ProMinent Makro/ 5, M5Ma Operating Instructions Manual
Operating instructions
Diaphragm Metering Pump
ProMinent® Makro/ 5 M5Ma
Two sets of operating instructions are required for the safe, correct and proper operation of the metering pumps: The
product-specific operating instructions and the "General Operating Instructions for ProMinent® motor-driven metering
pumps and hydraulic accessories".
Both sets of operating instructions are only valid when read together.
Please carefully read these operating instructions before use! · Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
Technical changes reserved.
Original Operating Instructions (2006/42/EC)Part no. 985753 BA MAK 005 10/11 EN
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg
Germany
Telephone: +49 6221 842-0
Fax: +49 6221 842-617
email: info@prominent.com
Internet: www.prominent.com
985754, 1, en_GB
© 2010
2
Supplementary information
Supplemental instructions
Read the following supplementary information in its entirety!
Should you already know this information, you have an even
greater need of the Operating Instructions.
The following are highlighted separately in the document:
Fig. 1: Please read!
General user instructions
n Enumerated lists
Instructions
Outcome of the handling instructions
ð
- see (reference)
Information
This provides important information relating to the cor‐
rect operation of the device or is intended to make
your work easier.
Safety notes
Safety notes are identified by pictograms - see Safety Chapter.
Two sets of operating instructions are required for the safe, correct
and proper operation of the metering pumps: The product-specific
operating instructions and the "General Operating Instructions for
ProMinent® motor-driven metering pumps and hydraulic accesso‐
ries".
State the identity code and serial
number
General non-discriminatory approach
Both sets of operating instructions are only valid when read
together.
Please read these operating instructions carefully before use! Do
not discard!
Please state identity code and serial number, which you can find
on the nameplate when you contact us or order spare parts. This
enables the device type and material versions to be clearly identi‐
fied.
In order to make it easier to read, this document uses the male
form in grammatical structures but with an implied neutral sense. It
is aimed equally at both men and women. We kindly ask female
readers for their understanding in this simplification of the text.
3
Table of contents
Table of contents
1 Identity code.......................................................................... 5
About this pump.................................................................... 7
2
3 Safety chapter....................................................................... 8
4 Storage, transport and unpacking....................................... 14
5 Overview of equipment, control elements........................... 16
6 Functional description......................................................... 19
7 Assembly............................................................................ 21
8 Installation........................................................................... 24
8.1 Installation, hydraulic.................................................. 24
8.2 Installation, electrical.................................................. 26
9 Start up............................................................................... 29
10 During use........................................................................... 31
11 Maintenance....................................................................... 32
Repairs................................................................................ 37
12
12.1 Replacing the membrane.......................................... 38
12.2 Valve repair............................................................... 40
12.2.1 Double ball valves.................................................. 40
12.2.2 Single ball valves................................................... 41
12.2.3 Plate valves........................................................... 42
13 Troubleshooting.................................................................. 45
14 Decommissioning and disposal.......................................... 48
14.1 Decommissioning..................................................... 48
14.2 Disposal.................................................................... 50
15 Technical data..................................................................... 51
15.1 Performance data..................................................... 51
15.2 Accuracy................................................................... 52
15.2.1 Reproducibility....................................................... 52
15.2.2 Metering precision................................................. 52
15.3 Viscosity.................................................................... 52
15.4 Wetted materials....................................................... 53
15.5 Ambient conditions................................................... 53
15.5.1 Temperatures........................................................ 53
15.5.2 Air humidity............................................................ 54
15.6 Housing degree of protection.................................... 54
15.7 Stroke sensor (option), intrinsically safe................... 55
15.8 Filling volumes.......................................................... 55
15.8.1 Gear oil.................................................................. 55
15.9 Sound pressure level................................................ 55
15.10 Compatibility........................................................... 56
15.11 Supplement for modified versions.......................... 56
16 EC Declaration of Conformity............................................. 57
17 Index................................................................................... 59
4
1 Identity code
M5Ma Makro/ 5 diaphragm metering pump
Power end type
H Main power end
D Main power end, doubled
A Add-on power end
B Add-on power end doubled
Type:
bar l/h
041540 4 1540
041900 4 1900
042600 4 2600
043400 4 3400
Identity code
044000 4 444000
Dosing head material
PC PVC
PV PVDF
TT PTFE + 25 % carbon
SS Stainless steel
Seal material
T PTFE
Displacement body material
T Metering diaphragm with PTFE coating
Dosing head version
1 with valve spring, Hastelloy C; 0.1 bar
Hydraulic connector
0 Standard connection
1 Union nut and PVC insert
2 Union nut and PP insert
3 Union nut and PVDF insert
4 Union nut and SS insert
Version
0
With ProMinent® logo, no frame
1
Without ProMinent® logo, no frame
A
With ProMinent® logo, with single frame
B
With ProMinent® logo, with double frame
5
Identity code
M5Ma Makro/ 5 diaphragm metering pump
C
With ProMinent® logo, with triple frame
D
With ProMinent® logo, with quadruple frame
M Modified* * order-related version, for pump
features see order paperwork
Electric power supply
S 3 ph, 230 V/400 V 50/60 Hz (WBS)
L 3 ph, 460 V, 60 Hz, (Exe, Exd)
P 3 ph, 230 V/400 V 50 Hz (Exe, Exd)
R Variable speed motor 4 pole, 230/400 V (R 1:5)
N 1 ph, 115 V, 60Hz
V(0) Motor with integral frequency converter
V(2) Motor with integral frequency converter (Exd)
Z Speed control 230/400 V assy.
5 No motor, with gear IEC 100
6 No motor, with gear IEC 112
0 No motor, no gear
Motor version
0 IP 55 (Standard) ISO class F
1 Exe version ATEX-T3
2 Exd version ATEX-T4
A Power end ATEX design
Stroke sensor
0 No stroke sensor
1 Stroke sensor (Namur), intrinsically safe
Stroke length adjustment
0 Stroke length adjustment, manual
3 Control drive 230 V 0-20 mA
4 Control drive 230 V 4-20 mA
5 Control drive 115 V 0-20 mA
6 Control drive 115 V 4-20 mAz
Applications
0 standard
6
2 About this pump
About this pump
All pumps
Externally mounted pumps
Double head version
The ProMinent® Makro/ 5 diaphragm metering pump is fitted as
standard with a 3 kW wide range AC motor. The stroke length can
be adjusted between 0...20 mm. The spheroidal graphite housing
can be combined with up to 7 liquid end sizes and 5 gear reduction
ratios (integrated in the spur geared motor). The liquid ends are
available in various material combinations which can be matched
to the feed chemicals being metered.
The ProMinent® Makro/ 5 externally mounted metering pump can
be combined with the Makro/ 5 main power end to form a double or
multiple pump. A main power end can be combined with up to four
add-on power ends. One power end can be used both as a single
or a double head version.
The double head versions are fitted with a second liquid end which
operates in push-pull mode (Boxer principle).
7
Safety chapter
3 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
situation. If this is disregarded,
you are in a life-threatening sit‐
uation and this can result in
serious injuries.
CAUTION Denotes a possibly dangerous
situation. If this is disregarded,
it could result in slight or minor
injuries or material damage.
The following warning signs are used in these operating instruc‐
tions to denote different types of danger:
Warning signs Type of danger
Warning – hand injuries.
Correct and proper use
Warning – high-voltage.
Warning – flammable sub‐
stances.
Warning – hot surface.
Warning – danger zone.
n The pump may only be used to meter liquid metering chemi‐
cals.
n In potentially explosive atmospheres in zone 1, device category
II 2G of explosion group II C, the pump must only be operated
according to the with the relevant nameplate (and the respec‐
tive EC Declaration of Conformity) for pumps for potentially
explosive atmospheres complying with Directive 94/9/EC in
accordance with the European guidelines. The explosion
group, category and degree of protection identified on the
marking must correspond with or be better than the given con‐
ditions in the intended field of application.
8
Safety chapter
n The pump may only be started up after it has been correctly
installed and commissioned in accordance with the technical
data and specifications contained in the operating instructions.
n The general limitations with regard to viscosity limits, chemical
resistance and density must be observed - see also ProMinent
resistance list (In the product catalogue or at
www.prominent.com
n Any other uses or modifications are prohibited.
n Pumps without the relevant nameplate (and the respective EC
Declaration of Conformity) for pumps for potentially explosive
atmospheres must never be operated in potentially explosive
atmospheres.
n The pump is not intended for the metering of gaseous media or
solids.
n The pump is not intended for unprotected outside use.
n The pump is only approved to meter flammable liquids, if the
operator takes appropriate safety measures.
n The pump should only be operated by trained and authorised
personnel, see also
n You are obliged to observe the information contained in the
operating instructions at the different phases of the device's
service life.
)!
Ä ‘Qualification of personnel’ on page 9
.
Qualification of personnel
In hazardous locations only the following combinations of identity
code variants is permitted:
Combi‐
Identity code specification values
nations
1 Electric power supply L, P
Motor version 1,2, V(2)
Stroke length adjustment 0, G, H
2 Electric power supply 0, 5.6
Motor version A
Stroke length adjustment 0, G, H
Activity Qualification level
Storage, transport, unpacking Instructed person
Assembly, installation of
Technical personnel, service
hydraulic system
Installation, electrical Electrical technician
Operation Instructed person
Maintenance, repair Technical personnel, service
9
Safety chapter
Activity Qualification level
Decommissioning, disposal Technical personnel, service
Troubleshooting Technical personnel, electrical
technician, instructed person,
service
Explanation of the terms:
Technical personnel
A qualified employee is deemed to be a person who is able to
assess the tasks assigned to him and recognise possible dangers
based on his/her technical training, knowledge and experience, as
well as knowledge of pertinent regulations.
Note:
A qualification of equal validity to a technical qualification can also
gained by several years employment in the relevant work area.
Electrical technician
Electrical technicians are deemed to be people, who are able to
complete work on electrical systems and recognize and avoid pos‐
sible dangers independently based on their technical training and
experience, as well as knowledge of pertinent standards and regu‐
lations.
Safety notes
Electrical technicians should be specifically trained for the working
environment in which the are employed and know the relevant
standards and regulations.
Electrical technicians must comply with the provisions of the appli‐
cable statutory directives on accident prevention.
Instructed person
An instructed person is deemed to be a person who has been
instructed and, if required, trained in the tasks assigned to him/her
and possible dangers that could result from improper behaviour, as
well as having been instructed in the required protective equipment
and protective measures.
Service
Customer Service department refers to service technicians, who
have received proven training and have been authorised by ProMi‐
nent or ProMaqua to work on the system.
WARNING!
Warning of dangerous or unknown feed chemical
Should a dangerous or unknown feed chemical be
used: It may escape from the hydraulic components
when working on the pump.
– Take appropriate protective measures before
working on the pump (e.g. safety glasses, safety
gloves, ...). Observe the safety data sheet for the
feed chemical.
– Drain and flush the liquid end before working on
the pump.
10
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 pro‐
vided 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 sub‐
stance 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 associ‐
ated 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 pres‐
sure in the liquid end and adjacent parts of the system.
– Disconnect the pump from the mains power supply
and ensure that it cannot be switched on again by
unauthorised persons.
– Depressurise the system before commencing any
work on hydraulic parts.
CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical can damage the parts of
the pump contacted by the chemical.
– Take into account the resistance of the materials
which will come into contact with the chemical
when selecting the feed chemical - see the ProMi‐
nent product catalogue or under
www.prominent.com
.
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in per‐
sonnel injuries and material damage.
– Only fit parts to metering pumps, which have been
tested and recommended by ProMinent.
11
1
6
5
2
3
4
P_MAK_0025_SW
Safety chapter
CAUTION!
Danger from incorrectly operated or inadequately
maintained pumps
Danger can arise from a poorly accessible pump due
to incorrect operation and poor maintenance.
– Ensure that the pump is accessible at all times.
– Adhere to the maintenance intervals.
CAUTION!
Warning of illegal operation
Observe the regulations that apply where the unit is to
be installed.
Information in the event of an emer‐
gency
Protective equipment
In the event of an electrical accident, disconnect the mains cable
from the mains or press the emergency cut-off switch fitted on the
side of the system!
If feed chemical escapes, also depressurise the hydraulic system
around the pump as necessary. Adhere to the safety data sheet for
the feed chemical.
Fig. 2: Isolating protective equipment Makro/ 5 with add-on power
end (shown here for piston version)
1 Cap (only single head version)
2 Fan impeller hood
3 Terminal box cover, motor
4 Cover plate (only with add-on power end)
5 Flange cover
6 Protective cover (only diaphragm and piston versions)
12
Safety chapter
WARNING!
Warning of personal injury and material damage
– The customer must only remove the protective
equipment if requested to do so by the operating
instructions.
– The pump must not operate without fitted protec‐
tive equipment.
Sound pressure level
Sound pressure level LpA < 75 dB in accordance with EN ISO
20361:2010-10
at maximum stroke length, maximum stroke rate, maximum back
pressure (water)
13
Storage, transport and unpacking
4 Storage, transport and unpacking
Safety notes
WARNING!
The transporting of pumps which have been used with
radioactive feed chemicals is forbidden!
They will also not be accepted by ProMinent!
WARNING!
Only return metering pumps for repair in a cleaned
state and with a flushed liquid end - refer to the section
on decommissioning!
Only send metering pumps with a filled in Decontami‐
nation Declaration form. The Decontamination Decla‐
ration 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.
Scope of supply
You can find the "Decontamination Declaration" form
under
www.prominent.com
CAUTION!
Danger of environmental and material damage
The unit can be damaged or oil may escape due to
incorrect or improper storage or transportation!
– The unit should only be stored or transported in a
well packaged state - preferably in its original
packaging.
– Only transport the unit with the locking screw - not
the bleed plug - fitted to the oil filling opening.
– The packaged unit should also only be stored or
transported in accordance with the stipulated
storage conditions.
–
The packaged unit should be protected from mois‐
ture and the ingress of chemicals.
Compare the delivery note with the scope of supply:
or on the CD.
n Metering pump with mains power cable
n Connector kit for tube/pipe connection
n Product-specific operating instructions with EC Declaration of
Conformity
n CD with order information, exploded diagrams, performance
diagrams, motor data sheet and dimension sheets
n Optional accessories if ordered
14
Storage
Storage, transport and unpacking
Personnel:
1. Place the caps on the valves.
2. Check whether the seal screw is screwed into oil filler
opening instead of the vent screw.
3. Preferably place the pump standing vertically on a pallet and
secure against falling over.
4. Cover the pump with a tarpaulin cover - allowing rear ventila‐
tion.
Store the pump is a dry, sealed place in the following ambient con‐
ditions.
Technical personnel
n
Ambient conditions
Data Value Unit
Minimum storage and transport tem‐
-10 °C
perature
Maximum storage and transport tem‐
+50 °C
perature
Maximum air humidity * 95 % rel.
humidity
* non-condensing
15
P_MAK_0027_SW
1
2
3
1
4
A
5
C
P_MAK_0027_SW
7
6
Overview of equipment, control elements
5 Overview of equipment, control elements
Power end, single head
Fig. 3: View from the motor side (here M5Ka H)
A Power end
C Liquid end
1 Lifting eye
2 Stroke length adjustment wheel
3 Indicating dial
4 motor
5 Oil drain plug
Fig. 4: View away from the motor (here M5Ka H)
6 Vent screw
7 Oil inspection window
16
P_MAK_0029_SW
1 1
2
3
5
C A C
4
P_MAK_0030_SW
6
7
Power end, double head
Overview of equipment, control elements
Fig. 5: View from the motor side (here M5Ka D)
A Power end
C Liquid end
1 Lifting eye
2 Stroke length adjustment wheel
3 Indicating dial
4 motor
5 Oil drain plug
Fig. 6: View away from the motor (here M5Ka D)
6 Vent screw
7 Oil inspection window
17
1
2
5
3
4
P_MAK_0031_SW
Overview of equipment, control elements
Liquid end
Fig. 7
1 Discharge valve
2 Dosing head
3 Suction valve
4 Tube nozzle for leakage
5 Protective cover
18
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