ProMinent Makro/ 5, M5Ma Operating Instructions Manual

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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
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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
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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.
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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
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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
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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
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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).
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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.
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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
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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.
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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.
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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)
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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)
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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
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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
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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
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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
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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
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6 Functional description

P_MAK_0035_SW
6 5
4
3
1
2
8
7
Functional description
Power end functional description
The Makro/ 5 metering pump is a motor-driven metering pump with a kinematic gear.
A motor drives the cam shaft (1). A connecting rod (2) rests on the cam shaft (1) which allows the oscillating crank (4) to rotate about a variable pivot point, see
Fig. 8. The lifting arm of the oscillating crank, which lies above the pivot point, moves the slide rod (8) which itself drives the liquid end.
The stroke is adjusted using the manual adjustment wheel (7). This causes a spindle (6) to move the fork (5; shown in cutaway view in the diagram). The fork (5) moves the sliding block (3) in a groove cut into the oscillating crank (4). The sliding block (3) determines the pivot point of the oscillating crank (4). This determines the stroke length. When the pivot point of the sliding block (3) is directly above the axle of the slide rod (8) the lifting arm of the oscillating crank above the pivot point is at zero and the slide rod stops. When the sliding block (3) is pushed down, the lifting arm of the oscillating crank (4) above the pivot point is greater than zero so that the slide rod (8) is driven
Liquid ends can be fitted to both ends of the slide rod. They then operate in push-pull mode (Boxer principle).
Fig. 8: Cross-section through the power end
1 Cam shaft 2 Connecting rod 3 Sliding block 4 Oscillating crank 5 Fork 6 Spindle 7 Manual adjustment wheel 8 Slide rod
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1
2
3
4
P_MAK_0036_SW
Functional description
Functional description of the dia‐ phragm liquid end (for M5Ma)
The diaphragm (3) hermetically shuts off the pump volume of the dosing head (2) from the outside. The suction valve (4) closes as soon as the diaphragm (3) is moved in to the dosing head (2) and the feed chemical flows through the discharge valve (1) out of the dosing head. The discharge valve (1) closes as soon as the metering diaphragm (3) is moved in the opposite direction due to the vacuum pressure in the dosing head and fresh feed chemical flows through the suction valve (4) into the dosing head. One cycle is thus completed.
Fig. 9: Cross-section through the liquid end
1 Discharge valve 2 Dosing head 3 Diaphragm 4 Suction valve
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7 Assembly

Safety notes
Assembly
WARNING!
Warning about personal and material damage
EX pumps only: When operating in EX areas, certain subjects must be observed.
The chapter "Important supplements for metering
pumps in EX zones" of the "General Operating Instructions on ProMinent Pumps and Hydraulic Accessories" must be observed in all cases.
CAUTION!
Warning about personal and material damage
Also observe the "General Operating Instructions for ProMinent
®
Motor-Driven Metering Pumps and
Hydraulic Accessories"!
®
Motor-Driven Metering
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.
CAUTION!
Warning about personal and material damage
Personal and material damage may be caused if the unit is operated outside of the permissible ambient conditions.
Please observe the permissible ambient conditions
- refer to the chapter entitled "Technical Data".
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h
P_MOZ_0016_SW
A
A
P_MOZ_0018_SW
1
3
2
f
f
f
P_MOZ_0017_SW
Assembly
Supporting floor
Fig. 10
WARNING!
Risk of electric shock
If water or other electrically conducting liquids pene‐ trate into the drive housing, an electric shock may occur.
Position the pump so that drive housing cannot be
flooded.
WARNING!
The pump can break through the supporting floor or slide off it
The supporting floor must be horizontal, smooth
and permanently load-bearing.
Space requirement
Fig. 11
Capacity too low Vibrations can disturb the valves of the liquid end.
The supporting floor must not vibrate.
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.
Position the pump so that control elements such as the stroke length adjustment knob, the indicating dial A or the oil inspection window are accessible.
In so doing, ensure there is enough space to carry out an oil change (vent screws, oil drain plugs, oil trough ...).
Fig. 12
1 Discharge valve
Dosing head
2 3 Suction valve
Ensure there is sufficient free space (f) around the dosing head as well as the suction and discharge valve so that maintenance and repair work can be carried out on these components.
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Liquid end alignment
DNm
m
P_MOZ_0015_SW
Fastening
Assembly
Capacity too low If the valves of the liquid end do not stand upright, they
cannot close correctly.
The discharge valve must be upright.
Capacity too low Vibrations can disturb the valves of the liquid end.
Secure the metering pump so that no vibrations can occur.
Take the dimensions (m) for the fastening holes from the appro‐ priate dimensional drawings or data sheets.
Fasten the pump base to the supporting floor using suitable screws.
Fig. 13
Instruction
Screw the pump to a support surface with 4 sufficiently strong screws through the 4 holes in the frame.
Nothing more need be fitted to the pump itself: the pump is filled with gear oil and completely assembled on a frame.
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Installation

8 Installation

8.1 Installation, hydraulic

CAUTION!
Danger of personnel injury and material damage
The disregard of technical data during installation may lead to personal injuries or damage to property.
Observe the technical data- refer to chapter "Tech‐
nical Data" and, where applicable, the operating instructions of the accessories.
WARNING!
Warning about personal and material damage
EX pumps only: When operating in EX areas, certain subjects must be observed.
The chapter "Important supplements for metering
pumps in EX zones" of the "General Operating Instructions on ProMinent Pumps and Hydraulic Accessories" must be observed in all cases.
WARNING!
Warning of feed chemical reactions to water
Feed chemicals that should not come into contact with water may react to residual water in the liquid end that may originate from works testing.
Blow the liquid end dry with compressed air
through the suction connector.
Then flush the liquid end with a suitable medium
through the suction connector.
WARNING!
The following measures are an advantage when working with highly aggressive or hazardous feed chemicals:
®
Motor-Driven Metering
Install a bleed valve with recirculation in the
storage tank.
Install an additional shut-off valve on the discharge
or suction ends.
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Installation
CAUTION!
Warning about personal and material damage
Also observe the "General Operating Instructions for ProMinent Hydraulic Accessories"!
CAUTION!
Suction problems possible
For feed chemicals with a particle size greater than 0.3 mm, the valves may no longer close properly.
Install a suitable filter in the suction line.
CAUTION!
Warning against the discharge line bursting
With a closed discharge line (e.g. due to a clogged dis‐ charge line or by closing a valve), the pressure that the metering pump generates can reach several times the permissible pressure of the system or the metering pump. This could lead to lines bursting resulting in dangerous consequences with aggressive or toxic feed chemicals.
®
Motor-Driven Metering Pumps and
Install a relief valve that limits the pressure of the
pump to the maximum permissible operating pres‐ sure of the system.
CAUTION!
Warning against the discharge line bursting
Tube lines with insufficient pressure rating may burst.
Only use tube lines with the required pressure
rating.
CAUTION!
Warning against lines disconnecting
With suction, discharge and relief lines installed incor‐ rectly can loosen / disconnect from the pump connec‐ tion.
Only use original tubing with the specified tube
diameter and wall thickness.
Only use clamp rings and tube nozzles that corre‐
spond with the respective hose diameter.
Always connect the lines without mechanical ten‐
sion.
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Installation
Precise metering is only possible when the back
pressure is maintained above 1 bar at all times.
If metering at atmospheric pressure, a back pres‐ sure valve should be used to create a back pres‐ sure of approx. 1.5 bar.
Route the leakage liquid drainage line

8.2 Installation, electrical

Personnel:
The leakage liquid is drained off via the flushing collar and a tube nozzle, without other parts of the liquid end coming into contact with the medium.
1. Connect a tube to the lower tube nozzle.
2. Route the tube into a collection device for the leakage liquid.
WARNING!
Danger of electric shock
Unprofessional installation may lead to electric shocks.
All cable cores cut to length must be provided with
cable end sleeves.
The Installation, electrical of the device may only
be undertaken by technically trained personnel.
Technical personnel
n
WARNING!
Danger of electric shock
In the event of an electrical accident, it must be pos‐ sible to quickly disconnect the pump, and any electrical ancillaries which may possibly be present, from the mains.
Install an emergency cut-off switch in the mains
supply line to the pump and any electrical ancilla‐ ries which may be present or
Integrate the pump and electrical ancillaries which
may be present in the emergency cut-off manage‐ ment of the system and inform personnel of the isolating option.
WARNING!
Danger of electric shock
This pump is equipped with a protective earth con‐ ductor, to reduce the risk arising from an electric shock.
Connect the PE conductor to "earth" with a clean
and permanent electrical connection.
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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 about personal and material damage
EX pumps only: When operating in EX areas, certain subjects must be observed.
The chapter "Important supplements for metering
pumps in EX zones" of the "General Operating Instructions on ProMinent Pumps and Hydraulic Accessories" must be observed in all cases.
®
Motor-Driven Metering
motor
CAUTION!
Warning about personal and material damage
Also observe the "General Operating Instructions for ProMinent
®
Motor-Driven Metering Pumps and
Hydraulic Accessories"!
Personnel:
Electrician
n
What requires electrical installation?
n motor n External fan (option) n Stroke control drive (Option) n Stroke adjusting drive (Option) n Diaphragm rupture sensor n Stroke sensor (Option) n Frequency converter (option)
CAUTION!
Pump can be damaged
The pump can be damaged if the motor drives the pump in the wrong direction.
When connecting the motor, pay attention to the
correct direction of rotation indicated by the arrow on the fan cover, as shown in Fig. 14.
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P_SI_0012_SW
Installation
Fig. 14: Direction of rotation of motor
CAUTION!
The motor may be damaged
The motor is not equipped with a fuse.
Install a suitable motor protection switch.
1. Use a suitable cable between the motor terminal box and power supply.
2. Install an emergency cut-off switch or include the motor in the emergency cut-off management of the system.
Key motor data can be found on the unit name‐ plate.
Motor data sheets can be requested for more infor‐ mation.
The terminal wiring diagram is located in the ter‐ minal box.
Notes on the speed controlled motor with external fan and temperature monitoring can be found in the "General operating instructions for ProMinent
®
motor-driven metering pumps and hydraulic acces‐ sories"!
The external fan requires an independent mains con‐ nection.
Stroke sensor (Option)
Other units
Connect the stroke sensor to a suitable monitoring device according to the details in the chapter "Technical Data". Also observe its technical data.
Install the other units according to their documentation.
28
Page 29

9 Start up

Safety notes
Start up
WARNING!
Warning about personal and material damage
EX pumps only: When operating in EX areas, certain subjects must be observed.
The chapter "Important supplements for metering
pumps in EX zones" of the "General Operating Instructions on ProMinent Pumps and Hydraulic Accessories" must be observed in all cases.
WARNING!
Hot surface
In event the power end motor is loaded excessively, its surface may become very hot.
Avoid contact. – If necessary, mount a guard plate.
®
Motor-Driven Metering
CAUTION!
Possible environmental and material damage
The screw plug in the oil filler neck is factory-fitted and, during operation, prevents any pressure equalisation between the power end housing and the surroundings. This ensure that oil can be pushed from the power end housing.
Replace the screw plug on the oil filler neck by the
air vent plug supplied.
Retain the sealing plug for subsequent transport of
the unit.
CAUTION!
Single head version only: Oil may escape
The screw plug in the oil filler neck is factory-fitted and, during operation, prevents any pressure equalisation between the power end housing and the surroundings. This ensure that oil can be pushed from the power end housing.
Ensure that the hole in the metal cap on the drive
flange is always clear - see "Overview of equip‐ ment, control elements".
CAUTION!
Warning about personal and material damage
Also observe the "General Operating Instructions for ProMinent
®
Motor-Driven Metering Pumps and
Hydraulic Accessories"!
29
Page 30
Start up
Installing a vent screw
Replace the sealing screw at the oil filler neck with the supplied vent screw - see chapter "Overview of equipment and control ele‐ ments".
Checking the oil level
Checking the direction of rotation
When the pump is idle, check whether the pump oil level slightly covers the lower oil inspection window.
This indicates that the pump has not lost oil and consequently been damaged.
When commissioning the unit, check whether the drive motor is rotating correctly - check this against the arrow on the motor housing or the diagram in the chapter entitled "Electrical Installa‐ tion."
Eliminating suction problems (only for single ball valves with PTFE ball seat)
For suction problems occurring during start up:
Exclude the possibility that there are foreign bodies in the valve.
Place the valve on a stable surface.
Using a hammer (1) and a brass bar (2), gently tap the PTFE ball seat above the valve ball - see figure below.
Then with the valve in a damp condition allow it to prime.
Fig. 15: Tapping the valve set disc
Adjusting the stroke length
Only adjust the stroke length when the pump is run‐ ning. This is easier and also better for the pump.
Correctly adjusting the pump:
n Select as large a stroke length as possible for viscous feed
chemicals.
n Select as large a stroke length as possible for outgassing feed
chemicals.
n Select as high a stroke rate as possible for good mixing. n For precise metering using quantity-proportional metering, do
not set the stroke length to less than 30 %.
The pump can now be released for operation.
30
Page 31

10 During use

During use
WARNING!
Warning about personal and material damage
EX pumps only: When operating in EX areas, certain subjects must be observed.
The chapter "Important supplements for metering
pumps in EX zones" of the "General Operating Instructions on ProMinent Pumps and Hydraulic Accessories" must be observed in all cases.
WARNING!
Personnel injury and material damage may occur
During use all units, protective equipment, additional devices must be fitted, operational and tightly closed.
®
Motor-Driven Metering
WARNING!
Hot surface
In event the power end motor is loaded excessively, its surface may become very hot.
Avoid contact. – If necessary, mount a guard plate.
WARNING!
Sparking caused by dry running
If the bearings in the power end run dry, sparks can be formed.
Check for oil leaks. – When the pump is idle, the pump oil level must
slightly cover the lower oil inspection window.
Observe the instructions in the "Start up" chapter and the operating instructions for the other machine com‐ ponents.
31
Page 32
Maintenance

11 Maintenance

Safety notes
WARNING!
Warning about personal and material damage
EX pumps only: When operating in EX areas, certain subjects must be observed.
The chapter "Important supplements for metering
pumps in EX zones" of the "General Operating Instructions on ProMinent
®
Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
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!
Hot surface
In event the power end motor is loaded excessively, its surface may become very hot.
Avoid contact. – If necessary, mount a guard plate.
WARNING!
Warning of hazardous or unknown feed chemical
Should a hazardous 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 (protective eyewear, protec‐ tive gloves, ...). Read the safety data sheet on the feed chemical.
Drain and flush the liquid end before working on
the pump.
WARNING!
Risk of fingers being crushed
Under unfavourable conditions, the stroke axle or dis‐ placement body can cause crushing of the fingers.
Disconnect the pump from the mains power supply
and ensure that it cannot be switched on again by unauthorised persons.
32
Page 33
Maintenance
WARNING!
Risk of injury from the fan impeller
The fan impeller beneath motor's fan cowling can cause severe injuries while it is turning.
The pump must only be connected to the mains
voltage with the fan cowling closed.
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.
Maintenance work
Under heavy loading (e.g. continuous operation) shorter maintenance intervals are recommended than those given.
Keep a spare parts kit in stock ready for maintenance work.
Order numbers are contained on the CD.
33
Page 34
3
1
(30 Nm)
2
(25 Nm)
P_MAK_0040_SW
Maintenance
Interval Maintenance work
Quarterly* EX pumps only: For special maintenance work see chapter "Important supplements for
metering pumps in hazardous locations" of the "General Operating Instructions for ProMi‐ nent® motor-driven metering pumps and hydraulic accessories"
Check the tightening torques for the dosing head screws (1) (30 Nm) and the drive flange screws (2) (25 Nm).
Check that the discharge valve and suction valve are correctly seated.
Check the correct seating and state of the metering lines at both discharge and suction ends.
Check for firm seating of the diaphragm rupture sensor.
Check the tightness of the entire liquid end - particularly around the leakage hole!
Check the oil level.
Single head versions only: Check that the hole in the metal cap on the drive flange is clear - see the figure in the "Safety Chapter".
Check that the electrical connections are intact
Check whether the pump is transporting media correctly - run briefly at high power. Observe the maximum permissible operating pressure!
Check, whether moisture can be detected at the tube nozzle (3); if so a diaphragm rupture has probably occurred.
Fig. 16: Liquid end
1 Dosing head screws 2 Drive flange screws 3 Tube nozzle
Interval Maintenance work
After approx. 5,000 operating hours Change the gear oil.
After approx. 10,000 operating hours ** Replace the diaphragm - refer to the "Repair" chapter -
"Changing the diaphragm".
* Under normal loading (approx. 30 % of continuous operation)
Under heavy loading (e.g. continuous operation): Shorter intervals.
** under normal loading.
With very unfavourable metering parameters: Shorter intervals.
34
Page 35
P_MAK_0043_SW
1
2
Changing the gear oil
Maintenance
WARNING!
Risk of burns due to hot gear oil
The gear oil may become very hot when the pump is heavily loaded
When draining oil, avoid contact with the oil run‐
ning out.
Gear oil
Gear oil Supplied quantity Part no.
Mobilgear 634 VG 460 20.0 l 1006284
Gear oil filling volumes
Types Volume, approx.
All 16.5 l
Draining the gear oil:
1. Remove the vent screw (1).
2. Place an oil trough under the oil drain plug (2). Expected oil quantity - see filling volumes, above.
3. Unscrew the oil drain plug (2) out of the power end housing.
4. Allow the gear oil to run out of the power end.
5. Screw in the oil drain plug (2) with a new seal.
Fig. 17: Oil change 1
1 Vent screw 2 Oil drain plug
35
Page 36
P_MAK_0044_SW
3
Maintenance
Filling with gear oil:
1. Start the pump.
2. Slowly pour gear oil through the vent screw (1) opening until the upper oil inspection window (3) is slightly covered.
3. Allow the pump to run for a further 1... 2 minutes.
4. Replace the vent screw (1).
Fig. 18: Oil change 2
3 Oil inspection windows
36
Page 37

12 Repairs

Safety notes
Repairs
WARNING!
Warning about personal and material damage
EX pumps only: When operating in EX areas, certain subjects must be observed.
The chapter "Important supplements for metering
pumps in EX zones" of the "General Operating Instructions on ProMinent Pumps and Hydraulic Accessories" must be observed in all cases.
WARNING!
It is mandatory that you read the safety information and specifications in the "Storage, Transport and Unpacking" chapter prior to shipping the pump.
®
Motor-Driven Metering
WARNING!
Hot surface
In event the power end motor is loaded excessively, its surface may become very hot.
Avoid contact. – If necessary, mount a guard plate.
WARNING!
Warning of hazardous or unknown feed chemical
Should a hazardous 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 (protective eyewear, protec‐ tive gloves, ...). Read the safety data sheet on the feed chemical.
Drain and flush the liquid end before working on
the pump.
WARNING!
Risk of fingers being crushed
Under unfavourable conditions, the stroke axle or dis‐ placement body can cause crushing of the fingers.
Disconnect the pump from the mains power supply
and ensure that it cannot be switched on again by unauthorised persons.
37
Page 38
Repairs
WARNING!
Risk of injury from the fan impeller
The fan impeller beneath motor's fan cowling can cause severe injuries while it is turning.
The pump must only be connected to the mains
voltage with the fan cowling closed.
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.

12.1 Replacing the membrane

WARNING!
Observe the safety notes at the beginning of the chapter.
1. Flush the suction line, discharge lines and liquid end (activate flushing equipment or immerse suction lance in a suitable medium and pump for a while (consider the effect of the medium on your system first!)) or proceed, as described below.
2. Set the stroke length to 0 % stroke with the pump running.
3. Switch off the pump.
4. Secure the pump to prevent it being switched back on.
5. If the liquid end has not been flushed according to the above processes, then protect yourself against the feed chemical -
protective clothing, safety glasses, ... .
After dismantling immediately place parts that have been wetting with the medium in a trough with a suitable medium for flushing, in dangerous media were used flush and rinse thoroughly.
6. Unscrew the hydraulic connectors on the discharge and suc‐ tion side.
38
Page 39
1
2
3
4
5
6
7
8
9
P_MAK_0045_SW
Fig. 19: Cross-section through the liquid end
1 Dosing head 2 Diaphragm 3 Reinforce plate 4 Screw 5 Protective cover 6 Backplate 7 Bellows 8 Slide rod 9 Tube nozzle
Repairs
7. Undo the screws (4) on the reinforce plate.
8. Remove the dosing head (1) with the screws from the back‐ plate (6).
While doing this, do not damage the black bellows (7) on the slide rod.
10. Remove the protective cover (5) from the backplate (6).
11. Unscrew the diaphragm (2) on the grooves of its shaft from the slide rod (8) and remove. Use a sickle spanner inserted through the slot in the backplate (6).
12. Clean the sealing surfaces.
13. Check the state of the bellows (7).
14. Screw the new diaphragm (5) up to the stop on the slide rod (8).
This must be done correctly to ensure the pump meters
ð
accurately.
15. Place the dosing head (1) and the reinforce plate (3) onto the backplate (6).
16. Position the screws
39
Page 40
Repairs

12.2 Valve repair

17. Start the pump and tighten the screws crosswise at a 100% stroke.
Tightening torque 30 Nm
18. Position the protective cover (5) on the backplate (6).
Check the tightening torque of the screws after 24­hours' operation.
With PP dosing heads, recheck the tightening torque again after three months.
Unsuitable spare parts for the valves may lead to prob‐ lems for the pumps.

12.2.1 Double ball valves

Cleaning a discharge valve
Only use new components that are especially adapted to fit your valve (both in terms of shape and chemical resistance).
Use the correct spare part kits. In case of doubt, refer to the exploded views and ordering informa‐ tion contained in the "Supplementary information CD for ProMinent® pump operating instructions".
Clean the discharge and suction valves only one after another as they cannot be differentiated using the arrow markings.
Taking the discharge valve apart
1. Unscrew the discharge valve from the dosing head and rinse out.
2. Dismantle the discharge valve.
3. Rinse and clean all parts.
4. Replace the worn parts and seals.
Assembling the discharge valve
40
Page 41
When assembling, take note of the orientation of the
1
2
3
4
*
5
*
6
7
valve seats (3). The valve seats (3) are used as a ball seat on the fine machined side and as a ball cage and spring guide on the other side. The fine machined side must point in the flow direction with all valve seats.
When assembling the valves, take note of the sequence:
Teflon – Metal – Teflon – Metal - ...
1. Slide into the valve body (1) one after another:
n one seal (2) and one valve seat (3) - correct! n one seal (2) and one valve bushing (4) n (If fitted: one spring (*) into the spring guide of the valve
seat (3)
n one ball (5) into the valve body (1) n one seal (2) and the second valve seat (3, correct!) n one seal (2) and the second valve bushing (4) n (If fitted: the second spring (*) into the spring guide of the
valve seat (3))
n the second ball (5) into the valve body (1) n one seal (2), the third valve seat (3) - (correct!) and a fur‐
ther seal (2)
Repairs
2. Position the insert disc (6) with the flare on the packing.
The distance between the edge of the valve body and the insert disk (6) is due to the construction.
3. Place the larger seal (7) between the insert disk (6) and the dosing head.
Fig. 20: Discharge valve (double ball
4. Screw in the valve until the stop.
valve).
Cleaning a suction valve
A suction valve is dismantled, cleaned and assembled in the same way as a discharge valve.
Please note, however, that when assembling, the valve seat (3) must be aligned in the other direction. The fine machined side must point in the flow direction with all valve seats (3).

12.2.2 Single ball valves

1. Screw the valve cap (5) on to the suction side - see Fig. 21.
2. Carefully remove the parts from the valve body (2).
3. Replace the worn parts.
4. Clean the remaining parts.
5. Check all parts.
41
Page 42
1
2
3
4
5
P_MAK_0054_SW
Repairs
6. If available: Place the compression spring inside the valve body (2).
7. Insert the valve ball (3 and the valve seat (4).
8. Screw on the valve cap (5).
Pay attention to the flow direction of the discharge and suction connectors when fitting the valve.

12.2.3 Plate valves

Fig. 21: Cross-section through the single ball valve
1 Seal 2 Valve body 3 Valve ball 4 Valve seat 5 Valve cap
Do not scratch the finely machined sealing surfaces on the valve plates (5) and valve inserts (6).
42
Page 43
1
2
3
4
5 6 7
P_MAK_0055_SW
Fig. 22: Section through a plate valve (DN65 shown)
V
N
P_MAK_0056_SW
1 Valve cap II (only DN 65) 2 Perforated disc (only DN 65) 3 Compression spring 4 Valve body 5 Valve plate 6 Valve insert 7 Valve cap
Repairs
1. Screw the valve cap (7) on to the suction side - see Fig. 22.
2. Carefully remove the parts from the valve body (4).
3. Replace the worn parts.
4. Clean the remaining parts.
5. Check all parts.
6. Only DN 65: Insert the perforated disc (2) in the valve body (4).
7. Place the compression spring (3) inside the valve body (4).
Position the compression spring with the end (see figure: arrow N, at the bottom) as shown on one of the lugs in the valve body.
Otherwise the valve plate may knock when in operation.
8. Insert the valve plate (5) and the valve insert (6).
9. Screw on the valve cap (7).
Pay attention to the flow direction of the discharge and suction connectors when fitting the valve.
43
Page 44
Repairs
Fig. 23: Inserting the compression spring
44
Page 45

13 Troubleshooting

Safety notes
Troubleshooting
WARNING!
Warning about personal and material damage
EX pumps only: When operating in EX areas, certain subjects must be observed.
The chapter "Important supplements for metering
pumps in EX zones" of the "General Operating Instructions on ProMinent Pumps and Hydraulic Accessories" must be observed in all cases.
WARNING!
Fire danger
Only with combustible media: These may start to burn when combined with oxygen.
When filling and draining the liquid end, the feed
chemical must not come into contact with oxygen.
®
Motor-Driven Metering
WARNING!
Hot surface
In event the power end motor is loaded excessively, its surface may become very hot.
Avoid contact. – If necessary, mount a guard plate.
WARNING!
Danger of an electric shock
Personnel working on electrical parts can be electro‐ cuted if all electrical lines carrying current have not been disconnected.
Disconnect the supply cable before working on the
motor and prevent it from being reconnected acci‐ dentally.
Any separately driven fans, servo motors, speed
controllers or diaphragm rupture sensors fitted should also be disconnected.
Check that the supply cables are de-energised.
45
Page 46
Troubleshooting
WARNING!
Warning of hazardous or unknown feed chemical
Should a hazardous 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 (protective eyewear, protec‐ tive gloves, ...). Read the safety data sheet on the feed chemical.
Drain and flush the liquid end before working on
the pump.
WARNING!
Risk of injury from the fan impeller
The fan impeller beneath motor's fan cowling can cause severe injuries while it is turning.
The pump must only be connected to the mains
voltage with the fan cowling closed.
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.
Tasks
Fault description Cause Remedy Personnel
Pump does not prime in spite of full stroke
The valves are dirty or worn.
Repair the valves - see chapter entitled "Repair".
Technical personnel
motion and bleeding
Pump does not reach high pressure rates.
The valves are dirty or worn.
The feed chemical has particles larger
Repair the valves - see chapter entitled "Repair".
Technical personnel
Install a suitable filter in the suction line. Technical
personnel
than 3 mm.
The motor is wired incorrectly.
The mains voltage has failed.
1. Check the mains voltage and mains fre‐
Electrician
quency.
2. Wire the motor correctly.
Eliminate the cause. Electrician
46
Page 47
Troubleshooting
Fault description Cause Remedy Personnel
The diaphragm rupture warning system gener‐ ates an alarm.
No hydraulic oil flows
The multi-layer dia‐ phragm is rup‐ tured.
- - - - Immediately switch off the pump and inform through the tube at the bleed valve
The power end motor is very hot.
The discharge line is seriously con‐ stricted.
All other faults. Other causes.
n Replace the multi-layer diaphragm
immediately - refer to the "Repair" chapter - "Changing the diaphragm".
n If necessary replace the separating dia‐
phragm of the diaphragm rupture sensor
- see "Replacing the separating dia‐ phragm, diaphragm rupture sensor" in the chapter "Repair".
n Check the diaphragm rupture warning
system for correct operation.
customer service.
n Rectify any constriction of the discharge
line.
n Have the safety relief valve checked.
Call ProMinent®
or ProMaqua® service.
Technical personnel
Technical personnel
47
Page 48
Decommissioning and disposal

14 Decommissioning and disposal

14.1 Decommissioning

WARNING!
Warning about personal and material damage
EX pumps only: When operating in EX areas, certain subjects must be observed.
The chapter "Important supplements for metering
pumps in EX zones" of the "General Operating Instructions on ProMinent Pumps and Hydraulic Accessories" must be observed in all cases.
WARNING!
Danger of an electric shock
When working on the motor or electrical auxiliary equipment, there is a danger of an electric shock.
®
Motor-Driven Metering
Before working on the motor, take note of the
safety instructions in its operating instructions!
Should external fans, servomotors or other auxil‐
iary equipment be installed, these should also be disconnected and checked that they are voltage free.
WARNING!
Danger from chemical residues
There is normally chemical residue in the liquid end and on the housing after operation. This chemical res‐ idue could be hazardous to people.
It is mandatory that the safety note relating to the
"Storage, Transport and Unpacking" chapter is read before shipping or transporting the unit.
Thoroughly clean the liquid end and the housing of
chemicals and dirt. Adhere to the safety data sheet for the feed chemical.
WARNING!
Warning of hazardous or unknown feed chemical
Should a hazardous 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 (protective eyewear, protec‐ tive gloves, ...). Read the safety data sheet on the feed chemical.
Drain and flush the liquid end before working on
the pump.
48
Page 49
Decommissioning and disposal
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.
WARNING!
Hot oil and hot components
The hydraulic oil and the hydraulic end may become very hot when the pump is exposed to heavy loading.
Allow the pump to cool before starting work.
Final decommissioning
CAUTION!
Danger of damage to the device
The device can be damaged by incorrect and improper storage or transportation.
Take into account the information in the "Storage,
Transport and Unpacking" chapter if the system is decommissioned for a temporary period.
Personnel:
Technical personnel
n
1. Disconnect the pump from the mains power supply.
2. Depressurise and bleed the hydraulic system around the pump.
3. Flush the liquid end with a suitable medium - Observe the safety data sheet! Flush the dosing head thoroughly when using hazardous feed chemicals!
4. Drain the gear oil - refer to the chapter entitled "Mainte‐ nance".
Temporary decommissioning
5. Thoroughly clean the liquid end and the housing of chemicals and dirt.
6. Possible additional work - see chapter "Storage, Transport and Unpacking".
In addition:
1. Place the caps on the valves.
2. Push the caps into place on the tube nozzles.
49
Page 50
Decommissioning and disposal
3. Preferably place the pump on a pallet.
4. Cover the pump with a tarpaulin cover - allowing rear ventila‐ tion!
5. Store the pump is a dry, sealed place under storage condi‐ tions according to the chapter "Storage, Transport and Unpacking".
14.2

Disposal

Personnel:
Technical personnel
n
CAUTION!
Environmental hazard due to gear oil
The pump contains gear oil, which can cause damage to the environment.
Drain the gear oil from the pump. – Note the local guidelines currently applicable in
your country!
CAUTION!
Note the local guidelines generally currently applicable in your country!
50
Page 51

15 Technical data

Only for "M - modified" version:

15.1 Performance data

Main pumps with motor 1500 rpm under 50 Hz operation
Technical data
WARNING!
Risk of personal injuries
Please observe the ”Supplement for modified ver‐ sion“ at the end of the chapter!
It replaces and supplements the technical data!
Type Minimum pump capacity at max‐
imum back pressure
bar l/h ml/stroke Strokes/min m WS G-DN kg
41540 4 1540 427 60 3 2 1/2"-50 320
41900 4 1900 427 75 3 2 1/2"-50 320
42600 4 2600 427 103 3 2 1/2"-50 320
43400 4 3400 427 133 3 2 1/2"-50 320
44000 4 4000 427 156 3 2 1/2"-50 320
* Stainless steel material version Shipping weight 340 kg
The shipping weight is applicable to single head pumps without an add-on power end.
The permissible priming pressure at the suction side is approxi‐ mately 50% of the max. permitted back pressure
All figures refer to water at 20 °C.
The suction lift applies to filled suction line and filled liquid end ­when installed correctly.
The priming lift of 2 m applies for clean and moistened valves and a clear outlet
Maximum stroke rate
Suction lift
Connector size
Shipping weight*
51
Page 52
Technical data
Main pumps with motor 1800 rpm under 60 Hz operation
Type Minimum pump capacity at max‐
imum back pressure
psi l/h gph Strokes/min m WS G-DN kg
41540 58 1822 482 71 3 2 1/2"-50 320
41900 58 2254 597 89 3 2 1/2"-50 320
42600 58 3104 822 123 3 2 1/2"-50 320
43400 58 4064 1076 159 3 2 1/2"-50 320
44000 58 - - - 3 2 1/2"-50 320
* Stainless steel material version Shipping weight 340 kg
The permissible priming pressure at the suction side is approxi‐ mately 50% of the max. permitted back pressure
All figures refer to water at 20 °C.
The suction lift applies to filled suction line and filled liquid end ­when installed correctly.
The priming lift of 2 m applies for clean and moistened valves and a clear outlet
Maximum stroke rate
Suction lift
Connector size
Shipping weight*
15.2
15.2.1

Accuracy

Reproducibility

15.2.2 Metering precision

Data Value Unit
Reproducibility ±2 % *
* for measurements taken under constant conditions, minimum 10 % stroke rate and water at 20 °C - when installed correctly, p< 1 bar
Data Value Unit
Metering precision ±1 % *
* at maximum stroke length and maximum back pressure

15.3 Viscosity

The liquid ends are generally suitable for the following viscosity ranges:
52
Page 53
Version Range Unit
no valve springs 0 ... 200 mPas
with valve springs 200 ... 500 mPas
Technical data
with appropriately laid out installation
with appropriately laid out installation and advice from ProMinent
* Only when the installation is correctly adjusted
500 ... 1000 mPas
> 1000 mPas

15.4 Wetted materials

Material ver‐ sion
PPT Polypropylene Polypropylene PTFE Ceramic / Hast. C
PCT PVC PVC PTFE Ceramic / Hast. C
Liquid end Suction/dis‐
charge con‐ nector
Seals Valve plates /
valve spring
+ CTFE**
+ CTFE**
Valve seat
PTFE
PTFE
TTT PTFE with
carbon
SST Stainless steel
1.4571//1.44041 .4404

15.5 Ambient conditions

15.5.1 Temperatures

Pump, compl.
PC liquid end
PTFE with carbon
Stainless steel
1.45711.4404
DEVELOPAN® metering diaphragm with PTFE coating.
** The valve spring is coated with CTFE (similar to PTFE)
Data Value Unit
Storage and transport temperature -10 ... +50 °C
Ambient temperature in operation (drive + motor):
Data Value Unit
PTFE Ceramic / Hast. C
+ CTFE**
PTFE Stainless steel
1.4404/ Hast. C
-10 ... +40 °C
PTFE
PTFE
Max. temperature long-term at max. operating pressure
Max. temperature for 15 min at max. 2 bar
53
45 °C
60 °C
Page 54
Technical data
Data Value Unit
Minimum temperature -10 °C
PP liquid end
TT liquid end
SST liquid end
Data Value Unit
Max. temperature long-term at max.
60 °C
operating pressure
Max. temperature for 15 min at max. 2
100 °C
bar
Minimum temperature -10 °C
Data Value Unit
Max. temperature long-term at max.
90 °C
operating pressure
Max. temperature for 15 min at max. 2
120 °C
bar
Minimum temperature -10 °C
Data Value Unit
Max. temperature long-term at max.
90 °C
operating pressure
Max. temperature for 15 min at max. 2 bar
Minimum temperature -10 °C

15.5.2 Air humidity

Data Value Unit
Maximum air humidity *: 95 % rel.
*non-condensing (according to DIN IEC 60068-2-30)

15.6 Housing degree of protection

Data Value
Protection against contact and humidity* IP 55
*according to DIN VDE 470 (EN IEC 60529)
120 °C
humidity
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15.7 Stroke sensor (option), intrinsically safe

Namur sensor (identity code specifica‐ tion "Stroke sensor": 1)
Install the sensor according to the chapter "Installation, electrical".
Technical data
Namur sensor (Specified for EX zones)
5–25 V DC, in accordance with Namur or DIN 19234, potential-free design.
Data Value Unit
Rated voltage * 8 VDC
Power consumption - active surface uncovered
Power consumption - active surface covered
Rated switching distance 1.5 mm
* Ri ~ 1 kΩ
Cable colour Polarity
blue -
brown +
> 3 mA
< 1 mA

15.8 Filling volumes

15.8.1 Gear oil

15.9 Sound pressure level

Sound pressure level
Gear oil
Gear oil Supplied quantity Part no.
Mobilgear 634 VG 460 20.0 l 1006284
Required amount of oil
Pump type Oil change, compl.
All: 16.5 l
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)
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Technical data

15.10 Compatibility

The hydraulic accessories of the Makro/ 5 metering pump Hydro are compatible with the Sigma and Makro TZ piston pumps.
The connecting dimensions of valves and dosing heads are the same size but have different materials. (This does not apply with different diaphragm materials).
15.11
Technical data
motor
Spare parts

Supplement for modified versions

(With Identcode specification "Version": "M" - "modified")
Technical data of pumps in the modified version can deviate from those of the standard pumps. They can be queried by stating the details of the serial number.
The motor data sheets for the modified version are valid. They may deviate from the standard motor data sheets.
With a modified version, it is absolutely necessary to specify the details of the serial number requesting and ordering the spare and replacement parts.
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16 EC Declaration of Conformity

- Original -
EC Declaration of Conformity for Machinery
We,
ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 - 11 DE - 69123 Heidelberg
hereby declare that the product specified in the following complies with the relevant basic health and safety rules of the EC Directive, on the basis of its functional concept and design and in the version marketed by us. This declaration loses its validity in the event of a modification to the product not agreed with us.
Description of the product:
Metering pump, Makro 5 series
Product type:
M5Ma..., M5Ka..., M5Ha...
Serial no.:
Please refer to nameplate on the device
Relevant EC Directives:
EC - Machinery Directive (2006/42/EC) EC EMC Directive (2004/108/EC) The safety objectives of the Low Voltage Directive 2006/95/EC are complied with in accordance with Appendix I, No. 1.5.1 of the Machinery Directive 2006/42/EC
Harmonised standards applied, in particular:
EN ISO 12100, EN 809, EN ISO 13732-1, EN 60034-5, EN 60034-6, EN 60034-9, EN 60204-1, EN 61000-6-2, EN 61000-6-3
Technical documents have been compiled by documentation specialists:
Norbert Berger Im Schuhmachergewann 5-11 DE-69123 Heidelberg
05/10/2011
Date / Manufacturer's signature:
Joachim Schall, Head of Development
Details of the signatory:
For pumps without explosion protec‐ tion:
EC Declaration of Conformity
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EC Declaration of Conformity
For pumps with explosion protection:
The EC Declaration of Conformity for pumps for potentially explo‐ sive atmospheres is enclosed with the pump.
The EC Declaration of Conformity, the EC type-test reports and the operating instructions for the individual components are also enclosed with the pump.
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17 Index

Index
A
Accuracy.............................................................. 52
Air humidity.......................................................... 54
Ambient conditions............................................... 53
Assembly
C
Capacity............................................................... 51
Climate
Compatibility......................................................... 56
Connector size..................................................... 51
Correct and proper use.......................................... 8
D
Decommissioning................................................. 48
Decontamination declaration............................... 14
Diaphragm............................................................ 20
Direction of rotation of.......................................... 27
Discharge valve.................................................... 20
Disposal............................................................... 50
Dosing head......................................................... 20
During use............................................................ 31
E
Emergency........................................................... 12
Emptying the liquid end........................................ 49
External fan.......................................................... 27
F
Functional description.......................................... 19
G
Gear oil................................................................. 55
H
Hydraulic oil.......................................................... 55
I
Identification of safety notes................................... 8
Identity code........................................................... 5
Information in the event of an emergency............ 12
Installation............................................................ 24
L
Liquid end............................................................. 20
M
Materials............................................................... 53
Metering precision................................................ 52
Modified................................................................ 56
..............................................................
................................................................. 54
21
motor.............................................................. 27, 56
N
Namur sensor....................................................... 55
O
Oil......................................................................... 55
P
Protection against contact and humidity.............. 54
Pump capacity...................................................... 51
Q
Qualification of personnel....................................... 9
R
Radioactive.......................................................... 14
Repairs........................................................... 32, 37
Reproducibility...................................................... 52
S
Safety chapter........................................................ 8
Scope of supply.................................................... 14
Shipping weight.................................................... 51
Sound pressure level..................................... 13, 55
Spare parts........................................................... 56
Start up................................................................. 29
Storage................................................................. 14
Storage and transport temperature...................... 53
Stroke length........................................................ 30
Stroke sensor....................................................... 55
Suction lift............................................................. 51
Suction valve........................................................ 20
T
Technical data................................................ 51, 56
Temperatures....................................................... 53
Transport.............................................................. 14
Troubleshooting................................................... 45
U
Unpacking............................................................ 14
V
Valve repair.......................................................... 40
Viscosity............................................................... 52
W
Warning sign.......................................................... 8
Wetted materials.................................................. 53
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