ProMinent TZ, TZMb, Makro TZ, Makro TZMb Operating Instructions Manual

Page 1

Diaphragm Metering Pump Makro TZ, TZMb

Operating instructions

P_MA_0022_SW

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. 985741 BA MA 007 11/11 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

985742, 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

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

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

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

6 Functional description.................................................................... 17

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

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

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

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

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

10 During use..................................................................................... 31

11 Maintenance.................................................................................. 32

12 Repairs

.......................................................................................... 36

12.1 Replacing the membrane.................................................... 37

12.2 Repair the diaphragm rupture sensor................................. 39

12.2.1 30 V version..................................................................... 39

12.2.2 EX Version....................................................................... 40

12.3 Valve repair......................................................................... 41

12.3.1 Double ball valves............................................................ 41

12.3.2 Single ball valves............................................................. 42

12.3.3 Plate valves...................................................................... 43

13 Troubleshooting............................................................................. 45

14 Decommissioning and disposal..................................................... 47

14.1 Decommissioning................................................................ 47

14.2 Disposal.............................................................................. 49

15 Technical data............................................................................... 50

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

15.2 Accuracy............................................................................. 51

15.2.1 Reproducibility.................................................................. 51

15.2.2 Metering precision............................................................ 51

15.3 Viscosity.............................................................................. 52

15.4 Wetted materials................................................................. 52

15.5 Ambient conditions.............................................................. 53

15.5.1 Temperatures................................................................... 53

15.5.2 Air humidity...................................................................... 53

15.6 Housing degree of protection.............................................. 54

15.7 Stroke sensor (option), intrinsically safe............................. 54

15.8 Diaphragm rupture sensor.................................................. 54

15.9 Motor data........................................................................... 55

15.10 Filling volumes.................................................................. 56

15.10.1 Gear oil........................................................................... 56

15.11 Sound pressure level........................................................ 56

15.12 Supplement for modified versions..................................... 56

16 Motor data sheet............................................................................ 58

17 EC Declaration of Conformity........................................................ 59

18 Index.............................................................................................. 61

Table of contents

Page 5

1 Identity code

TZMb 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 *

120260, 070430, 040840

120340, 070570, 041100

120430, 070720, 041400

120510, 070860, 041670

120650, 071070, 042100

Material dosing head **

PC PVC

PP Polypropylene

TT PTFE + 25 % carbon

SS Stainless steel

Material of seals / diaphragm

T PTFE

Displacement body material

T Multi-layer safety diaphragm with rupture signalling

Dosing head version

0 no valve spring

1 With valve spring

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

With ProMinent® logo, no frame

Without ProMinent® logo

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

Identity code

Page 6

TZMb Makro/ 5 diaphragm metering pump

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

L 3 ph, 230 V/400 V, 60 Hz, (Exe, Exd)

P 3 ph, 230 V/400 V 50 Hz (Exe, Exd)

R 4 pole, variable speed motor, 230/400 V

V(0) Motor with integral frequency converter

V(2) Motor with integral frequency converter (Exd)

Z Speed controller compl.

4 No motor, with flange 56 C

7 No motor, with flange 120/80

8 No motor, with flange 160/90

9 No motor, with flange 200/90

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

1 Actuator 230 V

2 Actuator 115 V

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 mA

Applications

0 standard

* Figure 1 + 2=back pressure [bar]; figure 3 - 6=pump capacity [l/h]

* Material versions PPT/PCT/TTT max. 10 bar

Identity code

Page 7

2 About this pump

The Makro TZ diaphragm metering pump is fitted as standard with a 0.75 kW wide range AC motor. The stroke length can be adjusted between

0...10 mm. The acrylic resin painted cast housing can be combined with up to 16 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 Makro TZMb is equipped as standard with a multi-layer diaphragm and diaphragm rupture sensor.

The Makro TZ externally mounted metering pump can be combined with the Makro TZ 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 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 with the appropriate nameplate (and the respective EC Declaration of Con‐ formity) 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 declared on the marking must correspond with or be better than the given condi‐ tions 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 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 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

2 Electric power supply 0, 4, 7, 8, 9

Motor version A

3 Electric power supply V

Motor version 2

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.

Qualification of personnel

Safety chapter

Page 10

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

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.

1 Terminal box cover, motor 2 Fan impeller hood 3 Flange cover 4 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.

Information in the event of an emergency

Protective equipment

P_MA_0042_SW

Fig. 2: Isolating protective equipment Makro TZ with add-on power end (shown here for piston version)

Safety chapter

Page 12

Sound pressure level LpA < 70 dB in accordance with EN ISO 20361:2010-10

at maximum stroke length, maximum stroke rate, maximum back pressure (water)

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 shipment:

n Metering pump n Product-specific operating instructions with EC Declaration of Con‐

formity

n "General Operating Instructions ProMinent® Motor-Driven Metering

Pumps and Hydraulic Accessories".

Personnel:

Technical personnel

1. Plug 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 delivery

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

1 2 3

C A 5

P_MA_0023_SW

Fig. 3: Side view (here TZMb H)

A Drive C Liquid end 1 Vent screw 2 Stroke length adjustment wheel 3 Oil inspection window 4 Motor 5 Oil drainage screw

1 2 3

A 5

P_MA_0024_SW

Fig. 4: Side view (here TZMb D)

A Drive C Liquid end 1 Vent screw 2 Stroke length adjustment wheel 3 Oil inspection window 4 Motor 5 Oil drainage screw

Power end, single head

Power end, double head

Overview of equipment, control elements

Page 16

P_MA_0025_SW

Fig. 5: View of the liquid end

1 Discharge valve 2 Dosing head 3 Diaphragm rupture sensor 4 Suction valve 5 Tube nozzle for leakage 6 Protective cover

Liquid end

Overview of equipment, control elements

Page 17

6 Functional description

The metering pump MAKRO TZ is an oscillating, continuously adjustable diaphragm pump. It is driven by an AC standard motor, the power end rotation of which is stepped down by a worm gear (1), transmitted via an adjustable cam (2), a connecting rod (3) and the slide rod (4) and hence converted into an oscillating movement - see . This drive principle ensures an exact, enforced execution of the prestroke and reciprocal stroke, which is particularly advantageous when overcoming large suction lifts or when metering highly viscous media. The adjustment of the stroke length takes place via a finely adjustable change to the eccentricity of the shift ring (TZ) (5) which influences the oscillating stroke movement. This drive principle ensures a harmonic, purely sinusoidal stroke movement for each stroke length adjustment. The harmony of the power end is expressed acousti‐ cally in the minimum running noise.

The power ends of the version TZMb have a maximum stroke length of 10 mm and are designed for operation with mechanically deflected diaphragm dosing heads. The power ends are also available for double-head TZMbD metering pumps.

P_MA_0028_SW

Fig. 6: Cross-section through the power end

1 Worm gear 2 Cam shaft 3 Connecting rod 4 Slide rod 5 Shift ring

The metering diaphragm (2) hermetically shuts off the pump volume of the dosing head (3) from the outside. The suction valve (4) closes as soon as the metering diaphragm (2) is moved in to the dosing head (3) 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 (2) 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.

Power end functional description

Functional description of the diaphragm liquid end

Functional description

Page 18

P_MA_0029_SW

Fig. 7: Cross-section through the liquid end

1 Discharge valve 2 Metering diaphragm 3 Dosing head 4 Suction valve 5 Diaphragm rupture signaller

The diaphragm rupture warning system monitors the leak-tightness of the multi-layer diaphragm. Together with the diaphragm rupture sensor and downstream analysis electronics, the multi-layer diaphragm forms the dia‐ phragm rupture warning system.

The multi-layer diaphragm has an expandable point (4) on its hole circle. If an outer layer of the multi-layer diaphragm breaks, feed chemical pene‐ trates into it under pressure and inflates this expandable point (4). Conse‐ quently the pin (2) of the safety piston (1) presses against the diaphragm (3) of the diaphragm rupture sensor signaller so that a contact signal switches off the pump or triggers an alarm signal (customer installed!).

Moreover, the multi-layer diaphragm prevents feed chemicals escaping in the event of diaphragm rupture.

Diaphragm rupture warning system func‐ tional description

Functional description

Page 19

P_MA_0030_SW

Fig. 8: Diaphragm rupture sensor: Cross-section view and multi-layer diaphragm

1 Safety piston 2 Pin

3 Diaphragm rupture signaller 4 Expandable point

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. 9

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. 10

P_MOZ_0017_SW

Fig. 11

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. 12

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 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. 13.

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. 13: 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.

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 drive housing and the surroundings. This ensure that oil can be pushed from the drive 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"!

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."

Safety notes

Installing a vent screw

Checking the oil level

Checking the direction of rotation

Start up

Page 29

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.

The stroke length can only be adjusted when the machine is stationary, provided the liquid ends are depressurised.

P_MA_0032_SW

Fig. 15: Stroke length adjustment wheel with scale

10 mm = 100 % stroke length (10

rotations)

6.3 mm = 63 % stroke length (6 rota‐ tions and 3 long scale mark‐ ings)

Stroke length adjustment wheel markings:

1 rotation = 10 %

1 long scale marking = 1 %

1 short scale marking = 0.5 %

Fig. 14: Tapping the valve set disc

Adjusting the stroke length

Start up

Page 30

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 %.

The pump can now be released for operation.

Start up

Page 31

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! 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 32

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! 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.

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

Maintenance

Page 33

Under heavy loading (e.g. continuous operation) shorter maintenance intervals are recommended than those given.

Place 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 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 max‐ imum permissible operating pressure!

Check, whether moisture can be detected at the tube nozzle (3); if so a diaphragm rupture has prob‐ ably occurred.

P_MA_0034_SW

(30 Nm)

(25 Nm)

Fig. 16: Liquid end tightening torques

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 dia‐

phragm".

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

Maintenance work

Maintenance

Page 34

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

** under normal loading.

With very unfavourable metering parameters: 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 1.0 l 1004542

Gear oil filling volumes

Types Volume, approx.

All 3.2 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 drive housing.

4. Allow the gear oil to run out of the drive.

5. Screw in the oil drain plug (2) with a new seal.

1 3

P_MA_0037_SW

Fig. 17: Oil change

1 Vent screw 2 Oil drainage screw 3 Oil inspection window

Filling with gear oil:

Changing the gear oil

Maintenance

Page 35

1. Start up the pump.

2. Slowly pour gear oil through the vent screw (1) opening until the upper oil inspection window (3) is nearly covered.

3. Allow the pump to run for a further 1... 2 minutes.

4. Replace the vent screw (1).

Maintenance

Page 36

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! 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.

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

Repairs

Page 37

12.1 Replacing the membrane

WARNING! Observe the safety instructions 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.

P_MA_0038_SW

Fig. 18: Cross-section through the liquid end

1 Dosing head 2 Diaphragm 3 Reinforce plate 4 Screw 5 Leakage hole 6 Slide rod 7 Threaded connection 8 Turret 9 Backplate

Repairs

Page 38

P_MA_0039_SW

Fig. 19: Cross-section through the diaphragm rupture warning system

1 Safety piston 2 Spring 3 Bushing 4 O-ring 5 Expandable point multi-layer diaphragm

8. Undo the safety screw and remove the protective cover (5) from the backplate (6).

9. Unscrew the diaphragm rupture signaller from the dosing head.

10. Unscrew the bushing (3) from the dosing head.

11. Take the safety piston (1) with the spring (2) out of the dosing head.

12. Undo the screws (4) on the reinforce plate.

13. Remove the dosing head (1) with the screws from the turret (8).

14. Unscrew the diaphragm (2) from the slide rod (6) and detach.

15. Clean the sealing surfaces.

16. Smear the thread of the threaded connection of the diaphragm slide rod with a little screw locking paste.

17. Screw the new diaphragm (2) up to the stop on the slide rod (8).

This must be done correctly to ensure the pump meters accu‐ rately.

18. Place the dosing head (1), the reinforce plate (3) and the backplate (9) onto the turret(8).

19. Position the screws

20. Push the safety piston (1) with the spring (2) into the channel of the dosing head.

21. Screw the bushing into the dosing head (O-ring (4)!) and tighten by hand.

22. Screw the diaphragm rupture signaller into the dosing head.

CAUTION! Failure of the diaphragm rupture signalling.

– Ensure the safety piston (1) and its pin can move

freely.

23. Start the pump and tighten the screws crosswise at a 100% stroke.

Tightening torque 30 Nm

24. Position the protective cover (5) on the turret (8) and screw in the safety screws.

Repairs

Page 39

–

Check the tightening torque of the screws after 24-hours' operation.

–

With PP dosing heads, recheck the tightening torque again after three months.

12.2 Repair the diaphragm rupture sensor

12.2.1 30 V version

Check diaphragm rupture sensor

1. When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head.

2. Check for electrical continuity:

3. Using a blunt insulating probe (Ø 2 ... 3 mm, no sharp edges), press into the channel of the diaphragm rupture sensor.

Check that there is no electrical continuity

4. Release the pin again.

Electrical continuity must be re-established.

5. Repeat the test several times.

6. If everything is working correctly, screw the diaphragm rupture sensor into the dosing head with a new seal (1).

7. If not, go to the next section.

Replace separating diaphragm of the diaphragm rupture sensor

1. Disconnect the diaphragm rupture sensor from the power supply.

2. When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head.

3. Grasp the upper section (2) of the diaphragm rupture sensor.

4. Hold the body (5) in place with an open-ended spanner.

5. Unscrew the top of the diaphragm rupture sensor.

6. Clean the soiled parts.

7. Lay the new separating diaphragm (3) with the light side (PTFE) down into the upper section (2).

8. Lay the plate (4) with the uneven side down into the upper section (2).

9. Screw the body (5) into the upper section and screw tighten.

10. Check the diaphragm rupture sensor as described in “Check dia‐ phragm rupture sensor".

11. If the diaphragm rupture sensor does not operate clearly and reli‐ ably, then a new diaphragm rupture sensor must be used without fail.

30 V version

Fig. 20

Repairs

Page 40

12.2.2 EX Version

Check diaphragm rupture sensor

1. When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head.

2. Check that the monitor does not indicate a diaphragm rupture:

3. Using a blunt insulating probe (Ø 2 ... 3 mm, no sharp edges), press into the channel of the diaphragm rupture sensor.

The monitor device must indicate a diaphragm rupture.

4. Release the pin again.

The monitor device must no longer indicate a diaphragm rup‐ ture.

5. Repeat the test several times.

6. If everything is working correctly, screw the diaphragm rupture sensor into the dosing head with a new seal (1).

7. If not, go to the next section.

Replace separating diaphragm of the diaphragm rupture sensor

1. Disconnect the diaphragm rupture sensor from the monitor device.

2. When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head.

3. Grasp the upper section (2) of the diaphragm rupture sensor.

Do not manipulate the lacquer-protected nut.

4. Hold the body (5) in place with an open-ended spanner.

5. Unscrew the top of the diaphragm rupture sensor.

6. Clean the soiled parts.

7. Lay the new separating diaphragm (3) with the light side (PTFE) down into the upper section (2).

8. Place the disc (4) in the upper section (2).

9. Place the spring inside the body (5).

10. Move the body (5) close to the upper section (2).

The spring (6) must sit correctly on the spring seat (3a).

11. Screw the body (5) into the upper section and screw tighten.

12. Connect the diaphragm rupture sensor back to the monitor device.

13. Check the diaphragm rupture sensor as described in “Check dia‐ phragm rupture sensor".

14. If the diaphragm rupture sensor does not operate clearly and reli‐ ably, then a new diaphragm rupture sensor must be used without fail.

EX Version

3 3a

5 6

P_HY_0015_SW

Fig. 21

Repairs

Page 41

12.3 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.

12.3.1 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 - ...

Cleaning a discharge valve

Repairs

Page 42

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).

12.3.2 Single ball valves

1. Screw the valve cap (5) on to the suction side - see Fig. 23.

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.

Fig. 22: Discharge valve (double ball valve).

Cleaning a suction valve

Repairs

Page 43

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

12.3.3 Plate valves

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

1 Compression spring 2 Valve body 3 Valve plate 4 Valve insert 5 Valve body bushing

1. Screw the valve cap (7) on to the suction side - see Fig. 24.

2. Carefully remove the parts from the valve body (4).

3. Replace the worn parts.

4. Clean the remaining parts.

5. Check all parts.

P_MAK_0054_SW

Fig. 23: Cross-section through the single ball valve

P_MA_0040_SW

Fig. 24: Cross-section through the plate valve

Repairs

Page 44

6. 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.

7. Insert the valve plate (5) and the valve insert (6).

8. 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. 25: Inserting the compression spring

V Viewing direction N Spring end position on the nose

Repairs

Page 45

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 46

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

personnel

Pump does not reach high pressure rates.

The valves are dirty or worn.

Repair the valves - see chapter entitled "Repair". Technical

personnel

The feed chemical has particles larger than 3 mm.

Install a suitable filter in the suction line. Technical

personnel

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.

The multi-layer dia‐ phragm is ruptured.

n Replace the multi-layer diaphragm immedi‐

ately - refer to the "Repair" chapter "Changing the diaphragm".

n If necessary replace the separating diaphragm

of the diaphragm rupture sensor - see "Replacing the separating diaphragm, dia‐ phragm rupture sensor" in the chapter "Repair".

n Check the diaphragm rupture warning system

for correct operation.

Technical personnel

No hydraulic oil flows through the tube at the bleed valve

- - - - Immediately switch off the pump and inform cus‐ tomer service.

The power end motor is very hot.

The discharge line is seriously constricted.

n Rectify any constriction of the discharge line. n Have the safety relief valve checked.

Technical personnel

All other faults. Other causes.

Call ProMinent®

or ProMaqua® service.

Tasks

Troubleshooting

Page 47

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 48

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 49

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 50

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!

15.1 Performance data

Type Minimum pump capacity at maximum

back pressure

Maximum stroke rate

Suction lift

Connector size Shipping

weight*

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

120260 12 260 60 72 4 1 1/2 - 25 46/54

120340 12 340 60 96 4 1 1/2 - 25 46/54

120430 12 430 60 120 4 1 1/2 - 25 46/54

120510 12 510 60 144 4 1 1/2 - 25 46/54

120650 12 640 60 180 4 1 1/2 - 25 46/54

70430 7 430 99 72 3.5 2 - 32 50/64

70570 7 570 99 96 3.5 2 - 32 50/64

70720 7 720 99 120 3.5 2 - 32 50/64

70860 7 860 99 144 3.5 2 - 32 50/64

71070 7 1070 99 180 3.5 2 - 32 50/64

40840 4 840 194 72 3 2 1/4 - 40 56/80

41100 4 1100 194 96 3 2 1/4 - 40 56/80

41400 4 1400 194 120 3 2 1/4 - 40 56/80

41670 4 1670 194 144 3 2 1/4 - 40 56/80

42100 4 2100 194 180 3 2 1/4 - 40 56/80

* Material versions PPT, PCT, TTT / SST

The shipping weight is applicable to single head pumps without an add-on power end.

The permissible priming pressure at the suction side is approximately 50% of the max. permitted back pressure

With double head pumps, the maximum permissible back pressure reduces from 7 to 5.5 bar or from 4 to 3 bar.

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

Only for "M - modified" version:

Main pumps with motor 1500 rpm under 50 Hz operation

Technical data

Page 51

Type Minimum pump capacity at maximum

back pressure

Maximum stroke rate

Suction lift

Connector size Shipping

weight*

psi l/h gph Strokes/min m WS G-DN kg

120260 174 309 81.8 86 4 1 1/2 - 25 46/54

120340 174 414 109.5 115 4 1 1/2 - 25 46/54

120430 174 518 137 144 4 1 1/2 - 25 46/54

120510 174 622 164.5 173 4 1 1/2 - 25 46/54

120650 174 – – – 4 1 1/2 - 25 46/54

70430 100 511 135 86 3.5 2 - 32 50/64

70570 100 683 180 115 3.5 2 - 32 50/64

70720 100 855 226 144 3.5 2 - 32 50/64

70860 100 1028 272 173 3.5 2 - 32 50/64

71070 100 – – – 3.5 2 - 32 50/64

40840 58 1001 264 86 3 2 1/4 - 40 56/80

41100 58 1339 354 115 3 2 1/4 - 40 56/80

41400 58 1676 443 144 3 2 1/4 - 40 56/80

41670 58 2014 532 173 3 2 1/4 - 40 56/80

42100 58 – – – 3 2 1/4 - 40 56/80

* Material versions PPT, PCT, TTT / SST

The permissible priming pressure at the suction side is approximately 50% of the max. permitted back pressure

With double head pumps, the maximum permissible back pressure reduces from 101.5 to 80 psi or from 58 to 43.5 psi.

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 ±2 % *

* for measurements taken under constant conditions, minimum 30 % stroke rate and water at 20 °C - when installed correctly, p< 1 bar

15.2.2 Metering precision

Data Value Unit

Metering precision ±1 % *

Main pumps with motor 1800 rpm under 60 Hz operation

Technical data

Page 52

* at maximum stroke length and maximum back pressure

15.3 Viscosity

The liquid ends are generally suitable for the following viscosity ranges:

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

with DN 25 ball valve

Material version Liquid end Suction/dis‐

charge connector

Seals Valve balls Valve seat

PPT Polypropylene PVDF PTFE Borosilicate glass PTFE

PCT PVC PVDF PTFE Borosilicate glass PTFE

TTT PTFE with carbon PTFE with

carbon

PTFE Ceramic PTFE

SST Stainless steel

1.4571/1.4404

Stainless steel

1.4571/1.4404

PTFE Stainless steel

1.4401

PTFE

HCT Hastelloy C4 Hastelloy C4 PTFE Ceramic PTFE

with DN 32 / DN 40 plate valves**

Material version Liquid end Suction/dis‐

charge connector

Seals Valve plates / valve

spring

Valve seat

PPT Polypropylene Polypropylene PTFE Ceramic / Hast. C +

CTFE**

PTFE

PCT PVC PVC PTFE Ceramic / Hast. C +

CTFE**

PTFE

TTT PTFE with carbon PTFE with

carbon

PTFE Ceramic / Hast. C +

CTFE**

PTFE

SST Stainless steel

1.4571/

1.4404

Stainless steel

1.4571/1.4404

PTFE Ceramic / Hast. C +

CTFE**

PTFE

HCT Hastelloy C4 Hastelloy C4 PTFE Hast. C PTFE

Patented, vacuum packed, multi-layer diaphragm.

** The valve spring is coated with CTFE (similar to PTFE)

Technical data

Page 53

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

45 °C

Max. temperature for 15 min at max. 2 bar 60 °C

Minimum temperature -10 °C

Data Value Unit

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

60 °C

Max. temperature for 15 min at max. 2 bar 100 °C

Minimum temperature -10 °C

Data Value Unit

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

90 °C

Max. temperature for 15 min at max. 2 bar 120 °C

Minimum temperature -10 °C

Data Value Unit

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

90 °C

Max. temperature for 15 min at max. 2 bar 120 °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.

PC liquid end

PP liquid end

TT liquid end

SST liquid end

Technical data

Page 54

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 Diaphragm rupture sensor

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

Contact loading, max.

at voltage Maximum current

30 V DC 1 A

The contact is an opener.

The contact is an potential-free.

Stroke sensor (option), intrinsically safe

Namur sensor (Specified for EX zones)

Contact (standard)

Technical data

Page 55

–

For safety reasons we recommend connecting to a pro‐ tective low voltage, e.g. in accordance with EN 60335-1 (SELV ).

–

The cable can be poled as required.

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 +

The monitor / power supply must be able to evaluate the cur‐ rent variations to indicate a diaphragm rupture!

15.9 Motor data

Motor data Makro TZ (TZMb)

Identity code specification

Phase, protection Rated voltage Mains supply fre‐

quency

Rated output Remarks

S 3 ph, IP 55 220-240 V/

380-420 V

50 Hz 0.75 kW

250-280 V/

440-480 V

60 Hz 0.75 kW

L1 3 ph, II2GEEX‐

eIIT3

220-240 V/

380-420 V

50 Hz 0.75 kW

L2 3 ph, II2GEEX‐

dIICT4

220-240 V/

380-420 V

50 Hz 0.75 kW with PTC, speed

control range 1:5

P1 3 ph, II2GEEX‐

eIIT3

250-280 V/

440-480 V

60 Hz 0.75 kW

P2 3 ph, II2GEEX‐

dIICT4

250-280 V/

440-480 V

60 Hz 0.75 kW with PTC, speed

control range 1:5

R 3 ph, IP 55 230 V/400 V 50/60 Hz 1.5 kW with PTC, speed

control range 1:20

with external fan

1 ph 230 V; 50/60

Namur sensor (Specified for EX zones)

Technical data

Page 56

Identity code specification

Phase, protection Rated voltage Mains supply fre‐

quency

Rated output Remarks

V0 1 ph, IP 55 400 V ±10 % 50/60 Hz 1.1 kW Variable speed

motor with inte‐

grated frequency

converter

V2 3 ph, II2GEEX‐

dIICT4

400 V ±10 % 50/60 Hz 1.5 kW EX variable

speed motor with

integrated fre‐

quency converter.

Motor data sheets can be requested for more information.

15.10 Filling volumes

15.10.1 Gear oil

Gear oil

Gear oil Supplied quantity Part no.

Mobilgear 634 VG 460 1.0 l 1004542

Gear oil filling volumes

Types Volume, approx.

All 3.2 l

15.11 Sound pressure level

Sound pressure level LpA < 70 dB in accordance with EN ISO 20361:2010-10

at maximum stroke length, maximum stroke rate, maximum back pressure (water)

15.12 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.

Sound pressure level

Technical data

motor

Technical data

Page 57

With a modified version, it is absolutely necessary to specify the details of the serial number requesting and ordering the spare and replacement parts.

Spare parts

Technical data

Page 58

16 Motor data sheet

Bestell Nr. 1039212 Hersteller order no. / no. de commade producer / producteur

Motor- Typ NF80/4H-13+E2 Leistungsfaktor

motor type power factor

type du moteur facteur de puissance

Maschinenart 3-Ph. Motor Wirkungsgrad

type of machine efficiency

désignation rendement

Schutzart IP55 Bemessungsfrequenz

degree of protection rated frequency

degré de protection fréquence nominale

Bauform IMB14 Bemessungsdrehzahl 1440 U/min

mounting rated speed 1750 rpm

construction vitesse nominale t/mn

Bemessungsleistung 0,75 kW Wärmeklasse

rated output temperature class

puissance nominale class d'isolement

Bemessungsspannung

 / D

Anzugsstrom 7,4 fach

rated voltage 400/230 +/-10% V starting current fold

tension nominale 440/254 +10 -15% V courant de démarrage fois

Bemessungsstrom 1,71 / 2,96 A Anzugsmoment 3,1 fach

rated current 1,54 / 2,67 A starting torque fold

courant nominale couple de démarrage fois

Geprüft nach

EN 60034

Kippmoment 3,6 fach

tested in acc. with pull-out torque fold

contrôlé selon couple de décrochage fois

ATEX Nr. Umgebungstemperatur

ambient temperature

température ambiante

Ex-Schutzklasse Schaltung

ex-protective system connection

branchement

Drehzahlregelbereich

speed ajustment range

Anmerkung * auf Anfrage beim Hersteller

comments * upon request at manufacturer

observation * sur demande auprès du producteur

ProMinent

Pumpentyp

ProMinent Dosiertechnik GmbH . 69123 Heidelberg . Germany Nr./No. MD-1039212

Datum/Date Jul 2011

Die Daten entsprechen den Angaben der Motorenhersteller. Kenndaten funktionsgleicher Motoren anderer Hersteller ändern sich nur unwesentlich. Angaben ohne Gewähr. The data correspond to the details given by the motor manufacturers. Ratings of motors with the same functions made by other producers show insignificant changes only. This information is supplied without liability. Les données techniques correspondent au descriptif du fabricant des moteurs. Les données techniques des moteurs similaires chez d’ autres fabricants varient très peu. Données sont d’ ordre général.

TZMaH _ _ _ _ _ _ _ _ _ _ _ _ _ S _ _ _ _

TZMbH _ _ _ _ _ _ _ _ _ _ _ _ _ S _ _ _ _

Motor Datenblatt / Motor data sheet / Fiche technique pour moteur

40°C

73%

76%

50 Hz

0,77

ATB

Mat.Nr. 570330

0,78F / D

60 Hz

Motor data sheet

Page 59

17 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 TZ series

Product type:

TZMa..., TZKa..., TZHa..., TZMb...

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 60034-1/5/6/9, EN 60204-1, EN 61000-6-1/2/3/4

Technical documents have been compiled by documentation

specialists:

Norbert Berger Im Schuhmachergewann 5-11 DE-69123 Heidelberg

Date / Manufacturer's signature: 05/10/2011

Details of the signatory: Joachim Schall, Head of Development

For pumps without explosion protection:

EC Declaration of Conformity

Page 60

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 61

18 Index

Accuracy....................................................................... 51

Air humidity................................................................... 53

Ambient conditions........................................................ 53

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

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

Climate.......................................................................... 53

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

Contact.......................................................................... 54

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

Decommissioning.......................................................... 47

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

Diaphragm..................................................................... 17

Diaphragm rupture sensor............................................ 54

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

Discharge valve............................................................. 17

Disposal........................................................................ 49

Dosing head.................................................................. 17

During use..................................................................... 31

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

Emptying the liquid end................................................. 48

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

Functional description................................................... 17

Gear oil.......................................................................... 56

Hydraulic oil................................................................... 56

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

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

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

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

Liquid end...................................................................... 17

Maintenance.................................................................. 32

Materials........................................................................ 52

Metering precision......................................................... 51

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

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

Motor data sheet........................................................... 58

Namur sensor.......................................................... 54,

Oil.................................................................................. 56

Protection against contact and humidity....................... 54

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

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

Repairs.......................................................................... 36

Reproducibility............................................................... 51

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

Scope of delivery .......................................................... 13

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

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

Spare parts.................................................................... 57

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

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

Storage and transport temperature............................... 53

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

Stroke sensor................................................................ 54

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

Suction valve................................................................. 17

Technical data......................................................... 50, 56

Temperatures................................................................ 53

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

Troubleshooting............................................................ 45

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

Valve repair................................................................... 41

Viscosity........................................................................ 52

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

Wetted materials........................................................... 52

Index

ProMinent TZ, TZMb, Makro TZ, Makro TZMb Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual