ProMinent DULCO flex Control User manual

Peristaltic metering pump
DULCO flex Control, DFXa
Operating instructions
EN
Original operating instructions (2006/42/EC)Part no. 981953 BA DX 031 04/21 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.
The latest version of the operating instructions are available on our homepage.

Read the following supplementary information in its entirety! You will ben‐
efit more from the operating instructions should you already know this
information.
The following are highlighted separately in the document:
nEnumerated lists
Instructions
ðOutcome of the instructions
Ä ‘State the identity code and serial number’ on page 2 : Links to points
in this chapter
- refer to ... : References to points in this document or another document
[Keys]
‘Menu level 1 è Menu level 2 è Menu level ...’ : Menu paths
‘Software interface texts’
Information
This provides important information relating to the cor‐
rect operation of the unit or is intended to make your
work easier.
Safety information
Safety information is identified by pictograms - see "Safety Chapter".
Please state the identity code and serial number, which you can find on
the nameplate or in the menu under
‘Setting / Menu è Information’ when
you contact us or order spare parts. This enables us to clearly identify the
unit type and material version.
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!
State the identity code and serial number
General non-discriminatory approach
Supplemental directives
2

Table of contents
1Identity code.................................................................................... 6
2 About this pump............................................................................... 9
3 Safety chapter............................................................................... 10
4 Storage, transport and unpacking................................................. 15
5 Overview of equipment and control elements............................... 16
5.1 Overview of equipment......................................................... 16
5.2 Control elements................................................................... 17
5.2.1 Control elements................................................................ 17
5.2.2 Key functions...................................................................... 19
6 Functional description.................................................................... 21
6.1 Unit........................................................................................ 21
6.2 Dosing rate............................................................................ 21
6.3 Operating modes................................................................... 21
6.4 Functions............................................................................... 21
6.5 Relays (options).................................................................... 22
6.6 LED displays......................................................................... 22
6.7 Hierarchy of operating modes, functions and fault sta‐
tuses...................................................................................... 23
7 Assembly....................................................................................... 24
7.1 Changing the dosing head alignment.................................... 24
8 Installation, hydraulic..................................................................... 27
9 Installation, electrical..................................................................... 30
9.1 Supply voltage connector - mains voltage............................ 31
9.2 Description of the terminals................................................... 32
9.2.1 “Config I/O” socket............................................................. 32
9.2.2 “External control” terminal.................................................. 33
9.2.3 “Level switch” terminal....................................................... 34
9.2.4 “Metering monitor” terminal................................................ 35
9.2.5 “Tube rupture indicator” terminal........................................ 35
9.2.6 Relays................................................................................ 36
10 Basic set-up principles................................................................... 39
10.1 Basic principles for setting up the control............................ 39
10.2 Checking adjustable variables............................................ 41
10.3 Changing to Setting mode................................................... 41
11 Initial commissioning..................................................................... 42
12 Set up /
‘Menu’ .............................................................................. 45
12.1 ‘Information’ ....................................................................... 45
12.2 ‘Settings’ ............................................................................ 45
12.2.1 ‘Operating mode’ ............................................................. 46
12.2.2 Dosing direction............................................................... 49
12.2.3 Concentration................................................................... 49
12.2.4 Calibration........................................................................ 55
12.2.5 System............................................................................. 57
12.2.6 Config-I/Os....................................................................... 58
12.2.7 Inputs/outputs................................................................... 59
12.2.8
‘Priming time’ .................................................................. 61
12.2.9 ‘Set time’ ......................................................................... 61
12.2.10 ‘Date’ ............................................................................. 62
12.3
‘Tube service’ ..................................................................... 62
12.4 Timer................................................................................... 62
12.4.1 Activation / deactivation................................................... 62
12.4.2 Setting the timer............................................................... 63
Table of contents
3

12.4.3 Clear all............................................................................ 68
12.4.4 Examples......................................................................... 68
12.4.5 Timer information............................................................. 70
12.4.6 Typical pitfalls Timer functional faults............................. 70
12.4.7 Brief explanation of selected functions............................. 71
12.5
‘Service’ ............................................................................. 71
12.5.1 ‘Access protection’ .......................................................... 72
12.5.2 ‘Password ’ ...................................................................... 72
12.5.3 ‘Clear counters’ ............................................................... 72
12.5.4 ‘Hose’ .............................................................................. 73
12.5.5 ‘Error log book’ ................................................................ 74
12.5.6 ‘Display’ ........................................................................... 74
12.5.7 ‘Factory setting’ ............................................................... 74
12.5.8 Spare parts kit number: XXXXXXX.................................. 75
12.6 ‘Language’ ......................................................................... 75
13 Operation....................................................................................... 76
13.1 Manual operation................................................................ 76
14 Maintenance.................................................................................. 78
15 Repair............................................................................................ 80
15.1 Replacing the pump tube.................................................... 81
15.2 Cleaning hose rupture indicator (option)............................. 83
16 Troubleshooting............................................................................. 84
16.1 Faults without error message.............................................. 84
16.2 Fault with error message..................................................... 84
16.2.1 Fault messages on the LCD screen................................. 84
16.2.2 Warning messages on the LCD screen........................... 86
16.2.3 All other faults.................................................................. 87
16.3 Log book............................................................................. 87
16.3.1 Fault messages in the log book....................................... 87
16.3.2 Warning messages in the log book.................................. 88
16.3.3 Event messages in the log book...................................... 88
16.3.4 Log book entry - detailed view......................................... 89
17 Decommissioning and disposal..................................................... 90
18 Technical data............................................................................... 92
18.1 Performance data................................................................ 92
18.2 Precision............................................................................. 92
18.3 Viscosity.............................................................................. 92
18.4 Material specifications......................................................... 93
18.5 Electrical data...................................................................... 93
18.6 Temperatures...................................................................... 93
18.7 Climate................................................................................ 94
18.8 Altitude of site ..................................................................... 94
18.9 Degree of Protection and Safety Requirements.................. 94
18.10 Sound pressure level........................................................ 94
18.11 Suction lance, continuous................................................. 94
19 Dimensional drawings................................................................... 96
20 Diagrams for adjusting the pump capacity.................................... 97
21 Declaration of Conformity for Machinery....................................... 98
22 UK Declaration of Conformity........................................................ 99
23 Operating / set-up overview DULCO flex Control - DFXa........... 100
24 DULCO flex Control - DFXa operating menu, overall.................. 102
25 Continuous displays and secondary displays.............................. 107
Table of contents
4

26 Installation instructions for retrofitting relays............................... 109
27 Index............................................................................................ 111
Table of contents
5

1 Identity code
Product identification
This identity code serves to identify the product.
Use the identity code from the Product Catalogue for
orders.
Product range DULCO flex Control - DFXa
DFXa
Regional design
EU Europe
US USA
CN China
Pump type
0518 5 bar, 18 l/h
0530 5 bar, 30 l/h
0730 7 bar, 30 l/h
0565 5 bar, 65 l/h
Tube material / Connectors / O-rings
SP TPV / PVDF / PTFE
VP PUR / PVDF / PTFE
Seal material
F FDA-compliant (PTFE)
T PTFE
Dosing head orientation (orientation of the hydraulic connectors - viewed from behind)
R right
L left
U top
D bottom
Hydraulic connector
0 Standard connector (12x9)
2 8x5 connector
5 12x6 connector, discharge side
7 without connector kit
8 9x5 connector
E DN10 connector, with nozzle
Tube rupture indicator
0 none
1 Optical tube rupture indicator
Design
0 Housing RAL5003 / hood RAL2003
Identity code
6

Product range DULCO flex Control - DFXa
2 Housing RAL5003 / hood RAL3001
M modified
Logo
0 with ProMinent logo
2 without ProMinent logo
Design of power unit
U 100-240 V
Cable and plug
A 2 m, Europe
B 2 m, Switzerland
C 2 m, Australia
D 2 m, USA / 115 V
1 2 m, open end
.. ...
Relay function
0 no relay -
1 1 x changeover contact
230 V AC – 6 A
Fault indicating relay normally
closed
4 1 x N/O 24 V DC – 1 A
1 x N/O 24 V DC – 100
mA
as 1 + pacing relay
C 1 x N/O 24 V DC – 100
mA, and 1 x 4-20 mA
output
as 1 + 4-20 mA output
.. ...
Accessories
0 no accessories
1 with 1/2” injection valve and foot valve
2 as 0 + measuring cup
3 as 1 + measuring cup
Control version
0 Manual + external contact with pulse control
3 Manual + external contact with pulse control + ana‐
logue 0/4-20mA
C As 3 + CANopen
P As 3 + PROFINET
RAs 3 + PROFIBUS® M12 plug
M As 3 + Modbus RTU
Communication
0 none
B Bluetooth
Language
Identity code
7

Product range DULCO flex Control - DFXa
DE German
EN English
ES Spanish
FR French
... ...
Identity code
8

2 About this pump
Pumps in the DULCO flex Control - DFXa product range are microproc‐
essor-controlled peristaltic metering pumps with the following characteris‐
tics:
nSimple adjustment of the dosing rate directly in l/h or in gph
nReverse flow is possible
nSimple tube replacement supported by software
nSole contact with media in the tube
nCIP-compatible - when the pump is running
nDirect input of the required and desired concentration in concentration
mode with volume-proportional metering tasks
nExternal control via potential-free contacts with pulse step-up and
step-down
nExternal control via 0/4-20 mA standard signal, scalable
nIntegrated 1-week/1-month timer
nConnection to process control systems via a BUS interface, such as
PROFIBUS, ProfiNET, Modbus RTU or CANopen bus
nDULCOnneX-compatible
About this pump
About this pump
9

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 – automatic start-up.
Warning – hand injuries.
Warning – high-voltage.
Warning – danger zone.
nOnly use the pump to meter liquid feed chemicals.
nOnly start up the pump once it has been correctly installed and started
up in accordance with the technical data and specifications contained
in the operating instructions.
nObserve 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! Use the "Resistance List
for DULCO flex Control DFXa and DFYa” available at www.promi‐
nent.com for the pump tube.
nAll other uses or modifications are prohibited.
nThe pump is neither a gas pump nor a solids pump. *
nThe pump is not designed for metering flammable media.
nThe pump is not designed for metering explosive media.
nThe pump is not designed for use outdoors without appropriate pro‐
tective measures.
nOnly allow the pump to be operated by trained and authorised per‐
sonnel - see the following "Qualifications" table.
nYou have a duty to observe the information contained in the operating
instructions during the different phases of the unit's service life.
* In spite of this, gas bubbles in the feed chemical can be pumped as well
as particles with a diameter of up to 1/3 of the inner diameter of the tube.
Identification of safety notes
Warning signs denoting different types of
danger
Intended use
Safety chapter
10

WARNING!
Warning about personal and material damage
The pump can start to pump, as soon as it is connected
to the mains voltage.
– Install an emergency cut-off switch in the pump
power supply line or integrate the pump in the emer‐
gency cut-off management of the system.
WARNING!
Warning of personal injury and material damage
The pump can start pumping as soon as it has cooled
down after the error ‘temperature’ .
– Take this into account with the pump and your
installation.
WARNING!
Danger of electric shock
A mains voltage may exist inside the pump housing.
– If the pump housing has been damaged, you must
disconnect it from the mains immediately. It may
only be returned to service after an authorised
repair.
WARNING!
Warning of hazardous feed chemical
Should a dangerous feed chemical be used: it may
escape from the hydraulic components when working on
the pump, material failure or incorrect handling of the
pump.
– Take appropriate protective measures before
working on the pump (e.g. safety glasses, safety
gloves, ...). Adhere to the material safety data sheet
for the feed chemical.
–Drain and flush the liquid end before working on the
pump.
WARNING!
Fire danger
The pumping of flammable media is prohibited.
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 assessment for the workstations affected.
Safety information
Safety chapter
11

CAUTION!
Warning of feed chemical spraying around
Feed chemical may spray out of the hydraulic compo‐
nents if they are tampered with or opened due to pres‐
sure 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
unauthorised persons.
–Ensure that the system is at atmospheric pressure
before commencing any work on hydraulic parts of
the system.
CAUTION!
Warning of body parts being drawn in
The rotor running in the liquid end may draw in and trap
body parts.
– Do not reach into the running rotor.
–Only remove the bearing cover once prompted to do
so by the operating instructions or operating soft‐
ware.
CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical can damage the parts of
the pump that come into contact with the chemical.
– Take into account the resistance of the wetted mate‐
rials and the ProMinent Resistance List when
selecting the feed chemical - see the ProMinent
Product Catalogue or visit ProMinent.
CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical may cause premature wear
of the pump tube.
– Pay attention to the resistance of the pump tube and
the "Resistance List for DULCO flex Control DFXa
and DFYa” available at www.prominent.com when
selecting the feed chemical.
CAUTION!
Danger of injury to personnel and material damage
The use of untested third party components can result in
injury to personnel and material damage.
– Only fit parts to metering pumps that have been
tested and recommended by ProMinent.
CAUTION!
Danger from incorrectly operated or inadequately main‐
tained 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.
Safety chapter
12

CAUTION!
Warning against illegal operation
Observe the regulations that apply where the device is
installed.
nCover of the slot for relays and optional modules - see the chapter
entitled “Overview of equipment and control elements”
nBearing cover for the liquid end - see “Overview of equipment and
control elements” chapter
The bearing cover only prevents people from reaching
into the rotor; it is not liquid-tight.
Customers should only remove the cover of the slot for relays and optional
modules and/or a relay or optional module in line with the supplementary
instructions for the relays and optional modules.
Customers should only remove the bearing cover for the liquid end in
accordance with the “Repair” chapter.
Only ProMinent Service is authorised to open the housing and hood
(housing the control elements).
Labels
WARNING!
– A warning sign indicating “Warning of injury to
hands” is attached to the pump and warns of
rotating parts and the risk of being drawn into the
liquid end.
–Ensure that the label is always fitted and legible.
Star-shaped handle with locking nut
WARNING!
– The bearing cover of the liquid end is fixed in place
with 4 star-shaped screws. 1 star-shaped screw is
additionally secured with a locking nut – to prevent
unintentional opening.
In an emergency, either disconnect the mains plug, press
[Start/Stop]
or the Emergency Stop switch installed on the customer's side, or discon‐
nect the pump from the mains/power supply in line with the Emergency
Stop management guidelines for your system.
If feed chemical escapes, ensure that the hydraulic environment of the
pump is also at atmospheric pressure. Pay attention to the material safety
data sheet for the feed chemical.
Task Qualification
Storage, transport, unpacking Instructed person
Assembly Technical personnel, service
Planning the hydraulic installation Technical personnel who have a thorough knowledge of peristaltic
pumps
Isolating protective equipment
Other protective equipment
Information in the event of an emergency
Qualification of personnel
Safety chapter
13

Task Qualification
Hydraulic installation Technical personnel, service
Electrical installation Electrical technician
Initial commissioning Technical personnel, service
Operation Instructed person
Maintenance, repair Technical personnel, service
Decommissioning, disposal Technical personnel, service
Troubleshooting Technical personnel, electrical technician, instructed person, service
Explanation of the table:
Technical personnel
Technical personnel are deemed to be people who are able to assess the
tasks assigned to them and recognise possible dangers based on their
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 of employment in the relevant field of work.
Electrical technician
An electrical technician is able to complete work on electrical systems and
recognise and avoid possible dangers independently based on his or her
technical training and experience as well as knowledge of pertinent stand‐
ards and regulations.
The electrical technician must be specifically trained for the working envi‐
ronment in which he or she is employed and be conversant with the rele‐
vant standards and regulations.
The electrical technician 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
The service department refers to service technicians, who have received
proven training and have been authorised by ProMinent to work on the
device / system.
Sound pressure level LpA < 70 dB according to EN ISO 20361
at maximum dosing rate and maximum back pressure (water)
Sound pressure level
Safety chapter
14

4 Storage, transport and unpacking
User qualification: Instructed person - see
Ä ‘Qualification of personnel’
on page 13
WARNING!
Only return metering pumps for repair in a cleaned state
and with a flushed liquid end - refer to "Decommis‐
sioning!
Only return metering pumps with a completed Decon‐
tamination Declaration form. The Decontamination Dec‐
laration constitutes an integral part of an inspection /
repair order. A unit can only be inspected or repaired
when a Declaration of Decontamination Form is sub‐
mitted that has been completed correctly and in full by
an authorised and qualified person on behalf of the
pump operator.
The "Decontamination Declaration Form" can be found
on our homepage.
CAUTION!
Danger of material damage
The device can be damaged by incorrect or improper
storage or transportation!
– The unit should only be stored or transported in a
well packaged state - preferably in its original pack‐
aging.
–The packaged unit should also only be stored or
transported in accordance with the stipulated
storage conditions.
– The packaged unit should be protected from mois‐
ture and the ingress of chemicals.
CAUTION!
Before shipping
Remove the pump hose from the pump before shipping.
Ambient conditions - see "Technical data" chapter.
Storage period of pump hose non-condensing, max.: 2 years
Compare the delivery note with the scope of delivery:
nMetering pump with mains cable
nPump hose
nRotor half
nProduct-specific operating instructions with EU Declaration of Con‐
formity
nOptional accessories
Safety information
Ambient conditions
Storage period, max.
Scope of delivery
Storage, transport and unpacking
15

5 Overview of equipment and control elements
5.1 Overview of equipment
1
P_G_0103_SW
2 3
Fig. 2: Overview of equipment DFXa, complete
1 Control unit
2 Drive unit
3 Liquid end
1
2
3
5
6
4
P DX 0177 SW_2
Fig. 3: Liquid end DFXa
1 Dosing head
2 Pressure connector (delivery status)
3 Suction connector (delivery status)
4 Domed nut on star-shaped screw
5 Star-shaped screws
6 Bearing cover
Overview of equipment and control elements
16

5.2 Control elements
a) b)
P_G_0105_SW
12 14 15 13
10 11
3
1
54
2
9
8
7
6
Fig. 4
1 LCD screen
2
[Menu] key
3Clickwheel
4
[Priming] key
5
[STOP/START] key
6
[Back] key
7 Fault indicator (red)
8 Warning indicator (yellow)
9 Operating indicator (green)
10 "Config I/O” terminal
11 "Hose rupture indicator" terminal
12 "External control" terminal
13 "Metering monitor" terminal (no function)
14 "Level switch" terminal
15 Slot for relays and optional modules
5.2.1 Control elements
Use this overview to familiarise yourself with the keys
and other control elements on the pump!
Control elements, overview
Overview of equipment and control elements
17

10.0
10.0 mA
ANALOG
4..20mA
l/h
B1150
1
3
2
AUX
Fig. 5: Structure of continuous display
1 Status bar
2 Continuous display, central area
3 Secondary display
Refer to the chapter entitled "Main displays and secondary displays" in the
Appendix for the different main displays and secondary displays.
The LCD screen supports the operation and adjustment of the pump using
various information and identifiers:
30.0
Level
MANUAL
l/h
Service: 600 h
MANUAL
Level error!
B1151
a) b)
Level
602371
Fig. 6: a) Continuous display with warning message; b) Continuous display
with fault message. Explanation of the symbols in the following tables.
The above Figure, Part a) shows that:
nthe pump is in operation
nis in
‘Manual’ operating mode
na
‘level’ warning message is pending
nthe capacity of 30.0 l/h has been set
nthe pump has performed 602371 revolutions to date
Tab. 1: Identifiers and error displays:
Identifier Meaning
The pump is working or waiting for a starting signal.
The pump was manually stopped using the
[STOP/START] key.
The pump was remotely stopped (Pause) - via the "External" terminal.
The pump was stopped by an error.
Only with cyclical batch metering: the pump is waiting for the next cycle.
Identifier and fault displays on the LCD
screen
Overview of equipment and control elements
18

Identifier Meaning
Only with
‘Access protection’ : the pump software is locked.
‘AUX’ The pump is currently pumping at auxiliary capacity.
‘memory’ Only in ‘CONTACT’ and ‘BATCH’ operating modes:
the auxiliary function "Memory" has been set.
The pump is in
‘ANALOG’ operating mode.
The
‘Curve è linear’ type of processing is set.
The pump is in ‘ANALOG’ operating mode.
The
‘Curve è Upper side band’ type of processing is set.
A hose rupture indicator is connected.
The pump is in the
‘Menu’ (Set up).
Further explanations can be found in the "Trouble‐
shooting" chapter.
The pump only shows the metering volume and the
capacity in the calibrated state in l or l/h or in gal or gal/h
(US gallons).
5.2.2 Key functions
Key Application In the continuous displays In the menu
[Back]
press - Go back to the previous menu
item (or a continuous display) -
without saving
[STOP/
START]
press Stop pump, Stop pump,
Start pump Start pump
[Menu]
press Go to the menu Go back to a continuous display
[Priming]
press Priming * Priming *
[Clickwheel]
press Start batch (only in ‘Batch’ operating
mode),
Acknowledge errors
Go to next menu item (or a contin‐
uous display)
Confirm entry and save
[Clickwheel]
turn Switch between the continuous dis‐
plays
Change figure or change selection
Overview of equipment and control elements
19

* When priming the pump does not run at maximum
number of revolutions.
If [Priming] is pressed in ‘Stop’ state, then [Priming]
has top priority as long as the button is pressed.
Refer to the "Set-up basics" chapter for how to adjust fig‐
ures
Overview of equipment and control elements
20