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Operating instructions
Piston Metering Pump
ProMinent
®
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
pumps and hydraulic accessories".
Both sets of operating instructions are only valid when read together.
Please carefully read these operating instructions before use! · Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
Part no. 985761
Makro/ 5 M5Ka
ProMinent
Technical changes reserved.
Original Operating Instructions (2006/42/EC)
®
motor-driven metering
BA MAK 007 10/11 EN
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Table of Contents
Related Manuals for ProMinent Makro/ 5 M5Ka
Summary of Contents for ProMinent Makro/ 5 M5Ka
- Page 1 Makro/ 5 M5Ka ® ProMinent Two sets of operating instructions are required for the safe, correct and proper operation of the metering pumps: The product-specific operating instructions and the "General Operating Instructions for ProMinent ® motor-driven metering pumps and hydraulic accessories".
- Page 2 ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 69123 Heidelberg Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-617 email: info@prominent.com Internet: www.prominent.com 985762, 1, en_GB © 2010...
- Page 3 General user instructions Two sets of operating instructions are required for the safe, correct and proper operation of the metering pumps: The product-specific operating instructions and the "General Operating Instructions for ProMinent motor- ® driven metering pumps and hydraulic accessories".
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Page 4: Table Of Contents
Table of contents Table of contents Identity code..................5 About this pump................7 Safety chapter................. 8 Storage, transport and unpacking..........13 Overview of equipment, control elements........15 Functional description..............18 Assembly..................20 Installation..................23 8.1 Installation, hydraulic............. 23 8.2 Installation, electrical............. 25 Start up.................. -
Page 5: Identity Code
Stainless steel piston, chromium dioxide coated Dosing head version no valve spring With valve spring Hydraulic connector Standard connection Union nut and SS insert Version With ProMinent ® logo, no frame Without ProMinent ® logo, no frame With ProMinent ®... - Page 6 Identity code M5Ka Makro/ 5 piston metering pumps 3 ph, 460 V, 60 Hz, (Exe, Exd) 3 ph, 230 V/400 V 50 Hz (Exe, Exd) Variable speed motor 4 pole, 230/400 V (R 1:5) 1 ph, 115 V, 60Hz V(0) Motor with integral Frequency converter V(2) Motor with integral frequency converter (Exd)
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Page 7: About This Pump
About this pump About this pump All pumps The ProMinent Makro/ 5 piston metering pump is fitted as standard with a ® 3 kW wide range AC motor. The stroke length can be adjusted between 0...50 mm. The spheroidal graphite housing can be combined with up to 10 liquid end sizes and 5 gear reduction ratios (integrated in the spur geared motor). -
Page 8: Safety Chapter
The general limitations with regard to viscosity limits, chemical resist‐ ance and density must be observed - see also ProMinent resistance www.prominent.com )! list (In the product catalogue or at Any other uses or modifications are prohibited. - Page 9 Safety chapter The pump is not intended for the metering of gaseous media or solids. The pump is not intended for unprotected outside use. The pumps is not intended for the dosing of combustible fluids. The pump should only be operated by trained and authorised per‐ Ä...
- Page 10 Service Customer Service department refers to service technicians, who have received proven training and have been authorised by ProMinent or Pro‐ Maqua to work on the system. Safety notes WARNING!
- Page 11 – Take into account the resistance of the materials which will come into contact with the chemical when selecting the feed chemical - see the ProMinent product catalogue www.prominent.com . or under CAUTION! Danger of personnel injury and material damage The use of untested third party parts can result in personnel injuries and material damage.
- Page 12 Safety chapter Protective equipment P_MAK_0025_SW Fig. 2: Isolating protective equipment Makro/ 5 with add-on power end (shown here for piston version) Cap (only single head version) Fan impeller hood Terminal box cover, motor Cover plate (only with add-on power end) Flange cover Protective cover (only diaphragm and piston versions) WARNING!
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Page 13: Storage, Transport And Unpacking
WARNING! The transporting of pumps which have been used with radio‐ active feed chemicals is forbidden! They will also not be accepted by ProMinent! WARNING! Only return metering pumps for repair in a cleaned state and with a flushed liquid end - refer to the section on decommis‐... - Page 14 Storage, transport and unpacking Store the pump in a dry, sealed place in the following ambient conditions. Ambient conditions Data Value Unit Minimum storage and transport tempera‐ -10 °C ture Maximum storage and transport tempera‐ +50 °C ture Maximum air humidity * 95 % rel.
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Page 15: Overview Of Equipment, Control Elements
Overview of equipment, control elements Overview of equipment, control elements Power end, single head P_MAK_0027_SW Fig. 3: View from the motor side (here M5Ka H) Power end Liquid end Lifting eye Stroke length adjustment wheel Indicating dial motor Oil drain plug P_MAK_0027_SW Fig. - Page 16 Overview of equipment, control elements Power end, double head P_MAK_0029_SW Fig. 5: View from the motor side (here M5Ka D) Power end Liquid end Lifting eye Stroke length adjustment wheel Indicating dial motor Oil drain plug P_MAK_0030_SW Fig. 6: View away from the motor (here M5Ka D) Vent screw Oil inspection window...
- Page 17 Overview of equipment, control elements Liquid end P_MAK_0034_SW Fig. 7 Discharge valve Dosing head Suction valve Support bracket Protective cover Tube nozzles for leakage/flushing connector...
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Page 18: Functional Description
Functional description Functional description Power end functional description The Makro/ 5 metering pump is a motor-driven metering pump with a kine‐ matic gear. A motor drives the cam shaft (1). A connecting rod (2) rests on the cam shaft (1) which allows the oscillating crank (4) to rotate about a variable pivot point, see Fig. - Page 19 Functional description P_MAK_0039_SW Fig. 9: Cross-section through the liquid end Discharge valve Piston Flushing collar Packing collar Suction valve...
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Page 20: Assembly
EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. CAUTION! Warning about personal and material damage Also observe the "General Operating Instructions for ProMi‐... - Page 21 Assembly WARNING! The pump can break through the supporting floor or slide off – The supporting floor must be horizontal, smooth and per‐ manently load-bearing. Capacity too low Vibrations can disturb the valves of the liquid end. The supporting floor must not vibrate. –...
- Page 22 Assembly Take the dimensions (m) for the fastening holes from the appropriate dimensional drawings or data sheets. Fasten the pump base to the supporting floor using suitable screws. P_MOZ_0015_SW Fig. 13 Instruction Screw the pump to a support surface with 4 sufficiently strong screws through the 4 holes in the frame.
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Page 23: Installation
EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. WARNING! - Page 24 Installation CAUTION! Suction problems possible For feed chemicals with a particle size greater than 0.3 mm, the valves may no longer close properly. – Install a suitable filter in the suction line. CAUTION! Warning against the discharge line bursting With a closed discharge line (e.g. due to a clogged discharge line or by closing a valve), the pressure that the metering pump generates can reach several times the permissible pressure of the system or the metering pump.
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Page 25: 8.2 Installation, Electrical
EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. CAUTION! Warning about personal and material damage Also observe the "General Operating Instructions for ProMi‐... - Page 26 The terminal wiring diagram is located in the terminal – box. Notes on the speed controlled motor with external fan – and temperature monitoring can be found in the "Gen‐ eral operating instructions for ProMinent ® motor-driven metering pumps and hydraulic accessories"!
- Page 27 Installation The external fan requires an independent mains connection. Stroke sensor (Option) Connect the stroke sensor to a suitable monitoring device according to the details in the chapter "Technical Data". Also observe its tech‐ nical data. Other units Install the other units according to their documentation.
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Page 28: Start Up
EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. WARNING! Hot surface In event the power end motor is loaded excessively, its sur‐... - Page 29 Start up Installing a vent screw Replace the sealing screw at the oil filler neck with the supplied vent screw - see chapter "Overview of equipment and control elements". Checking the oil level When the pump is idle, check whether the pump oil level slightly covers the lower oil inspection window.
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Page 30: During Use
EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. WARNING! -
Page 31: Maintenance
EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. WARNING! It is mandatory that you read the safety information and specifications in the "Storage, Transport and Unpacking"... - Page 32 Interval Maintenance work Quarterly* EX pumps only: For special maintenance work see chapter "Important supplements for metering pumps in hazardous locations" of the "General Operating Instructions for ProMinent motor-driven ® metering pumps and hydraulic accessories" Check the starting torque torques for the dosing head flange screws (1) (24 Nm) and the turret flange screws (2) (19 Nm).
- Page 33 Maintenance (24 Nm) (19 Nm) P_MAK_0042_SW Fig. 16: Liquid end torques Dosing head screws Turret flange screws Interval Maintenance work After approx. 5,000 operating hours Change the gear oil. * Under normal loading (approx. 30 % of continuous operation) Under heavy loading (e.g. continuous operation): Shorter intervals. Changing the gear oil WARNING! Risk of burns due to hot gear oil...
- Page 34 Maintenance P_MAK_0043_SW Fig. 17: Oil change 1 Vent screw Oil drain plug Filling with gear oil: Start the pump. Slowly pour gear oil through the vent screw (1) opening until the upper oil inspection window (3) is slightly covered. Allow the pump to run for a further 1... 2 minutes. Replace the vent screw (1).
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Page 35: Repairs
EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. WARNING! It is mandatory that you read the safety information and specifications in the "Storage, Transport and Unpacking"... -
Page 36: Changing The Piston
Repairs 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‐... - Page 37 Repairs P_MAK_0048_SW Fig. 19: View of the liquid end Bolt Safety collar Securing screws Protective cover Support bracket (option) Tube nozzles for leakage/flushing connector Repairing the liquid end P_MAK_0049_SW Fig. 20: Cross-section through the liquid end Piston Tube nozzle Tensioning screw Dosing head flange Guide bands Guide sleeves...
- Page 38 Repairs Remove the piston (1) Now record the sequence of parts as your remove them ready for the reassembly. Remove the guide sleeves (6) and guide bands (5), the packing col‐ lars (8) and flushing collar (7). Thoroughly clean the sealing area Clean the piston (1), the guide sleeves (6) and the flushing collar (7) Dispose of the packing collars and guide bands Insert the piston (1)
- Page 39 Repairs Positioning the liquid end Align the holes of the swivel head and fork head - see Fig. 20. Push the bolt through the holes and insert the safety collar in the bolt. Clamp the protective cover over the turret. If available: Screw the support bracket onto the liquid end.
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Page 40: Valve Repair
Use the correct spare part kits. In case of doubt, refer to – the exploded views and ordering information contained in the "Supplementary information CD for ProMinent ® pump operating instructions". Clean the discharge and suction valves only one after another as they cannot be differentiated using the arrow markings. -
Page 41: Double Ball Valves
Repairs 12.2.1 Double ball valves Cleaning a discharge valve Taking the discharge valve apart Unscrew the discharge valve from the dosing head and rinse out. Dismantle the discharge valve. Rinse and clean all parts. Replace the worn parts and seals. Assembling the discharge valve When assembling, take note of the orientation of the valve seats (3). -
Page 42: Single Ball Valves
Repairs 12.2.2 Single ball valves Screw the valve cap (5) on to the suction side - see . Carefully remove the parts from the valve body (2). Replace the worn parts. Clean the remaining parts. Check all parts. If available: Place the compression spring inside the valve body (2). Insert the valve ball (3 and the valve seat (4). - Page 43 Repairs P_MAK_0055_SW Fig. 25: Section through a plate valve (DN65 shown) Valve cap II (only DN 65) Perforated disc (only DN 65) Compression spring Valve body Valve plate Valve insert Valve cap Screw the valve cap (7) on to the suction side - see . Carefully remove the parts from the valve body (4).
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Page 44: Troubleshooting
EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. WARNING! - Page 45 The power end motor is very hot. The discharge line is Rectify any constriction of the dis‐ Technical per‐ seriously constricted. sonnel charge line. Have the safety relief valve checked. All other faults. Other causes. Call ProMinent or ProMaqua service. ® ®...
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Page 46: Decommissioning And Disposal
EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent Motor-Driven Metering Pumps and Hydraulic ® Accessories" must be observed in all cases. WARNING! - Page 47 Decommissioning and disposal CAUTION! Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic components if they are manipulated or opened due 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‐...
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Page 48: Disposal
Decommissioning and disposal 14.2 Disposal Personnel: Technical personnel CAUTION! Environmental hazard due to gear oil The pump contains gear oil, which can cause damage to the environment. – Drain the gear oil from the pump. – Note the local guidelines currently applicable in your country! CAUTION! Note the local guidelines generally currently applicable in... -
Page 49: Technical Data
Technical data Technical data Only for "M - modified" version: WARNING! Risk of personal injuries Please observe the ”Supplement for modified version“ at the end of the chapter! It replaces and supplements the technical data! -
Page 50: Performance Data
Technical data 15.1 Performance data Main pumps with motor 1500 rpm under 50 Hz operation Type Minimum pump capacity at max‐ Maximum Suction Connector Shipping Piston Ø imum back pressure stroke rate lift size weight* ml/stroke Strokes/min m WS G-DN 3200038 11.3 Rp 1/4- 8... - Page 51 Technical data Type Minimum pump capacity at max‐ Maximum Suction Connector Shipping Piston Ø imum back pressure stroke rate lift size weight* ml/stroke Strokes/min m WS G-DN 161212 1212 283.7 2 1/4- 40 161665 1665 283.7 2 1/4- 40 162150 2150 283.7 2 3/4- 50...
- Page 52 Technical data Main pumps with motor 1800 rpm under 60 Hz operation Type Minimum pump capacity at max‐ Maximum Suction Connector Shipping Piston Ø imum back pressure stroke rate lift size weight* ml/stroke Strokes/min m WS G-DN 3200038 4640 Rp 1/4- 8 3200048 4640 Rp 1/4- 8...
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Page 53: Accuracy
Technical data Type Minimum pump capacity at max‐ Maximum Suction Connector Shipping Piston Ø imum back pressure stroke rate lift size weight* ml/stroke Strokes/min m WS G-DN 161665 1988 2 1/4- 40 162150 2570 2 3/4- 50 162522 2 3/4- 50 121343 1589 2 3/4- 50... -
Page 54: Wetted Materials
500 ... 1000 mPas out installation with appropriately laid > 1000 mPas out installation and advice from ProMinent * Only when the installation is correctly adjusted 15.4 Wetted materials Pump type Liquid end Suction/dis‐ Valve seat/seals Valve balls... -
Page 55: Housing Degree Of Protection
Technical data 15.6 Housing degree of protection Data Value Protection against contact and humidity* IP 55 *according to DIN VDE 470 (EN IEC 60529) 15.7 Stroke sensor (option), intrinsically safe Namur sensor (identity code specification "Stroke sensor": 1) Install the sensor according to the chapter "Installation, elec‐ trical". -
Page 56: Sound Pressure Level
Technical data 15.9 Sound pressure level Sound pressure level Sound pressure level LpA < 75 dB in accordance with EN ISO 20361:2010-10 at maximum stroke length, maximum stroke rate, maximum back pressure (water) 15.10 Compatibility The hydraulic accessories of the Makro/ 5 metering pump Hydro are com‐ patible with the Sigma and Makro TZ piston pumps. -
Page 57: Ec Declaration Of Conformity
For pumps without explosion protection: - Original - EC Declaration of Conformity for Machinery ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 - 11 DE - 69123 Heidelberg hereby declare that the 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. - Page 58 EC Declaration of Conformity For pumps with explosion protection: The EC Declaration of Conformity for pumps for potentially explosive atmospheres is enclosed with the pump. The EC Declaration of Conformity, the EC type-test reports and the oper‐ ating instructions for the individual components are also enclosed with the pump.
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Page 59: Index
Index Index Accuracy............... 53 Namur sensor..............55 Air humidity..............54 Ambient conditions............54 Oil.................. 55 Assembly............... 20 Packing collar..............18 Capacity................ 50 Piston................18 Climate................54 Protection against contact and humidity....... 55 Compatibility..............56 Pump capacity............... 50 Connector size.............. 50 Correct and proper use...........
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