Piston Metering Pump
ProMinent
®
Makro/ 5 M5Ka
Operating instructions
ProMinent
Two sets of operating instructions are required for the safe, correct and proper operation of the metering pumps: The
product-specific operating instructions and the "General Operating Instructions for ProMinent
®
motor-driven metering
pumps and hydraulic accessories".
Both sets of operating instructions are only valid when read together.
Original Operating Instructions (2006/42/EC)Part no. 985761 BA MAK 007 10/11 EN
Please carefully read these operating instructions before use! · Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
Technical changes reserved.
985762, 1, en_GB
© 2010
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg
Germany
Telephone: +49 6221 842-0
Fax: +49 6221 842-617
email: [email protected]
Internet: www.prominent.com
2
Read the following supplementary information in its entirety! Should you
already know this information, you have an even greater need of the Oper‐
ating Instructions.
The following are highlighted separately in the document:
n Enumerated lists
Instructions
ð
Outcome of the handling instructions
- see (reference)
Information
This provides important information relating to the correct
operation of the device or is intended to make your work
easier.
Safety notes
Safety notes are identified by pictograms - see Safety Chapter.
Two sets of operating instructions are required for the safe, correct and
proper operation of the metering pumps: The product-specific operating
instructions and the "General Operating Instructions for ProMinent
®
motor-
driven metering pumps and hydraulic accessories".
Both sets of operating instructions are only valid when read together.
Please read these operating instructions carefully before use! Do not dis‐
card!
Please state identity code and serial number, which you can find on the
nameplate when you contact us or order spare parts. This enables the
device type and material versions to be clearly identified.
In order to make it easier to read, this document uses the male form in
grammatical structures but with an implied neutral sense. It is aimed
equally at both men and women. We kindly ask female readers for their
understanding in this simplification of the text.
Supplementary information
Fig. 1: Please read!
General user instructions
State the identity code and serial number
General non-discriminatory approach
Supplemental instructions
3
Table of contents
1 Identity code.................................................................................... 5
2 About this pump
............................................................................... 7
3 Safety chapter................................................................................. 8
4 Storage, transport and unpacking................................................. 13
5 Overview of equipment, control elements..................................... 15
6 Functional description.................................................................... 18
7 Assembly....................................................................................... 20
8 Installation..................................................................................... 23
8.1 Installation, hydraulic............................................................. 23
8.2 Installation, electrical............................................................. 25
9 Start up.......................................................................................... 28
10 During use..................................................................................... 30
11 Maintenance.................................................................................. 31
12
Repairs.......................................................................................... 35
12.1 Changing the piston............................................................ 36
12.2 Valve repair......................................................................... 40
12.2.1 Double ball valves............................................................ 41
12.2.2 Single ball valves............................................................. 42
12.2.3 Plate valves...................................................................... 42
13 Troubleshooting............................................................................. 44
14 Decommissioning and disposal..................................................... 46
14.1 Decommissioning................................................................ 46
14.2 Disposal.............................................................................. 48
15 Technical data............................................................................... 49
15.1 Performance data................................................................ 50
15.2 Accuracy............................................................................. 53
15.2.1 Reproducibility.................................................................. 53
15.2.2 Metering precision............................................................ 53
15.3 Viscosity.............................................................................. 53
15.4 Wetted materials................................................................. 54
15.5 Ambient conditions.............................................................. 54
15.5.1 Temperatures................................................................... 54
15.5.2 Air humidity...................................................................... 54
15.6 Housing degree of protection.............................................. 55
15.7 Stroke sensor (option), intrinsically safe............................. 55
15.8 Filling volumes.................................................................... 55
15.8.1 Gear oil............................................................................. 55
15.9 Sound pressure level.......................................................... 56
15.10 Compatibility...................................................................... 56
15.11 Supplement for modified versions..................................... 56
16 EC Declaration of Conformity........................................................ 57
17 Index.............................................................................................. 59
Table of contents
4
1 Identity code
M5Ka Makro/ 5 piston metering pumps
Power end type
H Main power end
D Main power end, doubled
A Add-on power end
B Add-on power end doubled
Type*
3200038 1400120 0500335 0250658 0121343
3200048 1400151 0500419 0250822 0121678
3200066 1400207 0500576 0251129 0122305
3200085 1270267 0450744 0231458 0122977
3200100 1000314 0350872 0181710 0103491
2400070 0800214 0350483 0160970 0062269
2400088 0800268 0350604 0161212 0062837
2400121 0800368 0350829 0161665 0063896
2160157 0700476 0301071 0162150 0065031
1700184 0560558 0251257 0162522 0066000
Dosing head material
SS Stainless steel
Seal material
T PTFE
Displacement body material
S Stainless steel piston, chromium dioxide coated
Dosing head version
0 no valve spring
1 With valve spring
Hydraulic connector
0 Standard connection
4 Union nut and SS insert
Version
0
With ProMinent
®
logo, no frame
2
Without ProMinent
®
logo, no frame
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 version, for pump fea‐
tures see order paperwork
Electric power supply
S 3 ph, 230 V/400 V 50/60 Hz (WBS)
Identity code
5
M5Ka Makro/ 5 piston metering pumps
L 3 ph, 460 V, 60 Hz, (Exe, Exd)
P 3 ph, 230 V/400 V 50 Hz (Exe, Exd)
R Variable speed motor 4 pole, 230/400 V (R 1:5)
N 1 ph, 115 V, 60Hz
V(0) Motor with integral Frequency converter
V(2) Motor with integral frequency converter (Exd)
5 No motor, with gear IEC 100
6 No motor, with gear IEC 112
0 No motor, no gear
Motor version
0 IP 55 (Standard) ISO class F
1 Exe version ATEX-T3
2 Exd version ATEX-T4
A Power end ATEX design
Stroke sensor
0 No stroke sensor
1 Stroke sensor (Namur), intrinsically safe
Stroke length adjustment
0 Stroke length adjustment, manual
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 mAz
Applications
0 standard
* Figure 1 - 3=back pressure [bar]; figure 4 - 7=flow rate [l/h]
Identity code
6
2 About this pump
The ProMinent
®
Makro/ 5 piston metering pump is fitted as standard with a
3 kW wide range AC motor. The stroke length can be adjusted between
0...50 mm. The spheroidal graphite housing can be combined with up to
10 liquid end sizes and 5 gear reduction ratios (integrated in the spur
geared motor). The liquid ends are available in various material combina‐
tions which can be matched to the feed chemicals being metered.
The ProMinent
®
Makro/ 5 externally mounted metering pump can be com‐
bined with the Makro/ 5 main power end to form a double or multiple
pump. A main power end can be combined with up to four add-on power
ends. One power end can be used both as a single or a double head ver‐
sion.
The double head versions are fitted with a second liquid end which oper‐
ates in push-pull mode (Boxer principle).
All pumps
Externally mounted pumps
Double head version
About this pump
7
3 Safety chapter
The following signal words are used in these operating instructions to
denote different severities of danger:
Signal word Meaning
WARNING Denotes a possibly dangerous sit‐
uation. If this is disregarded, you
are in a life-threatening situation
and this can result in serious inju‐
ries.
CAUTION Denotes a possibly dangerous sit‐
uation. If this is disregarded, it
could result in slight or minor inju‐
ries or material damage.
The following warning signs are used in these operating instructions to
denote different types of danger:
Warning signs Type of danger
Warning – hand injuries.
Warning – high-voltage.
Warning – flammable substances.
Warning – hot surface.
Warning – danger zone.
n The pump may only be used to meter liquid metering chemicals.
n In potentially explosive atmospheres in zone 1, device category II 2G
of explosion group II C, the pump must only be operated according to
the with the relevant nameplate (and the respective EC Declaration of
Conformity) for pumps for potentially explosive atmospheres com‐
plying with Directive 94/9/EC in accordance with the European guide‐
lines. The explosion group, category and degree of protection identi‐
fied on the marking must correspond with or be better than the given
conditions in the intended field of application.
n The pump may only be started up after it has been correctly installed
and commissioned in accordance with the technical data and specifi‐
cations contained in the operating instructions.
n The general limitations with regard to viscosity limits, chemical resist‐
ance and density must be observed - see also ProMinent resistance
list (In the product catalogue or at
www.prominent.com
)!
n Any other uses or modifications are prohibited.
n Pumps without the relevant nameplate (and the respective EC Decla‐
ration of Conformity) for pumps for potentially explosive atmospheres
must never be operated in potentially explosive atmospheres.
Identification of safety notes
Warning signs denoting different types of
danger
Correct and proper use
Safety chapter
8
n The pump is not intended for the metering of gaseous media or solids.
n The pump is not intended for unprotected outside use.
n The pumps is not intended for the dosing of combustible fluids.
n The pump should only be operated by trained and authorised per‐
sonnel, see also
Ä ‘Qualification of personnel’ on page 9
.
n You are obliged to observe the information contained in the operating
instructions at the different phases of the device's service life.
In hazardous locations only the following combinations of identity code
variants is permitted:
Combi‐
nations
Identity code specification values
1 Electric power supply L, P
Motor version 1,2, V(2)
Stroke length adjustment 0, G, H
2 Electric power supply 0, 5.6
Motor version A
Stroke length adjustment 0, G, H
Activity Qualification level
Storage, transport, unpacking Instructed person
Assembly, installation of hydraulic
system
Technical personnel, service
Installation, electrical Electrical technician
Operation Instructed person
Maintenance, repair Technical personnel, service
Decommissioning, disposal Technical personnel, service
Troubleshooting Technical personnel, electrical
technician, instructed person,
service
Explanation of the terms:
Technical personnel
A qualified employee is deemed to be a person who is able to assess the
tasks assigned to him and recognise possible dangers based on his/her
technical training, knowledge and experience, as well as knowledge of
pertinent regulations.
Note:
A qualification of equal validity to a technical qualification can also gained
by several years employment in the relevant work area.
Electrical technician
Electrical technicians are deemed to be people, who are able to complete
work on electrical systems and recognize and avoid possible dangers
independently based on their technical training and experience, as well as
knowledge of pertinent standards and regulations.
Electrical technicians should be specifically trained for the working envi‐
ronment in which the are employed and know the relevant standards and
regulations.
Qualification of personnel
Safety chapter
9
Electrical technicians must comply with the provisions of the applicable
statutory directives on accident prevention.
Instructed person
An instructed person is deemed to be a person who has been instructed
and, if required, trained in the tasks assigned to him/her and possible dan‐
gers that could result from improper behaviour, as well as having been
instructed in the required protective equipment and protective measures.
Service
Customer Service department refers to service technicians, who have
received proven training and have been authorised by ProMinent or Pro‐
Maqua to work on the system.
WARNING!
Warning of dangerous or unknown feed chemical
Should a dangerous or unknown feed chemical be used: It
may escape from the hydraulic components when working
on the pump.
– Take appropriate protective measures before working on
the pump (e.g. safety glasses, safety gloves, ...).
Observe the safety data sheet for the feed chemical.
– Drain and flush the liquid end before working on the
pump.
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious injuries.
Please ensure when handling hazardous substances that
you have read the latest safety data sheets provided by the
manufacture of the hazardous substance. The actions
required are described in the safety data sheet. Check the
safety data sheet regularly and replace, if necessary, as the
hazard potential of a substance can be re-evaluated at any
time based on new findings.
The system operator is responsible for ensuring that these
safety data sheets are available and that they are kept up to
date, as well as for producing an associated hazard assess‐
ment for the workstations affected.
CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic components if
they are manipulated or opened due to pressure in the liquid
end and adjacent parts of the system.
– Disconnect the pump from the mains power supply and
ensure that it cannot be switched on again by unauthor‐
ised persons.
– Depressurise the system before commencing any work
on hydraulic parts.
Safety notes
Safety chapter
10
CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical can damage the parts of the
pump contacted by the chemical.
– Take into account the resistance of the materials which
will come into contact with the chemical when selecting
the feed chemical - see the ProMinent product catalogue
or under
www.prominent.com
.
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in personnel
injuries and material damage.
– Only fit parts to metering pumps, which have been
tested and recommended by ProMinent.
CAUTION!
Danger from incorrectly operated or inadequately maintained
pumps
Danger can arise from a poorly accessible pump due to
incorrect operation and poor maintenance.
– Ensure that the pump is accessible at all times.
– Adhere to the maintenance intervals.
CAUTION!
Warning of illegal operation
Observe the regulations that apply where the unit is to be
installed.
In the event of an electrical accident, disconnect the mains cable from the
mains or press the emergency cut-off switch fitted on the side of the
system!
If feed chemical escapes, also depressurise the hydraulic system around
the pump as necessary. Adhere to the safety data sheet for the feed
chemical.
Information in the event of an emergency
Safety chapter
11
1
6
5
2
3
4
P_MAK_0025_SW
Fig. 2: Isolating protective equipment Makro/ 5 with add-on power end
(shown here for piston version)
1 Cap (only single head version)
2 Fan impeller hood
3 Terminal box cover, motor
4 Cover plate (only with add-on power end)
5 Flange cover
6 Protective cover (only diaphragm and piston versions)
WARNING!
Warning of personal injury and material damage
– The customer must only remove the protective equip‐
ment if requested to do so by the operating instructions.
–
The pump must not operate without fitted protective
equipment.
Sound pressure level LpA < 75 dB in accordance with EN ISO
20361:2010-10
at maximum stroke length, maximum stroke rate, maximum back pressure
(water)
Protective equipment
Sound pressure level
Safety chapter
12
4 Storage, transport and unpacking
WARNING!
The transporting of pumps which have been used with radio‐
active feed chemicals is forbidden!
They will also not be accepted by ProMinent!
WARNING!
Only return metering pumps for repair in a cleaned state and
with a flushed liquid end - refer to the section on decommis‐
sioning!
Only send metering pumps with a filled in Decontamination
Declaration form. The Decontamination Declaration consti‐
tutes an integral part of an inspection / repair order. A unit
can only be inspected or repaired when a Declaration of
Decontamination Form is submitted that has been completed
correctly and in full by an authorised and qualified person on
behalf of the pump operator.
You can find the "Decontamination Declaration" form under
www.prominent.com
or on the CD.
CAUTION!
Danger of environmental and material damage
The unit can be damaged or oil may escape due to incorrect
or improper storage or transportation!
– The unit should only be stored or transported in a well
packaged state - preferably in its original packaging.
– Only transport the unit with the locking screw - not the
bleed plug - fitted to the oil filling opening.
– The packaged unit should also only be stored or trans‐
ported in accordance with the stipulated storage condi‐
tions.
–
The packaged unit should be protected from moisture
and the ingress of chemicals.
Compare the delivery note with the scope of supply:
n Metering pump with mains power cable
n Connector kit for tube/pipe connection
n Product-specific operating instructions with EC Declaration of Con‐
formity
n CD with order information, exploded diagrams, performance diagrams,
motor data sheet and dimension sheets
n Optional accessories if ordered
Personnel:
n
Technical personnel
1. Place the caps on the valves.
2. Check whether the seal screw is screwed into oil filler opening
instead of the vent screw.
3. Preferably place the pump standing vertically on a pallet and secure
against falling over.
4. Cover the pump with a tarpaulin cover - allowing rear ventilation.
Safety notes
Scope of supply
Storage
Storage, transport and unpacking
13
Store the pump in a dry, sealed place in the following ambient conditions.
Data Value Unit
Minimum storage and transport tempera‐
ture
-10 °C
Maximum storage and transport tempera‐
ture
+50 °C
Maximum air humidity * 95 % rel.
humidity
* non-condensing
Ambient conditions
Storage, transport and unpacking
14
5 Overview of equipment, control elements
P_MAK_0027_SW
1
2
3
1
4
A
5
C
Fig. 3: View from the motor side (here M5Ka H)
A Power end
C Liquid end
1 Lifting eye
2 Stroke length adjustment wheel
3 Indicating dial
4 motor
5 Oil drain plug
P_MAK_0027_SW
7
6
Fig. 4: View away from the motor (here M5Ka H)
6 Vent screw
7 Oil inspection window
Power end, single head
Overview of equipment, control elements
15
P_MAK_0029_SW
1 1
2
3
5
C A C
4
Fig. 5: View from the motor side (here M5Ka D)
A Power end
C Liquid end
1 Lifting eye
2 Stroke length adjustment wheel
3 Indicating dial
4 motor
5 Oil drain plug
P_MAK_0030_SW
6
7
Fig. 6: View away from the motor (here M5Ka D)
6 Vent screw
7 Oil inspection window
Power end, double head
Overview of equipment, control elements
16
1
2
3
4
5
6
P_MAK_0034_SW
Fig. 7
1 Discharge valve
2 Dosing head
3 Suction valve
4 Support bracket
5 Protective cover
6 Tube nozzles for leakage/flushing connector
Liquid end
Overview of equipment, control elements
17
6 Functional description
The Makro/ 5 metering pump is a motor-driven metering pump with a kine‐
matic gear.
A motor drives the cam shaft (1). A connecting rod (2) rests on the cam
shaft (1) which allows the oscillating crank (4) to rotate about a variable
pivot point, see Fig. 8. The lifting arm of the oscillating crank, which lies
above the pivot point, moves the slide rod (8) which itself drives the liquid
end.
The stroke is adjusted using the manual adjustment wheel (7). This
causes a spindle (6) to move the fork (5; shown in cutaway view in the dia‐
gram). The fork (5) moves the sliding block (3) in a groove cut into the
oscillating crank (4). The sliding block (3) determines the pivot point of the
oscillating crank (4). This determines the stroke length. When the pivot
point of the sliding block (3) is directly above the axle of the slide rod (8)
the lifting arm of the oscillating crank above the pivot point is at zero and
the slide rod stops. When the sliding block (3) is pushed down, the lifting
arm of the oscillating crank (4) above the pivot point is greater than zero
so that the slide rod (8) is driven
Liquid ends can be fitted to both ends of the slide rod. They then operate
in push-pull mode (Boxer principle).
P_MAK_0035_SW
6
5
4
3
1
2
8
7
Fig. 8: Cross-section through the power end
1 Cam shaft
2 Connecting rod
3 Sliding block
4 Oscillating crank
5 Fork
6 Spindle
7 Manual adjustment wheel
8 Slide rod
The heart of the liquid end is a highly resistant piston (2) made from
coated stainless steel. The suction valve (5) closes as soon as the piston
(2) is moved in to the dosing head and the feed chemical flows through the
discharge valve (1) out of the dosing head. The discharge valve (1) closes
as soon as the piston moves in the opposite direction due to the vacuum
pressure in the dosing head and fresh feed chemical flows through the
suction valve (5) into the dosing head. The flushing collar (3) can be used
to flush the sealing surfaces of the piston or lead-off leakage liquid.
Power end functional description
Functional description of the piston liquid
end (for M5Ka)
Functional description
18
P_MAK_0039_SW
1 2 3 4
5
Fig. 9: Cross-section through the liquid end
1 Discharge valve
2 Piston
3 Flushing collar
4 Packing collar
5 Suction valve
Functional description
19
7 Assembly
WARNING!
Warning about personal and material damage
EX pumps only: When operating in EX areas, certain sub‐
jects must be observed.
– The chapter "Important supplements for metering pumps
in EX zones" of the "General Operating Instructions on
ProMinent
®
Motor-Driven Metering Pumps and Hydraulic
Accessories" must be observed in all cases.
CAUTION!
Warning about personal and material damage
Also observe the "General Operating Instructions for ProMi‐
nent
®
Motor-Driven Metering Pumps and Hydraulic Accesso‐
ries"!
CAUTION!
Danger of environmental and material damage
The unit can be damaged or oil may escape due to incorrect
or improper storage or transportation!
– The unit should only be stored or transported in a well
packaged state - preferably in its original packaging.
– Only transport the unit with the locking screw - not the
bleed plug - fitted to the oil filling opening.
– The packaged unit should also only be stored or trans‐
ported in accordance with the stipulated storage condi‐
tions.
–
The packaged unit should be protected from moisture
and the ingress of chemicals.
CAUTION!
Warning about personal and material damage
Personal and material damage may be caused if the unit is
operated outside of the permissible ambient conditions.
– Please observe the permissible ambient conditions -
refer to the chapter entitled "Technical Data".
WARNING!
Risk of electric shock
If water or other electrically conducting liquids penetrate into
the drive housing, an electric shock may occur.
– Position the pump so that drive housing cannot be
flooded.
Safety notes
Supporting floor
h
P_MOZ_0016_SW
Fig. 10
Assembly
20
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