ProMinent Makro/ 5 M5Ka Operating Instructions Manual

Piston Metering Pump

ProMinent

®

Makro/ 5 M5Ka

Operating instructions

ProMinent

Original operating instructions (2006/42/EC)Part no. 985761 BA MAK 011 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.

ООО "ПромХимТех" - официальный партнер и поставщик насосов Makro в России и СНГ

www.promhimtech.ru / [email protected]

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.................................................................................... 4

2 Safety chapter................................................................................. 6

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

4 Overview of equipment, control elements..................................... 13

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

6 Assembly....................................................................................... 17

7 Installation..................................................................................... 19

7.1 Installation, Hydraulic............................................................ 19

7.1.1 Basic installation notes....................................................... 21

7.2 Installation, electrical............................................................. 22

8 Start Up......................................................................................... 26

9

During Operation........................................................................... 28

10 Maintenance.................................................................................. 29

11 Repairs.......................................................................................... 34

11.1 Changing the piston............................................................ 35

11.2 Valve repair......................................................................... 39

11.2.1 Double ball valves............................................................ 40

11.2.2 Single ball valves............................................................. 41

11.2.3 Plate valves...................................................................... 41

12 Troubleshooting............................................................................. 43

13 Decommissioning and Disposal.................................................... 45

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

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

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

14.1 Performance data................................................................ 48

14.2 Precision............................................................................. 51

14.2.1 Reproducibility.................................................................. 51

14.2.2 Metering precision............................................................ 51

14.3 Viscosity.............................................................................. 51

14.4 Wetted Materials................................................................. 52

14.5 Ambient conditions.............................................................. 52

14.5.1 Temperatures................................................................... 52

14.5.2 Air humidity...................................................................... 52

14.6 Motor data........................................................................... 53

14.7 Housing Degree of Protection............................................. 53

14.8 Stroke Sensor (Optional), Intrinsically Safe........................ 53

14.9 Filling volumes.................................................................... 54

14.9.1 Gear oil............................................................................. 54

14.10 Sound pressure level........................................................ 54

14.11 Compatibility...................................................................... 54

14.12 Supplement for modified versions..................................... 54

15 Dimensional drawings................................................................... 55

16

Spare parts.................................................................................... 61

16.1 Spare parts.......................................................................... 61

16.2 Other material..................................................................... 61

16.2.1 Gear oil............................................................................. 61

17 Motor data sheets.......................................................................... 63

18

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

19 EC Declaration of Conformity........................................................ 70

20 EC Declaration of Conformity........................................................ 71

Table of contents

3

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*

_ _ _ _ _ _ Performance data at maximum back pressure and type: see nameplate on pump housing

Dosing head material

SS Stainless steel

Seal material

T PTFE

Displacement body material

S Stainless steel piston, chromium dioxide coated

Dosing head design

0 no valve spring

1 With valve spring

Hydraulic connector

0 Standard connection

4 Union nut and SS insert

Design

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 design, refer to order

paperwork for pump features

Electric power supply

_ Connection data - refer to nameplate on motor

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 design ATEX-T3

2 Exd version ATEX-T4

A ATEX design of power end

Stroke sensor

Identity code

4

M5Ka Makro/ 5 piston metering pumps

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

Identity code

5

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 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 with the

appropriate nameplate (and the respective EC Declaration of Con‐

formity) for pumps for potentially explosive atmospheres complying

with Directive 94/9/EC in accordance with the European guidelines.

The explosion group, category and degree of protection declared on

the marking must correspond with or be better than the given condi‐

tions 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. When working at tem‐

peratures arising using a heating cartridge, bear in mind their effect.

n Observe the general limitations 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 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.

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

6

n The pump is not intended for the metering of flammable fluids.

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 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

2 Electric power supply 0, 5.6

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 Certificated specialist personnel

who have a thorough knowledge of

diaphragm 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

7

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.

Customer 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 German

Ordinance on Industrial Safety and Health and the Ordi‐

nance on Hazardous Substances, with regard to the

installation and operation of equipment in areas at risk

from explosion.

– Note the European standards EN 1127-1, EN 60079-10,

EN 60079-14, EN 60079-17, and EN 60079-25 and EN

50039 for intrinsically safe power circuits. (These stand‐

ards are partially implemented in Germany by VDE 0165

and VDE 0118.)

– Observe the relevant national regulations outside of the

EU.

– Ensure that installations in areas at risk from explosion

are checked by a "recognisably qualified and skilled"

operative. This applies specifically to intrinsically safe

electrical power circuits.

– The following information relates essentially to specifics

in areas at risk from explosion and 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

8

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 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 Cata‐

logue or visit www.prominent.com/en/downloads.

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

9

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 of the system or system component, the system

operator is obliged to obtain the latest safety data sheet for the chemicals /

resources to be used with the system from the supplier. 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, the operator must create the legal

framework for safe operation of the system or system component, such as

for example the preparation of operating instructions (operator duties).

Ensure that all these parts are fixed in position during the operation of the

pump:

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)

Information in the event of an emergency

Safety information relative for the oper‐

ating instructions

Safety equipment

Protective equipment

Safety chapter

10

Ite

m

Protective equipment May only be

removed by*:

1 Cap (only single head version) Service

2 Protective cowling above the motor fan Service

3 Terminal box cover, motor Electrical techni‐

cian, service

4 Cover plate (only with add-on power end) Service

5 Flange cover, side Service

6 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!

– Adhere the following safety note to pumps with 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 < 75 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

11

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 at

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

12

4 Overview of equipment, control elements

P_MAK_0027_SW

1

2

3

1

4

A

5

C

Fig. 4: 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. 5: View away from the motor (here M5Ka H)

6 Vent screw

7 Oil inspection window

Power end, single head

Overview of equipment, control elements

13

P_MAK_0029_SW

1 1

2

3

5

C A C

4

Fig. 6: 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. 7: View away from the motor (here M5Ka D)

6 Vent screw

7 Oil inspection window

Power end, double head

Overview of equipment, control elements

14

1

2

3

4

5

6

P_MAK_0034_SW

Fig. 8

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

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 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.

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

Pump

Functional description of the piston liquid

end (for M5Ka)

Functional description

16

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. 10

Space requirement

A

P_MOZ_0018_SW

Fig. 11

1

3

2

f

P_MOZ_0017_SW

Fig. 12

Assembly

17

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. 13

Instruction

Assembly

18

7 Installation

7.1

Installation, Hydraulic

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.

WARNING!

The following measures are an advantage when working with

highly aggressive or hazardous feed chemicals:

– Install a bleed valve with recirculation in the storage

tank.

–

Install an additional shut-off valve on the discharge or

suction ends.

CAUTION!

Warning of backflow

A back pressure valve or a spring-loaded injection valve do

not represent absolutely leak-tight closing elements.

– For this purpose use a shut-off valve, a solenoid valve or

a vacuum breaker.

CAUTION!

Suction problems possible

For feed chemicals with a particle size greater than 0.3 mm,

the valves may no longer close properly.

– Install a suitable filter in the suction line.

CAUTION!

Warning against the discharge line bursting

With a closed discharge line (e.g. due to a clogged discharge

line or by closing a valve), the pressure that the metering

pump generates can reach several times the permissible

pressure of the system or the metering pump. This could

lead to lines bursting resulting in dangerous consequences

with aggressive or toxic feed chemicals.

– Install a relief valve that limits the pressure of the pump

to the maximum permissible operating pressure of the

system.

CAUTION!

Warning against the discharge line bursting

Tube lines with insufficient pressure rating may burst.

– Only use tube lines with the required pressure rating.

Installation

19

CAUTION!

Uncontrolled flowing feed chemicals

Feed chemicals can leak through a stopped metering pump

when there is back pressure.

– Use an injection valve or vacuum breaker for this pur‐

pose.

CAUTION!

Uncontrolled flowing feed chemicals

Feed chemicals can leak through the metering pump in an

uncontrolled manner in the event of excessive priming pres‐

sure on the suction side.

– Do not exceed the maximum permissible priming pres‐

sure for the metering pump.

– Organise the installation properly for this.

CAUTION!

Warning against lines disconnecting

With suction, discharge and relief lines installed incorrectly

can loosen / disconnect from the pump connection.

– Only use original tubing with the specified tube diameter

and wall thickness.

–

Only use clamp rings and tube nozzles that correspond

with the respective hose diameter.

– Always connect the lines without mechanical tension.

Only connect steel piping via a flexible piping section to

a plastic valve body - see the following figure.

1

2

3

P_MOZ_0021_SW

Fig. 14: Connect the steel piping to the plastic pump body as shown

1 Steel pipeline

2 Flexible pipe section

3 Plastic valve body

CAUTION!

Warning of feed chemical spraying around

PTFE seals, which have already been used / compressed,

can no longer reliably seal a hydraulic connection.

– New, unused PTFE seals must always be used.

Installation

20

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ProMinent Makro/ 5 M5Ka Operating Instructions Manual

ProMinent Makro/ 5 M5Ka Operating Instructions Manual

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