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Solenoid Metering Pump gamma/ L, GALa Operating instructions

1. Continuous display sors Fig 30 The pump can also be operated in the calibrated state In this case the corresponding continuous displays then indicate the metering volume or the capacity directly The calibration is maintained when the stroke length is altered by up to 10 scale divisions for a set stroke length of 40 this corresponds to a range from 30 50 96 If the stroke length is changed by more than 10 scale divisions the yellow warning light illuminates the continuous display flashes and the flashing identifier Ca ib appears Do not allow the stroke length to fall below 30 SEK type 50 Otherwise the calibration becomes very inaccurate The calibration becomes more accurate the more strokes the pump makes during calibration Recommen dation at least 200 strokes Calibration CAUTION Danger with dangerous feed chemicals Provided the following handling instructions are followed contact with the feed chemical is possible If the feed chemical is dangerous take appropriate safety precautions when carrying out the following han dling instructions Observe the feed chemical safety data sheet 1 Lead the suction hose into a measuring cylinder containing the feed chemical the discharge hose must be installed in a permanent manner operating pressure 2 Prime the feed chemical press both arrow keys simultaneously should the suction hose be empty
2. ates 38 Maintenance eie qtue oto ee 51 D Manual aan 19 21 38 Decommissioning sse 62 MA O em 31 Degree of protection usersnneeessnnnneennnnnnnnnnen nn 67 Material specifications eee 66 delete ar n om d se bte tubus 43 47 Memo yew ui se e e eii 43 Deleting the total number of strokes or total litres 47 Metering pumps with bleed valve 26 Discharge valve ann nee 28 Metering pumps without self bleeding 24 74 ProMinent Metering pumps with self bleeding 27 Minimum Stroke Length nenn 65 MODE Menu 19 37 O Operating indicator rererere 17 21 Operating mode sssssssssssse 38 41 43 Operating modes sss 19 21 Operating mode selection sssssssssss 37 Operating mode settings eeen 38 Options ett einer de eit cede o eee 19 Output relay 24 inem med RE 21 Overview of equipment ssssssssssse 16 P Pacing relay ice a 21 33 Parallel connection eene 30 Ini TS RR een ERE 20 21 31 Performance data uunnuesersnnneensnnnnnnnnnnnnnnnn ernennen 64 Power consumption 242440snnnnnnnnnennnnnnnnnnnnennnn nn 66 PRESS MENU 2 ers tee cte cises Dd 45 Press re ratings He en 45 Primingzii eene een a 20 21 P
3. 43 E Contact operating mode settings 41 Electrical data essen 66 External control terminal 31 Eirnergeney iie sheet en 12 Manual operating mode settings 38 Emptying the liquid end eene 62 1 2 3 Explanation of the safety information 9 Ah x20 m ecce obstet ob va teca ten n fonde ev 38 External contacten nenna 21 31 32 A External frequency Changeover 21 ACCUPACY C 65 F Adjustirient rece eve a heist eh need 35 EaCIOE icd e ee dh the eats pits 41 Adjustment mode esee 36 g EE 21 Afialog a Ee dea ete cette c e tan ERE 19 32 38 Fault indicating relay 21 33 Analog output eee 31 Fault indicator 17 21 Anti kink device ni ita eiie iae aiis 28 Fault processing miresi t a a atiesa tele 41 Assembly niit tite tp eiat ei 22 F ult statuses 4 2 20 2 eet other 21 Auxiliary frequency 20 31 32 46 lg m 20 Auxiliary rate pecu ee Ri 21 FLOW Men an ae kt 46 AUX MENU teen neuen 46 F riction i eee e ve eve ee veg 44 45 46 B Eunetion display 5 2 eni e a ei 21 Basic principles of pump adjustment 35 F nctioris 5 nenn en 19 21 43 Batch cs 20 43 H Bleeding es ENT 26 27 Hierarchy of operating Modes 21 Bleed valve tte ten t eh ege edo 28 BUS ara ten edes 20 Identity code 5 ee rs 6 C Inc
4. 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 14 1 Faults without a fault alert Faults without a fault alert Fault description Cause Remedy Personnel Pump does not prime in spite Minor crystalline deposits on Take suction hose out of the Technical per of full stroke motion and the ball seat due to the valves storage tank and thoroughly flush sonnel bleeding drying out out the liquid end Major crystalline deposits on Dismantle the valves and clean Technical per the ball seat due to the valves them refer to Repair sonnel drying out Fluid is escaping from the The screws in the dosing head Tighten the screws in the dosing Instructed per backplate are too loose head crosswise refer to Repair sonnel for tightening torque The metering diaphragm is not Replace the metering diaphragm Technical per tight refer to Repair sonnel Green LED display oper The wrong mains voltage orno The specified mains voltage can Electrician ating display does not light mains voltage is connected be found on the nameplate up 14 2 Faults with error message 14 2 1 Fault alerts Fault description Cause Remedy The red LED indicator illuminates on the dis The fluid level in the storage tank Fill storage tank play the identifiers Error and MINIM flash has reached liqui
5. appears on the LCD screen You can enter any stroke rate behaviour of the pump proportional to the current signal For this pur pose enter any two points P1 I1 F1 and P2 I2 F2 F1 is the stroke rate at which the pump is to operate at current 11 this defines a straight line and thus the behaviour is specified 39 Adjustment Upper lower sideband 40 Fmax P2 F2 P1 Fit gt 0 11 12 20 mA B0088 Fig 25 F1 Stroke rate at which the pump should operate with current 11 F2 Stroke rate at which the pump should operate with current I2 Plot a diagram similar to the one above with values for 11 F1 and 12 F2 so that you can set the pump control as required Using these processing types you can control a metering pump using the current signal as shown in the diagrams below Lower sideband The symbol __ appears on the LCD screen Below 11 the pump works at a rate of F1 above I2 it stops Between 11 and I2 the stroke rate varies between F1 and F2 in proportion to the signal current a b Fmax Fmax SE F2 Fe F2 P1 Fit N N gt t t gt 0 11 12 20 I mA 0 E 12 20 I ma B0089 Fig 26 Lower sideband e g alkali pump Upper sideband The symbol appears on the LCD screen Below 11 the pump is sta tionary above I2 the pump works at rate F2 Between 11 and I2 the stroke rate varies between F1 and F2 in propor
6. 11 13 12 P_G 0006 SW Fig 4 5 2 1 Key functions Key Application STOP STOP Pressed briefly START P Pressed briefly Pressed for 2 s Pressed for 3 s Pressed for 10 s Pressed for 15 s B0098 i Pressed 1x Pressed 2x oo UP DOWN Individually pressed until Se identifier appears Pressed simultaneously ProMinent Overview of equipment and control elements LCD screen Stroke length adjustment knob UP key P key DOWN key STOP START key i key Fault indicator red Warning indicator yellow 10 Operating indicator green 11 Dosing monitor terminal 12 External control terminal 13 Level Switch terminal OONDOABRWNDN In continuous displays operation Stop pump start pump Start batch only in Batch operating mode acknowledge fault Change to adjustment mode Display software version Load factory settings calibration Change between the continuous dis plays Change directly changeable variables Priming in Stroke rate continuous display In adjustment mode set up Stop pump start pump Confirm entry jump to next menu point or to continuous display Jump to continuous display Change between Changing indi vidual numbers and Changing a number Under change individual digits jump to the first number Select another setting change individual number or number 17 Overview of equipm
7. 2 and 3 Refer to the functional description for the hierarchy of func tions and operating modes The pump does not work if W the cable is connected and pin 1 and pin 4 are open The pump works if the cable is connected and pin 1 and pin 4 are connected no cable is connected 31 Installation electrical External contact operating mode Analog operating mode Auxiliary frequency operating mode 9 2 2 Level Switch terminal Nee 1 2 P BE 0016 SW Fig 11 Pump pin assignments 3 P_BE_0017_SW Fig 12 Cable conductor assignments 9 2 3 Dosing monitor terminal 2 1 3 NV 3 4 P DE 0009 SW Fig 13 Pump pin assignments 32 The pump performs one or more strokes if Wm Pin 2 and pin 4 are connected to each other for at least 20 ms At the same time pin 1 and pin 4 must also be connected to each other The pump stroke rate can be controlled by a current signal The current signal is connected between pin 3 and pin 4 In addition pin 1 and pin 4 must also be connected The pump works at a pre set stroke rate if Pin5 and pin 4 are connected to each other At the same time pin 1 and pin 4 must also be connected to each other The auxiliary fre quency is factory preset to the maximum stroke rate There is a connecting option for a 2 stage level switch with pre warning
8. 6 but only loosen Hold the pump housing 6 with one hand and clamp the diaphragm 3 with the other hand between the dosing head 2 and the back plate 4 Loosen the diaphragm 3 from the drive axle with a gentle back wards turn of the dosing head 2 diaphragm 3 and backplate 4 in an anticlockwise direction Unscrew the diaphragm 3 completely from the drive axle Remove the backplate 4 from the pump housing 6 Check the condition of the safety diaphragm 5 and replace if nec essary Push the safety diaphragm 5 onto the drive axle only until it lies flush with the pump housing 6 and no further Tentatively screw the new diaphragm 3 onto the drive axle until its stop position c The diaphragm 3 is now sitting at the stop of the thread Should this not work remove dirt or swarf out of the threads and screw the diaphragm 3 onto the drive axle correctly this time The diaphragm must be screwed exactly onto the drive axle otherwise the pump will subsequently not meter correctly 55 Repairs 10 11 12 13 14 15 16 17 Tightening torque Data Tightening torque for screws 56 Unscrew the diaphragm 3 again Place the backplate 4 onto the pump housing 6 A CAUTION Leakage may become apparent at a later stage The leakage hole must point downwards when the pump is installed later please refer to amp on page 5A Place the backplate 4 immediately int
9. Control option 19 Functional description Functions Relay option 20 Batch operating mode This operating mode provides the option of working with large transfer factors up to 65535 The metering can be trig gered either by pressing the P key or by a pulse received via the External control terminal or through a contact or a semiconductor Switching element It is possible to pre select a metering quantity batch or a number of strokes via the control unit BUS operating mode Identity code control variant CANopen or PRO FIBUS This operating mode provides the option of controlling the pump via a BUS see Supplementary instructions for ProMinent amp gamma L and ProMinent Sigma versions with PROFIBUS The following functions can be selected using the SET menu Calibrate function Identity code stroke length adjustment Manual calibration The pump can also be operated in the calibrated state in all operating modes In this case the corresponding continuous displays can then indicate the metering volume or the capacity directly Calibration is maintained within a stroke rate range of 0 180 strokes min The calibra tion is also maintained when the stroke length is altered by up to 10 96 scale divisions Auxiliary frequency function Enables a freely selectable and program mable stroke rate to be switched on in the SE7 menu which can be con trolled via the External Control terminal Th
10. FLOW menu Continuous display m Fig 32 The FLOW menu only appears if a dosing monitor is connected to the Dosing monitor terminal The metering monitor records the individual metering strokes of the pump at the discharge connector and reports them back to the pump control If this feedback is sequentially missing for as often as set in the FLOW menu after a fault or too low metering the pump is stopped 10 7 Setting the code CODE menu 46 In the CODE menu you can enter whether you want to block parts of the adjustment options oo oo Pane rane T cuss i LIE LLILLI e TIE Continuous display B0096 Fig 33 ProMinent Adjustment In the first menu option you can set either CODE 1 or CODE 2 both use the same number m Select CODE 7 to block adjustment mode in Operating adjust ment overview in the appendix In the next menu option enter the number you want to use as the code Select CODE 2 to block the option to adjust the directly changeable values in the continuous displays in Operating adjustment over view in the appendix In the next menu option enter the number you want to use as the code W Select NONE to clear a set security lock 10 8 Deleting the total number of strokes or total litres CLEAR window ProMinent Continuous display
11. Fig 34 In the CLEAR window you can delete the stored total number of strokes and simultaneously the total litres reset to 0 To do this quit the Window by quickly pressing the P key The values have been counted since pump commissioning or since they were last deleted 47 Operation 11 Operation 11 1 Manual operation Adjusting the stroke length Stopping starting the pump Starting batch Loading factory settings Changing to adjustment mode Checking adjustable values Changing directly changeable variables 48 This chapter describes all the operating options available to you if the pump control is showing a continuous display then the display does not contain the symbol for the P key A For supplementary information please read the over views Control elements and key functions and see the Operating setting diagram at the end of the operating Eme instructions A Also take note of the overview Continuous displays It shows which continuous displays are available in which operating mode and which variables are directly change able in the relevant continuous display The stroke length can be continuously adjusted using the stroke length adjustment knob in the range 0 100 The recommended stroke length range in which the set metering quantity can from a technical point of view be accurately reproduced is 30 100 or for the SEK type 50 100 The followi
12. Hazardous or extremely aggressive feed chemicals can leak out in the event that the metering pump is removed from the installation Shut off valves must be installed on the metering pump s pressure and discharge sides CAUTION Uncontrolled flowing feed chemicals Feed chemicals can leak through a stopped metering pump in the event of back pressure For this purpose use an injection valve or vacuum breaker ProMinent Install hose lines design PP NP PV TT ProMinent Installation hydraulic CAUTION Uncontrolled flowing feed chemicals Feed chemicals can leak through the metering pump in an uncontrolled manner in the event of excessive priming pres sure The maximum priming pressure for the metering pump may not be exceeded please refer to the product spe cific operating instructions The pipes are to be aligned in such a way as the metering pump and the liquid end can be removed from the side if necessary Cut off the ends of the hoses at right angles Pull the union nut 2 and clamp ring 3 over the tube 1 see figure Fig 6 Push the tube end 1 up to the stop over the nozzle 4 Widen it if necessary Ensure that the O ring and flat seal 5 is properly fitted to the valve 6 Used PTFE seals may never be re used An installa tion sealed in this way will not be watertight ct The reason for this is that this type of seal is perma nently distorted when subjected to pr
13. The hydraulic parts of the gamma L are identical to those of the Beta ProMinent 3 Safety chapter Explanation of the safety information Warning signs denoting different types of danger Correct and proper use ProMinent Safety chapter The following signal words are used in these operating instructions to identify different severities of a hazard Signal word Meaning WARNING Denotes a possibly hazardous 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 hazardous 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 automatic start up Warning high voltage Warning danger zone bb The pump may only be used to meter liquid metering chemicals 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 Observe the general limitations with regard to viscosity limits chem ical resistance and density see also ProMinent resistance list in the equipment catalogue or under www prominent com Any other uses or modifications are prohibited The pump is not intended for
14. and limit stop Electrical interface Data Value Unit Voltage with open contacts SW Input resistance 10 kQ Control via potential free connection contact load 0 5 mA at 5 V or m Semiconductor switch residual voltage 0 7 V Pin Function 3 conductor cable 1 Earth GND black 2 Minimum pre warning blue 3 Minimum limit stop brown There is a connecting option for a dosing monitor Electrical interface Data Value Unit Voltage with open contacts SW Input resistance 10 kQ Control via potential free connection contact load 0 5 mA at 5 V or ProMinent Installation electrical 4 3 P_DE_0010_SW Fig 14 Cable conductor assignments 9 2 4 Relay Pin Function 4 conductor cable 1 Power supply 5 V brown 2 Coding white 3 Feedback blue 4 Earth GND black 9 2 4 1 Fault indicating relay output identity code 1 3 or 4 5 P SI 0010 SW Fig 15 Pump pin assignments Identity code 1 3or4 5 Ci ch CT P SI 0043 Fig 16 Cable conductor assignments A fault indicating relay can optionally be ordered It switches in the event of a fault An identity code pre warns whether the relay closes or opens in the event of a fault If the fault indicating relay is retrofitted it closes by default in the event of a fault The relay board is fully functional once plugged in The pump is factory progr
15. 2 m open end Relay 0 1 3 4 5 No relay fault indicating relay NC change over relay fault indicating relay NO change over relay as 1 pacing relay per 1x ON as 3 pacing relay per 1x ON Accessories 0 No accessories 1 with foot and injection valve 2 m PVC suction line 5 m PE metering line only for PP PC and NP 2 as 0 calibration cylinder 3 as 1 calibration cylinder Control versions 0 Manual external 1 1 1 Manual external with pulse control 2 Manual external 1 1 analog current 3 Manual external with pulse control analog current 4 as 0 timer 5 as 3 timer P as 3 PROFIBUS Access code 0 no access code 1 with access code Dosing monitor 0 Input for pulses 1 Input for continuous contact Pause level 0 Pause N C level N C About this pump 2 About this pump Pumps in the ProMinent gamma L product range are microprocessor con trolled solenoid metering pumps with the following characteristics The capacity can be displayed in I h or gal h respectively in a cali brated state or in strokes min The stroke length is infinitely adjustable and is shown in the LCD dis play The stroke rate can be set digitally precisely and is shown in the LCD display The rated pressure of the gamma L can be adapted by pressure rat ings to a system Two pumps can be actuated differently by means of the same standard signal Large illuminated LCD display
16. E egg 0 i HN P G 0007 SW 72 ProMinent Continuous displays 19 Continuous displays Continuous displays Continuous Operating mode Manual operating Operating mode Batch operating displ Analog 0 20 mA mode Contact with mode with memory Isplay memory and transfer factor 5 Stroke rate cc MM m E NL TOM Iu iB Bn o Capacity cn jen LI in KA o o Total number of sti Ae en e Aus 4 eem A o Total litres m ee metering quantity 12358 12358 External display er uS om EAL EAI cAI o Signal current dm E LLLI zs Remaining strokes ae Lt Ie Batch size E ME m Remaining litres LLLI ILC Factor RG ILL Stroke length EE o5 UE o cr H rr Or eor B0100 ez B0101 a B0102 Lu B0103 Identifier Mem only in the event that function OQ OQ values which can be changed directly in the extension Memory is activated using the UP or DOWN arrow keys ProMinent 73 Index 20 Index Disposal 3 nueces nit ae 63 Analog operating mode settings 38 Dosing monitor eet Re 32 46 Batch operating mode settings
17. There are electronic components in the pump which can have a toxic effect on the environment Separate the electronic components from the remaining parts Note the pertinent regulations currently applicable in your country 63 Technical data 16 gamma L operating at 180 strokes minute Technical data 16 1 Performance data and 100 96 stroke length Type gamma L 1000 1601 1602 1005 0708 0413 0220 1605 1008 0713 0420 0232 Minimum pump capacity at maximum back pressure bar 10 16 16 10 7 4 2 16 10 7 4 2 l h 0 74 1 1 2 1 4 4 7 1 12 3 19 0 4 1 6 8 11 0 17 1 32 0 ml stroke 0 069 0 10 0 190 0 41 0 66 1 14 1 76 0 38 0 63 1 02 1 58 2 96 gamma L Metering pumps with self bleeding dosing head SEK 1601 1602 1005 0708 0413 0220 1605 1008 0713 0420 64 16 16 10 7 4 2 16 10 0 59 1 40 3 6 6 60 10 8 16 2 3 3 6 3 10 5 15 6 0 055 0 13 0 33 0 61 1 0 1 5 0 31 0 58 0 97 1 44 Minimum pump capacity Con Suction Priming Max 3 nector lift lift imum at medium back pressure size priming a a inside bar l h ml mm m WS m WS bar stroke 5 0 0 82 0 076 6x4 6 0 1 8 8 8 0 1 40 0 13 6x4 6 0 2 0 8 8 0 2 5 0 24 6x4 6 0 2 5 5 5 5 0 5 0 0 46 8x5 5 0 3 0 3 3 5 8 4 0 78 8x5 4 0 2 0 2 2 0 14 2 1 31 8x5 3 0 2 5 1 5 1 0 20 9 1 94 12x9 2 0 2 0 1 8 0 4 9 0 45 8x5 40 3 0 3 5 0 8 3 0 76 8x5 3 0 3 0 2 3 5 13 1 1 21 8x5 3 0 3
18. U o u i i i Ole P Araog rin n n 1 FL LI ar og 11 X a Eie zd A bali G e Araog Araog C ngg Lun Pim w Fl 9 Ar mu L i z i m 2 Een C wo uL El r be 3j n n LL ilic g kE Analog LUNCE LENRUFIF z Bas ED MN LEN Uit P SI 0040 SW ProMinent 71 Operating adjustment overview a Contact ncc a ure rwTrT Ese EINE gr Contact AN LT a a Contact Contact Contact n n n UM Ih eu Contact Contact 5j j Bach n n 5 L Li Baten a BIB k 3 B Baten n frs uu Du Batch a ag a auch ir a 2 PEC T a LI gaorru se DICH auch nw x LEY gt a ace LI a HL a ror io Edi CHL I0 n j ia L AN L LI a Q 8 Q IT the gt E INI c Hs gt oori HERNE IJ a a xx n tm nB m N m a Lu Lu Li H H H i gt 7 7 nz 1 re og J m bef NS k 5 8 PEE 10 LI a Ern a a a sa Fou L AN mou
19. be felt Place the dosing head 2 with the screws 1 onto the diaphragm 3 and the backplate 4 the suction connector must be pointing downwards in the pumps subsequent fitting position Gently tighten the screws 1 and then tighten in a diagonal pattern Tightening torque see above With types with bleed valve Allow the cover of the liquid end to rest in the dosing head then press the bleed valve star handle into the dosing head CAUTION Leakage possible Check the tightening torque of the screws after 24 hours of operation With PP and PVDF dosing heads recheck the tightening torque again after three months P G 0009 SW Fig 37 Partially exploded view of liquid end 58 ProMinent Troubleshooting 14 Troubleshooting Safety notes WARNING Warning of hazardous or unknown feed chemical Should a hazardous or unknown feed chemical be used it may escape from the hydraulic components when working on the pump Take appropriate protective measures before working on the pump protective eyewear protective gloves Read the safety data sheet on the feed chemical Drain and flush the liquid end before working on the pump CAUTION Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due to pressure in the liquid end and adjacent parts of the system
20. changing of individual digits and changing a number b Changes the position within the number c jump back in the number More detailed explanations are given in the following text Incremental changing of a value Press the key once You can toggle between altering the digits of a value change individual digits standard and incremental changing of a value change a number ProMinent 35 Adjustment Changing adjustable values Confirming adjustable values Correcting incorrectly set digits Press the arrow keys UP or DOWN c The flashing digit or number counts up or down Under change individual digits confirm each digit by pressing the P key c Upon confirming the last individual digit the display simultane ously changes to the next menu option or into a continuous dis play Under change a number Press the P key 1x c The display simultaneously changes to the next menu option or into a continuous display Press the key 2x c You jump back to the first digit 10 2 Checking adjustable values Before you adjust the pump control you can check the actual settings of the adjustable values Press the key i for Info if the LCD screen shows a contin uous display The display does not contain the P key symbol c Each press of the key toggles the continuous display output to the screen to another continuous display The number of continuous displays depends on
21. for contact operation identity code control variant External 1 1 External with pulse control Wm Batch for batch operation identity code control variant External with pulse control ProMinent 37 Adjustment e anne ANALOG HUE P mn nr MANUAL T PLL Analog Marne D D gt HULE os m nnr CONTACT HLL a Batch mnnr BATCH HWW Continuous display B0085 Fig 22 10 5 Operating mode settings SET menu First in the MODE menu select the operating mode Exceptions Timer and PROFIBUS In the SET menu you can make various settings dependent on the selected operating mode Setting menus are available in all operating modes for the following pro grammable functions Calibrate CAL B menu Auxiliary rate AUX menu E Flow FLOW menu only available if a dosing monitor is connected see also the chapter Programmable function settings SET menu As to whether or not a further setting menu is available depends on the selected operating mode 10 5 4 Manual operating mode settings Other than those described in more detail in the chapter Programmable function settings SET menu there are no other setting menus available in Manual operating mode via the SET menu 10 5 2 Analog operating mode settings ANALG menu Overview Alongside those describ
22. of 0 180 strokes min Self bleeding liquid ends SEK types are capable of independent priming when a discharge line is connected and diverting existent air pockets via a bypass During operation they are also capable of conveying away gases which are produced independently of the operating pressure in the System It is also possible to dose precisely in a depressurised state due to the integral back pressure valve 6 5 Functional description of control 6 5 1 Operating modes functions options Operating modes ProMinent The operating modes are selected via the MODE menu dependent on the identity code some operating modes may not be present Analog operating mode Identity code control variant analog The stroke rate is controlled using an analog current signal via the External control terminal Processing of the current signal can be preselected via the control unit Manual operating mode The stroke rate is set manually via the control unit 100 96 corresponds to 180 strokes min Contact operating mode This operating mode provides the option of making fine adjustments using small scaling or transfer factors The metering can be triggered either by a pulse received via the External con trol terminal or through a contact or a semiconductor switching element A metering quantity batch or a number of strokes scaling or transfer factor 0 01 to 99 99 can be pre selected via the control unit using the Pulse
23. 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 Sole noid Metering Pumps 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 a fF WN gt 10 Identity code arena 6 About this p imp anre eh His es ens 8 Safety chaplter Rp eed te e eto eda 9 Storage transport and unpacking seseeesesssss 14 Overview of equipment and control elements 16 5 1 Overview of equipment ssssssssseeeeenenes 16 5 2 Contr
24. resistance of the material con tacted by the chemical when selecting the feed chemical refer to ProMinent resistance list in the equipment catalogue or under www prominent com CAUTION Warning of feed chemical spraying around Pumps which are not fully installed hydraulically can eject feed chemicals from the outlet openings of the discharge valves as soon as they are connected to the mains The pump must first be hydraulically installed and then electrically nthe event that you have failed to do so press the STOFP START button or press the emergency stop Switch 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 CAUTION Danger from rupturing hydraulic components Peak loads during the dosing stroke can cause the maximum permissible operating pressure of the system and pump to be exceeded The discharge lines are to be properly designed CAUTION Danger of personnel injury and material damage The use of untested third party parts can result in personnel injuries and material damage Only fit parts to metering pumps which have been tes
25. safety notes for metering pumps without bleed valves also apply Installation of the return line A return line is connected in addition to the suction and discharge lines 1 Fasten the tube line to the return line tube nozzle or to the liquid end bleed valve PVC tube soft 6x4 mm is recommended for this 2 Feed the free end of the return line back to the storage tank 26 ProMinent Installation hydraulic 3 Shorten the return line hose so that it cannot submerge into the feed chemical in the storage tank 8 1 3 Installation for metering pumps with self bleeding SEK type CAUTION pumps without self bleeding also apply Safety notes All of the installation and safety notes for metering The maximum values for priming lift priming pressure and the viscosity of the feed chemical may not be exceeded The suction end hose line cross section may not exceed the hose line cross section of the suction valve Information about priming pressure Installation of the return line The priming pressure on the suction end must be at least equal to the return line pressure Priming pressure n the return line restricts the bleeding function However operation with priming pressure in the return line and the suction end at atmospheric pressure is pos sible A return line is connected in addition to the suction and discharge lines The return line is connected to the vertical valve on the upper side of the liquid end
26. the identity code the selected operating mode and the connected additional devices see over view Continuous displays in the appendix 10 3 Changing to adjustment mode 36 1 In a continuous display press the P key for at least 2 seconds c The pump control changes to adjustment mode 2 If CODE 7 was set then after pressing the P key the code must first be entered The following menus can initially be chosen in adjustment mode see also Operating setting overview in the appendix MODE menu CODE menu option SET menu CLEAR window ProMinent Adjustment To match the pump to your process requirements you must observe the following procedure 1 In the MODE menu select the operating mode 2 If necessary make the settings for this operating mode in the SET menu MODE m menu CODE a menu 2s Continuous display 2 ray OG SET I menu CLEAR z I window B0084 Fig 21 Exceptions Timer and PROFIBUSS Note the diagram 10 4 Operating mode selection MODE menu In the MODE menu dependent on the identity code some operating modes may not be present m Manual for manual operation identity code control variant Manual available as standard m Analog for current control identity code control variant Analog cur rent m Contact
27. with IEC Publ 127 2 3 Data Storage and transport temperature Ambient temperature in operation drive and control Permissible medium temperature Value Unit 10 50 C 10 45 C 10 35 C ProMinent Liquid end short term Ma PP NP PV TT SS Te Technical data terial version Unit Temporary 50 C 100 C 45 C 60 C 45 C 120 C 50 C 120 C 50 C 120 C mp max for 15 min at max 2 bar dependent on the ambient and feed chemical temperatures 16 7 Climate Data Value Unit Maximum air humidity 95 rel humidity non condensing Exposure in a humid and alternating climate FW 16 8 Protection class and Safety Degree of protection Prot 24 according to DIN 50016 Requirements ection against contact and humidity IP 65 in accordance with IEC 529 EN 60529 DIN VDE 0470 Part 1 Safety requirements Deg ree of protection 1 mains power connection with protective earth conductor 16 9 Compatibility Some hydraulic parts of the gamma L are identical to those of the Beta product range There is substantial compatibility with the following components and accessories with pumps in the product ranges Beta CONCEPT gamma and ProMinent gamma Classic Signal cable gamma Vario 2 4 and 5 wire for the External function Level switch 2 stage gamma Vario Beta Metering line cross sections Standard gamma connector kit gamma wall bra
28. 0 1 5 2 0 19 1 1 77 12x9 3 0 3 0 1 1 0 36 2 3 35 12x9 2 0 2 0 0 8 8 0 0 78 0 072 6x4 1 8 1 8 0 5 8 0 1 74 0 16 6x4 2 1 2 1 0 5 5 0 4 0 0 37 8x5 2 7 2 7 0 5 3 5 7 50 0 69 8x5 2 0 2 0 0 5 2 0 12 6 1 17 8x5 2 5 2 5 0 5 1 0 18 0 1 67 12x9 2 0 2 0 0 5 8 0 3 8 0 35 8x5 3 0 3 0 0 5 5 0 7 5 0 69 8x5 3 0 3 0 0 5 3 5 12 3 1 14 8x5 2 5 2 5 0 5 2 0 17 4 1 61 12x9 2 5 2 5 0 5 Suction lift with a filled suction line and filled liquid end With self bleeding dosing head with air in the suction line Tm Priming lift with clean and moist valves Priming lift at 100 96 stroke length and free outlet or opened bleed valve TUS The given performance data constitutes guaranteed minimum values calculated using medium water at room temperature The bypass connection with a self bleeding dosing head is 6x4 mm The connector width is 6 mm on SST material versions ProMinent Technical data 16 2 Accuracy 16 2 1 Standard Liquid End Data Value Unit Capacity range of the series 5 10 Reproducibility 221 a at max stroke length and max operating pressure for all material versions at constant conditions and min 30 96 stroke length 16 2 2 Self Bleeding Liquid End As the self bleeding liquid end is used with outgassing media and when operating with air bubbles no dosing accuracy or reproducibility can be provided The recommended minimum stroke length with self bleeding dosing pumps is 50 96 16 3 Visc
29. It is labelled with a red sleeve from factory see Fig 8 The discharge line is connected to the vertical valve 1 Fasten the tube line to the return line tube nozzle or to the liquid end bleed valve PVC tube soft 6x4 mm is recommended for this Feed the free end of the return line back to the storage tank SEK only Insert the return line into the anti kink device on the bleed valve and screw it in place until the anti kink device engages The anti kink device prevents the return line form kinking thereby avoiding the risk of self bleeding system failure 4 Shorten the return line hose so that it cannot submerge into the feed chemical in the storage tank ProMinent 27 Installation hydraulic 28 gt P_MAZ_0023_SW Fig 8 SEK liquid end IAUN Anti kink device Bleed valve for the return line in the storage tank 6 4 mm Red sleeve Discharge valve for discharge line to injection point 6 4 12 9 mm Suction valve for suction line in storage tank 6 4 12 9 mm ProMinent 9 Installation electrical ProMinent A A A A Installation electrical WARNING Danger of electric shock A mains voltage may exist inside the device Before any work disconnect the device s mains cable from the mains WARNING Risk of electric shock This pump is supplied with a grounding conductor and a grounding type attachment plug Toreduce the risk of electric shock ensur
30. ProMinent Operating instructions Solenoid Metering Pump gamma L GALa EN iy P_G 0003 SW Two sets of operating instructions are required for the safe correct and proper operation of the metering pumps The product specific operating instructions and the General Operating Instructions for ProMinent Solenoid Metering Pumps 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 987604 Original Operating Instructions 2006 42 EC BA G 033 09 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 987612 1 en GB 1999 Supplementary information 2d 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 Instructions The following are highlighted separately in the document E Enumerated lists Instructions c Outcome of the instructions Information This
31. Record the level in the measuring cylinder and the stroke length Select the CAL B menu and press the P key to change to the first menu option 5 With an arrow key select ON and press the P key to change to the next menu option 6 To start the calibration press the P key The pump starts to pump and indicates the stroke rate at certain intervals S7OP appears The pump works with the stroke rate set under MANUAL T After a reasonable number of strokes stop the pump with the P key 8 Determine the required metering volume difference initial volume residual volume 9 Enter this amount under the next menu option and then press the P key to change to the next menu option 44 ProMinent 10 6 2 ProMinent 10 Unde Adjustment r menu option UNIT select the units Z or ga using the arrow keys and press the P key c The pump is calibrated Consequence W The corresponding continuous displays indicate the calibrated values Total number of strokes and total litres are set to 0 by calibrate The pump is in the STOP state Pressure ratings function settings PRESS menu err HOH ssec p 9 Dauer anzeige B0098 Using the Pressure ratings function you can reduce the rated pressure of the gamma L A A A CAUTION Select the pump rated pressure so it is as large as
32. Technical documents have been compiled by Documentation specialist Date Manufacturers signature Details of the signatory ProMinent Metering pump Gamma L product range 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 in accordance with Appendix I No 1 5 1 of the Machinery Directive 2006 42 EC EN ISO 12100 EN 809 EN 60335 1 EN 60335 2 41 EN 50106 EN 61000 3 3 EN 61000 4 2 3 4 5 6 11 EN 61000 6 1 2 3 4 Norbert Berger Im Schuhmachergewann 5 11 DE 69123 Heidelberg E x d LL P Sale s ZA TE 5 10 2011 K Joachim Schall Head of Development 69 EC Declaration of Conformity For low voltage pumps Original EC Declaration of Conformity for Machinery ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 11 DE 69123 Heidelberg hereby declare that the product 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 special
33. 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 Danger of damage to the device Take into account the information in the Storage Transport and Unpacking chapter if the system is decommissioned for a temporary period Personnel W Technical personnel 1 Disconnect the pump from the mains power supply 2 Empty the liquid end by turning the pump upside down and allowing the feed chemical to run out 3 Flush the liquid end with a suitable medium flush the dosing head thoroughly when using hazardous feed chemicals 62 ProMinent Disposal ProMinent Decommissioning 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 Personnel W Technical personnel CAUTION Environmental hazard due to electronic waste
34. ad The flow direction of the suction connector is the opposite of that of the discharge connector ProMinent Repairs 13 2 Replacing the metering diaphragm WARNING A few cubic centimetres of feed chemical may have accumu Liquid end types with the exception of 0220 0232 and 0420 ProMinent lated behind the metering diaphragm in the backplate fol lowing a leak depending on the design Take this feed chemical into consideration when you are planning a repair especially if it is hazardous Personnel Technical personnel If necessary take protective measures Observe the safety data sheet for the feed chemical Depressurise the system 1 Empty the liquid end turn the liquid end upside down and allow the feed chemical to run out flush out with a suitable medium flush the liquid end thoroughly when using hazardous feed chemicals 2 Turn the stroke adjustment dial until the stop at 0 stroke length if the pump is running the drive axle is then difficult to turn Switch off the pump Unscrew the hydraulic connectors on the discharge and suction side 5 With types with bleed valve Firstly remove the bleed valve star handle then lift off the cover of the liquid end with a screwdriver 6 Remove the screws 1 For pump types 0220 0232 and 0420 refer to the following page there are 4 holes on the diaphragm edge Loosen the dosing head 2 and the backplate 4 from the pump housing
35. age during the metering operation the resultant number of strokes precisely matches the factor ProMinent Memory function extension Adjustment You can also activate the Memory function extension identifier Mem appears on the LCD screen Mem memory When Memory is acti vated the pump software adds up the remaining strokes which could not be processed up to the maximum capacity of the stroke memory of 65 535 strokes If this maximum capacity is exceeded the pump goes into fault mode You can thus optimally match the pump to the process in question for example in conjunction with contact water meters 10 5 4 Batch operating mode settings BATCH menu Memory function extension Alongside those described in more detail in the chapter Programmable function settings SET menu the BATCH menu is also available in Batch operating mode via the SET menu oo 9 a 9 Om OR Or Continuous display Boss Fig 29 The operating mode Batch is a variant of the operating mode Contact in the first place see Contact operating mode settings Here also you can select a number of strokes no fractions only integers from 1 to 65535 but also a metering quantity Batch To change between the input Number of strokes and Metering quantity press the key 1x under the corresponding menu opti
36. agm 3 again Check whether the diaphragm holes align correctly with the pump housing If not start the pump and adjust the stroke length to 100 96 With the pump running slowly turn the diaphragm 3 in the clock wise direction until the 4 diaphragm holes align correctly with the pump housing 6 Clamp the diaphragm 3 in this position adjust the stroke length to 0 96 and stop the pump Unscrew the diaphragm 3 again 57 Repairs 16 17 18 19 20 21 22 Place the backplate 4 onto the pump housing 6 CAUTION Leakage may become apparent at a later stage The leakage hole must point downwards when the pump is installed later please refer to amp Liquid end types 0220 0232 and 0420 on page 57 Place the backplate 4 immediately into the cor rect position on the pump housing 6 Do not twist the backplate on the pump housing so that the safety diaphragm 5 becomes warped Only type 0232 Screw the backplate 4 on tightly using the screws Place the diaphragm 3 into the backplate 4 CAUTION A Leakage may become apparent at a later stage Do not over tighten the diaphragm 3 in the fol lowing step The backplate 4 must remain in its position so that the safety diaphragm does not become warped Hold the backplate 4 firmly and screw the diaphragm 3 in a clock wise direction until it is sitting tightly the twisting resistance of the return spring can
37. ammed to Fault indicating relay Should another switching function be required the pump can be reprogrammed in the Heidelberg works Electrical interface Data Value Unit Maximum contact load at 250 V and 50 60 2 A Hz Minimum mechanical lifespan 200 000 Switching operations To pin VDE cable Contact CSA cable 1 white NO normally open white 2 green NC normally closed red 4 brown C common black 9 2 4 2 Fault indicating and pacing relay output identity code 4 5 ProMinent A fault indicating and a pacing relay can optionally be ordered refer to ordering information The pacing output is electrically isolated by means of an optocoupler with a semiconductor switch The second switch is a relay as with the Fault indicating relay version The fault indicating pacing relay can be retrofitted The pump is factory programmed to Fault indicating relay opening and Pacing relay closing Should another switching function be required the pump can be reprogrammed in the Heidelberg works 33 Installation electrical P SI 0010 SW Fig 17 Pump pin assignments Identity code 4 5 BZ N 7 OT E Fig 18 Cable conductor assignments 34 P_SI_0044 Electrical interface for fault indicating relay output Data Maximum contact load at 24 V and 50 60 Hz Minimum mechanical lifespan for semiconductor switch pacing relay Data Max
38. ause Press P key bear in mind the consequences for your process Remedy The liquid level in the storage tank has reached liquid Fill storage tank The pump is calibrated and the stroke length varies by Reset the stroke length or more than 10 scale divisions from the value at the recalibrate the pump at the desired stroke length ProMinent 14 3 All Other Faults ProMinent Troubleshooting Please contact the responsible ProMinent branch or representative 61 Decommissioning 15 Decommissioning Decommissioning A A A 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 information 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 CAUTION
39. cket Chemical feed containers and fastening plates Overall height distance between the suction and discharge con nector Distance between the connectors and the pump fixing holes Identical use of accessories such as back pressure valves multifunc tional valves dosing monitor and flushing equipment 67 Technical data 16 10 Sound pressure level Sound pressure level Sound pressure level LpA 70 dB in accordance with EN ISO 20361 2010 10 at maximum stroke length maximum stroke rate maximum back pressure water 16 11 Shipping weight Shipping weight of gamma L types in kg Material Types 1000 1601 1602 1005 0708 0413 1605 1008 0713 0420 0232 0220 PP NP PV TT 2 9 3 1 4 5 5 5 SS 3 6 4 5 5 9 8 6 68 ProMinent 17 EC Declaration of Conformity EC Declaration of Conformity For mains voltage pumps Original EC Declaration of Conformity for Machinery ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 11 DE 69123 Heidelberg that the following designated product complies with the pertinent fundamental safety and health requirements of the EC Directive in terms of its design and construction and in terms of 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 Pertinent EC Directives Applied harmonised standards in particular
40. correctly con nected The dosing monitor reported more defective strokes than was set in the FLOW menu The temperature inside the pump housing is too high due to too high outside temperature The temperature inside the pump housing is too high due to too high pump power consumption Metering diaphragm is ruptured Error in connection with fan in pump housing Fault on the control Stroke memory overflow has occurred level low 1st stage Green LED indicator illuminates and the identifier Ca ib flashes time of the calibration 60 Remedy Clear the cause of the low control current Switch the programming of the fault behaviour to OFF see chapter Adjustment Operating mode settings SET menu Press the P key the memory content is deleted Set up the pump again Connect the dosing monitor cor rectly Press the P key Press the P key Investigate and clear the cause Ensure lower outside tempera tures Allow the pump to cool Press the P key reset function Check the installation change if necessary Allow the pump to cool Press the P key reset function Replace metering diaphragm according to chapter Repairs Check the fan replace if neces sary Press the P key reset function Disconnect the pump from the mains power supply then recon nect If the error message continues to appear send the pump to ProMi nent Eliminate c
41. d level low 2nd stage ProMinent 59 Troubleshooting Fault description The red LED indicator illuminates on the dis play the identifiers Error and ANALG flash The red LED indicator illuminates on the dis play the identifiers Error and CNTCT flash The red LED indicator illuminates on the dis play the identifiers Error and FLOW flash The red LED indicator illuminates on the dis play the identifiers Error and TEMPERATURE flash The red LED indicator illuminates on the dis play the identifiers Error and D APH flash The red LED indicator illuminates on the dis play the identifiers Error and FAN flash The red LED indicator illuminates on the dis play the identifiers Error and SYSTEM flash The red LED indicator illuminates on the dis play the identifiers Error and MEM flash 14 2 2 Warning Alerts Fault description Cause Green LED indicator illuminates Cause The pump control is in Analog operating mode a fault behaviour has been programmed in the ANALG menu and the control current has fallen below 3 8 mA Pump control is in the operating mode Contact or Batch and the function extension Memory has been set Also a very large factor was set too many contacts have been received or the key P has been pressed too often Con sequently a stroke memory over flow has occurred Dosing monitor not
42. divisions that is with a stroke length of 40 if this is set at less than 30 96 or at greater than 50 96 The pump is in the FLOW menu The pump is in the SET menu The number of strokes achieves is higher than the maximum figures of 99999 that can be dis played in the LCD screen The pump only shows the metering volume and the capacity in the calibrated state in or h or in gal or gal h ProMinent Functional description 6 Functional description 6 1 Liquid End 6 2 Drive Unit 6 3 Capacity 6 4 Self Bleeding The dosing process is performed as follows The diaphragm is pressed into the dosing head the pressure in the dosing head closes the suction valve and the feed chemical flows through the discharge valve out of the dosing head The diaphragm is now drawn out of the dosing head the dis charge valve closes due to the negative pressure in the dosing head and fresh feed chemical flows through the suction valve into the dosing head One cycle is completed The diaphragm is driven by an electromagnet which is controlled by an electronic controller The capacity is determined by the stroke length and the stroke rate The stroke length can be adjusted between 0 and 100 using the stroke length adjustment knob A metering volume of between 30 to 100 is reproduced as being technically sensible SEK type 50 100 96 The stroke rate can be set using the arrow keys not in Analog operating mode within a range
43. e drive unit Fault indicating and pacing relay option In addition to the fault indicating relay the pacing relay can be used to make a contact every stroke The relay can be retrofitted via a knock out in the drive unit 6 5 2 Function and fault indicator The operating and fault statuses are indicated by the three LED indicators and the Error identifier on the LCD screen see also the Trouble shooting chapter LCD screen If a fault occurs the identifier Error appears and an additional error mes sage LED displays Operating indicator green The operating indicator illuminates if during pump operation there are no incoming fault or warning messages It goes out briefly with every stroke Warning indicator yellow The warning indicator illuminates if the pump electronics detect a condition which may lead to a fault e g liquid level low 1st stage Fault indicator red The fault indicator illuminates if a fault occurs e g liquid level low 2nd stage 6 5 3 Hierarchy of operating modes functions and fault statuses The different operating modes functions and fault statuses have a dif ferent effect on if and how the pump reacts The following list shows the order 1 Priming 2 Fault Stop Pause 3 Auxiliary frequency external frequency changeover 4 Manual external contact Comments re 1 Priming can take place in any mode of the pump providing it is functioning re 2 Faul
44. e ee ae ea eed uo 74 5 Identity code 1 Identity code Product range gamma L GALa Type 1000 1601 1602 1005 0708 0413 0220 1605 1008 0713 0420 0232 Performance bar l h 10 0 74 16 1 1 16 2 1 10 4 4 7 7 1 4 12 3 2 19 0 16 4 1 10 6 8 7 11 0 4 17 1 2 32 0 Solenoid 70 M70 Solenoid 85 M85 Material version PPE PPB NPE NPB PVT TTT SST Polypropylene EPDM Polypropylene FPM Clear acrylic EPDM Clear acrylic FPM PVDF PTFE PTFE PTFE Stainless steel 1 4571 PTFE Dosing head version 0 1 2 3 4 9 without bleed valve without valve spring only for NP TT and SS without bleed valve with valve spring only for NP TT and SS with bleed valve without valve spring only for PP NP PV not for type 0232 with bleed valve with valve spring only for PP NP PV not for type 0232 without bleed valve with valve spring for more highly viscous media self bleeding only for PP and NP not for types 1000 and 0232 Hydraulic connector 0 Standard connector in line with technical data 5 Connector for 12 6 tube discharge side only 9 Connector for 10 4 tube discharge side only Design 0 with ProMinent logo Power supply U 100 230 V 10 96 50 60 Hz M 12 24 V DC M 70 only N 24 V DC M 85 only ProMinent Product range gamma L ProMinent 24 V AC Identity code Cable and plug A B C D ET 2 m European 2 m Swiss 2 m Australian 2mUSA
45. e that it is con nected only to a proper grounding type receptacle WARNING Risk of electric shock In the event of an electrical accident the pump must be quickly disconnected from the mains nstall an emergency cut off switch in the pump power supply line or Integrate the pump in the emergency cut off manage ment of the system and inform personnel of the isolating option WARNING Danger of electric shock Incompletely installed electrical options can allow moisture into the inside of the housing Knock out openings in the pump housing must be equipped with matching modules or be sealed in a leak tight manner 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 CAUTION Risk of short circuiting caused by moist pins No moisture must reach the pins of the PROFIBUS jack A suitable PROFIBUS plug or protective cap must be screwed onto the PROFIBUS jack 29 Installation electrical CAUTION Material damage possible due to power surges Should the pump be connected to the mains power supply in parallel to inductive consumers such as solenoid valves motors inductive power surges can damage the controller when it is switched off Provide the pump with its own contacts and supply with voltage
46. ed in more detail in the chapter Programmable function settings SET menu the ANALG menu is also available in Analog operating mode via the SET menu The stroke rate is controlled using an analog current signal via the External control terminal 38 ProMinent Line ProMinent Adjustment Analog _ mA Continuous display B0086 Fig 23 You can select three types of current signal processing E 0 20mA AtO0 mA the pump is stationary At 20 mA the pump works at the maximum stroke rate Between these values the stroke rate is proportional to the cur rent signal E 4 20mMA At4mA the pump is stationary At 20 mA the pump works at the maximum stroke rate Between these values the stroke rate is proportional to the cur rent signal Forcurrent signals less than 3 8 mA a fault message appears and the pump stops e g if a cable has broken Curve Under the Curve processing type you can freely program the pump behaviour There are three options Line Lower sideband __ Upper sideband __ Hs gt oo B PA En mw HO LEN UI Continuous display PUT Fig 24 The symbol
47. ege e OREL TR PD he gc Ede Pte do 53 13 1 Cleaning valves Ar er 53 13 2 Replacing the metering diaphragm ssssse 55 Troubleshooting 0u424002200000000nnnnnnnnnnnnnnnnnnnnnnnnnnn 59 14 1 Faults without a fault alert 59 14 2 Faults with error message eeem 59 14 2 1 Faultalerts neret ee ea 59 14 2 2 Warning Alerts 60 14 3 All Other Faults ssssseenenenen enne 61 Decommissioning ssesssssseeeeeeneneeene 62 Technical data anite rode retos 64 16 1 Performance data isnin nanena me 64 16 2 ACCURACY er dene mr e be rut 65 16 2 1 Standard Liquid End sss 65 16 2 2 Self Bleeding Liquid End sees 65 16 3 VISCOS ya ee teh Een nice tate e pb Bnet eet 65 16 4 Material specifications sse 66 16 5 Electrical datai ann ans eite 66 16 6 Temperatures eie eere ed reme 66 16 7 Climates 2 ate one BERNER 67 16 8 Protection class and Safety Requirements 67 16 9 Gompoatibilily 2 t tnter niet 67 16 10 Sound pressure level se 68 16 11 Shipping weights irei ieina a em 68 EC Declaration of Conformity eseee 69 Operating adjustment overview ee 71 Continuous displays sssssssseeeenee 73 IND OX ec una es ere Siet
48. ent and control elements 5 2 2 Stroke length adjustment knob The stroke length can be adjusted using the stroke length adjustment knob and with it the volume per stroke 5 2 3 Control elements Identifiers Familiarise yourself with the pump control elements using the Control elements and key functions overview The LCD screen supports the operation and adjustment of the pump with different identifiers 2 Q Stop Aux Pause Error Mem Calib Flow s Set B0081 Fig 5 The identifiers have the following meanings Identifiers P Q Stop Aux Pause Error Mem Calib Flow Set 18 Meaning The pump is in adjustment mode In the continuous display Security lock if a code was set In adjustment mode Indicates entry into CODE menu The pump was stopped using the STOP START key The pump is currently pumping with the auxiliary rate as the stroke rate In the AUX menu The pump is in the AUX menu The pump was externally stopped by the Pause function externally In Contact and Batch operating modes The auxiliary function Memory has been set In the CNTCT or BATCH menu identifier Wem flashes The auxiliary function Memory can be set The pump is in the CAL B menu In the continuous display identifier Ca ib flashes Deviations of the stroke length from the value to the time of calibration by more than 10 scale
49. entative in particular the following Replacement of damaged mains connection lines Replacement of fuses Replacement of electronic control 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 Contact with the feed chemical Parts that come into contact with the feed chemical are uncovered and handled during overhaul work Protect yourself against the feed chemical in case it is hazardous Read the safety data sheet on the feed chemical 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 13 4 Cleaning valves Personnel Technical personnel Warning of faulty operation The exploded views on the CD should be referred to when working on the unit Cc ProMinent 53 Repairs Cleaning a discharge valve or a suction valve on types PP PV NP 1000 1005 1605 1601 1602 Cleaning a discharge valve or a suction valve on types PP PV NP 0708 1008 0220 0420 0413 0713 0232 54 Warning of faulty operation Discha
50. essure In order to enable it to be distinguished from the EPDM flat seal the FPM flat seal design PV has a dot Place the tube 1 with the nozzle 4 onto the valve 6 Clamp the hose connector Screw the union nut 2 tight while simultaneously pressing on the tube 1 Re tighten the hose connector Pull on the hose 1 briefly which is fastened to the dosing head and tighten up the union nut 2 once more 25 Installation hydraulic Tube Union nut Clamp ring Nozzle O ring and flat seal Valve Oahwhd oco Rl w n P_MAZ_0021_SW Fig 6 Designs PP NP PV TT Installing stainless steel pipe design SS 1 Pull the union nut 2 and clamp rings 3 4 over the pipe 1 with approx 10 mm overhang see Fig 7 Insert the pipe 1 up to the stop in the valve 5 Tighten the union nut 2 Pipe Union nut Rear clamp ring Front clamp ring Valve AUN oo 0 29 P MAZ 0022 SW Fig 7 Design SS Installing hose lines design SS CAUTION Warning of feed chemical spraying around Connections can come free in the event that hose lines are installed incorrectly on stainless steel valves Only use PE or PTFE hose lines n addition insert a stainless steel support insert into the hose line 8 1 2 Installation for metering pumps with bleed valve Safety notes CAUTION A All of the installation and
51. essurise the system before commencing any work on hydraulic parts CAUTION Warning of feed chemical spraying around An unsuitable feed chemical can damage the parts of the pump contacted by the chemical gt Take into account the resistance of the material con tacted by the chemical when selecting the feed chemical refer to ProMinent resistance list in the equipment catalogue or under www prominent com CAUTION Warning of feed chemical spraying around The metering pump can generate a multiple of its rated pres sure If a discharge line is blocked hydraulic parts may burst Correctly install a relief valve in the discharge line down stream of the metering pump CAUTION Danger of personnel injury and material damage The use of untested third party parts can result in personnel injuries and material damage Only fit parts to metering pumps which have been tested and recommended by ProMinent CAUTION Danger from incorrectly operated or inadequately maintained pumps Danger can arise from a poorly accessible pump due to incorrect operation and poor maintenance Ensure that the pump is accessible at all times Adhere to the maintenance intervals CAUTION Danger from incorrect metering Should a different liquid end size be fitted this will change the metering behaviour of the pump gt gt P Have the pump reprogrammed in the works ProMinent 11 Safety chapter Fi
52. f 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 Danger from hazardous substances Possible consequence Fatal or very serious injuries Please ensure when handling hazardous substances that you have read the latest safety data 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 ProMinent Safety chapter 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 Depr
53. is auxiliary frequency has pri ority over the operating mode stroke rate settings Flow function Stops the pump when the flow is insufficient provided a dosing monitor is connected The number of defective strokes after which the pump is switched off can be set in the SET menu The following functions are available as standard Level switch function Information about the liquid powder level in the chemical feed container is reported to the pump control To do so a two stage level switch must be fitted it is connected to the Level switch ter minal Pause function The pump can be remotely stopped via the External Control terminal The Pause function only works via the External Con trol terminal The following functions are triggered by a key press Stop function The pump can be stopped without disconnecting it from the mains power supply by pressing the STOP START key Priming function Priming short term transport at maximum frequency can be triggered by simultaneous pressing of the two arrow keys in the Stroke rate continuous display The pump has two connecting options not with PROFIBUS or timer ProMinent Functional description Option Fault indicating relay or Output relay In the event of fault sig nals warning signals or tripped level switches the relay connects to com plete an electric circuit for alarm horns etc The relay can be retrofitted via a knock out in th
54. ists Date manufacturer s signature Details of the signatory 70 Metering pump Gamma L product range M N P Please refer to nameplate on the device EC Machinery Directive 2006 42 EC EC EMC directive 2004 108 EC EN ISO 12100 EN 809 EN 60335 1 EN 60335 2 41 EN 50106 EN 61000 3 3 EN 61000 4 2 3 4 5 6 11 EN 61000 6 1 2 3 4 Norbert Berger Im Schuhmachergewann 5 11 DE 69123 Heidelberg ad 5 10 2011 Joachim Schall Head of Development ProMinent Operating adjustment overview 18 Operating adjustment overview Continuous display Stop start pump Lock CODE 1 Lock CODE 2 o fe Manual Contact Batch nalog Manual Contact Bate mane HO o He 2 Change directly changeable variables Prime gm Start batch only in Batch operating mode LU Acknowledge errors i E Check adjustable values c a E g
55. l 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 well 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 Electrical technicians must comply with the provisions of the applicable statutory directives on accident prevention Instructed person ProMinent Sound pressure level ProMinent Safety chapter 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 Customer Service department 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 Sound pressure level LpA lt 70 dB in accordance with EN ISO 20361 2010 10 at maximum stroke length maximum stroke rate maxi
56. mum back pressure water 13 Storage transport and unpacking 4 Storage transport and unpacking Safety information 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 the metering pump for repair in a cleaned state and with a flushed liquid end refer to the section on decom missioning 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 if a Decontamination Dec laration is submitted that has been completed correctly and in full by an authorised and qualified person on behalf of the pump operator The Decontamination Declaration form can be found in the General Operating Instructions or under www prominent com CAUTION Danger of material damage The device can be damaged by incorrect or improper storage or transportation The unit should only be stored or transported in a well packaged state preferably in its original packaging The packaged unit should also only be stored or trans ported in accordance with the stipulated storage condi tions The packaged unit should be protected from moisture and the ingress of chemicals Personnel W Technical personnel Ambient conditions Data Value Unit Minimum st
57. nd types 0220 0232 and 0420 ProMinent 10 11 12 13 14 15 Remove the dosing head 2 with the screws 1 from the pump Only type 0232 Remove the screws of the backplate 4 under the diaphragm 3 Replace the dosing head 2 and screws the screws 1 should still extend into the holes in the diaphragm 3 but not into the backplate Hold the pump housing 6 with one hand and clamp the diaphragm 3 with the other hand between the dosing head 2 and the back plate 4 Loosen the diaphragm 3 from the drive axle with a gentle back wards turn of the dosing head 2 diaphragm 3 and backplate 4 in an anticlockwise direction Pull the dosing head 2 with the screws 1 out of the diaphragm 3 and completely unscrew this from the drive axle Remove the backplate 4 from the pump housing 6 Check the condition of the safety diaphragm 5 and replace if nec essary Push the safety diaphragm 5 onto the drive axle only until it lies flush with the pump housing 6 and no further Tentatively screw the new diaphragm 3 onto the drive axle until its stop position c The diaphragm 3 is now sitting at the stop of the thread Should this not work remove dirt or swarf out of the threads and screw the diaphragm 3 onto the drive axle correctly this time The diaphragm must be screwed exactly onto the drive axle otherwise the pump will subsequently not meter correctly Unscrew the diaphr
58. necessary and as small as possible In doing so you are increasing the safety of your system reduced risk that lines will burst if blocked Moreover this preserves the diaphragm and saves power CAUTION The rated pressure can be considerably exceeded for stroke lengths less than 100 The rated pressure relates to a 100 stroke length CAUTION Should a different liquid end size be fitted then the pump must be reprogrammed in the factory The following rated pressures can be selected for these liquid end sizes Selectable rated pressure bar Size of liquid Pressure Pressure Pressure Pressure end rating 1 rating 2 rating 3 rating 4 1601 1602 4 7 10 16 1605 1000 1005 4 7 10 1008 0708 0713 4 7 45 Adjustment 10 6 3 10 6 4 No adjustment is possible for pump types 0413 0420 0220 and 0232 Auxiliary frequency function settings AUX menu e Continuous display B0094 Fig 31 The programmable function Auxiliary frequency facilitates the activating of an auxiliary stroke rate which can be set in the AUX menu It can be activated via the External control terminal If the auxiliary frequency is being used then the identifier Aux appears in the LCD screen This auxiliary frequency has priority over the stroke rate which is specified by the currently selected operating mode Flow function settings
59. ng operating options are available via the keys see the figure on the next page Stop the pump Press the START STOP key Start the pump Press the STAR7 STOP key again In operating mode Batch Briefly press the P key Press the P key for 15 s if you want to reload the factory settings prior to calibration co o This deletes the current settings In continuous display if you keep the P key pressed for 2 s the pump control switches into adjustment mode see Adjustment chapter If CODE 7 was set then after pressing the P key the code must first be entered Each press of the key toggles the continuous display output to the screen to another continuous display The number of continuous displays depends on the identity code the selected operating mode and the con nected additional devices To change a value see below directly in the corresponding continuous display press one of the arrow keys until the Set identifier appears The delay period has been programmed in to prevent unintentional changing of values If CODE 2 was set then after pressing an arrow key the code must first be entered ProMinent Stroke rate Capacity Factor Displaying the program versions Batch size Priming Fault acknowledgement ProMinent Operation The directly changeable variables are in detail In operating modes Manual Contact and Batch You can change the st
60. o the cor rect position on the pump housing 6 Do not twist the backplate on the pump housing so that the safety diaphragm 5 becomes warped Place the diaphragm 3 into the backplate 4 A CAUTION Leakage may become apparent at a later stage Do not over tighten the diaphragm 3 in the fol lowing step The backplate 4 must remain in its position so that the safety diaphragm does not become warped Hold the backplate 4 firmly and screw the diaphragm 3 in a clock wise direction until it is sitting tightly the twisting resistance of the return spring can be felt Set the stroke length to 100 96 Place the dosing head 2 with the screws 1 onto the diaphragm 3 and the backplate 4 the suction connector must be pointing downwards in the pumps subsequent fitting position Gently tighten the screws 1 and then tighten in a diagonal pattern See below for tightening torque With types with bleed valve Allow the cover of the liquid end to rest in the dosing head then press the knob on the bleed valve star handle into the dosing head A CAUTION Leakage possible Check the tightening torque of the screws after 24 hours of operation With PP and PVDF dosing heads recheck the tightening torque again after three months Value Unit 4 5 5 0 Nm ProMinent Repairs P G 0008 SW Fig 36 Partially exploded view of liquid end Liquid e
61. ockets 9 2 1 External control terminal 2 lt 1 r 4 P BE 0014 SW Fig 9 Pump p n assignments 1 2 KT N 3 5 4 P_BE_0015_SW Fig 10 Cable conductor assignments Pause function ProMinent Installation electrical The external control socket is a five pin panel jack It is compatible with two and four conductor cables The Auxiliary frequency and mA output functions can only be used with a five conductor cable Electrical interface for pin 1 Pause pin 2 External contact pin 5 Aux iliary frequency Data Value Unit Voltage with open contacts 5 V Input resistance 10 kQ Max pulse frequency 25 pulse s Minimum pulse duration 20 ms Control via potential free connection contact load 0 5 mA at 5 V or m Semiconductor switch residual voltage 0 7 V Electrical interface for pin 3 mA output identity code characteristic Con trol variant 2 and 3 Data Value Unit Input apparent ohmic resistance approx 120 Q The metering pump makes its first metering stroke at approx 0 4 mA 4 4 mA and starts continuous operation at approx 19 2 mA Pin Function 5 conductor 2 conductor cable cable 1 Pause brown bridged at pin 4 2 External contact white brown 3 mA output blue 4 Earth GND black white 5 Auxiliary frequency grey with identity code characteristic Control version
62. ol elements ennt nennen 17 52 1 Key functions 42 esta ne 17 5 2 2 Stroke length adjustment knob sees 18 5 2 3 Control elements a o 18 Functional description sm 19 6 1 Liquid End ae ma Ha 19 6 2 Drive Ult esed iren DU REPE Qus enm Oe 19 6 3 Capacityss ic cce einen etree ee dee uere Ed Pe edges 19 6 4 Self Bleeding 5 eene tnmen 19 6 5 Functional description of control 19 6 5 1 Operating modes functions options 19 6 5 2 Function and fault indicator eessseeeesess 21 6 5 3 Hierarchy of operating modes functions and fault sta lUS8S corrente em ates noe AC ERREUR ERU 21 Assembly incen ran eee eee 22 Installation hydraulic 23 8 1 Install Nose lines oerte 24 8 1 1 Installation for metering pumps without bleed valve 24 8 1 2 Installation for metering pumps with bleed valve 26 8 1 3 Installation for metering pumps with self bleeding SEK pis H m 27 Installation electrical esses 29 9 1 Supply voltage connector seeeee 30 9 2 Description of the sockets sssseeeeene 31 9 2 1 External control terminal 31 9 2 2 Level Switch terminal eene 32 9 2 3 Dosing monitor terminal 32 92 4 Relay eig ore e UE UE alee ie S 33 Adj
63. on see Operating adjustment overview in the appendix Batch operating mode is intended for large metering quantities The metering can be triggered either by pressing the P key or by a pulse received via the External control terminal The number of received pulses which could not yet be processed is stored by the pump control in the stroke memory The stroke memory is limited to the Batch size if Memory is not activated with Memory to 65535 strokes You can delete it by changing to another operating mode You can also activate the Memory function extension identifier Mem appears on the LCD screen Mem memory When Memory is acti vated the pump software adds up the remaining strokes which could not be processed up to the maximum capacity of the stroke memory of 65 535 strokes If this maximum capacity is exceeded the pump goes into fault mode You can thus optimally match the pump to the process in question for example in conjunction with contact water meters 10 6 Programmable function settings SET menu ProMinent Setting menus are available in the SET menu in all operating modes for the following programmable functions Calibrate CAL B menu Auxiliary rate AUX menu Flow FLOW menu only available if a dosing monitor is connected 43 Adjustment 10 6 1 Calibrate function settings CALIB menu
64. orage and transport tempera 10 C ture Maximum storage and transport tempera 50 C ture Air humidity lt 95 rel humidity non condensing 14 ProMinent Scope of supply ProMinent Storage transport and unpacking 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 CD with order information exploded diagrams performance diagrams and data sheets Optional accessories if ordered 15 Overview of equipment and control elements 5 Overview of equipment and control elements 5 1 Overview of equipment Fig 2 Overview of equipment total 1 Control unit 2 Drive unit 3 Liquid end P G 0027 SW Fig 3 3 1 Liquid end with bleed valve 3 2 Self bleeding liquid end SEK Backplate Dosing head Suction valve Discharge valve Bleed valve self bleeding Bleed valve Bypass hose nozzle concealed Q gt an ow 16 ProMinent 5 2 Control elements Control elements overview lo dk 9 ec Ce te OOF e LOH aA R wlrm
65. orrectly set digits sssseenee 36 CALIB menUu tiere edes 44 Incremental changing of a value 35 Calibration eeeeeecessseeenn 20 44 Inductive consumers eeeseseeeenn 30 Changing a number essen 35 Information in the event of an emergency 12 Changing individual numbers eeeessess 35 Installation electrical 29 Changing to adjustment mode 36 Installation hydraulic eee 23 Checked eb euren 36 Install hose lines ee ernennen nenn 24 Checking adjustable values eeeessesss 36 67 Cleaning valves esssse eee 53 K CLEAR window eeeeseeeneene emm een 47 XJ ne 17 Code Setting ne edere a a sande ees 46 L Compatibility uur4444r nenn nnennnnnnnennnnnnn nennen 67 LED screen un 17 Confirming an entry ueeenneeeesennnnnnnnnnnennnnn nenn ennnn nern 35 Leakage hole 240 essen 51 Connector S ZE reee aerea ean eO aN UNEEN anne 64 Level switch esee 20 32 33 CONTACT ie hai 19 41 Eine enm ai ee 39 Contacter relay edet etd 30 Lock Seat E 46 Control elements inec eer tree onere 16 Lower sideband sseseee 39 40 COITGCES uie ip iet puo san 36 M Correct and proper use 9 Mains Cable sie eet He 30 CUVE
66. osity The liquid ends are suitable for the following viscosity ranges Version Range Unit Standard 0 200 mPa With valve springs 200 500 mPa Self bleeding SEK 0 50 mPa Only when the installation is correctly adjusted ProMinent 65 Technical data 16 4 Material specifications Standard liquid ends Pump 16 5 Electrical data Version 100 230 V 10 96 50 60 Hz gamma L GALa 16 6 Temperatures Pump compl 66 Version Dosing head Suction dis Seals charge con nector PPE Polypropy Polypropy EPDM lene lene PPB Polypropy Polypropy FPM lene lene NPE Clear acrylic PVC EPDM NPB Clear acrylic PVC FPM PVT PVDF PVDF PTFE TTT PTFE with PTFE with PTFE carbon carbon SST Stainless Stainless PTFE Steel 1 4571 steel 1 4571 Valve balls Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Only the self bleeding design in material version PPE PPB NPE and NPB valve spring made of Hastealloy C valve insert made of PVDF Metering diaphragms with a PTFE coating FPM fluorine rubber Housing parts polyphenylene ether PPE with fibreglass Parameter Nominal power approx Current eff Peak current Switch on peak current within approx 1 ms Fuse M70 17 W 0 5 0 2A 3 6 1 4 A 15A 0 8 AT M85 23W 0 8 0 3 A 6 0 2 8 A 15A 0 8 AT Fuses must have VDE UL and CSA certification E G type 19195 manu factured by Wickmann in compliance
67. quid end particularly around the leakage hole please refer to Fig 35 Check that the flow is correct Allow the pump to prime briefly turn the multifunctional switch briefly to Test Check that the electrical connections are intact Check the integrity of the housing Check that the dosing head screws are tight Under normal loading approx 30 of continuous operation Under heavy loading e g continuous operation Shorter intervals For feed chemicals which particularly load the diaphragm e g those containing abrasive additives check the diaphragm frequently 51 Maintenance P BE 0012 SW Fig 35 Leakage hole Liquid ends with bleed valve Interval Maintenance work Personnel Quarterly In addition Technical personnel Check that the bypass line is fixed firmly to the liquid end Check that the bleed valve is tight Check the discharge and bypass line for kinks Check that the bleed valve is operating correctly Under normal loading approx 30 96 of continuous operation Under heavy loading e g continuous operation Shorter intervals Tightening torque Data Value Unit Tightening torque for screws 4 5 5 0 Nm 52 ProMinent Repairs 13 Repairs Safety notes WARNING Danger of an electric shock Unauthorised repairs inside the pump can result in an elec tric shock For this reason repairs inside the pump may only be per formed by a ProMinent branch or repres
68. remotely via a signal cable PRO FIBUS or CAN bus see chapter Settings selecting the operating mode MODE menu and chapter Operation in the Supplementary instruc tions for ProMinent gamma L and ProMinent Sigma versions with PRO FIBUS as well as your system documentation ProMinent Maintenance 12 Maintenance WARNING It is mandatory that you read the safety information and specifications in the Storage Transport and Unpacking chapter prior to shipping the pump CAUTION Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic 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 Further data on CD All product specitic operating instructions include a CD with order details exploded diagrams and dimensions sheets if m they are not included in the operating instructions Standard liquid ends Interval Maintenance work Personnel Quarterly m Check the metering diaphragm for damage refer to Repair Technical personnel ProMinent Check that the hydraulic lines are fixed firmly to the liquid end Check that the suction valve and discharge valve are correctly seated Check the tightness of the entire li
69. residual voltage when I 1 mA Maximum current Maximum voltage Pacing pulse duration approx To pin VDE cable yellow green white brown Contact NO normally open C common NO normally open C common Value 100 20 000 000 Value 0 4 100 24 100 Unit mA Switching operations Unit mA VDC ms Relay Fault indi cating relay Fault indi cating relay Pacing relay Pacing relay ProMinent Adjustment 10 Adjustment For supplementary information see Control elements and key functions in the chapter Overview of equipment and control elements and Operating setting overview in the appendix The pump control returns to the continuous display as soon as no key has been pressed for one minute 10 1 Basic principles of pump adjustment Installation option MH oo o a P D DT D set 5 p 3s 3s Continuous m Y Y display B0082 Fig 19 Confirming an entry Briefly press the P key c The display simultaneously changes to the next menu option or into a continuous display Quitting a menu point without confirming it Press and hold the P key for 3 seconds c Entry is cancelled and you jump back to a continuous display oo i2 m VICE B0083 Fig 20 a Toggle between
70. rge and suction valves differ from each other Only take them apart one after each other so that you do not confuse the components Only use new components which fit your valve both in terms of shape and chemical resistance Recalibrate the pump after replacing a valve Using an Allen key or similar insert it into the smaller hole of the discharge connector and push the valve inserts out of it A suction valve is constructed in almost the same way as a discharge valve Please note however that the two valve inserts are identical here There is an additional spacer between the valve inserts There is a shaped seal in the dosing head instead of an O ring The flow direction of the suction connector is the opposite of that of the discharge connector Warning of faulty operation Discharge and suction valves differ from each other Only take them apart one after each other so that you do not confuse the components A Only use new components which fit your valve both in terms of shape and chemical resistance A Readjust the pump after replacing a valve Using an Allen key or similar insert it into the smaller hole of the discharge connector and push the valve inserts out of it A suction valve is constructed in almost the same way as a discharge valve Please note however that The shaped seal is laid in the suction connector Only the O ring not the shaped seal is laid in the dosing he
71. riming press fe ood a a 27 Programmable function settings 43 Idem 46 Protection against contact and humidity 67 Protection class needed 67 Q Qualification of personnel esee 12 Quitting a menu point without confirming it 35 R R dioattive rre oerte ees 14 RG member 2 erahnen kenne 30 Reduction essen 42 Relay 2 2 2 ee delere p euis 33 Di0rpnme E 53 Replacing the Diaphragm eene 55 Replacing the metering diaphragm 55 Reproducibility essen 65 Return line RE RR Dee 24 26 27 ProMinent Index S Safety chapter 2 dee ee ed 9 Safety declaration form sess 14 Safety requirements see 67 Scope of supply e eub bas 15 Sl eins 27 DEK deca HT 19 Self Bleeding ssssssssseseeseene 19 Semiconductor switch uuenseesersnnnnnnneennnnnnnnnnnnnn nn 33 SET menu eI Eee ES 38 43 Shipping weight ssssssseeeee 68 9l88V6 iei eie deter e ee eire enin aed 28 SOCKkels 1 ndi etin ib Ghia teinu 17 Sound pressure level sssssssssssss 13 68 Ko 1121 01210 6 BrESPFARTEFFPEREITLPAFFELEETPARHEFFRGHRFTEFFFEIETOFRCFEFETTERFERFEFFERR 42 STOP sup tI Ei eei pens 20 21 otorage dieto petes 14 S
72. roke rate in the Stroke rate continuous display In operating mode Manual You can change the capacity in the Capacity continuous display The factor is the number of strokes which are triggered upon an external pulse or pressing of key P only in Batch operating mode In operating mode Batch You can change the factor from the Remaining strokes continuous dis play A couple of seconds after your have set the factor the pump control jumps back to the initial continuous display Press the P key for 10 s to display the program versions V1052 X1010 Under LOAD3 release the P key immediately In operating mode Batch You can change the batch size from the Batch size Remaining litres con tinuous display A couple of seconds after your have set the factor the pump control jumps back to the initial continuous display Simultaneous pressing of the two arrow keys triggers the Priming func tion Fault displays are acknowledged by brief pressing of the P key 49 Operation 11 2 Remote operation 50 Continuous display Stop start pump Change directly changeable variables H 2 Prime Start batch only in Batch operating mode Acknowledge errors Check adjustable values Adjustment Mode Lock CODE 1 Lock CODE 2 B0098 There is an option to control the pump
73. strokes per pulse depends on the factor which you input By use of the factor you can multiply incoming pulses by a factor between 1 01 and 99 99 or reduce them by a factor of 0 01 to 0 99 Number of strokes executed factor x number of incoming pulses ProMinent 41 Adjustment 42 Example Example table Factor Step up 1 25 99 99 1 50 1 25 Reduction 1 0 50 0 50 0 50 0 50 0 50 0 50 Explanation of step up Factor with a factor 1 with a factor 2 with a factor 25 Explanation of reduction Factor with a factor 1 with a factor 0 5 with a factor 0 1 with a factor 0 75 Pulse Number of sequence strokes sequence 1 1 1 2 1 25 1 99 99 1 1 50 1 2 1 1 25 1 1 1 2 1 1 2 1 10 1 100 1 4 1 2 5 3 2 1 1 1 33 2 1 1 1 111 Pulse and strokes 1 stroke is executed per pulse 2 strokes are executed per pulse 25 strokes are executed per pulse Pulse and strokes 1 stroke is completed after 1 pulse 1 stroke is completed after 2 pulses 1 stroke is completed after 10 pulses 1 stroke is completed after 2 pulses once then 1 stroke is completed after 1 pulse twice and then repeating 1 stroke after 2 pulses etc Ifa remainder is obtained when dividing by the factor then the pump software adds the remainders together AS soon as this sum reaches or exceeds 1 the pump executes an additional stroke Therefore on aver
74. t Stop and Pause stop everything apart from Priming re3 The stroke rate of Auxiliary rate always has priority over the stroke rate specified by an operating mode or priority 4 ProMinent 21 Assembly 7 22 Assembly 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 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 Capacity too low The liquid end valves can be disrupted by vibrations Secure the metering pump so that no vibrations can occur Capacity too low If the valves of the liquid end do not stand vertically upwards they cannot close correctly Suction and discharge valves must stand vertically upwards for self bleeding liquid end the bleed valve Mount the metering pump with the pump foot on a horizontal level and load bearing supporting surface ProMinent 8 Installation hydraulic Safety notes ProMinent Installation hydraulic 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
75. ted and recommended by ProMinent CAUTION Warning of illegal operation Observe the regulations that apply where the unit is to be installed 23 Installation hydraulic 8 1 Install hose lines 8 1 1 Installation for metering pumps without bleed valve Safety notes A 24 CAUTION Warning of feed chemical spraying around If the pipes are improperly installed they can come lose or burst Route all hose lines so they are free from mechanical stresses and kinks Only use original hoses with the specified hose dimen sions and wall thicknesses Toensure high durability of the connections only use clamp rings and hose nozzles that are intended for the hose diameter in question CAUTION Danger resulting from rupturing hydraulic components Hydraulic components can rupture if the maximum permis sible operating pressure is exceeded Always maintain the maximum permissible operating pressure of all hydraulic components please refer to the product specific operating instructions and system documentation Never allow the metering pump to run against a closed shut off device Install a relief valve CAUTION Hazardous feed chemicals can escape Hazardous or extremely aggressive feed chemicals can leak out when using conventional bleeding procedures with metering pumps Install a bleed line with recirculation into the storage tank CAUTION Hazardous feed chemicals can escape
76. the metering of gaseous media or solids The pump is not intended for the metering of explosive media The pump is not intended for operation in hazardous locations The pump is not intended for exterior applications without use of suit able protective equipment The pump should only be operated by trained and authorised per sonnel see the following Qualifications table You are obliged to observe the information contained in the operating instructions at the different phases of the device s service life Safety chapter Safety notes 10 gt FP b gt WARNING Warning about personal and material damage The pump can start to pump as soon as it is connected to the mains voltage nstall an emergency cut off switch in the pump power supply line or integrate the pump in the emergency cut off management of the system WARNING Danger of electric shock A mains voltage may exist inside the pump housing Ifthe 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 Fire danger Combustible media may only be transported using stainless steel dosing heads In exceptional cases where this is not possible PTFE with carbon can be used whereby our TT_ versions are manufactured from this conducting plastic Here the operator is urged to take special care due to the low mechanical strength WARNING Warning o
77. tion to the signal current The smallest processable difference between 11 and I2 is 4 mA A Fmax Fl P2 P1 F1 T I gt 0 11 12 20 I mA B0090 Fig 27 Upper sideband e g acid pump ProMinent Adjustment Fault processing Under menu option A Error you can activate error processing for the Curve processing type For current signals below 3 8 mA a fault mes sage appears and the pump stops 10 5 3 Contact operating mode settings CNTCT menu Alongside those described in more detail in the chapter Programmable function settings SET menu the CNTCT menu is also available in Contact operating mode via the SET menu Contact operating mode allows you to trigger individual strokes or a stroke series You can trigger the strokes via a pulse sent via the external control terminal The purpose of this operating mode is to convert the incoming pulses with a reduction bridge or small step up into strokes CAUTION If you change into another operating mode the factor is reset to 1 With identity code version Contact identity code External with pulse control you can enter after how many pulses a stroke should occur Contact identity code External with pulse control is intended for small metering quantities enter On al Continuous display B0091 Fig 28 The number of
78. troke length adjustment knob en 17 Supply Voltage ssssssssesssseeseeeeenn 30 T Technical data cene e 64 Total litres 5 ect ies a 47 Trans poftei oe o nenn 14 U Unpacking e eter ere rs 14 Upper sideband 3 ge eme 39 40 V MASTOT iced ruo rcgi a a ge iin 30 VISCOS aufn nr ete i En ds 65 W Warning alert e eee he tees 33 Warning indicator ssese eee 17 21 Warning Sign eiit te te teret eris e Eee ae 9 Auxiliary rate function settings essssse 46 Calibrate function settings 44 Flow function settings eee 46 Pressure ratings function settings 45 75
79. ustment reto unte aei 35 10 1 Basic principles of pump adjustment 35 10 2 Checking adjustable values eene 36 10 3 Changing to adjustment mode eee 36 10 4 Operating mode selection MODE menu 37 10 5 Operating mode settings SET menu 38 10 5 1 Manual operating mode settings 38 10 5 2 Analog operating mode settings ANALG menu 38 10 5 3 Contact operating mode settings CNTCT menu 41 10 5 4 Batch operating mode settings BATCH menu 43 10 6 Programmable function settings SET menu 43 10 6 1 Calibrate function settings CALIB menu 44 10 6 2 Pressure ratings function settings PRESS menu 45 10 6 3 Auxiliary frequency function settings AUX menu 46 10 6 4 Flow function settings FLOW menu 46 10 7 Setting the code CODE menu uumeesssnnnnnnnennnnennnen nen 46 10 8 Deleting the total number of strokes or total litres CLEAR WINGOW EE 47 ProMinent ProMinent 11 12 13 14 15 16 17 18 19 20 Table of contents OperatlOn eter trt sie 48 11 1 Manual operation sssemm em 48 11 2 Remote operation riae ee 50 Maintenance ee tede en e ode 51 Repairs tenetis pete EE L
80. via a contactor relay or relay Personnel m Electrician Install the pump technically correctly and in accordance with the operating instructions and applicable regulations 9 1 Supply voltage connector WARNING Unexpected startup is possible As soon as the pump is connected to the mains the pump may start pumping and consequently feed chemical may escape Prevent dangerous feed chemicals from escaping f you have not successfully prevented this immediately press the STOP START key or disconnect the pump from mains e g via an emergency cu off switch CAUTION If the pump is integrated into a system The system must be designed so that potential hazardous situations are avoided by pumps starting up automatically subsequent to unin tended power interruptions Connect the pump to the mains power supply using the mains cable Parallel connection to inductive con Should the pump be connected to the mains in parallel to inductive con sumers sumers e g solenoid valves motor the pump must be electrically iso lated when these consumers are switched off Supply the pumps with voltage via a contactor relay or relay using separate contacts for the pump If this is not possible then connect a varistor part no 710912 or an RC member 0 22 uF 220 Q in parallel Interference suppression aids Product Part no Varistor 710912 RC Gate 0 22 pF 220 Q 710802 30 ProMinent 9 2 Description of the s
81. xed separating protective equipment Information in the event of an emergency Qualification of personnel 12 CAUTION Warning of illegal operation Observe the regulations that apply where the unit is to be installed Dosing head Housing Hood houses the control elements The dosing head may only be removed by the customer in accordance with the Repair chapter The housing and the hood may only be removed by ProMinent customer service department In an emergency either pull out the mains plug or press the customer installed emergency off switch or disconnect the pump according to the emergency off management for your system If feed chemical escapes also depressurise the hydraulic system around the pump Adhere to the safety data sheet for the feed chemical 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 wel

Solenoid Metering Pump gamma/ L, GALa Operating instructions

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