ProMinent DULCOflex DF4a User manual

Peristaltic pump
DULCOflex DF4a
Assembly and operating instructions
A2536
EN
Original operating instructions (2006/42/EC)Part no. 986513 Version: BA DX 034 10/21 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
correct operation of the unit or is intended to make
your work easier.
Warning information
Warning information includes detailed descriptions of the haz‐
ardous situation, see
Ä Chapter 3.1 ‘Labelling of Warning Informa‐
tion’ on page 10 .
The following symbols are used to highlight instructions, links, lists,
results and other elements in this document:
Tab. 1: 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 directives
2

Table of contents
1About this product................................................................. 5
1.1 Nameplate.................................................................... 6
1.2 Construction and functional description........................ 6
1.3 Overview of equipment and control elements............... 7
2 Identity code.......................................................................... 8
3Safety chapter..................................................................... 10
3.1 Labelling of Warning Information................................ 10
3.2 User qualification........................................................ 12
3.3 General safety information.......................................... 13
3.4 Intended use............................................................... 14
4 Storage and transport......................................................... 15
4.1 Storage....................................................................... 15
4.2 Transport.................................................................... 15
4.3 Packaging material..................................................... 15
5 Assembly and installation................................................... 16
5.1 Dimensional drawing.................................................. 17
5.2 Assembly.................................................................... 18
5.3 Installation, hydraulic.................................................. 19
5.4 Installation, electrical.................................................. 21
5.4.1 Opening the housing................................................ 21
5.4.2 Preparing for mains connection (equipment without
mains plug).............................................................. 21
5.4.3 Additional connections............................................. 22
5.4.4 Close the housing.................................................... 25
6 Commissioning................................................................... 26
7 Setting................................................................................. 28
7.1 Control unit................................................................. 28
7.1.1 LCD display............................................................. 28
7.1.2 LED.......................................................................... 29
7.1.3 Control keys............................................................. 29
7.2 Continuous displays.................................................... 31
7.2.1 Chemical pump........................................................ 31
7.2.2 Active carbon pump or flocculant pump................... 32
7.2.3 Setting options for the continuous display............... 33
7.3 Operating menu.......................................................... 34
7.3.1 Operating menu overview........................................ 36
7.3.2 Modifying the operating mode ( ‘MODE’ menu)....... 38
7.3.3 Changing parameters ( ‘SET’ menu)....................... 38
7.3.4 Changing the configuration ( ‘CONFIG’ menu)........ 42
7.3.5 Service menu ( ‘SERVICE’ menu)........................... 44
7.3.6 Reading system information ( ‘INFO’ menu)............ 45
7.3.7 Security-relevant settings ( ‘SECURITY’ menu)...... 46
7.3.8 Calibrating the pump (CALIBRATION menu).......... 48
8 Operation............................................................................ 49
9 Maintenance....................................................................... 50
10 Troubleshooting.................................................................. 53
10.1 Errors without error messages.................................. 53
10.2 Faults with error messages....................................... 53
Table of contents
3

10.3 Warning with error message..................................... 54
10.4 All other faults........................................................... 54
11 Decommissioning and disposal.......................................... 55
11.1 Use Parts Disposal/Declaration of Decontamina‐
tion............................................................................ 56
12 Technical data..................................................................... 57
12.1 Performance data..................................................... 57
12.2 Precision................................................................... 57
12.3 Dimensions and weights........................................... 57
12.4 Material specifications.............................................. 58
12.5 Ambient conditions................................................... 58
12.6 Degree of protection and safety requirements.......... 59
12.7 Electrical data........................................................... 59
12.8 Sound pressure level................................................ 60
13 Ordering information for spare parts/accessories............... 61
14 Declaration of Conformity for Machinery............................. 62
15 Overview of setting parameters.......................................... 63
16 Index................................................................................... 67
Table of contents
4

1 About this product
The assembly and operating instructions for the peristaltic pump
DULCO®flex DF4a are targeted at people who, at the very least,
have the qualifications of a trained person, see
Ä Chapter 3.2
‘User qualification’ on page 12 . Should higher qualifications be
necessary, then this fact is described at the start of a chapter.
The printed version of the assembly and operating instructions is
naturally not updated. We would therefore ask you to regularly visit
the manufacturer’s homepage www.prominent.com to find out
about the new electronic versions of the assembly and operating
instructions. These versions may contain, among other things,
information about new fault remedies or spare parts.
The peristaltic pump DULCO®flex DF4a is a pump designed for
metering liquids. The feed chemical is pumped by the rotor
squeezing on the hose. No valves are needed for this, which
ensures gentle handling of the feed chemical.
A2537
Fig. 1: DULCO®flex DF4a
Typical applications include processes where only a low feed pres‐
sure is required.
The metering pump features several inputs for setting the capacity.
The step motor means that the capacity can be set continuously
variably.
The key features:
nCapacity range 0.5 – 12 l/h, 4 ... 2 bar.
nPharMed® hose material.
nStep motor, speed-controlled.
nContinuously variable adjustment of the capacity either man‐
ually or externally via contacts or analogue signal 0/4 ... 20 mA
and 0 ... 10 V.
nPriming function (high-speed run).
nSpring-mounted rollers for uniform roller pressure and
increased service life of the hose.
nSelectable capacity adjustment, e.g. increase as required or
night set-back.
nCapacity appears on the display in l/h.
nReverse direction of rotation, among other things useful for
backflushing.
nHousing degree of protection IP 65.
The target group
Assembly and operating instructions
The peristaltic pump
About this product
5

1.1 Nameplate
A2547
Fig. 2: Nameplate
The nameplate provides information on:
nManufacturer with address and phone number
nPlace and country of origin,
nManufacturing date in week/year
nType of pump with identity code
[Type] ,
nElectrical connection
[EL. ANSCHLUSS] in Volts / Hertz, watts
and amps
nSerial number
[SER.NR. / TN.]
nCapacity [DOSIERLEISTUNGLEISTUNG] in bar and psi and/or
l/h and gph
n
[IP65] degree of protection.
1.2 Construction and functional description
The pump comprises three main components:
nDrive unit (step motor)
nLiquid end (rotor, rollers and pump hose)
nControl unit
The pump features a plastic housing. The plastic housing com‐
prises an upper and lower part, which are screwed together. The
lower part contains the PCBs for the motor control. The upper part
of the housing accommodates the motor and display PCB with dis‐
play and keys.
The liquid end is mounted at the front and is sealed by a screw-on
transparent cover. The pump hose can easily be replaced after the
transparent cover has been removed.
The step motor drives the rotor. Two spring-mounted rollers at the
ends of the rotor press against the pump housing. The pump hose
runs along the inner curve of the dosing head.
The rotary movement of the rotor alternately presses and releases
the rollers in relation to the pump hose. The liquid is drawn in by
suction and pumped into the pressure hose.
The pump is operated by the control unit. The required metering
level and operating mode are set on the control unit. Metering is
controlled by the control unit or by an external contact, level and/or
pause input.
About this product
6

1.3 Overview of equipment and control elements
P_DX_0032_SW_2
1
13
12
11 10 9 8
76
5
43
2
Fig. 3: Overview of DF4a equipment. A) Front view, B) Side view / Functional plug for “Level” socket
1 Rotor
2 Control keys
3 LCD display
4 Housing lower part
5 Housing upper part
6 Liquid end
7 Transparent cover
8 Pressure connector
9 “Level” socket, if required with functional plug for
the “Level” socket
10 Leakage fitting with end cap
11 Suction connector
12 Hose rupture monitoring device
13 Pump hose
About this product
7

2 Identity code
Product range DULCO®flex DF4a
DF4a Applications
0 Chemical pump
A Metering of active carbon
F Metering of flocculants
Installation type
W Wall-mounted
Design
0with ProMinent® logo
1without ProMinent® logo
Type Pump capacity
bar l/h
04004 4.0 0.35
04015 4.0 1.50
03060 2.5 6.00
02120 2.0 12.00
Hose material
PPharMed®
Hydraulic connector
0 Standard
9 Special connection 10x4 discharge side
Operating voltage
U 100 - 240 VAC, 50/60 Hz
Cable and plug
0 without cable
1 with cable 2 m; open end
A with 2 m cable; standard European plug
B with 2 m cable; standard Swiss plug
Accessories
0 no accessories
2 with lip-seal metering valve PCB and 10 m PE
metering line
Hardware extension
0 none
Default language
00 language-neutral
Relay
1 Fault indicating relay (N/C)
Identity code
8

Product range DULCO®flex DF4a
3 Fault indicating relay (N/O)
Control version
8 manual + external contact
and analogue 0/4-20 mA +
0-10 V
C as 8 and CANopen
D as 8 and CANopen and CAN
connector
Additional inputs
1 Pause + 2-stage level +
AUX_1
2 Pause + 1-stage level +
AUX_1 + AUX_2
Pause/level
0 Pause N/C + level
N/C
Certification
01 CE mark
Identity code
9

3 Safety chapter
3.1 Labelling of Warning Information
These operating instructions provide information on the technical
data and functions of the product. These operating instructions pro‐
vide detailed warning information and are provided as clear step-
by-step instructions.
The warning 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.
Description of hazard
–Denotes an immediate threatening danger. If
the situation is disregarded, it will result in fatal
or very serious injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or very serious inju‐
ries.
Measure to be taken to avoid this danger.
– Denotes a possibly hazardous situation. If the
situation 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.
– Denotes a possibly hazardous situation. If the
situation is disregarded, it could result in slight
or minor injuries. May also be used as a
warning about material damage.
NOTICE!
Nature and source of the danger
Damage to the product or its surroundings.
Measure to be taken to avoid this danger.
– Denotes a possibly damaging situation. If the
situation is disregarded, the product or an
object in its vicinity could be damaged.
Introduction
Safety chapter
10

Type of information
Hints on use and additional information.
Source of the information. Additional measures.
– Denotes hints on use and other useful informa‐
tion. It does not indicate a hazardous or dam‐
aging situation.
Safety chapter
11

3.2 User qualification
WARNING!
Danger of injury with inadequately qualified per‐
sonnel
The operator of the system / equipment is respon‐
sible for ensuring that the qualifications are ful‐
filled.
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.
The pertinent accident prevention regulations, as
well as all other generally acknowledged safety
regulations, must be adhered to.
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 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 the manufacturer or another authorised distribution partner.
Trained, qualified per‐
sonnel
A trained, 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
training, knowledge and experience, as well as knowledge of pertinent regula‐
tions. A trained, qualified employee must be able to perform the tasks
assigned to him independently with the assistance of drawing documentation
and parts lists. The assessment of a person's technical training can also be
based on several years of work in the relevant field.
Electrical technician An electrical technician is able to complete work on electrical systems and rec‐
ognise and avoid possible dangers independently based on his technical
training and experience as well as knowledge of pertinent standards and regu‐
lations. An electrical technician must be able to perform the tasks assigned to
him independently with the assistance of drawing documentation, parts lists,
terminal and circuit diagrams. The electrical technician must be specifically
trained for the working environment in which the electrical technician is
employed and be conversant with the relevant standards and regulations.
Service The Service department refers to service technicians, who have received
proven training and have been authorised by the manufacturer to work on the
system.
Safety chapter
12

3.3 General safety information
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious inju‐
ries.
Please ensure when handling hazardous sub‐
stances that you have read the latest safety data
sheets provided by the manufacture of the haz‐
ardous substance. The actions required are
described in the safety data sheet. Check the
safety data sheet regularly and replace, if neces‐
sary, 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 worksta‐
tions affected.
CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic com‐
ponents if they are tampered with or opened due to
pressure in the liquid end and adjacent parts of the
system.
Depressurise, drain and flush the hydraulic section
prior to undertaking work on the system.
nThe pump is not designed to meter gaseous media or solids.
nNever use the pump outdoors without additional protection
(outer housing, weather protection roof).
nOnly allow trained and authorised personnel to operate the
pump.
nYou have a responsibility to adhere to the information con‐
tained in the operating instructions at the different phases of
the unit's service life.
The transparent cover on the liquid end protects personnel from
the rotating rotor and prevents feed chemical escaping in the event
of a hose rupture.
In the event of an emergency, disconnect the mains plug or press
the emergency stop switch.
If feed chemical escapes, ensure that the hydraulic environment
around the pump is at atmospheric pressure as well. Refer to the
material safety data sheet for the feed chemical.
Safety information
Protective equipment
Information in the event of an emer‐
gency
Safety chapter
13

3.4 Intended use
nOnly use the pump to meter liquid feed chemicals.
nOnly use the system in accordance with the technical data and
specifications outlined in the operating instructions.
nOnly use the pump if it has been correctly installed and started
up.
nAll other uses or modifications are prohibited.
Safety chapter
14

4 Storage and transport
4.1 Storage
User qualification: instructed user, see
Ä Chapter 3.2 ‘User qualifi‐
cation’ on page 12
Permissible ambient temperature: - 10 °C ... +55 °C.
Humidity: maximum 95% relative air humidity, non-condensing.
Other ambient conditions: No dust, no direct sunlight.
4.2 Transport
The sensor should be transported in its original packaging and in
compliance with the permissible environmental conditions. No fur‐
ther special conditions have to be observed in relation to transport.
4.3 Packaging material
Dispose of packaging material in an environmentally responsible
way. All packaging components carry the corresponding recycling
code .
Storage and transport
15

5 Assembly and installation
nUser qualification: trained qualified personnel or electrical tech‐
nician,
Ä Chapter 3.2 ‘User qualification’ on page 12
WARNING!
Carry out mechanical and hydraulic assembly work
before commencing the electrical installation.
Outdoors
The unit is resistant to normal atmospheres in
plant rooms.
Always use a housing or weatherproof cover when
operating the unit outdoors.
P_DX_0033_SW
136
176
88
Fig. 4: DF4a drilling points - dimensions in mm (not true to scale).
Assembly and installation
16

5.1 Dimensional drawing
P_DX_0037_SW
226
59
125,4
29
162
165
Fig. 5: Dimensional drawing of DF4a - dimensions in mm (not true to scale)
Assembly and installation
17

5.2 Assembly
nUser qualification: trained qualified personnel,
Ä Chapter 3.2
‘User qualification’ on page 12
P_DX_0034_SW
5,2
Fig. 6: Wall-mounted, parked position - dimensions in mm (not true
to scale).
1. Mark the drill holes on the wall - see Fig. 4.
2. Drill the Ø 8 mm holes and position the rawlplugs supplied -
see Fig. 6.
3. Screw a cheese-head screw into the upper drill hole. The
screw head should then have an approx. 5.2 mm gap from
the wall.
4. Suspend the top of the unit into the screw head.
Carefully remove the upper part of the housing
from the lower part of the housing to avoid tearing
the ribbon cable.
A2569
Fig. 7: 4 screws (arrows) on the upper part of the housing
5. To do this, loosen the 4 screws (arrows) on the upper part of
the housing.
Assembly and installation
18

A2570
3
2
1
Fig. 8: Parked position
6. Slide the upper part of the housing (1) with the side flaps (3)
up into the recesses in the lower part of the housing (2)
(parked position).
7. Screw the right and left side of the unit to the wall using the
remaining screws.
8. Close the housing,
Ä Chapter 5.4.4 ‘Close the housing’
on page 25
5.3 Installation, hydraulic
nUser qualification: trained qualified personnel,
Ä Chapter 3.2
‘User qualification’ on page 12
CAUTION!
Warning of escaping feed chemical
Feed chemical can escape in the event that the
hose lines are incorrectly installed.
– Only use original hoses with the specified hose
dimensions 6 x 4 mm or 10 x 4 mm.
–Avoid reducing the hose sizes.
– Only use hose lines capable of withstanding
twice the operating pressure of the peristaltic
pump.
1. Connect the discharge line to the right hose connector (1).
2. Connect the suction line to the left hose connector (4).
Installing the suction and metering
lines:
Assembly and installation
19

P
r
o
M
i
n
e
n
t
R
A2563
5
3
2
4
1
Fig. 9: Assembling the suction and metering line
3. Shorten the end of the hose at right angles.
4. Unscrew the union nut (2) and slide the union nut over the
hose (3).
5. Push the hose end over the hose connector (4) as far as the
stop.
6. Tighten the union nuts.
7. If you are only using a hose line and not a suction lance:
Shorten the free end of the suction line so that the end of the
suction line hangs just above the base of the feed chemical
storage tank.
8. If necessary, feed a hose line from the leakage fitting (5)
back into the feed chemical storage tank.
Assembly and installation
20