ProMinent EXtronic EXBb Operating Instructions Manual

Metering pump

ProMinent EXtronic

®

EXBb

Operating instructions

0158

EN

Original operating instructions (2006/42/EC)Part No. 987094 BA EX 0 16 09/19 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! You

will benefit more from using the operating instructions should you

already know this information.

The following are highlighted separately in the document:

n Enumerated lists

Instructions

ð

Outcome of the instructions

Ä ‘State the identity code and serial number’ on page 2

: Links to

points in this chapter

- refer to ... : References to points in this document or another

document

[Keys]

Information

This provides important information relating to the

correct operation of the unit or is intended to make

your work easier.

Safety Information

Safety information is identified by pictograms - see Safety Chapter.

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 us to clearly identify the unit type and material versions.

Supplementary information

Fig. 1: Please read!

Validity

State the identity code and serial

number

Supplemental directives

2

Table of contents

1

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

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

3 Storage, transport and unpacking....................................... 12

4 Overview of equipment....................................................... 13

5 Functional description......................................................... 15

5.1 Drive Unit.................................................................... 15

5.2 Liquid End................................................................... 15

5.3 Self-Bleeding.............................................................. 15

5.4 Diaphragm rupture sensor (optional).......................... 15

5.5 Metering rate............................................................... 16

5.6 Control types............................................................... 17

5.7 Button for maximum stroke rate.................................. 17

6 Assembly............................................................................ 18

7

Installation, hydraulic.......................................................... 19

7.1 Standard installation................................................... 22

7.2 Information on the suction-side installation................. 22

7.3 Information on the discharge-side installation............ 23

7.4 How not to install........................................................ 24

7.5 Special installation instructions................................... 25

8 Installation, electrical........................................................... 27

9 Start up............................................................................... 31

9.1 Determining pump capacity........................................ 33

9.2 Setting the pump capacity.......................................... 34

10 Troubleshooting.................................................................. 36

11 Maintenance....................................................................... 38

12 Repair................................................................................. 40

12.1 Replacing metering diaphragm................................. 40

12.2 Checking diaphragm rupture sensor......................... 42

12.3 Replacing separating diaphragm of the diaphragm

rupture sensor........................................................... 43

12.4 Installing dosing head............................................... 43

13 Decommissioning and disposal.......................................... 45

13.1 Decommissioning..................................................... 45

13.2 Disposal.................................................................... 46

14 Technical data..................................................................... 47

14.1 Performance data..................................................... 47

14.2 Precision................................................................... 49

14.3 Material specifications.............................................. 50

14.4 Weight....................................................................... 50

14.5 Electrical data........................................................... 50

14.5.1 Electrical data for actuation current circuits........... 50

14.5.2 Electrical data for supply current circuit................. 52

14.5.3 Electrical data, details............................................ 52

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

14.7 Sound pressure level................................................ 54

15 Dimensional drawing........................................................... 55

16 Nomographs....................................................................... 58

Table of contents

3

17 Ordering information for fuses............................................ 66

18

Declaration of Conformity................................................... 68

19 Index................................................................................... 69

Table of contents

4

1 Identity code

Product range ProMinent EXtronic

®

, Version b

EXBb Degree of protection

G Gas explosion protection

M Firedamp and gas explosion protection

Pump

type

bar l/h

refer to nameplate

Dosing head material

PP1 PP with bleed valve, O-ring: EPDM

PP4 PP without bleed valve/ HV, O-ring: EPDM

NP1 Acrylic with bleed valve, O-ring: FPM-A

NP3 Acrylic with bleed valve, O-ring: FPM-A

NS3 Acrylic self-bleeding, O-ring: FPM-A

PS3 PVC self-bleeding, O-ring: FPM-A

TT1 PTFE + 25% carbon, flat seal: PTFE

SS1 Stainless steel 1.4571 with clamp rings, flat seal: PTFE

SS2 Stainless steel 1.4571 with internal thread1/4” NPT, seal: PTFE

SB1 Stainless steel 1.4571 with internal thread, Rp 1/4 or 1/2

SSM As SS1, with diaphragm rupture sensor

SBM As SB1, with diaphragm rupture sensor

Valve spring

0 With valve spring

1 With 2 valve springs (1.4571), 0.1 bar

Electrical connection

A 230 V, 50/60 Hz, open end

B 115 V, 50/60 Hz, open end

C 200 V, 50/60 Hz, open end

D 100 V, 50/60 Hz, open end

E 500 V, 50/60 Hz, open end

Control type

0 Internal stroke rate setting

1 External contact control

2 Analogue control 0–20 mA

3 Analogue control 4–20 mA

4 External contact control [i,a]

5 Analogue control 0–20 mA [i,a]

6 Analogue control 4–20 mA [i,a]

7 Manual with potential-free ON / OFF

Identity code

5

Product range ProMinent EXtronic

®

, Version b

8 Manual with potential-free ON / OFF, [i,a]

Control version

0 with potentiometer

1 with push-button for maximum frequency

2 with push-button switch-over for maximum

frequency

Certification/voltage/language

0 BVS Europe / 100–500 V / German

1 BVS Europe / 100–500 V / English

2 FM-USA / 115 V / English

3 CSA Canada / 115 V, 230 V / English

Identity code

6

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

situation. If this is disregarded,

you are in a life-threatening sit‐

uation and this can result in

serious injuries.

CAUTION Denotes a possibly dangerous

situation. If this is disregarded,

it could result in slight or minor

injuries or material damage.

The following warning signs are used in these operating instruc‐

tions to denote different types of danger:

Warning signs Type of danger

Warning – high-voltage.

Warning – danger zone.

n Only use the pump to meter liquid feed chemicals.

n In potentially explosive premises, the pump may only be oper‐

ated with the appropriate nameplate (and the respective Decla‐

ration of Conformity) for pumps for use in areas at risk of explo‐

sion in compliance with Directive 2014/34/EU in accordance

with the European guidelines. The explosion group, category

and degree of protection specified on the label must corre‐

spond to or be better than the conditions in the intended appli‐

cation.

n The pump may only be used after it has been correctly

installed and started up in accordance with the technical data

and specifications contained in the operating instructions.

n Observe the general limitations with regard to viscosity limits,

chemical resistance and density - see also ProMinent

®

Resist‐

ance List in the Product Catalogue or at

www.prominent.com

!

n All other uses or modifications are prohibited.

n Never operate pumps in premises at risk of explosion without

the relevant nameplate (and the respective EU Declaration of

Conformity) for pumps for premises at risk of explosion.

n The pump is not intended for the metering of gaseous media

and solids.

n The pump is not intended for the metering of flammable media

without implementing suitable protective measures. Only the

“SB” design is approved for this.

n The pump is not designed to meter explosive media or mix‐

tures.

Identification of safety notes

Warning signs denoting different

types of danger

Intended use

Safety chapter

7

n The pump is not intended for exterior applications without the

implementation of suitable protective measures.

n The pump should only be operated by trained and authorised

personnel - see the following "Qualifications" table.

n You have a responsibility to adhere to the information con‐

tained in the operating instructions at the different phases of

the unit's service life.

Task Qualification

Storage, transport, unpacking Instructed person

Assembly Technical personnel, service

Planning the hydraulic installa‐

tion

Technical personnel who have

a thorough knowledge of dia‐

phragm pumps

Hydraulic installation Technical personnel, service

Electrical installation Electrical technician with knowl‐

edge of explosion protection

Operation Instructed person

Maintenance, repair Technical personnel, service

Decommissioning, disposal Technical personnel, service

Troubleshooting Technical personnel, electrical

technician with knowledge of

explosion protection, instructed

person, service

Explanation of the table:

Technical personnel

Technical personnel are deemed to be people who are able to

assess the tasks assigned to them and recognise possible dangers

based on their technical training, knowledge and experience, as

well as knowledge of pertinent regulations.

Note:

A qualification of equal validity to a technical qualification can also

be gained by several years of employment in the relevant field of

work.

Electrical technician with knowledge of 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 rec‐

ognise and avoid possible dangers based on his technical training

and experience.

The electrical technician with an additional explosion protection

qualification is familiar with all the standards and regulations appli‐

cable to explosion protection, in particular, but not however exclu‐

sively, 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 stat‐

utory directives on accident prevention.

Qualification of personnel

Safety chapter

8

Instructed person

An instructed person is deemed to be a person who has been

instructed and, if required, trained in the tasks assigned to him/her

and possible dangers that could result from improper behaviour, as

well as having been instructed in the required protective equipment

and protective measures.

Service

The Service department refers to service technicians, who have

received proven training and have been authorised by ProMinent

to work on the system.

WARNING!

Warning of personal injury and material damage

– The pump may start to pump as soon as it is

connected to mains voltage.

–

Mains voltage may be present inside the pump

housing.

– Should a dangerous or unknown feed chemical

be used: It may escape from the hydraulic

components when working on the pump.

– When pumping flammable media the operator

must take suitable safety precautions.

WARNING!

Danger from hazardous substances!

Possible consequence: Fatal or very serious inju‐

ries.

Please ensure when handling hazardous sub‐

stances that you have read the latest safety data

sheets provided by the manufacture of the haz‐

ardous substance. The actions required are

described in the safety data sheet. Check the

safety data sheet regularly and replace, if neces‐

sary, 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 worksta‐

tions affected.

Safety information

Safety chapter

9

CAUTION!

Warning of personal injury and material damage

– Feed chemical may spray out of the hydraulic

components if they are tampered with or

opened due to pressure in the liquid end and

adjacent parts of the system.

–

The metering pump may generate a multiple of

its rated pressure. Hydraulic parts may rupture

if a discharge line is blocked.

– An unsuitable feed chemical may damage the

parts of the pump that come into contact with it.

– The use of untested third party components

may result in injury to personnel and material

damage.

– Danger may result from a poorly accessible

pump due to incorrect operation and poor

maintenance.

– The metering behaviour of the pump changes if

a different liquid end size is fitted.

Only ProMinent Service may open the housing.

Adhesive labels

WARNING!

– The following safety information must be

affixed to pumps that contain parts made of

electrically non-conducting plastic.

–

Ensure that the label is always fitted and

legible.

– The label should indicate that:

– plastic parts may only be wiped down care‐

fully with a damp cloth.

– the discharge line and suction line must

always be earthed before working on the

pump.

electrostatic charging hazard

- see instructions

Potential

W a r n i n g

Fig. 2

WARNING!

– The following safety information for ProMinent

Service needs to be adhered to the pump foot.

–

Ensure that the label is always fitted and

legible.

Isolating protective equipment

Other safety equipment

Safety chapter

10

Do not open when

e

nergised!

After switching off,

wait two minutes

before opening!

Fig. 3

In an emergency, either press the mains switch (optional) or press

the emergency-off switch installed by the customer or disconnect

the pump from the mains in line with the emergency-shut-down

guidelines for your system.

If feed chemical escapes, also ensure that the pump's hydraulic

environment is at atmospheric pressure. Adhere to the material

safety data sheet for the feed chemical.

Sound pressure level LpA < 70 dB according to EN ISO 20361

at maximum stroke length, maximum stroke rate, maximum back

pressure (water)

Information in the event of an emer‐

gency

Sound pressure level

Safety chapter

11

3 Storage, transport and unpacking

WARNING!

Only return metering pumps for repair in a cleaned

state and with a flushed liquid end - refer to

"Decommissioning!

Only return metering pumps with a completed

Decontamination Declaration form. The Decon‐

tamination Declaration constitutes 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 oper‐

ator.

The "Decontamination Declaration Form" can be

found on our homepage.

CAUTION!

Danger of material damage

The device can be damaged by incorrect or

improper storage or transportation!

– The unit should only be stored or transported in

a well packaged state - preferably in its original

packaging.

–

The packaged unit should also only be stored

or transported in accordance with the stipu‐

lated storage conditions.

– The packaged unit should be protected from

moisture and the ingress of chemicals.

Compare the delivery note with the scope of supply.

- refer to "Technical Data" chapter.

Safety information

Scope of delivery

Ambient conditions

Storage, transport and unpacking

12

4 Overview of equipment

1

2

3

4

5

6

7

8

9

12

14

15

13

11

16

10

17

Overview of equipment

13

1 - Drive unit with controller

2 - Pressure connector

3 - Backplate

4 - Liquid end

5 - Bleed valve (only for the 1000 - 0417 NP and PP types)

6 - Bypass hose sleeve (only for the 1000 - 0417 NP and PP

types)

7 - Suction connector

8 - Nameplate

9 - Operating display

10 - Inspection window stroke length control knob

11 - External connection

12 - Mains connection

13 - Mains switch (not for 500 V version)

14 - Stroke length control knob

15 - Locking lever

16 - Control knob for stroke rate or pushbutton/pushbutton switch

for priming

17 - Transparent cover

Overview of equipment

14

5 Functional description

5.1

Drive Unit

The diaphragm is driven by an electromagnet, which is controlled

by an electronic controller.

5.2 Liquid End

The dosing process is performed as follows: The diaphragm is

pressed into the dosing head; the pressure in the dosing head

closes the suction valve and the feed chemical flows through the

discharge valve out of the dosing head. The diaphragm is now

drawn out of the dosing head; the discharge valve closes due to

the negative pressure in the dosing head and fresh feed chemical

flows through the suction valve into the dosing head. One cycle is

completed.

5.3 Self-Bleeding

Self-bleeding liquid ends (SEK types) are capable of independent

priming when a discharge line is connected and diverting existent

air pockets via a bypass. During operation they are also capable of

conveying away gases which are produced, independently of the

operating pressure in the system. It is also possible to dose pre‐

cisely in a depressurised state due to the integral back pressure

valve.

5.4

Diaphragm rupture sensor (optional)

The diaphragm rupture warning system monitors the leak-tightness

of the metering diaphragm. The associated liquid end also has a

separating diaphragm, which prevents the feed chemical from

escaping for some time.

The diaphragm rupture warning system is equipped with an inher‐

ently safe diaphragm rupture sensor.

Functional description

15

5

2

1

3

4

6

7

8

9

10

Fig. 4

1 Backplate

2 Adapter

3 Intermediate bushing

4 Additional diaphragms

5 Adapter plate

6 Metering diaphragm

7 Dosing head

8 Fixing bolt

9 Diaphragm rupture sensor

10 Feed channel

CAUTION!

Only above approximately 2 bar system back pres‐

sure is an electrical signal triggered in the event of

diaphragm rupture.

CAUTION!

Once the operating membrane has ruptured, a pre‐

cise metering rate can no longer be guaranteed.

5.5 Metering rate

The stroke length can be continuously adjusted between 100 %

and 10 % using the stroke length control knob (14).

The stroke rate control knob (16) can be used to manually set 0 to

110 (120) strokes/min.

Functional description

16

5.6 Control types

(Identity code characteristic "Control type": 0)

The controlling pulse is internally generated and adjusted using the

stroke rate control knob (16).

(Identity code characteristic "Control type": 1, 4):

The controlling pulse is externally generated from potential-free or

semiconductor contacts and fed to the drive unit via the "external

control" jack. Examples are contact water meter or controls.

(Identity code characteristic "Control type": 2, 3, 5, 6):

An external, analogue signal is fed to the drive unit via the

"External control” jack, the stroke rate changes proportionally

according to the 0 .. 20 mA or 4 .. 20 mA signal.

(Identity code characteristic "Control type": 7, 8):

As for "Internal stroke rate setting” version, however there is also

the possibility of switching the metering on and off via an external

semiconductor contact or potential-free contact.

All control types, that can be controlled via an

input, can be supplied with an "External control"

input of a "non-intrinsically safe" [i, a] or "intrinsi‐

cally safe" type.

5.7 Button for maximum stroke rate

(Identity code characteristic "Control variant": 1):

A push-button is available as an option to allow the pump to run at

maximum stroke rate.

(Identity code characteristic "Control variant": 2):

A key switch is available as an option to allow the pump to run at

maximum stroke rate.

”Internal stroke rate setting”

“External contact control”

"Analogue control x - 20 mA"

“Internal stroke rate setting with pause

function”

Push-button for max. frequency

Key switch for max. frequency

Functional description

17

6 Assembly

–

Compare the dimensions on the dimension

sheet with those of the pump.

WARNING!

Danger of electric shock

If water or other electrically conducting liquids pen‐

etrate into the drive housing, in any other manner

than via the pump's suction connection, an electric

shock may occur.

– Position the pump so that it cannot be flooded.

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.

Capacity too low

The liquid end valves can be disturbed by vibra‐

tions.

–

Secure the metering pump so that no vibra‐

tions can occur.

Capacity too low

If the valves of the liquid end are not vertical, they

cannot close correctly.

–

Suction and discharge valves must stand verti‐

cally upwards (for self-bleeding liquid end, the

bleed valve).

Mount the metering pump with the pump foot on a horizontal,

level and load-bearing supporting surface.

Assembly

18

7 Installation, hydraulic

WARNING!

EX pumps in areas at risk of explosion

– Metering pumps in areas at risk of explosion

are provided, as a matter of course, with an

appropriate safety relief valve on the outlet side

of the metering pump (which is used to protect

against excessive heating due to overloading

and impact sparks caused by the breakage of

power end parts triggered by overloading.)

–

Should the various components have differing

temperature classes, scope for using the com‐

plete pump depends on the component with

the lowest temperature class.

– The version with an Ex”i” version of diaphragm

rupture sensor should always be used.

– Ensure that installations in areas at risk of

explosion are checked by a "recognised com‐

petent" person.

– Please note the relevant national regulations

during installation!

WARNING!

Risk of fire with flammable feed chemicals

– Flammable media may only be transported

using stainless steel dosing heads. In excep‐

tional cases where this is not possible, PTFE

with carbon can be used, whereby our TT_ ver‐

sions are manufactured from this conducting

plastic. Here, the operator is urged to take spe‐

cial care due to the low mechanical strength.

–

The metering pumps may meter flammable

media, but only in principle versions with the

“intrinsically safe [i,a]" version of the diaphragm

rupture sensor.

– The following applies to all metering pumps for

metering flammable media:

During filling and draining of the liquid end, an

expert must ensure that feed chemical does

not come into contact with air.

WARNING!

Warning of feed chemical reactions to water

Feed chemicals that should not come into contact

with water may react to residual water in the liquid

end that may originate from works testing.

– Blow the liquid end dry with compressed air

through the suction connector.

–

Then flush the liquid end with a suitable

medium through the suction connector.

Installation, hydraulic

19

WARNING!

The following measures are beneficial when

working with highly aggressive or hazardous feed

chemicals:

– Install a bleed valve with recirculation in the

storage tank.

–

Install a shut-off valve on the discharge or suc‐

tion side.

CAUTION!

Warning of feed chemical spraying around

PTFE seals, which have already been used / com‐

pressed, can no longer reliably seal a hydraulic

connection.

– New, unused PTFE seals must always be

used.

CAUTION!

Suction problems are possible

The valves may no longer close properly with feed

chemicals with a particle size of greater than 0.3

mm.

– Install a suitable filter in the suction line.

CAUTION!

Warning of the discharge line rupturing

With a closed discharge line (e.g. from a clogged

discharge line or by closing a valve), the pressure

that the metering pump generates may reach sev‐

eral times more than the permissible pressure of

the system or the metering pump. This could lead

to lines rupturing resulting in dangerous conse‐

quences with aggressive or hazardous feed chemi‐

cals.

– Install a relief valve that limits the pressure of

the pump to the maximum permissible oper‐

ating pressure of the system.

CAUTION!

Uncontrolled flow of feed chemical

Feed chemical may press through a stopped

metering pump if there is back pressure.

– Use an injection valve or a vacuum breaker.

Installation, hydraulic

20

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ProMinent EXtronic EXBb Operating Instructions Manual

ProMinent EXtronic EXBb Operating Instructions Manual

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