Operating instructions Diaphragm Metering Pump ProMinent Makro/ 5 M5Ma

Transcription

1 Operating instructions Diaphragm Metering Pump ProMinent Makro/ 5 M5Ma 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 MAK /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 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 Motor data Housing Degree of Protection Stroke Sensor (Optional), Intrinsically Safe Filling volumes Gear oil Sound pressure level Compatibility Supplement for modified versions Dimension sheets Spare parts Spare parts Other material Gear oil

4 Table of contents 17 Motor data sheets Diagrams for adjusting the capacity EC Declaration of Conformity EC Declaration of Conformity

5 Identity code 1 Identity code M5Ma Makro/ 5 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: see nameplate on pump housing Dosing head material PC PV TT SS PVC PVDF PTFE + 25 % carbon Stainless steel Seal material T PTFE Displacement body material T Metering diaphragm with PTFE coating Dosing head design 1 with valve spring, Hastelloy C; 0.1 bar 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 1 Without ProMinent logo, no frame 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 5 No motor, with gear IEC 100 5

6 Identity code M5Ma Makro/ 5 diaphragm metering pump 6 No motor, with gear IEC No motor, no gear 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 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 maz 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 The pump may only be used to meter liquid metering chemicals. In potentially explosive atmospheres in zone 1, device category II 2G of explosion group II C, the pump must only be operated with the appropriate nameplate (and the respective EC Declaration of Conformity) for pumps for potentially explosive atmospheres complying with Directive 94/9/EC in accordance with the European guidelines. The explosion group, category and degree of protection declared on the marking must correspond with or be better than the given conditions in the intended field of application. The pump may only be started up after it has been correctly installed and commissioned in accordance with the technical data and specifications contained in the operating instructions. When working at temperatures arising using a heating cartridge, bear in mind their effect. Observe the general limitations with regard to viscosity limits, chemical resistance and density - see also ProMinent Resistance List (in the Product Catalogue or at en/downloads)! 7

8 Safety chapter All other uses or modifications are prohibited. Pumps without the relevant nameplate (and the respective EC Declaration of Conformity) for pumps for potentially explosive atmospheres must never be operated in potentially explosive atmospheres. The pump is not intended for the metering of gaseous media or solids. The pump is not intended to meter explosive substances and mixtures. 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. You are obliged to observe the information contained in the operating instructions at the different phases of the device's service life. In hazardous locations only the following combinations of identity code variants is permitted: Combinations Identity code specification values 1 Electric power supply L, P Motor version Electric power supply 0, 5.6 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 Qualification Instructed person Technical personnel, service Certificated specialist personnel who have a thorough knowledge of diaphragm pumps Technical personnel, service Electrical technician Instructed person Technical personnel, service 8

9 Safety chapter Action Decommissioning, disposal Troubleshooting Qualification 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 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. Customer Service Customer Service department refers to service technicians, who have received proven training and have been authorised by ProMinent or ProMaqua 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. 9

10 Safety chapter Observe the European Operator Directive 99/92/ EC (ATEX 137), implemented in Germany by the German Ordinance on Industrial Safety and Health and the Ordinance on Hazardous Substances, with regard to the installation and operation of equipment in areas at risk from explosion. Note the European standards EN , EN , EN , EN , and EN and EN for intrinsically safe power circuits. (These standards are partially implemented in Germany by VDE 0165 and VDE 0118.) Observe the relevant national regulations outside of the EU. Ensure that installations in areas at risk from explosion are checked by a "recognisably qualified and skilled" operative. This applies specifically to intrinsically safe electrical power circuits. The following information relates essentially to specifics in areas at risk from explosion and does not replace the standard operating instructions. Only clean plastic parts carefully with a damp cloth to avoid electrostatic charges and sparks. 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. 10

11 Safety chapter 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 contacted by the chemical. Take into account the resistance of the materials which will come into contact with the chemical 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. 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. 11

12 Safety chapter Safety information relative for the operating instructions Prior to commissioning of the system or system component, the system operator is obliged to obtain the latest safety data sheet for the chemicals / resources to be used with the system from the supplier. 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, the operator must create the legal framework for safe operation of the system or system component, such as for example the preparation of operating instructions (operator duties). Safety equipment Protective equipment Ensure that all these parts are fixed in position during the operation of the pump: P_MAK_0025_SW 4 Fig. 2: Isolating protective equipment Makro/ 5 with add-on power end (shown here for piston version) 1 Cap (only single head version) 2 Fan impeller hood 3 Terminal box cover, motor 4 Cover plate (only with add-on power end) 5 Flange cover 6 Protective cover (only diaphragm and piston versions) Ite m Protective equipment May only be removed by*: 1 Cap (only single head version) Service 2 Protective cowling above the motor fan Service 3 Terminal box cover, motor Electrical technician, service 4 Cover plate (only with add-on power end) Service 5 Flange cover, side Service 6 Protective cover (only diaphragm and piston versions) - Only with protective devices: their corresponding parts Technical personnel, service Technical personnel, service 12

13 Safety chapter * Only if the mains cable remains disconnected (no mains voltage). Other safety equipment Adhere the following safety note to pumps with 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 < 75 db according to EN ISO at maximum stroke length, maximum stroke rate, maximum back pressure (water) 13

14 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 at 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. 14

15 Overview of equipment, control elements 4 Overview of equipment, control elements Power end, single head C 5 A P_MAK_0027_SW Fig. 4: View from the motor side (here M5Ka H) A Power end C Liquid end 1 Lifting eye 2 Stroke length adjustment wheel 3 Indicating dial 4 motor 5 Oil drain plug 6 7 P_MAK_0027_SW Fig. 5: View away from the motor (here M5Ka H) 6 Vent screw 7 Oil inspection window 15

16 Overview of equipment, control elements Power end, double head P_MAK_0029_SW 5 C A C Fig. 6: View from the motor side (here M5Ka D) A Power end C Liquid end 1 Lifting eye 2 Stroke length adjustment wheel 3 Indicating dial 4 motor 5 Oil drain plug 6 7 Fig. 7: View away from the motor (here M5Ka D) 6 Vent screw 7 Oil inspection window P_MAK_0030_SW 16

17 Overview of equipment, control elements Liquid end P_MAK_0031_SW Fig. 8 1 Discharge valve 2 Dosing head 3 Suction valve 4 Tube nozzle for leakage 5 Protective cover 17

18 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 (for M5Ma) The diaphragm (3) hermetically shuts off the pump volume of the dosing head (2) from the outside. The suction valve (4) closes as soon as the diaphragm (3) is moved in to the dosing head (2) 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 (3) 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 P_MAK_0036_SW Fig. 9: Cross-section through the liquid end 1 Discharge valve 2 Dosing head 3 Diaphragm 4 Suction valve 18

19 Assembly 6 Assembly Compare the dimensions on the dimension sheet and pump. Supporting floor Fig. 10 h P_MOZ_0016_SW 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. 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 A 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. Fig. 11 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...). 19

20 Assembly 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. 12 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. m P_MOZ_0015_SW Fig. 13 Instruction 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. 20

21 Installation 7 Installation 7.1 Installation, Hydraulic EX pumps in areas at risk from explosion Metering pumps in areas at risk from explosion are provided in principle with a suitable safety relief valve on the outlet side of the metering pump (which is used to protect against excessive heating due to overloading and impact sparks caused by the breakage of power end parts triggered by overloading). 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 Only pump flammable media 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. 21

22 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 For feed chemicals with a particle size greater than 0.3 mm, the valves may no longer close properly. 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 Tube lines with insufficient pressure rating may burst. Only use tube lines with the required pressure rating. Uncontrolled flowing feed chemicals Feed chemicals can leak through a stopped metering pump when there is back pressure. Use an injection valve or vacuum breaker for this purpose. 22

23 Installation Uncontrolled flowing feed chemicals Feed chemicals can leak through the metering pump in an uncontrolled manner in the event of excessive priming pressure on the suction side. Do not exceed the maximum permissible priming pressure for the metering pump. Organise the installation properly for this. Warning against lines disconnecting With suction, discharge and relief lines installed incorrectly can loosen / disconnect from the pump connection. Only use original tubing with the specified tube diameter and wall thickness. Only use clamp rings and tube nozzles that correspond with 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. 14: Connect the steel piping to the plastic pump body as shown 1 Steel pipeline 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. For this purpose use a shut-off valve, a solenoid valve or a vacuum breaker. 23

24 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 leakage liquid is drained off via the flushing collar and a tube nozzle, without other parts of the liquid end coming into contact with the medium. 1. Connect a tube to the lower tube nozzle. 2. Route the tube into a collection device 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 valve Install a relief valve in the discharge line. Hazardous feed chemicals can escape With hazardous feed chemicals Hazardous feed chemicals can leak out when using conventional bleeding procedures with metering pumps. Install a bleed line with return into the storage tank. Shorten the return line hose so that it cannot submerge into the feed chemical in the storage tank. 24

25 Installation 1 2 P_MAZ_0001_SW Fig. 15: Standard Installation 1 Main line 2 Storage tank Legend for hydraulic diagram Symbol Explanation Symbol Explanation Metering pump Injection valve Multifunctional valve Foot valve with filter meshes Level switch Manometer 25

26 Installation 7.2 Installation, electrical EX pump in areas at risk from explosion Potential-free switches can be assessed as simple electrical devices (EN and EN 50020). Only connect potential-free as well as non-isolating low voltage switch accessories, such as diaphragm rupture indicators, stroke rate 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. Danger of electric shock Unprofessional installation may lead to electric shocks. All cable cores cut to length must be provided with cable end sleeves. The Installation, electrical of the device may only be undertaken by technically trained personnel. 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. 26

27 Installation 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 (option) Stroke control drive (Option) Stroke adjusting drive (Option) Stroke sensor (Option) Frequency converter (option) Motor P_SI_0012_SW Fig. 16: Direction of rotation of motor EX pumps in areas at risk from explosion Protect power end motors using a suitable motor protection switch. Use approved motor protection for Ex"e" motors. (Protection against warming caused by overloading). Ensure that motors are only installed and checked in areas at risk of explosion by a "recognisably qualified and skilled" operative. Observe the enclosed operating instructions for the Ex motor. The motor may 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. 27

28 Installation 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. 16. Use an electrical isolating device in the mains supply cable, such as a mains switch, to be able to switch off the pump independently from the entire installation (e.g. for repairs). 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 of the system. 3. Use a suitable cable between the motor terminal box and power supply. Key motor data can be found on the unit nameplate. The terminal wiring diagram is located in the terminal box. 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 other motors "S", "M" or "N" as identity code specifications: Pay special attention to the operating instructions of the motors. Special motors or special motor flanges are possible on request. External fans Provide a separate power supply for the external fan with motors with external fans (identity code characteristic "R" or "Z"). Variable speed motors with frequency converter Connect the motor according to the wiring diagram for the control unit, if it is controlled by an electronic control unit (such as AC motors by frequency converters). 28

29 Installation Stroke length actuators /control drives Connect the motors in accordance with the enclosed wiring diagram or according to the wiring diagram affixed to 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. Overpressure sensor Warning of damage by overpressure Electrically connect the overpressure sensor to a suitable monitoring device. Stroke sensor (Option) 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 according to their documentation. 29

30 Start Up 8 Start Up Safety notes EX pumps in areas at risk from explosion A qualified or skilled operative should check whether the 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. 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. 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". 30

31 Start Up Feed chemical could escape Check suction and discharge lines, liquid end and valves for leak-tightness and tighten if necessary. Check whether the necessary flushing pipes or bleed lines have been connected. Prior to commissioning check the drive motor and corresponding ancillary equipment is connected according to regulations. When using pumps with speed control, observe the instructions in the frequency converter operating instructions. Installing a vent screw Replace the sealing screw at the oil filler neck with the supplied vent screw - 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. 31

32 Start Up Fig. 17: Tapping the valve set disc Adjusting the stroke length Only adjust the stroke length when the pump is running. This is easier and also better for the pump. The pump can now be released for operation. 32

33 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. 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. 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. 33

34 Maintenance 10 Maintenance Safety notes EX pumps in areas at risk from explosion Generally check the proper operation, particularly of the power end and bearings, by regular monitoring (for leaks, noises, temperatures, smell... ). Do not allow the pump to heat up because of lack of oil. With lubricated metering pumps, regularly check the presence of lubricant, for example by checking the fill level, visual leak control etc. If oil is escaping, investigate the leak immediately and eliminate the cause. Check the proper operation of the relief valve downstream of the pump. The purpose of the relief valve is to prevent the gear becoming overloaded and overheating in the event of a failure in plants at risk of explosion. 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 repairs in compliance with DIN EN IEC and ensure that they are only performed by "experienced personnel with the requisite knowledge". These measures are deemed to be minimum protection measures by ProMinent. It is the duty of the operator to take appropriate measures to eliminate any further hazards known to him. 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. 34

35 Maintenance 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. 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 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. 35

36 Maintenance 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. Interval Quarterly* Maintenance work 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 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. 36

37 Maintenance 1 (30 Nm) 2 (25 Nm) P_MAK_0040_SW 3 Interval After approx. 5,000 operating hours Fig. 18: Liquid End 1 Dosing head screws 2 Drive flange screws 3 Tube nozzle Maintenance work Change the gear oil. After approx. 10,000 operating hours ** 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. Gear oil Gear oil Supplied quantity Part no. Mobilgear 634 VG l Gear oil filling volumes Types All Volume, approx l Draining the gear oil: 37

38 Maintenance 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 Fig. 19: Oil change 1 1 Vent screw 2 Oil drainage screw Filling with gear oil: 1. Start the pump. 2 P_MAK_0043_SW 2. Slowly pour gear oil through the vent screw (1) opening until the upper oil inspection window (3) is slightly covered. 3. Allow the pump to run for a further minutes. 4. Replace the vent screw (1). 38

39 Maintenance 3 P_MAK_0044_SW Fig. 20: Oil change 2 3 Oil inspection windows 39

40 Repairs 11 Repairs Safety notes EX pump in areas at risk from explosion Generally check the proper operation, 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. 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. 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. 40

41 Repairs 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 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. 41

42 Repairs P_MAK_0045_SW Fig. 21: Cross-section through the liquid end 1 Dosing head 2 Diaphragm 3 Reinforce plate 4 Screw 5 Protective cover 6 Backplate 7 Bellows 8 Slide rod 9 Tube nozzle 7. Undo the screws (4) on the reinforce plate. 8. Remove the dosing head (1) with the screws from the backplate (6). While doing this, do not damage the black bellows (7) on the slide rod. 10. Remove the protective cover (5) from the backplate (6). 11. Unscrew the diaphragm (2) on the grooves of its shaft from the slide rod (8) and remove. Use a sickle spanner inserted through the slot in the backplate (6). 12. Clean the sealing surfaces. 13. Check the state of the bellows (7). 14. Screw the new diaphragm (5) up to the stop on the slide rod (8). ð This must be done correctly to ensure the pump meters accurately. 15. Place the dosing head (1) and the reinforce plate (3) onto the backplate (6). 16. Position the screws 17. Start the pump and tighten the screws crosswise at a 100% stroke. Tightening torque 30 Nm 18. Position the protective cover (5) on the backplate (6). 42

43 Repairs Check the tightening torque of the screws after 24- hours' operation. With PP dosing heads, recheck the tightening torque again after three months 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. 6 7 Fig. 22: Discharge valve (double ball valve). Cleaning a suction valve 3. Place the larger seal (7) between the insert disk (6) and the dosing head. 4. Screw in the valve until the stop. 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 P_MAK_0054_SW Fig. 23: Cross-section through the single ball valve 1 Seal 2 Valve body 3 Valve ball 4 Valve seat 5 Valve cap Plate valves Do not scratch the finely machined sealing surfaces on the valve plates (5) and valve inserts (6) P_MAK_0055_SW Fig. 24: Section through a plate valve (DN65 shown) 1 Valve cap II (only DN 65) 2 Perforated disc (only DN 65) 3 Compression spring 4 Valve body 5 Valve plate 6 Valve insert 7 Valve cap 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. 6. Only DN 65: Insert the perforated disc (2) in the valve body (4). 45

46 Repairs V 7. 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. 8. Insert the valve plate (5) and the valve insert (6). 9. 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. 25: Inserting the compression spring 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 48

49 Troubleshooting Fault description Cause Remedy 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. Electrician 2. Wire the motor correctly. The mains voltage has failed. Eliminate the cause. Electrician The diaphragm rupture warning system generates an alarm. The multi-layer diaphragm is ruptured. ** 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 The power end motor is very hot. The discharge line is seriously constricted. 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 multi-layer 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 bar l/h ml/stroke Strokes/min m WS G-DN kg /2" /2" /2" /2" /2" Shipping weight* * Stainless steel material version Shipping weight 340 kg 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 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 psi l/h gph Strokes/min m WS G-DN kg /2" /2" /2" /2" /2" Shipping weight* * Stainless steel material version Shipping weight 340 kg The permissible priming pressure at the suction side is approximately 50% of the max. permitted back pressure 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 10 % stroke rate and water at 20 C - when installed correctly, p< 1 bar 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: 54

55 Technical data Design Range Unit no valve springs mpas with valve springs mpas with appropriately laid out installation with appropriately laid out installation and advice from ProMinent mpas > 1000 mpas * Only when the installation is correctly adjusted 14.4 Wetted Materials Liquid end Material version 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 SST PTFE with carbon Stainless steel // PTFE with carbon Stainless steel PTFE PTFE Ceramic / Hast. C + CTFE** Stainless steel / Hast. C Valve seat PTFE PTFE PTFE PTFE DEVELOPAN metering diaphragm with PTFE coating. ** 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 Max. temperature for 15 min at max. 2 bar 45 C 60 C Minimum temperature -10 C 55

56 Technical data PP liquid end Data Value Unit Max. temperature long-term at max. operating pressure Max. temperature for 15 min at max. 2 bar 60 C 100 C Minimum temperature -10 C TT liquid end Data Value Unit Max. temperature long-term at max. operating pressure Max. temperature for 15 min at max. 2 bar 90 C 120 C Minimum temperature -10 C SST liquid end Data Value Unit Max. temperature long-term at max. operating pressure Max. temperature for 15 min at max. 2 bar 90 C 120 C Minimum temperature -10 C Air humidity Data Value Unit Maximum air humidity *: 95 % rel. humidity *non-condensing (according to DIN IEC ) 14.6 Motor data Electrical data For motor data - refer to 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 other motors "S", "M" or "N" as identity code specifications: Pay special attention to the operating instructions of the motors. Special motors or special motor flanges are possible on request. 56

57 Technical data 14.7 Housing Degree of Protection Data Value Protection against contact and humidity* IP 55 *according to DIN VDE 470 (EN IEC 60529) 14.8 Stroke Sensor (Optional), Intrinsically Safe Namur sensor (identity code specification "Stroke sensor": 1) 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 Filling volumes Gear oil Gear oil Gear oil Supplied quantity Part no. Mobilgear 634 VG l Required amount of oil Pump type All: Oil change, compl l 57

58 Technical data Sound pressure level Sound pressure level Sound pressure level LpA < 75 db according to EN ISO at maximum stroke length, maximum stroke rate, maximum back pressure (water) Compatibility The hydraulic accessories of the Makro/ 5 metering pump Hydro are compatible with the Sigma and Makro TZ piston pumps. The connecting dimensions of valves and dosing heads are the same size but have different materials. (This does not apply with different diaphragm materials) 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. 58

59 Dimension sheets 15 Dimension sheets Dimension sheet Makro/ 5/20 M5Ma H 755 (Standardmotor) Main power end DN50 G 2 3/ Ø 300 P_MAK_0019_SW 61_03_101_00_04_74_ A 189 B Ø C Ø 16 Dimensions Makro/ 5 (in mm) Size M5Ma... S M5Ma... PP, P, T A B C

60 Dimension sheets Dimension sheet Makro/ 5/20 M5Ma H + M5Ma A Main power end with add-on power end DN50 G 2 3/ Ø U 100 A B C Ø (Standardmotor) 35 P_MAK_0020_SW 61_03-101_00_04_74_2 Dimensions Makro/ 5 (in mm) Size M5Ma... S M5Ma... PP, P, T A B C

61 Dimension sheets Dimensional sheet Makro/ 5 M5Ma D Double head version 755 (Standardmotor) DN50 G 2 3/4 846 Ø Ø Ø A B C P_MAK_0021_SW 61_03_101_00_04_74_3 Dimensions Makro/ 5 (in mm) Size M5Ma... S M5Ma... PP, P, T A B C

62 Spare parts 16 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 16.1 Spare parts Spare parts kit Makro/ 5 HM Spare parts kit contents 1 - Diaphragm 1 - Suction valve compl. 1 - Discharge valve compl. 2 - Valve plate and Hastelloy C spring 1 - Complete sealing set (cover rings, valve seat, valve seat bushing Pump type Part no. FM 4000 PCT FM 4000 PPT FM 4000 TTT FM 4000 SST (without valve assys.) 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. Pump type Part no. 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 l 62

63 Motor data sheets 17 Motor data sheets Motor Datenblatt / Motor data sheet / Fiche technique pour moteur Bestell Nr , , Hersteller order no. / no. de commade , producer / producteur Motor- Typ SK305 (V) F-100L/40 TF Leistungsfaktor motor type type du moteur power factor facteur de puissance Getriebebau Nord 0,78/0,75 Maschinenart 3ph. Motor Wirkungsgrad type of machine efficiency désignation rendement 81% Schutzart IP 55 Bemessungsfrequenz degree of protection rated frequency degré de protection fréquence nominale 50/60 Hz Bauform B5 Bemessungsdrehzahl 1410/1690 U/min mounting rated speed rpm construction vitesse nominale t/mn Bemessungsleistung 3,0 kw Wärmeklasse rated output temperature class puissance nominale class d'isolement F Bemessungsspannung / Anzugsstrom 4,8 fach rated voltage 400/230 V starting current fold tension nominale / V (50Hz) courant de démarrage fois / V (60Hz) Bemessungsstrom 6,9/12 A Anzugsmoment 2,3 fach rated current starting torque fold courant nominale couple de démarrage fois Geprüft nach / Kippmoment 2,7 fach tested in acc. with pull-out torque fold contrôlé selon couple de décrochage fois ATEX Nr. / Umgebungstemperatur ambient temperature température ambiante Ex-Schutzklasse / Schaltung ex-protective system connection branchement max. 40 C / Anmerkung Getriebemotor / Übersetzung (Hübe/min); gear motor / reduction (strokes/min); motoréducteur / braquet (Imp./min) comments / 9:1 (ca. 156) / 19:1 (ca. 75) observation / 11:1 (ca. 133) / 23:1 (ca. 60) / 14:1 (ca. 103) mit 3 Kaltleitertemperaturfühler für Regelbereich 1:5; with 3 PTC resistor temperature sensors for control range 1:5; avec 3 sondes pyrométrique de thermistor PTC pour plage de régulation 1:5 ProMinent Pumpentyp M5Ma S0 M5Ma R0 M5Ma Z0 M5Ha S0 M5Ha R0 M5Ha Z0 M5Ka S0 M5Ka R0 M5Ka Z0 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

64 Motor data sheets The data corresponds with the details of the motor manufacturer. Characteristics of motors with similar function of other manufacturers change insignificantly. Information subject to correction. The motor data sheets can be requested for more information. Special motors or special motor flanges are possible on request. 64

65 Diagrams for adjusting the capacity 18 Diagrams for adjusting the capacity Makro/ 5 M5Ma H/A Makro/ 5 M5Ma D/B - per liquid end C [l/h] C [l/h] 4500 s [%] p [bar] Fig. 26: 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 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 5 series M5Ma... M5Ha... M5Ka... 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 EN /4 Date: 30/09/

67 EC Declaration of Conformity 20 EC Declaration of Conformity For pumps with explosion protection: We, ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 DE 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 5 product range. Version "Explosion protection" in accordance with "ATEX 95" M5Ha _ XY _ M5Ka _ XY _ M5Ma _ XY _ Characteristic value "X" = "P" or "L" and characteristic value Y = "1" or "2" or "X" = "0, 5 or 6" and "Y" = "A" or "X" = "V" and "Y" = "2" refer to nameplate on the device EC Machinery Directive (2006/42/EC) EC EMC Directive (2004/108/EC) EC Explosion Prevention Directive (94/9/EC) Pump without motor: EN ISO /2, EN 809, EN /5 Motor Ex "e": EN , EN , EN Motor Ex "d": EN , EN , EN Sensor: EN , EN , EN Control drive EN 50014, EN 50018, EN The combination of the components does not give rise to any new explosion-related dangers Ex-designations: Pump without motor: II 2G c IIC T4 X Motor (characteristic value "Y"="1") : II 2G Ex e IIC T3 Motor (characteristic value "Y"="2" without V2) : II 2G Ex de IIC T4 Motor (characteristic value "XY"="V2") : II 2G Eex de IIC T4 Diaphragm rupture sensor: II 1G Ex ia IIC T6 Control drive II 2G Eex de IIC T4 Overall system: II 2G c IIC T3 X (for "Y"="1") or II 2G c IIC T4 X (for "Y"="2" or "A") Date: 16/10/

68 ProMinent GmbH Im Schuhmachergewann Heidelberg Germany Telephone: Fax: Internet: , 2, en_gb 2010