ProMinent Dulco Flex DF2a User manual

ProMinent® dulco®flex
DF2a
Assembly and operating instructions
A1666
A1666
EN
Original instructions (2006/42/EC)Part number 984881 BA DX 016 11/14 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
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
Read the following supplementary
information in its entirety!
The following are highlighted sepa‐
rately in the document:
nEnumerated lists
Instructions
ðResults of the instructions
Information
This provides important informa‐
tion relating to the correct opera‐
tion of the system or is intended to
make your work easier.
Safety information
Safety information are provided with
detailed descriptions of the endan‐
gering situation, see Ä Chapter 2.1
‘Explanation of the safety information’
on page 7
Supplemental instructions
2

Table of contents
1 About this pump......................................................................................... 4
2 Safety and responsibility............................................................................ 7
2.1 Explanation of the safety information................................................. 7
2.2 Safety notes....................................................................................... 8
2.3 Intended use.................................................................................... 10
2.4 Users' qualifications......................................................................... 11
3 Storage and Transport............................................................................. 13
4 Overview of equipment / Functional description...................................... 14
5 Assembly and Installation........................................................................ 15
5.1 Assembling the peristaltic pump...................................................... 15
5.2 Installing hose lines......................................................................... 17
5.3 Electrical installation of the peristaltic pump.................................... 18
6 Start up.................................................................................................... 21
7 Maintenance, repair and faults ............................................................... 22
7.1 Maintenance.................................................................................... 22
7.2 Repair.............................................................................................. 23
7.3 Troubleshooting............................................................................... 24
8 Decommissioning and disposal............................................................... 25
8.1 Disposal of used parts..................................................................... 25
9 Technical data......................................................................................... 27
9.1 Accessories..................................................................................... 31
9.2 Dimension sheet.............................................................................. 31
10 EC Declaration of Conformity for Machinery........................................... 32
11 Index........................................................................................................ 34
Table of contents
3

1 About this pump
ProMinent® dulco®flex peristaltic
pumps are designed for use in private
swimming pools and hotel swimming
pools.
About this pump
4

Identity code
DF
2a
dulco®flex, version a
Pump type:
02
04
1.5 bar; 0.4 litres
02
08
1.5 bar; 0.8 litres
02
16
1.5 bar; 1.6 litres
02
24
1.5 bar; 2.4 litres
Hose material:
PPharMed®
TTygon®
Design:
0With ProMinent® logo
1Without ProMinent® logo
Hydraulic connector:
0 Standard
9 Special connector 10 x 4, discharge side
Electrical connection:
A 230 V, 50/60 Hz
B 115 V, 50/60 Hz
Cable and plug:
0 without cable
1 with cable 2.0 m; open end
About this pump
5

DF
2a
dulco®flex, version a
4 with cable 0.8 m; open end
Control:
0 Mains power supply ON/OFF
Mounting type:
W Wall mounting
Accessories:
0 No accessories
1 Metering valve and foot valve;
suction and discharge line
About this pump
6

2 Safety and responsibility
2.1 Explanation of the safety
information
Introduction
These operating instructions provide
information on the technical data and
functions of the product. These oper‐
ating instructions provide detailed
safety information and are provided
as clear step-by-step instructions.
The safety information and notes are
categorised according to the following
scheme. A number of different sym‐
bols are used to denote different sit‐
uations. The symbols shown here
serve only as examples.
DANGER!
Nature and source of the danger
Consequence: Fatal or very
serious injuries.
Measure to be taken to avoid this
danger
Danger!
– Denotes an immediate threat‐
ening danger. If this is disre‐
garded, 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
situation. 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
situation. If this is disregarded,
it could result in slight or minor
injuries. May also be used as
a warning about material
damage.
Safety and responsibility
7

NOTICE!
Nature and source of the danger
Damage to the product or its sur‐
roundings
Measure to be taken to avoid this
danger
Note!
– Denotes a possibly damaging
situation. If this is disregarded,
the product or an object in its
vicinity could be damaged.
Type of information
Hints on use and additional infor‐
mation
Source of the information, addi‐
tional measures
Information!
– Denotes hints on use and
other useful information. It
does not indicate a hazardous
or damaging situation.
2.2 Safety notes
WARNING!
Danger from hazardous sub‐
stances!
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 manufac‐
ture of the hazardous substance.
The actions required are
described in the safety data sheet.
Check the safety data sheet regu‐
larly and replace, if necessary, as
the hazard potential of a sub‐
stance can be re-evaluated at any
time based on new findings.
The system operator is respon‐
sible 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 work‐
stations affected.
Safety and responsibility
8

WARNING!
Danger of electric shock
Mains voltage may be present
inside the pump housing.
Immediately disconnect the pump
from the mains power supply if the
pump housing has been dam‐
aged. Only return the pump to
service after an authorised repair.
CAUTION!
Warning of feed chemical
spraying around
The metering pump can generate
a multiple of its rated pressure.
Hydraulic parts may burst if a dis‐
charge line is blocked. -
Correctly install a relief valve in
the discharge line downstream of
the metering pump.
CAUTION!
Warning of backflow
Metering pumps are not abso‐
lutely leak-tight shut-off devices.
Use a shut-off valve, a solenoid
valve or a vacuum breaker for this
purpose.
CAUTION!
Personnel injury and material
damage
The pump can start to pump, as
soon as it is connected to mains
voltage.
Install an emergency cut-off
switch in the pump power supply
line or integrate the pump in the
emergency cut-off management of
the system.
CAUTION!
Device starts immediately
The unit does not have an On/Of
switch and begins to work as soon
as it is connected to the mains
voltage.
Only connect the device to the
mains voltage when all installation
work has been completed and the
pumped chemicals can no longer
escape in an uncontrolled
manner.
CAUTION!
Contact with chemicals
De-pressurise, drain and rinse the
hydraulic part of the unit before
working on it.
Safety and responsibility
9

Protective equipment
The transparent cover on the
liquid end serves to prevent direct
contact with the rotor and
escaping chemicals in the event
of a ruptured hose.
Information in the event of an emer‐
gency
In the event of an electrical accident,
disconnect the mains cable from the
mains power supply or press the
emergency cut-off switch fitted on the
side of the system. If feed chemical is
escaping, switch off the pump by
pressing [Stop/Start] . If necessary
ensure that the hydraulic system
around the pump is at atmospheric
pressure. Adhere to the safety data
sheet for the feed chemical.
2.3 Intended use
nOnly use the unit to meter liquid
media.
nOnly use the unit in accordance
with the technical data and speci‐
fications outlined in the operating
instructions.
nAny other uses or modifications to
the system are prohibited
nDo not use the unit to meter gas‐
eous media or solids.
nDo not use the unit to meter flam‐
mable media.
nOnly use the unit with further pro‐
tection (exterior housing, weather‐
proof roof) for external use. The
housing can be affected by direct
sunlight
nOnly allow adequately qualified
and technically expert personnel
to operate the unit
nObserve the general limitations
with regard to viscosity limits,
chemical resistance and density -
refer also to the ProMinent®
Resistance List in the Product
Catalogue or at www.promi‐
nent.com!
nThe pump is not intended for ope‐
ration in areas at risk from explo‐
sion.
All other uses or modifications are
prohibited.
Safety and responsibility
10

2.4 Users' qualifications
WARNING!
Danger of injury with inadequately qualified personnel!
The operator of the plant / device is responsible for ensuring that the qualifi‐
cations 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 per‐
sonnel.
– Unqualified personnel should be kept away from the hazard zone
Training Definition
Instructed per‐
sonnel
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 pro‐
tective 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
personnel
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 regu‐
lations. The assessment of a person's technical training
can also be based on several years of work in the rele‐
vant field.
Safety and responsibility
11

Training Definition
Electrician Electricians are deemed to be people, who are able to
complete work on electrical systems and recognize and
avoid possible hazards independently 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 regulations.
Electricians must comply with the provisions of the appli‐
cable statutory directives on accident prevention.
Customer Service
department
Customer Service department refers to service techni‐
cians, 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 and responsibility
12

3 Storage and Transport
Store and transport the unit in its orig‐
inal packaging.
Protect the unit against moisture and
the effects of chemicals, even while
still packaged.
Ambient conditions for storage and
transport
Permissible ambient temperature:
-10 ... 45 °C
Permissible storage temperature:
-10 ... 55 °C
Permissible medium temperature:
-10 ... 45 °C
Humidity: None. Rain and condensa‐
tion not permitted.
Other: No dust, no direct sunlight.
Storage and Transport
13

4 Overview of equipment / Functional description
Overview of equipment
2
11
1A
B
3
12
5
2
108
4
79
6
A1630
Fig. 1: Overview of equipment
1. Rollers with tensioning springs
2. Dosing head
3. Rotor
4. Pump hose
5. Hose connector, suction side
6. Leakage fitting
7. Hose connector, discharge side
8. Threaded connector
9. Wall bracket
10. Rear section of housing, power
end
11. Upper section of housing, power
end
12. Transparent cover
A. Drive unit
B. Liquid end
Functional description
An electric motor drives a rotor.
Spring-mounted rollers are fitted to
the ends of the rotors, which press
the pump hose against the inner cur‐
vature of the dosing head.
The peristaltic pump operates by the
rollers driving the feed chemical
through the pump hose. The feet
chemical is primed by the pump hose
returning to its initial position.
Overview of equipment / Functional description
14

5 Assembly and Installation
nUser qualification, mechanical
installation: trained qualified per‐
sonnel, see Ä Chapter 2.4 ‘Users'
qualifications’ on page 11
nUser qualification, electrical instal‐
lation: Electrical technician, see
Ä Chapter 2.4 ‘Users' qualifica‐
tions’ on page 11
General information on
installation and assembly
The unit is resistant to normal
atmospheres in plant rooms.
Permissible ambient temperature:
-10 ... 45 °C
Permissible medium temperature:
-10 ... 45 °C
Humidity: None. Rain and con‐
densation not permitted.
Other: No dust, no direct sunlight.
Please observe the applicable
national regulations and guide‐
lines during installation!
5.1 Assembling the peristaltic
pump
Wall mounting
2
1
A0273
Fig. 2: Removing the wall/tube
retaining bracket
1. Remove the wall/tube retaining
bracket. Pull the two snap-
hooks (1) outwards and push
upwards
2. Fold out the wall/tube retaining
bracket (2) and pull out in a
downwards direction
3. Mark two drill holes diagonally
to each other, using the wall/
tube retaining bracket as a
drilling template
4. Drill holes: Ø 8 mm, d = 50 mm
Assembly and Installation
15

A0274
Fig. 3: Screw the wall/tube retaining
bracket in place using the washers
5. Screw the wall/tube retaining
bracket in place using the
washers
6. Suspend the peristaltic pump at
the top of the wall/tube retaining
bracket and, using light pres‐
sure, press it against the wall/
tube retaining bracket at the
bottom. Then press upwards
until the peristaltic pump audibly
snaps into position.
Pipe assembly
Pipe diameter
Pipe diameter: 25 mm to 60 mm.
2
1
A0273
Fig. 4: Removing the wall/tube
retaining bracket
1. Remove the wall/tube retaining
bracket. Pull the two snap-
hooks (1) outwards and push
upwards
2. Fold out the wall/tube retaining
bracket (2) and pull out in a
downwards direction
3. Secure the wall/tube retaining
bracket to the pipe with cable
ties (or pipe clamps).
Assembly and Installation
16

A0275
3
2
1
Fig. 5: Suspend the peristaltic pump
and fix in place
4. Suspend the peristaltic pump
(1) at the top of the wall/tube
retaining bracket and, using
light pressure, press it against
the wall/tube retaining bracket
at the bottom (2). Then press
upwards (3) until the peristaltic
pump audibly snaps into posi‐
tion.
5.2 Installing hose lines
Only use original hoses with the
specified hose dimensions 6 x 4
mm or 10 x 4 mm, otherwise the
durability of the connection cannot
be guaranteed.
Avoid reducing the hose sizes.
The hose lines used must be able
to withstand twice the operating
pressure of the peristaltic pump.
Assembly and Installation
17

Assembling the suction and discharge
lines.
4
2
1
3
A1631
Fig. 6: Installation diagram
1. Peristaltic pump
2. Chemical tank
3. Foot valve or suction lance
4. Injection valve
1. Cut the end of the hose at right
angles.
2. Unscrew a union nut and slide
the union nut over the pump
hose.
3. Push the tube end over the
nozzle until it will go not further.
4. Connect the discharge line to
the right hose connector.
5. Connect the suction line to the
left hose connector.
6. Tighten the union nuts.
7. Shorten the free end of the suc‐
tion line so that the foot valve
hangs just above the base of
the tank. With feed chemicals
that can form sediment, ensure
that the foot valve is suspended
a minimum of 50 mm above the
base of the tank.
8. Guide a hose line into the
storage tank from the leakage
fitting.
5.3 Electrical installation of the
peristaltic pump
– Only carry out the electrical
installation once the mechan‐
ical and hydraulic installations
have been completed.
– During installation, ensure that
the mains cable is de-ener‐
gised and has been secured
to prevent it from being
switched on again.
– Fit a short-circuit fuse during
installation.
– Fit an Off switch for the mains
power supply during installa‐
tion.
Assembly and Installation
18

Mains cable
Let the mains cable project from
the housing so that the front sec‐
tion of the housing can be
removed.
Remove around 120 mm from the
outer insulation of the mains
cable.
N
L
gelb/grün yellow/green
A1632
Fig. 7: Terminal diagram
1. Loosen the four screws and
remove the upper part of the
housing
2. Break out the small bore hole at
the far right on the underside of
the housing
3. Screw the required threaded
connector in and tighten it prop‐
erly (not the clamping screw)
4. Insert the reducing insert into
the threaded connector
depending on the cable cross-
section used
5. Guide the mains cable into the
threaded connector
6. Insulate the mains cable and
press on the corresponding
cable end sleeves
7. Connect the mains cable
accordingly, see Fig. 7 (protec‐
tive conductor connection)
Assembly and Installation
19

8. Tighten the clamping nut of the
threaded connector so that they
are properly sealed
9. Place the front section of the
housing on the read section of
the housing
10.
Once again check that the
seal is seated properly. Pro‐
tection class IP 65 is only
achieved if it is correctly
assembled.
Manually tighten the four
housing screws
Assembly and Installation
20