ProMinent CONCEPTplus CNPb User manual

Solenoid Metering Pump
CONCEPTplus CNPb
Operating instructions
EN
Original Operating Instructions (2006/42/EC)Part no. 984976 BA CO 009 02/16 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.
Mahar Fan Abzar

Supplementary information
Fig. 1: Please read!
Read the following supplementary information
in its entirety! Should you already know this
information, you will benefit more from referring
to the operating instructions.
The following are highlighted separately in the
document:
nEnumerated lists
Operating guidelines
ðOutcome of the instructions
Information
This provides important information
relating to the correct operation of the unit
or is intended to make your work easier.
Safety notes
Safety notes are identified by pictograms - see
"Safety Chapter".
Validity
These operating instructions conform to current
EU regulations applicable at the time of publi‐
cation.
General user instructions
These operating instructions are only intended
for skilled users responsible for the operating of
oscillating metering pumps.
Supplemental instructions
2
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Table of contents
1 Identity code............................................................................................................................ 4
2 Overview of equipment .......................................................................................................... 6
3 Safety chapter......................................................................................................................... 7
4 Storage and Transport.......................................................................................................... 10
5 Assembly and Installation..................................................................................................... 11
6 Maintenance.......................................................................................................................... 14
7 Repairs.................................................................................................................................. 15
8 Faults.................................................................................................................................... 18
9 Decommissioning.................................................................................................................. 19
10 Technical data....................................................................................................................... 20
11 Accessories........................................................................................................................... 26
12 Dimensional drawings........................................................................................................... 27
13 EC / EU Declaration of Conformity for Machinery................................................................. 31
14 Installation instructions for External + Level retrofit kit CNPb (Part no. 1022099)................ 32
Table of contents
3
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1 Identity code
Product range CONCEPT plus, Version b
CNP
b
Type
_ _ _
_
Performance data at maximum back pressure and type: refer to nameplate on the
pump housing
Material
PP Polypropylene
NP Clear acrylic/PVC
PV PVDF
Diaphragm and seal
E Standard with EPDM seals
B Standard with FPM seals
T Standard with PTFE flat seal
Dosing head design
0 Without bleed valve, without valve spring
1 Without bleed valve, with valve spring
2 With bleed valve, without valve spring
3 With bleed valve, with valve spring
Hydraulic connector
0 Standard connection
Design
0 with ProMinent logo
Electrical connections
A 100 - 230 V, standard European plug
B 100 - 230 V, Swiss plug
C 100 - 230 V, Australian plug
D 100 - 230 V, USA plug
Cable assembly
Identity code
4
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Product range CONCEPT plus, Version b
0 Without cable and retrofit kit
A With external and level input retrofit
kit, loose, without level switch
B With external and level input retrofit
kit, fitted, without level switch
F With level input, fitted, with level
switch
G With external and level input, fitted,
with external cable and level switch
Accessories
0 without accessories
1 Supplied accessories
Control version
0 External contact
Identity code
5
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2 Overview of equipment
5
6
4
1
3
2
8
7
P_CO_0005_SW
Fig. 2: Overview of equipmentCONCEPT plus
1 Stroke length adjustment knob
2 Fault / operating indicator (fault red / opera‐
tion green)
3 Multifunctional switch (stroke rates (in % of
180 or 240 strokes/min), Stop, "External"
operating mode (retrofit kit))
4 Mains cable
5 "External control" terminal (in "External"
operating mode, control via contact signal;
optional)
6 "Level switch" terminal (for 1-stage level
switch; optional)
7 Suction valve
8 Discharge valve
The leakage hole is between the suction valve and the drive housing.
Overview of equipment
6
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3 Safety chapter
Explanation of the safety information
The following signal words are used in these
operating instructions to identify different
severities of a hazard:
Signal
word
Meaning
WARNI
NG
Denotes a possibly hazardous sit‐
uation. If this is disregarded, you
are in a life-threatening situation
and this can result in serious inju‐
ries.
CAU‐
TION
Denotes a possibly hazardous sit‐
uation. If this is disregarded, it
could result in slight or minor inju‐
ries 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 – high-
voltage.
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 for the metering
of flammable media without implementing
suitable protective measures.
nThe pump is not intended to meter explo‐
sive media.
nThe pump is not intended for operation in
areas at risk from explosion.
nThe pump is not intended to meter radio‐
active media.
nThe pump is not intended for exterior
applications without the implementation of
suitable protective measures.
nThe pump is only intended for industrial
use.
nThe pump should only be operated by
trained and authorised personnel.
Ensure that personnel are familiar with
oscillating metering pumps and their ope‐
ration.
nObserve the information contained in the
operating instructions at the different
phases of the unit's service life.
Safety chapter
7
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Safety notes
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 inte‐
grate the pump in the emergency cut-
off management of the system.
WARNING!
Danger of electric shock
If there is a damaged housing or an
opening is left open, the mains voltage
inside is no longer sufficiently shielded.
– Disconnect the pump from the mains
power supply if the housing is dam‐
aged or there is a gaping opening.
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.
CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the
hydraulic components if they are manipu‐
lated 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 unau‐
thorised persons.
–Depressurise the system before com‐
mencing any work on hydraulic parts.
Safety chapter
8
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CAUTION!
Warning of feed chemical spraying around
The metering pump can generate a mul‐
tiple of its rated pressure. Hydraulic parts
may burst if a discharge line is blocked.
– Correctly install a back pressure valve
in the discharge line behind the
metering pump.
CAUTION!
Warning of excessive demand
The pump can meter too much if there is a
negative pressure difference between the
discharge and suction sides.
– For example with a free outlet, use a
back pressure valve with a minimum
opening pressure of 1.5 bar (not pos‐
sible with 0213).
CAUTION!
Danger of injury to personnel and material
damage
The use of untested third party compo‐
nents can result in injury to personnel and
material damage.
– Only fit parts to metering pumps that
have been tested and recommended
by ProMinent.
CAUTION!
Warning against illegal operation
Observe the regulations that apply where
the unit is installed.
Information in the event of an emergency
In an emergency, either pull out the mains plug,
turn the multifunctional switch to "Stop" or press
the Emergency Stop switch installed on the
customer's side or disconnect the pump from
the mains power supply in line with the emer‐
gency shut-down management guidelines for
your system!
If feed chemical escapes, additionally ensure
that the hydraulic system around the pump is at
atmospheric pressure. Adhere to the safety
data sheet for the feed chemical.
Safety chapter
9
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4 Storage and Transport
WARNING!
Only return the metering pump for repair in a cleaned state and with a flushed liquid end - refer
to the section on decommissioning!
Only return metering pumps with a completed Decontamination Declaration form. The Decon‐
tamination Declaration constitutes an integral part of an inspection / repair order. We can only
inspect or repair a unit if a Decontamination Declaration is submitted 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 at www.prominent.com.
Ambient conditions
Data Value Unit
Minimum storage and transport temperature -10 °C
Maximum storage and transport temperature +50 °C
Maximum air humidity * 95 % rel. humidity
* non-condensing
Storage and Transport
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5 Assembly and Installation
CAUTION!
Warning of feed chemical spraying around
The pipes can loosen or rupture if they are
not installed correctly.
– 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 noz‐
zles that are intended for the hose
diameter in question to ensure the
long service life of the connections.
CAUTION!
Warning of feed chemical spraying around
PTFE seals, which have already been
used / compressed, can no longer reliably
seal a hydraulic connection.
– Always use new, unused PTFE seals.
CAUTION!
Warning of excessive demand
The pump can meter too much if there is a
negative pressure difference between the
discharge and suction sides.
– For example with a free outlet, use a
back pressure valve with a minimum
opening pressure of 1.5 bar (not pos‐
sible with 0213).
CAUTION!
Warning of destruction of the pump
An incorrect mains voltage or mains fre‐
quency can irreparably destroy the
metering pump.
– Check that the mains voltage and fre‐
quency agree with the values given
on the nameplate.
CAUTION!
Possibility of your switching relay contacts
bonding
The high starting current can cause the
contacts of the switching relay to bond
together if the mains voltage switches a
solenoid metering pump on and off in a
process.
– Use the switching options offered by
the external contact to control the
pump (functions: Pause or Contact).
–Use a starting current limiter (part no.
1059333 for 230 V) if it is impossible
to avoid switching the pump on and
off via a relay.
Assembly and Installation
11
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CAUTION!
Material damage possible due to power
surges
Should the pump be connected to the
mains power supply in parallel to inductive
consumers (such as solenoid valves,
motors), inductive power surges can
damage the control when it is switched off.
– Provide the pump with its own con‐
tacts (Phase) and supply with voltage
via a contactor relay or relay.
–Should this not be possible, then
switch a varistor (part no. 710912) or
an RC gate (0.22 µF/220 Ω, part no.
710802) in parallel.
CAUTION!
Warning against illegal operation
Observe the regulations that apply where
the unit is installed.
Capacity too low
The liquid end valves can be disturbed by
vibrations.
– Secure the metering pump so that no
vibrations can occur.
Installation instructions for retrofit kit
"Installation instructions for External +
Level retrofit kit CNPb (Part no. 1046731)"
- see Appendix.
Installing the hose line
1
3
2
4
5
6
P_PNM_0008_SW
Fig. 3
1. Assemble the metering pump on a
storage tank or a bracket using screws
and U-washers (Ø 6 mm).
2. Cut the pressure hose to the required
length.
3. Pull the union nut (5) and clamping ring
(4) over the hose line (6).
4. Push the shortened hose end up to the
stop over the nozzle (3).
5. Press the hose (6) on and tighten the
union nut (5).
Assembly and Installation
12
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6. Install the suction line.
To do this, shorten the free end of
the suction line so that the foot
valve hangs just above the base of
the storage tank.
With feed chemicals with impurities
or sediment, shorten the free end of
the suction line so that the foot
valve hangs at least 50 mm above
the base of the storage tank.
Keep the suction line and the suc‐
tion height as short as possible.
Route the suction line with an
upwards slope.
7. Install a foot valve.
Assembly and Installation
13
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6 Maintenance
Interval Maintenance work Personnel
Quarterly* nCheck the metering diaphragm for damage** - refer to
"Repair".
nCheck that the hydraulic lines are fixed firmly to the
liquid end.
nCheck that the suction valve and discharge valve are
correctly seated.
nCheck the leak-tightness of the entire liquid end - partic‐
ularly around the leakage hole.
nCheck that the flow is correct: Allow the pump to prime
briefly - turn the multifunction switch briefly to "100 %".
nCheck that the electrical connections are intact
nCheck the integrity of the housing.
nCheck that the dosing head screws are tight
Technical personnel
* Under normal loading (approx. 30 % of continuous operation)
Under heavy loading (e.g. continuous operation): Shorter intervals.
** For feed chemicals which particularly load the diaphragm, e.g. those containing abrasive addi‐
tives, check the diaphragm frequently.
Tightening torque
Data Value Unit
Tightening torque for screws: 4.5 ... 5.0 Nm
Maintenance
14
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7 Repairs
Carry out repairs, which should be performed
by qualified technical personnel, in line with the
safety notes:
nCleaning a valve
nReplacing the diaphragm
All other repairs: Contact your responsible
ProMinent branch!
Replacing the diaphragm
P_CO_0015_SW
1 2 3 4 5 6
Fig. 4
nIf necessary take protective measures.
nAdhere to the safety data sheet for the
feed chemical.
nEnsure that the system is at atmospheric
pressure.
1. Empty the liquid end (turn the liquid end
upside down and allow the feed chem‐
ical to run out; flush out with a suitable
medium; flush the liquid end thoroughly
when using hazardous feed chemicals!)
2. Turn the stroke adjustment dial as far as
0 % stroke length when the pump is run‐
ning (the drive axle is then difficult to
turn).
3. Switch off the pump.
4. Unscrew the hydraulic connectors on
the discharge and suction side.
5. Remove the screws (1).
6. Loosen the dosing head (2) and the
backplate (4) from the pump housing (6)
- but only loosen!
7. Hold the pump housing (6) with one
hand and clamp the diaphragm (3) with
the other hand between the dosing head
(2) and the backplate (4).
8. Loosen the diaphragm (3) from the drive
axle with a gentle backwards turn of the
dosing head (2), diaphragm (3) and
backplate (4) in an anticlockwise direc‐
tion.
Repairs
15
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9. Unscrew the diaphragm (3) completely
from the drive axle.
10. Remove the backplate (4) from the
pump housing (6).
11. Check the condition of the safety dia‐
phragm (5) and replace if necessary.
12. Push the safety diaphragm (5) onto the
drive axle only until it lies flush with the
pump housing (6) and no further!
13. Tentatively screw the new diaphragm
(3) onto the drive axle until it can go no
further.
ðThe diaphragm (3) is now sitting at
the stop of the thread.
14. Should this not work, remove dirt or
swarf from the threads and screw the
diaphragm (3) onto the drive axle cor‐
rectly this time.
Ensure that the diaphragm is
screwed exactly onto the drive axle
otherwise the pump will subse‐
quently not meter accurately!
15. Unscrew the diaphragm (3) again.
16. Place the backplate (4) onto the pump
housing (6).
CAUTION!
Leakage may become apparent at
a later stage.
– Make sure that the leakage
hole points downwards when
the pump is installed later -
please refer to !
–Place the backplate (4) imme‐
diately in the correct position
on the pump housing (6)! Do
not twist the backplate on the
pump housing to prevent the
safety diaphragm (5)
becoming warped!
17. Place the diaphragm (3) into the back‐
plate (4).
CAUTION!
Leakage may become apparent at
a later stage.
– Do not over-tighten the dia‐
phragm (3) in the following
step!
–Ensure that the backplate (4)
remains in its position so that
the safety diaphragm does not
become warped!
18. Hold the backplate (4) firmly and screw
the diaphragm (3) in a clockwise direc‐
tion until it is sitting tightly (the twisting
resistance of the return spring can be
felt).
19. Set the stroke length to 100 %.
20. Place the dosing head (2) with the
screws (1) onto the diaphragm (3) and
the backplate (4) - ensure that the suc‐
tion connector points downwards when
the pump is subsequently fitted.
Repairs
16
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21. Gently tighten the screws (1) and then
tighten them diagonally. See below for
tightening torque.
CAUTION!
Leakage possible
– Check the tightening torque of the
screws after 24 hours of operation!
– With PP and PV dosing heads, check
the tightening torque again after three
months!
Tightening torque
Data Value Unit
Tightening torque for screws: 4.5 ... 5.0 Nm
Repairs
17
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8 Faults
Fault description Cause Remedy
Pump does not prime in
spite of full stroke motion
and bleeding.
Minor crystalline deposits on
the ball seat due to the valves
drying out
Take the suction hose out of the
storage tank and thoroughly flush
out the liquid end
Major crystalline deposits on
the ball seat due to the valves
drying out
Dismantle and clean the valves.
Fluid is escaping from the
backplate.
The screws in the dosing head
are too loose
Tighten the screws in the dosing
head crosswise - see below for
the tightening torque.
The diaphragm is not tight. Replace the diaphragm - refer to
"Repair".
Fault/operating indicator
does not illuminate.
The wrong mains voltage or no
mains voltage is connected.
Connect the pump correctly to the
specified mains voltage -
according to the specification on
the nameplate
Fault/operating indicator is
red.
The fluid level in the storage
tank has reached "Liquid level
low".
Fill the storage tank.
The multifunctional switch is
positioned between 2 selection
options.
Allow the multifunctional switch to
lock into selection option 1.
Electronics fault Return the pump.
Tightening torque
Data Value Unit
Tightening torque for screws: 4.5 ... 5.0 Nm
Faults
18
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9 Decommissioning
WARNING!
Danger from chemical residues
There is normally chemical residue in the
liquid end and on the housing after opera‐
tion. This chemical residue could be haz‐
ardous to people.
– It is mandatory that the safety infor‐
mation relating to the "Storage, trans‐
port and unpacking" chapter is read
before shipping or transporting the
unit.
–Thoroughly clean the liquid end and
the housing of chemicals and dirt.
Observe the safety data sheet for the
feed chemical.
CAUTION!
Environmental hazard due to electronic
waste
There are electronic components in the
pump, which can have a toxic effect on the
environment.
– Separate the electronic components
from the remaining parts.
–Note the pertinent regulations cur‐
rently applicable in your country!
Decommissioning
19
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10 Technical data
CNPb performance table for 180 strokes/min
Type Minimum pump
capacity
at maximum back
pressure
Minimum pump
capacity
at medium back pres‐
sure
Connector
size
outside Æ
x inside Æ
Suc‐
tion
lift*
Pri‐
ming
lift**
Max.
priming
pres‐
sure on
the
suction
side
bar l/h ml/
stroke
bar l/h ml/
stroke
mm m WS m WS bar
concept plus
1000 10 0.74 0.07 5.0 0.97 0.09 6x4 6.0 1.8 8
1601 16 1.1 0.10 8.0 1.4 0.13 6x4 6.0 2.0 8
1002 10 2.1 0.19 5.0 2.6 0.24 6x4 5.0 2.5 5
0704 7 3.9 0.36 3.5 4.4 0.41 6x4 4.0 3.0 3
0309 3 9.0 0.83 1.5 13.0 1.20 8x5 2.0 2.0 1
0215 1.5 16.4 1.52 1.0 18.3 1.70 8x5 1.5 1.5 0.5
concept plus metering pumps with self-bleeding dosing head SER***
1002 10 1.8 0.17 5.0 2.7 0.2 6x4 1.8 1.8 5
0704 7 3.0 0.28 3.5 4.3 0.4 6x4 1.8 1.8 3
0309 3 9.0 0.83 1.5 13.6 1.3 8x5 1.8 1.8 1
0215 1.5 13.2 1.22 - - - 8x5 1.8 1.8 0.5
Technical data
20
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