ProMinent Meta MTKa User manual

Piston Metering Pump
Meta MTKa
Operating instructions
P_ME_0005_SW
Original operating instructions (2006/42/EC)Part no. 985036 BA ME 010 02/14 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.

Read the following supplementary information in its entirety!
Should you already know this information, you will benefit more
from referring to the operating instructions.
The following are highlighted separately in the document:
nEnumerated lists
Operating guidelines
ðOutcome of the operating guidelines
- see (reference)
Information
This provides important information relating to the
correct operation of the unit or is intended to make
your work easier.
Safety notes
Safety notes are identified by pictograms - see Safety Chapter.
These operating instructions conform to current EU regulations
applicable at the time of publication.
Please state identity code and serial number, which you can find
on the nameplate when you contact us or order spare parts. This
enables the device type and material versions to be clearly identi‐
fied.
The nameplate stuck on the cover page is identical with the pump
supplied so that a clear assignment is given between the operating
instructions and the pump.
Supplementary information
Fig. 1: Please read!
Validity
State the identity code and serial
number
EX pumps only
Supplemental directives
2

Table of contents
1 Identity code.......................................................................... 4
2 Safety chapter....................................................................... 6
3 Storage, transport and unpacking....................................... 12
4 Overview of equipment, control elements........................... 14
5 Functional description......................................................... 15
6 Assembly............................................................................ 16
7 Installation........................................................................... 18
7.1 Installation, hydraulic.................................................. 18
7.1.1 Basic installation notes............................................ 21
7.2 Installation, electrical.................................................. 22
8 Start up............................................................................... 26
9 During Operation................................................................. 28
10 Maintenance....................................................................... 29
11 Repairs................................................................................ 32
11.1 Changing the piston.................................................. 33
12 Troubleshooting.................................................................. 35
13 Decommissioning and Disposal.......................................... 37
13.1 Decommissioning..................................................... 37
13.2 Disposal.................................................................... 38
14 Technical data..................................................................... 40
14.1 Performance data for Meta MTKa............................ 41
14.2 Precision................................................................... 43
14.2.1 Reproducibility....................................................... 43
14.2.2 Metering precision................................................. 43
14.3 Viscosity.................................................................... 43
14.4 Wetted materials....................................................... 43
14.5 Ambient conditions................................................... 44
14.5.1 Temperatures........................................................ 44
14.5.2 Air humidity............................................................ 44
14.6 Motor data................................................................. 44
14.7 Housing degree of protection.................................... 45
14.8 Stroke sensor (optional), intrinsically safe................ 45
14.9 Sound pressure level................................................ 46
14.10 Supplement for modified versions.......................... 46
15 Meta MTKa dimensional drawing........................................ 47
16 Diagrams for adjusting the capacity MTKa......................... 48
17 Motor data sheets............................................................... 49
18 Spare parts......................................................................... 50
19 EC Declaration of Conformity for Machinery....................... 51
20 EC Declaration of Conformity for Machinery Used in Areas
at Risk of Explosion............................................................ 52
Table of contents
3

1 Identity code
MTKa Meta piston metering pump, version a
Power end type
H Main power end
A Add-on power end
Type
_ _ _ _
_
Performance data at maximum back pressure and type: refer to nameplate on the
pump housing
Dosing head material
SS Stainless steel
Seal material
T PTFE
Displacement body
S Oxide ceramic standard piston
Dosing head design
0 no valve springs
1 with 2 valve springs, Hasteloy C; 0.1 bar
Hydraulic connector
0 Standard threaded connector (in line with technical data)
Design
0With ProMinent® logo, no frame
2Without ProMinent® logo
MModified* * order-specific design, see order
paperwork for pump features
Electric power supply
_ Connection data - see nameplate on motor
1 No motor, with flange 90/63
0 Externally mounted pump (without motor)
2 No motor, with flange 140/71
3 No motor, with flange 160/71
4 No motor, with flange 56 C
Motor version
0 IP 55 (standard)
1 Exe design ATEX-T3
2 Exde design ATEX-T4
A ATEX design of power end
Stroke sensor
0 No stroke sensor
1 Stroke sensor (Namur), intrinsically safe
Identity code
4

MTKa Meta piston metering pump, version a
Stroke length adjustment
0 Manual (standard)
Identity code
5

2 Safety chapter
The following signal words are used in these operating instructions
to denote different severities of danger:
Signal word Meaning
WARNING Denotes a possibly dangerous
situation. If this is disregarded,
you are in a life-threatening sit‐
uation and this can result in
serious injuries.
CAUTION Denotes a possibly dangerous
situation. If this is disregarded,
it could result in slight or minor
injuries or material damage.
The following warning signs are used in these operating instruc‐
tions to denote different types of danger:
Warning signs Type of danger
Warning – hand injuries.
Warning – high-voltage.
Warning – danger zone.
nOnly use the pump to meter liquid metering chemicals.
nIn potentially explosive atmospheres in zone 1, device category
II 2G, explosion group II C, only operate the pump with the
appropriate nameplate (and the respective EC Declaration of
Conformity) for pumps for use in areas at risk of explosion in
compliance with Directive 94/9/EC in accordance with the
European guidelines. The explosion group, category and
degree of protection specified on the label should correspond
to or be better than the conditions given in the intended field of
application.
nOnly start up the pump after it has been correctly installed and
commissioned in accordance with the technical data and speci‐
fications contained in the operating instructions.
nObserve the general limitations with regard to viscosity limits,
chemical resistance and density - see also ProMinent Resist‐
ance List (in the Product Catalogue or at
www.prominent.com/en/downloads)!
nAll other uses or modifications are prohibited.
nNever operate pumps without the relevant nameplate (and the
respective EC Declaration of Conformity) for pumps for use in
atmospheres at risk from explosion in atmospheres potentially
at risk from explosion.
nThe pump is not intended for the metering of gaseous media or
solids.
Identification of safety notes
Warning signs denoting different
types of danger
Intended use
Safety chapter
6

nThe pump is not intended to meter explosive substances and
mixtures.
nThe pump is not intended for the metering of flammable fluids.
nThe pump is not intended for unprotected outside use.
nThe pump is only intended for industrial use.
nThe pump should only be operated by trained and authorised
personnel, see the following table.
nYou are obliged to observe the information contained in the
operating instructions at the different phases of the device's
service life.
Only the following combinations of identity codes are permitted in
areas at risk from explosion:
Combi‐
nations
Identity code specification values
1 Electric power supply L, P
Motor version 1, 2
2 Electric power supply 0, 1, 2, 3, 4
Motor version A
Action Qualification
Storage, transport, unpacking Instructed person
Assembly Technical personnel, service
Planning hydraulic installation Certificated specialist per‐
sonnel who have a thorough
knowledge of diaphragm
pumps
Hydraulic installation Technical personnel, service
Installation, electrical Electrical technician
Operation Instructed person
Maintenance, repair Technical personnel, service
Decommissioning, disposal Technical personnel, service
Troubleshooting Technical personnel, electrical
technician, instructed person,
service
Explanation of the terms:
Technical personnel
A qualified employee is deemed to be a person who is able to
assess the tasks assigned to him and recognise possible dangers
based on his/her technical training, knowledge and experience, as
well as knowledge of pertinent regulations.
Note:
A qualification of equal validity to a technical qualification can also
be gained by several years employment in the relevant work area.
Electrical technician
Qualification of personnel
Safety chapter
7

Electrical technicians are deemed to be people, who are able to
complete work on electrical systems and recognise and avoid pos‐
sible dangers independently based on their technical training and
experience, as well as knowledge of pertinent standards and regu‐
lations.
Electrical technicians should be specifically trained for the working
environment in which they are employed and know the relevant
standards and regulations.
Electrical technicians must comply with the provisions of the appli‐
cable statutory directives on accident prevention.
Instructed person
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.
Customer Service
Customer Service department refers to service technicians, who
have received proven training and have been authorised by ProMi‐
nent or ProMaqua to work on the system.
CAUTION!
These operating instructions include notes and
quotes from German guidelines relating to the
system operator's scope of responsibility. This
information does not discharge the operator from
his responsibility as an operator and is intended
only to remind him or make him aware of specific
problem areas. This information does not lay claim
to being complete, nor applicable to every country
and every type of application, nor to being uncon‐
ditionally up-to-date.
Safety notes
Safety notes
Safety chapter
8

WARNING!
– Observe the European Operator Directive
99/92/EC (ATEX 137), implemented in Ger‐
many by the Industrial Health and Safety Reg‐
ulation and the German Ordinance on Haz‐
ardous Substances, for the installation and
operation of equipment in areas at risk from
explosion.
– Observe the European standards EN 1127-1,
EN 60079-10, EN 60079-14, EN 60079-17 and
EN 60079-25 and EN 50039 for inherently safe
electrical circuits. (In Germany these standards
are partly implemented by VDE 0165 and VDE
0118).
–Adhere to the respective national regulations
outside of the EU.
– Ensure that installations in areas at risk from
explosion are checked by a "recognisably
trained" skilled operative. This applies specifi‐
cally to intrinsically safe electrical circuits.
– The following information relates essentially to
the unique characteristics in areas at risk from
explosion but does not replace the standard
operating instructions.
– Only clean plastic parts carefully with a damp
cloth to avoid electrostatic charges and sparks.
WARNING!
Warning of dangerous or unknown feed chemical
Should a dangerous or unknown feed chemical be
used: It may escape from the hydraulic compo‐
nents when working on the pump.
– Take appropriate protective measures before
working on the pump (e.g. safety glasses,
safety gloves, ...). Observe the safety data
sheet for the feed chemical.
– Drain and flush the liquid end before working
on the pump.
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.
Safety chapter
9

CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic com‐
ponents if they are manipulated or opened due to
pressure in the liquid end and adjacent parts of the
system.
– Disconnect the pump from the mains power
supply and ensure that it cannot be switched
on again by unauthorised persons.
– Depressurise the system before commencing
any work on hydraulic parts.
CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical can damage the parts
of the pump contacted by the chemical.
– Take into account the resistance of the mate‐
rials which will come into contact with the
chemical when selecting the feed chemical -
see the ProMinent Product Catalogue or visit
www.prominent.com/en/downloads.
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in
personnel injuries and material damage.
– Only fit parts to metering pumps, which have
been tested and recommended by ProMinent.
CAUTION!
Danger from incorrectly operated or inadequately
maintained pumps
Danger can arise from a poorly accessible pump
due to incorrect operation and poor maintenance.
– Ensure that the pump is accessible at all times.
– Adhere to the maintenance intervals.
In the event of an electrical accident, disconnect the mains cable
from the mains or press the emergency cut-off switch fitted on the
side of the system!
If feed chemical escapes, also depressurise the hydraulic system
around the pump as necessary. Adhere to the safety data sheet for
the feed chemical.
Information in the event of an emer‐
gency
Safety chapter
10

Prior to commissioning the system or system component, the
system operator is obliged to obtain the latest safety data sheet
from the supplier for the chemicals / resources to be used with the
system. The operator should create the legal framework for safe
operation of the system or system component, such as for example
the preparation of operating instructions (operator duties), based
on the information provided in the data sheets concerning health
and safety, water and environmental protection and taking into
consideration the actual operating environment on site.
Protective equipment May only be
removed by*:
Terminal box cover, motor Electrical techni‐
cian, service
Protective cowling above the motor fan Service
Flange cover, side Service
Motor connection cover with add-on power end Service
Turret protective cover Technical per‐
sonnel, service
Only with protective devices: their corre‐
sponding parts
Technical per‐
sonnel, service
* Only if the mains cable remains disconnected (no mains voltage).
WARNING!
– Attach the following safety note to pumps that
contain parts made of electrically non-conduc‐
tive plastic:
– Ensure that the label is always fitted and
legible.
WARNING
Electrostatic charge may
cause an explosion!
Clean plastic parts very
carefully using a damp cloth!
Fig. 2
Sound pressure level LpA < 70 dB according to EN ISO 20361
at maximum stroke length, maximum stroke rate, maximum back
pressure (water)
Safety information relating to the
operating instructions
Safety equipment
Protective equipment
Other safety equipment
Sound pressure level
Safety chapter
11

3 Storage, transport and unpacking
WARNING!
The transporting of pumps which have been used
with radioactive feed chemicals is forbidden!
They will also not be accepted by ProMinent!
WARNING!
Only return metering pumps for repair in a cleaned
state and with a flushed liquid end - refer to
"Decommissioning!
Only return metering pumps with a completed
Decontamination Declaration form. The Decon‐
tamination Declaration constitutes an integral part
of an inspection / repair order. A unit can only be
inspected or repaired when a Declaration of
Decontamination Form is submitted that has been
completed correctly and in full by an authorised
and qualified person on behalf of the pump oper‐
ator.
You can find the "Decontamination Declaration"
form at www.prominent.com/en/downloads or on
the CD.
CAUTION!
Danger of environmental and material damage
The unit can be damaged or oil may escape due to
incorrect or improper storage or transportation!
– The unit should only be stored or transported in
a well packaged state - preferably in its original
packaging.
– Only transport the unit with the locking screw -
not the bleed plug - fitted to the oil filling
opening.
–The packaged unit should also only be stored
or transported in accordance with the stipu‐
lated storage conditions.
– The packaged unit should be protected from
moisture and the ingress of chemicals.
Personnel: nTechnical personnel
1. Plug the caps on the valves.
2. Check whether the seal screw is screwed into oil filler
opening instead of the vent screw.
3. Preferably place the pump standing vertically on a pallet and
secure against falling over.
4. Cover the pump with a tarpaulin cover - allowing rear ventila‐
tion.
Safety notes
Storage
Storage, transport and unpacking
12

Store the pump in a dry, sealed place in the following ambient con‐
ditions.
Storage, transport and unpacking
13

4 Overview of equipment, control elements
P_ME_0006_SW
Fig. 3: Overview of the MTKa piston metering pump
1 Motor
2 Stroke length adjustment
2a Servomotor
3 Housing with gear
4 Liquid end
A Primary pump type MTKaH ...
B Externally mounted pump MTKaA ...
1
2
3
4
5
P_MA_0027_SW
Fig. 4: View of the liquid end
1 Discharge valve
2 Dosing head
3 Suction valve
4 Hose nozzles for leakage/flushing connector
5 Protective cover
Power end
Liquid end
Overview of equipment, control elements
14

5 Functional description
The metering pump is an oscillating displacement pump, the stroke
length of which can be adjusted. An electric motor drives the pump.
The heart of the liquid end is a highly resistant piston (4) made
from coated stainless steel. The suction valve (1) closes as soon
as the piston (4) is moved in to the dosing head and the feed
chemical flows through the discharge valve (3) out of the dosing
head. As soon as the piston moves in the opposite direction, the
discharge valve (3) closes due to the negative pressure in the
dosing head and fresh feed chemical flows through the suction
valve (1) into the dosing head.
Use the flushing collar (6) to flush the sealing surface of the piston.
P_SI_0144_SW
3
2
7
4
6
5
1
Fig. 5: Cross-section through the liquid end
1 Suction valve
2 Dosing head
3 Discharge valve
4 Piston
5 Packing collar
6 Flushing collar
7 Flushing connector
Pump
Functional description
15

6 Assembly
–
Compare the dimensions on the dimension
sheet and pump.
WARNING!
Danger of electric shock
If water or other electrically conducting liquids pen‐
etrate into the drive housing, in any other manner
than via the pump's suction connection, an electric
shock may occur.
– Position the pump so that it cannot be flooded.
WARNING!
The pump can break through the base or slide off it
– Ensure that the base is horizontal, smooth and
permanently load-bearing.
Capacity too low
Vibrations can disrupt the liquid end valves.
– The supporting floor must not vibrate.
CAUTION!
Danger from incorrectly operated or inadequately
maintained pumps
Danger can arise from a poorly accessible pump
due to incorrect operation and poor maintenance.
– Ensure that the pump is accessible at all times.
– Adhere to the maintenance intervals.
Install the pump so that control elements, such as the stroke length
adjustment knob, the indicating dial A or the oil inspection window,
are accessible.
In so doing, ensure there is enough space to carry out an oil
change (vent screws, oil drainage screws, oil trough ...).
1Discharge valve
2 Dosing head
3 Suction valve
Ensure that there is sufficient free space (f) around the dosing
head, as well as the suction and discharge valve, so that mainte‐
nance and repair work can easily be carried out on these compo‐
nents.
Safety notes
Base
h
P_MOZ_0016_SW
Fig. 6
Space requirement
A
A
P_MOZ_0018_SW
Fig. 7
1
3
2
f
f
f
P_MOZ_0017_SW
Fig. 8
Assembly
16

Capacity too low
If the liquid end valves are not upright, they cannot
close correctly.
– Ensure that the discharge valve is upright.
Capacity too low
Vibrations can disrupt the liquid end valves.
– Secure the metering pump so that no vibra‐
tions can occur.
Take the dimensions (m) for the fastening holes from the appro‐
priate dimensional drawings or data sheets.
Fasten the pump base to the base using suitable screws.
Screw the pump to the support surface with 4 sufficiently
strong screws through the 4 holes in the frame.
Liquid end alignment
Fastening
DNm
m
P_MOZ_0015_SW
Fig. 9
Instructions
Assembly
17

7 Installation
7.1 Installation, hydraulic
WARNING!
EX pumps in areas at risk from explosion
– It is essential that metering pumps to be used
in areas at risk from explosion are fitted with an
appropriate safety relief valve on the outlet side
of the metering pump (to protect it from exces‐
sive heating up from overloading and from
impact sparks resulting from overloading trig‐
gered by the breakage of drive parts).
– Piston metering pumps are designed for appli‐
cations in temperature class T3. Pumps are
suitable for T4 with an additional flow control
on the outlet side (to protect it from excess
temperature following running dry) or a suitable
temperature monitor.
–In the event of differing temperature classes
amongst the diverse components, operation of
the complete pumps should be based on the
component with the lowest temperature class.
– Ensure that installations in areas at risk from
explosion are checked by a "recognisably
trained" skilled operative.
– Please note the relevant national regulations
during installation!
WARNING!
Warning of feed chemical reactions to water
Feed chemicals that should not come into contact
with water may react to residual water in the liquid
end that may originate from works testing.
– Blow the liquid end dry with compressed air
through the suction connector.
– Then flush the liquid end with a suitable
medium through the suction connector.
WARNING!
The following measures are an advantage when
working with highly aggressive or hazardous feed
chemicals:
– Install a bleed valve with recirculation in the
storage tank.
– Install an additional shut-off valve on the dis‐
charge or suction ends.
CAUTION!
Warning of backflow
A back pressure valve or a spring-loaded injection
valve do not represent absolutely leak-tight closing
elements.
– For this purpose use a shut-off valve, a sole‐
noid valve or a vacuum breaker.
Installation
18

CAUTION!
Suction problems possible
The valve may no longer close properly with feed
chemicals with a particle size greater than 0.3 mm.
– Install a suitable filter in the suction line.
CAUTION!
Warning against the discharge line rupturing
With a closed discharge line (e.g. due to a clogged
discharge line or by closing a valve), the pressure
that the metering pump generates can reach sev‐
eral times the permissible pressure of the system
or the metering pump. This could lead to lines
bursting, resulting in dangerous consequences
with aggressive or toxic feed chemicals.
– Install a relief valve that limits the pressure of
the pump to the maximum permissible oper‐
ating pressure of the system.
CAUTION!
Warning against the discharge line bursting
Hose lines with insufficient pressure rating may
burst.
– Only use hose lines with the required pressure
rating.
CAUTION!
Uncontrolled flowing feed chemicals
Feed chemical can leak through a stopped
metering pump when there is back pressure.
– Use an injection valve or vacuum breaker for
this purpose.
CAUTION!
Uncontrolled flowing feed chemical
Feed chemical can leak through the metering
pump in an uncontrolled manner in the event of
excessive priming pressure on the suction side of
the metering pump.
– Do not exceed the maximum permissible pri‐
ming pressure for the metering pump.
– Organise installation properly.
Installation
19

CAUTION!
Warning against lines coming loose
Suction, discharge and relief lines installed incor‐
rectly can come loose from the pump connection.
– Only use original hoses with the specified tube
diameter and wall thickness.
– Only use clamp rings and hose nozzles that
correspond to the respective hose diameter.
–Always connect the lines without mechanical
tension.
Only connect steel piping via a flexible piping
section to a plastic valve body - see the fol‐
lowing figure.
1
2
3
P_MOZ_0021_SW
Fig. 10: Connect the steel piping to the plastic pump body as
shown
1 Steel pipe
2 Flexible pipe section
3 Plastic valve body
CAUTION!
Warning of feed chemical spraying around
PTFE seals, which have already been used / com‐
pressed, can no longer reliably seal a hydraulic
connection.
– New, unused PTFE seals must always be
used.
CAUTION!
Warning of backflow
Liquid ends, foot valves, back pressure valves,
relief valves or spring-loaded injection valves do
not constitute absolutely leak-tight sealing ele‐
ments.
– Use a shut-off valve, a solenoid valve or a
vacuum breaker for this purpose.
–
Precise metering is only possible when the
back pressure is maintained above 1 bar at all
times.
– If metering at atmospheric pressure, a back
pressure valve should be used to create a back
pressure of approx. 1.5 bar.
Installation
20