ProMinent MAKRO TZ Operating Instructions Manual
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ProMinent MAKRO TZ Operating Instructions Manual

ProMinent MAKRO TZ Operating Instructions Manual

Diaphragm metering pump
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Operating instructions
Diaphragm Metering Pump
Makro TZ, TZMb
P_MA_0022_SW
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. 985741
Original operating instructions (2006/42/EC)
BA MA 014 02/14 EN

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  • Page 1 Operating instructions Diaphragm Metering Pump Makro TZ, TZMb P_MA_0022_SW 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. 985741...
  • Page 2 Supplemental instructions Supplementary information Read the following supplementary information in its entirety! Should you already know this information, you will benefit more from referring to the operating instructions. The following are highlighted separately in the document: Enumerated lists Fig. 1: Please read! Operating guidelines ð...

  • Page 3: Table Of Contents

    Table of contents Table of contents Identity code..................5 Safety chapter................. 7 Storage, transport and unpacking..........13 Overview of equipment, control elements........14 Functional description..............16 Assembly..................18 Installation..................20 7.1 Installation, hydraulic............. 20 7.1.1 Basic installation notes............23 7.2 Installation, electrical............. 24 Start up..................
  • Page 4 Table of contents Diagrams for adjusting the capacity..........65 EC Declaration of Conformity............69...

  • Page 5: Identity Code

    Identity code Identity code TZMb Makro TZ diaphragm metering pump Power end type Main power end Main power end, doubled Add-on power end Add-on power end doubled Type _ _ _ _ _ Performance data at maximum back pressure and type: refer to nameplate on the pump...
  • Page 6 Identity code TZMb Makro TZ diaphragm metering pump No motor, with flange 160/90 No motor, with flange 200/90 Motor version IP 55 (Standard) ISO class F Exe design ATEX-T3 Exd version ATEX-T4 ATEX design of power end Stroke sensor no stroke sensor...

  • Page 7: Safety Chapter

    Observe the general restrictions with regard to viscosity limits, chem‐ ical resistance and density - see also ProMinent Resistance List (in the Product Catalogue or at www.prominent.com/en/downloads)! All other uses or modifications are prohibited.
  • Page 8 Safety chapter Only SS and TT pump designs with carbon and diaphragm rupture indicator are approved to meter flammable liquids, and if the operator takes appropriate safety measures. The pump is not intended for unprotected outside use. The pump is only intended for industrial use. The pump should only be operated by trained and authorised per‐...
  • Page 9 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 Safety notes...
  • Page 10 An unsuitable feed chemical can damage the parts of the pump that come into contact with the chemical. – Take into account the resistance of the wetted materials when selecting the feed chemical - see the ProMinent product catalogue or visit www.prominent.com/en/down‐ loads. CAUTION!
  • Page 11 Safety equipment Protective equipment P_MA_0042_SW Fig. 2: Isolating protective equipment Makro TZ with add-on power end (shown here for piston version) Terminal box cover, motor Protective cowling above the motor fan...
  • Page 12 Safety chapter Protective equipment May only be removed by*: Terminal box cover, motor Electrical techni‐ cian, service Protective cowling above the motor fan Service Flange cover, side Service Protective cover (only diaphragm and piston Technical per‐ versions) sonnel, service Only with protective devices: their corre‐ Technical per‐...

  • 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 "Decommissioning! Only return metering pumps with a completed Decontamina‐...

  • Page 14: Overview Of Equipment, Control Elements

    Overview of equipment, control elements Overview of equipment, control elements Power end, single head P_MA_0023_SW Fig. 4: Side view (here TZMb H) Drive Liquid end Vent screw Stroke length adjustment wheel Oil inspection window Motor Oil drainage screw Power end, double head P_MA_0024_SW Fig.
  • Page 15 Overview of equipment, control elements Liquid end P_MA_0025_SW Fig. 6: View of the liquid end Discharge valve Dosing head Diaphragm rupture sensor Suction valve Tube nozzle for leakage Protective cover...

  • Page 16: Functional Description

    Functional description Functional description Pump The metering pump is an oscillating diaphragm pump, the stroke length of which can be adjusted. An electric motor drives the pump. Functional description of the diaphragm The metering diaphragm (2) hermetically shuts off the pump volume of the liquid end dosing head (3) from the outside.
  • Page 17 Functional description P_MA_0030_SW Fig. 8: Diaphragm rupture sensor: Cross-section view and multi-layer diaphragm Safety piston Diaphragm rupture signaller Expandable point...

  • Page 18: Assembly

    Assembly Assembly Compare the dimensions on the dimension sheet and – pump. Supporting floor WARNING! Danger of electric shock If water or other electrically conducting liquids penetrate into the drive housing, in any other manner than via the pump's suction connection, an electric shock may occur. –...
  • Page 19 Assembly Liquid end alignment Capacity too low If the valves of the liquid end do not stand upright, they cannot close correctly. The discharge valve must be upright. – Fastening Capacity too low Vibrations can disturb the valves of the liquid end. Secure the metering pump so that no vibrations can –...

  • Page 20: Installation

    Installation Installation 7.1 Installation, hydraulic WARNING! EX pumps in areas at risk from explosion – It is essential that metering pumps to be used in areas at risk from explosion are fitted with an appropriate safety relief valve on the outlet side of the metering pump (to protect it from excessive heating up from overloading and from impact sparks resulting from overloading trig‐...
  • Page 21 Installation WARNING! The following measures are an advantage when working with highly aggressive or hazardous feed chemicals: – Install a bleed valve with recirculation in the storage tank. – Install an additional shut-off valve on the discharge or suction ends. CAUTION! Warning of backflow A back pressure valve or a spring-loaded injection valve do...
  • Page 22 Installation CAUTION! Uncontrolled flow of feed chemical Feed chemical can leak through the metering pump in an uncontrolled manner in the event of excessive priming pres‐ sure on the suction side of the metering pump. – Do not exceed the maximum permissible priming pres‐ sure for the metering pump.

  • Page 23: Basic Installation Notes

    Installation CAUTION! Danger due to incorrect use of the safety relief valve The safety relief valve can only protect the motor and the gear, only against illegal positive pressure that is monitored by the metering pump itself. It cannot protect the system against positive pressure.

  • Page 24: Installation, Electrical

    This can either be in the form of a decla‐ ration of conformity from the supplier (ProMinent) for the entire unit or, with the supply of individual components, with the operator's explosion protection document.
  • Page 25 Installation WARNING! Danger of electric shock Unprofessional installation may lead to electric shocks. – Provide all shortened cable cores with cable end sleeves. – Only technically trained personnel are authorised to undertake the electrical installation of the device. WARNING! Danger of electric shock In the event of an electrical accident, it must be possible to quickly disconnect the pump, and any electrical ancillaries which may possibly be present, from the mains.
  • Page 26 Installation Motor WARNING! EX pumps in areas at risk from explosion – Protect drive motors with appropriate motor protection switches. Only use motor protection permitted for this kind of application with Ex"e" motors. (Protection against heating from overloading) – Ensure that motors are only installed and inspected by a "recognisably trained"...
  • Page 27 Installation Motor data sheets, special motors, special motor flanges, external fan, temperature monitoring For further information for the motor with identity code – specification "S", refer to the motor data sheet in the Appendix. Motor data sheets can be requested for all other motors.
  • Page 28 Installation Overpressure sensor CAUTION! Warning of damage by overpressure – Electrically connect the overpressure sensor to a suit‐ able monitoring device. Stroke sensor (optional) Connect the stroke sensor to a suitable monitoring device according to the technical data provided with the monitoring device and that of the stroke sensor - see chapter "Technical data".

  • Page 29: Start Up

    Start up Start up Safety notes WARNING! EX pumps in areas at risk from explosion – An appropriately skilled operative should check whether the appropriate installation information from the "Installa‐ tion " chapter has been implemented correctly. WARNING! Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen.
  • Page 30 Start up CAUTION! When using pumps with speed control, observe the instruc‐ tions in the frequency converter operating instructions. Installing a vent screw Replace the sealing screw on the oil filler neck with the vent screw sup‐ plied - 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.
  • Page 31 Start up P_MA_0032_SW Fig. 17: Stroke length adjustment wheel with scale 10 mm = 100 % stroke length (10 6.3 mm = 63 % stroke length (6 rota‐ rotations) tions and 3 long scale mark‐ ings) Stroke length adjustment wheel markings: 1 rotation = 10 % 1 long scale marking =...

  • Page 32: During Operation

    During Operation During Operation WARNING! Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen. – During filling and draining of the liquid end, an expert must ensure that feed chemical does not come into con‐ tact with oxygen.

  • Page 33: Maintenance

    – These measures constitute the minimum protective measurements stipulated by ProMinent. It is the duty of the operator to eliminate any other dangers identified by appropriate measures. WARNING! Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen.
  • Page 34 Maintenance WARNING! Danger of an electric shock When working on the motor or electrical auxiliary equipment, there is a danger of an electric shock. – Before working on the motor, take note of the safety instructions in its operating instructions! –...
  • Page 35 Maintenance Interval Maintenance work quarterly* Check the tightening torques for the dosing head screws (1) (30 Nm) and the drive flange screws (2) (25 Nm). Check that the discharge valve and suction valve are correctly seated. Check the correct seating and state of the metering lines at both discharge and suction ends. Check for firm seating of the diaphragm rupture sensor.
  • Page 36 Maintenance Gear oil Gear oil Supplied quantity Part no. Mobilgear 634 VG 460 1.0 l 1004542 Gear oil filling volumes Types Volume, approx. 3.2 l Draining the gear oil: Remove the vent screw (1). Place an oil trough under the oil drain plug (2). Expected oil quantity - see filling volumes, above.

  • Page 37: Repairs

    Repairs Repairs Safety notes WARNING! EX pumps in areas at risk from explosion – Generally check the proper operation of the system, par‐ ticularly of the power end and bearings, by regular moni‐ toring (for leaks, noises, temperatures, smell ..). WARNING! Fire hazard with flammable media Only with combustible media: These may start to burn when...

  • Page 38: Replacing The Diaphragm

    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 39 Repairs P_MA_0038_SW Fig. 20: Cross-section through the liquid end Dosing head Diaphragm Reinforce plate Screw Leakage hole Slide rod Threaded connection Turret Backplate P_MA_0039_SW Fig. 21: Cross-section through the diaphragm rupture warning system Safety piston Spring Bushing O-ring Expandable point multi-layer diaphragm Undo the safety screw and remove the protective cover (5) from the backplate (6).

  • Page 40: Repair The Diaphragm Rupture Sensor

    Repairs Unscrew the diaphragm (2) from the slide rod (6) and detach. Clean the sealing surfaces. Smear the thread of the threaded connection of the diaphragm slide rod with a little screw locking paste. Screw the new diaphragm (2) up to the stop on the slide rod (8). ð...

  • Page 41: Ex Version

    Repairs When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head. Check for electrical continuity: Using a blunt insulating probe (Ø 2 ... 3 mm, no sharp edges), press into the channel of the diaphragm rupture sensor. ð...
  • Page 42 Repairs When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head. Check that the monitor does not indicate a diaphragm rupture: Using a blunt insulating probe (Ø 2 ... 3 mm, no sharp edges), press into the channel of the diaphragm rupture sensor. ð...

  • Page 43: Valve Repair

    Repairs 11.3 Valve repair Unsuitable spare parts for the valves may lead to problems for the pumps. Only use new components that are especially adapted to – fit your valve (both in terms of shape and chemical resistance). Use the correct spare parts kits. In case of doubt, refer –...

  • Page 44: Single Ball Valves

    Repairs Slide into the valve body (1) one after another: one seal (2) and one valve seat (3) - correct! one seal (2) and one valve bushing (4) (If fitted: one spring (*) into the spring guide of the valve seat (3) one ball (5) into the valve body (1) one seal (2) and the second valve seat (3, correct!) one seal (2) and the second valve bushing (4)

  • Page 45: Plate Valves

    Repairs Seal Valve body Valve ball Valve seat Valve cap P_MAK_0054_SW Fig. 25: Cross-section through the single ball valve 11.3.3 Plate valves Do not scratch the finely machined sealing surfaces on the valve plates (5) and valve inserts (6). Compression spring Valve body Valve plate Valve insert...
  • Page 46 Repairs Place the compression spring (3) inside the valve body (4). Place the compression spring with the end (see figure: arrow N, at the bottom) on one of the lugs in the valve body, as shown on the diagram. Otherwise the valve plate may knock when in opera‐ tion.

  • Page 47: Troubleshooting

    Troubleshooting Troubleshooting Safety notes WARNING! EX pumps in areas at risk from explosion – Generally ensure proper operation (no leaks, unusual noises, high temperatures, unusual smell ...) especially with the power end and the bearings. – Do not allow the pump to heat up because of lack of oil. If oil is escaping, investigate the leak immediately and eliminate the cause.
  • Page 48 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! 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.
  • Page 49 Rectify any constriction of the discharge line. Technical very hot. seriously constricted. personnel All other faults. Other causes. Call ProMinent ® Service. WARNING! Warning of escaping feed chemical When dosing combustible feed chemicals or in hazardous locations, under no circumstances must the second dia‐...

  • Page 50: Decommissioning And Disposal

    Decommissioning and Disposal Decommissioning and Disposal 13.1 Decommissioning WARNING! Fire hazard with flammable media Only with combustible media: These may start to burn when combined with oxygen. – During filling and draining of the liquid end, an expert must ensure that feed chemical does not come into con‐ tact with oxygen.

  • Page 51: Disposal

    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‐...
  • Page 52 Decommissioning and Disposal CAUTION! Environmental hazard due to gear oil The pump contains gear oil, which can cause damage to the environment. – Drain the gear oil from the pump. – Note the local guidelines currently applicable in your country! CAUTION! Note the local guidelines generally currently applicable in your country!

  • Page 53: Technical Data

    Technical data Technical data Only for "M - modified" design: 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! 14.1 Performance data Main pumps with 1500 rpm motor at 50 Hz operation Type Minimum pump capacity at maximum...

  • Page 54: Precision

    Technical data Main pumps with 1800 rpm motor at 60 Hz operation Type Minimum pump capacity at maximum Maximum Suction Connector size Shipping back pressure stroke rate lift weight* Strokes/min m WS G-DN 120260 81.8 1 1/2 - 25 46/54 120340 109.5 1 1/2 - 25...

  • Page 55: Metering Precision

    Technical data 14.2.2 Metering precision Data Value Unit Metering precision ±1 % * * at maximum stroke length and maximum back pressure 14.3 Viscosity The liquid ends are generally suitable for the following viscosity ranges: Design Range Unit no valve springs 0 ...

  • Page 56: Ambient Conditions

    Technical data Material version Liquid end Suction/pressure Seals Valve plates / valve Valve seat connector spring Stainless steel Stainless steel PTFE Ceramic / Hast. C + PTFE 1.4571/1.4404 1.4571/1.4404 CTFE** Hastelloy C4 Hastelloy C4 PTFE Hast. C PTFE Patented, vacuum packed, multi-layer diaphragm. ** The valve spring is coated with CTFE (similar to PTFE) 14.5 Ambient conditions...

  • Page 57: Air Humidity

    Technical data 14.5.2 Air humidity Data Value Unit Maximum air humidity *: 95 % rel. humidity *non-condensing (according to DIN IEC 60068-2-30) 14.6 Housing degree of protection Data Value Protection against contact and humidity* IP 55 *according to DIN VDE 470 (EN IEC 60529) 14.7 Stroke sensor (optional), intrinsically safe Stroke sensor (option), intrinsically safe...

  • Page 58: Motor Data

    Technical data Contact (standard) Contact loading, max. at voltage Maximum current 30 V DC The contact is an opener. The contact is an potential-free. For safety reasons we recommend connecting to a pro‐ – tective low voltage, e.g. in accordance with EN 60335-1 (SELV ).

  • Page 59: Filling Volumes

    Technical data 14.10 Filling volumes 14.10.1 Gear oil Gear oil Gear oil Supplied quantity Part no. Mobilgear 634 VG 460 1.0 l 1004542 Gear oil filling volumes Types Volume, approx. 3.2 l 14.11 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)

  • Page 60: Spare Parts

    ProMinent ® product catalogue 15.1 Spare parts Spare parts kit Makro TZ, TZMb Spare parts kit contents 1 - Diaphragm 1 - Suction valve compl. 1 - Discharge valve compl. 2 - Valve plate (DN40 with plate and spring)

  • Page 61: Other Material

    Spare parts Metering diaphragm PTFE ProMinent ® DEVELOPAN ® metering diaphragm from EPDM with woven inner layer, large area, vulcanised aluminium core and PTFE Teflon layer on the medium-contacted side. For 12(10) bar types: 120260, 120340, 120430, 120510, 120650 Liquid end type Part no.

  • Page 62: Dimensional Drawings

    Dimensional drawings Dimensional drawings Compare the dimensions on the dimension sheet and – pump. All dimensions are in mm. – Dimension sheet Makro TZ, TZMbH Main power end 557.5 (Standardmotor „S“) 436 (Standardm. „S“) Ø 9 11.5 P_MA_0041_SW_2 (93) 61_01_101_00_59_74_3 Fig.
  • Page 63 Dimensional drawings Dimension sheet Makro TZ, TZMbA with Main power end with add-on power end or double head version TZMbB or TZMbD 436 (Standardm. „S“) 549 (Standardmotor „S“) P_MA_0020_SW 61_01_101_00_59_74_2x01 Fig. 29 Dimensions Makro TZ (in mm) Type 120260, 120260,...

  • Page 64: Motor Data Sheet

    This information is supplied without liability. Les données techniques correspondent au descriptif du fabricant des moteurs. Les données techniques des moteurs similaires chez d’ autres fabricants varient très peu. Données sont d’ ordre général. ProMinent Dosiertechnik GmbH . 69123 Heidelberg . Germany Nr./No. MD-1039212...
  • Page 65 Diagrams for adjusting the capacity Diagrams for adjusting the capacity MakroTZ, TZMb H/A at 50 Hz MakroTZ, TZMb D/B - per liquid end at 50 Hz Fig. 30: Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis of back pressure p for the different types of a series.
  • Page 66 Diagrams for adjusting the capacity Fig. 31: Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis of back pressure p for the different types of a series.
  • Page 67 Diagrams for adjusting the capacity MakroTZ, TZMb H/A at 60 Hz MakroTZ, TZMb D/B - per liquid end at 60 Hz Fig. 32: Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis of back pressure p for the different types of a series.
  • Page 68 Diagrams for adjusting the capacity Fig. 33: Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis of back pressure p for the different types of a series.
  • Page 69 This declaration loses its validity in the event of a modification to the product not agreed with us. Designation of the product: Metering pump, Makro TZ series Product type: TZMb... TZKa... Serial number:...
  • Page 72 ProMinent GmbH Im Schuhmachergewann 5-11 69123 Heidelberg Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-612 email: info@prominent.com Internet: www.prominent.com 985742, 2, en_GB © 2002...

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