ProMinent gamma/ X GMXa Operating Instructions Manual

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Page 1

Operating instructions Solenoid Metering Pump

gamma/ X, GMXa

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. 984586 BA G 054 04/17 EN

Page 2

Supplemental directives

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:

n Enumerated lists

Instructions

Outcome of the instructions

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]

„Menu level 1 è Menu level 2 è Menu level ...“

: Menu paths

„Software interface text“

Information

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".

Please state the identity code and serial number, which you can find on the nameplate or in the menu under you contact us or order spare parts. This enables the unit type and mate‐ rial versions to be clearly identified.

„Setting / Menu è Information“

when

Page 3

Table of contents

Identity Code................................................................................... 6

2 About this pump............................................................................... 8

3 Safety Chapter................................................................................. 9

4 Storage, Transport and Unpacking................................................ 14

5 Overview of Equipment and Control Elements.............................. 15

5.1 Overview of equipment......................................................... 15

5.2 Control elements................................................................... 16

5.2.1 Control elements................................................................ 16

5.2.2 Key functions...................................................................... 20

6 Functional Description................................................................... 21

6.1 Liquid End............................................................................. 21

6.2 Drive unit............................................................................... 21

6.3 Capacity................................................................................ 23

6.4 Self-Bleeding......................................................................... 23

6.5 Operating modes................................................................... 23

6.6 Functions............................................................................... 24

6.7 Relay (Options)..................................................................... 24

6.8 LED Displays......................................................................... 25

6.9 Hierarchy of Operating Modes, Functions and Fault Sta‐

tuses......................................................................................

7 Assembly....................................................................................... 27

8 Installation, hydraulic..................................................................... 29

8.1 Installing hose lines............................................................... 30

8.1.1 Installation of Metering Pumps Without Bleed Valve......... 30

8.1.2 Installation of Metering Pumps With Bleed Valve.............. 33

8.1.3 Installation of Metering Pumps With Self-bleeding (SEK

Type).................................................................................. 33

8.2 Basic installation notes.......................................................... 35

9 Installation, electrical..................................................................... 36

9.1 Supply voltage connector - mains voltage............................ 37

9.2 Description of the Terminals................................................. 38

9.2.1 "External control" terminal.................................................. 38

9.2.2 "Level switch" terminal....................................................... 39

9.2.3 "Dosing monitor" terminal................................................... 39

9.2.4 "Diaphragm rupture indicator" terminal.............................. 40

9.2.5 Relay.................................................................................. 40

10 Basic Set-up Principles.................................................................. 44

10.1 Basic Principles for Setting up the Control.......................... 44

10.2 Checking adjustable variables............................................ 46

10.3 Changing to set up mode.................................................... 46

11 Set Up /

11.1

11.2

11.2.1

11.2.2

11.2.3

11.2.4 Metering........................................................................... 53

11.2.5 Concentration................................................................... 57

11.2.6 Calibration........................................................................ 63

11.2.7 System............................................................................. 64

11.2.8 Inputs/outputs................................................................... 66

11.2.9 Bleeding........................................................................... 69

„Menu“

............................................................................ 47

„Information“ „Settings“

....................................................................... 47

............................................................................ 47

„Operating Mode“ „Automatic“

...................................................................... 52

„Stroke length“

............................................................ 47

................................................................ 52

Page 4

Table of contents

11.2.10

11.2.11

11.2.12

11.3 Timer................................................................................... 71

11.3.1 Timer activation................................................................ 71

11.3.2 Setting the timer............................................................... 72

11.3.3 Clear all............................................................................ 74

11.3.4 Example........................................................................... 74

11.4

11.4.1

11.4.2

11.4.3

11.4.4

11.4.5

11.4.6

11.4.7

11.4.8 Diaphragm part number: XXXXXXX................................ 76

11.4.9 Spare parts kit part number: XXXXXXX........................... 77

11.5

12 Operation....................................................................................... 78

12.1 Manual operation................................................................ 78

13 Maintenance.................................................................................. 80

14 Carrying out repairs....................................................................... 82

14.1 Replacing the diaphragm.................................................... 83

14.2 Cleaning the Diaphragm Rupture Indicator......................... 85

14.3 Cleaning valves................................................................... 85

15 Troubleshooting............................................................................. 86

15.1 Faults without a fault message............................................ 86

15.2 Faults with error message................................................... 87

15.2.1 Fault messages on the LCD screen................................. 87

15.2.2 Warning messages on the LCD screen........................... 88

15.2.3 All Other Faults................................................................ 89

15.3 Log book............................................................................. 89

15.3.1 Fault messages in the log book....................................... 89

15.3.2 Warning messages in the log book.................................. 90

15.3.3 Event messages in the log book...................................... 90

15.3.4 Log book entry - Detailed view......................................... 91

16 Decommissioning.......................................................................... 92

17 Technical data............................................................................... 94

17.1 Performance data................................................................ 94

17.2 Accuracy............................................................................. 95

17.2.1 Standard Liquid End......................................................... 95

17.2.2 Self-Bleeding Liquid End.................................................. 95

17.3 Viscosity.............................................................................. 95

17.4 Material specifications......................................................... 96

17.5 Electrical data...................................................................... 96

17.6 Temperatures...................................................................... 96

17.7 Climate................................................................................ 97

17.8 Degree of Protection and Safety Requirements.................. 97

17.9 Compatibility........................................................................ 97

17.10 Shipping weight................................................................. 98

17.11 Sound pressure level........................................................ 98

18 Exploded Drawings and Ordering Information............................... 99

18.1 Exploded drawings.............................................................. 99

„Priming time“ „Set time“ „Date“

„Service“

............................................................................. 74

............................................................................ 71

................................................................ 70

...................................................................... 71

„Access protect.“ „Password “ „Clear counter“ „Log book“

..................................................................... 75

................................................................ 75

....................................................................... 75

„Replace diaphragm“ „Display“

.......................................................................... 76

„Factory settings“

„Language“

......................................................................... 77

............................................................. 74

...................................................... 76

............................................................ 76

Page 5

Table of contents

18.2 Ordering information ........................................................ 139

19 Dimensional Drawings................................................................. 140

Diagrams for Setting the Capacity............................................... 149

21 Declaration of Conformity for Machinery..................................... 152

22 Approvals..................................................................................... 153

23 Operating/Set-up Overview of the gamma/ X.............................. 154

24 Operating Menu of gamma/ X, Entire Unit................................... 156

25 Continuous Displays and Secondary Displays............................ 161

26 Installation instructions: Retrofitting Relays ................................ 163

27 Index............................................................................................ 165

Page 6

Identity Code

1 Identity Code

Product range gamma/ X

GMXa Type

- - - - Performance data and type - see nameplate

Dosing head material

PP Polypropylene

NP Clear acrylic

PV PVDF

TT PTFE + carbon

SS Stainless steel

Seal material

B FPM

E EPDM

T PTFE

F PTFE, 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 Without bleed valve, with valve spring for more high-viscosity media

7 Self-bleeding with groove (SEK)

9 Self-bleeding with bypass (SEK)

Hydraulic connector

0 Standard connection in line with technical data

5 Connector for 12/6 hose, suction side standard

9 Connector for 10/4 hose, discharge side only, suction side standard

Diaphragm rupture indicator

0 Without diaphragm rupture indicator

1 With diaphragm rupture indicator, optical sensor, electrical signal

Design

0 Hous. RAL5003 / Hood RAL2003

M modified

Logo

0 with ProMinent logo

Electrical connection

U 100-230 V ± 10%, 50/60 Hz

Cable and plug

A 2 m European

B 2 m Swiss

C 2 m Australian

Page 7

Product range gamma/ X

Identity Code

D 2 m USA / 115 V

E 2 m Great Britain

1 2 m open end

.. ...

Relay, pre-set to ...

0 No relay -

1 1 x changeover contact 230 V

Fault indicating relay (N/C)

– 8 A

4 2 x N/O 24 V – 100 mA as 1 + pacing relay

C 1 x N/O 24 V – 100 mA, and 1

As 1 + 4-20 mA output

x 4-20 mA output

F With automatic bleed valve 230 V

G with automatic bleed valve

24 VDC

and relay output

.. ...

Accessories

0 without accessories

1 With foot and injection valve, 2 m suction line, 5 m metering

line

4 Multifunctional valve and accessories

Control version

0 Manual + external contact with pulse control

3 Manual + external contact with pulse control + analogue

0/4-20mA

4 As 0 + 4-week process timer

5 As 3 + 4-week process timer

C As 3 + CANopen

As 3 + PROFIBUS® interface, M12

Dosing monitor

0 Dynamic dosing monitor

Remote stop / Remote control

0 without Bluetooth

B with Bluetooth

Language

EN German

EN English

ES Spanish

FR French

... ...

Page 8

About this pump

2 About this pump

About this pump

Pumps in the gamma/ X product range are microprocessor-controlled sole‐ noid metering pumps with the following characteristics:

n Simple adjustment of the capacity directly in l/h n Available material combinations: PP, PVDF, clear acrylic, PTFE and

stainless steel

n Special dosing head designs for gaseous and high-viscosity media n Illuminated LC display and 3-LED display for operating, warning and

error messages, visible from all sides

n Factor with external contact control 99:1 ... 1:99 n Batch operation with max. 99,999 strokes/start pulse n Input of concentration for simple adjustment with volume-proportional

metering tasks

n Stroke rate adjustment in 1 stroke/hour increments from 0 ... 12,000

strokes/h

n Electronic stroke length adjustment, continuous from 0 ... 100% (rec‐

ommended 30 ... 100%)

n Connector for 2-stage level switch n External control via 0/4-20 mA standard signal with adjustable assign‐

ment of signal value to stroke rate

n Optional 4-20 mA output for remote transmission of stroke length and

stroke rate

n Universal power supply unit 100 V - 230 V, 50/60 Hz n Optional 230 V relay module, can also be retrofitted easily and

securely

n Optional 24 V combined relay, can also be retrofitted easily and

securely

The hydraulic parts of the gamma/ X are identical to those of the Beta (not with types 0220, 0424 and 0245).

Page 9

3 Safety Chapter

Safety Chapter

Identification of safety notes

Warning signs denoting different types of danger

The following signal words are used in these operating instructions to denote different severities of danger:

Signal word Meaning

WARNING Denotes a possibly dangerous 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 dangerous 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 flammable media without

implementing suitable protective measures.

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 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 are obliged to observe the information contained in the operating

instructions at the different phases of the unit's service life.

Page 10

Safety Chapter

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.

WARNING! Warning of personal injury and material damage The pump can start pumping as soon as it has cooled

down after the error

„temperature“

– Take this into account with the pump and your

installation.

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! 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.

WARNING! Fire danger When pumping inflammable media the operator must

take suitable safety precautions.

Page 11

Safety Chapter

WARNING! 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.

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 The metering pump can generate a multiple of its rated

pressure. Hydraulic parts can rupture if a discharge line is blocked.

– Correctly install a relief valve in the discharge line

downstream of the metering pump.

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! Danger of injury to personnel and material damage The use of untested third party components can result in

injury to personnel and material damage.

– Only fit parts to metering pumps that have been

tested and recommended by ProMinent.

Page 12

Safety Chapter

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 dosing The metering behaviour of the pump changes if a dif‐

ferent liquid end size is fitted.

– Reprogram the pump in the

Settings è System è Change head type“

CAUTION! Warning against illegal operation Observe the regulations that apply where the device is

installed.

„Menu / Information

menu.

Isolating protective equipment

Information in the event of an emergency

Qualification of personnel

n Covers for the slots for relays and optional modules - see the chapter

entitled "Overview of Equipment and Control Elements"

Customers should only remove the cover for the slots for relays and optional modules and/or a relay or optional module in line with the supple‐ mentary instructions for the relays and optional modules.

Customer should only remove the dosing head in accordance with the "Repair" chapter.

Only the ProMinent Service department is authorised to open the housing and the hood (housing the control elements).

In an emergency, either disconnect the mains plug, press or press the Emergency Stop switch installed on the customer's side or disconnect the pump from the mains/power supply in line with the Emer‐ gency Stop management guidelines for your system.

If feed chemical escapes, also ensure that the pump's hydraulic environ‐ ment is at atmospheric pressure. Adhere to the material safety data sheet for the feed chemical.

Task Qualification

Storage, transport, unpacking Instructed person

Assembly Technical personnel, service

Planning the hydraulic installation Qualified personnel who have a

thorough knowledge of metering pumps

[Start/Stop]

Hydraulic installation Technical personnel, service

Installation, electrical Electrical technician

Operation Instructed person

Maintenance, repair Technical personnel, service

Page 13

Safety Chapter

Task Qualification

Decommissioning, disposal Technical personnel, service

Troubleshooting Technical personnel, electrical

technician, instructed person, service

Explanation of the table:

Qualified 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 of employment in the relevant field of work.

Electrical technician

An electrical technician is able to complete work on electrical systems and recognise and avoid possible dangers independently based on his/her technical training and experience, as well as knowledge of pertinent stand‐ ards and regulations.

The electrical technician should be specifically trained for the working environment in which he is employed and know the relevant standards and regulations.

An electrical technician 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

The Service department refers to service technicians, who have received proven training and have been authorised by ProMinent to work on the system.

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)

Page 14

Storage, Transport and Unpacking

4 Storage, Transport and Unpacking

Safety Information

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

Scope of delivery

Ambient conditions - refer to "Technical Data" chapter.

Compare the delivery note with the scope of delivery:

n Metering pump with mains cable n Connector kit for hose/pipe connection (optional) n Product-specific operating instructions with EC Declaration of Con‐

formity

n Optional accessories

Page 15

P_G_0063_SW

2 3

1 6

P_G_0053_SW

Overview of Equipment and Control Elements

5 Overview of Equipment and Control Elements

Overview of equipment

5.1

Fig. 2: Overview of equipment, complete

1 Control unit 2 Drive unit 3 Liquid end

Fig. 3: A. Liquid end with PV bleed valve; B. Liquid end with NP bleed valve; C. Self-bleeding liquid end (SEK)

1 Discharge valve 2 Backplate 3 Dosing head 4 Bleed valve

5 Bypass hose sleeve 6 Diaphragm rupture indicator (optional) 7 Suction valve 8 Bleed valve, self-bleeding

Self-bleeding liquid ends (SER) Externally self-bleeding liquid ends with groove (SER)

look identical to liquid ends with bleed valve.

Page 16

11 13

P_G_0051_SW

Overview of Equipment and Control Elements

5.2 Control elements

Control elements, overview

Fig. 4

1 LCD screen 2 3 4 5 6

[Menu]



Clickwheel

[Priming]

 

[STOP/START]



[Back]

key



key

key 7 Fault indicator (red) 8 Warning indicator (yellow) 9 Operating indicator (green) 10 "Diaphragm rupture indicator" terminal 11 "External control" terminal 12 "Dosing monitor" terminal 13 "Level switch" terminal 14 Slot for relays and optional modules

5.2.1 Control elements

Use this overview to familiarise yourself with the keys and the other control elements on the pump!

Page 17

12.012.0

12000

2.5

CONTACT

memory

bar

l/h

CAN

open

B0778

Pressure display, identifier and fault dis‐ plays on the LCD screen

Overview of Equipment and Control Elements

Fig. 5: Construction of continuous display

Page 18

12.012.0

12000

2.5

Dosing monitor!

CONTACT

memory

bar

l/h

CAN

open

12000

ANALOGUE

Input signal < 4 mA

i < 4 mAi < 4 mA

B0605

i < 4 mA!

Overview of Equipment and Control Elements

1 Status bar 2 Continuous display, central area 3 Secondary display

Refer to the chapter entitled "Main Displays and Secondary Displays" in the Appendix for the different main displays and secondary displays.

The LCD screen supports the operation and adjustment of the pump by providing different information and identifiers:

Fig. 6: a) Continuous display with warning message; b) Continuous display with fault message. Explanation of the symbols in the following tables.

The above Figure, Part a) shows that:

n The pump is in operation n Is in n The average system pressure is 2.5 bar n A dosing monitor is connected n A CAN module is being used n A log entry has been made n A warning message for the n The capacity of 12.0 l/h has been set n The stroke rate is 12,000 strokes / h

„Contact“

operating mode with "memory" stroke memory.

„dosing monitor“

is pending

Tab. 1: Pressure display

Display Meaning

Displays the average system pressure

Tab. 2: Identifier and error displays:

Identifier Meaning

The pump is working or waiting for a starting signal.

The pump was manually stopped using the

The pump was remotely stopped (Pause) - via the "External" terminal.

The pump was stopped by an error.

Only with cyclical batch metering: the pump waits for the next cycle.

[STOP/START]

key.

Page 19

Identifier Meaning

Overview of Equipment and Control Elements

„AUX“

„memory“

Only with

The pump is currently pumping at auxiliary capacity and/or auxiliary frequency.

Only in

The auxiliary function "Stroke memory" has been set.

The pump is in

The

The pump is in

The

„Metering è Discharge stroke è optimum“

„Metering è Discharge stroke è fast“

„Metering è Discharge stroke è sine mode“

„Access. protect“

„CONTACT“

„ANALOGUE“

„Curve è linear“

„ANALOGUE“

: the pump software is locked.

and

„BATCH“

operating mode.

type of processing is set.

operating mode.

„Curve è Upper side band“

operating modes:

type of processing is set.

metering profile has been set.

„Metering è Discharge stroke è continuous“

„Metering è Discharge stroke è DFMa“

„Metering è Discharge stroke è normal“

„Metering è Discharge stroke è HV1“

„Metering è Discharge stroke è HV2“

„Metering è Discharge stroke è HV3“

A dosing monitor "Flow Control" is connected.

metering profile has been set.

A diaphragm rupture indicator is connected.

The pump has created a log about the operation.

Page 20

Overview of Equipment and Control Elements

Identifier Meaning

The pump is in the

„Menu“

(Set up).

Further explanations can be found in the "Trouble‐ shooting" chapter.

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.

5.2.2 Key functions

Key Application In the continuous displays In the menu

[Back]

[STOP/ START]

press - Move back to the previous menu

point (or a continuous display) without saving

press Stop pump, Stop pump,

Start pump Start pump

[Menu key]

press Move to the menu Move back to a continuous display

press Priming * Priming *

[Priming key]

[Clickwheel]

press Start batch (only in

mode)

Acknowledge errors

turn Switch between the continuous dis‐

plays

„Batch“

operating

Move to next menu option (or a continuous display)

Confirm entry and save

Change figure or change selection

* When priming the pump does not run at maximum stroke rate.

[Priming] is pressed in „Stop“ state, then [Priming]

If has top priority as long as the button is pressed.

Refer to the "Set-up Basics" chapter to adjust figures

Page 21

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 diaphragm is driven by an electromagnet, controlled by an electronic control.

Functional Description

Drive technology

The drive technology on the gamma/ X enables the timed progress of the flow to be precisely matched to the requirements of the particular applica‐ tion.

This ensures that the user can set the optimum discharge stroke for his application, as required:

Pos.* Discharge

stroke

„optimum“

„fast“

„Sine mode“

„continuous“

„DFMa“

Application

For maximum accuracy when metering and the very best results with internal pressure measurement and special functions.

For as fast a discharge stroke as possible the duration of the discharge stroke is dependent on the stroke rate.

For a long, sine-shaped discharge stroke the duration of the discharge stroke is dependent on the stroke rate.

For a continuous discharge stroke e.g. for bottling processes. The duration of the dis‐ charge stroke is dependent on the stroke rate.

For optimum operation with a flow meter Dul‐ coFlow® DFMa.

* see following drawing.

Page 22

P_G_0074_SW

normal HV1 HV2 HV3

P_G_0075_SW

Functional Description

Fig. 7: Discharge stroke metering profiles with stroke L and time t (suction stroke shown as a dotted line)

It is possible to selectively also slow the suction stroke with all these metering profiles for the discharge stroke - see . In this way, it is possible to prevent the main cause of inaccurate metering with high viscosity feed chemicals, namely the incomplete filling of the liquid end. With gaseous feed chemicals, the slow suction stroke prevents cavitation and conse‐ quently increases dosing precision.

Fig. 8: Suction stroke metering profiles with stroke L and time t

Normal Normal suction stroke HV1 Suction stroke for viscous feed chemical HV2 Suction stroke for average viscosity feed chemical HV3 Suction stroke for high-viscosity feed chemical

Page 23

6.3

Capacity

6.4 Self-Bleeding

Functional Description

Oscillations in the back pressure in the metering line, which could lead to undesirable variations in the metering volume, are automatically compen‐ sated for by the power end/drive. This results in dosing precision, which otherwise could only be achieved with complex control circuits.

The capacity set regulates the pump even in SEK dosing heads).

By contrast, in conventional mode, the stroke length and stroke rate deter‐ mine the capacity. The stroke length can be adjusted between 0 and 100% via the continuous display or the menu. A metering volume of between 30 to 100% is reproduced as being technically sensible (SEK type: 50 - 100%)! The stroke rate can be set via the menu (not in "Ana‐ logue" operating mode) within a range of 0 - 12,000 strokes/h.

SER types

Self-bleeding liquid ends without bypass are capable of independent pri‐ ming when a discharge line is connected and diverting any air pockets present into the discharge line. During operation they are also capable of conveying away gases which are produced, independently of the oper‐ ating pressure in the system.

SEK types

Self-bleeding liquid ends with ball are capable of independent priming when a discharge line is connected and diverting any air pockets present via a bypass. During operation they are also capable of conveying away gases which are produced, independently of the operating pressure in the system. It is also possible to meter precisely under atmospheric pressure due to the integral back pressure valve.

„Automatic“

mode (not with

6.5 Operating modes

"Manual" operating mode

"Contact" operating mode

"Batch" operating mode

Operating modes are selected via the "Operating modes" menu.

Refer to the "Hierarchy of Operating Modes, Functions and Fault Statuses" for the order of the various operating modes, functions and fault statuses.

„Manual“

This operating mode provides the option of controlling the pump externally by means of potential-free contacts (e.g. by means of a contact water meter). The "Pulse Control" option enables you to preselect the number of strokes (a scaling or transfer factor of 0.01 to 99.99) in the

„Settings“

This operating mode provides the option of working with large transfer fac‐ tors (up to 99,999). Metering can be triggered either by pressing the

[Clickwheel]

through a contact or a semiconductor switching element. It is possible to pre-select a metering volume (batch) or a number of strokes using the

[Clickwheel]

operating mode permits you to operate the pump manually.

menu.

or by a pulse received via the "External control" terminal or

in the

„Settings“

menu.

Page 24

Functional Description

"Analogue" operating mode

6.6

Functions

The capacity and/or stroke rate is controlled via an analogue current signal via the "External control" socket. The processing of the current signal can be preselected via the control unit.

Refer to the "Hierarchy of Operating Modes, Functions and Fault Statuses" for the order of the various operating modes, functions and fault statuses.

"Calibrate" function

"Auxiliary capacity" / "Auxiliary frequency" function

"Bleed " function

"Timer" function

"Flow" function

The following functions can be selected using the

The pump can also be operated in a calibrated state in all operating modes if it is to meter extremely precisely. This can be useful with very vis‐ cous feed chemicals but less so with feed chemicals with a similar consis‐ tency to water. Calibration is retained over the entire stroke rate range and over a stroke length range from 0 - 100%.

This facilitates the switch-over to a fixed adjustable capacity / stroke rate in the

„menu“

via the "External control" terminal.

This permits simple bleeding - without the need for an additional bleed valve. The pump works at maximum stroke rate based on the selected signal in order to transport gas bubbles out of the liquid end.

This permits a simple timer program to be set up without the need for an additional timer module.

The following functions are available as standard:

It monitors the flow after every single stroke, if a dosing monitor is con‐ nected and if

Discharge stroke“

defective strokes, after which the pump is switched off, can be set in the

„Settings“

„Fast“

menu.

is set under

„DFMa“

„Settings è Metering

(for the DulcoFlow®). The number of

„Settings“

menu:

"Level switch" function

"Pause" function

"Stop" function

"Priming" function

6.7 Relay (Options)

Information about the liquid level in the dosing tank is reported to the pump. A two-stage level switch has to be fitted for this purpose, which is connected to the "Level switch" terminal.

The pump can be remotely stopped via the "External Control" terminal.

The pump can be stopped without disconnecting it from the mains/power



supply by pressing the

Priming can be triggered by pressing

The pump has several connecting options available:

[STOP/START]

key.

[Priming]



Page 25

"Fault indicating relay" option

Functional Description

The relay can close a connected power circuit (e.g. for an alarm horn) in the event of warnings or fault messages (

The relay can be retrofitted through the slot in the front of the pump - refer to the installation instructions for "Retrofitting relays".

e.g.

„Warning level“

"Fault indicating and pacing relay" option

"Automatic bleed" option

"mA output" option

6.8

LED Displays

Fault indicator (red)

This combined relay can generate a contact with each stroke via its pacing relay in addition to functioning as a fault indicating relay.

The relay can be retrofitted through the slot in the front of the pump.

The "Automatic bleed" option is used for controlled bleeding of the liquid end, if the pump has the "Automatic bleed" option. This option can be ret‐ rofitted through the slot in the front of the pump and conversion of the dosing head.

There are two versions:

n Version with only 1 relay – to control the electric bleed valve in the

dosing head.

n Version with only 2 relays – one relay to control the electric bleed

valve in the dosing head and one relay free for other uses.

The current output I signal indicates the pump's actual calculated metering volume. The relay can be retrofitted through the slot in the front of the pump.

The option also always includes a fault indicating relay or a pacing relay.

LED display Colour lit briefly goes out flashes

Fault indicator red A fault message is

pending

Warning indicator yellow A warning message is

pending

Operating indicator green The pump is ready for

operation

- undefined operating status

- -

At each stroke Stroke rate below 30

strokes / min

6.9 Hierarchy of Operating Modes, Functions and Fault Statuses

The different operating modes, functions and fault statuses have a dif‐ ferent effect on whether and how the pump reacts.

The following list shows the order:

1. - Stop

2. - Priming key

3. - Error, Pause, Level

4. - Auxiliary capacity / Auxiliary frequency

5. - Field bus

6. - Manual, Analogue, Contact, Batch

Page 26

Functional Description

Comments:

re 1 - "Stop" stops everything.

re 2 - "Priming" can take place in any mode of the pump (providing it is

functioning).

re 3 - "Error", "Pause" and "Level" stop everything apart from "Priming".

re 4 - The commands from a field bus always have priority over "Auxiliary

capacity" and/or "Auxiliary frequency" and the capacity / stroke rate specified by an operating mode listed under 6.

re 5 - The "Auxiliary capacity" and/or "Auxiliary frequency" always has

priority over the capacity / stroke rate specified by an operating mode listed under 5.

Page 27

7 Assembly

Assembly

Please refer to the online version of the operating instructions on our website for the right dimensional drawings for the pump and mounting plate.

Compare the dimensions on the dimensional drawing with those of the pump and/or mounting plate.

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.

–

Ensure that the suction and discharge valves are upright (with self-bleeding liquid ends: the bleed valve).

Several metering pumps can be arranged closely together as required.

1. To remove the mounting plate, press down the black flap below the front of the pump a little and press the mounting plate backwards.

2. Assemble the mounting plate on a level and load-bearing base sur‐ face (with a minimum of 2 bolts and 2 washers!).

You can also assemble the mounting plate on a vertical, level and load-bearing base surface (using 3 bolts and 3 washers!). You then need to rotate the liquid end (vertical valve position!)

You can also assemble the mounting plate on a wall bracket sories). 3 alignments are possible.

3. Lock the foot of the metering pump into the mounting plate – see Fig. 9.

(acces‐

Page 28

P_G_0064_SW

CLICK

Assembly

Fig. 9

Tab. 3: Suggested bolts and washers for fixing the assembly foot

Bolt Type Size Washer

DELTA-PT bolt 50 (WN5412/5452) A5.3 (DIN 125)

PT bolt 50 (WN1441/1411 KA/B) -

Flat-head bolt M5 (DIN EN ISO 7045) A5.3 (DIN 125)

Allen bolt/ M5 (DIN EN ISO 4762) A5.3 (DIN 125)

Page 29

8 Installation, hydraulic

Safety information

Installation, hydraulic

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 injury to personnel and material damage The use of untested third party components can result in

injury to personnel and material damage.

– Only fit parts to metering pumps that have been

tested and recommended by ProMinent.

Page 30

Installation, hydraulic

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

leak out when using conventional bleeding procedures 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

leak out in the event that the metering pump is removed from the installation.

– Install a shut-off valve on the metering pump's pres‐

sure and discharge sides.

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.

Page 31

Installing hose lines - PP, NP, PV, TT designs

Installation, hydraulic

CAUTION! Uncontrolled flow of feed chemical Feed chemicals can leak through the metering pump in

an uncontrolled manner in the event of excessive pri‐ ming pressure.

– Do not exceed the maximum permissible priming

pressure for the metering pump.

Align the pipes so that the metering pump and the liquid end can simply 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 figure Fig. 10.

3. Push the hose end (1) up to the stop over the nozzle (4) and widen, if necessary.

Ensure that the O-ring and flat seal (5) is properly fitted to 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.

In order to enable it to be distinguished from the EPDM flat seal, the FPM flat seal PV design has a dot.

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 line (1) briefly, which is fastened to the dosing head and then re-tighten the union nut (2).

Page 32

121

4 5

P_G_0066_SW

121

3 4

P_G_0067_SW

Installation, hydraulic

Fig. 10: 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

Fig. 11.

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. 11: SS design with pipe

1 pipe 2 Union nut 3 Rear clamp ring 4 Front clamp ring 5 Valve

Page 33

Installing hose lines - SS design

121

3 4

P_G_0079_SW

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.

1 Hose 2 Union nut 3 Rear clamp ring 4 Front clamp ring 5 Support insert 6 Valve

Installation, hydraulic

Fig. 12: SS design with hose

8.1.2 Installation of Metering Pumps With Bleed Valve

Safety information

CAUTION! – All the installation and safety notes for metering

pumps without bleed valves also apply.

Installation of the return line

8.1.3

Safety information

Installation of Metering Pumps With Self-bleeding (SEK Type)

A return line is also connected in addition to the suction and discharge line.

1. Attach the hose line to the return hose nozzle or to the liquid end bleed valve. PVC hose, soft, 6x4 mm is recommended.

2. Feed the free end of the return line back to the storage tank.

3. Shorten the return line so that it is not immersed in the feed chem‐ ical in the storage tank.

CAUTION! – All of the installation and safety notes for metering

pumps without self-bleeding also apply. Do not exceed the maximum values for priming lift,

–

priming pressure and viscosity of the feed chemical.

– Do not allow the suction side line cross-section to

exceed the line cross-section on the suction valve.

Page 34

P_MAZ_0023_SW_3

Installation, hydraulic

Information about priming pressure

–

Make sure that the priming pressure on the suction end is at least equal to the return line pressure.

–

Back pressure in the return line restricts the bleeding function.

–

In contrast, it is possible to operate the pump with back pressure in the return line and atmospheric pressure on the suction side.

Installation of the return line

A return line is also connected in addition to the suction and discharge line.

–

The return line is connected to the vertical valve on the upper side of the liquid end. It is factory-labelled with a red sleeve - see Fig. 10.

–

The discharge line is connected to the horizontal valve.

1. Attach the hose line to the return hose nozzle or to the liquid end bleed valve. PVC hose, soft, 6x4 mm is recommended.

2. Feed the free end of the return line back to the storage tank.

3. SEK only: Insert the return line into the anti-kink device on the bleed valve and screw it in place until the anti-kink device engages.

The anti-kink device prevents the return line from kinking, avoiding the risk of self-bleeding failure.

4. Shorten the return line so that it is not immersed in the feed chem‐ ical in the storage tank.

Fig. 13: SEK liquid end

1 Anti-kink device 2 Bleed valve for the return line into the storage tank, 6/4 mm 3 Red sleeve 4 Discharge valve for discharge line to the injection point, 6/4 - 12/9 mm 5 Suction valve for suction line in the storage tank, 6/4 - 12/9 mm

Page 35

8.2 Basic installation notes

P_MAZ_0001_SW

Safety notes

Installation, hydraulic

CAUTION! Danger resulting from rupturing hydraulic components Hydraulic components can rupture if the maximum per‐

missible operating pressure is exceeded.

– Never allow the metering pump to run against a

closed shut-off device. With metering pumps without integral relief valve:

–

Install a relief valve in the discharge line.

CAUTION! Hazardous feed chemicals can escape With hazardous feed chemicals: Hazardous feed chem‐

ical can leak out when using conventional bleeding pro‐ cedures with metering pumps.

– Install a bleed line with a return into the storage

tank.

Shorten the return line so that it does not dip into the feed chemical in the storage tank.

Fig. 14: Standard installation

1 Main line 2 Storage tank

Legend for hydraulic diagram

Symbol Explanation Symbol Explanation

Metering pump Foot valve with filter meshes

Injection valve Level switch

Multifunctional valve Manometer

Page 36

Installation, electrical

9 Installation, electrical

WARNING! Danger of electric shock A mains voltage may exist inside the device.

– Before any work, disconnect the device's mains

cable from the mains.

WARNING! Risk of electric shock This pump is supplied with a grounding conductor and a

grounding-type attachment plug.

– To reduce the risk of electric shock, ensure that it is

connected only to a proper grounding-type recep‐ tacle.

WARNING! Risk of electric shock In the event of an electrical accident, the pump must be

quickly disconnected from the mains.

– Install an emergency cut-off switch in the pump

power supply line or

–

Integrate the pump in the emergency cut-off man‐ agement of the system and inform personnel of the isolating option.

WARNING! Danger of electric shock Incompletely installed electrical options can allow mois‐

ture into the inside of the housing.

– Fit appropriate modules into the slot on the front of

the pump or use the original blank cover to seal it in a leak-tight manner.

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.

CAUTION! Risk of short circuiting caused by moist pins No moisture must reach the pins of the PROFIBUS

jack.

– A suitable PROFIBUS® plug or protective cap must

be screwed onto the PROFIBUS®

jack.

Page 37

Installation, electrical

CAUTION! Material damage possible due to power surges Should the pump be connected to the mains power

supply in parallel to inductive consumers (such as sole‐ noid valves, motors), inductive power surges can damage the control when it is switched off.

– Provide the pump with its own contacts (Phase) and

supply with voltage via a contactor relay or relay. Should this not be possible, then switch a varistor

–

(part no. 710912) or an RC gate (0.22 µF/220 Ω, part no. 710802) in parallel.

CAUTION! Bonding of the contacts of your switching relay The high starting current can cause the contacts of the

on-site switching relay to bond together if the mains voltage switches a solenoid metering pump on and off in a process.

– Use the switching options offered by the external

socket to control the pump (functions: Pause, Auxil‐ iary frequency or Operating modes: Contact, Batch, Analogue).

–

Use a starting current limiter if it is impossible to avoid switching the pump on and off via a relay.

9.1

Supply voltage connector - mains voltage

Install the pump in line with best working practice and in accordance with the operating instructions and applicable regulations.

WARNING! Unexpected startup is possible As soon as the pump is connected to the mains, the

pump may start pumping and consequently feed chem‐ ical may escape.

– Prevent dangerous feed chemicals from escaping. –

If you have not successfully prevented this, immedi‐ ately press the the pump from mains, e.g. via an emergency cu-off switch.

CAUTION! If the pump is integrated into a system: Design the

system so that potential hazardous situations are avoided by pumps starting up automatically subsequent to unintended power interruptions.

[STOP/START]

key or disconnect

Connect the pump to the mains voltage using the mains cable.

Page 38

P_BE_0014_SW

P_BE_0015_SW

Installation, electrical

9.2 Description of the Terminals

9.2.1

"External control" terminal

Fig. 15: Pump assignment

The "external control" terminal is a 5-pole panel terminal. It is compatible with 2- and 4-pole cables.

Only use a 5-pole cable with the "Auxiliary capacity" / "Auxiliary frequency" and "mA-input" functions.

Electrical interface for pin 1 "Pause" - pin 2 "External contact" - pin 5 "Aux‐ iliary capacity / Auxiliary frequency"

Data Value Unit

Voltage with open contacts 5 V

Input resistance 10 kΩ

Max. pulse frequency 25 pulse/s

Min. pulse duration 20 ms

Control via:

n potential-free contact (load: 0.5 mA at 5 V) or n Semiconductor switch (residual voltage < 0.7 V)

Electrical interface for pin 3 "mA input" (with identity code characteristic "Control version": 2 and 3)

Data Value Unit

Input apparent ohmic resistance, approx. 120 Ω

The metering pump makes its first metering stroke at approx. 0.4 mA (4.4

mA) and reaches maximum frequency at approx. 19.6 mA.

Pin Function 5-wire cable 2-wire cable

1 Pause brown bridged at pin 4

2 External contact white brown

3 mA input* blue -

4 Earth GND black white

Fig. 16: Cable assignment

5 Auxiliary capacity /

Auxiliary frequency

* with identity code characteristic "Control version": 3

grey -

Refer to the functional description for the sequence of functions and operating modes.

"Pause" function

The pump works if:

n Pin 1 and pin 4 are connected to each other and the cable is con‐

nected.

n no cable is connected.

The pump does not work if:

n Pin 1 and pin 4 are open and the cable is connected.

Page 39

P_BE_0016_SW

P_BE_0017_SW

Installation, electrical

Acknowledge fault with „Pause“ Certain errors requiring acknowledgement can also be

acknowledged using „Pause“ instead of using the [P] key. These are errors like: „Flow“ , „Air lock“ , „ p-“ (as soon as the conditions are in order).

"External contact" operating mode

"Analogue" operating mode

"Auxiliary capacity" / "Auxiliary frequency" operating mode

9.2.2 "Level switch" terminal

The pump performs one or more strokes if:

n Pin 2 and pin 4 are connected to each other for at least 20 ms. At the

same time, pin 1 and pin 4 must also be connected to each other.

The pump capacity and/or stroke rate can be controlled by a current signal. The current signal is connected between pin 3 and pin 4.

In addition, pin 1 and pin 4 must also be connected.

The pump works at a pre-set capacity / stroke rate if:

n Pin 5 and pin 4 are connected to each other. At the same time, pin 1

and pin 4 must also be connected to each other. The auxiliary capacity / auxiliary frequency is factory-preset to maximum capacity / stroke rate.

There is a connecting option for a 2-stage level switch with pre-warning and limit stop.

Electrical interface

Fig. 17: Pump assignment

Fig. 18: Cable assignment

9.2.3 "Dosing monitor" terminal

Data Value Unit

Voltage with open contacts 5 V

Input resistance 10 kΩ

Control via:

n potential-free contact (load: 0.5 mA at 5 V) or n Semiconductor switch (residual voltage < 0.7 V)

Pin Function 3-wire cable

1 Earth GND black

2 Minimum pre-warning blue

3 Minimum limit stop brown

There is a connection option for a dosing monitor.

Electrical interface

Page 40

P_DE_0009_SW

P_DE_0010_SW

P_DE_0011_SW

P_DE_0012_SW

Installation, electrical

Data Value Unit

Voltage with open contacts 5 V

Input resistance 10 kΩ

Control via:

n potential-free contact (load: 0.5 mA at 5 V) or

Fig. 19: Pump assignment

Pin Function 4-wire cable

1 Power supply (5 V) brown

2 Coding white

3 Feedback blue

4 Earth GND black

Fig. 20: Cable assignment

9.2.4 "Diaphragm rupture indicator" terminal

There is an option to connect a diaphragm rupture indicator.

Fig. 21: Pump assignment

Fig. 22: Cable assignment

Electrical interface

Specification Value

Supply voltage, approx.: +5 V, loadable with 20 mA (current limit

150 mA)

Power consumption: min. 10 mA, max. 20 mA (sensor pres‐

ence detection)

Sensor signal: potential-free contact (load: 0.5 mA at

+5 V) or

Semiconductor switch (residual voltage < 0.3 V)

Pin Function 4-wire cable

1 Power supply (5 V) brown

2 not assigned white

3 Sensor signal blue

4 Earth GND black

9.2.5 Relay

9.2.5.1

Tab. 4: gamma/ X GMXa

Identity Code Description Type Maximum voltage Maximum current

Relay functions

0 no relay - - -

1 Fault indicating relay NC changeover con‐

tact

230 V 8 A

Page 41

P_SI_0043

Installation, electrical

Identity Code Description Type Maximum voltage Maximum current

4 fault indicating relay +

Pacing relay

C fault indicating relay

N/O

24 V

2 A

100 mA

N/O 24 V 100 mA

+ 4-20 mA output

F Automatic bleeding N/O 230 V 24 VA or 8 W

G Automatic self-bleeding

N/O 24 V DC 24 VA or 8 W

and relay output

Tab. 5: Relay type switches in the event of...

Relay type* Level

Warning

Level

low

Dosing monitor

Fault

Calibrated stroke length

Processor

Fault

Fault indicating relay: X X X X X

Warning relay: X - - X -

* Can be reprogrammed in the

„Relay“

menu.

9.2.5.2 "Fault indicating relay" output (identity code 1)

A fault indicating relay can be ordered as an option - refer to ordering information in the appendix. It is used to emit a signal when there is a fault with the pump and for the "Liquid level low, 1st stage" warning message and "Liquid level low 2nd stage" fault message.

The fault indicating relay can be retrofitted and is operational once attached to the relay board - refer to "Retrofitting Relays" supplementary operating instructions.

The behaviour is factory-programmed. If another switching function is required, the pump can be reprogrammed in the

„Relay“

menu.

The relay can be retrofitted and operates once it is plugged into the relay board.

Fig. 23: Cable assignment

Electrical interface

Data Value Unit

Maximum contact load at 230 V and 50/60

8 A

Hz:

Minimum mechanical lifespan: 200,000 switching

operations

Page 42

P_G_0072_SW

P_SI_0044

P_G_0073_SW

Installation, electrical

Identity code 1

To pin VDE cable Contact CSA cable

1 white NO (normally open) white

2 green NC (normally closed) red

4 brown C (common) black

Fig. 24: Pump assignment

9.2.5.3 Output for Other Relays (Identity code 4)

A fault indicating and a pacing relay can optionally be ordered - refer to ordering information in the appendix. The pacing output is electrically-iso‐ lated by means of an optocoupler with a semiconductor switch. The second switch is a relay (also electrically isolated).

The behaviour is factory-programmed. If another switching function is required, the pump can be reprogrammed in the

The fault indicating/pacing relay can be retrofitted and is operational once attached to the relay board - refer to "Retrofitting Relays" supplementary operating instructions.

„Relay“

menu.

Fig. 25: Cable assignment

Identity code 4

Electrical interface

for fault indicating relay output:

Data Value Unit

Maximum contact load at 24 V and 50/60

2 A

Hz:

Minimum mechanical lifespan: 20,000,000 switching

operations

for semiconductor switch pacing relay:

Data Value Unit

Max. residual voltage at I

= 1 µA 0.4 V

off max

Maximum current 100 mA

Maximum voltage 24 VDC

Pacing pulse duration, approx. 100 ms

To pin VDE cable Contact Relay

1 yellow NO (normally open) other relay

Fig. 26: Pump assignment

4 green C (common) other relay

3 white NO (normally open) Pacing relay

2 brown C (common) Pacing relay

Page 43

9.2.5.4 Output "Current output plus relay" (identity code C)

P_SI_0044

P_G_0073_SW

A relay combined with a current output can optionally be ordered. The relay either switches off the pump as a fault indicating relay in the event of a fault on the pump and with "Liquid level low 1st stage" warning message and "Liquid level low 2nd stage" fault messages or is used as a pacing relay.

The behaviour is factory-programmed. If another switching function is required, the pump can be reprogrammed in the

In the

„ANALOG OUTPUT“

rent output can be selected.

The current output plus relay can be retrofitted and operates once it is plugged into the board.

Electrical interface

for current output

Data Value Unit

Open circuit voltage: 8 V

Current range: 4 ... 20 mA

Fig. 27: Cable assignment

Ripple, max.: 80 μA pp

Installation, electrical

„Relay“

menu.

menu, the variable to be signalled by the cur‐

Identity code c

Ripple, max.: 250 Ω

for semiconductor switch ("relay"):

Data Value Unit

Max. residual voltage at I

= 1 µA 0.4 V

off max

Maximum current 100 mA

Maximum voltage 24 VDC

Pacing pulse duration, approx. 100 ms

To pin VDE cable Contact Relay

1 yellow "+" Current

output

4 green "-" Current

output

3 white NC (normally closed) or

Relay

NO (normally open)

2 brown C (common) Relay

Fig. 28: Pump assignment

Page 44

12.012.0

2315

7.0

CONTACT

bar

l/h

Settings Service Language Makro operating mode

Information

German

English

... 〉Language

Language

German

Menu/Information

Path, derived:

... 〉Language

Language

English

German

Save

Menu/Information

Path, operating instructions:

Language

English

German

B0597

Basic Set-up Principles

10 Basic Set-up Principles

Please also refer to all the overviews covering

–

"Operating/set-up overview" and "Operating menu for gamma/ X, complete" in the appendix and the chapters "Overview of Equipment and Control Ele‐ ments" and "Control Elements".

–

The pump leaves the menu and returns to a contin‐ uous display if pressed for 60 seconds.

10.1 Basic Principles for Setting up the Control

Fig. 30 shows using the "Language" example how to set up something - in turn:

n Following the displays n The path derived from this n The path as presented in the operating instructions

Fig. 29: Please read

 [Menu] is pressed or no key is

Fig. 30: "Setting up the language": As an example of set-up and path displays

Tab. 6: Legend:

Symbol Explanation

Press

Turn the

Press the

"Setting up the language" in detail

To access the

The cursor points to

2. To switch from

3. To return to the

The cursor points to a language.

4. To switch to

„Deutsch“

„Menu“

„Information“

„Language“

5. To save: press the

The software shows a display by way of confirmation.

After 2 seconds, it returns to the higher-level

[Menu]

[Clickwheel]

: press

„Information“

menu: press the

: turn the

[Clickwheel]



[Menu]

„Language“

[Clickwheel]

: turn the

[Clickwheel]

„Menu“

[Clickwheel]

Page 45

B0777

5432

432

5432

543

Confirming an entry

Quitting a menu option without confirming it

Returning to a continuous display

To complete the setting: press 

Alternatively: wait 60 seconds or exit the via

„End“

Briefly press the

The software switches to the next menu point or back to the

menu and saves the entry.

Press 

The software switches to the next menu point or back to the

menu without saving anything.

Press 

The software cancels the entry and switches to a continuous

display without saving anything.

[Back]

[Menu]

[Clickwheel]

Basic Set-up Principles

[Menu]

„Menu“

via



[Menu]

Changing adjustable variables

Fig. 31: a) Changing from one figure to its initial figures; b) Changing the figure; c) Returning from the last figure to the (complete) figure (to correct a wrong figure, for example0.

Changing a (complete) number

Turn the

[Clickwheel]

The value of the figure highlighted is increased or lowered.

Changing figures

To adjust the value of a figure, press 

The first figure is highlighted - see Figure above, point a)

2. To adjust the value of a figure, turn the

To move to the next figure, press point b).

[Priming]

[Clickwheel]



[Priming]

- see Fig. above,

Page 46

Basic Set-up Principles

4. To run through the figures again, if necessary ( possibly because of

Confirming adjustable variables

10.2 Checking adjustable variables

Continuous displays

Before you adjust the pump, you can check the actual settings of the adjustable variables:

an incorrect figure), when you get to the last figure press 

[Priming]

Press the

Simply turn the display.

again - see Fig. above, point c).

Now you can start from the beginning again.

[Clickwheel]

The software saves the entry.

Each time the see a different continuous display.

1x.

[Clickwheel]

if the pump is showing a continuous

engages when you turn it, you will

Secondary displays

10.3 Changing to set up mode

The number of continuous displays depends on the iden‐ tity code, the selected operating mode and the con‐ nected additional devices, see overview "Continuous displays" in the appendix.

The lowest line of a continuous display shows different information (which cannot be adjusted in the secondary display) - see overview "Continuous displays and secondary displays" in the appendix.

You can access secondary displays via any continuous display as follows:

1. Press the

2. Providing there is a frame, you will see a different secondary display each time the

When you reach the secondary display you wish, leave the

[Clickwheel]

In a continuous display, if you press set-up mode - in the chapter entitled "Set-up / menu".

If under lock symbol), then after pressing the

„Access protect.“

„Password“

[Clickwheel]

A frame appears around the secondary display.

[Clickwheel]

and wait briefly.

„Menu“

for 3 seconds.

engages when turned.



„Menu“

. For more information refer to the following

only the

„Menu“

[Clickwheel]

, the pump changes to

„All“

has been set (top left

, first enter the

Page 47

Set Up /

„Menu“

11 Set Up /

11.1

„Information“

„Menu“

The

„Menu“

1 -

„Information“

2 -

„Settings“

3 -

„Timer“

4 -

„Service“

5 -

„Language“

Please also refer to all overviews covering "Oper‐

–

ating/set up overview" and "Operating menu for gamma/ X, complete" in the appendix and in the chapters "Overview of Equipment and Control Ele‐ ments".

–

The pump exits the menu and returns to a contin‐ uous display if pressed for 60 seconds.

is sub-divided as follows:

 [Menu] is pressed or no key is

11.2

„Settings“

„Menu / Information è ...“

The

„Information“

ters and counters. The number and type can depend on the pump set‐ tings.

„Menu / Information è Settings è ...“

The

„Settings“

1 -

„Operating mode“

2 -

„Automatic“

3 -

„Stroke length“

4 -

„Metering“

5 -

„Concentration“

6 -

„Calibration“

7 -

„System“

8 -

„Inputs/outputs“

9 -

„Bleeding“

10 -

„Priming time“

11 -

„Set time“

12 -

„Date“

provides information on your pump and certain parame‐

menu generally includes these setting menus:

11.2.1

„Operating Mode“

„Menu / Information è Settings è Operating mode è ...“

Page 48

Set Up /

11.2.1.1

„Menu“

„Manual“

„Menu / Information è Settings è Operating mode è Manual“

„Manual“

The capacity and/or stroke rate and stroke length can be set in the contin‐ uous displays in this operating mode.

operating mode permits you to operate the pump manually.

11.2.1.2

„Contact“

„Menu / Information è Settings è Operating mode è Contact

...“

„Contact“

stroke series.

You can trigger the strokes via a pulse sent via the "External control" ter‐ minal.

The purpose of this operating mode is to convert the incoming pulses into strokes with a step-down (fractions) or small step-up.

operating mode allows you to trigger individual strokes or a

CAUTION! The pump maintains the stroke rate when changing over

from

„Manual“

mode.

operating mode to

„Contact“

operating

The maximum stroke rate can be set in „Contact“ oper‐ ating mode. It should normally be set to 12,000 strokes/ hour.

Memory - Pulses not yet processed

Factor

You can also activate the fier ). When strokes, which could not be processed, up to the maximum capacity of the stroke memory of 4,200,000,000 strokes. If this maximum capacity is exceeded, the pump goes into fault mode.

The number of strokes per pulse depends on the factor which you can input. By using a factor you can multiply incoming pulses by a factor between 1.01 and 99.99 or reduce them by a factor of 0.01 to 0.99:

Number of strokes executed = factor x number of incoming pulses

„Memory“

CAUTION! – Only with

[STOP/START]



(

„Menu / Information è Service è Clear counters“

or the "Pause" function is activated, the cleared.

„Memory“

is activated, the pump adds up the remaining

„Memory“

function extension ("memory" identi‐

„off“

: If you press

or empty the contact memory

„Memory“

)

Page 49

Table of examples

Set Up /

„Menu“

Factor Pulse (sequence) Number of strokes

Step-up*

1 1 1

2 1 2

25 1 25

99.99 1 99.99

1.50 1 1.50 (1 / 2)

1.25 1 1.25 (1 / 1 / 1 / 2)

Step-down**

1 1 1

0.50 2 1

0.10 10 1

0.01 100 1

0.25 4 1

0.40 2.5 (3 / 2) (1 / 1)

0.75 1.33 (2 / 1 / 1) (1 / 1 / 1)

(sequence)

Tab. 7: * Explanation of the conversion ratio

With a factor of 1 ... 1 stroke is executed per 1 pulse.

With a factor of 2 ... 2 strokes are executed per 1 pulse

With a factor of 25 ... 25 strokes are executed per 1 pulse

Tab. 8: ** Explanation of step-down

With a factor of 1 ... 1 stroke is executed per 1 pulse.

With a factor of 0.5 ...1 stroke is executed after 2 pulses.

With a factor of 0.1 ...1 stroke is executed after 10 pulses.

With a factor of 0.75 ...1 stroke is executed once after 2 pulses,

then 1 stroke is executed twice after 1 pulse,

and then again 1 stroke after 2 pulses etc.

If a remainder is obtained when dividing by the factor, then the unit adds the remainders together. As soon as this sum reaches or exceeds "1", the pump executes an additional stroke. Therefore on average during the metering operation, the resultant number of strokes pre‐ cisely matches the factor.

Contact water meter

Using "Pulse Control" you can ideally adapt the pump to the relevant process, for example in conjunction with contact water meters.

Page 50

Set Up /

11.2.1.3

„Menu“

„Batch“

„Menu / Information è Settings è Operating mode è Batch è ...“

The

„Batch“

umes.

You can only select whole numbers but no fractions as the number of strokes (figures 1 to 99,999).

You can trigger the strokes using the switched to the pulse via the "External control" terminal.

operating mode enables you to pre-select large metering vol‐

„Push“

[Clickwheel]

continuous display. You can also trigger them via a

if you have already

The stroke rate can be set in „Batch“ operating mode. It should normally be set to 12,000 strokes/hour.

Memory - remaining strokes not yet pro‐ cessed

11.2.1.4

„Analogue“

(Option)

„Memory“

CAUTION! – The pump maintains its stroke rate when changing

over from

„Batch“

– If you press

tion is activated, the

„Memory“

is activated, the pump adds up the remaining

„Manual“

operating mode.

function extension ("memory" identi‐

operating mode to



[STOP/START]

„Memory“

or the "Pause" func‐

is cleared.

In operation, the batch size can be changed more easily by using the "Batch size" continuous display.

„Menu / Information è Settings è Operating mode è Analogue

...“

The secondary display "Signal current" indicates the incoming current.

You can select 5 types of current signal processing:

„0 - 20 mA“

„4 - 20 mA“

„Linear curve “

„Lower side band“

„Upper side band“

„0 - 20 mA“

At 0 mA the pump is stationary –

At 20 mA the pump works at maximum stroke rate.

Page 51

I [mA]

I 1

I 2

Fmax

0 20

B0088

Set Up /

„Menu“

„4 - 20 mA“

At 4 mA the pump is stationary –

At 20 mA the pump works at maximum stroke rate.

With current signals of less than 3.8 mA, an error message appears and the pump stops (e.g. if a cable has broken).

„Linear curve“

The symbol "Linear curve" appears on the LCD screen. You can enter any pump stroke rate behaviour proportional to the current signal. For this pur‐ pose, enter any two points P1 (I1, F1) and P2 (I2, F2) (F1 is the stroke rate at which the pump is to operate at current I1, F2 is the stroke rate at which the pump is to operate at current I2...); this defines a straight line and thus the behaviour is specified:

Error processing

Fig. 32: Frequency-current diagram for "Linear curve"

Plot a diagram similar to the one above – with values for (I1, F1) and (I2, F2) – so that you can set the pump as desired!

The smallest processable difference between I1 and I2 is 4 mA (ll I1-I2 ll ≥4 mA).

In the

„Error message“

menu item, you can activate an error process for

these types of processing.

„Lower side band“

Using this type of processing, you can control a metering pump using the current signal as shown in the diagram below.

However, you can also control two metering pumps for different feed chemicals via a current signal (e.g. one acid pump and one alkali pump using the signal of a pH sensor). To do this, connect the pumps electrically in series.

Error processing

In the

„Error message“

menu item, you can activate an error process for

these types of processing.

Page 52

I [mA]

I 1 I 2

0 20

a) b)

Fmax

B0089

I [mA]

I 1

I 2

0 20

Fmax

Set Up /

„Menu“

Fig. 33: Frequency-current diagram for a) Lower side band, b) Upper side band

„Upper side band“

Using this processing type, you can control a metering pump using the current signal as shown in the diagram above.

Everything functions according to the type of the processing

band“

„Lower side

11.2.2

„Automatic“

„Menu / Information è Settings è Automatic è ...“

In the

„Automatic“

menu, you can set whether the unit is to meter auto‐

matically or conventionally.

With

„Automatic“

„on“

, you set direct values, such as capacity, metering volume or dosing time, instead of stroke length and stroke rate. Other selection points then appear in the operating menu - refer to the chapter "Operating Menu for gamma/ X, complete" (in the appendix) for the selec‐ tion points highlighted with a "*1".

„Automatic“

„on“

metering mode, the gamma/ X specifies the stroke length and the stroke rate according to the conditions determined in order to meter the set capacity.

„Automatic“ - „on“ and „Automatic“ - „off“ metering modes are completely independent of each other. That is to say that „Automatic“ - „off“ metering mode does not carry over settings from „Automatic“ - „on“ .

Tab. 9: Setting ranges

„Automatic“

„on“ „Automatic“

„off“

Manual, continuous 1:2,000 1:2,000

11.2.3

„Stroke length“

Manual, discontinuous 1:40,000 1:40,000

„Menu / Information è Settings è Stroke length è ...“

The menu does not appear with

„Automatic“ „on“

Page 53

11.2.4 Metering

In the

„Stroke length“

menu, you can enter the stroke length manually.

In operation, the stroke length can be changed more easily by using the "Stroke length" continuous display:

–

Turn the [Clickwheel] to return to the "Stroke length" continuous display.

–

Press the [Clickwheel] and then turn it to set the stroke length.

–

Press the [Clickwheel] to save the stroke length.

„Menu / Information è Settings è Metering è ...“

Set Up /

„Menu“

11.2.4.1

„Discharge stroke“

„Menu / Information è Settings è Metering è Discharge stroke

...“

In the

„Settings“

the pump metering flow over time to the requirements of the particular application.

This ensures that the user can set the optimum discharge stroke for his application, as required:

Pos.* Discharge

„Discharge stroke“

stroke

„optimum“

„fast“

„Sine mode“

sub-menu, you can precisely match

Application

For maximum accuracy when metering and the very best results with internal pressure measurement and special functions.

For as fast a discharge stroke as possible the duration of the discharge stroke is dependent on the stroke rate.

For a long, sine-shaped discharge stroke the duration of the discharge stroke is dependent on the stroke rate.

„continuous“

„DFMa“

* see following drawing.

For a continuous discharge stroke e.g. for bottling processes. The duration of the dis‐ charge stroke is dependent on the stroke rate.

For optimum operation with a flow meter Dul‐ coFlow® DFMa.

Page 54

P_G_0074_SW

Set Up /

„Menu“

Fig. 34: Discharge stroke metering profiles with stroke L and time t (suction stroke shown as a dotted line)

11.2.4.2

„Suction stroke“

„Menu / Information è Settings è Metering è Suction stroke è ...“

Page 55

normal HV1 HV2 HV3

P_G_0075_SW

Set Up /

„Menu“

Fig. 35: Suction stroke metering profiles with stroke L and time t

Normal Normal suction stroke HV1 Suction stroke for viscous feed chemical HV2 Suction stroke for average viscosity feed chemical HV3 Suction stroke for high-viscosity feed chemical

Slowing down the suction stroke leads to a lower

–

stroke rate and thus to a lower capacity.

„Suction stroke“

setting Maximum stroke rate

Strokes/min

Normal 200

HV1 160

HV2 120

HV3 80

11.2.4.3

„Pressure stage“

„Menu / Information è Settings è Metering è Pressure stage

...“

You can use the programmable

„Pressure stage“

function to reduce the nominal pressure of the pump, thereby minimising the risk of lines rup‐ turing.

The switch-off pressure of the permanently active overpressure monitoring falls at the same time as the pressure stage - see .

Tab. 10: Nominal pressures depending on the size of the liquid ends and the pressure stages

Pressure

4 7 10 16 20 25

stage /

Size of liquid end

1602 X X X X - -

2002 X X X - X -

1604 X X X X - -

2504 X X X - - X

Page 56

Set Up /

„Menu“

Pressure stage /

Size of liquid end

1009 X X X - - -

0708 X X - - - -

0715 X X - - - -

0414 X - - - - -

0424 X - - - - -

4 7 10 16 20 25

Pressure stage Switch-off pressure*

2 2.8

4 5.2

7 8.5

10 12.5

16 19

20 23

25 28

11.2.4.4

11.2.4.4.1

11.2.4.4.2

„Monitoring“

„Air lock“

„Air sensitivity“

* above which the unit is switched off for the medium term in the event of excess pressure

„Menu / Information è Settings è Metering è Monitoring è ...“

„Menu / Information è Settings è Metering è Monitoring

Air lock è ...“

Should a message and the "Air lock" symbol there is gas in the liquid end (if

lock“

sub-menu).

„Warning“

appear, this may mean that

„Error“

was set in the

„Air

„Menu / Information è Settings è Metering è Monitoring

Air sensitivity è ...“

Using the sitivity of air detection a little to receive as few incorrect alarms as pos‐ sible.

„Air sensitivity“

programmable function, you can adjust the sen‐

Page 57

11.2.4.5 Compensation

Set Up /

„Menu“

Tab. 11: There are 3 levels of sensitivity:

normal maximum sensitivity

average average sensitivity

weak lowest sensitivity.

Only use at pressures < 2 bar.

Using the influence of back pressure oscillations and thus achieve a high dosing pre‐ cision.

„Compensation“

programmable function, you can minimise the

With difficult hydraulic conditions, it may be better to switch off the „Compensation“ function.

11.2.5 Concentration

The principle of entering the concentra‐ tion:

„Menu / Information è Settings è Concentration è ...“

The desired mass concentration of feed chemical that will subsequently be required in the dissolving medium (e.g. the main flow) can be entered directly in the "Concentration" continuous display.

1. Select the operating mode.

2. Set the data for the feed chemical and dissolving medium in the

„Set up“-„Concentration“

3. Set the desired concentration in the "Concentration" continuous dis‐

play.

The "Concentration" continuous display only

–

menu.

appears, if:

–

the pump is calibrated.

–

the „Concentration“ menu was run through in the operating mode used.

–

and „Concentration control“ was switched to

„active“ - in the operating mode being used.

–

The "Concentration" continuous display switches to the display mode "%" at concentrations above

999.99 ppm.

–

When changing between operating modes, the pump saves the settings for each operating mode providing it is connected to supply voltage.

–

If the pump is to display the concentration as a volume concentration, enter "1.00" kg/l for the den‐ sity of the feed chemical.

Page 58

Set Up /

11.2.5.1

„Menu“

„Manual“

operating mode (settings for the

„Menu / Information è Settings è Concentration

Concentration control è Flow of main medium è ...“

„Concentration“

function)

The prerequisites are that:

Procedure

The "Concentration input" in metering a substance into pipework containing a medium flowing at a con‐ stant rate ( tration in the flow.

n the flowing medium has the same density as water (1 kg/l n the mass concentration of the feed chemical is known - see the feed

n the density of the feed chemical is known - see the feed chemical

n The measurement unit for the liquid volume is set in the

„main flow“

CAUTION! Danger of too high concentrations The metering pump can continue to meter if the flow falls

or stops entirely.

– Take system-based precautions to prevent the

metering pump from continuing to meter in these cir‐ cumstances.

chemical safety data sheet (e.g. with 35% sulphuric acid: 35 %)

safety data sheet (e.g. with 35% sulphuric acid: 1.26 kg/l ≜ g/cm3)

Volume unit“

CAUTION! The precision of the concentration is strongly dependent

on:

– the precision of the metering pump calibration. –

menu.

the precision of the inputs.

„Manual“

) in such a way that it has a specific mass concen‐

operating mode is intended for

≜ g/cm3)

„System

1. Calibrate the metering pump if it is not yet calibrated - see chapter

„Settings“-„Calibration“

2. Check whether the metering pump is set to

„on“

metering mode.

3. Select

4. Select

5. Actively set

6. Set the

7. Set the

8. Set the (mass)

10. Press the

11. Enter the required mass concentration of the feed chemical in the

„Manual“

operating modes remain saved.).

„Concentration“

„active“

press the

[Clickwheel]

„Main medium flow“

[Clickwheel]

„Feed chemical mass concentration“

[Clickwheel]

„Feed chemical density“

The

Press

„Concentration“

[Menu]

A continuous display appears.

[Clickwheel]

play (ppm or %).

main flow by pressing and turning the

chapter.

„Automatic“

„Operating mode“

in the

„Concentration control“

(in the pipework) and then press the

menu appears.

to go to the "Concentration" continuous dis‐

(possible settings from other

„Set up“

menu.

and press the

[Clickwheel]

menu item and

[Clickwheel]

Page 59

Tab. 12: Possible values of adjustable variables

Adjustable variable Lower value Upper value Increment

Set Up /

„Menu“

Flow in m3/h

Mass concentration in % 000.01 100.00 000.01

Mass density in kg/l 0.50 2.00 0.01

11.2.5.2

„Contact“

0000.1 9999.9 0000.1

operating mode (settings on the

„Concentration“

function)

„Menu / Information è Settings è Concentration

Concentration control è Contact gap è ...“

The "Concentration input" in metering a substance into pipework containing a medium flowing at a vari‐ able rate in such a way that it has a specific mass concentration in the flow.

CAUTION! Danger of too high concentrations The metering pump can continue to meter if the flow falls

or stops entirely.

– Take system-based precautions to prevent the

metering pump from continuing to meter in these cir‐ cumstances.

„CONTACT“

operating mode is intended for

The prerequisites are that:

Procedure

n the flowing medium has the same density as water (1 kg/l n the mass concentration of the feed chemical is known - see the feed

chemical safety data sheet (e.g. with 35% sulphuric acid: 35 %)

n the density of the feed chemical is known - see the feed chemical

safety data sheet (e.g. with 35% sulphuric acid: 1.26 kg/l ≜ g/cm3)

n a contact water meter is hydraulically installed and connected to the

external input of the metering pump.

n The measurement unit for the liquid volume is set in the

Volume unit“

CAUTION! The precision of the concentration is strongly dependent

on:

– the precision of the metering pump calibration. – the precision of the inputs.

1. Calibrate the metering pump if it is not yet calibrated - see chapter

„Settings“-„Calibration“

2. Check whether the metering pump is set to

„on“

metering mode.

3. Select

ciated menu items with the other operating modes remain saved.)

4. Select

5. Actively set

press the

6. Set the

menu.

„Contact“

„Operating mode“

„Concentration“

„active“

in the

[Clickwheel]

„Contact gap“

chapter.

and simply confirm the asso‐

[Clickwheel]

in the

„Set up“

menu.

„Concentration control“

and press the

[Clickwheel]

„Automatic“

(possible settings from

≜ g/cm3)

„System

menu item and

Page 60

Set Up /

„Menu“

7. Set the (mass)

[Clickwheel]

8. Set the (mass)

The

Press

[Menu]

A continuous display appears.

10. Press the play (ppm or %).

11. You can enter the desired mass concentration using the

[Clickwheel]

„Feed chemical concentration“

„Feed chemical density“

„Concentration“

[Clickwheel]

menu appears.

to go to the "Concentration" continuous dis‐

and press the

Tab. 13: Possible values of adjustable variables

Adjustable variable Lower value Upper value Increment

Contact gap in l/contact 000.10 999.99 000.01

Mass concentration in % 000.01 100.00 000.01

Mass density in kg/l 0.50 2.00 0.01

and press the

[Clickwheel]

11.2.5.3

The prerequisites are that:

Procedure

„Batch“

operating mode (settings for the

„Concentration“

function)

„Menu / Information è Settings è Concentration

Concentration control è Volume of main medium è ...“

The "Concentration input" in metering a substance into the medium in a storage tank so that it then has a defined mass concentration in the storage tank (when batching a solu‐ tion – do not forget to stir!).

n the medium in the storage tank has the same mass density as water

(1 kg/l ≜ g/cm3)

n the mass concentration of the feed chemical is known - see the feed

chemical safety data sheet (e.g. with 35% sulphuric acid: 35 %)

n the density of the feed chemical is known - see the feed chemical

safety data sheet (e.g. with 35% sulphuric acid: 1.26 kg/l

n The measurement unit for the liquid volume is set in the

Volume unit“

CAUTION! The precision of the concentration is strongly dependent

on:

– the precision of the metering pump calibration. –

menu.

the precision of the inputs.

„Batch“

operating mode, is intended for

≜ g/cm3)

„System

1. Calibrate the metering pump if it is not yet calibrated - see

„Calibration“

2. Check whether the metering pump is set to

„on“

metering mode.

3. Select ated menu items with the operating modes remain saved.)

4. Select

chapter.

„Batch“

„Operating mode“

„Concentration“

[Clickwheel]

in the

„Set up“

„Automatic“

and simply confirm the associ‐

(possible settings from other

menu.

„Set up“

Page 61

5. Actively set press the

6. Set the and press the

7. Set the (mass)

[Clickwheel]

8. Set the (mass)

The

Press

A continuous display appears.

10. Press the play (ppm or %).

11. You can enter the desired mass concentration using the

[Clickwheel]

„active“

[Clickwheel]

in the

„Main medium volume“

[Clickwheel]

„Feed chemical concentration“

„Feed chemical density“

„Concentration“

[Menu]

[Clickwheel]

menu appears.

to go to the "Concentration" continuous dis‐

„Concentration control“

of the medium in the storage tank

and press the

Tab. 14: Possible values of adjustable variables

Adjustable variable Lower value Upper value Increment

Volume in l 0000.1 9999.9 0000.1

Set Up /

and press the

„Menu“

menu item and

[Clickwheel]

Mass concentration in % 000.01 100.00 000.01

Mass density in kg/l 0.50 2.00 0.01

11.2.5.4

„Analogue“

operating mode (settings on the

„Concentration“

function)

„Menu / Information è Settings è Concentration

Concentration control è Max. flow of main medium è ...“

The "Concentration input" in metering a substance into pipework containing a medium flowing at a vari‐ able rate in such a way that it has a specific mass concentration in the flow.

CAUTION! Danger of too high concentrations The metering pump can continue to meter if the flow falls

or stops entirely.

– Take system-based precautions to prevent the

metering pump from continuing to meter in these cir‐ cumstances.

„Analogue“

operating mode is intended for

The prerequisites are that:

CAUTION! Risk of incorrect concentrations – After adjusting, check whether the concentration at

various flows corresponds to the required result.

n the flowing medium has the same density as water (1 kg/l n the mass concentration of the feed chemical is known - see the feed

chemical safety data sheet (e.g. with 35% sulphuric acid: 35 %)

n the density of the feed chemical is known - see the feed chemical

safety data sheet (e.g. with 35% sulphuric acid: 1.26 kg/l ≜ g/cm3)

≜ g/cm3)

Page 62

Set Up /

Procedure

„Menu“

n a flow meter with analogue output is hydraulically installed and con‐

nected to the external input of the metering pump.

n The measurement unit for the liquid volume is set in the

Volume unit“

CAUTION! The precision of the concentration is strongly dependent

on:

– the precision of the metering pump calibration. –

1. Calibrate the metering pump if it is not yet calibrated - see chapter

„Settings“-„Calibration“

2. Check whether the metering pump is set to

„on“

metering mode.

3. Select

[Clickwheel]

4. Set

5. Select

6. Actively set

7. Set the

„0...20 mA“

and press the

press the

[Clickwheel]

8. Set the (mass)

[Clickwheel]

9. Set the (mass)

The

10.

Press

A continuous display appears.

11. Press the play (ppm or %).

12. You can enter the desired mass concentration using the

[Clickwheel]

menu.

the precision of the inputs.

chapter.

„Automatic“

„Analogue“

„Concentration“

[Clickwheel]

„Max. main medium flow“

operating mode and confirm with the

„4..20 mA“

[Clickwheel]

„active“

. (It is then assigned to the current value of 20 mA).

in the

„Select analogue“

„Set up“

menu.

„Concentration control“

(in the pipework) and press the

„Feed chemical concentration“

„Feed chemical density“

„Concentration“

[Menu]

[Clickwheel]

menu appears.

to go to the "Concentration" continuous dis‐

and press the

„System

menu item

menu item and

and press the

[Clickwheel]

CAUTION! – Note the decimal point.

The mass concentration is affected by

–

changes in the stroke rate and the stroke length.

– The pump limits the upper value of the mass

concentration, because otherwise the incre‐ mental jumps when adjusting would be unac‐ ceptably large. Adjust the stroke length as necessary - do not set it under 30%.

The least significant figures of the value in the continuous display cannot be changed at will using the [Arrow keys], rather only in incremental jumps resulting from the input data.

As necessary, change the stroke length and adjust the concentration; in doing so the pump compensates via the stroke rate.

Page 63

Tab. 15: Possible values of adjustable variables

P_G_0071_SW

Adjustable variable Lower value Upper value Increment

Set Up /

„Menu“

Max. flow in m3/h

0000.1 9999.9 0000.1

Mass concentration in % 000.01 100.00 000.01

Mass density in kg/l 0.50 2.00 0.01

11.2.6 Calibration

„Menu / Information è Settings è Calibration è ...“

Accuracy of calibration Normally the pump does not have to be calibrated.

The pump can be calibrated if viscous feed chemicals are used or extremely high accuracy is required.

In „Auto“ dosing mode - „off“ : Some menus only appear if the pump has been calibrated.

Calibration using a calibration factor

Select the

Calibration factor“

2. Use the

„Menu / Information è Settings è Calibration

menu and press the

The

„Calibration factor“

[Clickwheel]

The

„Calibration factor“

to enter the required

menu item appears.

menu item appears for confirmation.

[Clickwheel]

„Calibration factor“

Calibration

Preparation

WARNING! If the feed chemical is hazardous, take appropriate

safety precautions when performing the following cali‐ bration instructions. Observe the material safety data sheet for the feed chemical!

1. Use the

[Clickwheel]

to scroll through the continuous display to

check whether litres or gallons have been selected.

2. If the incorrect volume unit has been selected, correct it in the

„Menu / Information è Settings è System è Volume unit“

menu.

Page 64

Set Up /

„Menu“

3. Check whether the capacity or stroke rate in the continuous display is not too low for calibration.

4. Lead the suction hose into a measuring cylinder containing the feed chemical – make sure that the discharge hose is installed perma‐ nently (operating pressure, ...!).

Prime the feed chemical (press  empty.

[Priming]

) if the suction hose is

Calibration process

1. Record the level in the measuring cylinder.

Select the

Calibration“

3. To start calibration, press the

4. After a reasonable number of strokes (a minimum of 200), use the

[Clickwheel]

5. Determine the required metering volume (difference between initial volume - remaining volume in the measuring cylinder).

6. Use the

ended“

7. Press the

„Menu / Information è Settings è Calibration

menu and press the

The

„Start calibration“

The

„Calibrate ...“

and indicates the number of strokes.

to stop the pump.

The

„Calibration ended“

the calibration volume is entered.

[Clickwheel]

menu items and close.

The pump switches to the pump is calibrated.

[Clickwheel]

The pump returns to the

(PUSH) menu item appears.

menu item appears, the pump starts to pump

to enter this volume in the

[Clickwheel]

menu item appears. It requests that

„Calibration result“

„Menu / Information è Settings“

„Calibration

menu item - the

menu.

11.2.7 System

11.2.7.1

„Bluetooth “

„Menu / Information è Settings è System è ...“

The

„System“

1 -

„Bluetooth“

2 -

„Dosing head“

3 -

„Volume unit“

4 -

„Pressure unit“

5 -

„Pressure adjustment“

6 -

„Start behaviour“

menu splits into the following sub-menus:

„Menu / Information è Settings è System è Bluetooth è ...“

You can switch the pump’s Bluetooth communication on and off in the

„Bluetooth“

sub-menu.

11.2.7.2

„Dosing head “

„Menu / Information è Settings è System è Dosing head è ...“

Page 65

11.2.7.3 Volume unit

Set Up /

CAUTION! – Should a different liquid end size be fitted, then the

pump must be reprogrammed in the

head“

sub-menu.

– Reprogram the pump to

onstration purposes or if operating without feed chemical.

„No dosing head“

„Dosing

„Menu“

for dem‐

If „SEK“ has been selected as the type of head, the pressure is not displayed and the „Automatic“ menu is hidden. Only „fast“ can be selected for the „Discharge stroke“ and „normal“ for the „Suction stroke“ .

„Menu / Information è Settings è System è Volume unit è ...“

11.2.7.4 Pressure unit

11.2.7.5 Pressure adjustment

You can select another unit for the volume in the

„Volume unit“

sub-menu.

„Menu / Information è Settings è System è Pressure unit è ...“

In the

„Pressure unit“

sure.

sub-menu, you can select another unit for the pres‐

„Menu / Information è Settings è System è Pressure adjustment

...“

You can adjust the pressure value, which the pump displays in the

„Pressure adjustment“

the discharge line.

sub-menu, if it is to deviate from the pressure in

There is no „Pressure adjustment“ sub-menu with pumps with SER or SEK dosing heads.

Requirements:

n A manometer is installed in the discharge line. n Everything is set on the pump.

1. Shift to the

2. Use the

3. The sure value that the pump is missing. Below that it displays an adjustable pressure value.

„Pressure adjustment“

The

„Start pump“

[Clickwheel]

The pump starts up.

The

„Calibration pressure“

menu item appears.

to confirm

„Calibration pressure“

sub-menu.

„Yes“

menu item appears.

menu item shows at the top the pres‐

Page 66

Set Up /

11.2.7.6 Start behaviour

„Menu“

4. Use the eter as soon as the pressure value is stable.

5. Use the

[Clickwheel]

The pump stops.

to enter the pressure value from the manom‐

to confirm this pressure value.

„Pressure adjustment“

is now complete.

„Menu / Information è Settings è System è Start behaviour è ...“

You can specify the start behaviour of the pump once the supply voltage has been switched on in the

Start behaviour Description

„Start behaviour“

sub-menu.

11.2.8 Inputs/outputs

„always off“

„always on“

„last status“

The pump always wakes up in “Manual stop via

[STOP/START]

the

It can only be started by pressing

[STOP/START]

The pump always starts immediately.

The pump always adopts the last status it had before the supply voltage was switched off.

„Menu / Information è Settings è Inputs/Outputs è ...“

The

„Inputs/Output“

1 -

„Auxiliary capacity“

2 -

„Relay1“

3 -

„Relay2“

4 -

„mA output“

6 -

„Flow monitor“

5 -

„Diaphragm rupture“

7 -

„Pause input“

8 -

„Level warning“

9 -

„Level error“

menu splits into the following sub-menus:

„Auxiliary frequency“

(Optional)

(optional)

(only if connected)

(Option)

key" mode.

11.2.8.1

„Auxiliary capacity“

„Auxiliary frequency“

Auxiliary capacity / Auxiliary frequency è ...“

The programmable enables switch-over to an additional capacity / stroke rate that can be fixed in the

It can be activated via the "External control" terminal. If

capacity“

appears on the LCD screen.

„Menu / Information è Settings è Inputs/Outputs

„Auxiliary capacity“

„Auxiliary frequency“

menu.

is being used, then the identifier "AUX”

function

„Auxiliary

Page 67

Set Up /

Refer to the "Hierarchy of Operating Modes, Functions and Fault Statuses" for the order of the various operating modes, functions and fault statuses.

„Menu“

11.2.8.2

„Relay1 (Optional)“

„Menu / Information è Settings è Inputs/outputs è Relay1 è ...“

The setting options for the „Relay“ function are only available if a relay is fitted.

gamma/ X, GMXa

Tab. 16: Relay, physical and pre-set to ...

Identity code specification Relay, physical Pre-set to ...

1 1 x changeover contact 230 V – 8 A Fault indicating relay, N/C

4 2 x N/O 24 V – 100 mA Fault indicating relay, N/C, and pacing

C 1 x N/O 24 V – 100 mA, + 4...20 mA

Relay type

output

You can reprogram the relays to these types:

relay

Fault indicating relay, N/C

Menu setting Effect

Inactive The relay is inactive.

Fault The relay switches in the event of a fault message (red LED*).

Warning The relay switches in the event of a warning message (yellow LED*).

Warning + error The relay switches in the event of a warning message (yellow LED*) or a fault

Pump active The relay switches as soon as the pump is in standby and not in a state like

Metering / Batch The relay changes its state as soon as a batch has been processed.

Stroke rate** The relay switches at every stroke.

Optional The relay offers the option of the module being plugged in (e.g. the bleed

Bleeding The relay switches with the internal

Relay polarity

message (red LED*).

„Pause“

module).

pump is priming.

* see the "Troubleshooting" chapter

** only use

You can set here how a relay is to switch.

„Relay 2“

for this relay type (semiconductor relay).

„Air lock“

signal and for as long as the

Menu setting Effect

normally-closed (NC) The relay is closed in normal mode and opens

normally-open (NO) The relay is open in normal mode and opens

with a triggering event.

Page 68

Set Up /

11.2.8.3

„Menu“

„Relay2 (Optional)“

„Menu / Information è Settings è Inputs/outputs è Relay2 è ...“

Relay cycle quantity

11.2.8.4

11.2.8.5

„mA output (optional)“

„Flow control“

Here you can set the metering volume for which the pacing relay is to switch once.

For more information on

outputs“ on page 66

„Relay2“

- see

Ä Chapter 11.2.8 „Inputs/

„Menu / Information è Settings è Inputs/outputs è mA output

...“

Here you can set which current range is to be used at the mA output.

You can then set whether the current stroke rate (strokes / hour) is to be signalled at the mA output or the capacity (litres / hour) and the corre‐ sponding value for 20 mA.

„Menu / Information è Settings è Inputs/outputs è Flow control

...“

11.2.8.6

„Diaphragm rupture“

The setting options for the „Flow control“ function are only available if a flow control has been electrically installed. The symbol for flow control appears:

A metering monitor, such as a Flow Control (also DulcoFlow®), can reg‐ ister the individual pressure impacts of the pump and report them back to the pump.

The pump switches to fault mode if this feedback is missing in a sequence, as set under

It is possible to switch the function on and off under

It is possible to set whether the function is to be deactivated with auxiliary frequency under

„Error tolerance“

„if Auxiliary“

„Activation“

„Menu / Information è Settings è Inputs/outputs

Diaphragm rupture è ...“

The setting options for the „Diaphragm rupture“ function are only available if a diaphragm rupture indicator is electrically installed. The symbol for diaphragm appears

In the

„Diaphragm rupture“

generates a warning message or a fault message in the event of a dia‐ phragm rupture.

sub-menu you can select whether the pump

Page 69

11.2.8.7

„Pause input“

„Settings è Inputs/outputs è Pause è ...“

In the

„Pause“

menu you can select whether the pump switches to

with an "energising (NO)" or "releasing (NC)” input contact signal.

Set Up /

„Menu“

11.2.8.8

11.2.8.9

„Level warning“

„Level error“

11.2.9 Bleeding

„Settings è Inputs/outputs è Level warning è ...“

In the

„Level warning“

tact signal.

menu, you can select whether the pump switches

with an energising (NO)" or "releasing (NC)" input con‐

„Settings è Inputs/outputs è Level error è ...“

In the

„Level error“

signal.

menu, you can select whether the pump switches to

with an "energising (NO)" or "releasing (NC)" input contact

„Menu / Information è Settings è Bleeding è ...“

The

„Bleeding“

The software solution is always in the pump control. The pump presses the gas bubbles out of the liquid end at a high stroke rate during bleeding.

If the pump has "Automatic bleed" via the "relay identity code option (retro‐ fittable), the pump can be bled via a bleed relay.

There are 2 hardware options for automatically bleeding the discharge side:

n via ProMinent's bleed module in the liquid end. n via a customer implemented bleed facility in the discharge line.

function is used for controlled bleeding of the liquid end.

The relay - "Relay” – "with automatic bleed" - changes its switching status for the period during which the pump is priming.

The

„Bleed“

1 - Not (

2 -

3 - By the

4 - If one of the two signals occurs (

function can be triggered in 4 ways:

„Off“

„Periodically“ „Duration“

by an internal signal - defined by

„Air lock“

internal signal

„Both“

„Cycle“

and

Page 70

Set Up /

„Menu“

Detailed explanation:

1 - If

„Off“

has been selected in the menu, this function is deactivated.

2 - If

„Periodically“

odically triggers the bleed procedure with an adjustable 1440 min = 24 h) and an adjustable

Bleeding is always triggered at the start of a period. A bleed process is also started by the pump to mains voltage.

3 - If

„Air lock“

signal triggers the bleed procedure.

If the signal appears again within 8 minutes of the bleed procedure being carried out, the control unit repeats the bleed procedure up to a maximum of 3 times. However if the signal still appears, then an error message is generated, which has to be acknowledged via the

In the event of an message disappears for the menu branch in the available for the

4 - If

„Both“

a bleed process.

was selected in the menu, then the control unit peri‐

„cycle“

„duration“



[STOP/START]

has been selected in the menu, the

„Air lock“

„Bleed“

has been selected in the menu, then each trigger can trigger

the option of a direct error or warning

„Settings“

function.

„Air lock“

menu is also hidden. The signal is only

signal. The corresponding

(5 ... 300 s = 5 min).

key or by connecting the

„Air lock“

internal

(10 ...

[dial]

Sequence of the bleed procedure (auto‐ matic):

The pump control stops the normal metering operation - the "Stop Pause" symbol appears on the LCD screen.

2. Only with bleed relay: After 1 s, the pump control opens the bleed valve on the liquid end (via the bleed relay and the solenoid valve).

3. 1 s later, the pump starts to run at a high stroke rate (like during pri‐ ming) - the "Air lock" symbol appears on the LCD screen instead of the "Stop Pause" symbol.

4. The pump operates in this way for the total set time.

5. Once the set time has elapsed, the pump stops – the "Stop Pause” symbol

6. Only with bleed relay: After 1 s the pump control closes the liquid end bleed valve.

After 1 s the "Stop Pause" symbol disappears and the pump recommences normal operation.

If the pump was in the "Stop" state at the time of triggering ( 

[STOP/START]

- until this state has been cleared.

If the pump switched to "Stop" state during the bleed procedure, the pump control jumps immediately to phases 5 and 6. - see above. This definitely cancels the bleed procedure. As soon as the "Stop" state is cleared, the bleed procedure starts from the beginning.

appears on the LCD screen again.

, Pause, Error), the start of the bleed procedure is delayed

11.2.10

„Priming time“

„Menu / Information è Settings è Priming time è ...“

In the

„Priming time“

to prime once

menu, you can select how long the metering pump is

[Priming]



has been pressed.

Page 71

Set Up /

In operation, the stroke length can be changed more easily using the "Priming time" display:

–

Press  [Priming] - the pump starts to prime.

–

Turn the [Clickwheel] to set the priming time.

–

Press the [Clickwheel] to save the priming time.

„Menu“

11.2.11

11.2.12

„Set time“

„Date“

„Menu / Information è Settings è Set time è ...“

You can set the time in the

1. Use the dial to adjust a figure.

Under over to

You can also input when the pump is to change to and from

time“

Check under

„hemisphere“

You can set the date in the



Use

„Auto. Summer time“

„Summer time“

„Menu / Information è Settings è Date è ...“

[Priming]

„Location“

of the world.

„Set time“

to move to the next figure.

you can select whether you wish to change

whether the pump is also set to its own

„Date“

menu.

„Summer

11.3 Timer

11.3.1 Timer activation

„Menu / Information è Timer è ...“

The process timer can do the following to the pump at a predefined time:

n start n stop n work at a defined stroke rate n work at a defined capacity n work at a stroke length n change operating mode n open the relays n close the relays

„Menu / Information è Timer è Activation è ...“

To activate the timer, set

„Activation“

„active“

Page 72

Set Up /

„Menu“

11.3.2 Setting the timer

„Menu / Information è Timer è Set timer è ...“

A program set up in "Automatic" - "on" metering mode will not function in "Automatic" - "off" metering mode and vice versa.

You can create commands (program lines) for a timer program in the

timer“

You can create up to 32 commands (program lines).

You can then use the administration functions to manage the commands -

Ä Chapter 11.3.2 „Setting the timer“ on page 72

Use the

Create the command as follows:

1 - Create a command (program line)

2 - Select the triggering event and time

3 - Select the action and value

4 - Check the command

5 - Create the next command if necessary

11.3.2.1 Administration functions for commands

The following administration functions are available to manage the com‐ mands (program lines):

„New“

„Display“

„Change“

„Clear“

Use

„New“

menu.

„Clear all“

function to clear all commands (the program).

(only if commands entered)

to create a new command.

„Set

11.3.2.2

11.3.2.3 Selecting the

„Init“

Initial Conditions

„Time Event“

Use

„Init“

to specify initial conditions at the start of the program - see

Ä Chapter 11.3.2.4 „Select the action and value“ on page 73

and Time



You can select a time event (cycle) and a time as well:

Time event Time

„Hourly“

„Daily (Mon-Sun)“

„Weekdays1 (Mo-Fr)“

„Weekdays1 (Mo-Sa)“

hourly at the x minute

daily at the time mm.ss, Monday to Sunday

daily at the time mm.ss, Monday to Friday

daily at the time mm.ss, Monday to Saturday

Page 73

Time event Time

10:48

Manual

0.25 l/h

monthly

Command 01/05

B0781

on 21st

Set Up /

„Menu“

11.3.2.4 Select the action and value

„Weekend (Sa+Su)“

daily at the time mm.ss, Saturday and Sunday

„Weekly“

weekly at the time mm.ss on the day dd.

„Monthly“

weekly at the time mm.ss on the x. day of the month

CAUTION! If you wish to use automatic summer time adjustment

„Settings“

(

„Time“

) avoid any triggering events

between 02:00 a.m. and 03:00 a.m.

You can select an action and also a value:

Action Value

Manual Litre/h *1

Strokes/h *2

11.3.2.5 Checking the Finished Command

Stroke length * 2

Stop --

Frequency Litre/h *1

Strokes/h *2

Relay 1 open

closed

Relay 2 open

closed

*1: only available in

„Settings“

„Automatic“

operating mode - see Chapter

*2: only available, if metering is done the traditional/conventional way.

The pump displays the finished command (program line) as soon as you have finished programming the command:

Page 74

Set Up /

„Menu“

11.3.3 Clear all

11.3.4 Example

„Menu / Information è Timer è Clear all è ...“

Use the

„Clear all“

menu to clear all commands (the program).

Example of "Weekday metering"

Com‐ mand

01 workdays 1 (Mo-

02 workdays 1 (Mo-

03 workdays 1 (Mo-

04 workdays 1 (Mo-

05 workdays 1 (Mo-

06 workdays 1 (Mo-

Time event Time of day Action Capacity Comment

Fr)

The pump is to meter 2 litres every half hour every weekday (Mon-Fri) between 8:00 and 11:00:

08:30 Manual 12,000 l/h //Meter with

12,000 l/h//

08:40 Stop //Stop//

09:30 Manual 12,000 l/h //Meter with

12,000 l/h//

09:40 Stop //Stop//

10:30 Manual 12,000 l/h //Meter with

12,000 l/h//

10:40 Stop //Stop//

Explanation: At a capacity of 12 l/h, the pump has to work for 10 minutes to meter 2 litres.

11.4

11.4.1

„Service“

„Access protect.“

„Menu / Information è Service è ...“

„Menu / Information è Service è Access protect è ...“

You can lock parts of the setting options here.

The following locking options are available:

Selection Point ① Point ②

„none“

„ Lock menu“

„Lock all“

- -

X -

X X

Page 75

STOPSTOP

STARTSTART

Setting

mode

Continuous

display

Stop/start pump

Priming

Start batch (only in "Batch" operating mode)

Acknowledging errors

Check adjustable values

Changing directly changeable variables

B0598

Set Up /

„Menu“

11.4.2

11.4.3

„Password “

„Clear counter“

Fig. 36

If you have set a

„Password“

- see below, then the identifier

will appear after 1 minute in the top left and the specified areas will be locked, if no key has been pressed in the meantime.

Both locks use the same

„Password“

„Menu / Information è Service è Password è ...“

You can enter a password of your choice in the

password“

menu.

„Change

„Menu / Information è Service è Clear counter è ...“

You can reset the counter to "0" in the

„Stroke counter“

„Volume counter“

„Contact memory“

„All“

(total number of strokes)

(total litres)

To clear: exit the menu by briefly pressing the

„Clear counter“

[Clickwheel]

menu:

11.4.4

„Log book“

The values have increased since commissioning of the pump, the last cali‐ bration or the last deletion.

„Menu / Information è Service è Log book è ...“

Page 76

Set Up /

11.4.4.1 Log book entry - Detailed view

„Menu“

You can view the list of

„Filter“

helps with the overview.

If you need more detailed log book entries:

The metering pump gamma/ X with Bluetooth function‐ ality can display a more extensive log file with pumprelated events and e-mail it using a Bluetooth-compatible Android smart device and the “gamma/ X” app.

Press the

Tab. 17: Information on the detailed view

[Clickwheel]

Line Information

1 Date/time

2 Type of entry (fault, warning ...)

„Log book entries“

to obtain more information about a log book entry.

here.

11.4.5

11.4.6

„Replace diaphragm“

„Display“

3 Total operating time, total number of strokes

4 Switching-on duration, stroke rate since switching on

5 Room temperature, status information on the error (for

„Menu / Information è Service è Diaphragm replacement è ...“

You can move the slide rod into the "replacement position" here with

replacement position“

„Menu / Information è Service è Display è ...“

You can set the

developers)

to enable the diaphragm to be replaced more easily.

„Contrast“

and the

„Brightness“

of the LCD screen here.

„To

11.4.7

„Factory settings“

„Menu / Information è Service è Factory setting è ...“

You can reset the pump to its factory settings here with

11.4.8 Diaphragm part number: XXXXXXX

„Menu / Information è Service

Diaphragm part number: XXXXXXX è ...“

„Yes“

Page 77

Set Up /

You can read off the part number (order number) of the correct diaphragm here.

„Menu“

11.4.9

11.5

Spare parts kit part number: XXXXXXX

„Menu / Information è Service

Spare parts kit part number: XXXXXXX è ...“

You can read off the part number (order number) of the correct spare parts kit here.

„Language“

„Menu / Information è Language è ...“

In the

„Language“

menu, you can select the desired operating language.

Page 78

Operation

12 Operation

WARNING! 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.

This chapter describes all the operating options in a continuous display (several symbols and the pressure display appear at the top in the black bar) for the trained person at the pump.

–

Please also refer to the "Operating/Setting Over‐ view" and "Continuous Displays and Secondary Dis‐ plays" overviews at the end of the operating instruc‐ tions and also the "Overview of Equipment and Control Elements" chapter.

12.1 Manual operation

Stop/start pump

Priming

Starting a batch

Acknowledging errors

Checking adjustable variables

Changing directly changeable variables

Changing a variable in the relevant contin‐ uous display:

Stop the pump: Press

Start the pump: Press

[Priming]

Press

Turn the

In uous display.

Press the acknowledgement.

In a continuous display: Another continuous display will appear each time the figuration).

1. Press the

2. Turn the

3. Press the



[Clickwheel]

„Batch“

operating mode: Press the

[Clickwheel]

engages when turned. (The number depends on the con‐

[Clickwheel]

The variable can be changed (highlighted).

[Clickwheel]

The variable is changed.

[Clickwheel]

The variable is saved (the highlighting disappears).

[STOP/START]



[STOP/START]

to extend of shorten the priming time during priming.

to acknowledge error messages that require

again.

[Clickwheel]

in the

„Push“

contin‐

If the "lock" - "lock all" has been set - see

gamma/ X“ on page 79 [Clickwheel]

, first enter the

„Password“

Ä „Set Up Overview of the

after pressing the

Page 79

STOPSTOP

STARTSTART

Setting

mode

Continuous

display

Stop/start pump

Priming

Start batch (only in "Batch" operating mode)

Acknowledging errors

Check adjustable values

Changing directly changeable variables

B0598

Set Up Overview of the gamma/ X

Operation

List of directly changeable variables:

n Capacity n Stroke rate n Stroke length n Factor n Contact volume n Batch dosing time n Concentration

Fig. 37: Control options using keys and locking options

[Clickwheel]

Press

[Clickwheel]

Turn ① "Lock menu" ② "Lock all"

Page 80

Maintenance

13 Maintenance

WARNING! It is mandatory that you read the safety information and

specifications in the "Storage, Transport and Unpacking" chapter prior to shipping the pump.

WARNING! 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.

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.

Third party spare parts for the pumps may lead to prob‐ lems when pumping.

–

Use only original spare parts.

–

Use the correct spare parts kits. In the event of doubt, refer to the exploded views and ordering information in the appendix.

Standard liquid ends:

Interval Maintenance work Personnel

Quarterly*

n Check the metering diaphragm for damage** - refer to "Repair". n Check that the hydraulic lines are fixed firmly to the liquid end. n Check that the suction valve and discharge valve are fitted tightly. n Check that the entire liquid end is leak-tight - particularly around the

leakage hole - refer to

n Check that the flow is correct: Press

prime briefly.

n Check that the electrical connections are intact. n Check the integrity of the housing. n Check that the dosing head screws are tight.

Fig. 38.



[Priming]

* Under normal loading (approx. 30% of continuous operation)

Under heavy loading (e.g. continuous operation): Shorter intervals.

** Check the diaphragm frequently with feed chemicals that put particular pressure on the diaphragm, e.g. those containing abrasive additives.

to allow the pump to

Technical personnel

Page 81

P_G_0054_SW

Liquid ends with bleed valve:

Interval Maintenance work

Quarterly* In addition:

n Check that the bypass line is fixed firmly to the liquid end. n Check that the bleed valve is tight. n Check the discharge and bypass line for kinks. n Check that the bleed valve is operating correctly.

Maintenance

Fig. 38: Leakage hole

Tightening torque

* Under normal loading (approx. 30% of continuous operation).

Under heavy loading (e.g. continuous operation): Shorter intervals.

Data Value Unit

Tightening torque for screws: 4.5 ... 5.0 Nm

Page 82

Carrying out repairs

14 Carrying out repairs

Safety information

WARNING! Danger of electric shock Unauthorised repairs inside the pump can result in an

electric shock.

For this reason, only allow a ProMinentbranch or repre‐ sentative to perform repairs inside the pump, in partic‐ ular the following:

– Replacement of damaged mains connection lines

Replacement of fuses

– – Replacement of electronic control

WARNING! It is mandatory that you read the safety information and

specifications in the "Storage, Transport and Unpacking" chapter prior to shipping the pump.

WARNING! Contact with the feed chemical Parts that come into contact with the feed chemical are

exposed and touched during repair work.

– Protect yourself against the feed chemical in case it

is hazardous. Read the safety data sheet on the feed chemical.

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.

WARNING! Fire hazard with flammable media Only with flammable media: They can be ignited by

oxygen.

– The pump may not work if there is a mixture of feed

chemical with oxygen in the liquid end. A specialist may need to take appropriate actions (using inert gas, ...).

Page 83

14.1 Replacing the diaphragm

P_G_0050_SW

1 2 3 4 5 6

Carrying out repairs

The order no. (part number) of the appropriate dia‐ phragm or the spare parts kit can be found at the end of the „Service“ menu.

n If necessary take protective measures. n Adhere to the material safety data sheet for the feed chemical. n Prevent the escape of feed chemical. n Ensure that the system is at atmospheric pressure.

1. Empty the liquid end (turn the liquid end upside down and allow the

feed chemical to run out; flush out with a suitable medium; flush the liquid end thoroughly when using hazardous feed chemicals!)

Set up

To replacement position“

The pump moves the diaphragm away from the backplate.

„Service è Diaphragm replacement

Now leave the pump connected to the mains/ power supply so that this state is maintained.

3. Unscrew the hydraulic connectors on the discharge and suction

side.

4. With types with coarse/fine bleed valve: Firstly remove the coarse/

fine bleed valve (grip), then lift off the cover of the liquid end with a screw driver.

Fig. 39: Partially exploded view of liquid end

1 Screws 2 Dosing head 3 Diaphragm

Page 84

Carrying out repairs

4 Backplate 5 Safety diaphragm 6 Pump housing

5. Remove the screws (1).

6. Remove the dosing head (2) plus screws (1) from the pump - see figure

7. Loosen the diaphragm (3) from the drive axle with a gentle back‐ wards turn in an anticlockwise direction.

8. Unscrew the diaphragm (3) completely from the drive axle.

9. Remove the backplate (4) from the pump housing (6).

10. Check the condition of the safety diaphragm (5) and replace if nec‐ essary.

11. Push the safety diaphragm (5) onto the drive axle only until it lies flush with the pump housing (6) and no further!

12. Tentatively screw the new diaphragm (3) onto the drive axle up to the stop - ensure that this is successful, otherwise the pump will subsequently not meter correctly!

13. Unscrew the diaphragm (3) again.

14. Place the backplate (4) on the pump housing (6).

CAUTION! – Make sure that the leakage hole points down‐

wards when the pump is subsequently fitted see figure in the "Maintenance" chapter!

Place the backplate (4) immediately into the

–

correct position on the pump housing (6)! Do not twist the backplate on the pump housing to prevent the safety diaphragm (5) becoming warped!

15. Place the diaphragm (3) into the backplate (4).

CAUTION! – Do not over-tighten the diaphragm (3) in the

following step!

– Ensure that the backplate (4) remains in its

position so that the safety diaphragm does not become warped!

16. Hold the backplate (4) firmly and screw the diaphragm (3) in a clock‐ wise direction until it is sitting tightly.

17. Place the dosing head (2) with the screws (1) onto the diaphragm (3) and the backplate (4) - ensure that the suction connector points downwards when the pump is in its subsequent fitting position.

18.

Set up

The pump moves the diaphragm back to the backplate.

19. Gently tighten the screws (1) and then tighten them diagonally. See below for the tightening torque.

20. With types with coarse/fine bleed valve: Allow the cover of the liquid end to rest in the dosing head, then press the grip of the bleed valve into the coarse/fine bleed valve.

„Service è Diaphragm replacement è Back“

Check the tightening torque of the screws after 24 hours of operation!

Page 85

Tightening torque

Data Value Unit

Tightening torque for screws: 4.5 ... 5.0 Nm

14.2 Cleaning the Diaphragm Rupture Indicator

WARNING! Warning of unnoticed escape of feed chemical After the diaphragm rupture indicator has been triggered,

any residue of feed chemical residues can interfere with it.

– After the diaphragm rupture indicator has been trig‐

gered, clean and test it.

1. First replace the liquid end diaphragm - see above!

2. Unscrew the diaphragm rupture indicator using an SW 14 openended spanner.

3. Clean the diaphragm rupture indicator with suitable liquid - if pos‐ sible using water (polysulphone material).

4. Test the connected diaphragm rupture indicator: fully immerse the tapered section at the front in water.

The continuous display indicates a diaphragm rupture.

5. Thoroughly dry the diaphragm rupture indicator.

The continuous display no longer indicates a diaphragm rup‐

ture.

6. Screw the clean and dry diaphragm rupture indicator into the hole until hand-tight and liquid-tight - without using tools!

Carrying out repairs

14.3

Cleaning valves

Warning of faulty operation Refer to the exploded drawings in the appendix when

working on the unit.

The order no. (part number) of the appropriate spare parts kit can be found at the end of the „Service“ menu.

Page 86

Troubleshooting

15 Troubleshooting

Safety information

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.

WARNING! 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.

15.1 Faults without a fault message

Faults without a fault message

Fault description Cause Remedy Personnel

Pump does not prime in spite of full stroke motion and bleeding.

Fluid is escaping from the backplate.

Minor crystalline deposits on the ball seat due to the valves drying out.

Serious crystalline deposits on the ball seat due to the valves drying out.

The screws in the dosing head are too loose.

Take the suction hose out of the storage tank and thoroughly flush out the liquid end.

Dismantle the valves and clean them refer to the "Repair" chapter.

Tighten the screws in the dosing head crosswise - refer to the "Repair" chapter for the tightening torque.

Technical per‐ sonnel

Instructed per‐ sonnel

The diaphragm is not leaktight.

Replace the diaphragm - refer to the "Repair" chapter.

If a diaphragm rupture has been indicated, clean the diaphragm rupture indicator refer to the "Repair" chapter.

Technical per‐ sonnel

Page 87

i > 23i < 4 mAi < 4 mA

i > 23i > 20 mA

Troubleshooting

Fault description Cause Remedy Personnel

Green LED display (oper‐ ating indicator) does not light up.

The wrong mains voltage or no mains voltage is con‐ nected.

The specified mains voltage as per the voltage specification can be found on the nameplate.

Electrician

15.2 Faults with error message

15.2.1

Fault description Cause Remedy Personnel

No. 1 The following appear: the iden‐ tifier

signal < 4 mA“

No. 2 The following appear: the iden‐ tifier sage

Fault messages on the LCD screen

The pump is in

and the message

appears and the mes‐

„Input signal > 20 mA“

„Input

operating mode,“ „“

behaviour has been pro‐ grammed in the Analogue menu and the control current has fallen below 4 mA.

The pump is in

operating mode,“ „“

behaviour has been pro‐ grammed in the Analogue menu and the control current has risen above 20 mA.

In the event of a fault:

n the red LED display lights up. n an identifier and a message appear on the LCD screen. n the pump stops.

„Analogue

a fault

Eliminate the cause of the low control current or

switch the programming of the fault behaviour to

„off“

- refer to the chapter "Setting"-"Set‐ tings"-"Operating Mode"-"Ana‐ logue".

„Analogue

a fault

Eliminate the cause of the high control current or

switch the programming of the fault behaviour to

„off“

- refer to the chapter "Setting"-"Set‐ tings"-"Operating Mode"-"Ana‐ logue".

Technical personnel

No. 3 The following appear: the iden‐

and the message

tifier

„Level

error!“

No. 4 The following appear: the iden‐

and the message

tifier

rupture“

„Diaphragm

No. 5 The following appear: the iden‐ tifier and the message

stroke metering“

„Defective

No. 7 The following appear: the iden‐ tifier "Temperature"

„Temperature“

, the message

and the pump stops.

No. 11 The following appear: the identifier

„Overload “

and the message

No. 12 or 13 The following appear: the identifier

„Mains / Overvoltage “

and the message

No. 14 The following appear: the identifier

the dosing head“

and the message

„Air in

The fluid level in the storage

Top up the storage tank. Technical

tank has reached "Liquid level low 2nd stage".

The diaphragm is broken. Replace the diaphragm and

clean the diaphragm rupture indi‐ cator, refer to the "Repair" chapter.

The dosing monitor reported more defective strokes than was set in the Inputs/Outputs menu.

„“

The ambient temperature is too high or too low.

Press the

[Clickwheel]

Investigate and clear the cause.

Change the ambient tempera‐ ture. The pump starts up auto‐ matically.

The temperature is too high. Rectify the cause. The pump

starts up automatically.

The pump has detected too

Rectify the cause. Technical

high a back pressure.

The mains voltage is too high

Rectify the cause. Technical

or too low or not connected.

Gas bubbles in the liquid end (leaks, gaseous medium, cavi‐ tation).

Bleed the liquid end and rectify the cause. Seal the system or slow the suction stroke.

personnel

Technical personnel

personnel

Technical personnel

No. 16 The following appear: the identifier

„Storage tank overflow“

and the message

The stroke tank has over‐ flowed.

Remedy the cause (such as too low a factor, too high a contact frequency ...), then:

Technical personnel

Page 88

i > 23

i < Imin

i > 23i > Imax

Troubleshooting

Fault description Cause Remedy Personnel

No. 16 The following appear: the identifier and the message

„Storage tank overflow“

The stroke tank has over‐ flowed.

Press the the consequences for the process!).

[Clickwheel]

(think of

No. 17 The following appear: the identifier sage

„Control signal < lmin“

and the mes‐

The pump is in

operating mode“

band", „“ a fault behaviour

„Analogue

-"xx. side

has been programmed in the Analogue menu and the con‐ trol current has fallen below 4 mA.

No. 18 The following appear: the identifier sage

„Control signal > lmax“

appears and the mes‐

The pump is in

operating mode“

„Analogue

-"xx. side band", „“ a fault behaviour has been programmed in the Analogue menu and the con‐ trol current has risen above 20 mA.

No. 19 The following appear: the identifier

„Underpressure “

and the message

No. 20 The following appear: the identifier

„Module communication “

and the message

The pump has detected too low a back pressure.

The bus contact between the optional module and control room has been disconnected.

15.2.2 Warning messages on the LCD screen

In the event of a warning:

n the yellow LED display lights up! n an identifier and a message appear on the LCD screen.

Eliminate the cause of the low control current or

Technical personnel

switch the programming of the fault behaviour to

„off“

- refer to the chapter "Setting"-"Set‐ tings"-"Operating Mode"-"Ana‐ logue".

Eliminate the cause of the high control current or

Technical personnel

switch the programming of the fault behaviour to

„off“

- refer to the chapter "Setting"-"Set‐ tings"-"Operating Mode"-"Ana‐ logue".

Rectify the cause. Technical

personnel

Rectify the cause (cable, control room ...)

Technical personnel

Fault description Cause Remedy Personnel

„Level“

No. 0 The following appear: identifier

and the

The fluid level in the storage tank has reached "Liquid

Top up the storage tank.

Instructed per‐ sonnel

level low 1st stage".

No. 1 The following appear: the identifier and the message

„Diaphragm rupture“

The diaphragm is broken. Replace the dia‐

phragm and clean the

Technical per‐

sonnel diaphragm rupture indicator, refer to the "Repair" chapter.

No. 2 The following appear: the identifier and the message

metering“

„Defective stroke

No. 3 The following appear: the identifier and the message

„Invalid metering volume“

The dosing monitor reported more defective strokes than was set in the Inputs/Outputs menu.

„“

The set metering volume in concentration mode cannot

Press the

[Clickwheel]

Investigate and clear the cause.

Adapt the metering parameters.

Technical per‐

sonnel

Technical per‐

sonnel

be metered.

No. 4 The following appear: the identifier and the message

„Invalid parameter“

No. 7 The following appear: the identifier and the message

„Air in the dosing head“

A set parameter is invalid. Adjust the parameter. Technical per‐

sonnel

Gas bubbles in the liquid end (leaks, gaseous medium, ...)

Bleed the liquid end and rectify the cause.

Technical per‐

sonnel Seal the system or slow the suction stroke.

No. 8 The following appear: the identifier and the message

„Overload “

The pump has detected too high a back pressure.

Rectify the cause. Technical per‐

sonnel

Page 89

Troubleshooting

Fault description Cause Remedy Personnel

No. 10 The following appear: the identifier

and the message

No. 11 The following appear: the identifier

and the message

„Underpressure “

„Cavitation“

The pump has detected too low a back pressure.

Cavitation in the liquid end. Adapt the metering

Rectify the cause. Technical per‐

parameters.

sonnel

Technical per‐ sonnel

15.2.3 All Other Faults

Please contact the ProMinentbranch or representative responsible for you!

15.3

Log book

15.3.1 Fault messages in the log book

More information about the messages „ERROR“ - see chapter "Fault messages on the LCD screen".

Tab. 18: Errors

Log book no. Description Acknowledge?

0 System, EEProm error* X

1 The pump is in

been programmed in the Analogue menu and the control current has

2 The pump is in

been programmed in the Analogue menu and the control current has

3 The fluid level in the storage tank has reached "Liquid level low 2nd

4 The diaphragm is broken. -

5 The dosing monitor reports more defective strokes than is set in the

6 Fault on the sensor for the stroke length.* -

7 The ambient temperature is too high or too low. -

8 Fault during initialisation. -

9 Fault on the magnet. * -

10 Fault with the stroke parameters. -

11 The pump has detected too high a back pressure. X

12 The mains voltage is too high. X

13 The mains voltage is too low or not connected. -

„Analogue operating mode,“ „“

risen above 20 mA.

„Analogue operating mode,“ „“

fallen below 4 mA.

stage".

Inputs/Outputs menu.

„“

a fault behaviour has

14 Gas bubbles in the liquid end (leaks, gaseous medium, cavitation). X

15 Fault during bleeding. X

16 The stroke tank has overflowed. X

17 The pump is in

behaviour has been programmed in the Analogue menu and the control

„Analogue operating mode“

current has fallen below 4 mA.

-"xx. side band", „“ a fault

Page 90

Troubleshooting

Log book no. Description Acknowledge?

15.3.2

18 The pump is in

19 The pump has detected too low a back pressure. X

20 No connection between the optional module and the bus. -

21 An optional module is no longer found. -

Warning messages in the log book

behaviour has been programmed in the Analogue menu and the control

Tab. 19: Warnings

Log book no. Description

0 The fluid level in the storage tank has reached "Liquid level low 1st stage".

„Analogue operating mode“

current has risen above 20 mA.

*Please get in touch with the ProMinent head office with this fault.

-"xx. side band", „“ a fault

More information about the messages „WARNING“ see chapter "Warning messages on the LCD screen".

1 The diaphragm is broken.

2 The dosing monitor reports more defective strokes than is set in the Inputs/Outputs menu.

3 The metering volume cannot be metered.

4 Fault with the stroke parameters.

5 The fan is faulty or not connected.

6 Fault on the magnet.

7 Gas bubbles in the liquid end (leaks, gaseous medium, cavitation).

8 Back pressure too high in the liquid end.

9 The set capacity cannot be achieved.

10 Back pressure too low in the liquid end.

11 Cavitation in the liquid end.

15.3.3 Event messages in the log book

Tab. 20: Events

Log book no. Description

0 Dosing head is active ; dongle was inserted.

„“

1 Parameter menu called up ; dongle was inserted.

2 Air gap measured ; dongle was inserted.

3 Too high current was detected but no fault message generated.

4 The controller data was not plausible.

5 Automatic bleed was enabled.

6 The pump status was changed.

7 The pump was reset to factory settings.

Page 91

Log book no. Description

8 The pump was calibrated.

Troubleshooting

12 The diaphragm was replaced.

13 The timer performed an action.

14 A relay has triggered.

15 The magnet was identified.

[START/STOP key]

[Priming key]

[Menu key]

was pressed.

15.3.4 Log book entry - Detailed view

Press the

Tab. 21: Information on the detailed view

[Clickwheel]

Line Information

1 Date/time

2 Type of entry (fault, warning ...)

3 Total operating time, total number of strokes

to obtain more information about a log book entry.

4 Switching-on duration, stroke rate since switching on

5 Room temperature, status information on the error (for

developers)

Page 92

Decommissioning

16 Decommissioning

Decommissioning

WARNING! 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 notes in the "Storage,

Transport and Unpacking" chapter are read before shipping or transport.

Thoroughly clean the liquid end and the housing of

–

chemicals and dirt. Adhere to the material safety data sheet for the feed chemical.

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.

WARNING! Fire hazard with flammable media Only with flammable media: They can be ignited by

oxygen.

– The pump may not work if there is a mixture of feed

chemical with oxygen in the liquid end. A specialist may need to take appropriate actions (using inert gas, ...).

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.

Danger of damage to the device Take into account the information in the "Storage, Trans‐

port and Unpacking" chapter if the system is decommis‐ sioned for a temporary period.

Page 93

Disposal

Decommissioning

1. Disconnect the pump from the mains/power supply.

2. Drain the liquid end by turning the pump upside down and allowing the feed chemical to run out.

3. Flush the liquid end with a suitable medium; flush the dosing head thoroughly when using hazardous feed chemicals!

WARNING! Eye injury from compression spring A compression spring is fitted in the pump in the drive

magnet, which could cause eye injuries when opened.

– Do not dismantle the pump to dispose of it.

CAUTION! Risk to the environment from the battery There is a battery in the pump, which can have a toxic

effect on the environment.

– Separate the battery from the remaining parts. –

Note the pertinent regulations currently applicable in your country!

CAUTION! Environmental hazard due to electronic waste There are electronic components in the pump, which can

have a toxic effect on the environment.

– Separate the electronic components from the

remaining parts.

–

Note the pertinent regulations currently applicable in your country!

Page 94

Technical data

17 Technical data

17.1

Performance data

gamma/ X at 200 strokes/minute and 100%

stroke length

Type Pump capacity Connector

Suction lift1Priming lift

size

outside Æ x inside Æ

bar l/h ml/stroke mm m WS m WS bar

gamma/ X

2002 20 2.05 0.17 6x3 6.0 2.5 5.5

1602 16 2.3 0.20 6x4 6.0 2.5 5.5

1604 16 3.6 0.30

0708 7 7.6 0.63

0414 4 13.5 1.13

0220 2 19.7 1.64

2504 25 3.8 0.32

1009 10 9.0 0.75

0715 7 14.5 1.21

0424 4 24.0 2.00

6x4

8x5

12x9

8x4

8x5

12x9

4, ****

4, ***

4, ****

5.0 3.0 3

4.0 2.0 2

3.0 2.5 1.5

2.0 2.0 1

4.0 3.0 3

3.0 3.0 2

3.0 3.0 1.5

3.0 3.0 1

Max. priming pressure on the suction side

0245 2 45.0 3.70 12x9 2.0 2.0 0.8

gamma/ X Metering pumps with self-bleeding dosing head SER

1602 10 0.9* 0.08 6x4 1.8 1.2 0.5

1604 10 1.55* 0.13 6x4 1.8 1.2 0.5

0708 7 5.7 0.48 8x5 1.8 1.0 0.5

0414 4 12.0 1.00 8x5 1.8 1.4 0.5

0220 2 17.4 1.45 12x9 1.8 1.7 0.5

1009 10 6.0 0.50 8x5 1.8 1.0 0.5

0715 7 12.9 1.08 8x5 1.8 1.4 0.5

0424 4 19.2 1.60 12x9 1.8 1.7 0.5

gamma/ X Metering pumps with self-bleeding dosing head SEK

1602 10 1.3* 0.11 6x4 2.1 - 0.5

1604 10 2.4* 0.21 6x4 2.7 - 0.5

0708 7 6.8 0.57 8x5 2.0 - 0.5

0414 4 12.0 1.00 8x5 2.0 - 0.5

0220 2 18.0 1.50 12x9 2.0 - 0.5

1009 10 8.0 0.67 8x5 3.0 - 0.5

0715 7 13.5 1.12 8x5 2.5 - 0.5

0424 4 20.0 1.67 12x9 2.5 - 0.5

Page 95

Technical data

* - The capacity can significantly fall at pressures above the nominal

pressure.

1 - Suction lift with a filled suction line and filled liquid end. With self-

bleeding dosing head with air in the suction line.

2 - Priming lift with clean and moist valves. Priming lift at 100% stroke

length and free outlet or opened bleed valve.

3 - The given performance data represents guaranteed minimum

values, calculated using water as the medium at room temperature. The bypass connection with a self-bleeding dosing head SEK is 6x4 mm.

4 - These pump types are also available with dosing heads for higher-

viscosity media (HV). The pump types have a capacity and are not self-priming.

*** - With stainless steel design 6 mm connector width

**** - With stainless steel design 12 mm connector width

All data calculated with water at 20 °C.

10 ... 20 % lower

17.2

Accuracy

17.2.1 Standard Liquid End

17.2.2 Self-Bleeding Liquid End

17.3

Viscosity

Data Value Unit

Capacity range of the series -5 ... +10 % *

Reproducibility ±2 % **

* - at max. stroke length and max. operating pressure for all material

versions

** - at constant conditions and min. 30 % stroke length

As the self-bleeding liquid end is used with outgassing media and when operating with air bubbles, no dosing accuracy or reproducibility can be provided.

The recommended minimum stroke length with self-bleeding dosing pumps is 50 %.

The liquid ends are suitable for the following viscosity ranges:

Design Range Unit

Standard 0 ... 200 mPas

With valve springs 200 ... 500 mPas

With HV head 500 ... 3000* mPas

Self-bleeding (SEK) 0 ... 50 mPas

* Even significantly higher with corrected adjusted installation. Contact Technical; Support in Heidelberg.

Page 96

Technical data

17.4 Material specifications

Standard liquid ends

Design Dosing head Valves Seals Balls

PPT Polypropylene PVDF PTFE Ceramic

NPT Clear acrylic PVDF PTFE Ceramic

PVT PVDF PVDF PTFE Ceramic

PPE Polypropylene EPDM EPDM Ceramic

PPB Polypropylene FKM FKM Ceramic

NPE Clear acrylic EPDM EPDM Ceramic

NPB Clear acrylic FKM FKM Ceramic

TTT PTFE PTFE PTFE Ceramic

SST Stainless steel

Pump

17.5

Design: 100 - 230 V ±10%, 50/60 Hz, gamma/ X GMXa

Parameter M70 M85

Nominal power**, approx. 25 W 30 W

Current I eff 0.25 ... 0.10 A 0.30 ... 0.12 A

Switch on peak current (for 3 ...5 ms) 20 A 20 A

Fuse* 2.5 AT 2.5 AT

Electrical data

1.4404

Stainless steel

1.4404/1.4571

Diaphragm: with PTFE coating.

FKM = fluorine rubber

Housing parts: polyphenylene ether (PPE with fibreglass)

** with relay closed: The nominal power rises by 1 W.

PTFE Ceramic

17.6

Pump, fully assembled

Temperatures

* Fuses must have VDE, UL and CSA certification. e.g. type 19195 manu‐ factured by Wickmann in compliance with IEC Publ. 127 - 2/3

Data Value Unit

Storage and transport temperature: -20 ... +50 °C

Ambient temperature in operation (power end/drive and control):

Medium temperature: -10 °C ... see

-10 ... +45 °C

following table

Page 97

Liquid ends

Technical data

Material version Long term Temporary *

PP 50 °C 100 °C

NP 45 °C 60 °C

PV 50 °C 120 °C

SS 50 °C 120 °C

TT 50 °C 120 °C

* Max. temp., for 15 min at max. 2 bar, depending on the ambient temper‐ ature

17.7

17.8

Degree of protection

Safety Requirements

Climate

Degree of Protection and Safety Requirements

Data Value Unit

Maximum air humidity*: 95 % relative

humidity

* non-condensing

Test: Humid heat, cyclical

in accordance with EN 680068-2-30: 2005

Protection against contact and humidity:

IP 66 according to DIN EN 60529 with contamination level 2

NEMA 4X / indoor as per NEMA 250

Degree of protection:

1 - mains power connection with protective earth conductor

17.9 Compatibility

Unlike the gamma/ L product range, compatibility is guaranteed with the following components:

n Control cable Beta® 5-wire for "External" function. n Control cable gamma/Vario 2-, 4- and 5-wire for the "External" func‐

tion

n Level switch 2-stage (gamma / Beta® / delta®) n Dosing line cross-sections for gamma / Beta n Standard connector kit for gamma / Beta n Wall brackets for gamma / Beta n Dosing tanks and fixing plates n Distance between suction and pressure connector n Distance between the connectors and the pump fixing holes n Distance between the pump fixing holes n Identical use of accessories, such as back pressure valves, multifunc‐

tional valves and flushing assembly

n Compatibility of resistance by the equivalence of the material used for

the liquid ends

Page 98

Technical data

Compatibility to the gamma/ L product range is not guaranteed for the fol‐ lowing points:

n External dimensions of the pump n Distance between the support surface for the mounting foot and the

centre of the dosing head

n Dosing monitor

17.10

Shipping weight of gamma/ X types - in kg

Material Types

2002, 1602, 1604, 0708, 0414, 0220 2504, 1009, 0715, 0424, 0245

PP, NP, PV, TT 3.6 .. 3.7 4.9 ... 5.2

SS 4.1 ... 5.0 5.5 ... 7.0

Shipping weight

17.11 Sound pressure level

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)

Page 99

P_G_0032_SW

Exploded Drawings and Ordering Information

18 Exploded Drawings and Ordering Information

18.1

Liquid end gamma/ X 1602 - 1604 PP_2

Exploded drawings

Fig. 40

Page 100

Exploded Drawings and Ordering Information

Tab. 22: Spare parts for liquid end gamma/ X 1602 - 1604 PP_2

Pos. Description

1 Connector kit

5 Discharge valve

6 Diaphragm

8 Suction valve

Liquid end gamma/ X 1602 PP_2

Liquid end gamma/ X 1604 PP_2

PPE2 PPB2 PPT2

Liquid end 1050931 1050900 1050942

Spare parts kit 1001646 1001654 1023109

Diaphragm 1000246 1000246 1000246

PPE2 PPB2 PPT2

Liquid end 1050932 1050901 1050943

Spare parts kit 1039989 1039987 1035332

Diaphragm 1034612 1034612 1034612

100

ProMinent gamma/ X GMXa Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

1 Identity Code

2 About this pump

3 Safety Chapter

4 Storage, Transport and Unpacking

5 Overview of Equipment and Control Elements

Overview of equipment

5.2 Control elements

5.2.1 Control elements

5.2.2 Key functions

6 Functional Description

Liquid End

6.2 Drive unit

Capacity

6.4 Self-Bleeding

6.5 Operating modes

Functions

6.7 Relay (Options)

LED Displays

6.9 Hierarchy of Operating Modes, Functions and Fault Statuses

7 Assembly

8 Installation, hydraulic

8.1 Installing hose lines

Installation of Metering Pumps Without Bleed Valve

8.1.2 Installation of Metering Pumps With Bleed Valve

Installation of Metering Pumps With Self-bleeding (SEK Type)

8.2 Basic installation notes

9 Installation, electrical

Supply voltage connector - mains voltage

9.2 Description of the Terminals

"External control" terminal

9.2.2 "Level switch" terminal

9.2.3 "Dosing monitor" terminal

9.2.4 "Diaphragm rupture indicator" terminal

9.2.5 Relay

Relay functions

9.2.5.2 "Fault indicating relay" output (identity code 1)

9.2.5.3 Output for Other Relays (Identity code 4)

9.2.5.4 Output "Current output plus relay" (identity code C)

10 Basic Set-up Principles

10.1 Basic Principles for Setting up the Control

10.2 Checking adjustable variables

10.3 Changing to set up mode

„Information“

„Settings“

„Operating mode“

„Manual“

„Contact“

„Batch“

„Automatic“

„Stroke length“

11.2.4 Metering

„Discharge stroke“

„Suction stroke“

„Pressure stage“

„Monitoring“

„Air lock“

„Air sensitivity“

11.2.4.5 Compensation

11.2.5 Concentration

11.2.6 Calibration

11.2.7 System

„Bluetooth “

„Dosing head“

11.2.7.3 Volume unit

11.2.7.4 Pressure unit

11.2.7.5 Pressure adjustment

11.2.7.6 Start behaviour

11.2.8 Inputs/outputs

„Relay1 (Optional)“

„Relay2 (Optional)“

„mA output (optional)“

„Flow control“

„Diaphragm rupture“

„Pause input“

„Level warning“