ProMinent DULCO flex DFAa User manual

DULCO®flex DFAa
Peristaltic Pump
Assembly and operating instructions
A0380
EN
Original Operating Instructions (2006/42/EC)Part no. 986229 BA DX 019 12/15 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.

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.
Please read the supplementary information in its entirety.
Information
This provides important information relating to the cor‐
rect operation of the unit or is intended to make your
work easier.
Safety Information
The safety information includes detailed descriptions of the haz‐
ardous situation, see
Ä Chapter 2.1 ‘Explanation of the safety
information’ on page 8
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 documents
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
General non-discriminatory approach
Supplementary information
Supplemental instructions
2

Table of contents
1 Product identification............................................................. 4
1.1 Identity Code for DULCO®flex DFAa 003..................... 4
1.2 Identity Code for DULCO®flex DFAa 008..................... 6
2 Safety and Responsibility...................................................... 8
2.1 Explanation of the safety information............................ 8
2.2 Intended Use................................................................ 9
2.3 Users' qualifications.................................................... 10
2.4 Dulcoflex general safety information........................... 11
3 Transport and Storage........................................................ 13
3.1 Transport.................................................................... 13
3.2 Storage....................................................................... 13
4 Functional description......................................................... 14
4.1 Construction................................................................ 14
4.2 Overview of the device............................................... 15
5 Assembly............................................................................ 16
5.1 Ambient conditions..................................................... 16
5.2 Alignment of the suction side...................................... 16
5.3 Alignment of the discharge side.................................. 16
6 Commissioning................................................................... 17
6.1 Testing prior to commissioning the pump................... 17
7 Operation of the peristaltic pump........................................ 18
8 Maintenance....................................................................... 19
8.1 Maintenance............................................................... 19
8.2 Replacing the Pump Hose.......................................... 19
9 Troubleshooting.................................................................. 21
10 Disposal of Used Parts....................................................... 23
11 Spare parts......................................................................... 24
12 DFAa Technical Data.......................................................... 27
12.1 Technical Data.......................................................... 27
12.2 Performance curves.................................................. 28
12.3 Dimensions DFAa 003/008....................................... 29
13 EC Declaration of Conformity for Machinery....................... 30
14 Index................................................................................... 31
Table of contents
3

1 Product identification
1.1 Identity Code for DULCO®flex DFAa 003
Identity code
DFAa DULCO®flex DFAa 003
Type
003 DFAa 003, with 3.2 mm hose, wall thickness 2.4 mm,1.66 ml/revolution
Power end/drive
000 Pump without power end/drive
Reduction gear system / 3 x 230 / 400 VAC
A10 0.12 kW, 14 rpm, 1.4 l/h, 2 bar
A11 0.12 kW, 35 rpm, 3.5 l/h, 2 bar
A12 0.12 kW, 70 rpm, 7.0 l/h, 2 bar
A13 0.18 kW, 93 rpm, 9.3 l/h, 2 bar
A14 0.18 kW, 140 rpm, 13.9 l/h, 2 bar
Manual adjustment gears / 3 x 230 / 400 VAC
A21 0.12 kW, 10.9 ... 57 rpm, 1.1 ... 5.7 l/h, 2 bar
A22 0.25 kW, 34 ... 176 rpm, 3.4 ... 17.5 l/h, 2 bar
Gear motor with integrated frequency converter / 1x 230 VAC
A31 0.18 kW, 13 ... 130 rpm, 1.3 ... 12.9 l/h, 2 bar, 7 ... 70 Hz
Gear motor (external frequency converter required) / 3 x 230 / 400 VAC
A41 0.18 kW, 4 ... 105 rpm, 0.4 ... 10.5 l/h, 2 bar, 3 ... 75 Hz
Hose material
ANorprene® A60G
CSolva®
D Silicone
Base plate
0 Base plate, lacquered steel
1 Base plate, stainless steel
Batch control
0 No batch control
R With batch control
Special version of motor
0 Standard (3 phase) 3x230/400 VAC
D Single-phase motor, 0.12 kW (only for A10 ... A12) 1x230
VAC
E Single-phase motor, 0.18 kW (only for A13 ... A14) 1x230
VAC
Pump head
0 Standard with one pump head
Product identification
4

Identity code
C Double head version
Approvals
01 CE mark
Product identification
5

1.2 Identity Code for DULCO®flex DFAa 008
Identity code
DFAa DULCO®flex DFAa 008
Type
008 DFAa 008, with 8 mm hose, wall thickness 2.4 mm,10 ml/revolution
Power end/drive
000 Pump without power end/drive
Reduction gear system / 3 x 230 / 400 VAC
B10 0.12 kW, 14 rpm, 8.4 l/h, 2 bar
B11 0.12 kW, 35 rpm, 21 l/h, 2 bar
B12 0.12 kW, 70 rpm, 42 l/h, 2 bar
B13 0.18 kW, 93 rpm, 55.8 l/h, 2 bar
B14 0.18 kW, 140 rpm, 84 l/h, 2 bar
Manual adjustment gears / 3 x 230 / 400 VAC
B21 0.12 kW, 10.9 ... 57 rpm, 6.5 ... 34.2 l/h, 2 bar
B22 0.25 kW, 34 ... 176 rpm, 20.4 ... 105 l/h, 2 bar
Gear motor with integrated frequency converter / 1x 230 VAC
B31 0.18 kW, 13 ... 130 rpm, 7.8 ... 78 l/h, 2 bar, 7 ... 70 Hz
Gear motor (external frequency converter required) / 3 x 230 / 400 VAC
B41 0.18 kW, 4 ... 105 rpm, 2.4 ... 63 l/h, 2 bar, 3 ... 75 Hz
Hose material
ANorprene® A60G
BNorprene® A60F
CSolva®
D Silicone
Base plate
0 Base plate, lacquered steel
1 Base plate, stainless steel
Batch control
0 No batch control
R With batch control
Special version of motor
0 Standard (3 phase) 3x230/400 VAC
D Single-phase motor, 0.12 kW (only for B10 ... B12) 1x230
VAC
E Single-phase motor, 0.18 kW (only for B13 ... B14) 1x230
VAC
Pump head
0 Standard with one pump head
Product identification
6

Identity code
C Double head version
Approvals
01 CE mark
Product identification
7

2 Safety and Responsibility
The pump is intended for pumping pasty, viscose, abrasive, shear-
sensitive and/or gaseous media or media containing solids.
2.1 Explanation of the safety information
These operating instructions provide information on the technical
data and functions of the product. These operating instructions pro‐
vide 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 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 injuries.
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 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, mate‐
rial 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 inju‐
ries. May also be used as a warning about material
damage.
Introduction
Safety and Responsibility
8

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 situation. 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 sit‐
uation.
2.2 Intended Use
CAUTION!
Intended Use
Possible consequences if the instructions are not
observed: Minor injuries and material damage
– The pump is intended for pumping pasty, viscose,
abrasive, shear-sensitive and/or gaseous media or
media containing solids
– The pump is not intended for pumping gaseous
media
– Only use the pump in accordance with the tech‐
nical data and specifications outlined in the oper‐
ating instructions
– The pump is not designed for use in areas at risk
from explosion
– Only switch the pump on if it has been properly
fixed to the floor
– Only switch the pump on if it the front cover has
been attached
Safety and Responsibility
9

2.3 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 con‐
ducted 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 protective 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 regula‐
tions. The assessment of a person's technical training can also be based on
several years of work in the relevant field.
Electrician Electricians are deemed to be people, who are able to complete work on elec‐
trical 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 applicable statutory direc‐
tives on accident prevention.
Customer Service depart‐
ment
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 and Responsibility
10

2.4 Dulcoflex general safety information
WARNING!
Live parts
Possible consequence: Fatal or very serious injuries
– Isolate damaged or faulty pumps or pumps that
have been tampered with from the mains power
supply to de-energise them
WARNING!
Hazardous media / contamination of persons and
equipment
Possible consequence: Fatal or very serious injuries.
Material damage
– Ensure that the pump hose is resistant to the
medium being pumped
– Always observe the material safety data sheets for
the medium being pumped. It is the responsibility
of the system operator to ensure that the material
safety data sheet is available and kept up-to-date
– The material safety data sheet for the medium
being pumped is always essential when it comes
to initiating counter measures in the event of
leakage of the pumped media
– Note the general limitations regarding viscosity
limits, chemical resistance and density
WARNING!
Operational lifetime of the pump hose
Possible consequence: Fatal or very serious injuries
The service life of the pump hose cannot be precisely
specified. For this reason, consider the possibility of
fracture and subsequent leakage of liquid. If a hose
rupture alarm (optional) has been fitted, the pump can
be stopped and/or an electrical valve actuated.
In addition, avoid that particles of the leaking hose
enters the medium being pumped. This can be ach‐
ieved e.g. by means of filtration, a hose rupture alarm
or other measures suitable for the respective process.
CAUTION!
CIP (cleaning in place)
In the event of CIP (cleaning in place), it is necessary
to obtain information from the manufacturer about the
correct installation of the pump (a special installation is
required), as well as regarding the compatibility of the
cleaning agents with the pump's hose and other
hydraulic Connectors.
Perform cleaning at the recommended maximum tem‐
perature.
Safety and Responsibility
11

Operation in the open air and outdoors
– Take suitable measures to protect the device from
ambient influences when operating outside such
as:
– UV radiation
– Humidity
– frost etc., see Ä ‘Ambient conditions’
on page 27
Safety and Responsibility
12

3 Transport and Storage
nUser qualification, transport and storage: trained user, see
Ä Chapter 2.3 ‘Users' qualifications’ on page 10
WARNING!
Material safety data sheet
Possible consequence: Fatal or very serious injuries
Always refer to the relevant material safety data sheet
for the medium when carrying out any work that
involves contact with the medium being pumped.
3.1 Transport
Transport
nThe pump is protected by means of cardboard packaging
nThe packaging materials can be recycled
nConsider the ambient conditions
3.2 Storage
Storage
nRemove the pump hose from the housing during storage
nWith storage lasting longer than 60 days, protect the coupling
surfaces (terminals, reducing adaptors, motors) with appro‐
priate antioxidant agents
nConsider the ambient conditions
Transport and Storage
13

4 Functional description
The package contents supplied with the DULCO®flex DFAa is
selectable via the identcode.
The DULCO®flex DFAa is a displacement pump. The feed chem‐
ical is transported by the rotor squeezing the hose in the direction
of flow. No valves are needed for this. This ensures gentle han‐
dling of the metered media.
The DULCO®flex DFAa has been designed for safe and uncompli‐
cated operation, as well as straightforward maintenance.
The DULCO®flex DFAa can be used for many different media.
However, this pump type is often the optimal solution for abrasive,
shear-sensitive and viscose media.
Typical areas of use include processes where only a low discharge
pressure is required (max. 2 bar).
4.1 Construction
Main modules:
nDrive Unit
nHousing
nBase frame
The pump housing is closed off with a screwed front cover in order
to avoid the risk of injury.
The motor serves to drive the rotor. Rollers at the ends of the rotor
serve to press the pump hose against the pump housing.
The rotary movement of the rotors alternately press and relax the
rollers in relation to the pump hose. This serves to suck the media
in and convey it into the metering line.
Brief functional description
Functional description
14

4.2 Overview of the device
Fig. 1: Diagram of functional principle
1. Housing
2. Hose
3. Rotor
4. Rollers
Functional description
15

5 Assembly
nUser qualification, installation: trained qualified personnel, see
Ä Chapter 2.3 ‘Users' qualifications’ on page 10
nUser qualification, electrical installation: Electrical technician,
see Ä Chapter 2.3 ‘Users' qualifications’ on page 10
CAUTION!
Possible consequence: Slight or minor injuries. Mate‐
rial damage.
Carry out assembly work before commencing the elec‐
trical installation.
Observe the permissible ambient conditions.
5.1 Ambient conditions
NOTICE!
Ambient conditions
Possible consequence: Property damage and
increased wear and tear
Assembly is to be carried out in the following order. If
the pump has to be installed outdoors, then it is to be
equipped with protection against sunlight and weather
influences.
When positioning the pump, ensure that sufficient
room for access is provided for all types of mainte‐
nance work.
5.2 Alignment of the suction side
The pump is to be positioned as near as possible to the liquid con‐
tainer, so that the suction side is kept as short and straight as pos‐
sible.
The suction line must be absolutely airtight and made of a suitable
material, so that it is not squeezed together under vacuum.
The diameter must correspond to the rated diameter of the pump
hose. A larger diameter is recommended in the event of viscose
liquids.
The pump is self-priming and does not require an admission valve.
The pump is reversible and the suction connection can therefore
comprise of one of two options. Normally the option is selected
which is best suited to the physical conditions of the installation.
5.3 Alignment of the discharge side
The discharge line is to be kept as straight and short as possible,
in order to avoid performance reduction.
The diameter must correspond to the rated diameter of the pump
hose. A larger diameter is recommended in the event of viscose
liquids.
Assembly
16

6 Commissioning
nUser qualification, commissioning: trained user, see Ä Chapter
2.3 ‘Users' qualifications’ on page 10
6.1 Testing prior to commissioning the pump
The following tests are to be carried out:
nEnsure that the pump has not been damaged during transpor‐
tation or storage. Immediately report any damage to the sup‐
plier
nCheck that the mains voltage is suitable for the motor
nEnsure that the hose is suitable for the fluid to be conveyed
and that it is not damaged
nMake sure that the temperature of the liquid does not exceed
the recommended temperature range
nOnly switch the pump on if it the front cover has been properly
attached
nCheck that the rollers are correctly fitted and fastened
nCheck that the hose and rollers are sufficiently lubricated
nCheck that the thermal overload protection (not included in the
delivery scope) corresponds to the value specified on the
motor type plate
nCheck whether the direction of rotation is correctly adjusted
nCheck that the optional electrical components are connected
and are working properly
nInstall a manometer in the pressure line if the back-pressure
value is unknown
nCheck the operating instructions in order to ensure that the
flow values, pressures and power consumption of the motor do
not exceed the rated values
nInstall a pressure relief valve in the pressure line in order to
protect the pump in the event that a valve is unintentionally
closed off or the line is blocked in another way.
Commissioning
17

7 Operation of the peristaltic pump
nUser qualification, operation: instructed persons, see
Ä Chapter 2.3 ‘Users' qualifications’ on page 10
The peristaltic pump is to be fully integrated into the customer's
designated plant and is then controlled by this plant. It is not pos‐
sible to operate the pump directly.
Operation of the peristaltic pump
18

8 Maintenance
nUser qualification, maintenance: instructed personnel, see
Ä Chapter 2.3 ‘Users' qualifications’ on page 10
nUser qualification, repair: trained user, see Ä Chapter 2.3
‘Users' qualifications’ on page 10
8.1 Maintenance
CAUTION!
Disconnect the pump from the mains/power supply
Possible consequence: Personal injury
Only carry out work on the pump after it has previously
been switched off and disconnected from the mains/
power supply.
Lubrication
nCheck that the rollers and the hose are sufficiently lubricated
– Check every 200 operating hours
8.2 Replacing the Pump Hose
1. Close off all valves to prevent leakage of the feed chemical
2. Dismantle the pump hose from the discharge and suction line
3.
The M3 set screw to secure the front cover
screw is 4 mm long and is opened using an Allen
key (1.5 mm).
Remove the front cover
4. Dismantle the pump housing
5. Remove the pump hose to be replaced
1. Clean the interior surfaces of the pump housing
2. Lubricate the internal surfaces of the pump housing on the
contact surfaces to the pump hose
3. Check the rollers. Ensure that the roller surfaces are not
damaged
4. Insert the pump hose into the pump
5. Reassemble the pump housing
6. Attach the front cover to the pump housing with the inte‐
grated hose clip. Hold the pump hose under slight tension.
7. Tighten the knurled thumb screw for the integrated hose clip
just enough that the pump hose is sufficiently compressed
and does not come loose during operation
8. The M3 set screw to secure the front cover screw is 4 mm
long and is screwed in using an Allen key (1.5 mm)
9. Attach the pump hose to the discharge and suction line
Replacing the pump hose - disman‐
tling
Replacing the pump hose - installation
Maintenance
19

10. Open all valves
Maintenance
20