ProMinent Makro/ 5 HK User manual

ProMinent®Page 1
Two operating instruction manuals are required for the safe and correct use of ProMinent®Makro/5 metering pumps:
This product-specific Makro/5 operating instruction manual and the “General Operating Instructions”
for ProMinent®Motor-Driven Metering Pumps and Hydraulic Accessories” applies only when read in conjunction
with the other!
Please read through operating instruction manual carefully! Do not discard!
The guarantee is void in the event of damage caused by misuse!
Teile Nr. 987442 ProMinent Dosiertechnik GmbH · 69123 Heidelberg · Germany BA MAK 003 01/02 G
Part no. 987441 ProMinent Dosiertechnik GmbH · 69123 Heidelberg · Germany BA MAK 002 02/02 GB
Operating Instructions
ProMinent®Makro/ 5
Metering Pumps
Please affix nameplate here!
ProMinent
®
Makro/ 5 HK
Makro/ 5 HM
Makro/ 5 HMH
ProMinent
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Publishing details:
Operating Instruction Manual for ProMinent®Makro/ 5
© ProMinent Dosiertechnik GmbH, 2001
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg
Postfach 101760 · 69007 Heidelberg
Germany
[email protected]
www.prominent.de
Subject to revision
Printed in the F.R. Germany
Publishing details
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Contents
Page
Type code......................................................................................... 4
General user instructions ................................................................. 5
1 About this pump ................................................................. 6
2 Safety ..................................................................................... 6
3 Storage. transport. unpacking ....................................... 8
4 Device overview /controls ............................................... 8
5 Function description ......................................................... 13
6 Assembly .............................................................................. 18
7 Installation ........................................................................... 18
7.1 Installation, hydraulic ..................................................... 18
7.2 Installation, electrical ..................................................... 19
8 Commissioning ................................................................... 20
9 Operation ............................................................................. 21
10 Maintenance ........................................................................ 21
11 Repair .................................................................................... 25
11.1 Diaphragm liquid end ..................................................... 25
11.2 Hydraulic diaphragm liquid end ..................................... 26
11.3 Piston liquid end ............................................................ 28
11.4 Valve servicing ............................................................... 31
12 Troubleshooting.................................................................. 35
13 Decommissioning and disposal ..................................... 35
14 Technical data ..................................................................... 37
Appendix
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Type code
Type code
The nameplates affixed to the title page are identical to those on the pump supplied to enable clear identification of the correct
operating instruction manual for the pump.
Please give the order number and the serial number, which you will find on the nameplate of the pump itself, in the event of any
enquiry or spare part order. This will facilitate identification of the pump type.
Makro ProMinent®Makro/ 5
Gearbox type:
5 Makro/ 5
Max strokes:
20 20 mm (HM)
50 50 mm (HMK, HK)
Type:
H.. main power end ..M.. diaphragm liquid end ..D double head version
A.. add-on power end ..MH.. hydraulic diaphragm liquid end
..K.. piston liquid end
Gear ratio:
09 9:1
11 11:1
14 14:1
19 19:1
23 23:1
Liquid end size:
Diaphragm liquid end:
4000
Hydraulic diaphragm piston liquid end (Ø piston-stroke) :
60-50, 70-50, 75-50, 85-50, 100-50, 130-50
Piston liquid end (Ø piston) :
17 23 30 40 50 60 70 85 100 130
Component materials:
PP Polypropylene
P PVC
T Teflon with carbon
S stainless steel 1. 4571
Makro 5
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General user instructions
Please read through the following user instructions carefully! They will help you get the best use
out of the operating instruction manual.
The following are highlighted in the text:
• Enumerations
왘Instructions
Operating guidelines:
IMPORTANT
Notices are intended to make your work easier.
and safety guidelines:
WARNING
Describes a potentially dangerous situation. If not avoided. could cause fatal or
serous injury.
CAUTION
Describes a potentially dangerous situation. If not avoided. could cause slight or
minor injury or damage to property.
NOTICE
Describes a potentially damaging situation. If not avoided. could cause damage
to property.
Please also note the guidelines in “General Operating Instruction Manual for ProMinent®Motor-
Driven Metering Pumps and Hydraulic Accessories”!
The nameplates affixed to the title page are identical to those on the pump supplied to enable a
clear allocation of the correct operating instruction manual to the pump.
Please give the order number and the serial number, which you will find on the nameplates of the
pump itself, in the event of any query or spare part order. This facilitates identification of the
pump.
General user instructions
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1 About this pump
The ProMinent®Makro/5 metering pump is fitted as standard with a dual-wound 3 kW three
phase motor. The stroke length can be adjusted between 0. . . 50 mm (HM:0. . . 20 mm). The
bead-blasted graphite housing can be combined with up to 25 liquid end sizes and 5 gear ratios
(integrated into the spur wheel back-geared motor). The liquid ends are available in different
material combinations which are chosen to comply with the chemical media being metered. The
reproducible metering accuracy is better than ±0. 5 % in the stroke length range from 10 %-
100 % (HM:±1 %) under defined conditions and subject to correct installation.
The ProMinent®Makro/5 add-on metering pump can be combined with the Makro/5 main power
end to produce a duplex/multiplex pump. A main power end can be combined with up to four
add-on power ends. One power end can be used as both a single and a double head version.
The double head versions are fitted with a second liquid end which operates in counter cycle
(Boxer principle.).
2 Safety
Correct use
of equipment Use • The pump may be used for metering liquid media only!
• All other applications and modifications are prohibited!
• The pumps with piston liquid end are not suitable for metering life-threatening liquids.
• The pump is not suitable for metering gaseous media or solids.
• The pump may be used only within the stated pressure range.
• Please observe general limitations with regard to viscosity limits, chemical resistance and
density and the stated ambient conditions.
• It is essential that you read this operating instruction manual together with the “General
Operating Instructions for ProMinent®Metering Pumps and Hydraulic Accessories”
concerning assembly, installation and maintenance!
• The pump is to be operated by appropriately trained personnel only.
Safety instructions WARNING
• The pump starts to operate as soon as it is connected to the mains.
Ensure that hazardous media cannot leak out.
• The pump has no on/off switch.
In the event of an electrical fault, unplug the mains cable or switch off the
system at the emergency off-switch.
• Unplug the cable from the mains before working on the pump!
• Always depressurise the liquid end before working on the pump!
• Before working on the pump, empty the liquid end and rinse out if it has been
used with hazardous or unknown chemicals.
• Always wear suitable protective equipment when working on a liquid end
which has been used with hazardous or unknown chemicals.
• Pumps must be accessible at all times for operation and maintenance.
Access should never be impeded or blocked.
• Pumps which have been used with radioactiv media can not be sent.
• Before commissioning the pump, connect the overpressure sensor and the
diaphragm rupture sensor.
CAUTION
• It is prohibited to assemble and install ProMinent®metering pumps with parts
which have not been approved or recommended by ProMinent. Damage to
persons and property may ensue.
• When metering aggressive media, check the resistance of the pump materials
(See ProMinent®resistance list in the Product Catalogue or on our Homepage)
• Danger of burns from hot power end in the event of enfault.
• Observe all national directives which apply to installation!
About this pump / Safety
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Safety
Protective equipment:
1 Protective cover (piston and diaphragm version)
2 Cover plate (add-on power end only)
3 Flange cover
4 Cap (single-head version only)
Fig. 1 Makro/5 HK with AK add-on power end
3
4
2
1
Fig. 2 Safety relief valve (*) on HMH liquid end
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Sound intensity level The sound intensity level is 75 dB (A)
at max. strokes, max stroke rate, max back pressure (water) in accordance with:
DIN EN ISO 3744 (Replication capacity 2 - Determining sound intensity level)
PR DIN EN 12639 (Noise measurement, fluid pumps)
DIN 45635-24 (Noise measurement on machines)
3 Storage, transport, unpacking
The pump is delivered on a pallet.
NOTICE
• The pump is filled with oil on delivery.
• Never lift the pump by the turret or the liquid end.
• The pump must be placed on a level, stable base.
Ambient conditions for storage and transport
Temperature -10 °C to 50 °C
Humidity: max. 95 % relative humidity, non-condensing
Shipping weight: see “Technical data” table
4 Device overview, controls
Safety / Storage, transport, unpacking / Device overview, controls
A Power end
C Liquid end
1 Lifting eye
2 Manual adjustment wheel
3 Dial
4 Motor
5 Oil drain plug
6 Vent screw
7 Oil inspection window
C
5
A
2
11
3
4
Fig. 3 Makro/5 HK
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Device overview, controls
Fig. 4 Makro/5 HK
6
7
4
2
3
5
A
11
C C
4
A Power end
C Liquid end
1 Lifting eye
2 Manual adjustment wheel
3 Dial
4 Motor
5 Oil drain plug
6 Vent screw
7 Oil inspection window
Fig. 5 Makro/5 HKD
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Device overview, controls
6
7
Fig. 6 Makro/5 HKD
1
2
5
3
4
1 Discharge valve
2 Liquid end
3 Suction valve
4 Hose nozzle for
leakage fluid
5 Protective cover
Fig.7 Diaphragm liquid end (for HM)
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Device overview, controls
1
2
345
87 6
12
11
10
9
Fig. 9 Hydraulic diaphragm liquid end (for HMH)
1 Discharge valve
2 Liquid end
3 Suction valve
4 Oil drain plug, liquid end
5 Oil drain plug, feed tank
6 Filler opening, feed tank
7 Overpressure sensor terminal
8 Bleed valve
9 Bleed hose
10 Pressure relief valve
11 Oil inspection window – hydraulic oil
12 Diaphragm rupture sensor terminal
Fig. 8
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Device overview, controls
1
2
3
5
4
6
1 Discharge valve
2 Liquid end
3 Suction valve
4 Support bracket
5 Protective cover
6 Hose nozzle for leakage/
flushing connector
Fig. 10 Piston liquid end (for HK)
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5 Function description
Description of power end function
The Makro/5 metering pump is a motor-driven pump with a mechanical gearbox.
A motor drives the cam shaft (1). A connecting rod (2) rests on the cam shaft (1) which causes the
oscillating crank (4) to rotate around a variable axis (see below). The lifting arm of the oscillating
crank, which lies above the axis, moves the push rod (8) which actuates the liquid end.
The stroke can be adjusted with the manual adjustment wheel (7). In this case a spindle (6) moves
the fork (5; in section view in the diagram) . The fork (5) moves the sliding block (3) in a groove cut
into the oscillating crank (4). The sliding block (3) determines the axis of the oscillating crank. This
determines the stroke length. When the axis of the sliding stone (3) is directly above the axis of the
push rod (8) the lifting arm of the oscillating crank above the axis is equal to zero and the push rod
stops. When the sliding block (3) is pushed down, the lifting arm of the oscillating crank (4) above
the axis is greater than zero and drives the push rod (8).
Liquid ends can be attached to both ends of the push rod. They will then operate according to the
Boxer principle (counter-cycle).
Function description
6
7
5
3
2
1
8
4
Fig. 11
1 Cam shaft
2 Connecting rod
3 Sliding block
4 Oscillating crank
5 Fork
6 Spindle
7 Manual adjustment
wheel
8 Push rod
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Function description
1
2
3
4
1 Discharge valve
2 Discharge valve
3 Pump diaphragm
4 Suction valve
Fig. 12
Function description of a diaphragm liquid end (for HM)
The diaphragm (3) hermetically seals the pump volume inside the liquid end (2). When the
diaphragm (3) is moved into the liquid end (2) the suction valve (4) closes und and the metering
chemical flows out of the liquid end via the discharge valve (1). When the pump diaphragm (3)
moves in the opposite direction the discharge valve (1) closes due to the negative pressure in the
liquid end and fresh feed chemical flows into the liquid end via the suction valve (4).
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Description of the liquid end function
The HMH liquid end has a hydraulically actuated displacement element in the form of a highly
durable composite diaphragm (2). It hermetically seals the feed cavity in the liquid end (3) and
creates the displacement action within the liquid end at each pump stroke. The suction valve (4)
and the discharge valve (1) together with the diaphragm action perform the feed process.
As the diaphragm is hydraulically actuated – it is permanently connected to the piston (7) – it is
always pressure-compensated and is therefore suitable for high feed pressures.
As with a conventional motor-driven metering pump the motor moves the piston (7) forwards and
backwards. As it moves forwards the piston pushes in the hydraulic end and increases the
pressure in the hydraulic oil. The hydraulic oil then pushes the composite diaphragm (2) towards
the liquid end (3).
The stroke length of the composite diaphragm is adjusted by altering the stroke length of the
connecting rod.
The bleed valve (10) vents the hydraulic end and passes the gas bubble with a small amount of
oil into the storage tank (8). In this way the quantity of hydraulic oil in the hydraulic end decreases
and the composite diaphragm (2) moves slowly towards the piston (7). When contact with the
diaphragm position sensor (5) is made, the compensation valve (9) opens and hydraulic oil is
sucked out of the storage tank, thereby correcting the diaphragm position.
Function description
7
6
58
AB
1
4
3
2
10 9
A Liquid end
B Hydraulic end
1 Discharge valve
2 Composite diaphragm
3 Liquid end
4 Suction valve
5 Diaphragm position sensor
6 Compensation valve (snifting valve)
7 Piston
8 Feed tank
9 Overpressure sensor
10 Bleed valve
Fig. 13 HMH function
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The pump has a fixed setting pressure control valve (see Fig. ) in the hydraulic end. The pressure
control valve protects the pump (not the system! ) together with the overpressure sensor (9) and
switches off the pump when the feed pressure is too high (=overpressure fuse). If the discharge
side of the liquid end is blocked, the pressure control valve opens at the preset pressure and
allows the hydraulic oil to flow back into the storage tank (8). The overpressure sensor (9) behind
the pressure regulating valve then opens and its contact signal switches off the pump
immediately (to be carried out by the customer! ). Once the system is running within the correct
pressure range the hydraulic end is refilled after a few strokes via the compensation valve (6).
Description of the function of the diaphragm rupture warning system
The diaphragm rupture warning system monitors the composite diaphragm seal. The composite
diaphragm and the diaphragm rupture sensor and evaluation electronics connected downstream
together form the diaphragm rupture warning system.
The composite diaphragm (1) has a contact (2) on one side. If an outer layer of the composite
diaphragm ruptures, metering chemical is forced into it under pressure, inflating the contact. The
contact then pushes against the diaphragm rupture sensor (3), whose contact signal switches off
the pump immediately (to be carried out by the customer! ).
The composite diaphragm also prevents feed chemical from mixing with hydraulic oil in the event
of a diaphragm rupture.
Function description
Fig. 14 HMH diaphragm rupture system function
(enlarged)
AA
Section A - A
1
2
3
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Function description of a piston liquid end (for HK)
The heart of the liquid end is a highly resistant, coated stainless steel piston (2). When the piston
(2) moves into the liquid end (2) the suction valve (5) closes und and the feed chemical flows out
of the liquid end via the discharge valve (1). When the piston (3) moves in the opposite direction
the discharge valve (1) closes due to the negative pressure in the liquid end and fresh feed
chemical flows into the liquid end via the suction valve (4).
The flushing collar (3) enables the user to rinse the piston sealing surface or drain off leakage
fluid.
Function description
2341
5
Fig. 15
1 Discharge valve
2 Piston
3 Flushing collar
4 Packing collar
5 Suction valve
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Assembly / Installation
6 Assembly
Ambient temperature -10 °C to 40 °C
Humidity Max. 95 % rel. humidity, non-condensing
The pump itself is supplied ready to operate. It is filled with oil on arrival and mounted on a frame
(exceptions: Makro/5 HM und Makro/5 HMH 60-85).
The pump must be bolted to an even, stable base. The base must be capable of permanently
bearing the weight of the pump. Bolt the pump to the base with four bolts (M12) through the four
holes in the sub frame.
7 Installation
NOTICE
• Also note “General Operating Instruction Manual for ProMinent®Motor-Driven
Metering pumps and Hydraulic Accessories”!
7.1 Installation, hydraulic
Liquid end
WARNING
• The liquid ends may still contain traces of water from the factory tests! If using
with media which must not come into contact with water, ensure that the
liquid ends are dried before installation. Dry with compressed air. Then rinse
out by inserting a suitable rinse aid through the suction connection.
• Discharge line should be arranged to ensure that the maximum admissible
pump and system operating pressures are not exceeded during the discharge
stroke.
NOTICE
• It is necessary to install a filter in the suction line for the piston liquid end (HK)
if using with media with particle sizes greater than 0. 3 mm.
• Accurate metering is possible only at a constant back pressure above 1 bar.
If metering at atmospheric pressure, use a back pressure valve to generate a
back pressure of approx. 1.5 bar.
Maximum admissible priming pressure (suction side) :1 bar
Viscosity The liquid ends are designed for a maximum viscosity of:
200 mPa s valves without valve springs
500 mPa s valves with valve springs
1000 mPa s correspondingly designed installation
> 1000 mPa s correspondingly designed installation and after consultation with ProMinent
Leakage discharge (HM and HK only)
Leakage fluid is drained off via the flushing collar and a hose nozzle. No other liquid end parts
come into contact with the fluid.
왘Connect a hose to the lower hose nozzle
왘Feed the hose into a leakage fluid bund.
NOTICE
Ensure that dust and foreign bodies cannot penetrate through the upper hose
nozzle.
The liquid end may otherwise be damaged.
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Connection of flushing collar (HK only)
NOTICE
• The flushing medium pressure may not exceed 0. 5 bar and the flow may not
exceed 100 l/h.
• The rinse aid must be suitable for the feed chemical and the liquid end
materials.
• It is essential to fit a flushing assembly if using very aggressive and poisonous
media, or media with low lubrication properties.
왘Connect the flushing assembly to the hose nozzles via two hoses.
7.2 Installation, electrical
NOTICE
• Observe the relevant directives for electrical installation.
• Observe applicable national directives.
• The device must be electrically installed by a trained and qualified person with
corresponding certification.
• Take suitable interference precautions when connecting ohmic/inductive
loads.
• The motor must stop immediately if the overpressure sensor is triggered,
the liquid end may otherwise be seriously damaged.
• If the power end motor has been stopped by the overpressure sensor it must
not restart automatically.
• For safety reason only protective low voltages may be connected to the
diaphragm rupture sensor and the overpressure sensor (SELV according to EN
60335-1).
Motor The nameplate contains important motor data.
The wiring diagram is in the terminal box.
You will find guidelines for connecting the motor in “General Operating Instruction Manual for
ProMinent®Motor-Driven Metering Pumps and Hydraulic Accessories”!
Stroke sensor (optional) 5 - 25 V DC. Namur type and/or DIN 19234, zero volt connection.
The sensor can be used in EX zone circuits with a suitable power adapter:
Cable terminals:
Diaphragm rupture sensor (HMH only)
Switch output: 0. 1 A, 250 V AC/DC
Contact type: N/C (micro switch)
Enclosure rating: IP67
Cable terminals:
Overpressure sensor (HMH only)
Switch output: 0. 5 A, 150 V AC/DC
Contact type: N/C (reed contact)
Enclosure rating: IP67
Cable terminals:
Installation
blue -
brown +
blue -
brown +
blue -
brown +
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8 Commissioning
CAUTION
• Danger of burns from hot power end motor in the event of enfault!
NOTICE
• The pump is designed to meter liquid media within the stated capacity limits.
• Note the limitations regarding high viscosity or density of the medium.
• Ensure that the liquid end materials are resistant to the feed chemical. (See
ProMinent®resistance list in the Product Catalogue or on our Homepage)
• The pump must be operated in accordance with the operating conditions
stated in the “Technical data” section.
• It is necessary to install a filter in the suction line for the piston liquid end (HK)
if using with media with particle sizes greater than 0. 3 mm.
• If no hydraulic oil flows through the hose to the bleed valve, switch off the
pump immediately and contact customer service.
• Before commissioning the pump, connect the overpressure sensor and the
diaphragm rupture sensor.
• The hole in the metal cap on the power end flange must never be blocked
(see Fig. 1) ! Oil will otherwise leak out of the power end.
• The pressure control valve is designed to protect only the motor and the
gearbox against inadmissible overpressure caused by the pump.
• The pressure control valve must not be used to bypass metering stoppages
while the pump is running. It is a safety element.
• Do not use the pressure regulating valve to protect the system. It cannot
protect the system.
Setting stroke length The stroke length can be set by hand or via an actuator (optional)
IMPORTANT
• It is possible to adjust the stroke length when the pump is at rest only when the
liquid ends have been depressurised.
• First push the manual adjustment wheel down and then adjust the stroke length.
• If the diaphragm rupture warning system signals a diaphragm rupture, you may
continue metering for a short period at your own risk. However, metering
reproducibility is impaired.
Checking flow of hydraulic oil HMH only: after the pump has been running for a short while, check that hydraulic oil is flowing
through the hose to the bleed valve.
Checking leakage HK only: check that the leakage of the feed chemical is between 10 to 120 drops/min.
Checking oil level Check that the oil level in the pump is between the two oil inspection windows.
You should carry out this check to ensure that the pump has not lost oil due to unprofessional
transportation. It may have suffered damage as a consequence.
Correct pump set up is as follows:
Stroke length Feed rate
Highly viscous medium +-
Good mixing -+
Commissioning
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