ProMinent mikro delta User manual

Precision Piston Metering Pump
mikro delta® MDLa
Operating instructions
with controlled optoDrive® solenoid drive
Original Operating Instructions (2006/42/EC)Part no. 986160 BA DE 024 08/12 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.
ООО "ПромХимТех" официальный партнер ипоставщик насосов ProMinent
www.promhimtech.ru / [email protected]

Read the following supplementary information in its entirety!
Should you already know this information, you have an even
greater need of the Operating Instructions.
The following are highlighted separately in the document:
nEnumerated lists
Instructions
ðResults of the instructions
Information
This provides important information relating to the cor‐
rect operation of the system or is intended to make
your work easier.
Safety information
Safety information is identified by pictograms - see Safety Chapter.
Please read these operating instructions carefully before use! Do
not discard!
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.
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.
Supplementary information
Fig. 1: Please read!
User information
State the identity code and serial
number
General non-discriminatory approach
Supplemental instructions
2

Table of contents
1 Identity code.......................................................................... 5
2 About this pump.................................................................... 7
3Safety chapter....................................................................... 8
4 Storage, transport and unpacking....................................... 13
5 Device overview and control elements............................... 15
5.1 Device overview.......................................................... 15
5.2 Control elements......................................................... 16
5.2.1 Key functions........................................................... 16
5.2.2 Stroke length adjustment knob................................ 17
5.2.3 Identifiers................................................................. 17
6 Functional description......................................................... 20
6.1 Liquid end................................................................... 20
6.2 Drive unit..................................................................... 20
6.3 Capacity...................................................................... 20
6.4 Operating modes........................................................ 21
6.5 Functions.................................................................... 21
6.6 Relay (options)............................................................ 22
6.7 Functional and fault Indicator...................................... 22
6.8 LCD display................................................................ 22
6.9 LED indicators............................................................ 23
6.10 Hierarchy of operating modes, functions and fault
statuses.................................................................... 23
7 Assembly............................................................................ 24
8 Hydraulic installation........................................................... 25
9 Electrical installation........................................................... 28
9.1 Supply voltage connector........................................... 29
9.2 Description of the jacks............................................... 30
9.2.1 "External control" terminal....................................... 30
9.2.2 "Level Switch" terminal............................................ 31
9.2.3 "Dosing monitor" terminal........................................ 31
9.3 Relay........................................................................... 32
9.3.1 "Fault indicating relay" output (identity code 1 + 3 or
4 + 5)........................................................................ 32
9.3.2 Output pacer relay (identity code 4 + 5)................... 33
10 Set-up................................................................................. 34
10.1 Basic principles of control adjustment...................... 34
10.2 Checking adjustable values...................................... 34
10.3 Changing to adjustment mode.................................. 35
10.4 Selecting the operating mode (Menu "Operation")... 36
10.5 Operating mode settings (menu "Settings").............. 36
10.5.1 "Manual" operating mode settings......................... 37
10.5.2 Settings for the “Batch” operating mode (BATCH
menu)..................................................................... 38
10.5.3 "Contact" operating mode settings........................ 39
10.5.4 "Analog" operating mode settings.......................... 41
10.6 Programmable function settings ("Settings" menu ). 44
10.6.1 Settings for the “Auxiliary frequency” function
(AUX menu)........................................................... 44
10.6.2 Settings for the “Flow” function (FLOW menu)...... 44
Table of contents
3

10.6.3 Settings for the “Calibrate” function (CALIBRATE
menu)..................................................................... 45
10.6.4 Settings for the “Metering” function (DOSING
menu)..................................................................... 46
10.6.5 Settings for the “Relay” function (RELAY menu)... 48
10.6.6 Settings for the “Analog output” function
(ANALOG OUTPUT menu).................................... 50
10.6.7 Settings in the "System" menu" (SYSTEM menu). 51
10.7 Set code (SECURITY menu).................................... 52
10.8 Delete total number of strokes or total litres (CLEAR
menu)........................................................................ 53
10.9 Set language (LANGUAGE menu)........................... 53
11 Operation............................................................................ 54
11.1 Manual...................................................................... 55
11.2 Remote operation..................................................... 57
12 Maintenance....................................................................... 58
13 Overhaul............................................................................. 60
13.1 Cleaning valves........................................................ 60
13.2 Replacing liquid end parts........................................ 63
14 Troubleshooting.................................................................. 67
14.1 Faults without a fault alert......................................... 67
14.2 Fault alerts................................................................ 68
14.3 Fault alerts / warning alerts....................................... 68
14.4 Warning Alerts.......................................................... 69
14.5 All Other Faults......................................................... 69
15 Decommissioning................................................................ 70
16 Technical data..................................................................... 72
16.1 Performance data..................................................... 72
16.2 Viscosity.................................................................... 72
16.3 Material data............................................................. 73
16.4 Electrical data........................................................... 73
16.5 Temperatures........................................................... 74
16.6 Climate...................................................................... 74
16.7 Protection class and Safety Requirements............... 74
16.8 Weight....................................................................... 75
16.9 Sound pressure level................................................ 75
17 Dimensions sheets.............................................................. 76
18 Diagrams for setting the metering capacity......................... 77
19 Exploded view drawings..................................................... 79
20 Ordering Information........................................................... 81
21 EC Declaration of Conformity............................................. 85
22 Decontamination declaration.............................................. 86
23 Operating / adjustment overview........................................ 87
24 Continuous displays............................................................ 89
25 Index................................................................................... 91
Table of contents
4

1 Identity code
Product range delta® , version a
MDL
a
Type Performance
bar ml/h
100150 10 150 (only TT)
600150 60 150 (only SS)
10 600 10 600 (only TT)
40 600 40 600 (only SS)
101500 10 1500 (only TT)
201500 20 1500 (only SS)
Material dosing head
SS Stainless steel
TT PTFE with 25 % carbon
Seal material
T PTFE seals, pure white
G PTFE seals, graphite
Dosing head version
0 Without bleed valve, without valve spring
1 Without bleed valve, with valve spring
Hydraulic connection
0 Standard connection in line with technical data
Version
0 With ProMinent logo
2 Without ProMinent logo
Electrical connection
U Universal control 100-230 V ±10 %, 50/60 Hz
Cable and plug
A 2 m European
B 2 m Swiss
C 2 m Australian
D 2 m USA
... ...
Relay
0 No relay
1 Fault indi‐
cating
relay N/C
1 x changeover contact 230 V – 8 A
Identity code
5

Product range delta® , version a
3 Fault indi‐
cating
relay mag‐
netic
1 x changeover contact 230 V – 8 A
4 As 1 +
pacing
relay
2 x N/O 24 V – 100 mA
5 As 3 +
pacing
relay
2 x N/O 24 V – 100 mA
... ...
Accessories
0 No accessories
Control versions
0 Manual + external contact with pulse control
3 Manual + external contact with pulse control +
analog 0/4-20mA
4 As 0 +14-day process timer
5 As 3 +14-day process timer
C CANopen
RAs 3 + PROFIBUS® interface, M12
Access code
0 No access code
1 With access code
Language
DE German
EN English
FR French
ES Spanish
... ...
Pause / level
0 Pause N/C, level N/C
Identity code
6

2 About this pump
The solenoid metering pumps belonging to the mikro delta®
product range with controlled optoDrive® solenoid drive are micro‐
processor-controlled solenoid metering pumps with the following
characteristics:
nOutput range 150-1500 ml/h, 60 - 20 bar
nLifting volume 1-250 µl
nMaterial versions PTFE and stainless steel
nMetering reproducibility: ±0.5 %
nContinuous or pulsing operation
nAdaptation of the pump to the feed chemical
nContinuous stroke length adjustment from 0 - 100 %
nAdjustment and display of the feed rate, either as strokes/min,
strokes/h or l/h via the keyboard
nLarge illuminated graphic display
nExternal activation via potential-free contacts with pulse step-
up and step-down
nOption of external activation by standard signal 0/4-20 mA
(optional)
nInterface for PROFIBUS® or CANopen (optional)
n14-day process timer* for time- and event-dependent metering
tasks (optional)
nConnection for 2-stage level switch
n3 LED display for operation, LCD screen for warning and fault
reporting in the display
Properties of the device
About this pump
7

3 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 – automatic start-up.
Warning – hand injuries.
Warning – high-voltage.
Warning – danger zone.
nThe pump may only be used to dose liquid metering chemicals.
nThe pump may only be started up after it has been correctly
installed and commissioned in accordance with the technical
data and specifications 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 equipment catalogue or at
www.prominent.com )!
nAny other uses or modifications are prohibited.
nThe pump is not intended for the metering of gaseous media or
solids.
nThe pump is not intended for the metering of explosive media.
nThe pump is not intended for operation in hazardous locations.
nThe pump is not intended for exterior applications without use
of suitable protective equipment.
Explanation of the safety instructions
Warning signs denoting different
types of danger
Correct and proper use
Safety chapter
8

nThe pump should only be operated by trained and authorised
personnel, see the following "Qualifications" table.
nYou are obliged to observe the information contained in the
operating instructions at the different phases of the device's
service life.
WARNING!
Warning about personal and material damage
The pump can start to pump, as soon as it is con‐
nected to the mains voltage.
– Install an emergency cut-off switch in the pump
power supply line or integrate the pump in the
emergency cut-off management of the system.
WARNING!
Danger of electric shock
A mains voltage may exist inside the pump housing.
– If the pump housing has been damaged, you must
disconnect it from the mains immediately. It may
only be returned to service after an authorised
repair.
WARNING!
Warning of crushing of the fingers
The moving parts in the turret can crush fingers.
– The protective bush on the liquid end must always
be closed when the pump is ready for operation.
WARNING!
Fire danger
Combustible media may only be transported using
stainless steel dosing heads. In exceptional cases
where this is not possible, PTFE with carbon can be
used, whereby our TT_ versions are manufactured
from this conducting plastic. Here, the operator is
urged to take special care due to the low mechanical
strength.
WARNING!
Warning of hazardous or unknown feed chemical
Should a hazardous or unknown feed chemical be
used, it may escape from the hydraulic components
when working on the pump.
– Take appropriate protective measures before
working on the pump (protective eyewear, protec‐
tive gloves, ...). Read the safety data sheet on the
feed chemical.
–Drain and flush the liquid end before working on
the pump.
Safety information
Safety chapter
9

CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic compo‐
nents if they are manipulated or opened due to pres‐
sure 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 materials
which will come into contact with the chemical
when selecting the feed chemical - refer to the
ProMinent resistance list in the product equipment
catalogue under
www.prominent.com .
CAUTION!
Warning of feed chemical spraying around
The metering pump can generate a multiple of its rated
pressure. If a discharge line is blocked, hydraulic parts
may burst.
– Correctly install a back pressure valve in the dis‐
charge line behind the metering pump.
CAUTION!
Small quantities of feed chemical can escape
Due to its design, small quantities of feed chemical
escape at the piston. Therefore appropriate safety pre‐
cautions must be taken if toxic media are being
metered.
– If toxic feed chemicals are being metered, take
appropriate safety precautions.
Observe the safety data sheet for the feed chem‐
ical.
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in per‐
sonnel injuries and material damage.
– Only fit parts to metering pumps, which have been
tested and recommended by ProMinent.
Safety chapter
10

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.
CAUTION!
Danger from incorrect metering
Should a different liquid end size be fitted, this will
change the metering behaviour of the pump.
– Have the pump reprogrammed in the works.
CAUTION!
Warning of illegal operation
Observe the regulations that apply where the unit is to
be installed.
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 exits, switch off the pump by pressing the
[Stop/Start] key. If necessary depressurise the hydraulic system
around the pump. Observe the safety data sheet for the feed
chemical.
Activity Qualification level
Storage, transport, unpacking Instructed person
Assembly, installation of
hydraulic system
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:
Information in the event of an emer‐
gency
Qualification of personnel
Safety chapter
11

A qualification of equal validity to a technical qualification can also
gained by several years employment in the relevant work area.
Electrical technician
Electrical technicians are deemed to be people, who are able to
complete work on electrical systems and recognize 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 the 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 department
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.
Sound pressure level LpA < 70 dB in accordance with EN ISO
20361:2010-10
at maximum stroke length, maximum stroke rate, maximum back
pressure (water)
Sound pressure level
Safety chapter
12

4 Storage, transport and unpacking
WARNING!
The pump can tip over when lifting
The pump can tip over when lifting, as the centre of
gravity of the pump is quite a distance from the liquid
end.
– Grip the pump quite close to the liquid end.
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 the section
on decommissioning!
Only send metering pumps with a filled in Decontami‐
nation Declaration form. The Decontamination Decla‐
ration constitutes an integral part of an inspection /
repair order. A unit can only be inspected or repaired
when a Declaration of Decontamination Form is sub‐
mitted that has been completed correctly and in full by
an authorised and qualified person on behalf of the
pump operator.
The "Decontamination Declaration Form" can be found
in the Appendix or at
www.prominent.com .
CAUTION!
Danger of material damage
The device can be damaged by incorrect or improper
storage or transportation!
– The unit should only be stored or transported in a
well packaged state - preferably in its original
packaging.
– The packaged unit should also only be stored or
transported in accordance with the stipulated
storage conditions.
– The packaged unit should be protected from mois‐
ture and the ingress of chemicals.
Safety information
Safety information
Storage, transport and unpacking
13

Personnel: nTechnical personnel
Data Value Unit
Minimum storage and transport tem‐
perature
-10 °C
Maximum storage and transport tem‐
perature
+50 °C
Air humidity < 95 % rel.
humidity*
* non-condensing
Compare the delivery note with the scope of supply:
nMetering pump with mains power cable
nConnector kit for hose/pipe connection
nEdge pin (TT_ only)
nProduct-specific operating instructions with EC Declaration of
Conformity
nRelay cable, as necessary
Ambient conditions
Scope of supply
Storage, transport and unpacking
14

5 Device overview and control elements
5.1 Device overview
1
2
3
P_DE_0005_SW
Fig. 2
1 Control unit
2 Drive unit
3 Liquid end
1
5
6
2
3
4
P_DE_0028_SW
Fig. 3
1 Back pressure valve
2 Vent screw
3 Discharge valve
4 Suction valve
5 Protective bush
6 Threaded hole for grounding screw
Device overview and control elements
15

5.2 Control elements
11 13 15 161412
10
9
8
73
1
a) b)
5
4
2
6
P_DE_0018_SW
Fig. 4: a) Displays and keys, b) Electrical control connections
1 LCD display
2 Stroke length adjustment knob
3 Key [UP]
4 Key [P]
5 Key [DOWN]
6 Key [STOP/START]
7 Key [i]
8 Operating indicator (green)
9 Warning indicator (yellow)
10 Fault indicator (red)
11 "External control" jack
12 "Dosing monitor" jack
13 "Level Switch" jack
14 "Diaphragm rupture reporter" jack
15 Optional module slot (timer, PROFIBUS®, CAN-Bus)
16 Relay and mA-output (option)
5.2.1 Key functions
Key Application In continuous displays (operation) In adjustment mode (set up)
STOP
START
[STOP/
START]
Pressed briefly Stop pump, Stop pump,
start pump start pump
P
[P]
Pressed briefly Start batch (only in
‘ Batch’ oper‐
ating mode), acknowledge fault
Confirm entry - jump to next
menu point or to continuous
display
Pressed for 2 s Change to adjustment mode -
Pressed for 3 s - Jump to continuous display
Device overview and control elements
16

Key Application In continuous displays (operation) In adjustment mode (set up)
i
B0098
[i]
Pressed 1x Change between the continuous
displays
Change between "Changing
individual numbers" and
"Changing a number"
Pressed 2x - Under "Changing individual
numbers": jump to the first
number
Press and hold Change to the secondary display -
[UP] ,
[DOWN]
Individually pressed
(until double arrow
appears)
Changing directly changeable vari‐
ables
Select another setting, change
individual number or number.
At the top end of a selection,
effect similar to an ESC key.
Pressed simultane‐
ously
Suction (in continuous display
"Stroke rate")
-
5.2.2 Stroke length adjustment knob
The stroke length can be adjusted using the stroke length adjust‐
ment knob and with it the volume per stroke.
5.2.3 Identifiers
The LCD screen supports the operation and adjustment of the
pump with different identifiers:
P
10548
Analog
100 /min
Stop Aux
cal
Fig. 5
The identifiers have the following meanings:
Symbol Additional
symbol
Name Meaning
Priming: The pump is currently priming (both arrow keys
pressed).
P
Symbol for P-key: The pump is in adjustment mode.
Lock symbol: Lock (if a code was set. Flashes).
Device overview and control elements
17

Symbol Additional
symbol
Name Meaning
Double arrow
symbol:
the value in the continuous display can be changed
with the arrow keys.
ii
Info symbol: It is possible to change between continuous dis‐
plays.
Stop: The pump was stopped using the
[STOP/START]
key (i.e. manually).
Pause: The pump was externally stopped by the Pause
contact.
Aux: The pump is currently pumping with the auxiliary
rate as the stroke rate.
During this time, the pump is in operating mode
‘Manual.’
Fault: A fault has occurred, which has stopped the
system.
Stroke length: The pump is set to
‘Dosing’ ‘slow’ and this
metering mode is also active (less than 61 strokes/
min). Below 30 strokes/min the operating indicator
flashes during operation and illuminates for slightly
longer at the end of each stroke.
The symbol relates to the symbol, which is located
beneath the stroke adjustment dial.
Stroke length
adjustment:
Deviation in the stroke length from the value set at
the time of the last locking of the adjustment menu.
Level: The "Warning" level in the storage tank was under‐
shot. If the symbol flashes, the level has fallen
below the "Fault" level in the storage tank and the
pump stops.
Flow: A flow control is connected. Together with a call
sign, the symbol indicates problems with the flow.
Contact: The pump is in operating mode
‘Contact’ .
The symbol closes every time a contact signal is
generated.
Contact signal: The pump is in operating mode
‘Batch’ .
The symbol flashes every time a contact signal is
generated.
mm
Memory: The pump is in operating mode
‘Contact’ or
‘Batch’ : the auxiliary function "Memory" has been
set.
0..200..20
0...20 mA: The pump is in operating mode
‘Analog’ . The pro‐
cessing type ‘0...20’ is set.
4..204..20
4...20 mA: The pump is in operating mode
‘Analog’ . The pro‐
cessing type ‘4...20’ is set.
i < 4i < 4
i less than 4 mA: Problems with the standard signal at the standard
signal input e.g. broken cable.
i > 23i > 23
i greater than 23
mA:
The standard signal at the standard signal input
indicates a fault with the connected unit.
Device overview and control elements
18

Symbol Additional
symbol
Name Meaning
Line: The pump is in operating mode
‘Analog’ .
The processing type ‘Curve’ - ‘Line’ is set.
Upper sideband: The pump is in operating mode
‘Analog’ .
The processing type ‘Curve’ - ‘Upper sideband’ is
set.
Lower sideband: The pump is in operating mode ‘Analog’ . The pro‐
cessing type ‘Curve’ - ‘Lower sideband’ is set.
The pump only shows the metering volume and the
capacity in the calibrated state in ml or ml/h.
Device overview and control elements
19

6 Functional description
6.1 Liquid end
The dosing process is performed as follows: The piston is pressed
into the dosing head; the pressure in the dosing head closes the
suction valve and the feed chemical flows through the discharge
valve out of the dosing head. The piston is now drawn out of the
dosing head; the discharge valve closes due to the negative pres‐
sure in the dosing head and fresh feed chemical flows through the
suction valve into the dosing head. One cycle is thus completed.
6.2 Drive unit
The displacement body is driven by an electromagnet, which is
controlled by an electronic control.
The optoDrive® drive technology means the variation over time of
the metering flow can be precisely matched to the requirements of
the particular application. Hence the user can, dependent on
requirements, set a slow discharge stroke for nearly continuous
metering or a quick stroke e.g. for quick clocked filling processes.
In both operating modes it is possible, to selectively also slow the
suction stroke, see figure. In this way, it is possible to prevent the
main cause for imprecise metering with high viscosity feed chemi‐
cals, namely the incomplete filling of the liquid end. For the case of
gaseous feed chemicals, the slow suction stroke prevents cavita‐
tion and consequently increases metering accuracy. Oscillations in
the back pressure in the metering line, which could lead to undesir‐
able variations in the metering volume, are automatically compen‐
sated for by the drive. Consequently, a dosing precision is attained,
which otherwise could only be achieved using a complex control
circuit.
p Pressure
t Time
6.3 Capacity
The capacity is determined by the stroke length and rate.
The stroke length is adjusted by the stroke length adjustment knob
within a range of 0 ... 100 %. A stroke length of between 4 ... 100
%) is recommended to achieve the specified reproducibility.
The stroke rate can be set using the arrow keys (not in "Analog"
operating mode) in the range 0 - 100 strokes/min (100 strokes/min
≜6000 strokes/h). The "Stroke rate (strokes / min)" continuous dis‐
play shows decimal places if a stroke frequency is set in the
"Stroke rate (strokes / h)" continuous display, which cannot be
divided by 60 without a remainder.
optoDrive® drive technology
P_DE_0006_SW
pa) b)
t
Fig. 6: Metering types: a) pulsing, b)
nearly continuous
Functional description
20