ProMinent Makro/ 5 Operating Instructions Manual
Diaphragm metering pump
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Operating instructions
Diaphragm 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. 985753
Makro/ 5 M5Ma
Technical changes reserved.
Original Operating Instructions (2006/42/EC)
®
motor-driven metering
BA MAK 005 10/11 EN
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Table of Contents
Related Manuals for ProMinent Makro/ 5
Summary of Contents for ProMinent Makro/ 5
- Page 1 Makro/ 5 M5Ma ® 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 985754, 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 accesso‐ ries".
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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........14 Overview of equipment, control elements......16 Functional description............19 Assembly................21 Installation................24 8.1 Installation, hydraulic..........24 8.2 Installation, electrical..........26 Start up................ -
Page 5: Identity Code
Identity code Identity code M5Ma Makro/ 5 diaphragm metering pump Power end type Main power end Main power end, doubled Add-on power end Add-on power end doubled Type: 041540 4 1540 041900 4 1900 042600 4 2600 043400 4 3400... - Page 6 Identity code M5Ma Makro/ 5 diaphragm metering pump C With ProMinent ® logo, with triple frame D With ProMinent logo, with quadruple frame ® M Modified* * order-related version, for pump features see order paperwork Electric power supply 3 ph, 230 V/400 V 50/60 Hz (WBS)
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Page 7: About This Pump
® Makro/ 5 externally mounted metering pump can be combined with the Makro/ 5 main power end to form a double or multiple pump. A main power end can be combined with up to four add-on power ends. One power end can be used both as a single or a double head version. -
Page 8: Safety Chapter
Safety chapter Safety chapter Identification of safety notes The following signal words are used in these operating instructions to denote different severities of danger: Signal word Meaning WARNING Denotes a possibly dangerous situation. If this is disregarded, you are in a life-threatening sit‐ uation and this can result in serious injuries. - Page 9 The general limitations with regard to viscosity limits, chemical resistance and density must be observed - see also ProMinent resistance list (In the product catalogue or at www.prominent.com )! Any other uses or modifications are prohibited.
- Page 10 Safety chapter Activity Qualification level Decommissioning, disposal Technical personnel, service Troubleshooting Technical personnel, electrical technician, instructed person, service Explanation of the terms: Technical personnel A qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognise possible dangers based on his/her technical training, knowledge and experience, as well as knowledge of pertinent regulations.
- Page 11 . CAUTION! Danger of personnel injury and material damage The use of untested third party parts can result in per‐ sonnel injuries and material damage. – Only fit parts to metering pumps, which have been tested and recommended by ProMinent.
- Page 12 Adhere to the safety data sheet for the feed chemical. 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...
- Page 13 Safety chapter WARNING! Warning of personal injury and material damage – The customer must only remove the protective equipment if requested to do so by the operating instructions. – The pump must not operate without fitted protec‐ tive equipment. Sound pressure level Sound pressure level LpA <...
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Page 14: Storage, Transport And Unpacking
WARNING! The transporting of pumps which have been used with radioactive 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 decommissioning! Only send metering pumps with a filled in Decontami‐... - Page 15 Storage, transport and unpacking Storage Personnel: Technical personnel Place the caps on the valves. Check whether the seal screw is screwed into oil filler opening instead of the vent screw. Preferably place the pump standing vertically on a pallet and secure against falling over.
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Page 16: 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) A Power end C Liquid end Lifting eye Stroke length adjustment wheel Indicating dial motor Oil drain plug P_MAK_0027_SW Fig. - Page 17 Overview of equipment, control elements Power end, double head P_MAK_0029_SW Fig. 5: View from the motor side (here M5Ka D) A Power end C 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 18 Overview of equipment, control elements Liquid end P_MAK_0031_SW Fig. 7 Discharge valve Dosing head Suction valve Tube nozzle for leakage Protective cover...
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Page 19: Functional Description
Functional description Functional description Power end functional description The Makro/ 5 metering pump is a motor-driven metering pump with a kinematic 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 20 Functional description Functional description of the dia‐ The diaphragm (3) hermetically shuts off the pump volume of the phragm liquid end (for M5Ma) dosing head (2) from the outside. The suction valve (4) closes as soon as the diaphragm (3) is moved in to the dosing head (2) and the feed chemical flows through the discharge valve (1) out of the dosing head.
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Page 21: Assembly
EX pumps only: When operating in EX areas, certain subjects 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. - Page 22 Assembly Supporting floor WARNING! Risk of electric shock If water or other electrically conducting liquids pene‐ trate into the drive housing, an electric shock may occur. – Position the pump so that drive housing cannot be flooded. P_MOZ_0016_SW Fig. 10 WARNING! The pump can break through the supporting floor or slide off it...
- Page 23 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 –...
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Page 24: Installation
EX pumps only: When operating in EX areas, certain subjects 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. - Page 25 Installation CAUTION! Warning about personal and material damage Also observe the "General Operating Instructions for ProMinent Motor-Driven Metering Pumps and ® Hydraulic Accessories"! CAUTION! Suction problems possible For feed chemicals with a particle size greater than 0.3 mm, the valves may no longer close properly.
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Page 26: 8.2 Installation, Electrical
Installation Precise metering is only possible when the back – pressure is maintained above 1 bar at all times. If metering at atmospheric pressure, a back pres‐ – sure valve should be used to create a back pres‐ sure of approx. 1.5 bar. Personnel: Technical personnel Route the leakage liquid drainage line... - Page 27 EX pumps only: When operating in EX areas, certain subjects 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.
- Page 28 Notes on the speed controlled motor with external – fan and temperature monitoring can be found in the "General operating instructions for ProMinent ® motor-driven metering pumps and hydraulic acces‐ sories"! The external fan requires an independent mains con‐...
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Page 29: Start Up
EX pumps only: When operating in EX areas, certain subjects 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. - Page 30 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 ele‐ ments". 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 31: During Use
EX pumps only: When operating in EX areas, certain subjects 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. -
Page 32: Maintenance
EX pumps only: When operating in EX areas, certain subjects 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. - Page 33 Maintenance WARNING! Risk of injury from the fan impeller The fan impeller beneath motor's fan cowling can cause severe injuries while it is turning. – The pump must only be connected to the mains voltage with the fan cowling closed. CAUTION! Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic compo‐...
- Page 34 Maintenance 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 ProMi‐ nent motor-driven metering pumps and hydraulic accessories" ® Check the tightening torques for the dosing head screws (1) (30 Nm) and the drive flange screws (2) (25 Nm).
- Page 35 Maintenance Changing the gear oil WARNING! Risk of burns due to hot gear oil The gear oil may become very hot when the pump is heavily loaded – When draining oil, avoid contact with the oil run‐ ning out. Gear oil Gear oil Supplied quantity Part no.
- Page 36 Maintenance 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). P_MAK_0044_SW Fig.
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Page 37: Repairs
EX pumps only: When operating in EX areas, certain subjects 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. -
Page 38: Replacing The Membrane
Repairs WARNING! Risk of injury from the fan impeller The fan impeller beneath motor's fan cowling can cause severe injuries while it is turning. – The pump must only be connected to the mains voltage with the fan cowling closed. CAUTION! Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic compo‐... - Page 39 Repairs P_MAK_0045_SW Fig. 19: Cross-section through the liquid end Dosing head Diaphragm Reinforce plate Screw Protective cover Backplate Bellows Slide rod Tube nozzle Undo the screws (4) on the reinforce plate. Remove the dosing head (1) with the screws from the back‐ plate (6).
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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 informa‐ tion 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: Single Ball Valves
Repairs When assembling, take note of the orientation of the valve seats (3). The valve seats (3) are used as a ball seat on the fine machined side and as a ball cage and spring guide on the other side. The fine machined side must point in the flow direction with all valve seats. -
Page 42: Plate Valves
Repairs If available: Place the compression spring inside the valve body (2). Insert the valve ball (3 and the valve seat (4). Screw on the valve cap (5). Pay attention to the flow direction of the discharge and suction connectors when fitting the valve. P_MAK_0054_SW Fig. - Page 43 Repairs P_MAK_0055_SW Fig. 22: 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 Fig. 22. Carefully remove the parts from the valve body (4).
- Page 44 Repairs Fig. 23: Inserting the compression spring...
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Page 45: Troubleshooting
EX pumps only: When operating in EX areas, certain subjects 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. - Page 46 Troubleshooting 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, protec‐ tive gloves, ...).
- Page 47 The power end motor is The discharge line Technical Rectify any constriction of the discharge very hot. is seriously con‐ line. personnel stricted. Have the safety relief valve checked. All other faults. Other causes. Call ProMinent or ProMaqua service. ® ®...
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Page 48: Decommissioning And Disposal
EX pumps only: When operating in EX areas, certain subjects 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. - Page 49 Decommissioning and disposal CAUTION! Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic compo‐ nents if they are manipulated or opened due to pres‐ sure in the liquid end and adjacent parts of the system. –...
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Page 50: Disposal
Decommissioning and disposal Preferably place the pump on a pallet. Cover the pump with a tarpaulin cover - allowing rear ventila‐ tion! Store the pump is a dry, sealed place under storage condi‐ tions according to the chapter "Storage, Transport and Unpacking". -
Page 51: Technical Data
Technical data Technical data Only for "M - modified" version: WARNING! Risk of personal injuries Please observe the ”Supplement for modified ver‐ sion“ at the end of the chapter! It replaces and supplements the technical data! 15.1 Performance data Main pumps with motor 1500 rpm under 50 Hz operation Type Minimum pump capacity at max‐... -
Page 52: Accuracy
Technical data Main pumps with motor 1800 rpm under 60 Hz operation Type Minimum pump capacity at max‐ Maximum Suction Connector Shipping imum back pressure stroke rate lift size weight* Strokes/min m WS G-DN 41540 1822 2 1/2"-50 41900 2254 2 1/2"-50 42600 3104... -
Page 53: Wetted Materials
500 ... 1000 mPas laid out installation with appropriately > 1000 mPas laid out installation and advice from ProMinent * Only when the installation is correctly adjusted 15.4 Wetted materials Material ver‐ Liquid end Suction/dis‐ Seals Valve plates /... -
Page 54: Air Humidity
Technical data Data Value Unit Minimum temperature -10 °C PP liquid end Data Value Unit Max. temperature long-term at max. 60 °C operating pressure Max. temperature for 15 min at max. 2 100 °C Minimum temperature -10 °C TT liquid end Data Value Unit Max. -
Page 55: Stroke Sensor (Option), Intrinsically Safe
Technical data 15.7 Stroke sensor (option), intrinsically safe Namur sensor (identity code specifica‐ tion "Stroke sensor": 1) Install the sensor according to the chapter "Installation, electrical". Namur sensor (Specified for EX 5–25 V DC, in accordance with Namur or DIN 19234, potential-free zones) design. -
Page 56: 15.10 Compatibility
Technical data 15.10 Compatibility The hydraulic accessories of the Makro/ 5 metering pump Hydro are compatible with the Sigma and Makro TZ piston pumps. The connecting dimensions of valves and dosing heads are the same size but have different materials. (This does not apply with different diaphragm materials). -
Page 57: Ec Declaration Of Conformity
- 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 explo‐ sive atmospheres is enclosed with the pump. The EC Declaration of Conformity, the EC type-test reports and the operating instructions for the individual components are also enclosed with the pump.
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Page 59: Index
Index Index motor.............. 27, 56 Accuracy.............. 52 Air humidity............54 Namur sensor............55 Ambient conditions..........53 Assembly.............. 21 Oil................. 55 Capacity............... 51 Protection against contact and humidity....54 Climate..............54 Pump capacity............51 Compatibility............56 Connector size............. 51 Qualification of personnel........9 Correct and proper use..........