User Information ................................................................................................................................................................................4
Please read through the following user guidelines. Familiarity with these points ensures optimum
use of the operating instructions.
Key points in the text are indicated as follows:
•Enumerated points,
왘 Hints
Working Guidelines:
NOTE
Notes on operation.
Safety Guidelines:
WARNING
There is a danger to life or the risk of serious injury if the notes on safety are disregarded!
CAUTION
There is a danger of slight injury and damage to property if the notes on safety are
disregarded!
IMPORTANT
There is a danger of damage to property if the notes on safety are disregarded.
These general operating instructions for motor-driven metering pumps and hydraulic assemblies
apply only in conjunction with the product-related pump operating instructions for e.g. alpha,
Vario, Meta, Sigma, Hydro, Makro/ 5 and Makro TZ motor-driven metering pumps.
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Page 5
Application of Motor-Driven Metering Pumps / Safety Notes
1Application of Motor-Driven Metering Pumps
ProMinent® motor-driven metering pumps and accessories are to be used solely for the purpose
of metering liquid media!
In explosion-threatened workplaces in zone 1, device category II 2G of explosion group II C
the pump may not be operated without the corresponding rating plate (and the corresponding
EC conformity declaration) for pumps for explosion-threatened workplaces in accordance with
guideline 94/9/EC of the European guidelines. The explosion group, category and type of
protection shown on the marking must correspond to or exceed the conditions prevailing in the
intended area of application.
All other uses or modifications are prohibited!
Pumps may never be operated in explosion-threatened workplaces without a corresponding
rating plate (and the corresponding EC conformity declaration) for pumps for explosionthreatened workplaces.
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ProMinent
metering gasses and solids!
Refer to the relevant product-related operating instructions and product cataloque for the
technical data of the type of motor-driven metering pump used!
Decisive criteria relating to the intended use of the pumps are
• EX-protection of the pump
• Resistance of parts coming in contact with metered medium
• Pressure and temperature of metered medium
motor-driven metering pumps and accessories are not to be used for the purpose of
2Safety Notes
WARNING
• Explosion-proof pump only: it is essential that you observe the contents of section 9!
• Immediately switch off the pump in case of emergency! Use the power switch on
the pump or an emergency switch in your immediate operating environment!
• Pumps for radioactive medium must not be shipped through standard channels!
• Observe applicable national regulations for installation abroad!
CAUTION
• Do not obstruct or block access areas!
Pumps must be accessible at all times to facilitate operation and maintenance.
• Only specially trained and authorized persons are permitted to carry out maintenance
and repairs on metering pumps and their periphery!
• Always depressurize the liquid end first before carrying out any work on the pump!
• If hazardous or unknown metering media are used, discharge and flush the liquid end
before carrying out any work on the pump!
• Observe safety specifications for liquid metered media! Corresponding protection and
emergency measures must be implemented prior to initial operation.
• Always wear protective clothing (safety goggles, gloves,...) when handling hazardous or
unknown liquid media! This applies particularly when working on the liquid end!
• Do not use parts which have not been tested and approved by ProMinent for assembly of
ProMinent
property, for which no liability will be accepted!
• Install safety devices in the system, e.g. overflow valves!
ProMinent
whether the delivery line is closed, e.g. by closing off the delivery line or by closing a valve,
the pressure produced by the pump can reach a multiple of the permissible working
pressure of the system or of the metering pump. This can result in lines bursting with
dangerous consequences particularly in the presence of aggressive or toxic media!
• Piston pumps must always be equipped with a dry-run protection facility to avoid the
pump packing running dry as this may cause overheating and thus premature wear.
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motor-driven metering pumps since this can result in damage to persons and
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motor-driven pumps are oscillating displacement pumps. Irrespective of
ProMinent
ProMinent
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Safety Notes / Mounting
DN
fig.1
m
m
fig. 2
fig. 3
Head valve
Intake valve
Liquid end
f
f
f
IMPORTANT
• Based on state-of-the-art technology, the manufacturer carefully selects the materials
•Avoid over-feed with positive pressure difference (at least 1 bar) between discharge
• Only specially trained personnel are permitted to operate the metering pump.
3Mounting
IMPORTANT
• Mount the metering pump upright with the feet on a horizontal base. Refer to the
• The frame or the foundation for mounting the pump must be designed such as to
for parts coming into contact with the medium as specified by the customer.
The manufacturer shall not be liable for any damage caused by metering other media
or media which has been modified with regard to its properties (concentration, density,
temperature, additives, impurities etc.).
and suction sides.
The operator must ensure by applying appropriate accident prevention measures that
operating personnel are not endangered under given operating conditions (pressure,
temperature, aggressivity etc.).
corresponding data sheets for the dimensions (m) of the securing holes.
ensure the unit is free of vibration and stable.
• Install pump at convenient operating level and mount such that the valves are vertical:
head valve always at top and intake valve always at bottom.
• Ensure adequate clearance (f) in area of liquid end as well as intake valve and head
valve so that these parts can be easily removed if required.
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Mounting / Installation, hydraulic
fig. 4
A
A
fig. 5
DN
pipe
DN
pump valve
DN
pump valve
fig. 6
Pressure
gauge sleeve
Pipe
(delivery line)
Pressure
control valve
Intake valve
Pipe
(intake line)
Pressure
gauge sleeve
fig. 7
Steel/stainless steel
pipe
Flexible pipe adapter
Plastic connecting piece
• Set up the pump such that the stroke length adjustment, indicator scale A, oil level
indicator, oil filler and drain plugs as well as the valves are easily accessible for
servicing.
• Ensure nominal diameters of pipes and installed fittings are the same size or larger
than the nominal diameters of the pump valves (intake and head valves).
4Installation, hydraulic
WARNING
• Explosion-proof pump only: it is essential that you observe the contents of section 9!
IMPORTANT
• Observe the relevant national directives with regard to installation!
• In order to verify the pressure conditions in the piping system it is recommended to
provide connection options for manometer close to the suction and pressure port.
• Connect pipes to the pump such that there is no stress or strain whatsoever acting
on the pump, such as offset, weight or expansion of the pipe. Only use a flexible pipe
adapter for connecting steel/stainless steel pipes to plastic pump housings.
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Mounting
Delivery line
Metering tank
PD
4.1 Standard Installation
Diagram 8
Metering pumpDirt trap
Metering valveSolenoid valve
Adjustable pressure control valve
Pulsation damper
(Overflow valve)
Foot valve with sieve filterFloat valve
Pressure gaugeFiller device
Ball check valveSiphon vessel
Shut-off cock valve
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Page 9
Installation, hydraulic
h
fig. 9
fig. 10
fig. 11
fig. 12
4.2Notes on Installation on Intake Side
NOTE
Avoid the intake line running empty:
• Install foot valve at end of intake line when the pump is higher than the max. liquid level
in the intake tank.
• The calculated size h (see diagram) must not be greater than the specified pump
suction head divided by the density of the delivered medium.
• Use short intake line and avoid thin-walled hoses.
NOTE
Connect intake line to tank slightly above the base of the tank.
IMPORTANT
Provide suitable means for retaining impurities!
Otherwise they can cause faults in the pump and system!
E.g. install a dirt trap (mesh size 100–400 µm depending on medium and type of metering
pump).
NOTE
Install pump with inlet on intake side for gas-emitting media.
NOTE
Intake via siphon line for high-level tanks without connection facilities at base of tank:
• Install filler facility for siphon line (intake line).
• Observe acceleration pressures due to the longer intake line.
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fig. 15
Installation, hydraulic
fig. 13
fig. 14
4.3Notes on Installation on Delivery Side
IMPORTANT
Do not exceed permissible nominal pressure! Otherwise the pump may be damaged!
Provide an overpressure facility if the permissible pressure in the pump head can be
exceeded, e.g. by closing a shut-off element or a blockage in the line:
• Install overflow valve in the delivery line or
• use an overflow valve integrated in the pump housing (depending on type, refer to
data sheet of the type of pump used).
The following points must be observed with regard to the overflow line when using an
overflow valve:
• Route the overflow line with a drop into the supply tank under atmospheric pressure
or into an open runoff channel.
• Connect the overflow line to the intake line, however, only if there is no check valve in
the intake line.
IMPORTANT
Do not use a non-return check valve on the intake side for the overflow return as it may
cause the intake line to tear off.
IMPORTANT
Cut off the return flow from the main line!
Otherwise unwanted mixing in the metering line can occur.
• Install the metering valve at the injection point.
IMPORTANT
Dampen pulsation by installing pulsation dampers if
• low-pulsation delivery flow is required for process reasons;
• acceleration forces have to be reduced due to the geometry of the piping system.
Page 10
The following can occur if acceleration forces are not dampened
• Fluctuations in delivery, metering faults, pressure surges, valve knocking and wear
as a result of cavitation on the intake and delivery side of the pump.
• Mechanical destruction of pump, leakages and knocking of valves as a result of the
permissible maximum pressure being exceeded on the pump delivery side.
ProMinent
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Installation, hydraulic
fig. 16
*
PD
fig. 17
*
PD
fig. 18
*
PD
Pulsation damper in delivery line
(refer to section 5.3)
Pulsation damper for free outlet:
• Install pressure control valve or metering valve at end of metering line.
Pusation damper without trails
(e.g. together with nozzles):
• Interlock the solenoid valve electrically with the voltage supply of the metering pump.
* Accumulators without diaphragm: fit a vent valve
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Installation, hydraulic
fig. 19
fig. 20
PD
2
1
fig. 21
fig. 22
4.4How not to install pumps
IMPORTANT
Intake line cannot be bled
• Air pocket in intake line.
Pulsation damper not effective
• Arrangement of pulsation damper (2) and pressure retension valve (1) incorrect.
Siphon effect
Admission pressure on intake side too high
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Page 13
Installation, hydraulic
fig. 23
fig. 24
fig. 25
fig. 26
fig. 27
4.5Special Notes on Installation
IMPORTANT
Avoid overloading by positive pressure difference between delivery side and intake side:
• Install end of delivery line higher than the liquid level in the intake tank.
or:
• Install the discharge line outlet of the pump such that its position is higher than the
level of liquid in the chemical storage tank
or:
• Install pressure control valves in the pump delivery line.
IMPORTANT
Ensure constant pressure in the intake line!
Irregular pump flow can occur if the pressure from the take-off line or the intake tank
is transmitted.
• Ensure constant supply height when pump intake is from pressurized lines!
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• Ensure constant supply level if intake is from high supply level!
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Installation, hydraulic
fig. 28
Flushing water
Flushing device
fig. 29
Flushing water
Timer
autom. flushing device
fig. 30
•Avoid siphon (suction) effect when metering into a main line under vacuum:
Install pressure control valve (DHV-SR) or metering valve in the metering line!
NOTE
When metering suspensions it is necessary to flush the pump head in order to avoid
deposits forming
• as intermittent flushing or
• flushing after switching off the pump.
IMPORTANT
Switch off metering pump before flushing!
Maximum permissible flushing pressure: 2 bar
Manual flushing device
Automatic flushing device
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Page 15
Installation, hydraulic
- circuit
circuit
-
L1L2L3
L1
L2L3
W1
U2V2
V1U1
W2
W1V1U1
U2V2W2
Low voltage
High voltage
fig. 31
5Installation, electrical
WARNING
• Explosion-proof pump only: it is essential that you observe the contents of section 9!
5.1Motor
IMPORTANT
• Connect electric motor in accordance with VDE regulations as illustrated in the circuit
diagram provided.
• Check that the mains voltage and frequency agree with the values specified on the
motor ratings plate.
•Provide corresponding motor protection devices in order to protect the motor from
overload (e.g. motor protection switch with thermal overcurrent release).
Fuses are not motor protection devices!
• The specified rated motor output applies at a maximum ambient temperature of 40 °C
and installation altitudes below 1000 m above sea level.
The motor output will be reduced if these values are exceeded (refer to VDE 0530).
• Ensure unobstructed supply of cooling air!
• Installation in wet rooms or in the open:
왘 Arrange terminal box such that the cable lead-ins point downwards (can be taken into
account when ordering).
왘 Select PG screw glands suitable for the supply line, use reducer if necessary.
Seal cable lead-in well otherwise all other measures will be of little use.
왘 Apply sealing compound to PG screw glands and thread of dummy plugs, firmly tighten and
coat once again with sealing compound.
왘 Thoroughly clean sealing surfaces of terminal box and terminal box cover before re-
installing.
Seals must be bonded on one side.
After a longer operating period, replace brittle seals by new ones.
Different types of motors are used depending on the application and required output.
ProMinent will send you the motor data sheets for the desired motor versions on request.
Motors connected to three-phase AC network
Three-phase squirrel-cage motor
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Example:
Specified rating230/400 V
Three-phase network available400 V:
Correct motor connectionY-circuit
Direction of rotation reversal:Interchange 2 supply lines
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Installation, hydraulic
L1L2L3
W1
V2W2
V
1
U1
U2
L1L2L3
W1V1U1
V2W2U2
Low speed
High speed
fig. 32
L1N
CB
W1
V2W2
V1U1
U2
fig. 33
Pole-changing three-phase AC motor (2 speeds in Dahlander circuit)
When changing over speed with pole selector switch, the star bridge 1U-1V-1W is realized
externally (in switch).
Motors connected to alternating current network
Any three-phase AC motor can be operated in conjunction with a corresponding running
capacitor on the alternating current network. However, care must be taken to ensure that the
starting torque is only approx. 30 % of the rated torque.
Three-phase AC motor with running capacitor (Steinmetz circuit)
Page 16
Motors with electronic speed adjustment
Refer to the circuit diagram of the control system for connection of the motor if electric motors
are driven by electronic control devices, e.g. three-phase AC motors by frequency converters or
DC motors by thyristor controllers.
External fans
IMPORTANT
For motors with separate cooling fan (identification code feature “R“ or “Z“), a separate
power supply is used for the separate cooling fan!
Actuators/servomotors for stroke length adjustment
Electrical connection of the motors is shown on the enclosed terminal connection diagram and
on the connection diagram provided on the inside of the housing.
IMPORTANT
Stroke length adjustment/control drives must only be operated with the pump running!
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Start-Up
6Start-Up
WARNING
• Explosion-proof pump only: it is essential that you observe the contents of section 9!
IMPORTANT
• Based on state-of-the-art technology, the manufacturer carefully selects the materials
for parts coming in contact with the medium as specified by the customer.
The manufacturer shall not be liable for any damage caused by metering other media
or media which has been modified with regard to its properties (concentration, density,
temperature, additives, impurities etc.).
• Only specially trained personnel are permitted to operate the metering pump.
The operator must ensure by applying appropriate accident prevention measures that
operating personnel are not endangered under given operating conditions (pressure,
temperature, aggressivity etc.).
• Refer to the information provided in the product-specific operating instructions.
• Before starting up, check correct connection of the drive motor as well as the
corresponding additional equipment!
• Check intake and delivery lines for leaks!
• Check whether necessary flushing lines are connected!
•Provide suitable type of safety overflow valves in all delivery lines!
왘 Bleed delivery side:
Switch on pump and run at 100 % stroke length until liquid end is full.
Switch off pump.
왘 Close bleeder on delivery side.
Pump is now ready for operation.
왘 Open shut-off valve in metering line, operate pump.
왘 Check cut-in pressure of overflow valve.
왘 Check delivery capacity and correct if necessary.
IMPORTANT
• If a compressed air vessel is installed on the delivery side, vent at regular intervals!
• Ensure the correct gas admission pressure (approx. 60–80 % of the mean operating
pressure).
• Observe the information provided in the operating instructions of the frequency
converter if using pumps with speed control.
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Maintenance/Troubleshooting
7Maintenance
WARNING
• Explosion-proof pump only: it is essential that you observe the contents of section 9!
IMPORTANT
• Refer to notes in product-specific operating instructions!
• If metering pumps are sent for repair to the manufacturer or a ProMinent dealer,
clean all parts which come into contact with the medium before shipping.
Essentially, maintenance is restricted to checking the metering capacity and for leaks.
Diaphragm failure:
왘 Change diaphragm as described in Section “Diaphragm-type metering unit” in the
product-specific operating instructions.
Impermissibly high leakage from piston-type liquid ends:
왘 Replace packing as described in Section “Piston-type metering unit“ and “Notes on packing
seal” in the product-specific operating instructions.
Replace packing as described in Section “Piston-type metering unit” and “Notes on packing
seal” in the product-specific operating instructions. In order to maintain the delivery unit, we
recommend to keep a spare parts kit in stock, consisting of the wearing parts such as
diaphragm or piston packing and the necessary valve parts, balls and seals. We can quote a
spare parts package for your metering system.
8Troubleshooting
WARNING
• Explosion-proof pump only: it is essential that you observe the contents of section 9!
IMPORTANT
Follow instructions in the product’s operating manual!
FaultCauseCorrective measures
No metering pump intakeSuction head too high왘 Install pump closer to
(during initial operation)intake tank
Backpressure in metering line왘 Eliminate backpressure
(delivery side)(e.g. via bypass line)
No metering although drive is Stroke setting 0 %왘 Increase stroke length
running (after longer period of( 씮 100 %)
operation)Intake tank empty왘 Top up medium and restart
Gas cushion in intake line and왘 Bleed intake line, check for
liquid endleaks and restart
Metered liquid emerges from Diaphragm defective왘 Replace diaphragm
leakage opening of delivery
unit
Loss of metering capacityWearing parts in valves왘 Replace wearing parts
(after longer period ofdefective
operation)
Deposits in valves왘 Clean or replace valve parts
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Page 19
Other important considerations for dosing pumps in ex-zones
ATTENTION
Because of electrostatical flammable
danger, use damp cloth only to wipe
off plastic parts !
9Other important considerations for dosing pumps in ex-zones
9.1Application in accordance with regulations
• In areas of operation where there is a risk of explosion, the pump may only be operated with
the appropriate nameplate and the corresponding EU declaration of conformity for areas of
operation where there is a risk of explosion in accordance with directive 94/9/EU concordant
with the European directives. The explosion group, category and protection system stated
on the label must be equivalent to or better than the conditions specified in the designated
area of application.
• Any other application or modification is prohibited!
• Pumps which do not have the appropriate nameplate and the corresponding EU declaration
of conformity for areas of operation where there is a risk of explosion may under no
circumstances be operated in areas of operation where there is a risk of explosion.
9.2Safety instructions
WARNING
• When installing and operating equipment in ex-zones in Europe, you must observe the
European directive 99/92/EU (ATEX 137). In Germany this is incorporated within the
occupational safety regulations and German regulations on hazardous materials.
•You must observe the European standards EN 1127-1, EN 60079-10, EN 60079-14, EN
60079-17 as well as EN 50020 and EN 50039 for intrinsically safe electrical circuits. (In
Germany, these standards are partly covered by VDE 0165 and VDE 0118.)
• For countries outside the EU, you should observe the appropriate national directives.
• Installations in ex-zones must be checked by a “recognised qualified” person. This
particularly applies to intrinsically safe electrical circuits.
• The information detailed below chiefly refers to particular features found in ex-zones. It does
not replace the standard information in the operating instructions manual!
• When cleaning plastic components, you should ensure that no electrostatic charge is
created through excessive friction. - see warning sign
9.2.1 Safety equipment
WARNING
• Please adhere to the following safety instructions for pumps containing non-
9.2.2 EU declaration of conformity / certification
The EU declaration of conformity is attached for the whole pump (also for pumps without
motors).
The EU declarations of conformity, EU design inspection reports and the operating instructions
manuals for the individual components are attached.
9.3Assemble
No specific notes.
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conductive components.
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Page 20
Other important considerations for dosing pumps in ex-zones
9.4Installation, hydraulic
WARNING
• Dosing pumps used in ex-zones must be fitted with an appropriate safety relief valve
on the output side of the dosing pump (serves to protect against overheating resulting
from overloading and arcing due to interruption of drive components as a result of
overloading.)
• Piston dosing pumps are designed for use in temperature class T3. The pumps can be
used in T4 if they are fitted with an additional flow controller on the output side (serves
to protect against a rise in temperature resulting from dry running) or with an
appropriate temperature controller.
• Similarly, dosing pumps whose diaphragm is driven hydraulically must be fitted with a
temperature or flow controller for use in T4. (The internal relief valve protects against
overheating in the event of extended operation.) Without this protection, temperature
class T3 is applicable.
• With different temperature classes being available for different components, the
possible application of the entire pump corresponds to the component with the lowest
temperature class.
• Combustible media may only be extracted using stainless steel dosing heads. In
exceptional circumstances, where stainless steel is not available, PTFE with carbon
can also be used. Our TT designs are manufactured from this conductive synthetic
material. The operator should take special care in this instance due to reduced
mechanical stability.
• Piston dosing pumps may not be used for combustible media. Where it is impossible to
avoid the use of piston pumps, additional control measures should be implemented to
ensure the required level of safety. This includes flow controller + piston leakage
controller, and an additional temperature controller on the dosing head for media with
critical friction characteristics.
• Hydraulic diaphragm pumps are perfectly suitable, however it is compulsory to have
those whose construction includes diaphragm-rupture controller Ex “i” and flow
controller.
• Diaphragm pumps with mechanically linked diaphragm, e.g. Zt. MTMa..., TZMa...,
Sigma’s S1Ba..., S2BaHM..., S3Ba: no additional measures are required, although it is
essential to use the construction with diaphragm-rupture indicator, in the Ex “i”
construction.
• Installations in ex-zones must be checked by a “recognised qualified” person.
• The following applies to all dosing pumps when metering combustible media: Start up
and drain only under the supervision of an appropriately qualified person.
• Observe the relevant national directives with regard to installation!
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Page 21
Other important considerations for dosing pumps in ex-zones
9.5Installation, electrical
WARNING
• Zero-volts switches can be rated as simple electrical equipment (EN 60079-14 or
EN 50020).
• Both zero-volts and extra-low voltage circuit-breaking accessories such as diaphragm
–rupture indicator, stroke rate equipment, etc. may only be connected to an intrinsically
safe electrical circuit in ex-zones.
• If several electrical components are connected together, the safety of the entire
connection needs to be tested and confirmed in accordance with safety regulations.
This can be evidenced by means of a declaration of conformity from the supplier
(ProMinent) for the equipment in its entirety, or if components are delivered
individually, by means of a document from the operator confirming the components to
be explosion-proof.
• For electrical components in ex-zones you may only use the approved motor
protection switch, mains switch and fuses in accordance with the manufacturer’s
specifications for the application in the relevant ex-zone!
• Observe the documentation attached for the individual electrical components!
• Observe the relevant national directives with regard to installation!
For hydraulic equipment switches in macro-hydraulic diaphragm dosing pumps
(diaphragm rupture sensor, excess pressure sensor):
These switches may be used in areas where there is a risk of gas explosions, category II 2G.
WARNING
• The switches may only be connected to an intrinsically safe electrical circuit! Only use
switches with a blue connection cable!
• The data in the operating instructions manuals is specific to the design of the switches!
Lower values apply in an intrinsically safe electrical circuit, according to the ex-zone!
NOTE
You may disregard the inductivity and capacity of the cable (cable length less than 10m).
Motor
WARNING
• Drive motors should be protected by a suitable motor protection switch. For Ex”e”
motors you should use a motor protection that has been approved for this application.
(Protection against overheating due to overload)
• Motors may only be installed and checked in ex-zones by a “recognised qualified”
person!
• Observe the attached operating instructions manual for EX motors!
9.6Commissioning
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WARNING
• The following applies to all dosing pumps when metering combustible media: Start up
and drain only under the supervision of an appropriately qualified person.
• Combustible media may only be extracted with stainless steel dosing heads. In
exceptional circumstances, where stainless steel is not available, PTFE with carbon
can also be used. Our TT designs are manufactured from conductive synthetic
material. The operator should take special care in this instance due to reduced
mechanical stability.
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Page 22
Other important considerations for dosing pumps in ex-zones
• Piston dosing pumps may not be used for combustible media.
Where it is impossible to avoid the use of piston pumps, additional control measures
should be used to ensure the required level of safety: flow controller + piston leakage
controller, and an additional temperature controller on the dosing head for media with
critical friction characteristics.
• Hydraulic diaphragm pumps are perfectly suitable, however it is compulsory to have
those whose construction includes diaphragm-rupture controller Ex “i” and flow
controller.
• Diaphragm pumps with mechanically linked diaphragm, e.g. MTMa..., TZMa..., Sigma’s
S1Ba..., S2BaHM..., S3Ba: no additional measures are necessary, although it is essential to use the construction with diaphragm-rupture indicator, in the Ex “i”* construction.
• Dosing pumps used in ex-zones must be fitted with an appropriate safety relief valve
on the output side of the dosing pump (serves to protect against overheating resulting
from overloading and arcing due to interruption of drive components as a result of
overloading).
• Piston dosing pumps are designed for use in temperature class T3.
The pumps are suitable for use in T4 if they are fitted with an additional flow controller
on the output side (serves to protect against a rise in temperature resulting from dry
running) or with an appropriate temperature controller.
• Similarly, dosing pumps whose diaphragm is driven hydraulically must be fitted with a
temperature or flow controller for use in T4. (The internal relief valve protects against
overheating in the event of extended operation.) Without this protection, temperature
class T3 is applicable.
• With different temperature classes being available for different components, the
possible application of the entire pump corresponds to the component with the lowest
temperature class.
9.7Maintenance
WARNUNG
•You should make regular checks (on leakages, noise, temperatures, odours, etc.) to
ensure general regular operation, particularly with regard to the actuator and bearing.
• Do not allow the pump to overheat due to a lack of oil!
For lubricated dosing pumps, you should make regular checks to ensure sufficient
lubricant is present, e.g. by checking the level of lubricant, visual check for leakages,
etc. If oil is leaking, you must locate the point of leakage immediately and eliminate
the cause of the leak.
• Check the regular operation of the relief valve behind the pump!
In the event of a fault in areas of operation where there is a risk of explosion, the relief
valve must prevent the gears from being overloaded and overheating!
• When cleaning plastic components, you should ensure that no electrostatic charge is
created through excessive friction. - see warning sign
• The following applies to all dosing pumps when metering combustible media: Start up
and drain only under the supervision of an appropriately qualified person.
• Expendable parts, such as bearings, must be replaced when there are visible signs of
unacceptable wear. (It is not possible to calculate the nominal service life for lubricated
bearings.)
• Original spare parts must be used as replacements.
• Inspection and repair must be carried out in compliance with DIN EN IEC 60079-17
and should only be done by “experienced personnel with the necessary expertise”
(section 4.2).
• These measures are prescribed by ProMinent as the minimum required for protection.
If the operator is aware of other risks, it is his responsibility to eliminate these by
implementing the appropriate measures.
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Page 23
Other important considerations for dosing pumps in ex-zones
9.8Troubleshooting
WARNING
•You should make regular checks (on leakages, noise, temperatures, odours, etc.) to
ensure general regular operation, particularly with regard to the actuator and bearing.
• Do not allow the pump to overheat due to a lack of oil!
For lubricated dosing pumps, you should make regular checks to ensure sufficient
lubricant is present, e.g. by checking the level of lubricant, visual check for leakages,
etc. If oil is leaking, you must locate the point of leakage immediately and eliminate
the cause of the leak.
• When cleaning plastic components, you should ensure that no electrostatic charge is
created through excessive friction. - see warning sign
• The following applies to all dosing pumps when metering combustible media: Start up
and drain only under the supervision of an appropriately qualified person.
• Expendable parts, such as bearings, must be replaced when there are visible signs of
unacceptable wear. (It is not possible to calculate the nominal service life for lubricated
bearings.)
• Original spare parts must be used as replacements.
• Inspection and repair must be carried out in compliance with DIN EN IEC 60079-17 and
should only be done by “experienced personnel with the necessary expertise” (section
4.2).
9.9Repair
WARNING
• The following applies to all dosing pumps when metering combustible media: Start up
and drain only under the supervision of an appropriately qualified person.
•You should make regular checks (on leakages, noise, temperatures, odours, etc.) to
ensure general regular operation, particularly with regard to the actuator and bearing.
9.10Decommissioning
WARNING
• The following applies to all dosing pumps when metering combustible media: Start up
and drain only under the supervision of an appropriately qualified person.
ProMinent
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Hydraulic Accessories
Metering pump A
external activation and
control facility A1
Metering valve B
Shut-off fitting C
Flow meter D
Pulsation damper E
Pressure control valve F
Overflow valve
in bypass line G
Level switch H
Foot valve I
Pressure gauge J
fig. 34
Filling
Venting
Intake line
Bypass
System line
A
B
C
D
E
F
G
H
I
J
A1
C
10Hydraulic Accessories
10.1 Overview and Notes on Accessories
To ensure trouble-free operation of metering systems, not only is correct selection of the
metering pump decisive but also of the individually compiled hydraulic and electrical
accessories. On the following pages, many accessories are illustrated which are not always
necessary but which provide a general overview of the various possibilities.
We would be pleased to be of assistance in selecting the right accessories for your metering
task and e.g. offer our advisory services for calculating the piping system.
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Page 25
Hydraulic Accessories
System Components
FunctionApplication
Metering pump*AMetering of a defined quantity of liquid in aVariable adjustment of metered quantity and
system;external activation facility enable optimum
Activation: Manual or automatic (externaladaptation to any metering applications.
signal)
Pressure control/overflow valves for installation in metering line:
• Adjustable pressure control valve for installation in metering lines.
• Used to produce a constant backpressure to ensure precision delivery
when metering with free outlet,for admission pressure on intake side, for fluctuating
backpressure or metering to vacuum.
• Also used as safety overflow valve.
• If used as pressure control valve for avoiding resonance:
Installation at end of metering line or set pressure (set pressure / line pressure) loss.
IMPORTANT
Pressure control/overflow valves are shut-off elements which do not close absolutely tight.
The DHV-S, DHV-S-DL series is used in conjunction with pulsation dampers only with free
outlet and a short metering line.
The DHV-SR/RM series is not subject to the effect of backpressure and is therefore particularly
suitable for use in cases of fluctuating backpressure at the pipe outlet and for use in
conjunction with pulsation dampers or longer metering lines. The DHV-SR/RM series can be
installed at any point along the metering line.
Type DHV-RM 1-10 bar
왘 Remove protective cap.
왘 Prior to pump operation:
Unscrew pressure setting screw for pressure relief until it turns easily.
왘 During pump operation: Produce required operating pressure by turning in pressure setting
screw:
Read off set pressure at pressure gauge installed in pipe system.
왘 Secure pressure setting screw:
왘 Tighten lock nut.
왘 At required pressure relief, release lock nut and unscrew pressure setting screw until it
moves easily.
10.3 Pulsation Dampers
Pulsation dampers are often used in conjunction with oscillatory displacement pumps.
They are necessary when:
• Low-pulsation flow is required, for example, for process reasons.
• Depending on the piping situation, it is necessary to reduce impermissibly high pressure
peaks during operation of oscillatory displacement pumps or pressure loss must
be avoided; in this case, it is necessary to use pulsation dampers both on the intake
side as well as the delivery side.
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Hydraulic Accessories
Intake valve
Safety overflow valve
Metering line
In-line damper
fig. 39
Intake line
Safety overflow valve
Metering line
Diaphragm pulsation damper
fig. 38
fig. 37
p
V
0
12
pp
VV
0
1
2
V
1
2
3
p=
p=
p=
V=
V=
V=
0
1
2
0
1
2
V= Change in volume for
pulsation compensation
Schematic:
Diaphragm-type pulsation damper
Gas filling pressure
Minimum operating pressure
Maximum operating pressure
Effective gas volume
Gas volume at p
1
Gas volume at p
2
Function
Their function is based on compression and expansion of a gas cushion in order to release
energy.
As the pressure increases, a part of the medium to be delivered is stored and then released to
the pipe network as the pressure decreases.
In principle, a differentiation is made between pulsation dampers with and without a separating
diaphragm.
In pulsation dampers without a separating diaphragm (e.g. air tank), the medium has direct
contact with the gas cushion which is formed by feeding in compressed air. After start-up, the
compressed air is compressed to the damping volume. Since the compressed air is gradually
released in the medium, venting is necessary from time to time with the system depressurized.
This disadvantage is avoided by using pulsation dampers with a separating diaphragm.
In this case, the damping gas cushion is separated from the delivered medium by a flexible
diaphragm and thus protected from absorption.
Installation
IMPORTANT
Observe the regulations valid at the place of installation prior to initial operation and
during operation of pulsation dampers!
The Pressure Vessel Ordinance (Druckbeh.V.) is applicable in the Federal Republic of
Germany.
ProMinent
ProMinent
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IMPORTANT
Pulsation dampers can only fulfil their task of damping pressure peaks and pulses if they
are installed correctly.
• Integrate pulsation dampers in the system so that they are well accessible and free
of vibration!
• Install pulsation damper in the immediate vicinity of the point where pressure peaks
are to be dampened. For metering pumps this means installation at the shortest
possible distance after the head valve of the liquid end (or immediately before the
intake valve if a suction-air vessel is installed).
• Install connection line straight and corresponding to the connection diameter of the
pulsation damper in order to avoid unnecessary deflection and pipe friction losses.
IMPORTANT
Do not use oxygen for preloading diaphragm-type pulsation dampers (or bubble accumulators) for air or nitrogen!
The greatest efficiency of pulsation dampers is achieved when the preload pressure is approx.
60–80 % of the subsequent mean operating pressure.
If the pulsation damper is not equipped with a pressure gauge, it is recommended to check the
preload pressure (pv):
• After 500 hours of operation.
• Before resuming operation after a prolonged downtime.
A regular check every three months is recommended.
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Warranty Application for Metering Pumps and Accessories
Order No.: .......................................................................................Date of delivery: ..................................................................
Short fault description: .......................................................................................................................................................................
Operating period (approx. operating hours):.........................................................................................................................
Installation data/system schematic (provided by customers)
Page 28
(Please completely fill in enclosed form "Data for calculating metering line"!)
A completed form must always be returned with the equipment!
This declaration must only be completed and signed by an authorized member of the technical
staff!
The equipment or its parts will only be repaired or serviced if it is accompanied by a correctly
completed and signed safety declaration form. The work could be delayed if no form is returned.
ProMinent Hellas Ltd.
24, Mitrodorou Str. + Athinon Ave.
10441 Athens (Greece)
Tel.: +30 210 5134621, Fax: 5134500
promin@hol.gr
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