ProMinent alpha ALPc 1001 User manual

Motor-driven Metering Pump
alpha ALPc
Operating instructions
EN
Original operating instructions (2006/42/EC)Part no. 986353 BA ALP 015 08/18 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.

Supplementary information
Fig. 1: Please read!
Read the following supplementary information
in its entirety! You will benefit more from using
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 docu‐
ment or another document
[Keys]
Information
This provides important information
relating to the correct operation of the
unit or is intended to make your work
easier.
Safety Information
Safety information is identified by pictograms -
see Safety Chapter.
Validity
These operating instructions conform to current
EU regulations applicable at the time of publi‐
cation.
State the identity code and serial number
Please state identity code and serial number,
which you can find on the nameplate when you
contact us or order spare parts. This enables
us to clearly identify the unit type and material
versions.
Supplemental directives
2

Table of contents
1 Identity code............................................................................................................................ 5
2 Safety chapter......................................................................................................................... 7
3 Storage, Transport and Unpacking....................................................................................... 12
4 Overview of equipment......................................................................................................... 13
5 Functional description........................................................................................................... 14
5.1 Power end.................................................................................................................... 14
5.2 Liquid End.................................................................................................................... 14
6 Assembly............................................................................................................................... 15
7Installation, hydraulic............................................................................................................. 16
7.1 Installing hose lines...................................................................................................... 17
7.1.1 Installation of the suction and discharge line............................................................ 17
7.1.2 Installation of metering pumps with bleed valve........................................................ 20
7.1.3 Basic installation notes.............................................................................................. 20
8 Electrical installation.............................................................................................................. 23
9 Start up.................................................................................................................................. 24
10 Maintenance.......................................................................................................................... 28
11 Repairs.................................................................................................................................. 31
11.1 Cleaning valves.......................................................................................................... 31
11.2 Replacing the diaphragm........................................................................................... 32
11.3 Replacing the complete dosing head......................................................................... 36
12 Troubleshooting.................................................................................................................... 37
12.1 Faults and troubleshooting......................................................................................... 38
12.2 All other faults............................................................................................................. 39
13 Decommissioning and disposal............................................................................................. 40
13.1 Decommissioning....................................................................................................... 40
13.2 Disposal...................................................................................................................... 41
14 Technical data....................................................................................................................... 42
15 Design Documents................................................................................................................ 46
16 Dimensional drawings........................................................................................................... 47
17 Further order information ..................................................................................................... 48
Table of contents
3

18 Declaration of Conformity for Machinery............................................................................... 49
Table of contents
4

1 Identity code
alpha product range, version c
ALPc Type Capacity
bar l/h (at 50 Hz)
1001 10 0.9
1002 10 1.8
1004 10 3.5
1008 10 7.7
0707 7 6.9
0417 4 17.0
0230 2 29.7
Dosing head material
PPE PP/PP/EPDM
PPB PP/PP/FPM-B
NPE Clear acrylic/PVC//EPDM
NPB Clear acrylic/PVC/FPM
PVT PVDF/PVDF/PTFE
Seal material
2 Without valve spring, with bleed valve
3 with 2 valve springs (approx. 0.1 bar, material 1.4571), with bleed valve
Hydraulic connector
0 Standard connection in line with technical data
Design
0 with ProMinent logo
M modified
Electrical connection
Identity code
5

alpha product range, version c
A 230 V , 50/60 Hz, 2 m European
B 230 V, 50/60 Hz, 2 m Swiss
C 230 V, 50/60 Hz, 2 m Australian
D 115 V , 50/60 Hz, 2 m USA
Accessories
0 no accessories
1 with foot and injection valve, 2 m PVC suction line, 5 m
metering line
Identity code
6

2 Safety chapter
Identification of safety notes
The following signal words are used in these
operating instructions to denote different severi‐
ties of danger:
Signal word Meaning
WARNING Denotes a possibly
dangerous situation.
If this is disregarded,
you are in a life-
threatening situation
and this can result in
serious injuries.
CAUTION Denotes a possibly
dangerous situation.
If this is disregarded,
it could result in slight
or minor injuries or
material damage.
Warning signs denoting different types of
danger
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 inju‐
ries.
Warning – high-
voltage.
Warning signs Type of danger
Warning – danger
zone.
Intended use
nOnly use the pump to meter liquid feed
chemicals.
nOnly use the pump after it has been cor‐
rectly installed and started up in accord‐
ance with the technical data and specifica‐
tions contained in the operating
instructions.
nObserve the general limitations with regard
to viscosity limits, chemical resistance and
density - see also ProMinent® Resistance
List in the Product Catalogue or at
www.prominent.com!
nAll other uses or modifications are pro‐
hibited.
nThe pump is not intended for the metering
of gaseous media and solids.
nThe pump is not intended to meter flam‐
mable media.
nThe pump is not intended for the metering
of explosive media.
nThe pump is not intended for operation in
areas at risk from explosion.
nThe pump is not intended for exterior
applications without the implementation of
suitable protective measures.
nThe pump should only be operated by
trained and authorised personnel, see the
following "Qualifications" table.
nYou have a responsibility to adhere to the
information contained in the operating
instructions at the different phases of the
unit's service life.
Safety chapter
7

Qualification of personnel
Action Qualification
Storage, transport,
unpacking
Instructed person
Assembly Technical personnel,
service
Planning hydraulic
installation
Qualified personnel
who have a thorough
knowledge of
metering 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 expe‐
rience, as well as knowledge of pertinent regu‐
lations.
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
Electrical technicians are deemed to be people,
who are able to complete work on electrical
systems and recognise and avoid possible dan‐
gers 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 environment in which
they are employed and know the relevant
standards and regulations.
Electrical technicians must comply with the pro‐
visions 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 dangers that could result from
improper behaviour, as well as having been
instructed in the required protective equipment
and protective measures.
Service
Customer Service department refers to service
technicians, who have received proven training
and have been authorised by ProMinent or Pro‐
Maqua to work on the system.
Safety chapter
8

Safety information
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!
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 han‐
dling of the pump.
– Take appropriate protective meas‐
ures 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!
Danger from hazardous substances!
Possible consequence: Fatal or very
serious injuries.
Please ensure when handling haz‐
ardous 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 chapter
9

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 unauthorised 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 that
come into contact with the chemical.
– Take into account the resistance
of the wetted materials 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
The metering pump can generate a
multiple of its rated pressure. Hydraulic
parts can rupture if a discharge line is
blocked.
– Correctly install a relief valve in the
discharge line downstream of the
metering pump.
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 rec‐
ommended by ProMinent.
CAUTION!
Danger from incorrectly operated or
inadequately maintained pumps
Danger can arise from a poorly acces‐
sible pump due to incorrect operation
and poor maintenance.
– Ensure that the pump is acces‐
sible at all times.
–Adhere to the maintenance inter‐
vals.
Safety chapter
10

CAUTION!
Warning against illegal operation
Observe the regulations that apply
where the device is installed.
Fixed separating protective equipment
nCover
nDosing head
nHousing
The customer may only remove the cover to
adjust the stroke length.
Customer should only remove the dosing head
in accordance with the "Repair" chapter.
Only the ProMinent Service department are
authorised to remove the housing.
Ensure that all protective equipment is properly
fitted before the pump is operated.
Other safety equipment
Vor Deckelabnahme
Pumpe abschalten
Switch off pump
before opening
Arrêtez la pompe
avant de l‘ouvrir
P_ALP_0010_SW
Fig. 2
Ensure that the warning label is always fitted
and legible.
Circuit breaker
The driver motor is fitted with a circuit breaker,
which automatically switches off the motor
when it overheats to more than 106 °C.
The circuit breaker switches the pump on again
once the motor has cooled down.
Information in the event of an emergency
In an emergency, either pull out the mains plug
or press the emergency-off switch, installed by
the customer, or disconnect the pump in line
with the emergency-shut-down guidelines for
your system!
If feed chemical escapes, also ensure that the
pump's hydraulic environment is at atmospheric
pressure. Adhere to the material safety data
sheet for the feed chemical.
Sound pressure level
Sound pressure level LpA < 70 dB according to
EN ISO 20361
at maximum stroke length, maximum stroke
rate, maximum back pressure (water)
Safety chapter
11

3 Storage, Transport and Unpacking
Safety Information
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 Decontamination Declara‐
tion form. The Decontamination Decla‐
ration constitutes an integral part of an
inspection / repair order. A unit can only
be inspected or repaired when a Decla‐
ration of Decontamination Form is sub‐
mitted that has been completed cor‐
rectly 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 incor‐
rect or improper storage or transporta‐
tion!
– The unit should only be stored or
transported in a well packaged
state - preferably in its original
packaging.
–The packaged unit should also
only be stored or transported in
accordance with the stipulated
storage conditions.
– The packaged unit should be pro‐
tected from moisture and the
ingress of chemicals.
Ambient conditions
Ambient conditions - refer to "Technical Data"
chapter.
Scope of delivery
Compare the delivery note with the scope of
delivery:
nMetering pump with mains cable
nConnector kit for hose/pipe connection
nProduct-specific operating instructions with
Declaration of Conformity
Storage, Transport and Unpacking
12

4 Overview of equipment
1
2
3
10
9
87
6
5
4
P_ALP_0007_SW
Fig. 3
1 Cover
2 Motor mounting
3 Housing
4 Pressure connector
5 Bleed valve
6 Bypass hose nozzle
7 Suction connector
8 Dosing head
9 Eccentric disc with scale
10 Latched slide
Overview of equipment
13

5 Functional description
5.1 Power end
The cam for the stroke movement is guided in
an eccentric disc. Pumps of this size do not
therefore require conventional return springs –
the suction and pressure stroke are positively
driven.
The stroke length can be adjusted by a latched
slide (9) from 100% to 0 in increments of 10%.
The diaphragm is always deflected from the
neutral centre position, producing a smooth
sinusoidal stroke motion.
5.2 Liquid End
The dosing process is performed as follows:
The diaphragm is pressed into the dosing head;
the pressure in the dosing head closes the suc‐
tion valve and the feed chemical flows through
the discharge valve out of the dosing head. The
diaphragm is now drawn out of the dosing
head; the discharge valve closes due to the
negative pressure in the dosing head and fresh
feed chemical flows through the suction valve
into the dosing head. One cycle is completed.
Functional description
14

6 Assembly
WARNING!
The IP 23 protection against moisture
and accidental contact only applies to
horizontal pump bases with vertically
installed pumps.
CAUTION!
When assembling the pump, ensure
that there is sufficient room around the
pump for operation, maintenance,
repairs and quick disconnection of the
mains plug.
Capacity too low
Vibrations can disturb the liquid end
valves.
– Secure the metering pump to
ensure that no vibrations can
occur.
Capacity too low
If the liquid end valves are not upright,
they cannot close correctly.
– Ensure that the discharge valve is
upright.
Assemble the metering pump on a
storage tank or a bracket using screws
and U-washers (Ø 5 mm).
Assembly
15

7 Installation, hydraulic
Safety notes
CAUTION!
Warning of feed chemical spraying
around
An unsuitable feed chemical can
damage the parts of the pump con‐
tacted 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.
CAUTION!
Warning of feed chemical spraying
around
Pumps which are not fully installed
hydraulically can pump feed chemical
from the outlet opening of the discharge
valve as soon as they are connected to
the mains power supply.
– First install the pump hydraulically,
then electrically.
–In the event that you have failed to
do so, press the On/Off switch (on
site) or the Emergency Stop
switch.
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 unauthorised persons.
–Depressurise the system before
commencing any work on
hydraulic parts.
CAUTION!
Danger from rupturing hydraulic com‐
ponents
Peak loads during the dosing stroke
can cause the maximum permissible
operating pressure of the system and
pump to be exceeded.
– The discharge lines are to be
properly designed.
Installation, hydraulic
16

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 rec‐
ommended by ProMinent.
7.1 Installing hose lines
7.1.1 Installation of the suction and
discharge line
Safety notes
CAUTION!
Warning of feed chemical spraying
around
If the pipes are not installed correctly,
they can come lose or burst.
– Route all hose lines so they are
free from mechanical stresses and
kinks.
–Only use original hoses with the
specified hose dimensions and
wall thicknesses.
– Only use clamp rings and hose
nozzles that are intended for the
hose diameter in question to
ensure the long service life of the
connections.
CAUTION!
Danger resulting from rupturing
hydraulic components
Hydraulic components can rupture if
the maximum permissible operating
pressure is exceeded.
– Always adhere to the maximum
permissible operating pressure of
all hydraulic components - please
refer to the product-specific oper‐
ating instructions and system doc‐
umentation.
–Never allow the metering pump to
run against a closed shut-off
device.
– Install a relief valve.
CAUTION!
Hazardous feed chemicals can escape
Hazardous or extremely aggressive
feed chemicals can leak out when
using conventional bleeding procedures
with metering pumps.
– Install a bleed line with return into
the storage tank.
Installation, hydraulic
17

CAUTION!
Hazardous feed chemicals can escape
Hazardous or extremely aggressive
feed chemicals can leak out in the
event that the metering pump is
removed from the installation.
– Install a shut-off valve on the
metering pump's pressure and dis‐
charge sides.
CAUTION!
Uncontrolled flow of feed chemical
Feed chemicals can leak through a
stopped metering pump if there is back
pressure.
– Use an injection valve or a
vacuum breaker.
CAUTION!
Uncontrolled flow of feed chemical
Feed chemicals can leak through the
metering pump in an uncontrolled
manner in the event of excessive pri‐
ming pressure.
– Do not exceed the maximum per‐
missible priming pressure for the
metering pump.
Align the pipes so that the metering
pump and the liquid end can be
removed from the side if necessary.
Installation, hydraulic
18

Installing hose lines
1. Cut off the ends of the hoses at right
angles.
2. Pull the union nut (20) and clamp ring
(21) over the hose (24) - see figure
Ä ‘Installing hose lines’ on page 18 .
3. Push the hose end (24) up to the stop
over the nozzle (4) and widen, if neces‐
sary.
Ensure that the O-ring and the
flat seal (23) is sitting properly.
Never re-use used PTFE seals.
An installation sealed in this way
is not watertight.
This type of seal is permanently
distorted when subjected to
pressure.
4. Place the hose (24) with the nozzle (22)
onto the valve.
5. Clamp the hose connector: Tighten the
union nut (20) while simultaneously
pressing on the hose (24).
6. Re-tighten the hose connector: Pull on
the hose (24) briefly, which is fastened
to the dosing head and then tighten the
union nut (20) once more.
P_ALP_0009_SW
A
20
21
22
23
24
Fig. 4
A Pressure connector
20 Union nut
21 Clamp ring
22 Nozzle
23 O-ring or flat seal
24 Hose
Installation, hydraulic
19

7.1.2 Installation of metering
pumps with bleed valve
Safety notes
CAUTION!
– All the installation and safety notes
for metering pumps without bleed
valves also apply.
Installation of the return line
A return line is additionally connected to the
suction and discharge line.
1. Fasten the tube line to the return hose
nozzle or to the liquid end bleed valve.
PVC hose, soft, 6x4 mm is recom‐
mended.
2. Feed the free end of the return line back
to the storage tank.
3. Shorten the return line so that it does
not dip into the feed chemical in the
storage tank.
7.1.3 Basic installation notes
Safety notes
CAUTION!
Danger from rupturing hydraulic com‐
ponents
Hydraulic components can rupture if
the maximum permissible operating
pressure is exceeded.
– Never allow the metering pump to
run against a closed shut-off
device.
–With metering pumps without inte‐
gral relief valve Install a relief
valve in the discharge line.
CAUTION!
Hazardous feed chemicals can escape
With hazardous feed chemicals Haz‐
ardous feed chemicals can leak out
when using conventional bleeding pro‐
cedures with metering pumps.
– Install a bleed line with return into
the storage tank.
Shorten the return line so that it cannot
dip into the feed chemical in the storage
tank.
Installation, hydraulic
20