ProMinent Flow Control 3 User manual

ProMinent Metering Monitor
Flow Control 3 - 5
Operating instructions
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Flow Control
SN: 000X
A2235
EN
Part no. 983686 BA MAZ 025 01/16 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.

General non-discriminatory approach In order to make it easier to read, this docu‐
ment uses the male form in grammatical struc‐
tures but with an implied neutral sense. It is
aimed equally at both men and women. We
kindly ask female readers for their under‐
standing in this simplification of the text.
Supplementary information
Please read the supplementary information in its entirety.
Information
This provides important information relating to the correct operation of the unit or is intended to
make your work easier.
Safety Information
The safety information includes detailed descriptions of the hazardous situation, see
Ä Chapter 2.1
‘Explanation of the safety information’ on page 5
The following symbols are used to highlight instructions, links, lists, results and other elements in
this document:
More symbols
Symbol Description
Action, step by step
⇨Outcome of an action
Links to elements or sections of these instructions or other applicable docu‐
ments
nList without set order
[Button] Display element (e.g. indicators)
Operating element (e.g. button, switch)
‘Display /GUI’ Screen elements (e.g. buttons, assignment of function keys)
CODE Presentation of software elements and/or texts
Supplemental instructions
2

Table of contents
1 Overview of Types.................................................................................................................. 4
2 Safety Chapter........................................................................................................................ 5
2.1 Explanation of the safety information............................................................................. 5
2.2 Users' qualifications....................................................................................................... 7
2.3 General Safety Information............................................................................................ 9
2.4 Intended Use................................................................................................................ 10
3 Storage and Transport.......................................................................................................... 11
4 Overview of Equipment and Functional Description............................................................. 12
5 Installation............................................................................................................................. 13
5.1 Installation, Hydraulic................................................................................................... 13
5.2 Installation, Electrical.................................................................................................... 13
6 Start Up................................................................................................................................. 14
7 Maintenance.......................................................................................................................... 17
8 Repair.................................................................................................................................... 18
9 Troubleshooting.................................................................................................................... 21
10 Disposal of Used Parts.......................................................................................................... 24
11 Technical Data...................................................................................................................... 25
11.1 Dimensional drawing.................................................................................................. 26
12 Index..................................................................................................................................... 27
Table of contents
3

1 Overview of Types
Flow Control for pump type Material design Order number
Size 3 - DN10 Sigma/ 1: 12017, 10022,
12035, 10044, 10050,
07065
delta: 0450, 0280
PVDF / EPDM 1021168
PVDF / FPM 1021169
Size 3 - DN15 Sigma/ 1: 07042, 04084,
04120
Sigma/ 2: 12050, 12090,
12130
PVDF / EPDM 1021170
PVDF / FPM 1021171
Size 4 - DN25 Sigma/ 2: 07120, 04350
Sigma/ 3: 120145, 120190,
120270
PVDF / EPDM 1021164
PVDF / FPM 1021165
Size 5 - DN32 Sigma/ 3: 07410, 07580,
04830
PVDF / EPDM 1021166
PVDF / FPM 1021167
Metering Monitors "Flow Control" sizes 3 ... 5 are suitable for metering pumps of product range
Sigma/ 1, Sigma/ 2 and Sigma/ 3 and size 3 for metering pumps of the product range delta® with
plastic liquid ends. The metering monitor can be mounted directly onto the dosing head with liquid
ends with built-in relief valve. The metering monitor is supplied complete with a connecting cable.
The metering monitor enables the pulse of the volume flow to be monitored based on the float prin‐
ciple. The partial volume of the feed chemical flowing past the float is adjusted to the stroke volume
set on the metering pump by the rotary dial. An alarm is triggered if capacity falls below the set value
The maximum permitted number of incompletely performed strokes can be set at between 1 ... 127
on the metering pump to ensure optimum adaptation to the requirements of the process.
Overview of Types
4

2 Safety Chapter
2.1 Explanation of the safety
information
Introduction
These operating instructions provide informa‐
tion on the technical data and functions of the
product. These operating instructions provide
detailed safety information and are provided as
clear step-by-step instructions.
The safety information and notes are categor‐
ised according to the following scheme. A
number of different symbols are used to denote
different situations. The symbols shown here
serve only as examples.
DANGER!
Nature and source of the danger
Consequence: Fatal or very serious inju‐
ries.
Measure to be taken to avoid this danger
Danger!
– Denotes an immediate threatening
danger. If this is disregarded, it will
result in fatal or very serious injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or very
serious injuries.
Measure to be taken to avoid this danger
Warning!
– Denotes a possibly hazardous situa‐
tion. If this is disregarded, it could
result in fatal or very serious injuries.
CAUTION!
Nature and source of the danger
Possible consequence: Slight or minor
injuries, material damage.
Measure to be taken to avoid this danger
Caution!
– Denotes a possibly hazardous situa‐
tion. If this is disregarded, it could
result in slight or minor injuries. May
also be used as a warning about
material damage.
Safety Chapter
5

NOTICE!
Nature and source of the danger
Damage to the product or its surroundings
Measure to be taken to avoid this danger
Note!
– Denotes a possibly damaging situa‐
tion. If this is disregarded, the product
or an object in its vicinity could be
damaged.
Type of information
Hints on use and additional information
Source of the information, additional
measures
Information!
– Denotes hints on use and other useful
information. It does not indicate a
hazardous or damaging situation.
Safety Chapter
6

2.2 Users' qualifications
WARNING!
Danger of injury with inadequately qualified personnel!
The operator of the plant / device is responsible for ensuring that the qualifications are fulfilled.
If inadequately qualified personnel work on the unit or loiter in the hazard zone of the unit, this
could result in dangers that could cause serious injuries and material damage.
– All work on the unit should therefore only be conducted by qualified personnel.
– Unqualified personnel should be kept away from the hazard zone
Training Definition
Instructed personnel 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 dangers that could result from improper behaviour, as well as
having been instructed in the required protective equipment and protec‐
tive measures.
Trained user A trained user is a person who fulfils the requirements made of an
instructed person and who has also received additional training specific
to the system from ProMinent or another authorised distribution partner.
Trained qualified per‐
sonnel
A qualified employee is deemed to be a person who is able to assess
the tasks assigned to him and recognize possible hazards based on
his/her training, knowledge and experience, as well as knowledge of
pertinent regulations. The assessment of a person's technical training
can also be based on several years of work in the relevant field.
Safety Chapter
7

Training Definition
Electrician Electricians are deemed to be people, who are able to complete work
on electrical systems and recognize and avoid possible hazards inde‐
pendently based on his/her technical training and experience, as well
as knowledge of pertinent standards and regulations.
Electricians should be specifically trained for the working environment
in which the are employed and know the relevant standards and regu‐
lations.
Electricians must comply with the provisions of the applicable statutory
directives on accident prevention.
Customer Service
department
Customer Service department refers to service technicians, who have
received proven training and have been authorised by ProMinent to
work on the system.
Note for the system operator
The pertinent accident prevention regulations, as well as all other generally acknowledged
safety regulations, must be adhered to!
Safety Chapter
8

2.3 General Safety Information
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 manu‐
facture 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.
WARNING!
Unauthorised access!
Possible consequence: Fatal or very
serious injuries.
– Measure: Ensure that there can be no
unauthorised access to the unit
WARNING!
Operating faults!
Possible consequence: Fatal or very
serious injuries.
– Ensure that the unit is only operated
by adequately qualified and techni‐
cally expert personnel
– Please also observe the operating
instructions for any other units, such
as the metering pump etc.
– The operator is responsible for
ensuring that personnel are qualified
WARNING!
When metering aggressive media, take
into consideration the resistance of the
materials used – refer to the ProMinent®
Resistance List in the latest product cata‐
logue or at www.prominent.com.
NOTICE!
Life phases of the unit
You have a duty to observe the informa‐
tion contained in the operating instructions
at the different phases of the system's
service life
Safety Chapter
9

NOTICE!
National regulations
Please observe the relevant national regu‐
lations and the information provided in the
operating instructions at all phases of the
unit's service life
2.4 Intended Use
NOTICE!
Intended use
The Flow Control is solely designed for
reporting back to a metering pump of the
product range gamma/ L the pulses of the
volume flow in the liquid feed chemical
from it. If there are no acknowledgement
pulses, the Flow Control thereby indicates
that no medium is being metered, e.g. pos‐
sibly due to a blocked suction or discharge
line on the metering pump, empty dosing
tank or air in the liquid end etc.
Only use the unit in accordance with the
technical data and specifications provided
in these operating instructions and in the
operating instructions for the individual
components.
All other uses or modifications are pro‐
hibited.
NOTICE!
Without adapter
The Flow Control can only be screwed
directly (without adapter) onto plastic liquid
ends.
Rupturing of the discharge line
The Flow Control cannot display a rupture
of the discharge line on the metering
pump.
Safety Chapter
10

3 Storage and Transport
Permissible storage temperature: -10 °C ... +50
°C.
Air humidity: < 98 % relative air humidity, non-
condensing.
Storage and Transport
11

4 Overview of Equipment and Functional Description
1
2
3
4
1
2
3
4
A2236
Fig. 1: Overview of equipment
1. Counter-magnet
2. Reed switch
3. Float
4. Control valve (rotary dial)
The Metering Monitor "Flow Control" essentially consists of a tube with a float (3) and a bypass with
an adjustable cross-section. The "Flow Control" can be adjusted to the stroke volume of the
metering pump using the adjustable control valve (rotary dial), thereby adjusting its response sensi‐
tivity.
There is always a flow with this design of metering monitor, as the float only narrows the bypass,
rather than the hole.
Overview of Equipment and Functional Description
12

5 Installation
nUser qualification, mechanical installation:
trained qualified personnel, see Ä Chapter
2.2 ‘Users' qualifications’ on page 7
nUser qualification, electrical installation:
Electrical technician, see Ä Chapter 2.2
‘Users' qualifications’ on page 7
5.1 Installation, Hydraulic
Testing
The Flow Control always needs a relief
valve upstream of it to be able to test the
Flow Control.
The Flow Control threaded connections
and the connections to the lines need to
be leak-free.
Operating status
Never allow the Flow Control's maximum
permissible operating pressure (10 bar) to
be exceeded in any operating status of the
system.
Only operate the Flow Control vertically.
Using a foot valve
Install a foot valve on the suction side of
the metering pump. Deposits in the Flow
Control can block the float.
Wetted materials:
nHousing: PVDF
nFloat: PTFE coating
nSeals: FPM-B or EPDM, depending on the
order number.
When metering aggressive media, take into
consideration the resistance of the materials
used – refer to the ProMinent® Resistance List
in the latest product catalogue or at
www.prominent.com .
5.2 Installation, Electrical
Insert the plug of the metering monitor
cable into the pump's "Metering monitor"
socket
ðThe
[Flow] identifier now appears at
the bottom left of the pump's LCD
display. If not, then switch from
[OFF] to [ON] in the [FLOW] menu
and set the number of permitted
defective strokes. The [FLOW]
menu can only be accessed if the
plug is inserted into the "Metering
monitor" socket.
Installation
13

6 Start Up
nUser qualification for diagnosis: trained
user, see Ä Chapter 2.2 ‘Users' qualifica‐
tions’ on page 7 .
Recalibration
Recalibrate the pump if you need to after
installation if the pump was calibrated
before the Flow Control was installed.
Not a shut-off device
Never use the Flow Control as a shut-off
device. The rotary dial cannot be used to
block the hole for the float.
Turning the rotary dial under pressure can
temporarily cause leakage, therefore refer
to the latest material safety data sheet for
your feed chemical.
Pump delta®
Set the delta® to "Pressure stroke setting"
– "fast" to ensure that it operates reliably.
Error
Press the P key to acknowledge if the
metering pump goes into "Error" mode
during start up.
Priming
Press both error keys at the same time
on the metering pump.
Dynamic adjustment
Minimum values
With low-viscosity feed chemicals up to a
viscosity of approx. 100 mPa. Higher vis‐
cosities on request.
Start Up
14

"Flow" identifier
The "Flow" identifier disappears when the
reed switch is closed, that is when the float
is in its uppermost position.
1. Disconnect the metering monitor cable
to temporarily disable the metering mon‐
itor.
2. Turn the rotary dial fully to the left ("-")
3. Enter the required operating pressure
on the discharge line, max. 10 bar.
4.
Only set the Flow Control initially to
a stroke rate of 90 Hz even on
pumps with speed control (stroke
control motor or frequency con‐
verter). The Flow Control then gen‐
erally operates faultlessly even at
stroke rates of up to 200 Hz, which
you can test after setting it.
Set a stroke rate of 90 Hz.
5. Reconnect the metering monitor cable.
ðThe "Flow" identifier on the
metering pump's LCD display goes
out with each pressure surge.
6. Slowly turn the rotary dial on the
metering monitor to the right ("+") until
the "Flow" identifier stops flashing.
7. Turn the rotary dial back a little until the
"Flow" identifier starts flashing again.
8. Use the frequency to set the required
capacity on the running pump.
9. Open the relief valve upstream of the
Flow Control; the "Flow" identifier should
stop flashing. If not, slowly turn the
rotary dial on the metering monitor to
the right ("+") again until the "Flow" iden‐
tifier stops flashing.
10. Close the relief valve upstream of the
Flow Control again and adjust it.
ðThe "Flow" identifier should flash
again.
Start Up
15

Static adjustment
Identity code characteristic "Metering
monitor = 1"
This is only possible with high viscosities.
Not possible with pumps of the delta®
product range.
Reed switch is closed
The "Flow" identifier disappears when the
reed switch is closed, that is when the float
is in its uppermost position
1. Disconnect the metering monitor cable
to temporarily disable the metering mon‐
itor.
2. Turn the rotary dial fully to the left ("-")
3. Enter the required operating pressure
on the discharge line, max. 10 bar.
4.
Only set the Flow Control initially to
a stroke rate of 90 Hz even on
pumps with speed control (stroke
control motor or frequency con‐
verter). The Flow Control then gen‐
erally operates faultlessly even at
stroke rates of up to 200 Hz, which
you can test after setting it.
Set a stroke rate of 90 Hz.
5. Reconnect the metering monitor cable.
ðThe "Flow" identifier on the LCD
display of the metering pump goes
out.
6. Slowly turn the rotary dial on the
metering monitor to the right ("+") until
the "Flow" identifier appears.
7. Turn the rotary dial back a little until the
"Flow" identifier disappears again.
8. Use the frequency to set the required
capacity on the running pump.
9. Open the relief valve upstream of the
Flow Control; the "Flow" identifier should
appear. If not, slowly turn the rotary dial
on the metering monitor to the right ("+")
again until the "Flow" identifier appears.
10. Close the relief valve upstream of the
Flow Control again and adjust it.
ðThe "Flow" identifier should disap‐
pear again.
Start Up
16

7 Maintenance
nUser qualification: instructed user, see
Ä Chapter 2.2 ‘Users' qualifications’
on page 7
Maintenance interval
Check that the metering monitor is working
correctly every 3 months. Shorter mainte‐
nance intervals are recommended with a
heavier workload.
Checking the setting
Dynamic operation
1. Open the relief valve upstream of the
Flow Control – the "Flow" identifier
should stop flashing. If not, search for
the cause and readjust the Flow Control
if you need to.
2. Close the relief valve upstream of the
Flow Control again and adjust it.
ðThe "Flow" identifier should flash
again.
Static operation
3. Open the relief valve upstream of the
Flow Control; the "Flow" identifier should
appear. If not, search for the cause and
readjust the Flow Control if you need to.
4. Close the relief valve upstream of the
Flow Control again and adjust it.
ðThe "Flow" identifier should disap‐
pear again.
Maintenance
17

8 Repair
nUser qualification: instructed user, see Ä Chapter 2.2 ‘Users' qualifications’ on page 7
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 neces‐
sary, 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.
Wet contacts
Avoid the plug contacts becoming wet. Dry the contacts before attaching them.
Repair
18

A2237
Fig. 2: Exploded drawing of the Flow Control 3
Reed switch
The reed switch has to be fixed in the upper position, see Fig. 1
Repair
19

Cleaning the inside of the Flow Control
Cleaning
Clean the inside of the Flow Control if it is blocked or sticking, see exploded drawing
Ä further information on page 18.
1. Unscrew the top of the dismantled Flow Control.
2. Remove the counter-magnet and O-ring from the hole for the float.
3. Remove the float.
4. Clean everything with a suitable cleaning agent and tool.
5. Check in which direction the float and counter-magnet repel each other
6. Allow the float to slide into the hole.
7. Flow Control 3: Use tweezers to insert the O-ring into the hole for the float.
8. Flow Control 4 and 5: Push the O-ring from below onto the counter-magnets and push the
insert on from above.
9. Adjust the counter-magnet so that the counter-magnet repels the float.
10. Screw the Flow Control tightly closed.
Repair
20