ProMinent Plasma PSMa User manual

Plasma PSMa
Motorised Diaphragm Metering Pump
Operating Manual
P_PL_0001_SW
Two sets of operating instructions are required for the safe, correct and proper operation of the metering pumps: The
product-specific operating instructions and the "General Operating Instructions ProMinent® Motor-Driven Metering Pumps
and Hydraulic Accessories".
Both sets of operating instructions are only valid when read together.
Translation of Original operating instructions (2006/42/EC) Vers. 10/2009
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.

BA PL 001, 1, en_GB
© 2009
Heidelberg ProMinent Fluid Controls India Pvt. Ltd.
2/2 M.E.S. Road
Yeshwanthpur, Bangalore – 560 022
India
Telephone: 080 - 2357 8872 / 73 / 74
Fax: 080 - 2357 3743 / 2347 7984
email: [email protected]
Internet: www.prominentindia.com
2

Please read the following supplementary information in its entirety!
This information will enable you to make better use of the operating
instructions.
The following are highlighted separately in the document:
nEnumerated lists
.Operating instructions
Information
This provides important information relating to the
correct operation of the unit or is intended to make your
work easier.
Safety information
Safety information is identified by pictograms - see Safety Chapter.
Two sets of operating instructions are required for the safe, correct
and proper operation of the metering pumps: The product-specific
operating instructions and the "General Operating Instructions ProM‐
inent® Motor-Driven Metering Pumps and Hydraulic Accessories".
Both sets of operating instructions are only valid when read
together.
Please read these operating instructions carefully before use! Do not
discard!
Please state the identcode and the serial number that you find on the
specification label in all correspondence or when you order spare
parts. This enables us to clearly identify the unit type and material
version.
Supplementary information
Fig. 1: Please read carefully!
User information
State the identcode and serial number
Supplemental directives
3

Table of contents
1 Identcode ............................................................................. 5
2 About this Pump ................................................................... 6
3 Safety Chapter ..................................................................... 7
4 Storage, Transport and Unpacking .................................... 10
5 Overview of the Unit and Control Elements ....................... 12
6 Functional Description ....................................................... 13
6.1 Drive Unit ................................................................... 13
6.2 Liquid End .................................................................. 14
7 Assembly ........................................................................... 15
8Installation .......................................................................... 16
8.1 Hydraulic Installation .................................................. 16
8.2 Electrical Installation .................................................. 16
9 Commissioning .................................................................. 18
10 Maintenance ...................................................................... 20
11 Repair ................................................................................ 22
11.1 Cleaning Valves ....................................................... 22
11.2 Replacing the Diaphragm ........................................ 24
12 Troubleshooting ................................................................. 26
13 Decommissioning ............................................................... 27
14 Technical Data ................................................................... 29
14.1 Performance Data .................................................... 29
14.2 Degree of Protection and Safety Requirements ...... 29
14.3 Ambient Conditions .................................................. 30
14.3.1 Temperatures ....................................................... 30
14.3.2 Climate .................................................................. 31
14.4 Gear Oil ................................................................... 31
14.5 Sound Pressure Level.............................................. 31
15 Appendix ............................................................................ 32
15.1 Dimensional Drawings ............................................. 32
15.2 Diagrams for Setting the Metering Capacity ............ 33
15.3 Ordering Information ................................................ 34
15.3.1 Spare Parts Sets ................................................... 34
15.3.2 Diaphragms .......................................................... 35
15.4 EC Declaration of Conformity .................................. 36
15.5 Decontamination Declaration ................................... 37
16 Index................................................................................... 38
Table of contents
4

1 Identcode
Plasma Series, Version I
PSMa Type Power
bar l/h
05050 5 50
05065 5 65
05100 5 90
05120 5 120
05200 5 200
05260 5 260
Material of dosing head/valves
PC PVC with EPDM sealing material
PP Polypropylene with EPDM sealing material
TT PTFE with PTFE sealing material
SS Stainless steel with PTFE sealing material
Dosing head design
0 Standard
Hydraulic connection
0 Standard connection - cap nut with hose
connection
1 Cap nut with stainless steel insert (standard
with stainless steel)
Motor connection
S 3-ph, 400 V ± 10 %, 50 Hz
(60 Hz versions on request)
1 without motor
Stroke sensor
0 no stroke sensor
Stroke length adjust‐
ment
0 manual
(standard)
Identcode
5

2 About this Pump
ProMinent ® Plasma PSMa motorised metering pumps are very
effective diaphragm metering pumps. They are compact, energy-
saving, provide excellent precision and reflect the high standards of
quality of ProMinent motorised metering pumps.
ProMinent ® Plasma PSMa motorised metering pumps are available
up to metering outputs of 260 l/h. There are six different maximum
metering output levels available.
About this Pump
6

3 Safety Chapter
The following signal words are used in these operating instructions
to identify different severities of a hazard:
Signal word Meaning
WARNING Denotes a possibly hazardous
situation. If this is disregarded,
you are in a life-threatening
situation and this can result in
serious injuries.
CAUTION Denotes a possibly hazardous
situation. If this is disregarded, it
could result in slight or minor
injuries or material damage.
The following warning signs are used in this operating instructions to
denote different types of hazard:
Warning sign Type of hazard
Warning of a hazardous area
Warning of hazardous electrical
voltage
nThe pump may only be used to dose liquid feed chemicals.
nThe pump may only be used after it has been correctly installed
and commissioned in accordance with the technical data and
specifications contained in the operating instructions.
nAny other uses or modifications are prohibited.
nThe pump is not intended to dose gaseous media or solids.
nThe pump is not intended for operation in EX zones.
nThe pumps is not intended to dose combustible fluids.
nThe pump should only be operated by trained and authorised
personnel.
nYou are obliged to observe the information contained in the oper‐
ating instructions at the different phases of the device''s service
life.
Explanation of the safety information
Warning signs denoting different types
of hazard
Correct and Proper Use
Safety information
Safety Chapter
7

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, protective
gloves, ...). Read the safety data sheet on the feed
chemical.
– Drain and flush the liquid end before working on the
pump.
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 pressure
in the liquid end and adjacent parts of the system.
– Depressurise the system prior to undertaking any
maintenance or repair work!
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 material
contacted by the chemical when selecting the feed
chemical - refer to the ProMinent ® resistance list
in the product equipment catalogue or at
www.prominent.com .
CAUTION!
Danger of personal and material damage
The use of untested third party parts can result in
damage to personnel and material damage.
– Only fit parts to dosing pumps, which have been
tested and recommended by ProMinent.
CAUTION!
Danger from incorrectly operated or inadequately main‐
tained 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.
CAUTION!
Warning of illegal operation
Observe the regulations that apply where the unit is to
be installed.
Safety information
Safety Chapter
8

The pump cannot be de-energised!
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!
Should feed chemical leak out, refer to the feed chemical's safety
data sheet. To switch off the pump in such an event, disconnect the
mains cable from the mains or press the emergency cut-off switch
fitted on the side of the system. If necessary depressurise the
hydraulic system around the pump.
Activity Qualification
Storage, transport, unpacking Technical personnel
Installation, installation of
hydraulic system
Technical personnel
Electrical Installation Electrician
Operation Instructed personnel
Maintenance, repair Technical personnel
Decommissioning, disposal Technical personnel
Troubleshooting Technical personnel, electri‐
cian, instructed personnel
Electrician
Electricians are deemed to be people, who are able to complete work
on electrical systems and recognise and avoid possible hazards
independently based on his/her technical training and experience, as
well as knowledge of pertinent standards and regulations.
Electricians should be specifically trained for the working environ‐
ment in which the are employed and know the relevant standards
and regulations.
Electricians must comply with the provisions of the applicable statu‐
tory directives on accident prevention.
Instructed personnel
The instructed personnel have been instructed by the operator in a
training session about the tasks allocated to them and potential
hazards with incorrect and improper conduct.
Technical personnel
Technical personnel are deemed to be people, who are able to
complete the tasks allocated to them and recognise and avoid
hazards independently based on his/her technical training and expe‐
rience, as well as knowledge of pertinent regulations.
The sound pressure level is < 70 dB (A)
at a maximum stroke length, maximum stroke rate, maximum
counter pressure (water) according to:
DIN EN 12639 (Noise testing on liquid pumps).
Information in the event of an emer‐
gency
Qualification of personnel
Sound Pressure Level
Safety Chapter
9

4 Storage, Transport and Unpacking
WARNING!
It is prohibited to ship pumps for radioactive media!
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 chapter on
decommissioning! Should safety precautions neverthe‐
less be necessary, in spite of carefully cleaning the
pumps, the requisite information must be entered on the
Decontamination Declaration form.
The Decontamination Declaration form constitutes an
integral part of an inspection/repair order. A unit can only
be inspected or repaired if a Decontamination Declara‐
tion form 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 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 pack‐
aging.
– 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 stipulated
storage conditions.
– The packaged unit should be protected from mois‐
ture and the ingress of chemicals.
Compare the delivery note with the shipment:
nMetering pump
nProduct-specific operating instructions with EC Declaration of
Conformity
n"General Operating Instructions ProMinent® Motor-Driven
Metering Pumps and Hydraulic Accessories".
Personnel: nTechnical personnel
1. Place the caps on the valves.
2. Preferably place the pump on a pallet.
Safety information
Scope of delivery
Storage
Storage, Transport and Unpacking
10

3. Cover the pump with a tarpaulin cover - allowing for rear venti‐
lation.
Store the pump in a dry, sealed place in the following ambient condi‐
tions.
Specification Value Unit
Minimum storage and transport
temperature
-10 °C
Maximum storage and transport
temperature
+50 °C
Maximum air humidity * 95 % rel.
humidity
* non-condensing
Ambient Conditions
Storage, Transport and Unpacking
11

5 Overview of the Unit and Control Elements
1
3
4P_PL_0002_SW
2
5
6
Fig. 2: Complete overview
1 Drive motor
2 Bleed plug / Locking plug
3 Liquid end
4 Oil drain screw
5 Drive unit
6 Stroke length adjustment knob
not shown Oil level indicator (on rear)
Overview of the Unit and Control Elements
12

6 Functional Description
6.1 Drive Unit
The metering pump is an oscillating displacement pump, the stroke
length of which can be adjusted. An electric motor (1) drives the
pump. A worm gear (2) reduces the drive rotation of the pump. An
eccentric cam (3) converts it together with the receiving fork (8) into
an oscillating movement of the driving rod (4). A return spring (5)
presses the receiving fork together with the driving rod in a force-fit
manner against the eccentric cam and thus triggers the return
stroke. The stroke length can be adjusted by the stroke adjustment
knob (6) and the shaft (7). The different stroke lengths are in effect
caused by the limitation of the return stroke (cf. Ä “Illustration of the
stroke movement ” on page 13
). The driving rod transmits the stoke
motion to the diaphragm.
1
2
3
6
4
5
7
P_PL_0003_SW
Fig. 3: Cross-section through drive unit
1 Electric motor
2 Worm gear
3 Eccentric cam
4 Driving rod
5 Return spring
6 Stroke adjustment knob
7 Shaft
8 Receiving fork
0
s s
a)
180 360 0
b)
180 360
ω ω
P_PL_0009_SW
Fig. 4: Stroke movement at a) maximum stroke length and b) reduced
stroke length.
s Stroke velocity
⍵ Angle of rotation of eccentric cam
+ Pressure stroke
- Suction stroke
Illustration of the stroke movement
Functional Description
13

6.2 Liquid End
The diaphragm (3) hermetically closes the pump volume of the
dosing head (2) towards the outside. The suction valve (4) closes as
soon as the diaphragm (3) is moved in the dosing head and the feed
chemical flows out of the dosing head through the discharge valve
(1). As soon as the diaphragm (3) is moved in a counter direction,
the discharge valve (1) closes due to the negative pressure in the
dosing head and fresh feed chemical flows through the suction valve
(4) into the dosing head. One cycle is thus completed.
Fig. 5: Cross-section through the liquid end
1 Discharge valve
2 Dosing head
3 Diaphragm
4 Suction valve
Functional Description
14

7 Assembly
CAUTION!
Maintenance to prevent personal and material damage
Also refer to the "General Operating Instructions ProM‐
inent® Motor-Driven Metering Pumps and Hydraulic
Accessories"!
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 pack‐
aging.
– 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 stipulated
storage conditions.
– The packaged unit should be protected from mois‐
ture and the ingress of chemicals.
CAUTION!
Warning about personal and material damage
Personal and material damage may be caused if the unit
is operated outside of the permissible ambient condi‐
tions.
– Please observe the permissible ambient conditions
- refer to the chapter entitled "Technical Data".
Assembly
15

8 Installation
8.1 Hydraulic 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.
CAUTION!
Maintenance to prevent personal and material damage
Also refer to the "General Operating Instructions ProM‐
inent® Motor-Driven Metering Pumps and Hydraulic
Accessories"!
Personnel: nTechnical personnel
8.2 Electrical Installation
WARNING!
Risk of electric shock
The electrical installation of the unit may only be under‐
taken by technically trained personnel with a proven
qualification.
CAUTION!
Maintenance to prevent personal and material damage
Also refer to the "General Operating Instructions ProM‐
inent® Motor-Driven Metering Pumps and Hydraulic
Accessories"!
CAUTION!
The pump can be damaged
The pump can be damaged if the motor drives the pump
in the wrong direction.
– When wiring the motor, pay due care and attention
to the correct direction of rotation indicated by the
arrow on the motor housing (cf. diagram below).
Installation
16

P_SI_0012_SW
Fig. 6: Direction of rotation of motor
–
Key motor data can be found on the unit specification
label.
– The terminal wiring diagram is located in the terminal
box.
– The motor can only be wired in star (Y) configura‐
tion.
Personnel: nElectrician
Installation
17

9 Commissioning
CAUTION!
Maintenance to prevent personal and material damage
Also refer to the "General Operating Instructions ProM‐
inent® Motor-Driven Metering Pumps and Hydraulic
Accessories"!
CAUTION!
Possible environmental and material damage
The locking screw on the oil filling opening is factory-
fitted and, during operation, prevents any pressure
compensation between the drive housing and the
surroundings. This ensures that oil can be pushed out of
the drive housing.
– Replace the locking screw on the oil filling opening
with the bleed plug supplied.
– Retain the locking screw for subsequent transporta‐
tion of the unit.
When the pump is idle, check whether the oil level in the pump is in
the middle of the oil level indicator.
This will rule out the pump losing oil and suffering damage.
When commissioning the unit, check whether the drive motor is
rotating correctly - check this against the arrow on the motor housing
or the diagram in the chapter entitled "Electrical Installation."
CAUTION!
– Only adjust the stroke length when the pump is
running.
–Only turn the stroke adjustment knob one revolu‐
tion, corresponding to 100% stroke length. The
figures on the stroke adjustment knob x 10 corre‐
spond to the stroke length set in % - see diagram
below.
0
1
9
P_PL_0006_SW
Fig. 7: 1 revolution = 100 % stroke length
Safety information
Fitting the bleed plug
Checking the oil level
Checking the direction of rotation
Adjusting the stroke length
Commissioning
18

Correctly adjusting the pump:
nSelect as large a stroke length as possible for viscous feed
chemicals.
nSelect as large a stroke length as possible for outgassing feed
chemicals.
nSelect as high a stroke rate as possible for good mixing.
nDo not set the stroke length at less than 30 % for precise
dosing.
Eliminating priming problems (only with TTT and SST)
Should you experience priming problems during
commissioning, unscrew the valves from the liquid
end, place on a solid surface and, using a brass bar
(2), gently tap with a hammer (1) the PTFE ball seat disc
through the valve ball - see diagram below. Then allow
the valves to prime in a damp state.
Fig. 8: Tapping the valve seat disc
1 Hammer, approx. 300 g
2 Brass bar Ø 9 x approx. 200 mm
Commissioning
19

10 Maintenance
WARNING!
It is mandatory that you read the safety information and
specifications in the "Storage, Transport and
Unpacking" chapter prior to shipping the pump.
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 pressure
in the liquid end and adjacent parts of the system.
– Depressurise the system before commencing work
on hydraulic parts!
Interval Maintenance task Personnel
After approx. 5,000 oper‐
ating hours
Change gear oil - refer to "Changing gear oil" in this chapter. Instructed
personnel
Quarterly* nCheck that the dosing lines are fixed firmly to the liquid
end.
nCheck that the suction valve and discharge valve are tight.
nCheck the tightness of the entire liquid end - particularly
around the leakage hole!
nCheck that the flow is correct: allow the pump to prime
briefly.
nCheck that the electrical connections are intact
nCheck that the dosing head screws are tight
Technical
personnel
* under normal loading (approx. 30 % of continuous operation)
Under heavy loading (e.g. continuous operation): Shorter intervals.
Draining gear oil
1. Remove the bleed plug (1).
2. Place an oil tray under the oil drain screw (2).
3. Unscrew the oil drain screw (2) from the drive housing.
4. Allow the gear oil to run out of the drive.
5. Replace the oil drain screw (2) with a new seal.
Filling gear oil
1. Start up the pump.
2. Slowly fill gear oil through the opening for the bleed plug (1)
until the oil level indicator (3) is half-covered.
3. Allow the pump to run for a further 1... 2 minutes.
4. Replace the bleed plug (1).
Standard liquid ends:
Changing gear oil
Maintenance
20