ProMinent Alpha Betriebsanleitung

ProMinent®

General Operating Instructions

ProMinent®Motor-Driven Metering Pumps

and Hydraulic Accessories

Hydro

Two sets of operating instructions are necessary to ensure safe operation of the metering pumps corresponding to their

intended purpose: The product-specific operating instructions (e.g. for Sigma) and the general operating instructions

for ProMinent® motor-driven metering pumps.

Both are only applicable in conjunction with each other.

Please completely read through these operating instructions first! Do not discard!

The warranty shall be invalidated by damage caused by operating errors!

Part No. 987702 ProMinent Dosiertechnik GmbH • 69123 Heidelberg • Germany BA MOZ 013 07/03 GB

Meta

Makro TZ

Sigma

alpha Vario

Makro/ 5

ProMinent®

Page 2

Imprint

Imprint:

General Operating Instructions for

ProMinent® Motor-Driven Metering Pumps

Address:

ProMinent Dosiertechnik GmbH

Im Schuhmachergewann 5-11

69123 Heidelberg

Germany

[email protected]

www.prominent.de

Subject to technical modifications.

ProMinent®

ProMinent®Page 3

Table of Contents

User Information ................................................................................................................................................................................... 4

1 Application of Motor-Driven Metering Pumps ............................................................................................... 5

2 Safety Notes ................................................................................................................................................................................... 5

2.1 Summary of additional safety instructions for the EX version of the pump

(in accordance with ATEX) ....................................................................................................................................... 6

2.1.1 Additional remarks for the application for metering inflammable media ........................... 7

2.1.2 Safety devices ................................................................................................................................................................... 7

2.1.3 EC conformity declaration / certificates ....................................................................................................... 7

3 Mounting ............................................................................................................................................................................................ 8

4 Installation, hydraulic ............................................................................................................................................................ 9

4.1 Standard Installation .................................................................................................................................................... 10

4.2 Notes on Installation on Intake Side ............................................................................................................... 11

4.3 Notes on Installation on Delivery Side ........................................................................................................... 12

4.4 How not to install pumps ......................................................................................................................................... 14

4.5 Special Notes on Installation ................................................................................................................................. 15

5 Installation, electrical ............................................................................................................................................................ 17

5.1 Motor ........................................................................................................................................................................................ 17

5.2 Other electrical components in explosive zones ) ............................................................................... 19

6 Start-Up .............................................................................................................................................................................................. 19

7 Maintenance ................................................................................................................................................................................... 20

8 Troubleshooting .......................................................................................................................................................................... 21

9 Hydraulic Accessories .......................................................................................................................................................... 22

9.1 Overview and Notes on Accessories .............................................................................................................. 22

9.2 Pressure Control/Safety Overflow Valve ...................................................................................................... 24

9.3 Pulsation Dampers ........................................................................................................................................................ 25

Appendix ............................................................................................................................................................................................ 27

Warranty Application for Metering Pumps and Accessories .................................................................... 27

Data for Calculating Metering Line ................................................................................................................................. 28

Installing Drawing ......................................................................................................................................................................... 29

ProMinent®

Page 4

User Information

Please read through the following user guidelines. Familiarity with these points ensures optimum

use of the operating instructions.

Key points in the text are indicated as follows:

• Enumerated points,

SHints

Working Guidelines:

NOTE

Notes on operation.

Safety Guidelines:

WARNING

There is a danger to life or the risk of serious injury if the notes on safety are disregarded!

CAUTION

There is a danger of slight injury and damage to property if the notes on safety are

disregarded!

IMPORTANT

There is a danger of damage to property if the notes on safety are disregarded.

These general operating instructions for motor-driven metering pumps and hydraulic assemblies

apply only in conjunction with the product-related pump operating instructions for e.g. alpha,

Vario, Meta, Sigma, Hydro, Makro/ 5 and Makro TZ motor-driven metering pumps.

User Information

ProMinent®

ProMinent®Page 5

Application of Motor-Driven Metering Pumps / Safety Notes

1 Application of Motor-Driven Metering Pumps

ProMinent ®motor-driven metering pumps and accessories are to be used solely for the purpose

of metering liquid media!

In explosion-threatened workplaces in zone 1, device category II 2G of explosion group II C the

pump may not be operated without the corresponding rating plate (and the corresponding EC

conformity declaration) for pumps for explosion-threatened workplaces in accordance with

guideline 94/9/EC of the European guidelines. The explosion group, category and type of

protection shown on the marking must correspond to or exceed the conditions prevailing in the

intended area of application.

All other uses or modifications are prohibited!

Pumps may never be operated in explosion-threatened workplaces without a corresponding

rating plate (and the corresponding EC conformity declaration) for pumps for explosion-

threatened workplaces.

ProMinent® motor-driven metering pumps and accessories are not to be used for the purpose of

metering gasses and solids!

Refer to the relevant product-related operating instructions and product cataloque for the

technical data of the type of motor-driven metering pump used!

Decisive criteria relating to the intended use of the pumps are

•EX-protection of the pump

•Resistance of parts coming in contact with metered medium

•Pressure and temperature of metered medium

2 Safety Notes

WARNING

• Immediately switch off the pump in case of emergency! Use the power switch on

the pump or an emergency switch in your immediate operating environment!

• Pumps for radioactive medium must not be shipped through standard channels!

• If using the metering pump for metering flammable media for Europe e.g. the European

operator’s guideline 99/92/EC* (ATEX 137**), (in Germany implemented via the new

operating safety ordinance (Official Federal Gazette for 2002, Part 1, No. 70, issued

in Bonn 2.10.2002) and the German dangerous chemicals ordinance))!

* previously Ex Vo, Vb F

** previously ATEX118A

• Observe applicable national regulations for installation abroad!

CAUTION

• Do not obstruct or block access areas!

Pumps must be accessible at all times to facilitate operation and maintenance.

• Only specially trained and authorized persons are permitted to carry out maintenance

and repairs on metering pumps and their periphery!

• Always depressurize the liquid end first before carrying out any work on the pump!

• If hazardous or unknown metering media are used, discharge and flush the liquid end

before carrying out any work on the pump!

• Observe safety specifications for liquid metered media! Corresponding protection and

emergency measures must be implemented prior to initial operation.

• Always wear protective clothing (safety goggles, gloves,...) when handling hazardous or

unknown liquid media! This applies particularly when working on the liquid end!

• Do not use parts which have not been tested and approved by ProMinent for assembly of

ProMinent®motor-driven metering pumps since this can result in damage to persons and

property, for which no liability will be accepted!

• Install safety devices in the system, e.g. overflow valves!

ProMinent®motor-driven pumps are oscillating displacement pumps. Irrespective of

whether the delivery line is closed, e.g. by closing off the delivery line or by closing a valve,

the pressure produced by the pump can reach a multiple of the permissible working

pressure of the system or of the metering pump. This can result in lines bursting with

dangerous consequences particularly in the presence of aggressive or toxic media!

• Piston pumps are always equipped with a dry-run protection facility to avoid the pump

ProMinent®

Page 6

Safety Notes

packing running dry as this may cause overheating and thus premature wear.

IMPORTANT

• Based on state-of-the-art technology, the manufacturer carefully selects the materials

for parts coming into contact with the medium as specified by the customer.

The manufacturer shall not be liable for any damage caused by metering other media

or media which has been modified with regard to its properties (concentration, density,

temperature, additives, impurities etc.).

• Avoid over-feed with positive pressure difference (at least 1 bar) between discharge

and suction sides.

• Only specially instructed personnel are permitted to operate the metering pump.

The operator must ensure by applying appropriate accident prevention measures that

operating personnel are not endangered under given operating conditions (pressure,

temperature, aggressivity etc.).

2.1 Summary of additional safety instructions for the EX version of the pump

(in accordance with ATEX)

WARNING

• In explosion-threatened workplaces in zone 1, device category II 2G of explosion

group II C the pump may not be operated without the corresponding rating plate (and

the corresponding EC conformity declaration) for pumps for explosion-threatened

workplaces in accordance with guideline 94/9/EC of the European guidelines.

• All other uses or modifications are prohibited!

• Pumps may never be operated in explosion-threatened workplaces without a corres-

ponding rating plate (and the corresponding EC conformity declaration) for pumps for

explosion-threatened workplaces.

• Installations in potentially explosive atmospheres must be inspected by a „accredited

qualified“ person. This applies in particular also for intrinsically safe electrical circuits.

• Observe all relevant standards e.g. DIN EN 60079, DIN EN 50020, DIN VDE 0165 and/

or DIN VDE 0118 “Installing electrical equipment in explosion-threatened areas”!

• When installing the metering pump, observe the directives for the installation of

devices in explosion-threatened areas, e.g. for Europe the European operator’s

guideline 99/92/EC (ATEX137)*, (in Germany implemented via the new operating safety

ordinance (Official Federal Gazette for 2002, Part 1, No. 70, issued in Bonn 2.10.2002))!

* previously ElexV

• Read the documentation provided for the individual electrical components.

• On principle, metering pumps in potentially explosive atmospheres must be equipped

with a safety overflow valve at the outlet side of the pump (serves as protection against

overheating due to overload and against sparks produced by shock due to overload

which has led to the breakage drive parts.)

• Piston metering pumps, used in temperature class T4, must be equipped with a flow

control at the outlet side (serves as protection against excess temperature due to dry-

running.)

• For metering pumps with hydraulically actuated diaphragm, the pump must also be

provided with a flow control, if used in temperature class T4. (Protection against

improper heating in case of permanent operation via the internal overflow valve.)

• Drive motors must be secured by an appropriate motor protection switch. A motor

protection approved for this application must be used for Ex”e”-motors. (Protection

against heating due to overload)

• Observe also all relevant standards e.g. DIN EN 60079-10/14 and DIN EN 50020

for installations in explosion-threatened areas!

• Note all national directives which apply to the installation!

• The proper general function, in particular of the drive, must be safeguarded by regular

inspections (leakages, noises, temperatures, possible discoloration due to excess

temperatures....).

• Use original spare parts should exchange become necessary!

ProMinent®

ProMinent®Page 7

Safety Notes

• Wear parts (diaphragms, bearings etc.) of metering pumps used in potentially explosive

atmospheres must be replaced after having completed 90% of their nominal product

life.

• The lubricant supply must be regularly checked for lubricated pumps, for instance by

checking the fill level, visual inspection for leakages etc.

The pump must never be allowed to overheat due to lack of oil!

• Examine the pump for oil leaks and remedy the cause!

The pump must never be allowed to overheat due to lack of oil!

• Check that the pressure relief valve downstream from the pump is functioning

correctly!

The pressure relief valve must prevent the gearbox from being overloaded and

overheating in explosion-threatened workplaces!

• When cleaning plastic parts, attention must be paid to not generating any electrostatic

charge by rubbing excessively. - see danger sign.

• These measures are the minimum protection measures specified by ProMinent.

Should the user know about any further risks, it is his duty to eliminate them by taking

corresponding measures.

2.1.1 Additional remarks for the application for metering inflammable media

• Inflammable media may only be lifted with stainless steel liquid ends. - For exceptional

cases, where this is not possible, also PTFE with carbon may be used, our versions TT_ are

made of conductive plastics. In this case, special attention must be paid by the user due to

the lower mechanical stability.

• Piston metering pumps must not be used for inflammable media. - Suitable additional

control measures must be taken for safeguarding the necessary safety where the application

of piston pumps cannot be avoided: flow control + control of leaking pistons, as well as an

additional temperature control at the liquid end in case of media used having critical frictional

behaviour.

• Hydraulic diaphragm pumps are well suited, however, version with diaphragm rupture

monitor Ex”i” and a flow control is obligatory.

• Diaphragm pumps with mechanically actuated diaphragm, at present MTMa.., TZMa..,

Sigma’s S1Ba...., S2BaHM..., S3Ba: no additional measures necessary, however, version with

diaphragm rupture indicator, version Ex”i”*, must be used on principle.

• For all metering pumps for metering inflammable media applies: starting up and emptying

only supervised by a competent person.

WARNING

• If using the metering pump for metering flammable media for Europe e.g. the European

operator’s guideline 99/92/EC* (ATEX 137**), (in Germany implemented via the new

operating safety ordinance (Official Federal Gazette for 2002, Part 1, No. 70, issued in

Bonn 2.10.2002) and the German dangerous chemicals ordinance))!

* previously Ex Vo, Vb F

** previously ATEX118A

• When installing the metering pump, observe the directives for the installation of

devices in explosion-threatened areas, e.g. for Europe the European operator’s guide-

line 99/92/EC (ATEX 137)*, (in Germany implemented via the new operating safety

ordinance (Official Federal Gazette for 2002, Part 1, No. 70, issued in Bonn 2.10.2002))!

* previously ElexV

2.1.2 Safety devices

The following safety notice must be

affixed to the the pump

(PP, PC and PV liquid ends, acrylic glass cover, ...)

2.1.3 EC conformity declaration / certificates

The EC conformity declaration for pumps for explosion-threatened workplaces is supplied with

the pump (the copy of the EC conformity declaration for the pump itself does not apply to

pumps designed for explosion-threatened workplaces).

The EC conformity declarations, the EC series prototype test reports and the operating manuals

for the individual components are also supplied with the pump.

Because of electrostatical flamable

danger , use damp cloth only to wip

off plastic parts !

!! ATTENTION !!

ProMinent®

Page 8

3 Mounting

IMPORTANT

• Mount the metering pump upright with the feet on a horizontal base. Refer to the

corresponding data sheets for the dimensions (m) of the securing holes.

DNm

fig..1

• The frame or the foundation for mounting the pump must be designed such as to

ensure the unit is free of vibration and stable.

fig. 2

• Install pump at convenient operating level and mount such that the valves are vertical:

head valve always at top and intake valve always at bottom.

fig. 3

Head valve

Intake valve

Liquid end

• Ensure adequate clearance (f) in area of liquid end as well as intake valve and head

valve so that these parts can be easily removed if required.

fig. 4

• Set up the pump such that the stroke length adjustment, indicator scale A, oil level

indicator, oil filler and drain plugs as well as the valves are easily accessible for

servicing.

fig. 5

DN pipe

DN pump valve

•

Ensure nominal diameters of pipes and installed fittings are the same size or larger

than the nominal diameters of the pump valves (intake and head valves).

Mounting

ProMinent®

ProMinent®Page 9

4 Installation, hydraulic

WARNING

• EX-pump only: when installing the metering pump, observe the directives for the

installation of devices in explosion-threatened areas, e.g. for Europe the European

operator’s guideline 99/92/EC (ATEX 137)*, (in Germany implemented via the new

operating safety ordinance (Official Federal Gazette for 2002, Part 1, No. 70,

issued in Bonn 2.10.2002))!

* previously ElexV

• EX-pump only:

also observe relevant standards e.g. DIN EN 60079-10/14 and DIN EN 50020 for

installations in explosion-threatened areas!

• Note all national directives which apply to the installation!

IMPORTANT

• In order to check pressure conditions in the piping system, it is recommended to

provide connection facilities for pressure gauges in the vicinity of the intake and

delivery connection piece.

• Connect pipes to the pump such that there is no stress or strain whatsoever acting

on the pump, such as offset, weight or expansion of the pipe. Only use a flexible pipe

adapter for connecting steel/stainless steel pipes to plastic pump housings.

fig. 6

Pressure

gauge sleeve

Pipe

(delivery line)

Pressure

control valve

Intake valve

Pipe

(intake line)

Pressure

gauge sleeve

Installation, hydraulic

fig. 7

Steel/stainless steel

pipe

Flexible pipe adapter

Plastic connecting piece

ProMinent®

Page 10

Installation, hydraulic

4.1 Standard Installation

Delivery line

Metering tank

Diagram 8

Metering pump Dirt trap

Metering valve Solenoid valve

Adjustable pressure control valve

Pulsation damper

(Overflow valve)

Foot valve with sieve filter Float valve

Pressure gauge Filler device

Ball check valve Siphon vessel

Shut-off cock valve

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