ProMinent Makro TZ Operating Instructions Manual

Diaphragm Metering Pump

Makro TZ, TZMb

Operating instructions

P_MA_0022_SW

Original operating instructions (2006/42/EC)Part no. 985741 BA MA 014 02/14 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.

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:

n Enumerated lists

Operating guidelines

ð

Outcome of the operating guidelines

- see (reference)

Information

This provides important information relating to the correct

operation of the unit or is intended to make your work easier.

Safety notes

Safety notes are 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 the

device type and material versions to be clearly identified.

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

so that a clear assignment is given between the operating instructions and

the pump.

Supplementary information

Fig. 1: Please read!

Validity

State the identity code and serial number

EX pumps only

Supplemental instructions

2

Table of contents

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

2

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

3 Storage, transport and unpacking................................................. 13

4 Overview of equipment, control elements..................................... 14

5 Functional description.................................................................... 16

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

7 Installation..................................................................................... 20

7.1 Installation, hydraulic............................................................. 20

7.1.1 Basic installation notes....................................................... 23

7.2 Installation, electrical............................................................. 24

8 Start up.......................................................................................... 29

9 During Operation........................................................................... 32

10

Maintenance.................................................................................. 33

11 Repairs.......................................................................................... 37

11.1 Replacing the diaphragm.................................................... 38

11.2 Repair the diaphragm rupture sensor................................. 40

11.2.1 30 V version..................................................................... 40

11.2.2 EX Version....................................................................... 41

11.3 Valve repair......................................................................... 43

11.3.1 Double ball valves............................................................ 43

11.3.2 Single ball valves............................................................. 44

11.3.3 Plate valves...................................................................... 45

12 Troubleshooting............................................................................. 47

13 Decommissioning and Disposal.................................................... 50

13.1 Decommissioning................................................................ 50

13.2 Disposal.............................................................................. 51

14 Technical data............................................................................... 53

14.1 Performance data................................................................ 53

14.2 Precision............................................................................. 54

14.2.1 Reproducibility.................................................................. 54

14.2.2 Metering precision............................................................ 55

14.3 Viscosity.............................................................................. 55

14.4 Wetted materials................................................................. 55

14.5 Ambient conditions.............................................................. 56

14.5.1 Temperatures................................................................... 56

14.5.2 Air humidity...................................................................... 57

14.6 Housing degree of protection.............................................. 57

14.7 Stroke sensor (optional), intrinsically safe........................... 57

14.8 Diaphragm rupture sensor.................................................. 57

14.9 Motor data........................................................................... 58

14.10 Filling volumes.................................................................. 59

14.10.1 Gear oil........................................................................... 59

14.11 Sound pressure level........................................................ 59

14.12 Supplement for modified versions..................................... 59

15 Spare parts.................................................................................... 60

15.1 Spare parts.......................................................................... 60

15.2 Other material..................................................................... 61

15.2.1 Gear oil............................................................................. 61

16 Dimensional drawings................................................................... 62

17 Motor data sheet

............................................................................ 64

Table of contents

3

18 Diagrams for adjusting the capacity.............................................. 65

19 EC Declaration of Conformity........................................................ 69

Table of contents

4

1 Identity code

TZMb Makro TZ 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

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

housing

Dosing head material

PC PVC

PP Polypropylene

TT PTFE + 25 % carbon

SS Stainless steel

Material of seals / diaphragm

T PTFE

Displacement body material

1 Multi-layer safety diaphragm with rupture signalling

Dosing head design

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

Design

0

With ProMinent

®

logo, no frame

2 Without ProMinent® logo

A

With ProMinent

®

logo, with single frame

B

With ProMinent

®

logo, with double frame

C

With ProMinent

®

logo, with triple frame

D

With ProMinent

®

logo, with quadruple frame

M Modified* * order-related design, refer to order

paperwork for pump features

Electric power supply

_ Connection data - refer to nameplate on motor

4 No motor, with flange 56 C

7 No motor, with flange 120/80

Identity code

5

TZMb Makro TZ diaphragm metering pump

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 design ATEX-T3

2 Exd version 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

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 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.

n Only use the pump to meter liquid feed chemicals.

n In potentially explosive atmospheres in zone 1, device category II 2G,

explosion group II C, only operate the pump with the appropriate

nameplate (and the respective EC Declaration of Conformity) for

pumps for use in areas at risk of explosion in compliance with Direc‐

tive 94/9/EC in accordance with the European guidelines. The explo‐

sion group, category and degree of protection specified on the label

should correspond to or be better than the conditions given in the

intended field of application.

n Only start up the pump after it has been correctly installed and com‐

missioned in accordance with the technical data and specifications

contained in the operating instructions.

n Observe the general restrictions with regard to viscosity limits, chem‐

ical resistance and density - see also ProMinent Resistance List (in

the Product Catalogue or at www.prominent.com/en/downloads)!

n All other uses or modifications are prohibited.

n Never operate pumps without the relevant nameplate (and the respec‐

tive EC Declaration of Conformity) for pumps for use in atmospheres

at risk from explosion in atmospheres potentially at risk from explo‐

sion.

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

n The pump is not intended to meter explosive substances and mix‐

tures.

Identification of safety notes

Warning signs denoting different types of

danger

Intended use

Safety chapter

7

n Only SS and TT pump designs with carbon and diaphragm rupture

indicator are approved to meter flammable liquids, and if the operator

takes appropriate safety measures.

n The pump is not intended for unprotected outside use.

n The pump is only intended for industrial use.

n The pump should only be operated by trained and authorised per‐

sonnel, see the following table.

n Observe the information contained in the operating instructions at the

different phases of the device's service life.

Only the following combinations of identity codes are permitted in areas at

risk from explosion:

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

Action Qualification

Storage, transport, unpacking Instructed person

Assembly Technical personnel, service

Planning hydraulic installation Qualified personnel who have a

thorough knowledge of metering

pumps.

Hydraulic installation 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 be

gained by several years employment in the relevant work area.

Electrical technician

Qualification of personnel

Safety chapter

8

Electrical technicians are deemed to be people, who are able to complete

work on electrical systems and recognise and avoid possible dangers

independently based on their technical training and experience, as well as

knowledge of pertinent standards and regulations.

Electrical technicians should be specifically trained for the working envi‐

ronment in which they 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.

CAUTION!

These operating instructions include notes and quotes from

German guidelines relating to the system operator's scope of

responsibility. This information does not discharge the oper‐

ator from his responsibility as an operator and is intended

only to remind him or make him aware of specific 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!

– Observe the European Operator Directive 99/92/EC

(ATEX 137), implemented in Germany by the Industrial

Health and Safety Regulation and the German Ordi‐

nance on Hazardous Substances, for the installation and

operation of equipment in areas at risk from explosion.

– Observe the European standards EN 1127-1, EN

60079-10, EN 60079-14, EN 60079-17 and EN

60079-25 and EN 50039 for inherently safe electrical cir‐

cuits. (In Germany these standards are partly imple‐

mented by VDE 0165 and VDE 0118).

– Adhere to the respective national regulations outside of

the EU.

– Ensure that installations in areas at risk from explosion

are checked by a "recognisably trained" skilled opera‐

tive. This applies specifically to intrinsically safe elec‐

trical circuits.

– The following information relates essentially to the

unique characteristics in areas at risk from explosion but

does not replace the standard operating instructions.

– Only clean plastic parts carefully with a damp cloth to

avoid electrostatic charges and sparks.

Safety notes

Safety chapter

9

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.

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 materials

when selecting the feed chemical - see the ProMinent

product catalogue or visit www.prominent.com/en/down‐

loads.

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.

Safety chapter

10

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.

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.

Prior to commissioning the system or system component, the system oper‐

ator is obliged to obtain the latest safety data sheet from the supplier for

the chemicals / resources to be used with the system. The operator should

create the legal framework for safe operation of the system or system

component, such as for example the preparation of operating instructions

(operator duties), based on the information provided in the data sheets

concerning health and safety, water and environmental protection and

taking into consideration the actual operating environment on site.

1

2

3

4

P_MA_0042_SW

Fig. 2: Isolating protective equipment Makro TZ with add-on power end

(shown here for piston version)

1 Terminal box cover, motor

2 Protective cowling above the motor fan

3 Flange cover, side

4 Protective cover (only diaphragm and piston versions)

Information in the event of an emergency

Safety information relating to the operating

instructions

Safety equipment

Protective equipment

Safety chapter

11

Ite

m

Protective equipment May only be

removed by*:

1 Terminal box cover, motor Electrical techni‐

cian, service

2 Protective cowling above the motor fan Service

3 Flange cover, side Service

4 Protective cover (only diaphragm and piston

versions)

Technical per‐

sonnel, service

- Only with protective devices: their corre‐

sponding parts

Technical per‐

sonnel, service

* Only if the mains cable remains disconnected (no mains voltage).

WARNING!

– Attach the following safety note to pumps that contain

parts made of electrically non-conductive plastic:

–

Ensure that the label is always fitted and legible.

WARNING

Electrostatic charge may

cause an explosion!

Clean plastic parts very

carefully using a damp cloth!

Fig. 3

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

at maximum stroke length, maximum stroke rate, maximum back pressure

(water)

Other safety equipment

Sound pressure level

Safety chapter

12

3 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 "Decommissioning!

Only return metering pumps with a completed Decontamina‐

tion Declaration form. The Decontamination Declaration con‐

stitutes 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/en/downloads 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.

Personnel:

n

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.

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

Safety notes

Storage

Storage, transport and unpacking

13

4 Overview of equipment, control elements

1 2 3

4

C A 5

P_MA_0023_SW

Fig. 4: 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

4

C

A 5

P_MA_0024_SW

Fig. 5: 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

14

1

2

3

4

5

6

P_MA_0025_SW

Fig. 6: 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

15

5 Functional description

The metering pump is an oscillating diaphragm pump, the stroke length of

which can be adjusted. An electric motor drives the pump.

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.

1

2

3

5

4

P_MA_0029_SW

Fig. 7: Cross-section through the liquid end

1 Discharge valve

2 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.

Pump

Functional description of the diaphragm

liquid end

Diaphragm rupture warning system func‐

tional description

Functional description

16

1

2

3

4

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

17

6 Assembly

–

Compare the dimensions on the dimension sheet and

pump.

WARNING!

Danger of electric shock

If water or other electrically conducting liquids penetrate 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.

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.

Supporting floor

h

P_MOZ_0016_SW

Fig. 9

Space requirement

A

P_MOZ_0018_SW

Fig. 10

1

3

2

f

P_MOZ_0017_SW

Fig. 11

Assembly

18

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.

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.

Liquid end alignment

Fastening

DNm

m

P_MOZ_0015_SW

Fig. 12

Instruction

Assembly

19

7 Installation

7.1 Installation, hydraulic

WARNING!

EX pumps in areas at risk from explosion

– It is essential that metering pumps to be used in areas at

risk from explosion are fitted with an appropriate safety

relief valve on the outlet side of the metering pump (to

protect it from excessive heating up from overloading

and from impact sparks resulting from overloading trig‐

gered by the breakage of power end components).

– In the event of different temperature classes with the

various components, the possible uses of the complete

pump are based on the component with the lowest tem‐

perature class.

–

Diaphragm pump with mechanically actuated diaphragm,

e.g. MTMa.., TZMa.., Sigmas S1Ba...., S2BaHM...,

S3Ba: no additional action is required, but in principle

use the design with Ex"i" diaphragm rupture indicator.

– Ensure that installations in areas at risk from explosion

are checked by a "recognisably qualified and skilled"

operative.

– Please observe the relevant national regulations and

guidelines during installation!

WARNING!

Danger of fire with flammable feed chemicals

– Combustible media may only be transported using stain‐

less steel dosing heads. In exceptional cases where this

is not possible, PTFE with carbon can be used, whereby

our TT_ versions are manufactured from this conducting

plastic. Here, the operator is urged to take special care

due to the low mechanical strength.

– Only designs of metering pump with Ex"i" diaphragm

rupture indicators are permitted in principle to meter

flammable media.

–

The following applies to all metering pumps for the

metering of combustible media:

During filling and draining of the liquid end, an expert

must ensure that feed chemical does not come into con‐

tact with oxygen.

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.

Installation

20

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ProMinent Makro TZ, Makro TZMb Operating Instructions Manual

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