Operating Instructions ProMinent® alpha ALPb
Contents
1. For long lines and viscous media the next highest line diameter 72 x 9 mm should be used For the connection of 12x 9 mm lines the 12 mm connection set s needed 7 Order specifications The following table provides an overview of the pump features which can be ordered using the IDENTITY CODE The type of pump with counter pressure and capacity the liquid end material the valve spring the connection the version and the electrical connection can be selected ALPb range alpha version b Pump type capacity at 50 Hz capacity at 60 Hz 1001 1 2l h 10 0 bar 1 4 I h 10 0 bar 1002 2 4 1 h 10 0 bar 2 9 I h 10 0 bar 1003 3 5 1 h 10 0 bar 4 2 I h 10 0 bar 0804 4 0l h 7 5bar 5 0l h 7 5 bar 0808 8 0l h 7 5bar 9 5 I h 7 5 bar 0612 12 0 l h 5 5 bar 14 0 I h 5 5 bar 0419 18 51 h 4 0 bar 21 5 l h 4 0 bar Liquid end material PP1 Polypropylene EPDM with bleed valve PP2 Polypropylene FPM A Viton A with bleed valve PP3 Polypropylene FPM B Viton B with bleed valve NP3 Acrylic PVC FPM B Viton B with bleed valve NP6 Acrylic PVC FPM Viton9 without bleed valve Valve springs 0 no valve springs 1 with 2 valve springs approx 0 1 bar stainless steel 1 4571 Hydraulic Connectors 0 standard Version 0 with ProMinent logo Electrical connectors A 230 V 50 60 Hz 2 m Euro plug B 230 V 50 60 Hz 2 m Swiss plug C 230 V 50 60 Hz 2 m Austral plug D 115 V 50 60 Hz 2 m2. 0 Safety certificate Please copy and send in with the pump Safety certificate We herewith certify that the enclosed device Serial no is free of chemical biological or radioactive substances which are a health hazard The device has been thoroughly cleaned before being dispatched Date signature Company stamp Version 1 0 Page 31 of 32 pages
3. USA plug Ancillary equipment 0 no ancillary equipment 1 with foot and dosing valve 2 as 1 additional 2 m PVC and 3 m PE hose 4 as 2 additional 100 PE tank v v v v Y Y Viton is a registered trademark of DuPont Dow Elastomers Version 1 0 Page 9 of 32 pages e Secondary packaging Delivery scope Page 10 of 32 pages ALPa 006 D Unpacking 8 Unpacking ATTENTION Polystyrene parts are reusable they should therefore not be disposed of in the household waste but rather separately special waste acceptance centres Itis bestif you keep secondary packaging complete with the polystyrene so that you can send the metering pump and accessories back in case of repair or warranty cases Compare the delivery note with the contents of the package Metering pump with 2 m mains cable and plug 8mmconnection set for the hose connection in accordance with the identity code Operating instructions and short operating instructions pushed into the base of the pump ATTENTION Check if the specifications on the name plate of the pump match your order specifications ProMinent Dosiertechnik TYPE Im Schuhmachergewann SER NR PN D 69123 Heidelberg POWER SUPPLY Tel 06221 8420 AMP PULS Made in Germany DOSING RATE A 93 000000 ALPa 005 GB If they do not immediately notify the ProMinent subsidiary or representative responsible
4. closed or if there is a blockage Eliminate the blockage Page 21 of 32 pages Troubleshooting Eliminating Errors 13 1 5 Fluid is leaking out at the recess of the liquid end support Possible cause The liquid end is not leak proof at the pump diaphragm Remedy Tighten the screws arrow in the liquid end crosswise ALPa 010 I ATTENTION t is essential that the torques 4 5 to 5 Nm for the screws are observed PLEASE NOTE The torque of the liquid end screws is to be checked after 24 hours operation For PP pumps the torques are to be checked additionally every guarter of a year e If fluid is still leaking the diaphragm has ruptured and must be exchanged PLEASE NOTE The pump diaphragm is a part subject to wear its service life depends on counter pressure in the system operating temperature qualities of the medium to be metered PLEASE NOTE When using abrasive media the service life of the diaphragm is restricted and the diaphragm must be checked more often Under such operating conditions we recommend that the diaphragm is changed annually or every half a year Page 22 of 32 pages Version 1 0 Troubleshooting Eliminating Errors Exchanging the pump diaphragm Remove the cover 1 e A Push the locking bar 9 back onto the eccentric plate B Set the eccentric plate 10 to 0 ALPb 008 1 D PLEASE NOTE The locking bar cannot be snapped in in this position Loosen
5. side closes There is now a vacuum in the liquid end the balls on the suction side open and the medium is sucked into the liquid end suction stroke The capacity per stroke can be set in 10 steps using the locking bar 9 In doing sothe eccentricity is altered this meansthatthe diaphragm deflection always takes place from the neutral centre position The stroke length adjustment takes place when the pump is idle The stroking rates according to the pump type are 27 54 82 or 120 strokes per minute at 50 Hz or 32 63 94 or 142 strokes per minute at 60 Hz The drive motoris equipped with a thermal safety device which automatically switches off the motor if the motor overheats more than 106 C after the motor has cooled down the safety device switches the pump on again Liquid ends for alpha pumps are available in two material versions Polypropylene PP Acrylic PVC NP with double ball valve on the suction and discharge sides The liquid ends of the PP1 PP2 PP3 and NP 3 version additionally feature a combined bleed valve with fine adjustment for continuous automatic bleeding It enables priming and bleeding without the discharge line having to be interrupted and relieved of pressure For highly viscous media spring loaded valves are available recommendation from approx 200 mPas viscosity A DEVELOPAN compound diaphragm with long service life from high quality fabric reinforced EPDM material vulcanised steel core an
6. the series program Mounting plate for supply tank Wall bracket Back pressure valves Supply tank p SAFETY INSTRUCTIONS WARNING Pumps must be accessible at all times for operation and service Accesses may not be closed off or blocked WARNING Before opening the pump pull out the mains plug or switch off the power supply Check that the pump is voltage free and ensure the power cannot be switched on again by unauthorised persons WARNING Always relieve the discharge line of pressure first when carrying out maintenance or repair work If hazardous or unknown media are used always first empty out the liquid end and rinse it out Observe the safety data sheets of the fluids When working on the liquid end protective clothing must be worn glasses gloves ATTENTION The stroke length may only be set when the pump is switched off ATTENTION The stroke adjustment device locking bar 9 and eccentric plate 10 can heat up in the event of continuous operation highambient temperature overvoliage or high counterpressure f necessary wear protective gloves to adjust the stroke Version 1 0 SAFETY INSTRUCTIONS Order Specifications PLEASE NOTE Only use the gripper rings and hose nozzles specitied for the respective hose dlameteras wellas originalhoses with specified hose dimensions and wall thickness as otherwise the stability of the connection is not guaranteed Avoid reducing the hose sizes
7. 1 PP2 PP3 NP3 NP6 polypropylene polypropylene Acrylic Acrylic with bleed valve with bleed valve with bleed valve without bleed polypropylene polypropylene PVC PVC EPDM Viton Viton Viton ceramic ceramic ceramic ceramic DEVELOPAN pump diaphragm with PTFE layer Viton FKM is a registered trademark of DuPont Dow Elastomers Version 1 0 Installation Dimensions Accessories 4 Installation dimensions PP 970 NP 985 PP 186 NP 187 PP 19 NP 13 ALPa 003 D 5 Accessories WARNING ProMinent metering pumps may not be assembled with third party parts which have not been tested and recommended by ProMinent Failure to observe this can lead to personal injury and damage to property for which no liability is accepted Version 1 0 Page 7 of 32 pages Accessories SAFETY INSTRUCTIONS 5 1 Ordering using identity code Page 8 of 32 pages Foot valve dia o 8 With suction filter and ball check valve to connect at the end of the suction line Injection valve dia 8 1 2 With spring loaded ball check valve for metering into open and closed systems and for fastening the discharge line assembly directly onto the liquid end Alternative option 5 2 5 3 Foot and injection valve with 2 m PVC suction line and 3 m PE discharge line dia 8 x 5 mm Other accessories from
8. Operating Instructions Motor Driven Metering Pump Diaphragm Type ProMinent alpha ALPb G ProMinent ALPa 001 D Affix type identification plate here For safe and correct operation of ProMinent alpha ALPb motor driven metering pumps two sets of Operating Instructions are required The product specific alpha ALPb Operating Instructions and ProMinent motor driven dosing pump Operating Instructions must be read together Please completly read through these operating instructions first Do not discard The warranty shall be invalidated by damage caused by operating errors Part No 997729 ProMinent Dosiertechnik GmbH 69123 Heidelberg Germany BA ALP 008 01 02 GB Tests EC Conformity Declaration ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 11 D 69123 Heidelberg hereby declare that on the basis of its functional concept and design and in the version brought into circulation by us the product specified in the following complies with the relevant fundamental safety and health stipulations laid down by EC regulations Any modification to the product not approved by us will invalidate this declaration Product description Product type Serial number Relevant EC regulations Harmonised standards used in particular National standards and technical specifications used in particular Date manufacturer s signature The undersigned Metering pump Series Alpha ALPb See type identif
9. b 008 1 D Refit the cover 1 Version 1 0 Version 1 0 Coarse bleeding Commissioning ATTENTION The metering pump may only be operated when the cover 1 s closed Switch on the pump and allow it to operate at 100 stroke length until the medium has completely filled the liquid end without bubbles This can be recognised when the medium can be seen in the discharge line Switch off the metering pump Connect the discharge line to the injection valve The pump is now ready to operate 10 3 Commissioning PP1 PP2 PP3 NP3 version e f possible proceed as for NP6 version If this is not possible Connect the suction and discharge lines securely There is fluid in the suction tank Remove the cover 1 and check whether the stroke length is set to 100 e If not A push back locking bar 9 to eccentric plate B set eccentric plate 10 to 100 C slot in locking bar again ALPb 008 1 D Refit the cover 1 ATTENTION The metering pump may only be operated when the cover 1 Is closed Open the bleed valve 5 by turning it one turn anti clockwise e Nowthe passage is open for coarse suction bleeding via the bypass Page 15 of 32 pages Page 16 of 32 pages Commissioning Switch on the pump and allow it to operate at 10096 stroke length until the medium has completely filled the liquid end without bubbles This can be recognised when the medium can be s
10. d PTFE layer on the media contacted side Page 5 of 32 pages Max capacity at max counter pressure Pump type ALPb 1001 Power supply Power drain DINVDE Permissible ambient temperature Shipping weight Media contacted materials for version Liquid end Suctiorvdischarge connection Seals Balls Page 6 of 32 pages Max capacity counter pressure Technical Data 3 Technical data Stroking Connection Suction Priming Max perm starting pressure at medium o dia x i dia m oa i 2 3 4 8 127 88 85 Re a ea 15 39 89 a2 69 85 s4 36 85 19 69 85 Suction lift with empty liquid end valves dampened The capacity was established using water and a metering pump warm from operating Metering deviances for all material versions 10 Metering reproducibility 5 with constant conditions minimum counter pressure 1 bar stroke adjustment 40 to 100 and media similar to water during short time intervals approx 5 min 3 6 8 j 4 5 6 j 2 30 58 88 30 58 88 36 36 m m n m m Please note For types 1001 1002 and 1003 at a stroke length of 20 and counter pressure gt 4 bar the capacity can converge towards zero Permissible temperature of the medium for PP 60 C and for NP 45 C Standard version 230 V 10 50 Hz 57W 0 5A Electrical technical safety according to DIN VDE 0700 EN 60335 10 C to 45 C 3 0 kg PP
11. e respective national regulations in your country WARNING As there is no on off switch on the pump the pump starts immediately after plugging in the mains plug or turning on the power supply Mains voltage Power supply Standard version 230 V 10 50 Hz 57W 0 5A Power supply Multi range motor 100 120 V and 200 240 V at 50 60 Hz Page 13 of 32 pages Page 14 of 32 pages Commissioning 10 10 1 A 10 2 Commissioning General instructions WARNING The metering pump may still contain water in the liquid end from the test at the factory For media which may not come into contact with water the water must be emptied from the liquid end before the pump isused Forthis purposeturn the pump 180 and empty the liquid end then rinse with a suitable agent via the suction connection from above ATTENTION The metering pump may only be operated when the cover 1 s closed ATTENTION The stroke length may only be adjusted when the pump fs switched off Commissioning NP6 version Connect the suction and discharge lines securely PLEASE NOTE Do not connect the discharge line to the injection valve only to the discharge connection 4 There is fluid in the suction tank Remove the cover 1 and check whether the stroke length is set to 100 If not A push back locking bar 9 to eccentric plate B set eccentric plate 10 to 100 C slot in locking bar again ALP
12. een in the discharge line or bleed line Switch off the metering pump Close the bleed valve 5 by one turn clockwise The pump is now ready to operate The fine venting facility can be permanently switched on when processing media with slight gas emission e For this purpose after removing the attached star handle 5b the fine bleed screw 5a inside the bleed valve is opened approx 1 turn anti clockwise A ALPa 009 2 D e As a result a partial flow of the metering quantity is constantly fed back to the supply tank e The backfeed quantity should be approx 20 of the metering quantity e The media must be fluid and without any solid particles WARNING These measures above do not guarantee any absolute reliable metering after the pump has come to a standstill It is essential that the pump is checked regularly e Refit the star handle 5b Please note After approx 24 operating hours the screws in the liquid end are to be tightened crosswise Attention t is essential that the torques of the screws are observed Torques for M5 screws 4 5 to 5 Nm Version 1 0 Version 1 0 Operation 11 Operation General DANGER When handling dangerous media protective glasses and gloves must be worn ATTENTION The metering pump may only be operated with the cover 1 closed PLEASE NOTE Check correct assembly see chapter 9 Installation from page 11 PLEASE NOTE Metering
13. for you Addresses can be found on the back page page 32 of these operating instructions Each alpha metering pump is provided with a name plate This can be found on the base of the pump In addition to the technical basic data the Identity Code and the serial no are specified Both numbers are to be stated during any enquiry or when ordering spare parts as they permit a clear identification of the type of pump and material variant Please make a note of the following details of the pump delivered so that these are always available when required IDENTITY CODE Serial number Place of installation Metering application Commissioning Version 1 0 Installation 9 Installation 9 1 Installing the pump mechanical part 9 1 1 Pump installation with console or tank Assemble metering pump onto a tank or a console with screws and washers dia 5 mm PLEASE NOTE The pump must be fastened in such a way that no vibrations can arise The valves ofthe liquidend mustalways be keptuprightin order to guarantee that they function smoothly 9 1 2 Connection of suction discharge line to the pump Arrangement of the individual parts Union nut gt Discharge connection lt Gripper ring gt Hose line gt Position of the Nozzle gt gripper ring ALPa 007 GB PLEASE NOTE Always shorten the suction line to the necessary length and lay ascending IMPORTANT Heigh
14. g pumps may only be repaired by trained and authorised persons 13 2 1 Mains connection line system cable with thermal safety device damaged Have the connection line thermal safety device exchanged by an authorised customer service PLEASE NOTE Only use correct connection lines from the manufacturer with EURO plug For all alpha pump types Order no 79 06 32 4 For all other mains cables see list of spare parts Version 1 0 Repair 14 A Customer service Pumps for radioactive media A N Version 1 0 Repair WARNING Metering pumps may only be repaired by trained and authorised persons Inform your customer service responsible Or contact the ProMinent subsidiary or representative responsible for you Addresses can be found on the back page page 32 of these operating instructions WARNING Pumps for radioactive media may not be sent PLEASE NOTE Only send the metering pump back for repair once it has been cleaned and the liquid end has been rinsed PLEASE NOTE The legalregulations foroccupational safety e g the regulation govemingplacesofwork hazardous substances the prevention of accidents and environmental protection regulations law governing waste or water resources oblige all industrial entrepreneurs to protect their employees or people and the environmentagainst damaging effects from handling hazardous substances An inspection or repair of pumps and their parts therefore onl
15. gh counter pressure the thermal safety device has switched off the motor automatically as the motor has overheated more than 106 C Switch off the mains Reduce counter pressure After the motor has cooled down the safety device automatically Switches the pump on again e f there is no success check the discharge line and the following pressure system to establish whether the stop valve is closed or if there is a blockage Eliminate the blockage Switch the mains on again The thermal safety device has switched off the motor automatically as the motor has overheated more than 106 C because the intake and drain opening of the motor cooling air are blocked Switch off the mains Eliminate the blockage by cleaning the air intake opening at the bottom of the pump and the drain opening of the cover After the motor has cooled down the safety device automatically Switches the pump on again f there is no success check the discharge line and following pressure system to establish whether the stop valve is closed or if there is a blockage Eliminate the blockage Switch on the mains again 13 1 4 Pump does not operate in spite of activated power supply The counter pressure applied is higher than the permissible working pressure or starting pressure Reduce counter pressure e f there is no success check the discharge line and the following pressure system to establish whether the stop valve is
16. ication plate overleaf and on device EC machine regulation 89 392 EEC subsequently 93 44 EEC EC low voltage regulation 73 23 EEC EC EMC regulation 89 336EEC subsequently 92 31 EEC EN 292 1 EN 292 2 EN 809 EN 563 EN 60335 1 EN 60335 2 41 EN 50081 1 2 EN 50082 1 2 EN 55014 EN 55104 DIN VDE 0700 T1 DIN VDE 0700 T41 DIN VDE 0700 T500 07 11 1997 Mister Manfred H holt factury manager OMAN DOA 0 mw eo Explanation of Devices and Operating Parts N e AZ Uf Ziff SS 4 T LL uL A C v c mit ti 8 7 6 ALPb 002 D More detailed information on pages elg PED 14 15 17 18 23 25 28 IWIOLOE SUP POM tine pn 5 28 EncloSUl itid ete AE ein Or Or fes aud Eds 5 28 Discharge COnflection nre bt e t Rep Dade 11 28 Bleed valve with fine bleed screw 12 13 15 16 19 20 25 28 Liquid End oe 5 19 20 22 24 28 S ction connection sssrin eaea EE 11 28 Bypass hose nozzle ete exe ette tach dien cue ap eon a 12 28 LOCKING DAN ete tn iter prie in 8 14 15 18 23 25 28 Eccentric plate with scale esssssssssssss 8 14 15 18 23 28 Device identification identity code Device identification identity code The type identification plate affixed on the title page is identical to that on the supplied pump thus enabling specific allocation between operating instructions and the pump Please enterthe iden
17. ications given in the operating manual All other uses and modifications are forbidden The pump is not suitable for dosing gases or solids The pump must only be used by trained and authorised personnel Sound intensity level The sound intensity level is 70 dB A at maximum stroke maximum Stroke rate maximum back pressure water in accordance with DIN EN ISO 3744 Reproducibility 2 Determining Sound intensity level PR DIN EN 12639 Metering Pump Noise Measurement DIN 45635 24 Machine Noise Measurement They feature very good priming capacity soft discharge stroke and constantly accurate metering with the lowest mechanical load of the pump diaphragm in the capacity range of 1 2 to 18 5 I h and from 4 to 10 bar This sophisticated technology is usually only offered for metering pumps in the top performance range 2 Functions 2 1 Functional principle alpha metering pumps basically consist of a power end with enclosure gear split pole motor with thermal safety device stroke length adjustment with eccentric and connecting rod as well as ofa liquid end with liquid end suction and discharge connection pump diaphragm and intermediate disk The eccentric for the stroke movement is guided in an eccentric plate thus the recuperating spring common for this size of pump can be dispensed with The suction stroke and discharge stroke are force guided The feed procedure takes place in batches the stroke length is
18. it out for maintenance and repair work WARNING When metering hazardous or unknown metering media protective clothing glasses gloves must be worn when working on the liquid end ATTENTION The stroke length may only be set when the pump is switched off Pump is operating but no metering takes place Collection of air in the liquid end Bleed the liquid end Switch off the pump Open the bleed valve 5 by turning once anti clockwise Switch on the pump again and allow it to operate so long until metering takes place for every discharge stroke Page 19 of 32 pages Remedy for NP6 pumps Other possible cause for PP1 PP2 PP3 NP3 version Remedy Possible cause Page 20 of 32 pages Remedy Troubleshooting Eliminating Errors If the metering continues to operate incorrectly switch off the pump set the stroke length to 100 and execute the bleed procedure at a stroke length of 100 Close the bleed valve 5 by turning once clockwise Bleed the liquid end Switch off the pump Remove pressure from the discharge line by removing the hose on the injection valve or relieving the relief valve Switch the pump on again and allow it to operate so long until metering takes place for every discharge stroke If the metering continues to operate incorrectly switch off the pump set the stroke length to 100 and execute the bleed procedure at a stroke length of 100 Stop the pump and connec
19. max 2 or 3mm The stroke length adjustment can be made using a locking bar 9 in 10 steps from 100 to 0 The diaphragm deflection always takes place from the neutral centre position this results in a soft sinus shaped stroke curve The metering pumps can be retrofitted to suit customers needs options alpha metering pumps are available with a Euro motor 230 V 50 Hz and a multiple range motor 100 120 V and 200 240 V at 50 60 Hz Version 1 0 The enclosure The power end Thermal safety device Version 1 0 The liquid end Pump diaphragm Functions 2 2 The pump components The enclosure consists of PPE with 20 glass fibre Protection against foreign bodies gt 12 mm dia and spray water at an angle up to 60 The single phase split pole motor drives an eccentric through the gear The eccentric is guided in an eccentric plate which is directly connected with the connecting rod and pump diaphragm Thus the suction and discharge strokes are force guided without a recuperating spring for the suction stroke The feed process of the suction and discharge stroke is executed in batches in a sinus shaped stroke curve Duringthe discharge stroke the pump diaphragm displaces the medium in the liquid end by means of a head valve and the balls on the suction side close After the front end position is reached the diaphragm is led back to the initial position via the eccentric and the ball valve on the discharge
20. nt subsidiary or representative responsible for you will take back your old parts for a small fee addresses can be found at the back page 32 of these operating instructions 16 Cross section of the pump 5 5a 5b 14 15 16 8 17 18 j U ALPa 015 D This figure shows ALPa 0419PP1 000A0 Cover 6 Liquidend Mains connection Motor support 8 Bypasshose nozzle Intermediate disk Enclosure 9 Locking bar Pump diaphragm with steel Hoze nozzle 10 Eccentric plate with scale core and PTFE layer Gripper ring 10a Thrust piece spring loaded Thread rod Bleed valve with fine bleed screw 5a 11 Eccentric shaft Hexagon nut and star handle 5b 12 Motor Connecting rod Page 28 of 32 pages Version 1 0 Warranty Application Please copy and send in with the pump If the pump breaks down within the warranty period please clean the pump and send it back along with the fully completed warranty application v Please complete in full Warranty application for metering pumps top i e gp M Delivery date tenens Pump type identity Code emet tete rente ene nee Type of fault Mechanical fault Electrical fault Unusual wear Connections such as plugs or cables loose Parts subject to wear Operating elements e g switches Rupture other damage Contr
21. o diaphragm and intermediate disk with screws 6a and tighten Screws crosswise ATTENTION t is essential that the torques of 4 5 to 5 Nm are observed for the screws Twist the hexagon nut 17 against the connecting rod 18 and tighten lightly e Set the stroke length desired Slot in the locking bar 9 Replace the cover 1 Bleed the pump in accordance with chapter 11 2 or 11 3 Commissioning pages 16 or 17 PLEASE NOTE The torque of the liquid end screws is to be checked after 24 hours operation For PP pumps the torques are to be checked additionally every quarter of a year 13 1 6 Exchanging the complete liquid end PLEASE NOTE Complete liquid ends are delivered with the bleed valve open After priming and bleeding the tine bleed screw 5a and the bleed valve 5 must be retightened Check that the suction and discharge valves fit firmly Version 1 0 Page 25 of 32 pages Page 26 of 32 pages Hemedy Troubleshooting Eliminating Errors 13 2 Errors which require customer service assistance DANGER IN Electrical repairs may only be carried out by trained electricians safety regulations of the employers insurance associations VBG 4 and ZH 1 11 DANGER Before opening the pump pull out the mains plug or cut off the power supply Check that the pump is voltage free During the repair work ensure the power cannot be switched on again by unauthorised persons WARNING Meterin
22. ol Corrosion Damage during transport Leakage No or poor capacity Connections Diaphragm defective Liquid end Other aape aaan Application conditions of ProMinent pumps Location system description Pump accessories used Commissioning date Running time approx Operating NOUrS essasi ikidai E N EEEa pcr A E NEENU NECESE Please specify set up data and enclose sketch of the system Version 1 0 Page 29 of 32 pages Installation Data Customer Project no Date O Sketch enclosed Metering pump Type Capacity Vh Stroking rate s min Stroke length Valve spring pressure suction side bar Valve spring pressure discharge side bar Medium Designation concentration 96 Share of solids size of particle 9e mm Material solid hardness Mohs Dynamic viscosity mPas cP Density kg m3 Vapour pressure at operating temp bar C System suction side Pressure in suction tank Nominal width suction line DN mm Suction lift min max m Weir height min max m Length suction line m Number of angles valves Accumulator o Bubble tank Itr Accumulator Itr System discharge side Static system pressure min max bar Nominal width discharge line DN mm Length discharge line m Delivery head m Number angles valves Accumulator o Bubble tank Itr Accumulator Itr Page 30 of 32 pages Version 1
23. peration e g continuous operation The maintenance of the alpha metering pumps is limited to checking the liquid end screws fitting tightly 4 5 5 Nm the discharge lines fitting tightly the head and suction valves fitting tightly the bleed valve for the PP version fitting tightly the drain bore behind the liquid end side dampness can indicate a diaphragm rupture Version 1 0 Possible cause Remedy by pumps PP PE NE Version 1 0 Troubleshooting Eliminating Errors 13 13 1 gt Pe 13 1 1 Troubleshooting eliminating errors Errors you can eliminate yourself PLEASE NOTE n order to be able to rectify minor failures at any time we recommend that you always have a spare parts set available consisting of diaphragms valves balls and seals The order numbers for these can be found in our product catalogue under Spare parts kits for alpha DANGER Before opening the pump pull out the mains plug or switch off the power supply Check that the pump is voltage free WARNING Always first relieve the discharge line of pressure before working on the pump Always empty the liquid end and rinse it out Observe the safety data sheets of the metering fluids WARNING Metering pumps and their peripheral equipment may only be serviced by trained and authorised personnel WARNING If hazardous or unknown metering media are used always firstempty out the liquid end and rinse
24. pumps can for a short time in certain circumstances operate against excessively high operating pressure without the electrical safety devices responding e g for closed or blocked discharge line As an overload protection a safety relief valve with backfeed into the chemical tank is to be provided Setting the capacity ATTENTION Settings to the stroke length may only be made when the pump s switched off e Read off the capacity required from the diagram Capacity in relation to the stroke length of the counter pressure SUCTION DISCHARGE z Q o 5 D DISCHARGE STROKE LENGTH 100 DISCHARGE STROKE L SUCTION STROKE STROKE LENGTH 100 DISCHARGE STROKE SUCTION STROKE ALPa 014 GB Page 17 of 32 pages Page 18 of 32 pages Operation Maintenance Stop the pump Remove the cover 1 A Push back the locking bar 9 to the eccentric plate B Set the eccentric plate 10 to the stroke length desired in 96 arrow head of the locking bar must point precisely to the graduation mark desired ofthe eccentric plate the capacity can be set in 10 steps between 100 to 10 C Slot in the locking bar again ALPb 008 1 D Replace cover 1 12 Maintenance WARNING Metering pumps and their peripheral equipment may only be serviced by trained and authorised personnel PLEASE NOTE Service intervals every quarter of a year Shorter intervals for heavy duty o
25. s Page 1 ntroductiOn eoe e EEE 4 2 FUDCIlIOnS metre titre eter etes 4 3 Technical d ta retten 6 4 Installation dimensions em 7 5 2AGCOSSOTIOS ect ce Directe eee toes ite en ede eee 7 6 SAFETY INSTRUCTIONS rar Donat desine een 8 T Order specifications rettet 9 8 Unpacking inci oii rennes 10 9 Installation ter nter 11 10 Commissioning nett t et steer enteens 14 11 Operation crane tenetis 17 12 MAINA CS senars eire tes eene tette te 18 13 Troubleshooting eliminating errors 19 14 Repair 27 15 Bisposal of old parte nine nreeet 28 16 Cross section of pump s eerte edem re 28 Imprint Operating Instructions alpha ALP b metering Pump ProMinent Dosiertechnik GmbH 1993 ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 11 D 69123 Heidelberg Germany P O Box 101760 D 69007 Heidelberg Germany info prominent de www prominent de Subject to alterations Techn documentation Bartha Docu Media GmbH D 64629 Bensheim Issue 1 02 version 1 0 Printed in Germany Page 3 of 32 pages Page 4 of 32 pages Introduction Functions 1 Introduction ProMinent alpha are motor driven metering pumps diaphragm type for continuous or non continuous metering of fluids Correct use The pump must be used for liquids only Thepump may be used only in compliance with the technical data and specif
26. t h x density d max suction lift in mWC Version 1 0 Page 11 of 32 pages Liquid end with bleed valve Page 12 of 32 pages Installation e f the suction discharge connection is closed with a plug please remove this Shorten the hose to the necessary length with a straight cut Pullthe union nut and gripper ring over the hose line e Push the shortened hose end over the nozzle until it stops f necessary widen the hose end a little e f attached several times shorten the hose end by approx 10 mm with a straight cut PLEASE NOTE Only use the gripper rings and hose nozzles for the respective hose diameter as well as original hoses with specified hose dimensions and wall thickness If this is not observed the stability of the connection is not guaranteed Avord reducing the hose sizes For long lines and viscous media the next highest line diameter 12 9 should be used Press on the hose and simultaneously tighten the union nut PLEASE NOTE You obtain a rigid pump connection If you pull briefly on the line connected to the liquid end and subsequently tighten the union nut again until hand tight retighten Assemble foot valve Forthis purpose shorten the free end of the suction line to such an extent that the foot valve is just hanging slightly above the bottom of the tank Formetering solutions with impurities or feculency shorten the free suction line end so far that the foot valve is hanging at leas
27. t 50 mm above the floor of the tank 9 1 3 Installation ofthe bypass hose line only for PP1 PP2 PP3 NP3 version For liquid end PP1 PP2 PPS NP3 versions a bleed valve 5 with bypass 8 is present on the liquid end e Plug the hose line with an internal diameter of 4 5 mm preferably soft PVC 6 x 4 mm onto the bypass hose nozzle and secure with a pipe clamp or fast action clamp e Lead the free end of the line back into the metering tank e Connect the discharge line directly to the discharge connection and injection valve Version 1 0 Version 1 0 Power arain Installation ALPa 009 1 D Open the bleed valve 5 by turning it one turn anticlockwise Nowthe path is open for the coarse suction bleeding using the bleed valve 9 2 1 A A PLEASE NOTE For med a which easily emit vapours the fne bleeding can be switched on continuously As a resulta partal How of the metering quantity is constantly fed back into the supply tank The feedback quantity should be approx 20 of the metering quantity PLEASE NOTE f the backfeed line ends above the fluid level the fine bleeding valve operates as a vacuum breaker and prevents the supply tank from being sucked empty if vacuum leaks out in the discharge line Installation pump electrical part Electrical connection WARNING Only connect the pump to the mains supply with the corresponding mains cable and plug Observe VDE 0165 abroad th
28. t the discharge line to the injection valve again or reload the relief valve The fine bleeding connected is not working as the bleeding bore is blocked Remove the star handle 5b from the bleed valve 5 Open the fine bleed screw 5a with the pump operating by about two turns anti clockwise until the blockage is rinsed clear If this is not successful with the pump switched off unscrew the bleed valve 5 with the fine bleed screw 5a from the liquid end 6 and clean all parts including the bores Following this screw in the bleed valve with the fine bleed screw in reverse order again and reset the original setting 13 1 2 Pump does not prime in spite of full stroke movement and bleeding Crystalline deposits due to dryed out valves Remove suction hose from the supply tank and rinse the liquid end well Possibly decrease the suction lift or with the suction hose filled support the initial priming by means of inlet operation If the pump is idle the media can also be sucked in by means of a disposable syringe applied to the head valve If no improvement occurs the valves should be disassembled and cleaned The valve set in the suction and discharge valve can be pushed out with a 3 mm mandrel Version 1 0 Version 1 0 Possible cause Remedy Possible cause Remedy Possible cause Remedy Troubleshooting Eliminating Errors 13 1 3 Pump switches off automatically during metering Due to too hi
29. the fastening screws 6a and completely remove the liquid end 6 from the motor support 2 For PP version Additionally remove the start handle 5a and the panel from the liquid end 6 ALPb 012 D Version 1 0 Page 23 of 32 pages Troubleshooting Eliminating Errors Loosen the hexagon nut arrow in front of the connecting rod with a size 8 spanner approx 1 turn ALPb 011 D Remove the pump diaphragm 15 with intermediate disk 14 and threaded rod 16 from the motor support 2 by turning to the left S ALPb 013 D Unscrew the thread rod 16 from the diaphragm 15 if necessary hold the thread rod with some pliers and remove the diaphragm by turning to the left e Screw the thread rod 16 into a new diaphragm and twist in with the pliers so far that it fits tightly in the diaphragm ATTENTION No gap may be visible between the diaphragm and the bearing surface of the thread rod Page 24 of 32 pages Version 1 0 Troubleshooting Eliminating Errors e Screwonthe hexagon nut 17 until the stop onto the thread rod 16 Insert a new diaphragm with thread rod into the intermediate disk 14 and screw on the entire assembly onto the connecting rod 18 until the stop The stroke length must be set to 0 Turn back the diaphragm so far that the 4 bores of the diaphragm and intermediate disk match precisely Place liquid end 6 suction connection must point downwards ont
30. tity code specified under Type on the type identification plate in the grey entry field below ALPb Viton is a registered trademark of DuPont Dow Elastomers range alpha version b 1001 1002 1003 0804 0808 0612 0419 Pump type capacity at 50 Hz capacity at 60 Hz 1 2 I h 10 0 bar 1 4 I h 10 0 bar 2 4 I h 10 0 bar 2 9 I h 10 0 bar 3 5 I h 10 0 bar 4 2 I h 10 0 bar 4 0Vh 7 5 bar 5 0V h 7 5 bar 8 0 h 7 5 bar 9 5V h 7 5 bar 12 0Vh 5 5 bar 14 0 I h 5 5 bar 18 5 Vh 4 0 bar 21 5 l h 4 0 bar PP1 PP2 PP3 NP3 NP6 Liquid end material Polypropylene EPDM with bleed valve Polypropylene FPM A Viton A with bleed valve Polypropylene FPM B Viton B with bleed valve Acrylic PVC FPM B Viton B with bleed valve Acrylic PVC FPM Viton without bleed valve A B C D Ancillary equipment no ancillary equipment Y M v A v v Valve springs 0 no valve springs 1 with 2 valve springs approx 0 1 bar stainless steel 1 4571 Hydraulic Connectors 0 standard Version 0 with ProMinent logo Electrical connectors 230 V 50 60 Hz 2 m Euro plug 230 V 50 60 Hz 2 m Swiss plug 230 V 50 60 Hz 2 m Austral plug 115 V 50 60 Hz 2 m USA plug with foot and dosing valve as 1 additional 2 m PVC and 3 m PE hose as 2 additional 100 PE tank 4 an Page 2 of 32 pages Version 1 0 Version 1 0 Content
31. y takes place f a correctly and completely filled in certificate confirming the quality as being recognised as safe can be submitted by authorised and qualified specialists of the pump operator f n spite of emptying and cleaning the pump carefully safety measures are necessary the necessary Information must be listed in the certificate confirming the pump is recognised as being safe The certificate confirming the pump s recognised as being safe s a part of the inspectior repair contract There is a standard form at the end of these operating instructions for this purpose We reserve the right not to accept the contract due to other reasons Pumps which were operated with materials with a radioactive load are not accepted as a general rule Page 27 of 32 pages Disposal of Old Parts Pump Cross Section 15 Disposal of old parts WARNING Never throw metering pumps in the bin domestic refuse Plastic and mechanical parts are special waste and must be recycled Ab g AbfRestberwV Waste old parts is to be disposed of in an orderly manner for the common good especially the protection of the environment Therefore old parts have to be disposed of in accordance with the German Waste Avoidance and Waste Management Act Abfg or recycled in accordance with the German Waste and Residual Materials Monitoring Act AbfRestberwV Taking back old parts If you should not find any appropriate collection point the ProMine
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