ProMinent Makro TZ Bedienungsanleitung

Plunger metering pump

Makro TZ, TZKa

Operating instructions

P_MA_0019_SW

Original operating instructions (2006/42/EC)Part no. 985749 BA MA 017 12/18 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.

The latest version of the operating instructions are available on our homepage.

Read the following supplementary information in its entirety! Should you

already know this information, you will benefit more from referring to the

operating instructions.

The following are highlighted separately in the document:

nEnumerated lists

Operating guidelines

ðOutcome of the operating guidelines

- see (reference)

Information

This provides important information relating to the cor‐

rect operation of the unit or is intended to make your

work easier.

Safety Information

Safety information is identified by pictograms - see Safety Chapter.

Refer to the precise designation of suppliers' components in the "Technical

Data" chapter for ease of finding the relevant information.

These operating instructions conform to current EU regulations applicable

at the time of publication.

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 unit

type and material versions to be clearly identified.

The nameplate stuck on the cover page is identical to the pump supplied

so that there is a clear link between the operating instructions and the

pump.

Supplementary information

Fig. 1: Please read!

Information in supplier instructions

Validity

State the identity code and serial number

EX pumps only

Supplemental directives

Table of contents

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

2Safety chapter................................................................................. 7

2.1 Safety information for ATEX designs.................................... 13

2.2 Explanation of the ATEX label.............................................. 20

3 Storage, transport and unpacking................................................. 23

4 Overview of equipment, control elements..................................... 24

5Functional description.................................................................... 26

6 Assembly....................................................................................... 27

7 Installation..................................................................................... 30

7.1 Installation, hydraulic............................................................. 30

7.2 Basic installation notes.......................................................... 33

7.3 Installation, electrical............................................................. 34

8 Start up and operation................................................................... 38

8.1 Bleeding the liquid end.......................................................... 41

8.2 Calibrate the stroke control drive (optional).......................... 41

9 Maintenance.................................................................................. 42

10 Repairs.......................................................................................... 47

10.1 Changing the plunger.......................................................... 48

10.2 Valve repair......................................................................... 52

10.2.1 Double ball valves............................................................ 53

10.2.2 Plate valves...................................................................... 54

10.3 Replace power end bearings.............................................. 55

11 Troubleshooting............................................................................. 56

12 Decommissioning and disposal..................................................... 59

12.1 Decommissioning................................................................ 59

12.2 Disposal.............................................................................. 60

13 Technical data............................................................................... 62

13.1 Performance data................................................................ 63

13.2 Precision............................................................................. 66

13.2.1 Reproducibility.................................................................. 66

13.2.2 Dosing precision............................................................... 66

13.3 Viscosity.............................................................................. 66

13.4 Wetted materials................................................................. 67

13.5 Ambient conditions.............................................................. 67

13.5.1 Temperatures................................................................... 67

13.5.2 Air humidity...................................................................... 68

13.6 Housing degree of protection.............................................. 68

13.7 Installation height................................................................ 68

13.8 Motor data........................................................................... 68

13.9 Stroke sensor (optional), intrinsically safe........................... 69

13.10 Filling volumes.................................................................. 70

13.10.1 Gear oil........................................................................... 70

13.11 Sound pressure level........................................................ 70

13.12 Supplement for modified versions..................................... 70

14 Dimensional Drawings................................................................... 71

15 Earthing/equipotential bonding drawings for TZKa........................ 74

16 Motor data sheet............................................................................ 76

17 Diagrams for adjusting the capacity.............................................. 77

18 Spare parts.................................................................................... 78

18.1 Spare parts.......................................................................... 78

Table of contents

18.2 Other material..................................................................... 78

18.2.1 Gear oil............................................................................. 78

19 Declaration of Conformity for Machinery....................................... 79

20 ATEX Declaration of Conformity.................................................... 80

21 Declaration of Incorporation.......................................................... 82

22 ATEX Declaration of Incorporation................................................ 83

Table of contents

1 Identity code

TZKa Makro TZ 20 plunger 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

_ _ _ _ _ Performance data at maximum back pressure and type: refer to nameplate on the pump

housing

Dosing head material

SS Stainless steel

Seal material

T PTFE

Displacement body material

S Stainless steel plunger, chromium dioxide coated

Dosing head design

0 No valve spring

1 with valve spring

Hydraulic connector

0 Standard connection

4 Union nut and SS insert

Design

0With ProMinent® logo, no frame

2Without ProMinent® logo, no frame

AWith ProMinent® logo, with single frame

BWith ProMinent® logo, with double frame

CWith ProMinent® logo, with triple frame

Mmodified* * order-related design, refer to order

paperwork for pump features

Electric power supply

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

R 4-pin speed stroke control motor, 230/400 V

V(0) Variable speed stroke control motor with integrated

frequency converter

Z Speed control complete

P 3-phase, 230 V/400 V, 60 Hz, (Exe, Exd)

L 3-phase, 230 V/400 V 50 Hz (Exe, Exd)

V(2) Variable speed stroke control motor with integrated

frequency converter (Exd)

4 No motor, with flange 56 C

7 without motor, with flange 120/80

Identity code

TZKa Makro TZ 20 plunger metering pump

8 without motor, with flange 160/90

0 No motor, add-on power end

Degree of protection

0 IP 55 (standard) ISO class F

1 Exe design ATEX-T3 *

2 Exd design ATEX-T4 *

A ATEX design of power end *

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

* ATEX specification - refer to the nameplate on the pump, corresponding

EU Declaration of Conformity for ATEX Machinery and

Ä Chapter 2.2

‘Explanation of the ATEX label’ on page 20

Identity code

2 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 – hot surface.

Warning – danger zone.

nOnly use the pump to meter liquid feed chemicals.

nThe pump is only approved for flammable feed chemicals if the oper‐

ator takes appropriate safety measures.

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

and started up in accordance with the technical data and specifica‐

tions contained in the operating instructions.

nObserve the general limitations with regard to viscosity limits, chem‐

ical resistance and density - see also the ProMinent Resistance List

(in the Product Catalogue or at www.prominent.com)!

nAll other uses or modifications are prohibited.

nThe pump is not intended for the metering of gaseous media and

solids.

nThe pump is not intended for the metering of explosive substances

and explosive mixtures.

nThe pump is not intended for unprotected use outdoors.

nThe pump is only intended for industrial use.

nOnly allow trained and authorised personnel to operate the pump -

see the following table.

nOther people may only access the pump if they have been informed

about the dangers.

nYou have a responsibility to adhere to the information contained in the

operating instructions at the different phases of the unit's service life.

Identification of safety notes

Warning signs denoting different types of

danger

Intended use

Safety chapter

nYou have a responsibility to observe the information contained in the

operating instructions for the auxiliary equipment at the different

phases of their respective service lives.

nATEX designs only: Refer to the chapter

Ä Chapter 2.1 ‘Safety infor‐

mation for ATEX designs’ on page 13

Task Qualification

Storage, transport, unpacking Instructed person

Assembly Technical personnel, service

Planning the hydraulic installation Qualified personnel who have a

thorough knowledge of oscillating

metering pumps

Hydraulic installation Technical personnel, service

Electrical installation Electrical technician,

Start up Technical personnel

Operation Instructed person

Maintenance, repair Technical personnel, service

Decommissioning, disposal Technical personnel, service

Troubleshooting Qualified person, electrical techni‐

cian, instructed person, service -

depending on the requirement

Explanation of the table:

Trained, qualified personnel

A trained, qualified employee is deemed to be a person who is able to

assess the tasks assigned to him and recognise possible hazards based

on his training, knowledge and experience, as well as knowledge of perti‐

nent regulations. A trained, qualified employee must be able to perform

the tasks assigned to him/her independently with the assistance of

drawing documentation and parts lists. The assessment of a person's

technical training can also be based on several years of work in the rele‐

vant field.

Electrical technician

An electrical technician is able to complete work on electrical systems and

recognise and avoid possible dangers independently based on his tech‐

nical training and experience as well as knowledge of pertinent standards

and regulations. An electrical technician must be able to perform the tasks

assigned to him/her independently with the assistance of drawing docu‐

mentation, parts lists, terminal and circuit diagrams. The electrical techni‐

cian must be specifically trained for the working environment in which the

electrical technician is employed and be conversant with the relevant

standards and regulations.

Electrical technician with knowledge of ATEX explosion protection

An electrical technician with an additional explosion protection qualification

should be specifically trained for the field of work in which he is employed

and be familiar with the relevant standards and regulations. An electrical

technician with an additional explosion protection qualification can work on

electrical systems and independently recognise and avoid possible dan‐

gers based on his technical training and experience.

The electrical technician with an additional explosion protection qualifica‐

tion is familiar with all the standards and regulations applicable to explo‐

sion protection, in particular, but not exclusively, with all parts of EN 60079

[Electrical equipment for areas at risk of a gas explosion].

An electrical technician with an additional explosion protection qualification

must comply with the provisions of the applicable statutory directives on

accident prevention.

Qualification of personnel

Safety chapter

Recognised competent person

To carry out explosion hazard inspections the competent person must

have:

ncompleted a relevant course of study or

nhave a comparable technical qualification or

nanother technical qualification combined with long-term experience of

safety technology.

Make sure that the person is familiar with the relevant body of standards

and regulations and has worked in the field for at least one year. The

person needs to have opportunities for an exchange of experiences.

Specific requirements are placed on competent persons who perform tests

on repaired devices/parts. They must be recognised by the responsible

authorities (e.g., district council) in this respect.

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.

Trained user

A trained user is a person who fulfils the requirements demanded of an

instructed person and who has also received additional training specific to

the system from ProMinent or another authorised distribution partner.

Service

Service refers to service technicians, who have received proven training

and have been authorised by ProMinent or ProMaqua to work on the

system.

CAUTION!

These operating instructions include notes and extracts

from German regulations relating to the operator's scope

of responsibility. This information does not discharge the

operator from his responsibility as an operator and is

intended only to remind him or make him aware of spe‐

cific problem areas. This information does not lay claim

to being complete, nor applicable to every country and

every type of application, nor to being unconditionally

up-to-date.

WARNING!

Warning of hazardous feed chemical

Should a dangerous feed chemical be used: it may

escape from the hydraulic components when working on

the pump, material failure or incorrect handling of the

pump.

– Take appropriate protective measures before

working on the pump (e.g. safety glasses, safety

gloves, ...). Adhere to the material safety data sheet

for the feed chemical.

– Drain and flush the liquid end before working on the

pump.

Safety information

Safety chapter

WARNING!

Danger from hazardous substances!

Possible consequence: Fatal or very serious injuries.

Please ensure when handling hazardous substances

that you have read the latest safety data sheets 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 assessment for the workstations affected.

WARNING!

Risk of burns with hot feed chemicals

If hot feed chemicals can heat the liquid ends above the

permissible surface temperatures, persons can suffer

burns from them.

– Consider attaching a "Hot surface" label to the liquid

end or ...

– fitting a guard plate.

WARNING!

Hot surface

In event the power end motor is loaded excessively, its

surface may become very hot.

– Avoid contact.

– If necessary, mount a guard plate.

CAUTION!

Warning of feed chemical spraying around

Feed chemical can spray out of the hydraulic compo‐

nents if they are manipulated or opened due to 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

unauthorised persons.

– Depressurise the system before commencing any

work on hydraulic parts.

CAUTION!

Warning of feed chemical spraying around

An unsuitable feed chemical can damage the parts of

the pump that come into contact with the chemical.

– Take into account the resistance of the wetted mate‐

rials and the ProMinent Resistance List when

selecting the feed chemical - see the ProMinent

Product Catalogue or visit ProMinent.

Safety chapter

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