ProMinent delta DLTa Operating Instructions Manual
Operating instructions
P
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P_DE_0002_SW
Solenoid Metering Pump
delta®
DLTa
with controlled optoDrive®
solenoid drive
EN
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.
The latest version of the operating instructions are available on our homepage.
Original operating instructions (2006/42/EC)Part no. 986691 BA DE 036 08/18 EN
Supplemental directives
Supplementary information
Fig. 1: Please read!
Read the following supplementary information in its entirety! You will ben‐
efit more from using the operating instructions should you already know
this information.
The following are highlighted separately in the document:
n Enumerated lists
Instructions
Outcome of the instructions
ð
Ä ‘State the identity code and serial number’ on page 2
in this chapter
- refer to ... : References to points in this document or another document
: Links to points
[Keys]
Information
Validity
State the identity code and serial number
This provides important information relating to the cor‐
rect operation of the unit or is intended to make your
work easier.
Safety Information
Safety information is identified by pictograms - see Safety Chapter.
These operating instructions conform to current EU regulations applicable
at the time of publication.
Please state identity code and serial number, which you can find on the
nameplate when you contact us or order spare parts. This enables us to
clearly identify the unit type and material versions.
2
Table of contents
Table of contents
Identity code.................................................................................... 6
1
2 About this pump............................................................................... 9
3 Safety chapter............................................................................... 10
4 Storage, transport and unpacking................................................. 15
5 Overview of equipment and control elements............................... 17
5.1 Overview of equipment......................................................... 17
5.2 Control elements................................................................... 18
5.2.1 Key functions...................................................................... 18
5.2.2 Stroke length adjustment knob........................................... 19
5.2.3 Identifier............................................................................. 19
6 Functional description.................................................................... 22
6.1 Liquid End............................................................................. 22
6.2 Drive unit............................................................................... 22
6.3 Capacity................................................................................ 22
6.4 Operating modes................................................................... 23
6.5 Functions............................................................................... 23
6.6 Relay (options)...................................................................... 24
6.7 Functional and fault Indicator................................................ 24
6.8 LCD display........................................................................... 25
6.9 LED indicators....................................................................... 25
6.10 Hierarchy of operating modes, functions and fault sta‐
tuses....................................................................................
7 Assembly....................................................................................... 26
8 Hydraulic Installation..................................................................... 27
8.1 Installing hose lines............................................................... 28
8.1.1 Installation of metering pumps without bleed valve............ 28
8.1.2 Installation of metering pumps with bleed valve................. 30
8.2 Basic installation notes.......................................................... 31
9 Electrical installation...................................................................... 33
9.1 Supply voltage connector...................................................... 34
9.2 Description of the Terminals................................................. 35
9.2.1 "External control" terminal.................................................. 35
9.2.2 "Level switch" terminal....................................................... 36
9.2.3 "Metering monitor" terminal................................................ 36
9.2.4 "Diaphragm rupture sensor" terminal................................. 37
9.3 Relay..................................................................................... 37
9.3.1 Relay functions................................................................... 37
9.3.2 "Fault indicating relay" output (identity code 1 + 3 or 6 +
7)........................................................................................ 38
9.3.3 Output for other relays (identity code 4 + 5, 8 + 9, A + B).. 39
9.3.4 Output "Current output plus relay" (identity code C + D +
E)........................................................................................ 39
10 Setting........................................................................................... 41
10.1 Basic principles for setting up the control............................ 41
10.2 Checking adjustable variables............................................ 41
10.3 Changing to Setting mode................................................... 42
10.4 Selecting the operating mode (Menu "Mode").................... 43
10.5 Operating mode settings (menu "Settings")........................ 43
10.5.1 "Manual" operating mode settings................................... 45
10.5.2 Settings for the “Batch” operating mode (BATCH
menu)...............................................................................
10.5.3 "Contact" operating mode settings................................... 46
10.5.4 "Analog" operating mode settings.................................... 48
25
45
3
Table of contents
10.6 Programmable function settings ("Settings" menu )............ 50
10.6.1 Settings for the “Concentration” function (CONCENTRA‐
TION menu).....................................................................
51
10.6.2 Settings for the “Auxiliary frequency” function (AUX
menu)...............................................................................
58
10.6.3 Settings for the “Flow” function (FLOW menu)................. 59
10.6.4 Settings for the “Calibration” function (CALIBRATION
menu)............................................................................... 59
10.6.5 Settings for the “Metering” function (METERING menu).. 61
10.6.6 Settings for the "Bleeding" function)................................. 65
10.6.7 Settings for the “Relay” function (RELAY menu).............. 67
10.6.8 Settings for the “Analogue output” function (ANALOG
OUTPUT menu)............................................................... 68
10.6.9 Settings in the "System" menu" (SYSTEM menu)........... 69
10.7 Set code (SECURITY menu).............................................. 70
10.8 Delete total number of strokes or total litres (CLEAR
menu).................................................................................. 71
10.9 Set language (LANGUAGE menu)...................................... 71
11 Operation....................................................................................... 72
11.1 Manual................................................................................ 72
11.2 Remote operation................................................................ 74
12 Maintenance.................................................................................. 75
13 Repair............................................................................................ 77
13.1 Cleaning valves................................................................... 78
13.2 Replacing the diaphragm.................................................... 79
13.3 Cleaning the Diaphragm Rupture Indicator......................... 81
14 Troubleshooting............................................................................. 82
14.1 Faults without a fault message............................................ 82
14.2 Fault messages................................................................... 83
14.3 Fault alerts / warning alerts................................................. 83
14.4 Warning messages............................................................. 84
14.5 All other faults..................................................................... 84
15 Decommissioning and disposal..................................................... 85
15.1 Decommissioning................................................................ 85
15.2 Disposal.............................................................................. 86
16 Technical data............................................................................... 87
16.1 Performance data................................................................ 87
16.2 Accuracy............................................................................. 88
16.2.1 Standard liquid ends........................................................ 88
16.3 Viscosity.............................................................................. 88
16.4 Material data....................................................................... 88
16.5 Electrical data...................................................................... 89
16.6 Temperatures...................................................................... 89
16.7 Climate................................................................................ 89
16.8 Degree of Protection and Safety Requirements.................. 90
16.9 Compatibility........................................................................ 90
16.10 Weight............................................................................... 90
16.11 Sound pressure level........................................................ 90
17 Dimensional drawings................................................................... 91
18
Diagrams for setting the metering capacity................................... 95
19 Exploded view drawings................................................................ 97
20 Further order information............................................................. 117
21 EU Declaration of Conformity for Machinery............................... 118
22 Operating menu overview............................................................ 119
4
Table of contents
23 Continuous displays.................................................................... 121
24
Index............................................................................................ 123
5
Identity code
1 Identity code
product range, version a
delta®
DLTa Type Capacity
bar l/h
2508 25 7.5
1608 16 7.8
1612 16 11.3
1020 10 19.1
0730 7 29.2
0450 4 49.0
0280 2 75.0
Material of dosing head / valves
SS Stainless steel / stainless steel
PV PVDF / PVDF
NP Clear acrylic / PVC
Material of seals / diaphragm
T PTFE / PTFE-coated
S PTFE / Diaphragm also coated with FPM
B FPM-B / PTFE-coated
E EPDM / PTFE-coated
F FDA-compliant
Dosing head design
0 without bleed valve, without valve spring
1 without bleed valve, with valve spring
2 with bleed valve, without valve spring
3 with bleed valve, with valve spring
4 HV version for media of higher viscosity
7 Self-bleeding without bypass (SER)
Hydraulic connector
0 Standard connection in line with technical data
5 Connector for 12/6 hose, suction side standard
F Connector on discharge side for 8/4 hose, standard on suction side
Diaphragm rupture indicator
0 without diaphragm rupture indicator
1 Diaphragm rupture indicator
2 With dual diaphragm system and diaphragm rupture indicator, pres‐
sure sensor
Design
0 with ProMinent logo
Electrical connection
U Universal control 100-230 V ±10%, 50/60 Hz
6
product range, version a
delta®
Identity code
Cable and plug
A 2 m European
B 2 m Swiss
C 2 m Australian
D 2 m USA / 115 V
1 2 m open end
... ...
Relay
0 no relay
1 Fault indicating
relay (N/C)
3 Fault indicating
relay (N/O)
1 x changeover con‐
tact 230 V – 8 A
1 x changeover con‐
tact 230 V – 8 A
4 as 1 + pacing relay 2 x N/O 24 V – 100
mA
5 as 3 + pacing relay 2 x N/O 24 V – 100
mA
A Shut-down and
warning relays
2 x N/O 24 V – 100
mA
(N/C)
C As 1 + 4-20 mA
mA output
F With automatic
1 x N/O 24 V – 100
mA
230 V
bleed valve
G with automatic
24 VDC
bleed valve and
relay output
... ...
Accessories
0 no accessories
1 with foot and injection valve, 2 m
suction line, 5 m metering line
2 As 0 + measuring cup
3 As 1 + measuring cup
Control version
0 Manual + external contact
with pulse control
3 Manual + external contact
with pulse control + ana‐
logue 0/4-20mA
4 As 0 + 4-week process
timer
5 As 3 + 4-week process
timer
C As 3 + CANopen
M As 3 + pH, ORP and
chlorine + DFMA control
module
7
Identity code
product range, version a
delta®
R
As 3 + PROFIBUS® inter‐
face, M12
Access code
0 No access code
1 With access code
Language
EN German
EN English
FR French
ES Spanish
IT Italian
... ...
Pause / level
0 Pause
N/C, level
N/C
8
2 About this pump
About this pump
Properties of the device
The solenoid metering pumps belonging to the delta® product range with
controlled optoDrive® solenoid drive are microprocessor-controlled sole‐
noid metering pumps with the following characteristics:
n Continuous or pulsing operation
n Adaptation of the pump to the feed chemical
n Detection of blocked points of injection, broken metering lines and
trapped air or gas bubbles in the dosing head by the integral injection
point monitor optoGuard.
n Output range 7.5 l/h, 25 - 2 bar
n Stroke length continuously adjustable between 0 - 100 % (recom‐
mended 30 - 100 %)
n Material versions PVDF and stainless steel
n Patented coarse/fine adjustment
n Diaphragm rupture detection and signalling (optional)
n Adjustment and display of the feed rate, either as strokes/min or l/h
via the keyboard
n Large illuminated graphic display
n External activation via potential-free contacts with optional pulse step-
up and step-down
n Option of external activation by standard signal 0/4-20 mA
n Interface for PROFIBUS®or CANopen (optional)
n 14-day process timer* for time- and event-dependent metering tasks
n Connection for 2-stage level switch
n 3 LED display for operation, warning and fault messages in plain text
n Concentration input for volume-proportional metering
n Automatic bleed
n Pump type 2508 with 7.5 l/h at 25 bar
n Material version NP for pump types 2508, 1612, 1608, 1020 and 0730
9
Safety chapter
3 Safety chapter
Labelling of safety information
Warning signs denoting different types of
danger
The following signal words are used in these operating instructions to
denote different levels of danger:
Signal word Meaning
WARNING Denotes a possibly hazardous sit‐
uation. If this is disregarded, you
are in a life-threatening situation
and this can result in serious inju‐
ries.
CAUTION Denotes a possibly hazardous sit‐
uation. If this is disregarded, it
could result in slight or minor inju‐
ries or material damage.
The following warning signs are used in these operating instructions to
denote different types of danger:
Warning signs Type of danger
Warning – automatic start-up.
Warning – high-voltage.
Intended use
Warning – danger zone.
n Only use the pump to meter liquid feed chemicals.
n Only use the pump after it has been correctly installed and started up
in accordance with the technical data and specifications contained in
the operating instructions.
n Observe the general limitations with regard to viscosity limits, chem‐
ical resistance and density - see also ProMinent® Resistance List in
the Product Catalogue or at www.prominent.com!
n All other uses or modifications are prohibited.
n The pump is not intended for the metering of gaseous media and
solids.
n The pump is not intended for the metering of explosive media.
n The pump is not intended for operation in areas at risk from explosion.
n The pump is not intended for flammable media without suitable pro‐
tective measures.
n The pump is not intended for exterior applications without the imple‐
mentation of suitable protective measures.
n The pump should only be operated by trained and authorised per‐
sonnel, see the following "Qualifications" table.
n You have a responsibility to adhere to the information contained in the
operating instructions at the different phases of the unit's service life.
10
Qualification of personnel
Safety chapter
Action Qualification
Storage, transport, unpacking Instructed person
Assembly Technical personnel, service
Planning hydraulic installation Qualified personnel who have a
thorough knowledge of metering
pumps.
Hydraulic installation Technical personnel, service
Installation, electrical Electrical technician
Operation Instructed person
Maintenance, repair Technical personnel, service
Decommissioning, disposal Technical personnel, service
Troubleshooting 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 envi‐
ronment 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 dan‐
gers 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 information
WARNING!
Warning about personal and material damage
The pump can start to pump, as soon as it is connected
to the mains voltage.
– Install an emergency cut-off switch in the pump
power supply line or integrate the pump in the emer‐
gency cut-off management of the system.
11
Safety chapter
WARNING!
Danger of electric shock
A mains voltage may exist inside the pump housing.
– If the pump housing has been damaged, you must
disconnect it from the mains immediately. It may
only be returned to service after an authorised
repair.
WARNING!
Fire danger
When pumping inflammable media the operator must
take suitable safety precautions.
WARNING!
Warning of hazardous feed chemical
Should a dangerous feed chemical be used: it may
escape from the hydraulic components when working on
the pump, material failure or incorrect handling of the
pump.
– Take appropriate protective measures before
working on the pump (e.g. safety glasses, safety
gloves, ...). Adhere to the material safety data sheet
for the feed chemical.
–
Drain and flush the liquid end before working on the
pump.
CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic compo‐
nents 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.
CAUTION!
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 mate‐
rials and the ProMinent Resistance List when
selecting the feed chemical - see the ProMinent
Product Catalogue or visit ProMinent.
12
Safety chapter
CAUTION!
Warning of feed chemical spraying around
The metering pump can generate a multiple of its rated
pressure. Hydraulic parts can rupture if a discharge line
is blocked.
– Correctly install a back pressure valve in the dis‐
charge line behind the metering pump.
CAUTION!
Only with SER dosing heads: Warning of feed chemical
spraying around
If there is a high pressure acting on the other side of the
discharge valve, opening of the bleed valve can result in
feed chemical escaping even if the pump is at a stand‐
still.
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in per‐
sonnel injuries and material damage.
– Only fit parts to metering pumps, which have been
tested and recommended by ProMinent.
CAUTION!
Danger from incorrectly operated or inadequately main‐
tained 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.
–
CAUTION!
Danger from incorrect metering
Should a different liquid end size be fitted, this will
change the metering behaviour of the pump.
– Have the pump reprogrammed in the works.
CAUTION!
Warning against illegal operation
Observe the regulations that apply where the device is
installed.
Fixed separating protective equipment
n Dosing head
n Housing
n Hood (houses the control elements)
The dosing head may only be removed by the customer in accordance
with the "Repair" chapter.
The housing and the hood may only be removed by ProMinent customer
service department.
13
Safety chapter
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 exits, switch off the pump by pressing the
[Stop/Start]
key.
If necessary depressurise the hydraulic system around the pump. Observe
the safety data sheet for the feed chemical.
Sound pressure level
Sound pressure level LpA < 70 dB according to EN ISO 20361
at maximum stroke length, maximum stroke rate, maximum back pressure
(water)
14
4 Storage, transport and unpacking
Safety information
WARNING!
The pump can tip over when lifting
The pump can tip over when lifting, as the centre of
gravity of the pump is quite a distance from the liquid
end.
– Grip the pump quite close to the liquid end.
Safety information
WARNING!
The transporting of pumps which have been used with
radioactive feed chemicals is forbidden!
They will also not be accepted by ProMinent!
Storage, transport and unpacking
WARNING!
Only return metering pumps for repair in a cleaned state
and with a flushed liquid end - refer to "Decommis‐
sioning!
Only return metering pumps with a completed Decon‐
tamination Declaration form. The Decontamination Dec‐
laration constitutes an integral part of an inspection /
repair order. A unit can only be inspected or repaired
when a Declaration of Decontamination Form is sub‐
mitted that has been completed correctly and in full by
an authorised and qualified person on behalf of the
pump operator.
The "Decontamination Declaration Form" can be found
on our homepage.
CAUTION!
Danger of material damage
The device can be damaged by incorrect or improper
storage or transportation!
– The unit should only be stored or transported in a
well packaged state - preferably in its original pack‐
aging.
The packaged unit should also only be stored or
–
transported in accordance with the stipulated
storage conditions.
– The packaged unit should be protected from mois‐
ture and the ingress of chemicals.
Ambient conditions
Refer to the "Technical Data" chapter
15
Storage, transport and unpacking
Scope of delivery
Compare the delivery note with the scope of delivery:
n Metering pump with mains cable
n Connector kit for hose/pipe connection
n Product-specific operating instructions with EC Declaration of Con‐
formity
n Optional accessories
n Relay cable, as necessary
16
1 2
3
P_DE_0027_SW
P_DE_0019_SW
a
b
c
d
e
f
g
Overview of equipment and control elements
5 Overview of equipment and control elements
Overview of equipment
5.1
Fig. 2
1 Control unit
2 Drive unit
3 Liquid end
Fig. 3
a Discharge valve
b Backplate
c Dosing head
d Bleed valve
e Bypass hose sleeve
f Diaphragm rupture sensor
g Suction valve
17
11 13 15 161412
10
9
8
7
3
1
a)
b)
5
4
2
6
P_DE_0017_SW
STOP
START
P
i
B0098
Overview of equipment and control elements
5.2 Control elements
Fig. 4: a)Displays and keys, b) Electrical control connections
1 LCD screen
2 Stroke length adjustment knob
3
[UP]
4
5
6
7
key
[P]
key
[DOWN]
key
[STOP/START]
[i]
key
key
8 Operating indicator (green)
9 Warning indicator (yellow)
10 Fault indicator (red)
11 "External control" socket
12 "Metering monitor" socket
13 "Level switch" socket
14 "Diaphragm rupture indicator" socket
15
Slot for optional modules (timer, PROFIBUS®, CAN-Bus)
16 Relay and mA-output (optional)
5.2.1 Key functions
Key Application In continuous displays (operation) In adjustment mode (set up)
[STOP/
START]
Pressed briefly Stop pump, Stop pump,
Start pump Start pump
[P]
Pressed briefly Start batch (only in
Pressed for 2 s Change to adjustment mode -
Pressed for 3 s - Jump to continuous display
‘Batch’
operating
mode), acknowledge fault
18
Confirm entry - jump to next menu
option or to continuous display
P
10548
Analog
200
/min
Stop
Aux
cal
P
ii
Overview of equipment and control elements
Key Application In continuous displays (operation) In adjustment mode (set up)
[i]
Pressed 2x - Under "change individual digits":
Press and hold Change to the secondary display -
[UP], [DOWN]
Pressed simultaneously Priming (in "Stroke rate" continuous
Pressed 1x Switch between the continuous dis‐
Individually pressed
(until double arrow
appears)
plays
Change directly adjustable variables Select another setting, change
display)
Change between "Change indi‐
vidual digits" and "Change one
number"
Jump to the first digit
individual number or number.
At the top end of a selection,
effect similar to an ESC key.
-
5.2.2 Stroke length adjustment knob
The stroke length can be adjusted using the stroke length adjustment knob
and with it the volume per stroke.
5.2.3
Symbol Additional
Identifier
symbol
Priming: The pump is currently priming (both arrow keys pressed).
Symbol for P-key: The pump is in adjustment mode.
The LCD screen supports the operation and adjustment of the pump using
different identifiers:
Fig. 5
The identifiers have the following meanings:
Name Meaning
Lock symbol: Lock (if a code was set. Flashes).
Double arrow symbol: the value in the continuous display can be changed with
Info symbol: It is possible to change between continuous displays.
the arrow keys.
19
p+
p -
mm
Overview of equipment and control elements
Symbol Additional
symbol
Aux: The pump is currently pumping with the auxiliary fre‐
Fault: A fault has occurred, which has stopped the system.
Stroke length: The pump is set to
Stroke length adjust‐
Name Meaning
Stop: The pump was stopped using the
Pause: The pump was externally stopped by the Pause contact.
(therefore manually).
quency as the stroke rate.
During this time, the pump is in
mode.
‘Metering’ ‘slow’
mode is also active (less than 61 strokes/min). Below 30
strokes/min the operating indicator flashes during opera‐
tion and illuminates for slightly longer at the end of each
stroke.
The symbol relates to the symbol, which is located
beneath the stroke adjustment dial.
ment:
Deviation in the stroke length from the value set at the
time of the last locking of the setting menu.
[STOP/START]
‘Manual’
operating
and this metering
key
Diaphragm rupture: The diaphragm is broken. The message appears as a
Air lock: There is air in the liquid end. The message appears as a
Level: The "Warning" level in the storage tank was trans‐
Flow: A flow control is connected. Together with a call sign, the
Contact: The pump is in
Contact signal: The pump is in
Overpressure moni‐
toring:
warning or fault, dependent upon the setting.
The symbol represents a section through the membrane.
warning or fault, dependent upon the setting.
The symbol represents a liquid end with air bubbles in it.
gressed. If the symbol flashes, the level has fallen below
the "Fault" level in the storage tank and the pump stops.
symbol indicates problems with the flow.
‘Contact’
The symbol closes every time a contact signal is gener‐
ated.
‘Batch’
The symbol flashes every time a contact signal is gener‐
ated.
A constriction or a closed shut-off valve on the discharge
side allows the pressure to increase above the maximum
permissible operating pressure. The message appears
as a warning or fault, dependent upon the setting.
operating mode.
operating mode.
Low pressure: There is a leak or a burst or torn line on the discharge
Memory: The pump is in operating mode
side. The message appears as a warning or fault,
dependent upon the setting.
the auxiliary function "Memory" is set.
‘Contact’
20
or
‘Batch’
and
0..200..20
4..204..20
i < 4i < 4
i > 23i > 23
Overview of equipment and control elements
Symbol Additional
symbol
0...20 mA: The pump is in operating mode
4...20 mA: The pump is in operating mode
i less than 4 mA: Problems with the standard signal at the standard signal
i greater than 23 mA: The standard signal at the standard signal input indicates
Line: The pump is in operating mode
Upper sideband: The pump is in operating mode
Lower sideband: The pump is in operating mode
Name Meaning
type
‘0...20’
type
‘4...20’
input e.g. broken cable.
a fault with the connected unit.
The processing type
The processing type
type
‘Curve’-‘Lower sideband’
The pump only shows the metering volume and the
capacity in the calibrated state in l or l/h or in gal or
gal/h.
is set.
is set.
‘Analog’
‘Analog’
‘Analog’
‘Curve’-‘Linear’
‘Analog’
‘Curve’-‘Upper sideband’
‘Analog’
is set.
. The processing
. The processing
.
is set.
.
. The processing
is set.
21
P_DE_0006_SW
p
a) b)
t
Functional description
6 Functional description
Liquid End
6.1
The dosing process is performed as follows: The diaphragm is pressed
into the dosing head; the pressure in the dosing head closes the suction
valve and the feed chemical flows through the discharge valve out of the
dosing head. The diaphragm is now drawn out of the dosing head; the dis‐
charge valve closes due to the negative pressure in the dosing head and
fresh feed chemical flows through the suction valve into the dosing head.
One cycle is completed.
6.2 Drive unit
The displacement body is driven by an electromagnet, which is controlled
by an electronic control.
optoDrive® drive technology
Fig. 6: Metering types: a) pulsing, b)
nearly continuous
The optoDrive® drive technology means the variation over time of the
metering flow can be precisely matched to the requirements of the partic‐
ular application. Hence the user can, dependent on requirements, set a
slow discharge stroke for nearly continuous metering or a quick stroke e.g.
for quick clocked filling processes. In both operating modes it is possible,
to selectively also slow the suction stroke, see figure. In this way, it is pos‐
sible to prevent the main cause for imprecise metering with high viscosity
feed chemicals, namely the incomplete filling of the liquid end. For the
case of gaseous feed chemicals, the slow suction stroke prevents cavita‐
tion and consequently increases metering accuracy. Oscillations in the
back pressure in the metering line, which could lead to undesirable varia‐
tions in the metering volume, are automatically compensated for by the
drive. Consequently, a dosing precision is attained, which otherwise could
only be achieved using a complex control circuit.
p Pressure
t Time
The integral injection point monitoring of the hydraulic metering parame‐
ters, optoGuard® is integrated in the drive. It automatically detects blocked
points of injection or broken metering lines. Consequently, dependent on
the hydraulic installation situation, separate relief valves and pressure sen‐
sors need not be used, and no uncontrolled metering through a broken
line occurs. It also detects air or gases (airlock) trapped in the liquid end.
This prevents metering of incorrect quantities and thus increases process
reliability. The relevant messages are shown on the pump's display. The
system operator can determine, depending on the type of fault, whether a
message is to be sent to the process control system via the fault signal
relay and whether metering is automatically stopped.
6.3
Capacity
The capacity is determined by the stroke length and rate.
22
6.4 Operating modes
Functional description
The stroke length is adjusted by the stroke length adjustment knob within
a range of 0 ... 100 %. A stroke length of between 30 ... 100 %) is recom‐
mended to achieve the specified reproducibility.
The stroke rate can be set using the arrow keys (not in "Analog" operating
mode) in the range 0 - 200 strokes/min (200 strokes/min
strokes/h). The "Stroke rate (strokes / min)" continuous display shows dec‐
imal places if a stroke frequency is set in the "Stroke rate (strokes / h)"
continuous display, which cannot be divided by 60 without a remainder.
Data Value Unit
Recommended stroke length 30 ... 100 %
The stroke speed can be set in the "Dosing" menu.
Operating modes are selected via the "Operating modes" menu.
≜12,000
"Manual" operating mode
"Batch" operating mode
Operating mode "Contact"
"Analog" operating mode
6.5 Functions
"Calibrate" function
The stroke rate is set manually via the control unit.
This operating mode provides the option of working with large transfer fac‐
tors (up to 65535). Metering can be triggered by pressing the button
by a pulse received via the "External control" jack through a contact or a
semiconductor switching element. A metering volume (batch) or a number
of strokes can be selected in the
This operating mode offers the option of activating the pump externally by
means of potential-free contacts (e.g. by means of a contact water gauge).
The number of strokes (reducing or transfer factor 0.01 to 99.99) can be
pre-selected in the
The stroke rate is controlled using an analog current signal via the
"External control" jack. Processing of the current signal can be preselected
via the control unit.
The following functions can be selected vin the menu
The stroke rate is controlled using an analog current signal via the
"External control" jack. Processing of the current signal can be preselected
via the control unit.
The pump can also be operated in the calibrated state in all operating
modes. The corresponding continuous displays can then either display the
metering volume or the capacity (in the 2nd level continuous display). The
calibration remains valid over the entire stroke rate range and over a
stroke length range from 0 - 100 %.
‘Settings’
‘Settings’
menu using the
menu using the
[arrow keys]
‘Settings’
[arrow keys]
.
[P]
or
.
:
"Auxiliary rate" function
"Flow" function
This enables switching to an adjustable stroke rate which can be fixed in
the
‘Settings’
quency has priority over the operating mode stroke rate settings .
This monitors the flow in "pulsing" dosing mode after every individual
stroke, if a dosing monitor is connected. The number of sequential faulty
strokes above which it is to be stopped, can be set in the
menu via the "External control" jack. This auxiliary fre‐
‘Settings’
23
menu.
Functional description
The following functions are available as standard:
"Level switch" function
"Pause" function
"Stop" function
"Priming" function
6.6 Relay (options)
"Fault indicating relay" option
Information about the liquid/powder level in the feed chemical container is
reported to the pump. To do so, a two-stage level switch must be fitted; it
is connected to the "Level switch" jack.
The pump can be remotely stopped via the "External control" jack.
The following functions are triggered by a key press:
The pump can be stopped by pressing the key
disconnecting it from the power supply.
Priming (short-term transport at maximum frequency) can be triggered by
simultaneous pressing of the two
The pump has several connection options for:
The relay can, in the event of fault or warming alerts or messages (e.g.
‘Warning level’
The relay can be retrofitted through a knock-out opening in the pump foot refer to "Retrofitting relays".
), close a connected electric circuit (e.g. for an alarm horn).
[arrow keys]
[STOP/START]
.
, without
"Fault indicating and pacing relay" option
"Automatic bleed" option
"mA output" option
6.7
Functional and fault Indicator
This combined relay can generate a contact with each stroke via its pacing
relay in addition to its function as a fault indicating relay.
The relay can be retrofitted through a knock-out opening in the pump foot refer to "Retrofitting relays".
The function "Bleeding" is used for controlled bleeding of the liquid end, if
the pump is provided with the option "Automatic bleed". The "Automatic
bleed" option can be retrofitted, i.a. via a knock-out in the control unit.
There are two versions:
n version with only 1 relay - to control the bleed valve.
n Version with only 2 relays - one relay to control the bleed valve and
one relay free for other uses.
The I signal of the current output signals the currently calculated pump
metering volume. The option "mA output" can be retrofitted via a knock-out
in the control unit.
The option additionally always provides a fault indicating relay or a pacing
relay.
The operating and fault statuses are indicated by the three LED indicators
and the "Fault" identifier of the LCD screen, see also the "Troubleshooting"
chapter.
24
6.8 LCD display
LED indicators
6.9
Fault indicator (red)
Functional description
If a fault occurs, the identifier "Fault" appears as well an additional, explan‐
atory symbol.
The fault indicator lights up if the liquid level in the chemical feed container
falls below the second switching point of the level switch (
filling level in the chemical feed container).
This LED flashes in the event of an undefined operating mode.
20 mm residual
Warning indicator (yellow)
Operating indicator (green)
6.10
Hierarchy of operating modes, functions and fault statuses
The warning indicator lights up if the fluid level in the chemical feed con‐
tainer falls below the first switching point of the level switch.
The operating indicator lights up if the pump is ready for operation and
there are no fault or warning alerts. It goes out quickly as soon as the
pump has performed a stroke. It starts to flash as soon as the stroke rate
falls below 30 strokes / min.
The different operating modes, functions and fault statuses have a dif‐
ferent effect on if and how the pump reacts.
The following list shows the order:
1. - Priming
2. - Fault, Stop, Pause
3. - Auxiliary rate
4. - Manual, Analog, Contact, Batch
Comments:
re 1 - "Priming" can take place in any mode of the pump (providing it is
functioning).
re 2 - "Fault", "Stop" and "Pause" stop everything apart from "Priming".
re 3 - The stroke rate of "Auxiliary rate" always has priority over the
stroke rate specified by an operating mode or priority 4.
25
Assembly
7 Assembly
Compare the dimensions on the dimension sheet
–
with those of the pump.
WARNING!
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.
CAUTION!
Danger from incorrectly operated or inadequately main‐
tained 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.
–
Capacity too low
The liquid end valves can be disturbed by vibrations.
–
Secure the metering pump so that no vibrations can
occur.
Capacity too low
If the valves of the liquid end are not vertical, they
cannot close correctly.
–
Suction and discharge valves must stand vertically
upwards (for self-bleeding liquid end, the bleed
valve).
Mount the metering pump with the pump foot on a horizontal, level
and load-bearing supporting surface.
26
8 Hydraulic Installation
Safety information
Hydraulic Installation
CAUTION!
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 mate‐
rials and the ProMinent Resistance List when
selecting the feed chemical - see the ProMinent
Product Catalogue or visit ProMinent.
CAUTION!
Warning of feed chemical spraying around
Pumps which are not fully installed hydraulically can
eject feed chemicals from the outlet openings of the dis‐
charge valves as soon as they are connected to the
mains.
– The pump must first be hydraulically installed and
then electrically.
– In the event that you have failed to do so, press the
[STOP/START]
switch.
button or press the emergency-stop
CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic compo‐
nents 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.
CAUTION!
Danger from rupturing hydraulic components
Peak loads during the dosing stroke can cause the max‐
imum permissible operating pressure of the system and
pump to be exceeded.
– The discharge lines are to be properly designed.
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in per‐
sonnel injuries and material damage.
– Only fit parts to metering pumps, which have been
tested and recommended by ProMinent.
27
Hydraulic Installation
8.1 Installing hose lines
8.1.1
Safety information
Installation of metering pumps without bleed valve
CAUTION!
Warning of feed chemical spraying around
The pipes can loosen or rupture if they are not installed
correctly.
– Route all hose lines so they are free from mechan‐
ical stresses and kinks.
Only use original hoses with the specified hose
–
dimensions and wall thicknesses.
– Only use clamp rings and hose nozzles that are
intended for the hose diameter in question to ensure
the long service life of the connections.
CAUTION!
Danger from rupturing hydraulic components
Hydraulic components can rupture if the maximum per‐
missible operating pressure is exceeded.
– Always adhere to the maximum permissible oper‐
ating pressure of all hydraulic components - please
refer to the product-specific operating instructions
and system documentation.
–
Never allow the metering pump to run against a
closed shut-off device.
– Install a relief valve.
CAUTION!
Hazardous feed chemicals can escape
Hazardous or extremely aggressive feed chemicals can
escape outside when using conventional bleeding proce‐
dures with metering pumps.
– Install a bleed line with return line into the storage
tank.
CAUTION!
Hazardous feed chemicals can escape
Hazardous or extremely aggressive feed chemicals can
escape outside in the event that the metering pump is
removed from the installation.
– Install a shut-off valve on the pressure and dis‐
charge side of the metering pump.
CAUTION!
Uncontrolled flow of feed chemical
Feed chemical can press through a stopped metering
pump if there is back pressure.
– Use an injection valve or a vacuum breaker.
28
Installing hose lines - PP, NP, PV, TT
designs
Hydraulic Installation
CAUTION!
Uncontrolled flow of feed chemical
The feed chemical can leak through the metering pump
in an uncontrolled manner in the event of excessive pri‐
ming pressure.
– Do not exceed the maximum priming pressure for
the metering pump - please refer to the product-spe‐
cific operating instructions.
Align the pipes so that the metering pump and the liquid
end can be removed from the side if necessary.
1. Cut off the ends of the hoses at right angles.
2. Pull the union nut (2) and clamp ring (3) over the hose (1) - see .
3. Push the hose end (1) up to the stop over the nozzle (4) and widen,
if necessary.
Ensure that the O-ring and/or the flat seal (5) is
sitting properly in the valve (6).
Never re-use used PTFE seals. An installation
sealed in this way is not watertight.
This type of seal is permanently distorted when
subjected to pressure.
The FPM flat seal PV design has a dot to enable it
to be distinguished from the EPDM flat seal.
4. Place the hose (1) with the nozzle (4) onto the valve (6).
5. Clamp the hose connector: Tighten the union nut (2) while simulta‐
neously pressing on the hose (1).
6. Re-tighten the hose connector: Pull on the hose (1) briefly, which is
fastened to the dosing head and then tighten the union nut (2) once
more.
29
1
2
4
5
6
3
P_MAZ_0021_SW
1
2
4
5
3
P_MAZ_0022_SW
Hydraulic Installation
Fig. 7: PP, NP, PV and TT designs
Installing stainless steel pipe - SS design
1 Hose
2 Union nut
3 Clamp ring
4 Nozzle
5 O-ring or flat seal
6 Valve
1. Pull the union nut (2) and clamp rings (3, 4) over the pipe (1) with
approx. 10 mm overhang - see .
2. Insert the pipe (1) up to the stop in the valve (5) and then withdraw
1...2 mm.
3. Tighten the union nut (2).
Fig. 8: SS design
Installing hose lines - SS design
1 Pipe
2 Union nut
3 Rear clamp ring
4 Front clamp ring
5 Valve
CAUTION!
Warning of feed chemical spraying around
Connections can come loose in the event that hose lines
are installed incorrectly on stainless steel valves.
– Only use PE or PTFE hose lines.
In addition, insert a stainless steel support insert into
–
the hose line.
8.1.2 Installation of metering pumps with bleed valve
Safety information
CAUTION!
– All the installation and safety information for
metering pumps without bleed valves also apply.
Installation of the return line
A return line is also connected in addition to the suction and discharge
line.
30
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