ProMinent Makro/ 5 M5Ka Operating Instructions Manual

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

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

Page is loading ...

ProMinent Makro/ 5 M5Ka Operating Instructions Manual

ProMinent Makro/ 5 M5Ka Operating Instructions Manual

Related papers

Other documents