ProMinent DULCO flex DFCa User manual

DULCO®flex DFCa
Peristaltic Pump
Operating instructions
A0374
Original operating instructions (2006/42/EC)Part no. 986227 BA DX 010 02/10 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!
Technical changes reserved.

986227, 1, en_GB
© 2010
ProMinent Dosiertechnik Heidelberg GmbH
Im Schuhmachergewann 5 - 11
69123 Heidelberg Germany
Telephone: [phone]
Fax: [phone]
email: [email protected]
Internet: www.prominent.com
2

Table of contents
1Introduction........................................................................... 4
1.1 Explanation of the Safety Information........................... 4
1.2 Users' qualifications...................................................... 5
1.3 Identcode DULCO ® flex DFCa 030.............................. 6
1.4 Identcode DULCO ® flex DFCa 040.............................. 8
1.5 Identcode DULCO ® flex DFCa 050.............................. 9
1.6 Identcode DULCO ® flex DFCa 060............................ 11
1.7 Identcode DULCO ® flex DFCa 070............................ 13
1.8 Identcode DULCO ® flex DFCa 70D............................ 14
2 Safety and responsibility..................................................... 16
2.1 General safety information.......................................... 16
3 Functional description......................................................... 19
3.1 Construction................................................................ 19
3.2 Overview of the Device............................................... 20
4 Transport, storage, assembly and Installation.................... 21
4.1 Transport.................................................................... 21
4.2 Storage....................................................................... 21
4.3 Assembly.................................................................... 21
4.3.1 Ambient conditions.................................................. 22
4.3.2 Alignment of the suction side................................... 22
4.3.3 Alignment of the discharge side............................... 23
4.3.4 Adjusting the roller pressure.................................... 23
4.3.5 Performance curves................................................. 26
5 Commissioning................................................................... 29
5.1 Testing prior to commissioning the pump................... 29
6 Operation of the peristaltic pump........................................ 30
7Maintenance, repair, malfunctions, disposal and spare
parts.................................................................................... 31
7.1 Maintenance............................................................... 31
7.2 Exchanging the pump hoses...................................... 31
7.3 Troubleshooting.......................................................... 32
7.4 Disposal of Used Parts............................................... 34
7.5 Spare parts................................................................. 34
8 DFCa technical data........................................................... 46
8.1 Dimensions DFCa 030................................................ 47
8.2 Dimensions DFCa 040................................................ 48
8.3 Dimensions DFCa 050................................................ 49
8.4 Dimensions DFCa 060................................................ 50
8.5 Dimensions DFCa 070................................................ 51
9 DFCa technical appendices................................................ 52
9.1 Declaration of Conformity........................................... 52
10 Index................................................................................... 53
Table of contents
3

1 Introduction
These operating instructions provide information on the technical
data and functions of the DULCOMETER® BFDa series peristaltic
pump.
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.
1.1 Explanation of the Safety Information
These operating instructions provide information 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 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.
General non-discriminatory approach
Introduction
Introduction
4

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
situation.
1.2 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
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 distribu‐
tion 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 regulations. The assessment of a person's technical training
can also be based on several years of work in the relevant field.
Introduction
5

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!
1.3 Identcode DULCO ® flex DFCa 030
Identcode
DFCa DULCO ® flex DFCa 030
Type
030 DFCa 030, 0.433 l/revolution
Drive
000 Pump without drive
Step-down gears / 3 x 230 / 400 VAC
A11 0.25 kW, 18 1/min, 467 l/h, 8 bar
A12 0.37 kW, 28 1/min, 727 l/h, 8 bar
A13 0.55 kW, 38 1/min, 987 l/h, 4 bar
A14 0.55 kW, 55 1/min, 1,428 l/h, 2 bar
A15 0.75 kW, 66 1/min, 1,714 l/h, 2 bar
Manual adjustment gears / 3 x 230 / 400 VAC
A21 0.75 kW, 10-59 1/min, 259-1,532 l/h, 2 bar
Adjustment gears with integrated frequency converter / 1x 230 VAC
A31 0.55 kW, 11.5-40 1/min, 298-1,039 l/h, 4 bar
A32 0.75 kW, 18-64 1/min, 467-1,662 l/h, 2 bar
A33 1.10 kW, 23-80 1/min, 597-2,078 l/h, 1 bar
Adjustment gears (external frequency converter required) / 3 x 230 / 400 VAC
A41 0.37 kW, 2-28 1/min, 51-727 l/h, 8 bar
A42 0.75 kW, 4-57 1/min, 103-1,480 l/h, 2 bar
A43 1.10 kW, 5-80 1/min, 129-2,078 l/h, 1 bar
Introduction
6

Identcode
DFCa DULCO ® flex DFCa 030
Hose material
0 NR
B NBR
E EPDM
R NR-A
A NBR-A
H Hypalon
Hydraulic connection
A VA BSP 1 1/4"
B VA NPT 1 1/4"
C PP BSP 1 1/4"
D PVDF BSP 1 1/4"
F PVC NPT 1 1/4"
G Tri-Clamp, VA, 1 1/2"
H DIN 11851, VA, NW32
I DIN flange VA DN32
L ANSI flange VA DN32
P ANSI flange PVC DN32
Base plate
0 Base plate, lacquered steel
1 Base plate, stainless steel
2 Portable unit + lacquered steel base plate
3 Portable unit + stainless steel base plate
Leakage sensor
0 without leakage sensor
L with leakage sensor
Rotor
0 Rotor with 2 rollers
Batch control
0 without batch control
C with batch control
Special version
0 Standard
Vacuum system
0 none
V with vacuum system
Introduction
7

Identcode
DFCa DULCO ® flex DFCa 030
Certification
01 CE mark
1.4 Identcode DULCO ® flex DFCa 040
Identcode
DFCa DULCO ® flex DFCa 040
Type
040 DFCa 040, 0.91 l/revolution
Drive
000 Pump without drive
Step-down gears / 3 x 230 / 400 VAC
B11 0.55 kW, 18 1/min, 982 l/h, 8 bar
B12 0.55 kW, 29 1/min, 1,583 l/h, 8 bar
B13 0.75 kW, 38 1/min, 2,074 l/h, 4 bar
B14 1.10 kW, 54 1/min, 2,948 l/h, 2 bar
B15 1.50 kW, 66 1/min, 3,603 l/h, 2 bar
Manual adjustment gears / 3 x 230 / 400 VAC
B21 1.10 kW, 16-56 1/min, 873-3,057 l/h, 2 bar
Adjustment gears with integrated frequency converter / 1x 230 VAC
B31 1.10 kW, 12-36 1/min, 655-1,965 l/h, 4 bar
B32 1.50 kW, 15-53 1/min, 819-2,893 l/h, 2 bar
B33 2.20 kW, 22-77 1/min, 1201-4,204 l/h, 1 bar
Adjustment gears (external frequency converter required) / 3 x 230 / 400 VAC
B41 1.10 kW, 2-49 1/min, 109-2,675 l/h, 2 bar
B42 1.50 kW, 4-53 1/min, 218-2,893 l/h, 2 bar
B43 2.20 kW, 7-80 1/min, 382-4,368 l/h, 1 bar
Hose material
0 NR
B NBR
E EPDM
R NR-A
A NBR-A
H Hypalon
N Norprene (max. 2 bar)
Hydraulic connection
Introduction
8

Identcode
DFCa DULCO ® flex DFCa 040
A VA BSP 1 1/2"
B VA NPT 1 1/2"
C PP BSP 1 1/2"
D PVDF BSP 1 1/2"
G Tri-Clamp, VA, 1 1/2"
H DIN 11851, VA, NW40
I DIN flange VA DN40
L ANSI flange VA DN40
P ANSI flange PVC DN40
Base plate
0 Base plate, lacquered steel
1 Base plate, stainless steel
2 Portable unit + lacquered steel base plate
3 Portable unit + stainless steel base plate
Leakage sensor
0 without leakage sensor
L with leakage sensor
Rotor
0 Rotor with 2 rollers
Batch control
0 without batch control
C with batch control
Special version
0 Standard
Vacuum system
0 none
V with vacuum system
Certification
01 CE mark
1.5 Identcode DULCO ® flex DFCa 050
Identcode
DFCa DULCO ® flex DFCa 050
Type
050 DFCa 050, 1.46 l/revolution
Introduction
9

Identcode
DFCa DULCO ® flex DFCa 050
Drive
000 Pump without drive
Step-down gears / 3 x 230 / 400 VAC
C11 0.55 kW, 14.1 1/min, 1,235 l/h, 8 bar
C12 0.75 kW, 21 1/min, 1,839 l/h, 8 bar
C13 1.10 kW, 30 1/min, 2,628 l/h, 4 bar
C14 1.50 kW, 38 1/min, 3,328 l/h, 4 bar
C15 1.50 kW, 48 1/min, 4,204 l/h, 2 bar
C16 2.20 kW, 58 1/min, 5,080 l/h, 2 bar
Manual adjustment gears / 3 x 230 / 400 VAC
C21 1.15 kW, 8.8-44 1/min, 770-3,854 l/h, 4 bar
Adjustment gears with integrated frequency converter / 1x 230 VAC
C31 1.50 kW, 9-32 1/min, 788-2,803 l/h, 4 bar
C32 2.20 kW, 15-54 1/min, 1314-4,730 l/h, 2 bar
C33 3.00 kW, 22-77 1/min, 1927-6,745 l/h, 1 bar
Adjustment gears (external frequency converter required) / 3 x 230 / 400 VAC
C41 1.50 kW, 2-32 1/min, 175-2,803 l/h, 4 bar
C42 2.20 kW, 4-54 1/min, 350-4,730 l/h, 2 bar
C43 3.00 kW, 5.5-77 1/min, 481-6,745 l/h, 1 bar
Hose material
0 NR
B NBR
E EPDM
R NR-A
A NBR-A
H Hypalon
Hydraulic connection
I DIN flange VA DN40
G Tri-Clamp, VA, 2"
H DIN 11851, VA, NW50
J DIN flange PP DN40
K DIN flange VA, Halar coated + PVDF inserts DN40
L ANSI flange VA DN40
M ANSI flange PP DN40
N ANSI flange VA, Halar coated + PVDF inserts DN40
Base plate
Introduction
10

Identcode
DFCa DULCO ® flex DFCa 050
0 Base plate, lacquered steel
1 Base plate, stainless steel
2 Portable unit + lacquered steel base plate
3 Portable unit + stainless steel base plate
Leakage sensor
0 without leakage sensor
L with leakage sensor
Rotor
0 Rotor with 2 rollers
Batch control
0 without batch control
Special version
0 Standard
Vacuum system
0 none
V with vacuum system
Certification
01 CE mark
1.6 Identcode DULCO ® flex DFCa 060
Identcode
DFCa DULCO ® flex DFCa 060
Type
060 DFCa 060, 3.12 l/revolution
Drive
000 Pump without drive
Step-down gears / 3 x 230 / 400 VAC
D11 2.20 kW, 18 1/min, 3.3 m3/h, 8 bar
D12 2.20 kW, 21 1/min, 3.9 m3/h, 8 bar
D13 3.00 kW, 27 1/min, 5.0 m3/h, 8 bar
D14 3.00 kW, 33 1/min, 6.1 m3/h, 4 bar
D15 3.00 kW, 42 1/min, 7.8 m3/h, 4 bar
D16 3.00 kW, 47 1/min, 8.7 m3/h, 2 bar
D17 3.00 kW, 57 1/min, 10.6 m3/h, 2 bar
Manual adjustment gears / 3 x 230 / 400 VAC
Introduction
11

Identcode
DFCa DULCO ® flex DFCa 060
D21 4.0 kW, 8-49 1/min,1.4-9.1 m3/h, 2 bar
Adjustment gears with integrated frequency converter / 1x 230 VAC
D31 3.0 kW, 7-25 1/min, 1.3-4.6 m3/h, 8 bar
D32 4.0 kW, 15-53 1/min, 2.8-9.9 m3/h, 2 bar
Hose material
0 NR
B NBR
E EPDM
R NR-A
A NBR-A
H Hypalon
Hydraulic connection
I DIN Flange, VA, DN50
G Tri-Clamp, VA, 2 1/2"
H DIN 11851, VA, NW50
K DIN flange VA, Halar coated + PVDF inserts, DN50
L ANSI flange VA DN50
M ANSI flange PP, DN50
N ANSI flange VA, Halar coated + PVDF inserts, DN50
Base plate
0 Base plate, lacquered steel
1 Base plate, stainless steel
2 Portable unit + lacquered steel base plate
3 Portable unit + stainless steel base plate
Leakage sensor
0 without leakage sensor
L with leakage sensor
Rotor
0 Rotor with 2 rollers
Batch control
0 without batch control
C with batch control
Special version
0 Standard
Vacuum system
0 none
Introduction
12

Identcode
DFCa DULCO ® flex DFCa 060
V with vacuum system
Certification
01 CE mark
1.7 Identcode DULCO ® flex DFCa 070
Identcode
DFCa DULCO ® flex DFCa 070
Type
070 DFCa 070, 8.05 l/revolution
Drive
000 Pump without drive
Step-down gears / 3 x 230 / 400 VAC
E11 2.20 kW, 14 1/min, 6.7 m3/h, 8 bar
E12 3.0 kW, 21 1/min, 10.1 m3/h, 8 bar
E13 4.0 kW, 26 1/min, 12.5 m3/h, 4 bar
E14 4.0 kW, 32 1/min, 15.4 m3/h, 4 bar
E15 5.5 kW, 37 1/min, 17.8 m3/h, 4 bar
E16 5.5 kW, 46 1/min, 22.2 m3/h, 2 bar
E17 5.5 kW, 54 1/min, 26.0 m3/h, 2 bar
Adjustment gears with integrated frequency converter / 1x 230 VAC
E31 5.5 kW, 9-23 1/min, 4.3-15.4 m3/h, 4 bar
E32 7.5 kW, 14-47 1/min, 6.7-22.7 m3/h, 2 bar
Hose material
0 NR
B NBR
E EPDM
R NR-A
A NBR-A
H Hypalon
Hydraulic connection
I DIN flange VA, DN65
G Tri-Clamp, VA, 3"
H DIN 11851, VA, NW65
J DIN flange PP, DN65
L ANSI flange VA, DN65
Introduction
13

Identcode
DFCa DULCO ® flex DFCa 070
M ANSI flange PP, DN65
Q DIN flange VA Halar coated, DN65
R ANSI flange VA Halar coated, DN65
Base plate
0 Base plate, lacquered steel
1 Base plate, stainless steel
2 Portable unit + lacquered steel base plate
3 Portable unit + stainless steel base plate
Leakage sensor
0 without leakage sensor
L with leakage sensor
Rotor
0 Rotor with 2 rollers
Batch control
0 without batch control
Special version
0 Standard
Vacuum system
0 none
V with vacuum system
Certification
01 CE mark
1.8 Identcode DULCO ® flex DFCa 70D
Identcode
DFCa DULCO ® flex DFCa 70D
Type
70D DFCa 70D, 15.83 l/revolution, double head version
Drive
000 Pump without drive
Step-down gears / 3 x 230 / 400 VAC
F11 5.5 kW, 15 1/min, 14.2 m3/h, 4 bar
F12 7.5 kW, 22 1/min, 20.8 m3/h, 2 bar
F13 7.5 kW, 31 1/min, 29.4 m3/h, 2 bar
F14 9.2 kW, 40 1/min, 38.0 m3/h, 2 bar
Introduction
14

Identcode
DFCa DULCO ® flex DFCa 70D
Hose material
0 NR
B NBR
E EPDM
R NR-A
A NBR-A
Hydraulic connection
I DIN Flange, VA, DN80
G Tri-Clamp, VA, 4"
H DIN 11851, VA, NW80
L ANSI flange, VA DN80
Base plate
0 Base plate, lacquered steel
1 Base plate, stainless steel
Leakage sensor
0 without leakage sensor
L with leakage sensor
Rotor
0 Rotor with 2 rollers
Batch control
0 without batch control
Special version
0 Standard
Vacuum system
0 none
Certification
01 CE mark
Introduction
15

2 Safety and responsibility
2.1 General safety information
WARNING!
Live parts
Possible consequence: Fatal or very serious injuries
– Measure: The device must be disconnected from
the power supply before it is opened
–Isolate damaged, faulty or manipulated devices
from the mains in order to de-energise.
WARNING!
Emergency stop switch
Possible consequence: Fatal or very serious injuries
An emergency stop switch is to be connected for the
entire plant. This should enable the entire plant to be
shut down in the event on an emergency in such a way
that the overall plant can be brought into a safe condi‐
tion.
WARNING!
Unauthorised access
Possible consequence: Fatal or very serious injuries
– Measure: Ensure that there can be no unauthor‐
ised access to the unit
WARNING!
Hazardous media / contamination of persons and
equipment
Possible consequence: Fatal or very serious injuries.
material damage
– Ensure that the pump hoses are resistance against
the media being conveyed
–Always observe the the safety data sheets for the
media to be conveyed. The system operator must
ensure that these safety data sheets are available
and that they are kept up-to-date
– The safety data sheets for the media being
conveyed are always decisive for initiating counter
measures in the event of leakage to the media
being conveyed
– Observe the general restrictions in relation to
viscosity limits, chemical resistance and density
– Always switch the pump off before exchanging the
pump hose
Safety and responsibility
16

WARNING!
Correct and proper use
Possible consequence: Fatal or very serious injuries
– The unit is not intended to convey or regulate
gaseous or solid media
–Do not exceed the rated pressure, speed or
temperature for the pump
– The unit may only be used in accordance with the
technical data and specifications provided in these
operating instructions and in the operating instruc‐
tions for the individual components
– The system is not designed for use in areas at risk
from explosion
– Only switch the pump on if it has been properly
fastened to the floor
– Only switch the pump on if it the front cover has
been attached.
WARNING!
Operational lifetime of the pump hoses
Possible consequence: Fatal or very serious injuries
The operational lifetime of the pump hoses cannot be
precisely specified. For this reason, the possibility of
fracture and consequential leakage of liquids must be
accounted for. If the hose rupture alarm (optional) is
fitted, then the pump can be stopped and / or an elec‐
trical valve can be actuated.
In addition, you must avoid particles from untight
hoses being introduced into the media being
conveyeed. This can be achieved e.g. by means of
filtration, a hose rupture alarm or other means suitable
for the respective process.
CAUTION!
CIP cleaning
In the event of CIP cleaning, it is necessary to obtain
information from the manufacturer about correct instal‐
lation of the pump (a special installation is required),
as well as regarding the compatibility of the cleaning
agents with the pump hoses of the pump and the other
hydraulic connections.
Cleaning should be undertaken at the recommended
maximum temperature.
CAUTION!
Direction of rotation / flow direction
Possible consequence: Material damage right through
to destruction of the unit
– The pump's direction of rotation in relation to the
desired flow direction must be checked prior to
every start.
Safety and responsibility
17

CAUTION!
Environmental influences
Possible consequence: Material damage right through
to destruction of the unit
– The device is not suitable for outdoor operation
–Take suitable measures to protect the device from
environmental influences such as:
– UV rays
– Moisture
– Frost, etc.
Safety and responsibility
18

3 Functional description
The package contents supplied with the DULCOflex® DFCa is
selectable via the identcode.
The DULCOflex® DFCa 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
handling of the metered media.
The DULCOflex® DFCa has been designed for safe and uncompli‐
cated operation, as well as straightforward maintenance.
The DULCOflex® DFCa 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. 8 bar).
3.1 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. Two 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
19

3.2 Overview of the Device
P_DX_0017_SW
Fig. 1: Diagram of functional principle
1 Housing
2 Rotor
3 Rollers
4 Hose
Functional description
20