture sensor. ð Check that there is no electrical continuity 4. Release the pin again. ð Electrical continuity must be re-established. 5. Repeat the test several times. 6. If everything is working correctly, screw the diaphragm rupture sensor into the dosing head with a new seal (1). 7. If not, go to the next section. Replace separating diaphragm of the diaphragm rupture sensor Fig Disconnect the diaphragm rupture sensor from the power supply. 2. When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head. 3. Grasp the upper section (2) of the diaphragm rupture sensor. 4. Hold the body (5) in place with an open-ended spanner. 5. Unscrew the top of the diaphragm rupture sensor. 6. Clean the soiled parts. 7. Lay the new separating diaphragm (3) with the light side (PTFE) down into the upper section (2). 8. Lay the plate (4) with the uneven side down into the upper section (2). 9. Screw the body (5) into the upper section and screw tighten. 10. Check the diaphragm rupture sensor as described in Check diaphragm rupture sensor". 11. If the diaphragm rupture sensor does not operate clearly and reliably, then a new diaphragm rupture sensor must be used without fail EX Version EX Version Check diaphragm rupture sensor 41

42 Repairs a When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head. 2. Check that the monitor does not indicate a diaphragm rupture: 3. Using a blunt insulating probe (Ø mm, no sharp edges), press into the channel of the diaphragm rupture sensor. ð The monitor device must indicate a diaphragm rupture. 4. Release the pin again. ð The monitor device must no longer indicate a diaphragm rupture. 5. Repeat the test several times. 6. If everything is working correctly, screw the diaphragm rupture sensor into the dosing head with a new seal (1). 7. If not, go to the next section. Replace separating diaphragm of the diaphragm rupture sensor P_HY_0015_SW Fig Disconnect the diaphragm rupture sensor from the monitor device. 2. When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head. 3. Grasp the upper section (2) of the diaphragm rupture sensor. Do not manipulate the lacquer-protected nut. 4. Hold the body (5) in place with an open-ended spanner. 5. Unscrew the top of the diaphragm rupture sensor. 6. Clean the soiled parts. 7. Lay the new separating diaphragm (3) with the light side (PTFE) down into the upper section (2). 8. Place the disc (4) in the upper section (2). 9. Place the spring inside the body (5). 10. Move the body (5) close to the upper section (2). ð The spring (6) must sit correctly on the spring seat (3a). 11. Screw the body (5) into the upper section and screw tighten. 12. Connect the diaphragm rupture sensor back to the monitor device. 13. Check the diaphragm rupture sensor as described in Check diaphragm rupture sensor". 14. If the diaphragm rupture sensor does not operate clearly and reliably, then a new diaphragm rupture sensor must be used without fail. 42

43 Repairs 11.3 Valve repair Unsuitable spare parts for the valves may lead to problems for the pumps. Only use new components that are especially adapted to fit your valve (both in terms of shape and chemical resistance). Use the correct spare parts kits. In case of doubt, refer to the exploded views and ordering information in the appendix. Clean the discharge and suction valves only one after another as they cannot be differentiated using the arrow markings Double ball valves Cleaning a discharge valve Taking the discharge valve apart 1. Unscrew the discharge valve from the dosing head and rinse out. 2. Dismantle the discharge valve. 3. Rinse and clean all parts. 4. Replace the worn parts and seals. Assembling the discharge valve When assembling, take note of the orientation of the valve seats (3). The valve seats (3) are used as a ball seat on the fine machined side and as a ball cage and spring guide on the other side. The fine machined side must point in the flow direction with all valve seats. When assembling the valves, take note of the sequence: Teflon Metal Teflon Metal

44 Repairs * 5 1. Slide into the valve body (1) one after another: one seal (2) and one valve seat (3) - correct! one seal (2) and one valve bushing (4) (If fitted: one spring (*) into the spring guide of the valve seat (3) one ball (5) into the valve body (1) one seal (2) and the second valve seat (3, correct!) one seal (2) and the second valve bushing (4) (If fitted: the second spring (*) into the spring guide of the valve seat (3)) the second ball (5) into the valve body (1) one seal (2), the third valve seat (3) - (correct!) and a further seal (2) 2. Position the insert disc (6) with the flare on the packing. * The distance between the edge of the valve body and the insert disk (6) is due to the construction Place the larger seal (7) between the insert disk (6) and the dosing head. 4. Screw in the valve until the stop. Fig. 24: Discharge valve (double ball valve). Cleaning a suction valve A suction valve is dismantled, cleaned and assembled in the same way as a discharge valve. Please note, however, that when assembling, the valve seat (3) must be aligned in the other direction. The fine machined side must point in the flow direction with all valve seats (3) Single ball valves 1. Screw the valve cap (5) on to the suction side - see Fig Carefully remove the parts from the valve body (2). 3. Replace the worn parts. 4. Clean the remaining parts. 5. Check all parts. 6. If fitted: Place the compression spring inside the valve body (2). 7. Insert the valve ball (3 and the valve seat (4). 8. Screw on the valve cap (5). Note the flow direction of the discharge and suction connectors when fitting the valve. 44

45 Repairs Seal 2 Valve body 3 Valve ball 4 Valve seat 5 Valve cap P_MAK_0054_SW Fig. 25: Cross-section through the single ball valve Plate valves Do not scratch the finely machined sealing surfaces on the valve plates (5) and valve inserts (6) Compression spring 2 Valve body 3 Valve plate 4 Valve insert 5 Valve body bushing P_MA_0040_SW Fig. 26: Cross-section through the plate valve 1. Screw the valve cap (7) on to the suction side - see Fig Carefully remove the parts from the valve body (4). 3. Replace the worn parts. 4. Clean the remaining parts. 5. Check all parts. 45

46 Repairs V 6. Place the compression spring (3) inside the valve body (4). Place the compression spring with the end (see figure: arrow N, at the bottom) on one of the lugs in the valve body, as shown on the diagram. Otherwise the valve plate may knock when in operation. 7. Insert the valve plate (5) and the valve insert (6). 8. Screw on the valve cap (7). Note the flow direction of the discharge and suction connectors when fitting the valve. N P_MAK_0056_SW Fig. 27: Inserting the compression spring V Viewing direction N Spring end position on the nose 46

47 Troubleshooting 12 Troubleshooting Safety notes EX pumps in areas at risk from explosion Generally ensure proper operation (no leaks, unusual noises, high temperatures, unusual smell...) especially with the power end and the bearings. Do not allow the pump to heat up because of lack of oil. If oil is escaping, investigate the leak immediately and eliminate the cause. When cleaning plastic parts, ensure that excessive friction does not cause electrical charges - see warning label. Replace wear parts, such as bearings, when there is an identifiable incidence of unacceptable wear. (The nominal service life cannot be calculated with lubricated bearings.) Only use genuine spare parts as replacements. Carry out inspections and repair in in compliance with DIN EN IEC and ensure that they are only performed by "experienced personnel with the requisite knowledge". Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen. During filling and draining of the liquid end, an expert must ensure that feed chemical does not come into contact with oxygen. Hot surface In event the power end motor is loaded excessively, its surface may become very hot. Avoid contact. If necessary, mount a guard plate. Danger of an electric shock Personnel working on electrical parts can be electrocuted if all electrical lines carrying current have not been disconnected. Disconnect the supply cable before working on the motor and prevent it from being reconnected accidentally. Any separately driven fans, servo motors, speed controllers or diaphragm rupture sensors fitted should also be disconnected. Check that the supply cables are de-energised. 47

48 Troubleshooting Warning of dangerous or unknown feed chemical Should a dangerous or unknown feed chemical be used: It may escape from the hydraulic components when working on the pump. Take appropriate protective measures before working on the pump (e.g. safety glasses, safety gloves,...). Observe the safety data sheet for the feed chemical. Drain and flush the liquid end before working on the pump. Risk of injury from the fan impeller The fan impeller beneath motor's fan cowling can cause severe injuries while it is turning. The pump must only be connected to the mains voltage with the fan cowling closed. Danger of personnel injury and material damage The use of untested third party parts can result in personnel injuries and material damage. Only fit parts to metering pumps, which have been tested and recommended by ProMinent. Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system. Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthorised persons. Depressurise the system before commencing any work on hydraulic parts. Tasks Fault description Cause Remedy Personnel Pump does not prime in spite of full stroke motion and bleeding. The valves are dirty or worn. Repair the valves - see chapter entitled "Repair". Technical personnel Pump does not reach high pressure rates. The valves are dirty or worn. Repair the valves - see chapter entitled "Repair". Technical personnel The feed chemical has particles larger than 0.3 mm. Install a suitable filter in the suction line. Technical personnel The motor is wired incorrectly. 1. Check the mains voltage and mains frequency. 2. Wire the motor correctly. Electrician The mains voltage has failed. Eliminate the cause. Electrician 48

49 Troubleshooting Fault description Cause Remedy Personnel The diaphragm rupture warning system generates an alarm. The power end motor is very hot. The multi-layer diaphragm is ruptured. ** The discharge line is seriously constricted. Replace the multi-layer diaphragm immediately - refer to the "Repair" chapter - "Changing the diaphragm". If necessary replace the separating diaphragm of the diaphragm rupture sensor - see "Replacing the separating diaphragm, diaphragm rupture sensor" in the chapter "Repair". Check the diaphragm rupture warning system for correct operation. Technical personnel Rectify any constriction of the discharge line. Technical personnel All other faults. Other causes. Call ProMinent Service. ** Warning of escaping feed chemical When dosing combustible feed chemicals or in hazardous locations, under no circumstances must the second diaphragm also rupture. If the pump diaphragm rupture sensor triggers, stop the pump immediately and only operate once a new multilayer safety diaphragm has been fitted. 49

50 Decommissioning and Disposal 13 Decommissioning and Disposal 13.1 Decommissioning Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen. During filling and draining of the liquid end, an expert must ensure that feed chemical does not come into contact with oxygen. Danger of an electric shock When working on the motor or electrical auxiliary equipment, there is a danger of an electric shock. Before working on the motor, take note of the safety instructions in its operating instructions! Should external fans, servomotors or other auxiliary equipment be installed, these should also be disconnected and checked that they are voltage free. Danger from chemical residues There is normally chemical residue in the liquid end and on the housing after operation. This chemical residue could be hazardous to people. It is mandatory that the safety note relating to the "Storage, Transport and Unpacking" chapter is read before shipping or transporting the unit. Thoroughly clean the liquid end and the housing of chemicals and dirt. Adhere to the safety data sheet for the feed chemical. Warning of dangerous or unknown feed chemical Should a dangerous or unknown feed chemical be used: It may escape from the hydraulic components when working on the pump. Take appropriate protective measures before working on the pump (e.g. safety glasses, safety gloves,...). Observe the safety data sheet for the feed chemical. Drain and flush the liquid end before working on the pump. 50

51 Decommissioning and Disposal Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system. Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthorised persons. Depressurise the system before commencing any work on hydraulic parts. Danger of damage to the device The device can be damaged by incorrect and improper storage or transportation. Take into account the information in the "Storage, Transport and Unpacking" chapter if the system is decommissioned for a temporary period. Final decommissioning 1. Disconnect the pump from the mains power supply. 2. Depressurise and bleed the hydraulic system around the pump. 3. Flush the liquid end with a suitable medium - Observe the safety data sheet! Flush the dosing head thoroughly when using hazardous feed chemicals! 4. Drain the gear oil - refer to the chapter entitled "Maintenance". 5. Thoroughly clean the liquid end and the housing of chemicals and dirt. 6. Possible additional work - see chapter "Storage, Transport and Unpacking". Temporary decommissioning In addition: 1. Plug the caps on the valves. 2. Push the caps into place on the tube nozzles. 3. Preferably place the pump on a pallet. 4. Cover the pump with a tarpaulin cover - allowing rear ventilation! 5. Store the pump in a dry, sealed place under storage conditions according to the chapter "Storage, Transport and Unpacking" Disposal 51

52 Decommissioning and Disposal Environmental hazard due to gear oil The pump contains gear oil, which can cause damage to the environment. Drain the gear oil from the pump. Note the local guidelines currently applicable in your country! Note the local guidelines generally currently applicable in your country! 52

53 Technical data 14 Technical data Only for "M - modified" design: Risk of personal injuries Please observe the Supplement for modified version at the end of the chapter! It replaces and supplements the technical data! 14.1 Performance data Main pumps with 1500 rpm motor at 50 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate Suction lift Connector size Shipping weight* bar l/h ml/stroke Strokes/min m WS G-DN kg / / / / / / / / / / / / / / / / / / / / / / / / /80 * Material versions PPT, PCT, TTT / SST The shipping weight is applicable to single head pumps without an add-on power end. The permissible priming pressure at the suction side is approximately 50% of the max. permitted back pressure With double head pumps, the maximum permissible back pressure reduces from 7 to 5.5 bar or from 4 to 3 bar. All figures refer to water at 20 C. The suction lift applies to filled suction line and filled liquid end - when installed correctly. The priming lift of 2 m applies for clean and moistened valves and a clear outlet 53

54 Technical data Main pumps with 1800 rpm motor at 60 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate Suction lift Connector size Shipping weight* psi l/h gph Strokes/min m WS G-DN kg / / / / / / / / / / / / / / / / / / / / / / / / /80 * Material versions PPT, PCT, TTT / SST The permissible priming pressure at the suction side is approximately 50% of the max. permitted back pressure With double head pumps, the maximum permissible back pressure reduces from to 80 psi or from 58 to 43.5 psi. All figures refer to water at 20 C. The suction lift applies to filled suction line and filled liquid end - when installed correctly. The priming lift of 2 m applies for clean and moistened valves and a clear outlet 14.2 Precision Reproducibility Data Value Unit Reproducibility ±2 % * * for measurements taken under constant conditions, minimum 30 % stroke rate and water at 20 C - when installed correctly, p< 1 bar 54

55 Technical data Metering precision Data Value Unit Metering precision ±1 % * * at maximum stroke length and maximum back pressure 14.3 Viscosity The liquid ends are generally suitable for the following viscosity ranges: Design Range Unit no valve springs mpas with valve springs mpas with appropriately designed installation with appropriately designed installation and advice from ProMinent mpas > 1000 mpas * Only when the installation is correctly adjusted 14.4 Wetted materials with DN 25 ball valve Material version Liquid end Suction/pressure connector Seals Valve balls Valve seat PPT Polypropylene PVDF PTFE Borosilicate glass PTFE PCT PVC PVDF PTFE Borosilicate glass PTFE TTT PTFE with carbon PTFE with carbon PTFE Ceramic PTFE SST Stainless steel / Stainless steel / PTFE Stainless steel PTFE HCT Hastelloy C4 Hastelloy C4 PTFE Ceramic PTFE with DN 32 / DN 40 plate valves** Material version Liquid end Suction/pressure connector Seals Valve plates / valve spring PPT Polypropylene Polypropylene PTFE Ceramic / Hast. C + CTFE** PCT PVC PVC PTFE Ceramic / Hast. C + CTFE** TTT PTFE with carbon PTFE with carbon PTFE Ceramic / Hast. C + CTFE** Valve seat PTFE PTFE PTFE 55

56 Technical data Material version Liquid end Suction/pressure connector SST Stainless steel / Stainless steel / Seals Valve plates / valve spring PTFE Ceramic / Hast. C + CTFE** Valve seat PTFE HCT Hastelloy C4 Hastelloy C4 PTFE Hast. C PTFE Patented, vacuum packed, multi-layer diaphragm. ** The valve spring is coated with CTFE (similar to PTFE) 14.5 Ambient conditions Temperatures Pump, compl. Data Value Unit Storage and transport temperature C Ambient temperature in operation (drive + motor): C PC liquid end Data Value Unit Max. temperature long-term at max. operating pressure 45 C Max. temperature for 15 min at max. 2 bar 60 C Minimum temperature -10 C PP liquid end Data Value Unit Max. temperature long-term at max. operating pressure 60 C Max. temperature for 15 min at max. 2 bar 100 C Minimum temperature -10 C TT liquid end Data Value Unit Max. temperature long-term at max. operating pressure 90 C Max. temperature for 15 min at max. 2 bar 120 C Minimum temperature -10 C SST liquid end Data Value Unit Max. temperature long-term at max. operating pressure 90 C Max. temperature for 15 min at max. 2 bar 120 C Minimum temperature -10 C 56

57 Technical data Air humidity Data Value Unit Maximum air humidity *: 95 % rel. humidity *non-condensing (according to DIN IEC ) 14.6 Housing degree of protection Data Value Protection against contact and humidity* IP 55 *according to DIN VDE 470 (EN IEC 60529) 14.7 Stroke sensor (optional), intrinsically safe Stroke sensor (option), intrinsically safe Install the sensor according to the chapter "Installation, electrical". Namur sensor (Specified for EX zones) 5 25 V DC, in accordance with Namur or DIN 19234, potential-free design. Data Value Unit Rated voltage * 8 VDC Power consumption - active surface uncovered Power consumption - active surface covered > 3 ma < 1 ma Rated switching distance 1.5 mm * Ri ~ 1 kω Cable colour Polarity blue - brown Diaphragm rupture sensor Install the sensor according to the chapter "Installation, electrical". 57

58 Technical data Contact (standard) Contact loading, max. at voltage Maximum current 30 V DC 1 A The contact is an opener. The contact is an potential-free. For safety reasons we recommend connecting to a protective low voltage, e.g. in accordance with EN (SELV ). The cable can be poled as required. Namur sensor (Specified for EX zones) 5 25 V DC, in accordance with Namur or DIN 19234, potential-free design. Data Value Unit Rated voltage * 8 VDC Power consumption - active surface uncovered Power consumption - active surface covered > 3 ma < 1 ma Rated switching distance 1.5 mm * Ri ~ 1 kω Cable colour Polarity blue - brown + The monitor / power supply must be able to evaluate the current variations to indicate a diaphragm rupture! 14.9 Motor data Electrical data For motor data - refer to the nameplate. Motor data sheets, special motors, special motor flanges, external fan, temperature monitoring For further information for the motor with identity code specification "S", refer to the motor data sheet in the Appendix. Motor data sheets can be requested for all other motors. For motors other than those with identity code specifications "S", "M" or "N": Pay special attention to the operating instructions for the motors. Special motors or special motor flanges are possible on request. 58

59 Technical data Filling volumes Gear oil Gear oil Gear oil Supplied quantity Part no. Mobilgear 634 VG l Gear oil filling volumes Types All Volume, approx. 3.2 l Sound pressure level Sound pressure level Sound pressure level LpA < 70 db in accordance with EN ISO 20361: at maximum stroke length, maximum stroke rate, maximum back pressure (water) Supplement for modified versions (With Identcode specification "Version": "M" - "modified") Technical data Technical data of pumps in the modified version can deviate from those of the standard pumps. They can be queried by stating the details of the serial number. motor The motor data sheets for the modified version are valid. They may deviate from the standard motor data sheets. Spare parts With a modified version, it is absolutely necessary to specify the details of the serial number requesting and ordering the spare and replacement parts. 59

60 Spare parts 15 Spare parts Further sources of information Further information on spare parts, accessories and options can be found in: the identity code the ProMinent product catalogue 15.1 Spare parts Spare parts kit Makro TZ, TZMb Spare parts kit contents 1 - Diaphragm 1 - Suction valve compl. 1 - Discharge valve compl. 2 - Valve plate (DN40 with plate and spring) 1 - Complete sealing set (O-rings or gasket, valve seat, valve seat bushing) For 12(10) bar types: , , , , FM DN 25 Part no. PP P T S S (without valve assys.) For 7 bar types: , , , , FM DN 32 Part no. PP P T S S (without valve assys.) For 4 bar types: , , , , FM DN 40 Part no. PP P T S S (without valve assys.)

61 Spare parts Metering diaphragm PTFE ProMinent DEVELOPAN metering diaphragm from EPDM with woven inner layer, large area, vulcanised aluminium core and PTFE Teflon layer on the medium-contacted side. For 12(10) bar types: , , , , Liquid end type Part no. FM For 7 bar types: , , , , Liquid end type Part no. FM For 4 bar types: , , , , Liquid end type Part no. FM 1500 / FM Other material Gear oil Gear oil Gear oil Supplied quantity Part no. Mobilgear 634 VG l Gear oil filling volumes Types All Volume, approx. 3.2 l 61

62 Dimensional drawings 16 Dimensional drawings Compare the dimensions on the dimension sheet and pump. All dimensions are in mm. Dimension sheet Makro TZ, TZMbH Main power end (Standardmotor S ) 436 (Standardm. S ) C /705# B A 160 F 220 D 245 Ø E (93) P_MA_0041_SW_2 61_01_101_00_59_74_3 Fig. 28: Dimension # with manual adjustment wheel Dimensions Makro TZ (in mm) Type , , , , , , , , , , , , , , , , , , , , , , , , S PP, P, T S PP, P, T S PP, P, T A B C DN25* DN25* DN32* DN32* DN40* DN40* G 1 1/2 A G 1 1/2 A G 2A G 2A G 2 1/4 A G 2 1/4 A D E F * External thread 62

63 Dimensional drawings Dimension sheet Makro TZ, TZMbA with TZMbB or TZMbD Main power end with add-on power end or double head version 436 (Standardm. S ) 549 (Standardmotor S ) F 220 G H P_MA_0020_SW 61_01_101_00_59_74_2x01 Fig. 29 Dimensions Makro TZ (in mm) Type , , , , , , , , , , , , , , , , , , , , , , , , S PP, P, T S PP, P, T S PP, P, T F G H

64 Motor data sheet 17 Motor data sheet Motor Datenblatt / Motor data sheet / Fiche technique pour moteur Bestell Nr Hersteller order no. / no. de commade producer / producteur ATB Mat.Nr Motor- Typ NF80/4H-13+E2 Leistungsfaktor motor type power factor type du moteur facteur de puissance 0,77 0,78 Maschinenart 3-Ph. Motor Wirkungsgrad type of machine efficiency désignation rendement 73% 76% Schutzart IP55 Bemessungsfrequenz degree of protection rated frequency degré de protection fréquence nominale 50 Hz 60 Hz Bauform IMB14 Bemessungsdrehzahl 1440 U/min mounting rated speed 1750 rpm construction vitesse nominale t/mn Bemessungsleistung 0,75 kw Wärmeklasse rated output temperature class puissance nominale class d'isolement F Bemessungsspannung / D Anzugsstrom 7,4 fach rated voltage 400/230 +/-10% V starting current fold tension nominale 440/ % V courant de démarrage fois Bemessungsstrom 1,71 / 2,96 A Anzugsmoment 3,1 fach rated current 1,54 / 2,67 A starting torque fold courant nominale couple de démarrage fois Geprüft nach EN Kippmoment 3,6 fach tested in acc. with pull-out torque fold contrôlé selon couple de décrochage fois ATEX Nr. Umgebungstemperatur ambient temperature température ambiante 40 C Ex-Schutzklasse ex-protective system Schaltung connection branchement Drehzahlregelbereich speed ajustment range / D Anmerkung comments observation * auf Anfrage beim Hersteller * upon request at manufacturer * sur demande auprès du producteur ProMinent Pumpentyp TZMaH _ S TZMbH _ S Die Daten entsprechen den Angaben der Motorenhersteller. Kenndaten funktionsgleicher Motoren anderer Hersteller ändern sich nur unwesentlich. Angaben ohne Gewähr. The data correspond to the details given by the motor manufacturers. Ratings of motors with the same functions made by other producers show insignificant changes only. This information is supplied without liability. Les données techniques correspondent au descriptif du fabricant des moteurs. Les données techniques des moteurs similaires chez d autres fabricants varient très peu. Données sont d ordre général. ProMinent Dosiertechnik GmbH Heidelberg. Germany Nr./No. MD Datum/Date Jul

65 Diagrams for adjusting the capacity 18 Diagrams for adjusting the capacity MakroTZ, TZMb H/A at 50 Hz MakroTZ, TZMb D/B - per liquid end at 50 Hz C [l/h] C [l/h] s [%] p [bar] C [l/h] C [l/h] s [%] p [bar] Fig. 30: Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis of back pressure p for the different types of a series. 65

66 Diagrams for adjusting the capacity C [l/h] s [%] C [l/h] p [bar] Fig. 31: Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis of back pressure p for the different types of a series. 66

67 Diagrams for adjusting the capacity MakroTZ, TZMb H/A at 60 Hz MakroTZ, TZMb D/B - per liquid end at 60 Hz C [l/h] C [l/h] C [l/h] s [%] 0 C [l/h] s [%] p [bar] p [bar] Fig. 32: Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis of back pressure p for the different types of a series. 67

68 Diagrams for adjusting the capacity C [l/h] C [l/h] s [%] p [bar] Fig. 33: Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis of back pressure p for the different types of a series. 68

69 EC Declaration of Conformity 19 EC Declaration of Conformity For pumps without explosion protection: We, ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 D Heidelberg, hereby declares that the product specified in the following, complies with the relevant basic health and safety requirements of the EC Directive, on the basis of its functional concept and design and in the version distributed by us. This declaration loses its validity in the event of a modification to the product not agreed with us. Designation of the product: Product type: Serial number: Relevant EC directives: Harmonised standards applied, in particular: Metering pump, Makro TZ series TZMb... TZKa... refer to nameplate on the device EC Machinery Directive (2006/42/EC) EC EMC Directive (2004/108/EC) Compliance with the protection targets of the Low Voltage Directive (2006/95/EC) according to Appendix I, No of the Machinery Directive 2006/42/EC EN ISO EN 809 EN /5/6/9 EN EN /4 Date: 30/09/

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