HNP Mikrosysteme mzr-6359 Ex User manual

Operating manual for micro annular gear pump
mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
HNP Mikrosysteme GmbH
Bleicherufer 25
D-19053 Schwerin
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
http://www.hnp-mikrosysteme.de
Last update: October 2016

Impressum
Original instructions
Copyright
HNP Mikrosysteme GmbH
Bleicherufer 25
D-19053 Schwerin
All rights, including translation, reserved.
Without prior explicit written permission of HNP Mikrosysteme GmbH no part
of this manual may be, copied, reproduced or processed.
This manual has been prepared with care. HNP Mikrosysteme does assume no
liability for any errors in this manual and resulting consequences. Likewise, no
liability is assumed direct or subsequent damages arising from an incorrect use
of the devices.
While using micro annular gear pumps, the relevant standards regarding the
specifications of this manual have to be followed.
Subject to change without notice.

Contents Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
Last update: October 2016 Technical data subject to change without prior notice! i
Contents
1General information 1
1.1 Application scope of the pumps 1
1.2 Product information 2
1.3 Technical data of the micro annular gear pumps 3
1.4 Measurements 6
1.5 Flow charts 7
1.6 Technical data of the Ex-motor 9
1.7 Technical data of the altenativ brushless DC Ex-motor
(X2 version) 12
2Safety instructions 15
2.1 Safety symbols in this operating manual 15
2.2 Staff qualification and training 15
2.3 Safety-conscious work 16
2.4 Safety instructions for the operator 16
2.5 Safety instructions for maintenance, check and
assembly of the pump 16
2.6 Unauthorized pump conversions and spare part
manufacture 17
2.7 Improper modes of operation 17
2.8 General safety instructions 17
3Transport and intermediate storage 18
3.1 Shipment of the pumps and protection measures 18
3.2 Transport 18
3.3 Intermediate storage 18
4Description of the micro annular gear pump 19
4.1 Operating principle of the micro annular gear pump 19
4.2 Construction 21
4.3 Construction materials 22
4.4 Liquid supply 23
5Optional modules 24
5.1 Heat insulation module 25
5.1.1 Operation of the micro annular gear pumps with
heat insulation module in different temperature
classes 26
5.1.2 Monitoring of operation in the temperature class T4
and T5 27
5.1.3 Liquid temperature range for operation in
temperature class T4 and T5 28
5.1.4 Liquid temperature range for operation in
temperature class T6 28
5.1.5 Thermal element 29

Contents Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
ii Technical data subject to change without prior notice! Last update: October 2016
6System integration 30
6.1 Check before the first assembly 30
6.2 Details place of operation 30
6.3 Mounting of the micro annular gear pump 30
6.4 General instructions for the assembly of the liquid
supply network 31
6.5 Electrical Connections 32
6.6 Assembly instruction for tubing and accessories 32
6.7 Filter selection and use 34
6.8 Requirements for motor controller 35
6.9 Operation with external motion controller S-HD-KL 36
6.10 Connection of the micro annular gear pump with S-
G05 39
6.10.1 Startup with potentiometer 41
6.10.2 Startup with external 0-10 V signal 42
6.10.3 Startup with an external 0(4)-20 mA current signal 43
6.10.4 Startup with external potentiometer 45
6.10.5 Startup with the RS-232 interface 46
6.11 Installation of the software »Motion Manager« 47
7Startup/shutdown of a mzr-pump 48
7.1 Preparing for operation 48
7.2 Startup of the micro annular gear pump 48
7.3 Re-start after dry run 48
7.4 Operation of the micro annular gear pumps without
heat insulation module in different temperature
classes 49
7.5 Monitoring of operation in the temperature class T5,
T6 50
7.6 Flushing procedure after use 50
7.7 Shutdown of the micro annular gear pump 53
7.7.1 Conservation 55
7.7.2 Dismantling of the system 56
7.8 Trouble shooting 57
7.9 Return of the micro annular gear pump to the
manufacturer 57
8Software »Motion Manager« 58
8.1 Command mode 58
8.2 Programming of motion controller 60
8.3 Transfer of mcl-files to motor controller 60
9Accessories for microfluidic systems 63
10 Non-liability clause 63
11 Problems and their removal 64
12 EC Directive 67
12.1 Electromagnetic Compatibility (EMC) 68

Contents Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
Last update: October 2016 Technical data subject to change without prior notice! iii
12.1.1 EMC Directive and Standards 68
12.1.2 Information on use as intended 69
13 Declaration of conformity - manufacturer’s
declaration 70
14 Maintenance and service 84
14.1 Micro annular gear pumps 84
14.2 Magnetic coupling 84
14.3 Ex-Motor 84
15 Contact person 85
16 Legal information 86
17 Safety information for the return of already
employed micro annular gear pumps and
components 87
17.1 General information 87
17.2 Declaration of liquids in contact with the micro
annular gear pump 87
17.3 Shipment 87
18 Declaration of media in contact with the micro
annular gear pump and its components 88
19 Appendix 89

Contents Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
iv Technical data subject to change without prior notice! Last update: October 2016

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
Last update: October 2016 Technical data subject to change without prior notice! 1
1General information
This operating manual contains basic instructions to be followed during
integration, operation and maintenance of a mzr®micro annular gear pump.
For this reason it is necessary to read it carefully before any handling of the
device. The present manual should always be kept at the operation site of the
micro annular gear pump.
In case assistance is needed, please indicate the pump type visible on the
housing.
1.1 Application scope of the pumps
The micro annular gear pumps described in this manual are suitable for
continuous delivery and discrete dosage of water, watery solutions, solvents,
methanol, oils, lubricating liquids, paints and varnishes as well as many other
liquids.
!
If you intend to treat any aggressive, poisonous, or radioactive liquids, you
must conform to safety measures as according to the regulations in force. Any
project concerning handling of magnetic or corrosive liquids should be
previously discussed with the pump manufacturer.
!
The micro annular gear pumps must not be used for invasive medical
applications, in which the liquid having had contact with the pump is re-
introduced to the body.
!
Micro annular gear pumps exclusively are provided for use in the industrial
area. A private use is excluded.
!
The micro annular gear pumps must not be used in aircrafts and spacecrafts
or other vehicles without prior consent of the manufacturer.
!
The data concerning resistance of the pumps to manipulated liquids is
elaborated according to the best of HNP Mikrosysteme's knowledge.
However, operating parameters varying from one application case to another,
no warranty for this information can be given.
!
Information given in this manual does not release the customer from the
personal obligation to check the integrity, correct choice and suitability of the
pump for the intended use. The use of the micro annular gear pumps should
be conform with technical norms and regulations in force.
If you wish to receive more information than comprised in this operating
manual please contact directly HNP Mikrosysteme.

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
2Technical data subject to change without prior notice! Last update: October 2016
1.2 Product information
The present operating manual is valid for the micro annular gear pumps
mzr-6359 Ex, mzr-7259 Ex and mzr-6359X2 Ex, mzr-7259X2 Ex manufactured
after June 2016 by HNP Mikrosysteme GmbH, Bleicherufer 25, D-
19053 Schwerin, Germany.
The date of release of the present manual figures on the cover.
The micro annular gear pumps described in the operation manual are conform
to the applicable EC standards and are permitted to bear the CE mark.

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
Last update: October 2016 Technical data subject to change without prior notice! 3
1.3 Technical data of the micro annular gear pumps
mzr-6359 Ex,
mzr-6359X2 Ex
mzr-7259 Ex,
mzr-7259X2 Ex
Explosion-protection
Ex-certification CE II 2G IIC c T4 X
Temperature class
T4
Ambient temperature 0 … +40 °C
Installation place Ex-area zone 1, 2
Protection categories c, d (Ex-motor)
Technical data
Displacement volume [µl]
24
48
Measurements [mm] L x B x H see appendix see appendix
Weight [g] approx. 4900 4900
Internal volume [ml] 3.55 3.57
Rotor material partially stabilized ZrO2,
optional: tungsten carbide
Ni-based
 
Pump case material alloy C22 (2.4602),
optional: stainless steel
316L
 
Bearing material sintered silicon carbide
(SSiC), Al
2
O
3
 
Static sealing FFPM, optional: FPM  
Threaded fluid supply
connections
1/8"NPT (lateral)  
Coupling bellow coupling  
Performance parameters
Flow rate Q [ml/min] 0.024 - 112 0.048 - 225
Flow rate Q [ml/min] X2 version 0.024 - 96 0.048 - 192
Min. dosage volume [µl] 15 30
Max. system pressure [bar] inlet pressure+differential
pressure
80 (1160 psi)
60 (870 psi) for
pump made of 316L
80 (1160 psi)
60 (870 psi) for
pump made of 316L
Differential pressure range
[bar]
viscosity 1 mPas 5 (-hx) (72 psi)
15 (-cx) (217 psi)
15 (-dcx) (217 psi),
20 (-cx) (290 psi)
30 (-hx) (435 psi)
viscosity >16 mPas
40 (580 psi)
40 (580 psi)
Viscosity η[mPas] min. 0.3 0.3
max. 100* 100*
Dosage precision CV [%] <1 <1
Pulsation [%] 6 6
NPSHR-value [m] min. - -
Liquid temperature [°C]
min.
-5
-5
max. 60 (150 *) 60 (150 *)
Ambient temperature [°C] min. 0 0
max. 40 40
Storage temperature [°C]
min.
0
0
max. 40 40
Legend: available
optional / on demand
–not available
* with supplementary modules
table 1 Technical data and performance parameters of the micro annular gear pumps mzr-6359 Ex and mzr-6359 Ex

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
4Technical data subject to change without prior notice! Last update: October 2016
mzr-6359X2 Ex mzr-7259X2 Ex
Explosion-protection
Ex-certification CE II 2G IIC c T4 X
Temperature class T4
Ambient temperature 0 … +40 °C
Installation place
Ex-area zone 1, 2
Protection categories c, d (Ex-motor)
Technical data
Displacement volume [µl] 24 48
Measurements [mm] L x B x H 279 x 80 x 75 279 x 80 x 75
Weight [g]
4900
4900
Internal volume [ml] 3.55 3.57
Rotor material partially stabilized ZrO2,
optional: tungsten carbide
Ni-based
 
Pump case material alloy C22 (2.4602),
optional: stainless steel
316L
 
Bearing material sintered silicon carbide
(SSiC), Al2O3
 
Static sealing FFPM, optional: FPM  
Threaded fluid supply
connections
1/8"NPT (lateral)  
Coupling bellow coupling  
Performance parameters
Flow rate Q [ml/min] min. 0.024 0.048
[ml/min] max. 96 192
[l/h] max. 5,76 11.52
Min. dosage volume [µl]
15
30
Max. system pressure [bar] inlet pressure+differential
pressure
80 (1160 psi)
60 (870 psi) for
pump made of 316L
80 (1160 psi)
60 (870 psi) for
pump made of 316L
Differential pressure range
[bar]
viscosity 1 mPas 15 (218 psi) 20 (-cx) 290 psi
30 (-hx) 580 psi
viscosity >16 mPas
40
40
Viscosity η[mPas] min. 0.3 0.3
max. 100* 100*
Dosage precision CV [%]
<1
<1
Pulsation [%] 6 6
NPSHR-value [m] min. - -
Liquid temperature [°C] min. -5 -5
max. 60 (150 *) 60 (150 *)
Ambient temperature [°C] min. 0 0
max. 40 40
Storage temperature [°C] min. 0 0
max. 40 40
Legend: available
optional / on demand
–not available
* with supplementary modules
table 2 Technical data and performance parameters of the micro annular gear pumps mzr-6359X2 Ex and mzr-
6359X2 Ex

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
Last update: October 2016 Technical data subject to change without prior notice! 5
Warning The material properties of a liquid (e.g. viscosity, lubricating property, particle
content, corrosiveness) impacts the technical data and the lifetime of pumps.
Under appropriate conditions the characteristic values may be increased or
decreased.
Warning If you intend to operate the pump out of the range of the above given
specification, please consult the manufacturer. Modifications may be
necessary to ensure successful operation. Otherwise the pump or the system
may be damaged seriously.
Warning The manufacturer of the pump cannot guarantee the fatigue strength of the
pump case due to the unknown load impact defined by different specification
parameters like type of liquid, concentration, temperature. The cause for this
restriction is a non predictable corrosion at the pump case like pitting, micro
cracking and surface erosion which causes a wall thickness reduction and an
increase of the notch effect. This could reduce the fatigue strength limit
considerably. Under a particularly aggressive environment only a time
dependent stability can be assumed. Because of the mentioned above the
manufacturer cannot give specifications concerning the number of possible
load alternations.

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
6Technical data subject to change without prior notice! Last update: October 2016
1.4 Measurements
figure 1 Measurements of the micro annular gear pump mzr-6359 Ex and mzr-7259 Ex with lateral fluid connection
1/8" NPT

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
Last update: October 2016 Technical data subject to change without prior notice! 7
1.5 Flow charts
Liquid water Liquid methanol
0
20
40
60
80
100
120
0 5 10 15
Differential pressure [bar]
Flow rate [ml/min]
4700
4000
3000
2000
1000
Speed [rpm]
Viscosity 1 mPas
Liquid water
0
20
40
60
80
100
120
0510 15
4700
4000
3000
2000
1000
Speed [rpm]
Viscosity 0,58 mPas
Liquid methanol
Liquid oil, 16 mPas Liquid oil, 100 mPas
0
20
40
60
80
100
120
0510 15 20
Differential pressure [bar]
Flow rate [ml/min]
4700
4000
3000
2000
1000
Speed [rpm]
Viscosity 16 mPas
Liquid oil
0
20
40
60
80
100
120
0510 15 20
Differential pressure [bar]
Flow rate [ml/min]
4700
4000
3000
2000
1000
Speed [rpm]
Viscosity 100 mPas
Liquid oil
figure 2 Flow charts of the mzr-6359 Ex and mzr-6359X2 Ex

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
8Technical data subject to change without prior notice! Last update: October 2016
Liquid water Liquid methanol
0
50
100
150
200
250
0510 15 20
Differential pressure [bar]
Flow rate [ml/min]
4700
4000
3000
2000
1000
59
Speed [rpm]
Viscosity 1 mPas
Liquid water
0
50
100
150
200
250
0 5 10 15 20
4700
4000
3000
2000
1000
mzr 7259
Speed [rpm]
Viscosity 0,58 mPas
Liquid methanol
Liquid oil, 16 mPas Liquid oil, 100 mPas
0
50
100
150
200
250
010 20 30 40
Differential pressure [bar]
Flow rate [ml/min]
4700
4000
3000
2000
1000
mzr 7259
Speed [rpm]
Viscosity 16 mPas
Liquid oil
0
50
100
150
200
250
010 20 30 40
Differential pressure [bar]
Flow rate [ml/min]
4700
4000
3000
2000
1000
mzr 7259
Speed [rpm]
Viscosity 100 mPas
Liquid oil
figure 3 Flow charts of the mzr-7259 Ex and mzr-7259X2 Ex

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
Last update: October 2016 Technical data subject to change without prior notice! 9
1.6 Technical data of the Ex-motor
The micro annular gear pumps mzr-6359 Ex and mzr-7259 Ex are equipped
with an explosion-proof DC-motor. The parameters of the motor are described
in table 3. The speed of the motor can be controlled with the optional motion
controller S-HD-KL. One of the motor’s features is a highly dynamic behavior.
For operation it is recommended to use a power source of 24 V (with a power
rating of 5 A).
The motor of the pumps is corresponding to the applicable EC standards. The
confirmations according to EC 94/9/EG as well as of EC conformity are given.
Measurements
Diameter of motor casing
70 mm
Length of motor casing 210 mm
Weight approx. 1,8 kg
General data
Type EXR-1.24HEDL-L10
Manufacturer Edelweiss Actuators Srl,
Via Padergnone 21
I-24050 Zanika BG
Italy
Distribution / Service Mattke Antriebstechnik
Leinenweberstraße 12
D-79108 Freiburg
Germany
Test body
0948
Number of certificate TÜV-A 11ATEX0006X
Certification EN60079-0, EN60079-1, EU-
Richtlinie 94/9/EG, Anhang III
Ex-certification II 2G Ex d IIC T5 Gb
Installation place Ex-area zone 1, 2
Specification
Nominal voltage 24 V DC
Max. continuos current by
Temperature range T6
2 A
Max. continuos torque 75 mNm
Max. power 53 W
Max. dissipation 11 W
No load speed by 24 V 4700 rpm
Speed range
1 – 4700 rpm
Length of the cable 10 m
External compensation of potential wires:
4 mm² flexible
6 mm² single-wire
Protective class according EN60529 IP54
Operation temperature range -20 … +45 °C
table 3 Technical data Ex-motor for mzr-6359 Ex and mzr-7259 Ex

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
10 Technical data subject to change without prior notice! Last update: October 2016
Parameter
mzr-6359 Ex
mzr-7259 Ex
Max. Peak current 1800 mA 2000 mA
Max. Continuos current 1500 mA 1800 mA
max. Acceleration 550 U/s² 550 U/s²
table 4 Programming current parameters for mzr-6359 Ex and mzr-7259 Ex
Wire
Function
brown motor +
blue motor -
yellow/green screening / PE
red Vcc (5 VDC)
blue
SGND
pink channel A neg.
grey channel A
yellow channel B neg.
green channel B
brown
channel I neg. (index)
white channel I (index)
table 5 Pin configuration motor cable (10 Lead of cable) valid as of September 2012
Wire Function
white motor +
brown motor -
yellow/green screening / PE
red
V
cc
(5 VDC)
blue SGND
pink channel A neg.
grey channel A
violet channel B neg.
black
channel B
red/blue channel I neg. (index)
pink/grey channel I (index)
table 6 Pin configuration motor cable (10 Lead of cable) valid until September 2012

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
Last update: October 2016 Technical data subject to change without prior notice! 11
4 x M8, 8 mm deep
PUR - Drag chain cable
Type S200-Length 5...10 m
Figure 4 Measurements of the motor (standard cable length 10 m)
The motor is delivered with a digital encoder type HEDL5540 with line driver
and 500 counts per revolution.
Encoder
Max. voltage Vcc 5 VDC ± 10 %
Number of channels
3 (A, B, O)
Counts per revolution and channel 500
Output signal at Vcc = 5 VDC EIA standard RS422
used driver: DS26LS31
Output current max. 20 mA
Phase shift Φ(nominal) 90°
Operating temperature range 0 ... +40°C
table 7 Technical data encoder

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
12 Technical data subject to change without prior notice! Last update: October 2016
1.7 Technical data of the altenativ brushless DC Ex-motor (X2 version)
The micro annular gear pumps mzr-6359X2 Ex and mzr-7259X2 Ex are
equipped with a alternativ explosion-proof brushless DC-motor. The
parameters of the motor are described in table 3. The speed of the motor can
be controlled with the internal motion controller. One of the motor’s features
is a highly dynamic behavior. For operation it is recommended to use a power
source of 24 V (with a power rating of 5 A).
The motor of the pumps is corresponding to the applicable EC standards. The
confirmations according to EC 94/9/EG as well as of EC conformity are given.
Measurements
Diameter of motor casing
70 mm
Length of motor casing 285 mm
Weight approx. 2,3 kg (without cable)
General data
Type EXR-32.24-MC3-L10
Manufacturer Edelweiss Actuators Srl,
Via Padergnone 21
I-24050 Zanika BG
Italy
Distribution / Service Mattke Antriebstechnik
Leinenweberstraße 12
D-79108 Freiburg
Germany
Test body
0948
Number of certificate TÜV-A 11ATEX0006X
Certification EN60079-0, EN60079-1, EU-
Richtlinie 94/9/EG, Anhang III
Ex-certification II 2G Ex d IIC T5 Gb
Installation place Ex-area zone 1, 2
Specification
Nominal voltage 24 V DC
Max. continuos current by
Temperature range T5
2 A
Max. continuos torque 85 mNm
Max. power 53 W
Max. dissipation 11 W
No load speed by 24 V 4200 rpm
Speed range
1 – 4000 rpm
Length of the cable 10 m
External compensation of potential wires:
4 mm² flexible
6 mm² single-wire
Protective class according EN60529 IP54
Operation temperature range -20 … +40 °C
table 8 Technical data Ex-motor for mzr-6359X2 Ex and mzr-7259X2 Ex

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
Last update: October 2016 Technical data subject to change without prior notice! 13
Parameter
mzr-6359 Ex
mzr-7259 Ex
Max. Peak current 1700 mA 1700 mA
Max. Continuos current 1500 mA 1500 mA
max. Acceleration 500 U/s² 500 U/s²
table 9 Programming current parameters for mzr-6359X2 Ex and mzr-7259X2 Ex
Wire
Function
Cable cross-section
brown 24 VDC 0,5 mm²
blue GND 0,5 mm²
yellow/green screening / PE 0,5 mm²
red 3 IN 0,14 mm²
blue
n.c.
0,14 mm²
white Fault out 0,14 mm²
pink n.c. 0,14 mm²
grey AGND 0,14 mm²
yellow RxD / IN CAN_L 0,14 mm²
green
TxD / IN CAN_H
0,14 mm²
brown ANIN 0,14 mm²
table 10 Pin configuration motor cable (12 Lead of cable)

1General information Operating manual mzr-6359 Ex, mzr-6359X2 Ex, mzr-7259 Ex, mzr-7259X2 Ex
14 Technical data subject to change without prior notice! Last update: October 2016
Figure 5 Measurements of the motor (standard cable length 10 m)