ProMinent Makro/ 5 M5Ka Operating Instructions Manual

Page 1

Piston Metering Pump ProMinent® Makro/ 5 M5Ka

Operating instructions

ProMinent

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.

Original Operating Instructions (2006/42/EC)Part no. 985761 BA MAK 007 10/11 EN

Please carefully read these operating instructions before use! · Do not discard!

The operator shall be liable for any damage caused by installation or operating errors!

Technical changes reserved.

Page 2

985762, 1, en_GB

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

Page 3

Read the following supplementary information in its entirety! Should you already know this information, you have an even greater need of the Oper‐ ating Instructions.

The following are highlighted separately in the document:

n Enumerated lists

Instructions

Outcome of the handling instructions

- see (reference)

Information

This provides important information relating to the correct operation of the device or is intended to make your work easier.

Safety notes

Safety notes are identified by pictograms - see Safety Chapter.

Both sets of operating instructions are only valid when read together.

Please read these operating instructions carefully before use! Do not dis‐ card!

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 identified.

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.

Supplementary information

Fig. 1: Please read!

General user instructions

State the identity code and serial number

General non-discriminatory approach

Supplemental instructions

Page 4

Table of contents

1 Identity code.................................................................................... 5

2 About this pump

............................................................................... 7

3 Safety chapter................................................................................. 8

4 Storage, transport and unpacking................................................. 13

5 Overview of equipment, control elements..................................... 15

6 Functional description.................................................................... 18

7 Assembly....................................................................................... 20

8 Installation..................................................................................... 23

8.1 Installation, hydraulic............................................................. 23

8.2 Installation, electrical............................................................. 25

9 Start up.......................................................................................... 28

10 During use..................................................................................... 30

11 Maintenance.................................................................................. 31

Repairs.......................................................................................... 35

12.1 Changing the piston............................................................ 36

12.2 Valve repair......................................................................... 40

12.2.1 Double ball valves............................................................ 41

12.2.2 Single ball valves............................................................. 42

12.2.3 Plate valves...................................................................... 42

13 Troubleshooting............................................................................. 44

14 Decommissioning and disposal..................................................... 46

14.1 Decommissioning................................................................ 46

14.2 Disposal.............................................................................. 48

15 Technical data............................................................................... 49

15.1 Performance data................................................................ 50

15.2 Accuracy............................................................................. 53

15.2.1 Reproducibility.................................................................. 53

15.2.2 Metering precision............................................................ 53

15.3 Viscosity.............................................................................. 53

15.4 Wetted materials................................................................. 54

15.5 Ambient conditions.............................................................. 54

15.5.1 Temperatures................................................................... 54

15.5.2 Air humidity...................................................................... 54

15.6 Housing degree of protection.............................................. 55

15.7 Stroke sensor (option), intrinsically safe............................. 55

15.8 Filling volumes.................................................................... 55

15.8.1 Gear oil............................................................................. 55

15.9 Sound pressure level.......................................................... 56

15.10 Compatibility...................................................................... 56

15.11 Supplement for modified versions..................................... 56

16 EC Declaration of Conformity........................................................ 57

17 Index.............................................................................................. 59

Table of contents

Page 5

1 Identity code

M5Ka Makro/ 5 piston metering pumps

Power end type

H Main power end

D Main power end, doubled

A Add-on power end

B Add-on power end doubled

Type*

3200038 1400120 0500335 0250658 0121343

3200048 1400151 0500419 0250822 0121678

3200066 1400207 0500576 0251129 0122305

3200085 1270267 0450744 0231458 0122977

3200100 1000314 0350872 0181710 0103491

2400070 0800214 0350483 0160970 0062269

2400088 0800268 0350604 0161212 0062837

2400121 0800368 0350829 0161665 0063896

2160157 0700476 0301071 0162150 0065031

1700184 0560558 0251257 0162522 0066000

Dosing head material

SS Stainless steel

Seal material

T PTFE

Displacement body material

S Stainless steel piston, chromium dioxide coated

Dosing head version

0 no valve spring

1 With valve spring

Hydraulic connector

0 Standard connection

4 Union nut and SS insert

Version

With ProMinent® logo, no frame

Without ProMinent® logo, no frame

With ProMinent® logo, with single frame

With ProMinent®

logo, with double frame

With ProMinent® logo, with triple frame

With ProMinent® logo, with quadruple frame

M Modified* * order-related version, for pump fea‐

tures see order paperwork

Electric power supply

S 3 ph, 230 V/400 V 50/60 Hz (WBS)

Identity code

Page 6

M5Ka Makro/ 5 piston metering pumps

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)

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

* Figure 1 - 3=back pressure [bar]; figure 4 - 7=flow rate [l/h]

Identity code

Page 7

2 About this pump

The ProMinent® Makro/ 5 piston metering pump is fitted as standard with a 3 kW wide range AC motor. The stroke length can be adjusted between

0...50 mm. The spheroidal graphite housing can be combined with up to 10 liquid end sizes and 5 gear reduction ratios (integrated in the spur geared motor). The liquid ends are available in various material combina‐ tions which can be matched to the feed chemicals being metered.

The ProMinent® Makro/ 5 externally mounted metering pump can be com‐ bined 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 ver‐ sion.

The double head versions are fitted with a second liquid end which oper‐ ates in push-pull mode (Boxer principle).

All pumps

Externally mounted pumps

Double head version

About this pump

Page 8

3 Safety chapter

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

Signal word Meaning

WARNING Denotes a possibly dangerous sit‐

uation. If this is disregarded, you are in a life-threatening situation and this can result in serious inju‐ ries.

CAUTION Denotes a possibly dangerous sit‐

uation. If this is disregarded, it could result in slight or minor inju‐ ries or material damage.

The following warning signs are used in these operating instructions to denote different types of danger:

Warning signs Type of danger

Warning – hand injuries.

Warning – high-voltage.

Warning – flammable substances.

Warning – hot surface.

Warning – danger zone.

n The pump may only be used to meter liquid metering chemicals. 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 respective EC Declaration of Conformity) for pumps for potentially explosive atmospheres com‐ plying with Directive 94/9/EC in accordance with the European guide‐ lines. The explosion group, category and degree of protection identi‐ fied on the marking must correspond with or be better than the given conditions in the intended field of application.

n The pump may only be started up after it has been correctly installed

and commissioned in accordance with the technical data and specifi‐ cations contained in the operating instructions.

n The general limitations with regard to viscosity limits, chemical resist‐

ance 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 Decla‐

ration of Conformity) for pumps for potentially explosive atmospheres must never be operated in potentially explosive atmospheres.

Identification of safety notes

Warning signs denoting different types of danger

Correct and proper use

Safety chapter

Page 9

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 pumps is not intended for the dosing of combustible fluids. n The pump should only be operated by trained and authorised per‐

sonnel, see also

Ä ‘Qualification of personnel’ on page 9

n You are obliged to observe the information contained in the operating

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

In hazardous locations only the following combinations of identity code variants is permitted:

Combi‐ nations

Identity code specification values

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 hydraulic system

Technical personnel, service

Installation, electrical Electrical technician

Operation Instructed person

Maintenance, repair Technical personnel, service

Decommissioning, disposal Technical personnel, service

Troubleshooting Technical personnel, electrical

technician, instructed person, service

Explanation of the terms:

Technical personnel

A qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognise possible dangers based on his/her technical training, knowledge and experience, as well as knowledge of pertinent regulations.

Note:

A qualification of equal validity to a technical qualification can also 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 possible dangers independently based on their technical training and experience, as well as knowledge of pertinent standards and regulations.

Electrical technicians should be specifically trained for the working envi‐ ronment in which the are employed and know the relevant standards and regulations.

Qualification of personnel

Safety chapter

Page 10

Electrical technicians must comply with the provisions of the applicable statutory directives on accident prevention.

Instructed person

An instructed person is deemed to be a person who has been instructed and, if required, trained in the tasks assigned to him/her and possible dan‐ gers that could result from improper behaviour, as well as having been instructed in the required protective equipment and protective measures.

Service

Customer Service department refers to service technicians, who have received proven training and have been authorised by ProMinent or Pro‐ Maqua to work on the system.

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.

WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries.

Please ensure when handling hazardous substances that you have read the latest safety data sheets provided by the manufacture of the hazardous substance. The actions required are described in the safety data sheet. Check the safety data sheet regularly and replace, if necessary, as the hazard potential of a substance can be re-evaluated at any time based on new findings.

The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date, as well as for producing an associated hazard assess‐ ment for the workstations affected.

CAUTION! Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if

they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system.

– Disconnect the pump from the mains power supply and

ensure that it cannot be switched on again by unauthor‐ ised persons.

– Depressurise the system before commencing any work

on hydraulic parts.

Safety notes

Safety chapter

Page 11

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 ProMinent 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 personnel

injuries and material damage.

– Only fit parts to metering pumps, which have been

tested and recommended by ProMinent.

CAUTION! Danger from incorrectly operated or inadequately 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.

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.

Information in the event of an emergency

Safety chapter

Page 12

P_MAK_0025_SW

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)

WARNING! Warning of personal injury and material damage – The customer must only remove the protective equip‐

ment if requested to do so by the operating instructions.

–

The pump must not operate without fitted protective equipment.

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)

Protective equipment

Sound pressure level

Safety chapter

Page 13

4 Storage, transport and unpacking

WARNING! The transporting of pumps which have been used with radio‐

active 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 decommis‐ sioning!

Only send metering pumps with a filled in Decontamination Declaration form. The Decontamination Declaration consti‐ tutes an integral part of an inspection / repair order. A unit can only be inspected or repaired when a Declaration of Decontamination Form is submitted that has been completed correctly and in full by an authorised and qualified person on behalf of the pump operator.

You can find the "Decontamination Declaration" form under

www.prominent.com

or on the CD.

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 trans‐

ported in accordance with the stipulated storage condi‐ tions.

–

The packaged unit should be protected from moisture and the ingress of chemicals.

Compare the delivery note with the scope of supply:

n Metering pump with mains power cable n Connector kit for tube/pipe connection n Product-specific operating instructions with EC Declaration of Con‐

formity

n CD with order information, exploded diagrams, performance diagrams,

motor data sheet and dimension sheets

n Optional accessories if ordered

Personnel:

Technical 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 ventilation.

Safety notes

Scope of supply

Storage

Storage, transport and unpacking

Page 14

Store the pump in a dry, sealed place in the following ambient conditions.

Data Value Unit

Minimum storage and transport tempera‐ ture

-10 °C

Maximum storage and transport tempera‐ ture

+50 °C

Maximum air humidity * 95 % rel.

humidity

* non-condensing

Ambient conditions

Storage, transport and unpacking

Page 15

5 Overview of equipment, control elements

P_MAK_0027_SW

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

P_MAK_0027_SW

Fig. 4: View away from the motor (here M5Ka H)

6 Vent screw 7 Oil inspection window

Power end, single head

Overview of equipment, control elements

Page 16

P_MAK_0029_SW

1 1

C A C

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

P_MAK_0030_SW

Fig. 6: View away from the motor (here M5Ka D)

6 Vent screw 7 Oil inspection window

Power end, double head

Overview of equipment, control elements

Page 17

P_MAK_0034_SW

Fig. 7

1 Discharge valve 2 Dosing head 3 Suction valve 4 Support bracket 5 Protective cover 6 Tube nozzles for leakage/flushing connector

Liquid end

Overview of equipment, control elements

Page 18

6 Functional description

The Makro/ 5 metering pump is a motor-driven metering pump with a kine‐ matic 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 dia‐ gram). 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).

P_MAK_0035_SW

6 5

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

The heart of the liquid end is a highly resistant piston (2) made from coated stainless steel. The suction valve (5) closes as soon as the piston (2) is moved in to the dosing head and the feed chemical flows through the discharge valve (1) out of the dosing head. The discharge valve (1) closes as soon as the piston moves in the opposite direction due to the vacuum pressure in the dosing head and fresh feed chemical flows through the suction valve (5) into the dosing head. The flushing collar (3) can be used to flush the sealing surfaces of the piston or lead-off leakage liquid.

Power end functional description

Functional description of the piston liquid end (for M5Ka)

Functional description

Page 19

P_MAK_0039_SW

1 2 3 4

Fig. 9: Cross-section through the liquid end

1 Discharge valve 2 Piston 3 Flushing collar 4 Packing collar 5 Suction valve

Functional description

Page 20

7 Assembly

WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐

jects 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.

CAUTION! Warning about personal and material damage Also observe the "General Operating Instructions for ProMi‐

nent

Motor-Driven Metering Pumps and Hydraulic Accesso‐

ries"!

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 trans‐

ported in accordance with the stipulated storage condi‐ tions.

–

The packaged unit should be protected from moisture 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".

WARNING! Risk of electric shock If water or other electrically conducting liquids penetrate into

the drive housing, an electric shock may occur.

– Position the pump so that drive housing cannot be

flooded.

Safety notes

Supporting floor

P_MOZ_0016_SW

Fig. 10

Assembly

Page 21

WARNING! The pump can break through the supporting floor or slide off

it – The supporting floor must be horizontal, smooth and per‐

manently load-bearing.

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 ...).

1 Discharge valve 2

Dosing head

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.

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.

Space requirement

P_MOZ_0018_SW

Fig. 11

P_MOZ_0017_SW

Fig. 12

Liquid end alignment

Fastening

Assembly

Page 22

Take the dimensions (m) for the fastening holes from the appropriate dimensional drawings or data sheets.

Fasten the pump base to the supporting floor using suitable screws.

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.

DNm

P_MOZ_0015_SW

Fig. 13

Instruction

Assembly

Page 23

8 Installation

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 "Technical

Data" and, where applicable, the operating instructions of the accessories.

8.1 Installation, hydraulic

WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐

jects 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! 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 origi‐ nate 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:

– Install a bleed valve with recirculation in the storage

tank.

– Install an additional shut-off valve on the discharge or

suction ends.

CAUTION! Warning about personal and material damage Also observe the "General Operating Instructions for ProMi‐

nent

Motor-Driven Metering Pumps and Hydraulic Accesso‐

ries"!

Installation

Page 24

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 discharge

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.

– Install a relief valve that limits the pressure of the pump

to the maximum permissible operating pressure 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 incorrectly

can loosen / disconnect from the pump connection.

– Only use original tubing with the specified tube diameter

and wall thickness.

– Only use clamp rings and tube nozzles that correspond

with the respective hose diameter.

– Always connect the lines without mechanical tension.

–

Precise metering is only possible when the back pres‐ sure is maintained above 1 bar at all times.

–

If metering at atmospheric pressure, a back pressure valve should be used to create a back pressure of approx. 1.5 bar.

Personnel:

Technical 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.

Route the leakage liquid drainage line

Installation

Page 25

8.2 Installation, electrical

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.

WARNING! Danger of electric shock In the event of an electrical accident, it must be possible 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 ancillaries which may be present or

– Integrate the pump and electrical ancillaries which may

be present in the emergency cut-off management of the system and inform personnel of the isolating option.

WARNING! Danger of electric shock This pump is equipped with a protective earth conductor, to

reduce the risk arising from an electric shock.

– Connect the PE conductor to "earth" with a clean and

permanent electrical connection.

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

– If the pump housing has been damaged, you must dis‐

connect 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 sub‐

jects 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.

CAUTION! Warning about personal and material damage Also observe the "General Operating Instructions for ProMi‐

nent

Motor-Driven Metering Pumps and Hydraulic Accesso‐

ries"!

Installation

Page 26

Personnel:

Electrician

What requires electrical installation?

n motor n External fan (option) n Stroke control drive (Option) n Stroke adjusting drive (Option) 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.

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 emer‐ gency cut-off management of the system.

–

Key motor data can be found on the unit nameplate.

–

Motor data sheets can be requested for more informa‐ tion.

–

The terminal wiring diagram is located in the terminal box.

–

Notes on the speed controlled motor with external fan and temperature monitoring can be found in the "Gen‐ eral operating instructions for ProMinent® motor-driven metering pumps and hydraulic accessories"!

motor

P_SI_0012_SW

Fig. 14: Direction of rotation of motor

Installation

Page 27

The external fan requires an independent mains connection.

Connect the stroke sensor to a suitable monitoring device according to the details in the chapter "Technical Data". Also observe its tech‐ nical data.

Install the other units according to their documentation.

Stroke sensor (Option)

Other units

Installation

Page 28

9 Start up

WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐

jects 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! Hot surface In event the power end motor is loaded excessively, its sur‐

face may become very hot.

– Avoid contact. – If necessary, mount a guard plate.

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 equipment, control elements".

CAUTION! Warning about personal and material damage Also observe the "General Operating Instructions for ProMi‐

nent

Motor-Driven Metering Pumps and Hydraulic Accesso‐

ries"!

CAUTION! Liquid end may be damaged – For feed chemicals with a particle size greater than 0.3

mm, always fit a filter in the suction line

Safety notes

Start up

Page 29

Replace the sealing screw at the oil filler neck with the supplied vent screw

- see chapter "Overview of equipment and control elements".

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 dam‐ aged.

When commissioning the unit, check whether the drive motor is rotating correctly - check this against the arrow on the motor housing or the dia‐ gram in the chapter entitled "Electrical Installation."

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.

Only adjust the stroke length when the pump is running. 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 chemi‐

cals.

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 %.

Check whether the leakage for the feed chemical used is between 10 and 120 drops /min.

The pump can now be released for operation.

Installing a vent screw

Checking the oil level

Checking the direction of rotation

Fig. 15: Tapping the valve set disc

Adjusting the stroke length

Checking the leakage

Start up

Page 30

10 During use

WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐

jects 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! Personnel injury and material damage may occur During use all units, protective equipment, additional devices

must be fitted, operational and tightly closed.

WARNING! Hot surface In event the power end motor is loaded excessively, its sur‐

face 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 components.

During use

Page 31

11 Maintenance

WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐

jects 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 sur‐

face 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, protective 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 displace‐

ment 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 unauthor‐ ised persons.

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.

Safety notes

Maintenance

Page 32

CAUTION! Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if

they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system.

– Disconnect the pump from the mains power supply and

ensure that it cannot be switched on again by unauthor‐ ised persons.

– Depressurise the system before commencing any work

on hydraulic parts.

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.

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 ProMinent® motor-driven metering pumps and hydraulic accessories"

Check the starting torque torques for the dosing head flange screws (1) (24 Nm) and the turret flange screws (2) (19 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 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 max‐ imum permissible operating pressure!

Check whether the leakage level is OK: 10 ... 120 drops / min.

Maintenance work

Maintenance

Page 33

1 (24 Nm)

2 (19 Nm)

P_MAK_0042_SW

Fig. 16: Liquid end torques

1 Dosing head screws 2 Turret flange screws

Interval Maintenance work

After approx. 5,000 operating hours Change the gear oil.

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

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

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 running 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.

Changing the gear oil

Maintenance

Page 34

P_MAK_0043_SW

Fig. 17: Oil change 1

1 Vent screw 2 Oil drain plug

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).

P_MAK_0044_SW

Fig. 18: Oil change 2

3 Oil inspection windows

Maintenance

Page 35

12 Repairs

WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐

jects 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 sur‐

face 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, protective 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 displace‐

ment 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 unauthor‐ ised persons.

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.

Safety notes

Repairs

Page 36

CAUTION! Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if

they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system.

– Disconnect the pump from the mains power supply and

ensure that it cannot be switched on again by unauthor‐ ised persons.

– Depressurise the system before commencing any work

on hydraulic parts.

12.1 Changing the piston

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 pro‐ cesses, 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 suction side.

7. Remove the protective cover (4) from the turret - see Fig. 19.

8. Remove a safety collar (2) from the bolt at the swivel head and pull out the bolt (1)

9. Place a sling around the liquid end and suspend from a crane.

WARNING! Heavy parts may fall – A helper must steady the liquid end by hand. – Secure the piston to prevent it falling out.

10. If available: Remove the leakage or flushing tubes from the tube nozzles (6).

11. If available: Unscrew the support bracket (5) from the liquid end.

12. Remove the securing screws (3) from the turret flange

13. Remove the liquid end and place onto a solid, even surface

Removing the liquid end

Repairs

Page 37

P_MAK_0048_SW

1 2 3

Fig. 19: View of the liquid end

1 Bolt 2 Safety collar 3 Securing screws 4 Protective cover 5 Support bracket (option) 6 Tube nozzles for leakage/flushing connector

P_MAK_0049_SW

1 2 3

45678

Fig. 20: Cross-section through the liquid end

1 Piston 2 Tube nozzle 3 Tensioning screw 4 Dosing head flange 5 Guide bands 6 Guide sleeves 7 Flushing collar 8 Packing collars

1. Loosen the tensioning screw (3) using the face spanner and remove

- see Fig. 20.

2. Loosen the dosing head flange (4) screws and remove the dosing head flange.

Repairing the liquid end

Repairs

Page 38

3. Remove the piston (1)

Now record the sequence of parts as your remove them ready for the reassembly.

5. Remove the guide sleeves (6) and guide bands (5), the packing col‐ lars (8) and flushing collar (7).

6. Thoroughly clean the sealing area

7. Clean the piston (1), the guide sleeves (6) and the flushing collar (7)

8. Dispose of the packing collars and guide bands

9. Insert the piston (1)

Now reassemble the parts using a reverse sequence of steps:

1. Have new packing collars ready.

CAUTION! The piston may be damaged – Never push the packing collars on with a sharp object.

2. Evenly push in the guide sleeve (6) with a new guide band and a packing collar.

3. Insert the other packing collars with the cut ends alternately rotated through 180°.

4. Sequentially insert the flushing collar (7), two further packing collars and the guide sleeve (6) with a new guide band into the sealing area

5. Place the dosing head flange (4) on the liquid end and tighten.

Tightening torque 24 Nm

CAUTION! The piston may be damaged – Only lightly tighten the tensioning screw.

6. Position the tensioning screw and only hand-tighten.

1. Place a sling around the liquid end and suspend from a crane.

WARNING! Heavy parts may fall – A helper must steady the liquid end by hand. –

Secure the piston to prevent it falling out.

2. Place the liquid end on the drive flange and secure using the retaining screws.

Tightening torque 19 Nm

Fitting the liquid end

Repairs

Page 39

1. Align the holes of the swivel head and fork head - see Fig. 20.

2. Push the bolt through the holes and insert the safety collar in the bolt.

3. Clamp the protective cover over the turret.

4. If available: Screw the support bracket onto the liquid end.

5. If available: Fit the leakage or flushing tubes on to the tube nozzles.

Correct pressure of the tensioning screw Packing collars should limit, not prevent, the escaping of

feed chemical. Leakage is necessary to reduce the friction and dissipate the resulting friction heat.

In Fig. 21 the feed chemical presses from the left through the packing collar a (drop on the right!). The tensioning screw A presses on the packing collar from the right.

P_MAK_0050_SW

Fig. 21: Correct pressure of the tensioning screw

a Packing collar b Piston A Tensioning screw pressure B Feed chemical pressure

Allow the pump to run for the first 10 ... 15 min with this leakage rate:

Leakage in the first 10 ... 15 min 50 ... 200 drops / min

Then:

1. Stop the pump.

2. Remove the protective cover.

3. Carefully tighten the tensioning screw.

4. Clamp the protective cover over the turret.

5. Start the pump.

6. Check the leakage.

Repeat steps 1. – 6. until minimum leakage is achieved:

Minimum leakage 10 ... 120 drops / min

Positioning the liquid end

Installing of packing collars

Repairs

Page 40

The minimum leakage is dependent on the feed chemical, the feed chemical pressure, the temperature and the piston speed.

CAUTION! The piston may be damaged If the tensioning screw pressure is too high, dry running can

occur and then damage to the piston and the packing collars.

– Do not overtighten the tensioning screw.

The result of too high tensioning screw pressure The feed chemical can no longer press though the packing

collars - liquid lubrication is prevented. The piston runs dry. As a result the packing collars are scorched/burnt and the piston damaged. Leakage increases greatly.

P_MAK_0051_SW

Fig. 22: The result of too high tensioning screw pressure

a Packing collar b Piston A Tensioning screw pressure B Feed chemical pressure

12.2 Valve repair

Unsuitable spare parts for the valves may lead to problems for the pumps.

–

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 information 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.

Repairs

Page 41

12.2.1 Double ball valves

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

When assembling, take note of the orientation of the 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 further

seal (2)

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.

4. Screw in the valve until the stop.

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).

Cleaning a discharge valve

Fig. 23: Discharge valve (double ball valve).

Cleaning a suction valve

Repairs

Page 42

12.2.2 Single ball valves

1. Screw the valve cap (5) on to the suction side - see .

2. Carefully remove the parts from the valve body (2).

3. Replace the worn parts.

4. Clean the remaining parts.

5. Check all parts.

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 suc‐ tion connectors when fitting the valve.

P_MAK_0054_SW

Fig. 24: Cross-section through the single ball valve

1 Seal 2 Valve body 3 Valve ball 4 Valve seat 5 Valve cap

12.2.3 Plate valves

Do not scratch the finely machined sealing surfaces on the valve plates (5) and valve inserts (6).

Repairs

Page 43

5 6 7

P_MAK_0055_SW

Fig. 25: Section through a plate valve (DN65 shown)

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

1. Screw the valve cap (7) on to the suction side - see .

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 opera‐ tion.

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 suc‐ tion connectors when fitting the valve.

P_MAK_0056_SW

Fig. 26: Inserting the compression spring

Repairs

Page 44

13 Troubleshooting

WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐

jects 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! Fire danger Only with combustible media: These may start to burn when

combined with oxygen.

– When filling and draining the liquid end, the feed chem‐

ical must not come into contact with oxygen.

WARNING! Hot surface In event the power end motor is loaded excessively, its sur‐

face 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 electrocuted if

all electrical lines carrying current have not been discon‐ nected.

– Disconnect the supply cable before working on the motor

and prevent it from being reconnected accidentally.

– Any separately driven fans, servo motors, speed control‐

lers or diaphragm rupture sensors fitted should also be disconnected.

– Check that the supply cables are de-energised.

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, protective gloves, ...). Read the safety data sheet on the feed chemical.

– Drain and flush the liquid end before working on the

pump.

Safety notes

Troubleshooting

Page 45

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 components if

they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system.

– Disconnect the pump from the mains power supply and

ensure that it cannot be switched on again by unauthor‐ ised persons.

– Depressurise the system before commencing any work

on hydraulic parts.

Fault description Cause Remedy Personnel

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

The valves are dirty or worn.

Repair the valves - see chapter entitled "Repair".

Technical per‐ sonnel

Pump does not reach high pres‐ sure rates.

The valves are dirty or worn.

Repair the valves - see chapter entitled "Repair".

Technical per‐ sonnel

The feed chemical has particles larger than 3 mm.

Install a suitable filter in the suction line. Technical per‐

sonnel

The motor is wired incorrectly.

1. Check the mains voltage and mains frequency.

2. Wire the motor correctly.

Electrician

The mains voltage has failed.

Eliminate the cause. Electrician

The diaphragm rupture warning system generates an alarm.

No hydraulic oil flows through the tube at the bleed valve

- - - - Immediately switch off the pump and inform customer service.

The power end motor is very hot. The discharge line is

seriously constricted.

n Rectify any constriction of the dis‐

charge line.

n Have the safety relief valve

checked.

Technical per‐ sonnel

All other faults. Other causes.

Call ProMinent®

or ProMaqua® service.

Tasks

Troubleshooting

Page 46

14 Decommissioning and disposal

14.1 Decommissioning

WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐

jects 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! Danger of an electric shock When working on the motor or electrical auxiliary equipment,

there is a danger of an electric shock.

– Before working on the motor, take note of the safety

instructions in its operating instructions!

– Should external fans, servomotors or other auxiliary

equipment be installed, these should also be discon‐ nected 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 residue 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, protective gloves, ...). Read the safety data sheet on the feed chemical.

– Drain and flush the liquid end before working on the

pump.

Decommissioning and disposal

Page 47

CAUTION! Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if

they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system.

– Disconnect the pump from the mains power supply and

ensure that it cannot be switched on again by unauthor‐ ised 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.

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, Trans‐

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

Personnel:

Technical personnel

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 haz‐ ardous feed chemicals!

4. Drain the gear oil - refer to the chapter entitled "Maintenance".

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.

3. Preferably place the pump on a pallet.

4. Cover the pump with a tarpaulin cover - allowing rear ventilation!

5. Store the pump is a dry, sealed place under storage conditions according to the chapter "Storage, Transport and Unpacking".

Final decommissioning

Temporary decommissioning

Decommissioning and disposal

Page 48

14.2 Disposal

Personnel:

Technical personnel

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!

Decommissioning and disposal

Page 49

15 Technical data

WARNING! Risk of personal injuries Please observe the ”Supplement for modified version“ at the

end of the chapter!

It replaces and supplements the technical data!

Only for "M - modified" version:

Technical data

Page 50

15.1 Performance data

Type Minimum pump capacity at max‐

imum back pressure

Maximum stroke rate

Suction lift

Connector size

Shipping weight*

Piston Ø

bar l/h ml/stroke Strokes/min m WS G-DN kg mm

3200038 320 38 11.3 60 3 Rp 1/4- 8 300 17

3200048 320 48 11.3 75 3 Rp 1/4- 8 300 17

3200066 320 66 11.3 103 3 Rp 1/4- 8 300 17

3200085 320 85 11.3 133 3 Rp 3/4- 10 300 17

3200100 320 100 11.3 156 3 Rp 3/4- 10 300 17

2400070 240 70 20.7 60 3 Rp 3/4- 10 300 23

2400088 240 88 20.7 75 3 Rp 3/4- 10 300 23

2400121 240 121 20.7 103 3 1- 15 300 23

2160157 216 157 20.7 133 3 1- 15 300 23

1700184 170 184 20.7 156 3 1- 15 300 23

1400120 140 120 35.3 60 3 1- 15 302 30

1400151 140 151 35.3 75 3 1- 15 302 30

1400207 140 207 35.3 103 3 1- 15 302 30

1270267 127 267 35.3 133 3 1 1/4- 20 302 30

1000314 100 314 35.3 156 3 1 1/4- 20 302 30

800214 80 214 62.8 60 3 1 1/4- 20 303 40

800268 80 268 62.8 75 3 1 1/4- 20 303 40

800368 80 368 62.8 103 3 1 1/4- 20 303 40

700476 70 476 62.8 133 3 1 1/2- 25 303 40

560558 56 558 62.8 156 3 1 1/2- 25 303 40

500335 50 335 98.1 60 3 1 1/2- 25 303 50

500419 50 419 98.1 75 3 1 1/2- 25 303 50

500576 50 576 98.1 103 3 1 1/2- 25 303 50

450744 45 744 98.1 133 3 2- 32 303 50

350872 35 872 98.1 156 3 2- 32 303 50

350483 35 483 141.3 60 3 1 1/2- 25 311 60

350604 35 604 141.3 75 3 1 1/2- 25 311 60

350829 35 829 141.3 103 3 2- 32 311 60

301071 30 1071 141.3 133 3 2- 32 311 60

251257 25 1257 141.3 156 3 2- 32 311 60

250658 25 658 192.4 60 3 2- 32 311 70

250822 25 822 192.4 75 3 2- 32 311 70

251129 25 1129 192.4 103 3 2- 32 311 70

231458 23 1458 192.4 133 3 2 1/4- 40 311 70

181710 18 1710 192.4 156 3 2 1/4- 40 311 70

160970 16 970 283.7 60 3 2 1/4- 40 317 85

Main pumps with motor 1500 rpm under 50 Hz operation

Technical data

Page 51

Type Minimum pump capacity at max‐

imum back pressure

Maximum stroke rate

Suction lift

Connector size

Shipping weight*

Piston Ø

bar l/h ml/stroke Strokes/min m WS G-DN kg mm

161212 16 1212 283.7 75 3 2 1/4- 40 317 85

161665 16 1665 283.7 103 3 2 1/4- 40 317 85

162150 16 2150 283.7 133 3 2 3/4- 50 317 85

162522 16 2522 283.7 156 3 2 3/4- 50 317 85

121343 12 1343 392.6 60 3 2 3/4- 50 331 100

121678 12 1678 392.6 75 3 2 3/4- 50 331 100

122305 12 2305 392.6 103 3 2 3/4- 50 331 100

122977 12 2977 392.6 133 3 2 1/2- 65 331 100

103491 10 3491 392.6 156 3 2 1/2- 65 331 100

62269 6 2269 663.6 60 3 2 1/2- 65 350 130

62837 6 2837 663.6 75 3 2 1/2- 65 350 130

63896 6 3896 663.6 103 3 2 1/2- 65 350 130

65031 6 5031 663.6 133 3 2 1/2- 65 350 130

66000 6 6000 663.6 156 3 2 1/2- 65 350 130

* Stainless steel material version Shipping weight 340 kg

The permissible priming pressure at the suction side is 2 m WS.

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

Technical data

Page 52

Type Minimum pump capacity at max‐

imum back pressure

Maximum stroke rate

Suction lift

Connector size

Shipping weight*

Piston Ø

bar l/h ml/stroke Strokes/min m WS G-DN kg mm

3200038 4640 44 11 71 3 Rp 1/4- 8 300 17

3200048 4640 56 14 89 3 Rp 1/4- 8 300 17

3200066 4640 78 20 123 3 Rp 1/4- 8 300 17

3200085 4640 101 26 159 3 Rp 3/4- 10 300 17

3200100 - - - - 3 Rp 3/4- 10 300 17

2400070 3480 82 21 71 3 Rp 3/4- 10 300 23

2400088 3480 104 27 89 3 Rp 3/4- 10 300 23

2400121 3480 144 38 123 3 1- 15 300 23

2160157 3132 187 49 159 3 1- 15 300 23

1700184 - - - - 3 1- 15 300 23

1400120 2030 142 37 71 3 1- 15 302 30

1400151 2030 179 47 89 3 1- 15 302 30

1400207 2030 247 65 123 3 1- 15 302 30

1270267 1841.5 319 84 159 3 1 1/4- 20 302 30

1000314 - - - - 3 1 1/4- 20 302 30

800214 1160 253 67 71 3 1 1/4- 20 303 40

800268 1160 318 84 89 3 1 1/4- 20 303 40

800368 1160 439 116 123 3 1 1/4- 20 303 40

700476 1015 569 150 159 3 1 1/2- 25 303 40

560558 - - - - 3 1 1/2- 25 303 40

500335 725 396 104 71 3 1 1/2- 25 303 50

500419 725 497 131 89 3 1 1/2- 25 303 50

500576 725 687 182 123 3 1 1/2- 25 303 50

450744 652.5 889 235 159 3 2- 32 303 50

350872 - - - - 3 2- 32 303 50

350483 507.5 571 151 71 3 1 1/2- 25 311 60

350604 507.5 716 189 89 3 1 1/2- 25 311 60

350829 507.5 989 262 123 3 2- 32 311 60

301071 435 1280 339 159 3 2- 32 311 60

251257 - - - - 3 2- 32 311 60

250658 362.5 778 206 71 3 2- 32 311 70

250822 362.5 975 258 89 3 2- 32 311 70

251129 362.5 1348 357 123 3 2- 32 311 70

231458 333.5 1743 461 159 3 2 1/4- 40 311 70

181710 - - - - 3 2 1/4- 40 311 70

160970 232 1147 303 71 3 2 1/4- 40 317 85

161212 232 1438 381 89 3 2 1/4- 40 317 85

Main pumps with motor 1800 rpm under 60 Hz operation

Technical data

Page 53

Type Minimum pump capacity at max‐

imum back pressure

Maximum stroke rate

Suction lift

Connector size

Shipping weight*

Piston Ø

bar l/h ml/stroke Strokes/min m WS G-DN kg mm

161665 232 1988 526 123 3 2 1/4- 40 317 85

162150 232 2570 681 159 3 2 3/4- 50 317 85

162522 - - - - 3 2 3/4- 50 317 85

121343 174 1589 421 71 3 2 3/4- 50 331 100

121678 174 1991 527 89 3 2 3/4- 50 331 100

122305 174 2752 729 123 3 2 3/4- 50 331 100

122977 174 3558 942 159 3 2 1/2- 65 331 100

103491 - - - - 3 2 1/2- 65 331 100

62269 87 2684 711 71 3 2 1/2- 65 350 130

62837 87 3366 891 89 3 2 1/2- 65 350 130

63896 87 4652 1232 123 3 2 1/2- 65 350 130

65031 87 6014 1593 159 3 2 1/2- 65 350 130

66000 - - - - 3 2 1/2- 65 350 130

* Stainless steel material version Shipping weight 340 kg

The permissible priming pressure at the suction side is 2 m WS.

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

15.2 Accuracy

15.2.1 Reproducibility

Data Value Unit

Reproducibility ±0.5 % *

* for measurements taken under constant conditions, minimum 10 % stroke rate and water at 20 °C - when installed correctly, p< 1 bar

15.2.2 Metering precision

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:

Technical data

Page 54

Version Range Unit

no valve springs 0 ... 200 mPas

with valve springs 200 ... 500 mPas

with appropriately laid out installation

500 ... 1000 mPas

with appropriately laid out installation and advice from ProMinent

> 1000 mPas

* Only when the installation is correctly adjusted

15.4 Wetted materials

Pump type Liquid end Suction/dis‐

charge connector

Valve seat/seals Valve balls Piston

50 HK ...DN 8DN 10

Stainless steel

1.4571//1.4404

Stainless steel

1.4571//1.44041. 4404

SS/PTFE Oxide ceramic Stainless steel/

ceramic

50 HK ...DN 15DN 25

Stainless steel

1.4571//1.4404

Stainless steel

1.4581

PTFE/PTFE Stainless steel

1.4401

Stainless steel/ ceramic

50 HK ...DN 32DN 65

Stainless steel

1.4571//1.4404

Stainless steel

1.4571//1.44041. 4404

PTFE Hast. C Stainless steel/

ceramic (valve plate)

15.5 Ambient conditions

15.5.1 Temperatures

Data Value Unit

Storage and transport temperature -10 ... +50 °C

Ambient temperature in operation (drive + motor):

-10 ... +40 °C

Data Value Unit

Max. temperature long-term at max. oper‐ ating pressure

90 °C

Max. temperature for 15 min at max. 2 bar 150 °C

Minimum temperature -10 °C

15.5.2 Air humidity

Data Value Unit

Maximum air humidity *: 95 % rel.

humidity

*non-condensing (according to DIN IEC 60068-2-30)

Pump, compl.

SST liquid end

Technical data

Page 55

15.6 Housing degree of protection

Data Value

Protection against contact and humidity* IP 55

*according to DIN VDE 470 (EN IEC 60529)

15.7 Stroke sensor (option), intrinsically safe

Install the sensor according to the chapter "Installation, elec‐ trical".

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

> 3 mA

Power consumption - active surface cov‐ ered

< 1 mA

Rated switching distance 1.5 mm

* Ri ~ 1 kΩ

Cable colour Polarity

blue -

brown +

15.8 Filling volumes

15.8.1 Gear oil

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

Namur sensor (identity code specification "Stroke sensor": 1)

Namur sensor (Specified for EX zones)

Technical data

Page 56

15.9 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)

15.10

Compatibility

The hydraulic accessories of the Makro/ 5 metering pump Hydro are com‐ patible 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 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.

Sound pressure level

Technical data

motor

Spare parts

Technical data

Page 57

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 protection:

EC Declaration of Conformity

Page 58

The EC Declaration of Conformity for pumps for potentially explosive atmospheres is enclosed with the pump.

The EC Declaration of Conformity, the EC type-test reports and the oper‐ ating instructions for the individual components are also enclosed with the pump.

For pumps with explosion protection:

EC Declaration of Conformity

Page 59

17 Index

Accuracy....................................................................... 53

Air humidity................................................................... 54

Ambient conditions........................................................ 54

Assembly.......................................................................

Capacity........................................................................ 50

Climate.......................................................................... 54

Compatibility

.................................................................. 56

Connector size.............................................................. 50

Correct and proper use................................................... 8

Decommissioning.......................................................... 46

Decontamination declaration......................................... 13

Direction of rotation of................................................... 26

Discharge valve............................................................. 18

Disposal........................................................................ 48

Dosing head.................................................................. 18

During use..................................................................... 30

Emergency.................................................................... 11

Emptying the liquid end................................................. 47

External fan................................................................... 26

Flushing collar............................................................... 18

Functional description................................................... 18

Gear oil.......................................................................... 55

Hydraulic oil................................................................... 55

Identification of safety notes............................................ 8

Identity code.................................................................... 5

Information in the event of an emergency..................... 11

Installation..................................................................... 23

Liquid end...................................................................... 18

Materials........................................................................ 54

Metering precision......................................................... 53

Modified......................................................................... 56

motor....................................................................... 26, 56

Namur sensor................................................................ 55

Oil.................................................................................. 55

Packing collar................................................................ 18

Piston

............................................................................ 18

Protection against contact and humidity....................... 55

Pump capacity............................................................... 50

Qualification of personnel................................................ 9

Radioactive................................................................... 13

Repairs.................................................................... 31, 35

Reproducibility............................................................... 53

Safety chapter................................................................. 8

Scope of supply............................................................. 13

Shipping weight............................................................. 50

Sound pressure level.............................................. 12, 56

Spare parts.................................................................... 56

Start up.......................................................................... 28

Storage.......................................................................... 13

Storage and transport temperature............................... 54

Stroke length................................................................. 29

Stroke sensor................................................................ 55

Suction lift...................................................................... 50

Suction valve................................................................. 18

Technical data......................................................... 49, 56

Temperatures................................................................ 54

Transport....................................................................... 13

Troubleshooting............................................................ 44

Unpacking..................................................................... 13

Valve repair................................................................... 40

Viscosity........................................................................ 53

Warning sign................................................................... 8

Wetted materials........................................................... 54

Index

ProMinent Makro/ 5 M5Ka Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual