Piston Metering Pump ProMinent® Makro/ 5 M5Ka Operating
Contents
1. The packaged unit should also only be stored or trans ported in accordance with the stipulated storage condi tions The packaged unit should be protected from moisture and the ingress of chemicals Compare the delivery note with the scope of supply Metering pump with mains power cable Connector kit for tube pipe connection Product specific operating instructions with EC Declaration of Con formity W CD with order information exploded diagrams performance diagrams motor data sheet and dimension sheets Optional accessories if ordered Personnel W Technical personnel Place 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 ventilation 13 Storage transport and unpacking Store the pump in a dry sealed place in the following ambient conditions Ambient conditions Data Value Unit Minimum storage and transport tempera 10 C ture Maximum storage and transport tempera 50 C ture Maximum air humidity 95 rel humidity non condensing 14 ProMinent Overview of equipment control elements 5 Overview of equipment control elements Power end single head ProMinent n oo 0 ProMinent AH so P MAK 0027 SW C A Fig 3 View f2. 0 1 Slide into the valve body 1 one after another one seal 2 and one valve seat 3 correct one seal 2 and one valve bushing 4 If fitted one spring into the spring guide of the valve seat 3 one ball 5 into the valve body 1 one seal 2 and the second valve seat 3 correct one seal 2 and the second valve bushing 4 If fitted the second spring into the spring guide of the valve seat 3 the second ball 5 into the valve body 1 W one seal 2 the third valve seat 3 correct and a further seal 2 2 Position the insert disc 6 with the flare on the packing E N T DEG 060 de odd w DONNE Bu ui gt a E The distance between the edge of the valve body and the insert disk 6 is due to the construction 3 Place the larger seal 7 between the insert disk 6 and the dosing head 4 Screw in the valve until the stop 6 7 Fig 23 Discharge valve double ball valve Cleaning a suction valve A suction valve is dismantled cleaned and assembled in the same way as a discharge valve Please note however that when assembling the valve seat 3 must be aligned in the other direction The fine machined side must point in the flow direction with all valve seats 3 ProMinent 41 Repairs 12 2 2 Single ball valves Screw the valve cap 5 on to the suction side see Carefully remove the parts from the valve body 2 Repl
3. A CAUTION Danger from incorrectly operated or inadequately maintained pumps o H Danger can arise from a poorly accessible pump due to 1 incorrect operation and poor maintenance Ensure that the pump is accessible at all times A YY Adhere to the maintenance intervals yal o Position the pump so that control elements such as the stroke length P MOZ 0018 SW adjustment knob the indicating dial A or the oil inspection window are accessible Fig 11 In so doing ensure there is enough space to carry out an oil change vent Screws oil drain plugs oil trough E 1 1 Discharge valve f 2 Dosing head H2 3 Suction valve q 44H Ensure there is sufficient free space f around the dosing head as well as the suction and discharge valve so that maintenance and repair work can i be carried out on these components Lo Al a P_MOZ_0017_SW Fig 12 Liquid end alignment Capacity too low If the valves of the liquid end do not stand upright they cannot close correctly The discharge valve must be upright Fastening Capacity too low Vibrations can disturb the valves of the liquid end gt Secure the metering pump so that no vibrations can occur ProMinent 21 Assembly P_MOZ_0015_SW Fig 13 Instruction 22
4. Pump type Oil change compl All 16 51 ProMinent 55 Technical data 15 9 Sound pressure level Sound pressure level 15 10 Compatibility Sound pressure level LpA lt 75 dB in accordance with EN ISO 20361 2010 10 at maximum stroke length maximum stroke rate maximum back pressure water The hydraulic accessories of the Makro 5 metering pump Hydro are com patible with the Sigma and Makro TZ piston pumps The connecting dimensions of valves and dosing heads are the same size but have different materials This does not apply with different diaphragm materials 15 11 Supplement for modified versions Technical data motor Spare parts 56 With Identcode specification Version M modified Technical data of pumps in the modified version can deviate from those of the standard pumps They can be queried by stating the details of the serial number The motor data sheets for the modified version are valid They may deviate from the standard motor data sheets With a modified version it is absolutely necessary to specify the details of the serial number requesting and ordering the spare and replacement parts ProMinent EC Declaration of Conformity 16 EC Declaration of Conformity For pumps without explosion protection Original EC Declaration of Conformity for Machinery ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 11 DE 69123 Heidelberg hereby declare that the produc
5. External fan option Stroke control drive Option Stroke adjusting drive Option Stroke sensor Option Frequency converter option motor CAUTION Pump can be damaged The pump can be damaged if the motor drives the pump in the wrong direction When connecting the motor pay attention to the correct direction of rotation indicated by the arrow on the fan cover as shown in Fig 14 CAUTION The motor may be damaged The motor is not equipped with a fuse Install a suitable motor protection switch P_SI_0012_SW Fig 14 Direction of rotation of motor 1 Use a suitable cable between the motor terminal box and power supply 2 Install an emergency cut off switch or include the motor in the emer gency cut off management of the system Key motor data can be found on the unit nameplate A Motor data sheets can be requested for more informa tion The terminal wiring diagram is located in the terminal box Notes on the speed controlled motor with external fan and temperature monitoring can be found in the Gen eral operating instructions for ProMinent motor driven metering pumps and hydraulic accessories 26 ProMinent Stroke sensor Option Other units ProMinent Installation The external fan requires an independent mains connection Connect the stroke sensor to a suitable monitoring device according to the details in the
6. ProMinent Operating instructions Piston Metering Pump ProMinent Makro 5 M5Ka ER N L 000 o ProMinent 5 000 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 for ProMinent motor driven metering pumps and hydraulic accessories Both sets of operating instructions are only valid when read together 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 Part no 985761 Original Operating Instructions 2006 42 EC BA MAK 007 10 11 EN ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 11 69123 Heidelberg Germany Telephone 49 6221 842 0 Fax 49 6221 842 617 email info prominent com Internet www prominent com 985762 1 en_GB 2010 Supplementary information 24 Fig f Please read General user instructions State the identity code and serial number General non discriminatory approach ProMinent Supplemental instructions Read the following supplementary information in its entirety Should you already know this information you have an even greater need of the Oper ating
7. Take the dimensions m for the fastening holes from the appropriate dimensional drawings or data sheets Fasten the pump base to the supporting floor using suitable screws Screw the pump to a support surface with 4 sufficiently strong screws through the 4 holes in the frame Nothing more need be fitted to the pump itself the pump is filled with gear oil and completely assembled on a frame ProMinent 8 8 1 Installation Installation hydraulic ProMinent A A Installation CAUTION Danger of personnel injury and material damage The disregard of technical data during installation may lead to personal injuries or damage to property Observe the technical data refer to chapter Technical Data and where applicable the operating instructions of the accessories WARNING Warning about personal and material damage EX pumps only When operating in EX areas certain sub jects must be observed The chapter Important supplements for metering pumps in EX zones of the General Operating Instructions on ProMinent Motor Driven Metering Pumps and Hydraulic Accessories must be observed in all cases 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 origi nate from works testing Blow the liquid end dry with compressed air through the suction connector Then flush
8. 3200100 2400070 2400088 2400121 2160157 1700184 1400120 1400151 1400207 1270267 1000314 800214 800268 800368 700476 560558 500335 500419 500576 450744 350872 350483 350604 350829 301071 251257 250658 250822 251129 231458 181710 160970 161212 52 Minimum pump capacity at max imum back pressure bar 4640 4640 4640 4640 3480 3480 3480 3132 2030 2030 2030 1841 5 1160 1160 1160 1015 725 725 725 652 5 507 5 507 5 507 5 435 362 5 362 5 362 5 333 5 232 232 l h 44 56 78 101 82 104 144 187 142 179 247 319 253 318 439 569 396 497 687 889 571 716 989 1280 778 975 1348 1743 1147 1438 ml stroke 11 14 20 26 21 27 38 49 37 47 65 84 67 84 116 150 104 131 182 235 151 189 262 339 206 258 357 461 303 381 Maximum stroke rate Strokes min 71 89 123 159 71 89 123 159 71 89 123 159 71 89 123 159 71 89 123 159 71 89 123 159 71 89 123 159 71 89 Suction Connector lift m WS Co oO 0 0 Y Y CQ Y Y CQ Y Y CQ CQ wo CQ CQ CQ Y Y Y CQ Q CQ CQ CQ CQ CQ CQ OQ CO CO wo wo CO size G DN Rp 1 4 8 Rp 1 4 8 Rp 1 4 8 Rp 3 4 10 Rp 3 4 10 Rp 3 4 10 Rp 3 4 10 1 15 1 15 1 15 1 15 1 15 1 15 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 2 25 1 2 25 1 2 25 1 2 25 1 2 25 2 32 2 32 1 1 2 25 1 1 2 25 2 32 2 32 2 32 2 32
9. Have new packing collars ready CAUTION The piston may be damaged Never push the packing collars on with a sharp object Evenly push in the guide sleeve 6 with a new guide band and a packing collar Insert the other packing collars with the cut ends alternately rotated through 180 Sequentially insert the flushing collar 7 two further packing collars and the guide sleeve 6 with a new guide band into the sealing area Place the dosing head flange 4 on the liquid end and tighten Tightening torque 24 Nm CAUTION The piston may be damaged Only lightly tighten the tensioning screw Position the tensioning screw and only hand tighten Place a sling around the liquid end and suspend from a crane WARNING Heavy parts may fall A helper must steady the liquid end by hand Secure the piston to prevent it falling out Place the liquid end on the drive flange and secure using the retaining screws Tightening torque 19 Nm ProMinent Repairs Positioning the liquid end Installing of packing collars Align the holes of the swivel head and fork head see Fig 20 Push the bolt through the holes and insert the safety collar in the bolt Clamp the protective cover over the turret If available Screw the support bracket onto the liquid end If available Fit the leakage or flushing tubes on to the tube nozzles Correct pressure of the tensioning screw Packing collars should limit not p
10. Mobilgear 634 VG 460 20 01 1006284 Gear oil filling volumes Types Volume approx All 16 51 Draining the gear oil 1 Remove the vent screw 1 2 Place an oil trough under the oil drain plug 2 Expected oil quantity see filling volumes above Unscrew the oil drain plug 2 out of the power end housing Allow the gear oil to run out of the power end Screw in the oil drain plug 2 with a new seal ProMinent 33 Maintenance 34 A P MAK 0043 SW Fig 17 Oil change 1 1 2 Vent screw Oil drain plug Filling with gear oil 1 2 Start the pump Slowly pour gear oil through the vent screw 1 opening until the upper oil inspection window 3 is slightly covered Allow the pump to run for a further 1 2 minutes Replace the vent screw 1 P MAK 0044 SW Fig 18 Oil change 2 3 Oil inspection windows ProMinent 12 Safety notes ProMinent Repairs A A A Repairs WARNING Warning about personal and material damage EX pumps only When operating in EX areas certain sub jects must be observed The chapter Important supplements for metering pumps in EX zones of the General Operating Instructions on ProMinent Motor Driven Metering Pumps and Hydraulic Accessories must be observed in all cases WARNING It is mandatory that you read the safety inform
11. n IB dae de oed Se ee 8 Storage transport and upnpacking 13 Overview of equipment control elements 15 Functional description 18 Assembly tein ie ne sense nem nasse 20 Installation 2 34 n nre err t m bert 23 8 1 Installation bvdraultce neresen nene neennnnssrernne resene 23 8 2 Installation electrical eese 25 Startups de ee A o Deo 28 During se nette ci en 30 Maintenance eee e o beris 31 RED AIS visita recto nee estan ine 35 12 1 Changing the piston 36 12 25 Valve epa iinan rt eri tero DER Ep Ede HO EI de 40 12 2 1 Double ball vahes 41 12 2 2 Single ball valves mm 42 12 2 3 Plate valves sr ee e Eae E AT E S 42 Troubleshooting AAA 44 Decommissioning and depossl AAA 46 14 1 Decommissioning eee 46 14 2 Disposal ien een nennen 48 Technical data 2 on ree tre eem tien 49 15 1 Performance data 50 15 2 A6curacy nde rte ient ne Ua tes 53 15 2 1 Reproducibility AAA 53 15 2 2 Metering prechion 53 15 3 Viscosity fiat ite e M Birne 53 15 4 Wetted materals 54 15 5 Ambient conditions 54 15 051 Temperat res sure ees 54 15 52 Air humidity 2 22 A is 54 15 6 Housing degree of Drotecton 55 15 7 Stroke sensor option intrinsically safe 55 15 8 Filling volumes esses 55 AE arena een 55 15 9 Sound pressure level nenn 56 15 10 Compalibility ser een
12. 2 32 2 32 2 1 4 40 2 1 4 40 2 1 4 40 2 1 4 40 SN um Eau Eu uae x Shipping weight kg 300 300 300 300 300 300 300 300 300 300 302 302 302 302 302 303 303 303 303 303 303 303 303 303 303 311 311 311 311 311 311 311 311 311 311 317 317 Piston Y mm 17 17 17 17 17 23 23 23 23 23 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50 60 60 60 60 60 70 70 70 70 70 85 85 ProMinent Type Minimum pump capacity at max imum back pressure bar l h 161665 232 1988 162150 232 2570 162522 121343 174 1589 121678 174 1991 122305 174 2752 122977 174 3558 103491 62269 87 2684 62837 87 3366 63896 87 4652 65031 87 6014 66000 15 2 Accuracy 15 2 1 Reproducibility 15 2 2 Metering precision 15 3 Viscosity ProMinent Maximum stroke rate ml stroke Strokes min 526 681 421 527 729 942 711 891 1232 1593 123 159 71 89 123 159 71 89 123 159 Suction Connector lift m WS Co C 0 0 CQ wo CQ Y CO wo CO size G DN 2 1 4 40 2 3 4 50 2 3 4 50 2 3 4 50 2 3 4 50 2 3 4 50 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 65 Technical data Shipping Piston Y weight kg mm 317 85 317 85 317 85 331 100 331 100 331 100 331 100 331 100 350 130 350 130 350 130 350 130 350 130 Stainless steel material version Shipping weight 340 kg The permissible priming pressur
13. 38 48 66 85 100 70 88 121 157 184 120 151 207 267 314 214 268 368 476 558 335 419 576 744 872 483 604 829 1071 1257 658 822 1129 1458 1710 970 ml stroke 11 3 11 3 11 3 11 3 11 3 20 7 20 7 20 7 20 7 20 7 35 3 35 3 35 3 35 3 35 3 62 8 62 8 62 8 62 8 62 8 98 1 98 1 98 1 98 1 98 1 141 3 141 3 141 3 141 3 141 3 192 4 192 4 192 4 192 4 192 4 283 7 Maximum stroke rate Strokes min 60 75 103 133 156 60 75 103 133 156 60 75 103 133 156 60 75 103 133 156 60 75 103 133 156 60 75 103 133 156 60 75 103 133 156 60 Suction Connector lift m WS Co 0 0 CQ CQ Y CQ Y CQ Y Y CQ Y Y Y CQ Y CQ Y CQ Y CQ Q Y CQ CQ CQ www ww wow CO CO wo size G DN Rp 1 4 8 Rp 1 4 8 Rp 1 4 8 Rp 3 4 10 Rp 3 4 10 Rp 3 4 10 Rp 3 4 10 1 15 1 15 1 15 1 15 1 15 1 15 1 4 20 1 4 20 1 4 20 1 4 20 1 4 20 1 2 25 1 2 25 1 2 25 1 2 25 1 2 25 2 32 2 32 1 1 2 25 1 1 2 25 2 32 2 32 2 32 2 32 2 32 2 32 2 1 4 40 2 1 4 40 2 1 4 40 SN m uu ux Vu uu asf ss Shipping weight kg 300 300 300 300 300 300 300 300 300 300 302 302 302 302 302 303 303 303 303 303 303 303 303 303 303 311 311 311 311 311 311 311 311 311 311 317 Piston Y mm 17 17 17 17 17 23 23 23 23 23 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50 60 60 60 60 60 70 70 70 70 70 8
14. Instructions The following are highlighted separately in the document E Enumerated lists Instructions gt Outcome of the handling instructions see reference Information This provides important information relating to the correct operation of the device or is intended to make your work easier Safety notes Safety notes are 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 for ProMinent 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 dis card 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 identified 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 Table of contents Table of contents oN oO Om ON 10 11 12 13 14 15 16 17 Identity code arena 5 About this p imp iii RESO en 7 Safety chapter
15. burnt and the piston damaged Leakage increases greatly D P MAK 0051 SW Fig 22 The result of too high tensioning screw pressure a Packing collar b Piston A Tensioning screw pressure B Feed chemical pressure 12 2 Valve repair Unsuitable spare parts for the valves may lead to problems for the pumps 4 Only use new components that are especially adapted to fit your valve both in terms of shape and chemical resistance Use the correct spare part kits In case of doubt refer to the exploded views and ordering information contained in the Supplementary information CD for ProMinent pump operating instructions Clean the discharge and suction valves only one after another as they cannot be differentiated using the arrow markings 40 ProMinent Repairs 12 2 1 Double ball valves Cleaning a discharge valve Taking the discharge valve apart 1 Unscrew the discharge valve from the dosing head and rinse out 2 Dismantle the discharge valve 3 Rinse and clean all parts 4 Replace the worn parts and seals Assembling the discharge valve When assembling take note of the orientation of the valve seats 3 The valve seats 3 are used as a ball seat on the fine machined side and as a ball cage and spring guide on the other side The fine machined side must point in the flow direction with all valve seats When assembling the valves take note of the sequence Teflon Metal Teflon Metal
16. chapter Technical Data Also observe its tech nical data Install the other units according to their documentation 27 Start up 9 Startup Safety notes 28 gt WARNING Warning about personal and material damage EX pumps only When operating in EX areas certain sub jects must be observed The chapter Important supplements for metering pumps in EX zones of the General Operating Instructions on ProMinent Motor Driven Metering Pumps and Hydraulic Accessories must be observed in all cases WARNING Hot surface In event the power end motor is loaded excessively its sur face may become very hot A Avoid contact If necessary mount a guard plate CAUTION Possible environmental and material damage The screw plug in the oil filler neck is factory fitted and during operation prevents any pressure equalisation between the power end housing and the surroundings This ensure that oil can be pushed from the power end housing Replace the screw plug on the oil filler neck by the air vent plug supplied Retain the sealing plug for subsequent transport of the unit CAUTION Single head version only Oil may escape The screw plug in the oil filler neck is factory fitted and during operation prevents any pressure equalisation between the power end housing and the surroundings This ensure that oil can be pushed from the power end housing Ensure that the hole in the metal ca
17. nameplate and the respective EC Declaration of Conformity for pumps for potentially explosive atmospheres com plying with Directive 94 9 EC in accordance with the European guide lines The explosion group category and degree of protection identi fied on the marking must correspond with or be better than the given conditions in the intended field of application The pump may only be started up after it has been correctly installed and commissioned in accordance with the technical data and specifi cations contained in the operating instructions The general limitations with regard to viscosity limits chemical resist ance and density must be observed see also ProMinent resistance list In the product catalogue or at www prominent com Any other uses or modifications are prohibited Pumps without the relevant nameplate and the respective EC Decla ration of Conformity for pumps for potentially explosive atmospheres must never be operated in potentially explosive atmospheres ProMinent Qualification of personnel ProMinent Safety chapter The pump is not intended for the metering of gaseous media or solids The pump is not intended for unprotected outside use The pumps is not intended for the dosing of combustible fluids The pump should only be operated by trained and authorised per sonnel see also Qualification of personnel on page 9 You are obliged to observe the information contained in the operating
18. ne 56 15 11 Supplement for modified versions eeeeeeeeen 56 EC Declaration of Conformity sse 57 O E 59 ProMinent Identity code 1 Identity code M5Ka Makro 5 piston metering pumps Power end type H D A B ProMinent Main power end Main power end doubled Add on power end Add on power end doubled Type 3200038 3200048 3200066 3200085 3200100 2400070 2400088 2400121 2160157 1700184 1400120 0500335 0250658 0121343 1400151 0500419 0250822 0121678 1400207 0500576 0251129 0122305 1270267 0450744 0231458 0122977 1000314 0350872 0181710 0103491 0800214 0350483 0160970 0062269 0800268 0350604 0161212 0062837 0800368 0350829 0161665 0063896 0700476 0301071 0162150 0065031 0560558 0251257 0162522 0066000 Dosing head material SS Stainless steel Seal material Tr RIRE Displacement body material S Stainless steel piston chromium dioxide coated Dosing head version O no valve spring 1 With valve spring Hydraulic connector 0 Standard connection 4 Union nut and SS insert Version With ProMinent logo no frame Without ProMinent logo no frame With ProMinent logo with single frame With ProMinent logo with double frame With ProMinent logo with triple frame With ProMinent logo with quadruple frame SH NU OS RR CH DN ES Modified order related version for pump fea tures see order paperwork Electric power supply S 3 ph 230 V 4
19. 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 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 escapes also depressurise the hydraulic system around the pump as necessary Adhere to the safety data sheet for the feed chemical 11 Safety chapter Protective equipment Fig 2 Isolating protective equipment Makro 5 with add on power end shown here for piston version 1 2 3 4 5 6 Cap only single head version Fan impeller hood Terminal box cover motor Cover plate only with add on power end Flange cover Protective cover only diaphragm and piston versions WARNING Warning of personal injury and material damage The customer must only remove the protective equip ment if requested to do so by the operating instructions The pump must not operate without fitted protective equipment Sound pressure level Sound
20. pressure level LpA 75 dB in accordance with EN ISO 20361 2010 10 at maximum stroke length maximum stroke rate maximum back pressure water 12 ProMinent Storage transport and unpacking 4 Storage transport and unpacking Safety notes Scope of supply Storage ProMinent A A WARNING The transporting of pumps which have been used with radio active 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 decommis sioning Only send metering pumps with a filled in Decontamination Declaration form The Decontamination Declaration consti tutes 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 operator You can find the Decontamination Declaration form under www prominent com 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
21. 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 discharge or suction ends CAUTION Warning about personal and material damage Also observe the General Operating Instructions for ProMi nent Motor Driven Metering Pumps and Hydraulic Accesso ries 23 Installation CAUTION Suction problems possible For feed chemicals with a particle size greater than 0 3 mm the valves may no longer close properly Install a suitable filter in the suction line CAUTION Warning against the discharge line bursting 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 several 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 operating pressure of the system CAUTION Warning against the discharge line bursting Tube lines with insufficient pressure rating may burst gt Only use tube lines with the required pressure rating CAUTION Warning against lines disco
22. wired incorrectly The mains voltage has failed The discharge line is seriously constricted Other causes Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthor ised persons Depressurise the system before commencing any work on hydraulic parts Remedy Repair the valves see chapter entitled Repair Repair the valves see chapter entitled Repair Install a suitable filter in the suction line 1 Check the mains voltage and mains frequency 2 Wire the motor correctly Eliminate the cause Immediately switch off the pump and inform customer service m Rectify any constriction of the dis charge line m Have the safety relief valve checked Call ProMinent or ProMaqua service Personnel Technical per sonnel Technical per sonnel Technical per sonnel Electrician Electrician Technical per sonnel 45 Decommissioning and disposal 14 14 1 Decommissioning 46 Decommissioning and disposal WARNING Warning about personal and material damage EX pumps only When operating in EX areas certain sub jects must be observed The chapter Important supplements for metering pumps in EX zones of the General Operating Instructions on ProMinent Motor Driven Metering Pumps and Hydraulic Accessories must be observed in all cases WARNING Danger of an electric shock When working on the motor or electr
23. 00 V 50 60 Hz WBS Identity code M5Ka Makro 5 piston metering pumps L 3 ph 460 V 60 Hz Exe Exd E 3 ph 230 V 400 V 50 Hz Exe Exd R Variable speed motor 4 pole 230 400 V R 1 5 N 1 ph 115 V 60Hz V 0 Motor with integral Frequency converter V 2 Motor with integral frequency converter Exd 5 No motor with gear IEC 100 6 No motor with gear IEC 112 0 No motor no gear Motor version O IP 55 Standard ISO class F 1 Exe version ATEX T3 2 Exdversion ATEX T4 A Power end ATEX design Stroke sensor O Nostroke sensor 1 Stroke sensor Namur intrinsically safe Stroke length adjustment O Stroke length adjustment manual 3 Control drive 230 V 0 20 mA 4 Control drive 230 V 4 20 mA 5 Control drive 115 V 0 20 mA 6 Control drive 115 V 4 20 mAz Applications 0 standard Figure 1 3 back pressure bar figure 4 7 flow rate l h 6 ProMinent 2 About this pump All pumps Externally mounted pumps Double head version ProMinent About this pump The ProMinent Makro 5 piston metering pump is fitted as standard with a 3 kW wide range AC motor The stroke length can be adjusted between 0 50 mm The spheroidal graphite housing can be combined with up to 10 liquid end sizes and 5 gear reduction ratios integrated in the spur geared motor The liquid ends are available in various material combina tions which can be matched to the feed chemicals being metered The ProMinent Makro 5 externally mount
24. 5 ProMinent Type 161212 161665 162150 162522 121343 121678 122305 122977 103491 62269 62837 63896 65031 66000 ProMinent Minimum pump capacity at max imum back pressure bar 16 16 16 16 12 12 12 12 10 o o o Oo l h 1212 1665 2150 2522 1343 1678 2305 2977 3491 2269 2837 3896 5031 6000 Maximum stroke rate ml stroke Strokes min 283 7 283 7 283 7 283 7 392 6 392 6 392 6 392 6 392 6 663 6 663 6 663 6 663 6 663 6 75 103 133 156 60 75 103 133 156 60 75 103 133 156 Suction Connector lift m WS Co 0 0 0 CQ CQ OQ Y CQ OQ wow wo wo CO size G DN 2 1 4 40 2 1 4 40 2 3 4 50 2 3 4 50 2 3 4 50 2 3 4 50 2 3 4 50 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 65 Shipping weight kg 317 317 317 317 331 331 331 331 331 350 350 350 350 350 Technical data Piston Y mm 85 85 85 100 100 100 100 100 130 130 130 130 130 Stainless steel material version Shipping weight 340 kg The permissible priming pressure at the suction side is 2 m WS All figures refer to water at 20 C The suction lift applies to filled suction line and filled liquid end when installed correctly The priming lift of 2 m applies for clean and moistened valves and a clear outlet 51 Technical data Main pumps with motor 1800 rpm under 60 Hz operation Type 3200038 3200048 3200066 3200085
25. E Hast C 1 4571 1 44041 4404 Data Storage and transport temperature Ambient temperature in operation drive motor Data Max temperature long term at max oper ating pressure Max temperature for 15 min at max 2 bar Minimum temperature Data Maximum air humidity Unit mPas mPas mPas mPas Piston Stainless steel ceramic Stainless steel ceramic Stainless steel ceramic valve plate Value 10 50 C 10 40 C Value 90 C 150 C 10 C Unit 95 rel humidity Value non condensing according to DIN IEC 60068 2 30 ProMinent Technical data 15 6 Housing degree of protection Data Value Protection against contact and humidity IP 55 according to DIN VDE 470 EN IEC 60529 15 7 Stroke sensor option intrinsically safe Namur sensor identity code specification Stroke sensor 1 Install the sensor according to the chapter Installation elec trical Namur sensor Specified for EX zones 5 25 V DC in accordance with Namur or DIN 19234 potential free design Data Value Unit Rated voltage 8 VDC Power consumption active surface gt 3 mA uncovered Power consumption active surface cov lt 1 mA ered Rated switching distance 15 mm Ri 1KQ Cable colour Polarity blue brown 15 8 Filling volumes 15 8 1 Gear oil Gear oil Gear oil Supplied quantity Part no Mobilgear 634 VG 460 20 01 1006284 Required amount of oil
26. ace the worn parts Clean the remaining parts Check all parts If available Place the compression spring inside the valve body 2 Insert the valve ball 3 and the valve seat 4 COIN jS NA o N gt Screw on the valve cap 5 Pay attention to the flow direction of the discharge and suc tion connectors when fitting the valve Fig 24 Cross section through the single ball valve Seal Valve body Valve ball Valve seat Valve cap AUN 12 2 3 Plate valves Do not scratch the finely machined sealing surfaces on the valve plates 5 and valve inserts 6 42 ProMinent y P_MAK_0056_SW Fig 26 Inserting the compression spring ProMinent Repairs NOOO Rh O N Seed NSS e NS INN y SN 7 P MAK 0055 SW Fig 25 Section through a plate valve DN65 shown 1 Valve cap II only DN 65 2 Perforated disc only DN 65 3 Compression spring 4 Valve body 5 Valve plate 6 Valve insert 7 Valve cap 1 Screw the valve cap 7 on to the suction side see 2 Carefully remove the parts from the valve body 4 3 Replace the worn parts 4 Clean the remaining parts 5 Check all parts 6 Only DN 65 Insert the perforated disc 2 in the valve body 4 T Place the compression spring 3 inside the valve body 4 Position the compression spring with the end see c figure arrow N at the bottom as shown on o
27. ar Z gently tap the PTFE ball seat above the valve ball see figure below Then with the valve in a damp condition allow it to prime Only adjust the stroke length when the pump is running This is easier and also better for the pump Correctly adjusting the pump Select as large a stroke length as possible for viscous feed chemicals W Select as large a stroke length as possible for outgassing feed chemi cals Select as high a stroke rate as possible for good mixing For precise metering using quantity proportional metering do not set the stroke length to less than 30 96 Check whether the leakage for the feed chemical used is between 10 and 120 drops min The pump can now be released for operation 29 During use 10 30 During use gt Bb WARNING Warning about personal and material damage EX pumps only When operating in EX areas certain sub jects must be observed The chapter Important supplements for metering pumps in EX zones of the General Operating Instructions on ProMinent Motor Driven Metering Pumps and Hydraulic Accessories must be observed in all cases WARNING Personnel injury and material damage may occur During use all units protective equipment additional devices must be fitted operational and tightly closed WARNING Hot surface In event the power end motor is loaded excessively its sur face may become very hot A Avoid contact If necess
28. arts of the system Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthor ised persons Depressurise the system before commencing any work on hydraulic parts WARNING Observe the safety notes at the beginning of the chapter aa jo N 10 11 12 13 Flush the suction line discharge lines and liquid end activate flushing equipment or immerse suction lance in a suitable medium and pump for a while consider the effect of the medium on your system first or proceed as described below Set the stroke length to 0 stroke with the pump running Switch off the pump Secure the pump to prevent it being switched back on If the liquid end has not been flushed according to the above pro cesses then protect yourself against the feed chemical protective clothing safety glasses After dismantling immediately place parts that have been wetting with the medium in a trough with a suitable medium for flushing in dangerous media were used flush and rinse thoroughly Unscrew the hydraulic connectors on the discharge and suction side Remove the protective cover 4 from the turret see Fig 19 Remove a safety collar 2 from the bolt at the swivel head and pull out the bolt 1 Place a sling around the liquid end and suspend from a crane WARNING Heavy parts may fall A helper must steady the liquid end by hand Secure the piston to preven
29. ary mount a guard plate WARNING Sparking caused by dry running If the bearings in the power end run dry sparks can be formed Check for oil leaks When the pump is idle the pump oil level must slightly cover the lower oil inspection window Observe the instructions in the Start up chapter and the operating instructions for the other machine components ProMinent 11 Safety notes ProMinent Maintenance A A A Maintenance WARNING Warning about personal and material damage EX pumps only When operating in EX areas certain sub jects must be observed The chapter Important supplements for metering pumps in EX zones of the General Operating Instructions on ProMinent Motor Driven Metering Pumps and Hydraulic Accessories must be observed in all cases WARNING It is mandatory that you read the safety information and specifications in the Storage Transport and Unpacking chapter prior to shipping the pump WARNING Hot surface In event the power end motor is loaded excessively its sur face may become very hot A Avoid contact f necessary mount a guard plate 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 th
30. ation and specifications in the Storage Transport and Unpacking chapter prior to shipping the pump WARNING Hot surface In event the power end motor is loaded excessively its sur face may become very hot A Avoid contact f necessary mount a guard plate 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 WARNING Risk of fingers being crushed Under unfavourable conditions the stroke axle or displace ment body can cause crushing of the fingers Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthor ised persons WARNING Risk of injury from the fan impeller The fan impeller beneath motor s fan cowling can cause severe injuries while it is turning The pump must only be connected to the mains voltage with the fan cowling closed 35 Repairs 12 1 Changing the piston Removing the liquid end 36 CAUTION Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due to pressure in the liquid end and adjacent p
31. e General Operating Instructions for ProMinent motor driven metering pumps and hydraulic accessories Check the starting torque torques for the dosing head flange screws 1 24 Nm and the turret flange screws 2 19 Nm Check that the discharge valve and suction valve are correctly seated Check the correct seating and state of the metering lines at both discharge and suction ends Check the tightness of the entire liquid end particularly around the leakage hole Check the oil level Single head versions only Check that the hole in the metal cap on the drive flange is clear see the figure in the Safety Chapter Check that the electrical connections are intact Check whether the pump is transporting media correctly run briefly at high power Observe the max imum permissible operating pressure Check whether the leakage level is OK 10 120 drops min ProMinent Maintenance Fig 16 Liquid end torques 1 Dosing head screws 2 Turret flange screws Interval Maintenance work After approx 5 000 operating hours Change the gear oil Under normal loading approx 30 of continuous operation Under heavy loading e g continuous operation Shorter intervals Changing the gear oil WARNING Risk of burns due to hot gear oil The gear oil may become very hot when the pump is heavily loaded When draining oil avoid contact with the oil running out Gear oil Gear oil Supplied quantity Part no
32. e at the suction side is 2 m WS All figures refer to water at 20 C The suction lift applies to filled suction line and filled liquid end when installed correctly The priming lift of 2 m applies for clean and moistened valves and a clear outlet Data Reproducibility Value Unit 40 5 for measurements taken under constant conditions minimum 10 96 stroke rate and water at 20 C when installed correctly p lt 1 bar Data Metering precision Value Unit EA 1757 at maximum stroke length and maximum back pressure The liquid ends are generally suitable for the following viscosity ranges 53 Technical data 15 4 Wetted materials Pump type 50 HK DN 8 DN 10 50 HK DN 15 DN 25 50 HK DN 32 DN 65 15 5 Ambient conditions Temperatures 15 5 1 Pump compl SST liquid end Liquid end Stainless steel 1 4571 1 4404 Stainless steel 1 4571 1 4404 Stainless steel 1 4571 1 4404 15 5 2 Air humidity 54 Suction dis Version Range no valve springs 0 200 with valve springs 200 500 with appropriately laid 500 1000 out installation with appropriately laid gt 1000 out installation and advice from ProMinent Only when the installation is correctly adjusted Valve seat seals Valve balls charge connector Stainless steel SS PTFE Oxide ceramic 1 4571 1 44041 4404 Stainless steel PTFE PTFE Stainless steel 1 4581 1 4401 Stainless steel PTF
33. e safety data sheet on the feed chemical Drain and flush the liquid end before working on the pump WARNING Risk of fingers being crushed Under unfavourable conditions the stroke axle or displace ment body can cause crushing of the fingers Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthor ised persons WARNING Risk of injury from the fan impeller The fan impeller beneath motor s fan cowling can cause severe injuries while it is turning The pump must only be connected to the mains voltage with the fan cowling closed 31 Maintenance Maintenance work Interval Quarterly 32 CAUTION Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components 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 unauthor ised persons Depressurise the system before commencing any work on hydraulic parts Under heavy loading e g continuous operation shorter maintenance intervals are recommended than those given Keep a spare parts kit in stock ready for maintenance work Order numbers are contained on the CD Maintenance work EX pumps only For special maintenance work see chapter Important supplements for metering pumps in hazardous locations of th
34. ed metering pump can be com bined with the Makro 5 main power end to form a double or multiple pump A main power end can be combined with up to four add on power ends One power end can be used both as a single or a double head ver sion The double head versions are fitted with a second liquid end which oper ates in push pull mode Boxer principle Safety chapter 3 Safety chapter Identification of safety notes Warning signs denoting different types of danger Correct and proper use The following signal words are used in these operating instructions to denote different severities of danger Signal word Meaning WARNING Denotes a possibly dangerous sit uation If this is disregarded you are in a life threatening situation and this can result in serious inju ries CAUTION Denotes a possibly dangerous sit uation If this is disregarded it could result in slight or minor inju ries or material damage The following warning signs are used in these operating instructions to denote different types of danger Warning signs Type of danger Warning hand injuries Warning high voltage Warning flammable substances Warning hot surface Warning danger zone gt Pb pb bp The pump may only be used to meter liquid metering chemicals In potentially explosive atmospheres in zone 1 device category Il 2G of explosion group II C the pump must only be operated according to the with the relevant
35. etering Pumps and Hydraulic Accesso ries 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 trans ported in accordance with the stipulated storage condi tions The packaged unit should be protected from moisture 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 conditions Please observe the permissible ambient conditions refer to the chapter entitled Technical Data WARNING Risk of electric shock If water or other electrically conducting liquids penetrate into the drive housing an electric shock may occur Position the pump so that drive housing cannot be flooded ProMinent Assembly WARNING The pump can break through the supporting floor or slide off it The supporting floor must be horizontal smooth and per manently load bearing Capacity too low Vibrations can disturb the valves of the liquid end gt The supporting floor must not vibrate Space requirement n
36. ical auxiliary equipment there is a danger of an electric shock Before working on the motor take note of the safety instructions in its operating instructions Should external fans servomotors or other auxiliary equipment be installed these should also be discon nected and checked that they are voltage free WARNING Danger from chemical residues There is normally chemical residue in the liquid end and on the housing after operation This chemical residue could be hazardous to people Itis mandatory that the safety note relating to the Storage Transport and Unpacking chapter is read before shipping or transporting the unit Thoroughly clean the liquid end and the housing of chemicals and dirt Adhere to the safety data sheet for the feed chemical 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 ProMinent Final decommissioning Temporary decommissioning ProMinent Decommissioning and disposal CAUTION Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due
37. ilation 5 Store the pump is a dry sealed place under storage conditions according to the chapter Storage Transport and Unpacking 47 Decommissioning and disposal 14 2 Disposal Personnel 48 W Technical personnel CAUTION Environmental hazard due to gear oil The pump contains gear oil which can cause damage to the environment Drain the gear oil from the pump Note the local guidelines currently applicable in your country CAUTION Note the local guidelines generally currently applicable in your country ProMinent Technical data 15 Technical data Only for M modified version WARNING Risk of personal injuries Please observe the Supplement for modified version at the end of the chapter It replaces and supplements the technical data ProMinent 49 Technical data 15 1 Performance data Main pumps with motor 1500 rpm under 50 Hz operation Type 3200038 3200048 3200066 3200085 3200100 2400070 2400088 2400121 2160157 1700184 1400120 1400151 1400207 1270267 1000314 800214 800268 800368 700476 560558 500335 500419 500576 450744 350872 350483 350604 350829 301071 251257 250658 250822 251129 231458 181710 160970 50 Minimum pump capacity at max imum back pressure bar 320 320 320 320 320 240 240 240 216 170 140 140 140 127 100 80 80 80 70 56 50 50 50 45 35 35 35 35 30 25 25 25 25 23 18 16 l h
38. instructions at the different phases of the device s service life In hazardous locations only the following combinations of identity code variants is permitted Combi Identity code specification values nations 1 Electric power supply L P Motor version 1 2 V 2 Stroke length adjustment 0 G H 2 Electric power supply 0 5 6 Motor version A Stroke length adjustment 0 G H Activity Qualification level Storage transport unpacking Instructed person Assembly installation of hydraulic Technical personnel service system 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 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 possible dangers independently based on their technical training and experience as wel
39. iquid end is a highly resistant piston 2 made from coated stainless steel The suction valve 5 closes as soon as the piston 2 is moved in to the dosing head and the feed chemical flows through the discharge valve 1 out of the dosing head The discharge valve 1 closes as soon as the piston moves in the opposite direction due to the vacuum pressure in the dosing head and fresh feed chemical flows through the suction valve 5 into the dosing head The flushing collar 3 can be used to flush the sealing surfaces of the piston or lead off leakage liquid ProMinent ProMinent Functional description P_MAK_0039_SW Fig 9 Cross section through the liquid end AUN Discharge valve Piston Flushing collar Packing collar Suction valve Assembly 7 Assembly Safety notes gt P Supporting floor TIZZZ P_MOZ_0016_SW Fig 10 20 WARNING Warning about personal and material damage EX pumps only When operating in EX areas certain sub jects must be observed The chapter Important supplements for metering pumps in EX zones of the General Operating Instructions on ProMinent Motor Driven Metering Pumps and Hydraulic Accessories must be observed in all cases CAUTION Warning about personal and material damage Also observe the General Operating Instructions for ProMi nent Motor Driven M
40. l as knowledge of pertinent standards and regulations Electrical technicians should be specifically trained for the working envi ronment in which the are employed and know the relevant standards and regulations Safety chapter Safety notes 10 Electrical technicians must comply with the provisions of the applicable 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 dan gers that could result from improper behaviour as well as having been instructed in the required protective equipment and protective measures Service Customer Service department refers to service technicians who have received proven training and have been authorised by ProMinent or Pro Maqua to work on the system WARNING Warning of dangerous or unknown feed chemical Should a dangerous 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 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 injuries Please ensure when handling hazardous substances that you have read the latest safety da
41. ne of the lugs in the valve body Otherwise the valve plate may knock when n opera tion 8 Insert the valve plate 5 and the valve insert 6 9 Screw on the valve cap 7 Pay attention to the flow direction of the discharge and suc tion connectors when fitting the valve 43 Troubleshooting 13 Safety notes 44 Troubleshooting WARNING Warning about personal and material damage EX pumps only When operating in EX areas certain sub jects must be observed The chapter Important supplements for metering pumps in EX zones of the General Operating Instructions on ProMinent Motor Driven Metering Pumps and Hydraulic Accessories must be observed in all cases WARNING Fire danger Only with combustible media These may start to burn when combined with oxygen When filling and draining the liquid end the feed chem ical must not come into contact with oxygen WARNING Hot surface In event the power end motor is loaded excessively its sur face may become very hot A Avoid contact If necessary mount a guard plate WARNING Danger of an electric shock Personnel working on electrical parts can be electrocuted if all electrical lines carrying current have not been discon nected Disconnect the supply cable before working on the motor and prevent it from being reconnected accidentally Any separately driven fans servo motors speed control lers or diaphragm rup
42. nnecting With suction discharge and relief lines installed incorrectly can loosen disconnect from the pump connection gt Only use original tubing with the specified tube diameter and wall thickness Only use clamp rings and tube nozzles that correspond with the respective hose diameter A Always connect the lines without mechanical tension Precise metering is only possible when the back pres sure is maintained above 1 bar at all times D metering at atmospheric pressure a back pressure valve should be used to create a back pressure of approx 1 5 bar Personnel W Technical personnel Route the leakage liquid drainage line The leakage liquid is drained off via the flushing collar and a tube nozzle without other parts of the liquid end coming into contact with the medium 1 Connect a tube to the lower tube nozzle 2 Route the tube into a collection device for the leakage liquid 24 ProMinent 8 2 Installation electrical ProMinent A A A Installation WARNING Danger of electric shock Unprofessional installation may lead to electric shocks All cable cores cut to length must be provided with cable end sleeves The Installation electrical of the device may only be undertaken by technically trained personnel WARNING Danger of electric shock In the event of an electrical accident it must be possible to quickly disconnect the pump and any electrical ancillarie
43. osed with the pump 58 ProMinent 17 Index A ACCUraCY EE 53 Arucas 54 Ambient conditions 54 Assembly entend thon ERR RE E uS 20 C Capacily etae e 50 Climate ceteri ere e renin eves 54 Compatibilty sesei zos rtu de eu 56 Connector size en reote nr 50 Correct and proper use 8 D RN elle Tun DN 46 Decontamination declaration 13 Direction of rotation of 26 Discharge valve incedere eee 18 Disposal id alone 48 DOSING OEA isernia cipe hen tice pt reple cre et 18 During use inen ai SW Ree 30 E Emergency reiecit e pei eee nr 11 Emptying the liquid end 47 External Ta ii teris 26 F Flushing c6llar 2 32 2a 18 Functional description 18 G Gear oll inis ea 55 H Hydraulic E 55 l Identification of safety notes 8 Identity code n i ee na 5 Information in the event of an emergency 11 Installation u ee 23 L l iq id Haaren hiess 18 M M terials cias rd eee 54 Metering precision ee 53 Modified 222 nh des 56 MOO M nn niit 26 56 ProMinent Index N Namur Sensor ten sense 55 O EE 55 P Packing collar een 18 Pista ee dti darem D ees 18 Protection against contact and humidity 55 PUMP capacity cios e e eH Uns 50 Q Qualification of personnel 9 R Radioactive iii d eb t E REPRE RA 13 Repaifs va EE EE e eie ted 31 35 Reprodueibili
44. p on the drive flange is always clear see Overview of equipment control elements CAUTION Warning about personal and material damage Also observe the General Operating Instructions for ProMi nent Motor Driven Metering Pumps and Hydraulic Accesso ries CAUTION Liquid end may be damaged Forfeed chemicals with a particle size greater than 0 3 mm always fit a filter in the suction line ProMinent Installing a vent screw Checking the oil level Checking the direction of rotation Fig 15 Tapping the valve set disc Adjusting the stroke length Checking the leakage ProMinent 7 PS 0m sw Start up Replace the sealing screw at the oil filler neck with the supplied vent screw see chapter Overview of equipment and control elements When the pump is idle check whether the pump oil level slightly covers the lower oil inspection window This indicates that the pump has not lost oil and consequently been dam aged When commissioning the unit check whether the drive motor is rotating correctly check this against the arrow on the motor housing or the dia gram in the chapter entitled Electrical Installation Eliminating suction problems only for single ball valves with PTFE ball seat For suction problems occurring during start up Exclude the possibility that there are foreign bodies in the valve Place the valve on a stable surface Using a hammer 1 and a brass b
45. revent the escaping of feed chemical Leakage is necessary to reduce the friction and dissipate the resulting friction heat In Fig 21 the feed chemical presses from the left through the packing collar a drop on the right The tensioning screw A presses on the packing collar from the right b P_MAK_0050_SW Fig 21 Correct pressure of the tensioning screw a b A B Packing collar Piston Tensioning screw pressure Feed chemical pressure Allow the pump to run for the first 10 15 min with this leakage rate Leakage in the first 10 15 min 50 200 drops min Then 1 Stop the pump 2 Remove the protective cover 3 Carefully tighten the tensioning screw 4 Clamp the protective cover over the turret 5 Start the pump 6 Check the leakage Repeat steps 1 6 until minimum leakage is achieved Minimum leakage 10 120 drops min ProMinent 39 Repairs The minimum leakage is dependent on the feed chemical the feed chemical pressure the temperature and the piston speed CAUTION The piston may be damaged If the tensioning screw pressure is too high dry running can occur and then damage to the piston and the packing collars Do not overtighten the tensioning screw The result of too high tensioning screw pressure The feed chemical can no longer press though the packing collars liquid lubrication is prevented The piston runs dry As a result the packing collars are scorched
46. ro 5 metering pump is a motor driven metering pump with a kine matic gear A motor drives the cam shaft 1 A connecting rod 2 rests on the cam shaft 1 which allows the oscillating crank 4 to rotate about a variable pivot point see Fig 8 The lifting arm of the oscillating crank which lies above the pivot point moves the slide rod 8 which itself drives the liquid end The stroke is adjusted using the manual adjustment wheel 7 This causes a spindle 6 to move the fork 5 shown in cutaway view in the dia gram The fork 5 moves the sliding block 3 in a groove cut into the oscillating crank 4 The sliding block 3 determines the pivot point of the oscillating crank 4 This determines the stroke length When the pivot point of the sliding block 3 is directly above the axle of the slide rod 8 the lifting arm of the oscillating crank above the pivot point is at zero and the slide rod stops When the sliding block 3 is pushed down the lifting arm of the oscillating crank 4 above the pivot point is greater than zero so that the slide rod 8 is driven Liquid ends can be fitted to both ends of the slide rod They then operate in push pull mode Boxer principle O EN P_MAK_0035_SW Fig 8 Cross section through the power end Cam shaft Connecting rod Sliding block Oscillating crank Fork Spindle Manual adjustment wheel Slide rod OO Joo E UOUN The heart of the l
47. rom the motor side here M5Ka H Power end Liquid end Lifting eye Stroke length adjustment wheel Indicating dial motor Oil drain plug o bo ACHT P_MAK_0027_SW Fig 4 View away from the motor here M5Ka H 6 Vent screw 7 Oil inspection window Overview of equipment control elements Power end double head 0 ProMinent oo 7 P MAK 0029 SW 5 C A C Fig 5 View from the motor side here M5Ka D Power end Liquid end Lifting eye Stroke length adjustment wheel Indicating dial motor Oil drain plug NARON 0O gt P_MAK_0030_SW Fig 6 View away from the motor here M5Ka D 6 Vent screw 7 Oil inspection window 16 ProMinent Liquid end ProMinent Overview of equipment control elements P_MAK_0034_SW Fig 7 OO P GO Discharge valve Dosing head Suction valve Support bracket Protective cover Tube nozzles for leakage flushing connector 17 Functional description 6 Functional description Power end functional description Functional description of the piston liquid end for M5Ka 18 The Mak
48. s which may possibly be present from the mains Install an emergency cut off switch in the mains supply line to the pump and any electrical ancillaries which may be present or Integrate the pump and electrical ancillaries which may be present in the emergency cut off management of the system and inform personnel of the isolating option WARNING Danger of electric shock This pump is equipped with a protective earth conductor to reduce the risk arising from an electric shock Connect the PE conductor to earth with a clean and permanent electrical connection WARNING Danger of electric shock A mains voltage may exist inside the pump housing fthe pump housing has been damaged you must dis connect it from the mains immediately It may only be returned to service after an authorised repair WARNING Warning about personal and material damage EX pumps only When operating in EX areas certain sub jects must be observed The chapter Important supplements for metering pumps in EX zones of the General Operating Instructions on ProMinent Motor Driven Metering Pumps and Hydraulic Accessories must be observed in all cases CAUTION Warning about personal and material damage Also observe the General Operating Instructions for ProMi nent Motor Driven Metering Pumps and Hydraulic Accesso ries 25 Installation Personnel m Electrician What requires electrical installation motor
49. t it falling out If available Remove the leakage or flushing tubes from the tube nozzles 6 If available Unscrew the support bracket 5 from the liquid end Remove the securing screws 3 from the turret flange Remove the liquid end and place onto a solid even surface ProMinent Repairing the liquid end ProMinent Repairs P_MAK_0048_SW Fig 19 View of the liquid end OO P GO Bolt Safety collar Securing screws Protective cover Support bracket option Tube nozzles for leakage flushing connector 8 7 654 P MAK 0049 SW Fig 20 Cross section through the liquid end ONXODNIAON Piston Tube nozzle Tensioning screw Dosing head flange Guide bands Guide sleeves Flushing collar Packing collars Loosen the tensioning screw 3 using the face spanner and remove see Fig 20 Loosen the dosing head flange 4 screws and remove the dosing head flange 37 Repairs o IN jo Remove the piston 1 Now record the sequence of parts as your remove them ready for the reassembly Remove the guide sleeves 6 and guide bands 5 the packing col lars 8 and flushing collar 7 Thoroughly clean the sealing area Clean the piston 1 the guide sleeves 6 and the flushing collar 7 Dispose of the packing collars and guide bands Insert the piston 1 Now reassemble the parts using a reverse sequence of steps 1 Fitting the liquid end 38
50. t specified in the following complies with the relevant basic health and safety rules of the EC Directive on the basis of its functional concept and design and in the version marketed by us This declaration loses its validity in the event of a modification to the product not agreed with us Description of the product Product type Serial no Relevant EC Directives Harmonised standards applied in particular Technical documents have been compiled by documentation specialists Date Manufacturer s signature Details of the signatory ProMinent Metering pump Makro 5 series M5Ma M5Ka M5Ha Please refer to nameplate on the device EC Machinery Directive 2006 42 EC EC EMC Directive 2004 108 EC The safety objectives of the Low Voltage Directive 2006 95 EC are complied with in accordance with Appendix I No 1 5 1 of the Machinery Directive 2006 42 EC EN ISO 12100 EN 809 EN ISO 13732 1 EN 60034 5 EN 60034 6 EN 60034 9 EN 60204 1 EN 61000 6 2 EN 61000 6 3 Norbert Berger Im Schuhmachergewann 5 11 DE 69123 Heidelberg 05 10 2011 Joachim Schall Head of Development 57 EC Declaration of Conformity For pumps with explosion protection The EC Declaration of Conformity for pumps for potentially explosive atmospheres is enclosed with the pump The EC Declaration of Conformity the EC type test reports and the oper ating instructions for the individual components are also encl
51. ta sheets provided by the manufacture of the hazardous substance The actions required are described in the safety data sheet Check the safety data sheet regularly and replace if necessary 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 assess ment for the workstations affected CAUTION Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components 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 unauthor ised persons Depressurise the system before commencing any work on hydraulic parts ProMinent Information in the event of an emergency ProMinent Safety chapter 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 see the ProMinent product catalogue or under www prominent com CAUTION Danger of personnel injury and material damage The use of untested third party parts can result in
52. 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 unauthor ised persons Depressurise the system before commencing any work on hydraulic parts WARNING Hot oil and hot components The hydraulic oil and the hydraulic end may become very hot when the pump is exposed to heavy loading A Allow the pump to cool before starting work CAUTION Danger of damage to the device The device can be damaged by incorrect and improper storage or transportation Take into account the information in the Storage Trans port and Unpacking chapter if the system is decommis sioned for a temporary period Personnel Technical personnel 1 Disconnect the pump from the mains power supply Depressurise and bleed the hydraulic system around the pump Flush the liquid end with a suitable medium Observe the safety data sheet Flush the dosing head thoroughly when using haz ardous feed chemicals Drain the gear oil refer to the chapter entitled Maintenance Thoroughly clean the liquid end and the housing of chemicals and dirt 6 Possible additional work see chapter Storage Transport and Unpacking In addition 1 Place the caps on the valves 2 Push the caps into place on the tube nozzles 3 Preferably place the pump on a pallet 4 Cover the pump with a tarpaulin cover allowing rear vent
53. ture sensors fitted should also be disconnected Check that the supply cables are de energised 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 ProMinent Tasks Fault description Pump does not prime in spite of full stroke motion and bleeding Pump does not reach high pres sure rates The diaphragm rupture warning system generates an alarm No hydraulic oil flows through the tube at the bleed valve The power end motor is very hot All other faults ProMinent Troubleshooting WARNING Risk of injury from the fan impeller The fan impeller beneath motor s fan cowling can cause severe injuries while it is turning The pump must only be connected to the mains voltage with the fan cowling closed CAUTION Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system Cause The valves are dirty or worn The valves are dirty or worn The feed chemical has particles larger than 3 mm The motor is
54. ty inerte 53 S Safety chapter oc reete da 8 Scope of supply nie ee 13 Shipping Be UE 50 Sound pressure Jevel nnr rnr rrenen 12 56 Spare pars iner eel eere e eee 56 Saori metier une crede deter tT te ee 28 Storage siege nin e WEE RH EE Eds 13 Storage and transport temperature 54 Stroke length oen eH nn 29 Stroke Sensor nein 55 S ction Mii 50 SUCHON VIVO iii ia 18 T Technical data 49 56 Temperatures iic eire Pen ees 54 Transport 420510 a re infe 13 Troubleshooting eee 44 U Unpacking eee eterne es 13 V Valve repair iter re eek edes 40 VISGOSILy noi ern b ERE ERE RE 53 W duet Le EE 8 Wetted materials ei 54 59
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