ProMinent DULCOflex DF4a Assembly And Operating Instructions Manual
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ProMinent DULCOflex DF4a Assembly And Operating Instructions Manual

ProMinent DULCOflex DF4a Assembly And Operating Instructions Manual

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Assembly and operating instructions
Peristaltic pump
DULCOflex DF4a
EN
A2536
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.
The latest version of the operating instructions are available on our homepage.
Part no. 986513
Original operating instructions (2006/42/EC)
Version: BA DX 034 10/21 EN

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Summary of Contents for ProMinent DULCOflex DF4a

  • Page 1 Assembly and operating instructions Peristaltic pump DULCOflex DF4a A2536 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. The latest version of the operating instructions are available on our homepage.
  • Page 2 Supplemental directives General non-discriminatory approach 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.

  • Page 3: Table Of Contents

    Table of contents Table of contents About this product..............5 1.1 Nameplate..............6 1.2 Construction and functional description......6 1.3 Overview of equipment and control elements....7 Identity code................8 Safety chapter..............10 3.1 Labelling of Warning Information........ 10 3.2 User qualification............12 3.3 General safety information..........
  • Page 4 Table of contents 10.3 Warning with error message........54 10.4 All other faults............54 Decommissioning and disposal.......... 55 11.1 Use Parts Disposal/Declaration of Decontamina‐ tion................56 Technical data..............57 12.1 Performance data............. 57 12.2 Precision..............57 12.3 Dimensions and weights........... 57 12.4 Material specifications..........

  • Page 5: About This Product

    The printed version of the assembly and operating instructions is naturally not updated. We would therefore ask you to regularly visit the manufacturer’s homepage www.prominent.com to find out about the new electronic versions of the assembly and operating instructions. These versions may contain, among other things, information about new fault remedies or spare parts.

  • Page 6: Nameplate

    About this product 1.1 Nameplate A2547 Fig. 2: Nameplate The nameplate provides information on: Manufacturer with address and phone number Place and country of origin, Manufacturing date in week/year [Type] , Type of pump with identity code [EL. ANSCHLUSS] in Volts / Hertz, watts Electrical connection and amps [SER.NR.

  • Page 7: Overview Of Equipment And Control Elements

    About this product 1.3 Overview of equipment and control elements 11 10 9 8 P_DX_0032_SW_2 Fig. 3: Overview of DF4a equipment. A) Front view, B) Side view / Functional plug for “Level” socket Rotor Pressure connector Control keys “Level” socket, if required with functional plug for LCD display the “Level”...

  • Page 8: Identity Code

    Identity code Product range DULCO ® flex DF4a DF4a Applications Chemical pump A Metering of active carbon Metering of flocculants Installation type W Wall-mounted Design with ProMinent logo ® without ProMinent ® logo Type Pump capacity 04004 0.35 04015 1.50 03060 6.00...
  • Page 9 Identity code Product range DULCO flex DF4a ® 3 Fault indicating relay (N/O) Control version manual + external contact and analogue 0/4-20 mA + 0-10 V as 8 and CANopen as 8 and CANopen and CAN connector Additional inputs Pause + 2-stage level + AUX_1 Pause + 1-stage level + AUX_1 + AUX_2...

  • Page 10: Safety Chapter

    Safety chapter Safety chapter 3.1 Labelling of Warning Information Introduction These operating instructions provide information on the technical data and functions of the product. These operating instructions pro‐ vide detailed warning information and are provided as clear step- by-step instructions. The warning information and notes are categorised according to the following scheme.
  • Page 11 Safety chapter Type of information Hints on use and additional information. Source of the information. Additional measures. Denotes hints on use and other useful informa‐ – tion. It does not indicate a hazardous or dam‐ aging situation.

  • Page 12: User Qualification

    Safety chapter 3.2 User qualification WARNING! Danger of injury with inadequately qualified per‐ sonnel The operator of the system / equipment is respon‐ sible for ensuring that the qualifications are ful‐ filled. If inadequately qualified personnel work on the unit or loiter in the hazard zone of the unit, this could result in dangers that could cause serious injuries and material damage.

  • Page 13: General Safety Information

    Safety chapter 3.3 General safety information Safety information WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious inju‐ ries. Please ensure when handling hazardous sub‐ stances that you have read the latest safety data sheets provided by the manufacture of the haz‐ ardous substance.

  • Page 14: Intended Use

    Safety chapter 3.4 Intended use Only use the pump to meter liquid feed chemicals. Only use the system in accordance with the technical data and specifications outlined in the operating instructions. Only use the pump if it has been correctly installed and started All other uses or modifications are prohibited.

  • Page 15: Storage And Transport

    Storage and transport Storage and transport 4.1 Storage Ä Chapter 3.2 ‘User qualifi‐ User qualification: instructed user, see cation’ on page 12 Permissible ambient temperature: - 10 °C ... +55 °C. Humidity: maximum 95% relative air humidity, non-condensing. Other ambient conditions: No dust, no direct sunlight. 4.2 Transport The sensor should be transported in its original packaging and in compliance with the permissible environmental conditions.

  • Page 16: Assembly And Installation

    Assembly and installation Assembly and installation User qualification: trained qualified personnel or electrical tech‐ Ä Chapter 3.2 ‘User qualification’ on page 12 nician, WARNING! Carry out mechanical and hydraulic assembly work before commencing the electrical installation. Outdoors The unit is resistant to normal atmospheres in plant rooms.

  • Page 17: Dimensional Drawing

    Assembly and installation 5.1 Dimensional drawing 125,4 P_DX_0037_SW Fig. 5: Dimensional drawing of DF4a - dimensions in mm (not true to scale)

  • Page 18: Assembly

    Assembly and installation 5.2 Assembly Ä Chapter 3.2 User qualification: trained qualified personnel, ‘User qualification’ on page 12 P_DX_0034_SW Fig. 6: Wall-mounted, parked position - dimensions in mm (not true to scale). Mark the drill holes on the wall - see Fig. 4. Drill the Ø...

  • Page 19: Installation, Hydraulic

    Assembly and installation A2570 Fig. 8: Parked position Slide the upper part of the housing (1) with the side flaps (3) up into the recesses in the lower part of the housing (2) (parked position). Screw the right and left side of the unit to the wall using the remaining screws.
  • Page 20 Assembly and installation A2563 Fig. 9: Assembling the suction and metering line Shorten the end of the hose at right angles. Unscrew the union nut (2) and slide the union nut over the hose (3). Push the hose end over the hose connector (4) as far as the stop.

  • Page 21: Installation, Electrical

    Assembly and installation 5.4 Installation, electrical Ä Chapter 3.2 User qualification: trained electrical technician, ‘User qualification’ on page 12 WARNING! Danger of electric shock The operator must fit an RCD or another suitable measure to protect personnel and equipment. WARNING! Unexpected start-up is possible The pump can start pumping and consequently feed chemical may escape as soon as the pump is...

  • Page 22: Additional Connections

    Assembly and installation Risk of short circuit Cable ends without cable end sleeves can loosen over a period of time and come into contact with other cable ends. Only use cables with suitable cable end sleeves (0.75 Guide the mains cable into the threaded connector. Connect the mains cable to terminal block XP1 - see Fig.
  • Page 23 This means that the pump can be installed and operated immediately. The contact jumper may need to be removed when wiring the unit. A suction lance with a ProMinent ® round plug can be inserted directly into the “Level”...
  • Page 24 If you are using a suction lance with an open lead or if you have a plug that does not fit, you can cut off this plug and connect the cable leads directly to the terminals, Fig. 12. P_DX_0038_SW Fig. 12: Example: Terminal wiring diagram for ProMinent 2-stage level switch ® Fault, level 2...

  • Page 25: Close The Housing

    Assembly and installation 5.4.4 Close the housing Place the upper part of the housing onto the lower part of the housing. Manually tighten the 4 screws, approx. 3.5 Nm. WARNING! Danger of electric shock IP 65 degree of protection cannot be ensured if the seal is not properly fitted.

  • Page 26: Commissioning

    Commissioning Commissioning Ä Chapter 3.2 ‘User qualifica‐ User qualification: trained user tion’ on page 12 WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious inju‐ ries. Please ensure when handling hazardous sub‐ stances that you have read the latest safety data sheets provided by the manufacture of the haz‐...
  • Page 27 Commissioning Check that everything has been properly fitted. Set up the pump as is sensible and necessary for your metering process, see chapters Ä Chapter 7.3.2 ‘Modifying the operating mode ( ‘MODE’ menu)’ on page 38 and Ä Chapter 7.3.1 ‘Operating menu overview’ on page 36 . Operating Property Typical application...

  • Page 28: Setting

    Setting Setting 7.1 Control unit The unit is operated by the control unit on the right side of the unit. P_DX_0031_SW Fig. 13: Control unit LCD display Control keys 7.1.1 LCD display The LCD display consists of a two-line display. The brightness of the LCD display can be adjusted - see chapter entitled "Adjusting the LCD contrast".

  • Page 29: Led

    Setting 7.1.2 LED Tab. 3: The unit LEDs (left) show the following information: Information No supply voltage steady green Pump ready and stopped flashing green Pump ready and running steady red Fault, metering stopped steady orange Level error; storage tank is empty; pump stopped flashing orange Level warning Tab.
  • Page 30 Setting The control keys have different functions in the continuous display, in the operating menu and in the sub-menus: Tab. 6: Function of the control keys in conjunction with the continuous display Functions Lower / change the set value DOWN Increase / change the set value Move to the next menu item Tab.

  • Page 31: Continuous Displays

    Setting 7.2 Continuous displays 7.2.1 Chemical pump Display in STOP mode (calibrated) → Display in MANUAL mode Display in START mode (calibrated) Display in CONTACT mode Display in ANALOG mode → Concentration activated (calibrated) → Fig. 14: Overview of continuous displays Continuous display “...

  • Page 32: Active Carbon Pump Or Flocculant Pump

    Setting 7.2.2 Active carbon pump or flocculant pump No input >8 sec. Display in STOP mode → Display in MANUAL mode Display in START mode Display in CONTACT mode Display in START mode Display in ANALOG mode Display in START mode Fig.

  • Page 33: Setting Options For The Continuous Display

    Setting 7.2.3 Setting options for the continuous display The parameters and setting ranges The following parameters can be set directly on the continuous dis‐ play. The parameters can be modified both in Metering mode as well as in Stop mode. Description Meaning Setting range...

  • Page 34: Operating Menu

    Setting Would you like to set the final concen‐ Press [P] as often as required until ‘FLOW’ appears in the tration? first line of the LCD display. [P] and use the [arrow keys] to enter Press and hold down the circulation output. ‘CONC’...
  • Page 35 Setting Tab. 10: The operating menu comprises the following menus (depending of the unit ordered and settings): ‘MODE’ ‘SET’ ‘CONFIG’ ‘SERVICE’ ‘INFO’ ‘SECURITY’ ‘CALIBRATION’...

  • Page 36: Operating Menu Overview

    Setting 7.3.1 Operating menu overview Fig. 18: Overview of DF4a operating menu...
  • Page 37 Setting 2.2.2.0 Fig. 19: Overview of DF4a operating menu when MODE = ANALOG when LEVEL MODE = LEVEL 1ST when MODE = CONTACT with application ACTIVE CARBON In the event of blocked access...

  • Page 38: Modifying The Operating Mode ( 'Mode' Menu)

    Setting ‘MODE’ menu) 7.3.2 Modifying the operating mode ( There are two operating modes: ‘MANUAL’ ‘ANALOG’ ‘CONTACT’ . The operating mode setting determines whether the capacity of the pump is to be manually set, controlled by the analogue input (circu‐ lating output) or controlled by the contact input.
  • Page 39 Setting 7.3.3.2.1 Unit LED signals ‘MANUAL’ and ‘ANALOG’ operating modes, the unit Unlike in LED flashes with every contact signal. A contact frequency in excess of 10 Hz is displayed by a constant flashing frequency of 10 Hz. For this reason, the flashing frequency for frequencies over 10 Hz is merely an indication that contact sig‐...
  • Page 40 Setting P_DX_0030_SW Fig. 20: A Contact mode, B Frequency mode, C Constant range Special behaviour with extended Possible settings: function MEMORY Manual capacity: 10%, Metering volume per contact: 2.5 ml/p Factor (pulse interval): 1.0 Maximum capacity: 1.5 l/h The 20 contact signals correspond to: 20 x 2.5 ml = 50 ml If the contact signals are supplied rapidly (>...
  • Page 41 Setting Factor The pump is equipped for contact water meter operation and delivers 100% of its capacity at a contact frequency of 3 Hz (180 contacts/min). The contact frequency at which the pump works at ‘FACTOR’ parameter. 100% capacity can be modified by the Example For example, 100% capacity is achieved at 2 Hz with a factor of 1.5.

  • Page 42: Changing The Configuration ( 'Config' Menu)

    Setting The purpose of Factor mode is to convert the incoming pulses with a step-down (fraction) or small step-up to specific metering volumes. ‘P’ . Enter the required factor and press ‘ON’ ( [arrow keys] ) Enable the Concentration function using ‘P’...
  • Page 43 Setting ‘PAUSE’ sub-menu) 7.3.4.1 Pause input configuration ( ‘Pause’ can be used to trigger a remote stop for the Switch input pump, without the need to disconnect the pump from the mains. You can set the standard position of the switch, which is connected to the pause input, in the operating menu.

  • Page 44: Service Menu ( 'Service' Menu)

    Setting ‘PAUSE DELAY’ ) 7.3.4.5 Configuring the pause delay timer ( This setting menu enables pump metering to be delayed after a ‘PAUSE’ ). remote stop ( ‘SERVICE’ menu) 7.3.5 Service menu ( In the service menu you can: ‘CLEAR COUNTER’ ) 1 - Reset the counter ( ‘REVERSE’...

  • Page 45: Reading System Information ( 'Info' Menu)

    Setting The unit can only be backflushed after the pump has been switched on after a metering time of 1 minute. Backflushing speed We recommend leaving the maximum speed set so that the deposits can be removed more effectively. You can set the backflushing speed in the ‘REVERSE FREQ.’...

  • Page 46: Security-Relevant Settings ( 'Security' Menu)

    Setting Press [P] . ‘IDENTCODE 2/2’ display shows the second half of ð The the identity code. Press [P] for approx. 3 seconds. ð A continuous display appears. ‘SECURITY’ menu) 7.3.7 Security-relevant settings ( The following security-relevant settings can be set: ‘ACCESS LEVEL’...
  • Page 47 Setting If the hose type is changed, then the corre‐ sponding rotor must also be used. 7.3.7.4 Setting the access code (CHANGE CODE sub-menu) You can activate, enter or change an access code in this sub- menu. The factory setting for the access code is 1111. Once you have set an access code, the access code then limits access to operation, .

  • Page 48: Calibrating The Pump (Calibration Menu)

    Setting 7.3.8 Calibrating the pump (CALIBRATION menu) Only calibrate the pump with water for reasons of safety and ease of use. Requirements: The pump is stopped. The suction hose hangs freely into a filled measuring tank or into a tank filled with water standing on scales. Note down the liquid level of the weight.

  • Page 49: Operation

    Operation Operation Starting / stopping the pump Ä Chapter 3.2 ‘User qualifi‐ User qualification: instructed user, see cation’ on page 12 The pump can be started / stopped using: [Start/Stop] key Pause input Mains switch Replacing the feed chemical storage tank WARNING! Danger from hazardous substances!

  • Page 50: Maintenance

    Maintenance Maintenance Ä Chapter 3.2 ‘User qualifica‐ User qualification: trained user, tion’ on page 12 Expected service life of the pump hose Determining the service life of the pump hose At the start of the pumping process, regularly check the pump hose for wear, several times a day if necessary.
  • Page 51 Maintenance Replacing the pump hose WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious inju‐ ries. Please ensure when handling hazardous sub‐ stances that you have read the latest safety data sheets provided by the manufacture of the haz‐ ardous substance.
  • Page 52 Maintenance Press [P] for approx. 2 seconds. ‘MAIN’ input page appears. ð The [DOWN] 4x ... Press ‘4.SERVICE’ menu appears. ð ... the [P] as often as needed ... Press ‘CHANGE TUBE’ appears. ð ... until [arrow keys] . Simultaneously press the ð...

  • Page 53: Troubleshooting

    Troubleshooting Troubleshooting Ä Chapter 3.2 ‘User qualifica‐ User qualification: trained user, tion’ on page 12 10.1 Errors without error messages Fault description Cause Remedy The pump is not working despite The black functional plug or the Insert the black functional plug or the having been started and con‐...

  • Page 54: Warning With Error Message

    * The warning only appears if the warning has been set up in the ‘CONFIG’ menu under ‘RELAY-LEVEL’ . 10.4 All other faults Inform Service or your ProMinent branch. You will find the current contact addresses on the manufacturer's homepage www.promi‐ nent.com.

  • Page 55: Decommissioning And Disposal

    Decommissioning and disposal Decommissioning and disposal Decommissioning Ä Chapter 3.2 ‘User User qualification: instructed user, see qualification’ on page 12 WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious inju‐ ries. Please ensure when handling hazardous sub‐ stances that you have read the latest safety data sheets provided by the manufacture of the haz‐...

  • Page 56: Use Parts Disposal/Declaration Of Decontamination

    NOTICE! Regulations governing the disposal of used parts – Note the national regulations and legal stand‐ ards that currently apply in your country when disposing of the product. ProMinent GmbH, Heidelberg/Germany will take back clean used parts.

  • Page 57: Technical Data

    Technical data Technical data 12.1 Performance data Tab. 12: DULCO flex DF4a ® Type Operating Capacity* Speed Pump Connector Suction Priming Permissible pressure* of hose size lift** lift** priming pressure on PharMed ® outer Ø x outer Ø x the suction inner Ø...

  • Page 58: Material Specifications

    Technical data 12.4 Material specifications Part Material Pump hose PharMed ® Hose connection PVDF Rollers on the rotor PVDF Rotor and roller lever Transparent cover Dosing head Housing upper part PPE+GF Housing lower part Damping plate Soft PVC Cable threaded connectors PA / Neoprene ®...

  • Page 59: Degree Of Protection And Safety Requirements

    Technical data 12.6 Degree of protection and safety requirements Degree of protection Specification Information Protection against contact and moisture IP 65 according to DIN EN 60529. Safety requirements Specification Information Protection class 1 - according to DIN EN 60335-1 (protective conductor connection required).

  • Page 60: Sound Pressure Level

    Technical data Input Specification Parameter Filter time constants: 1 second 0 ... 10 V input Input resistance: 13 kΩ against +5 V Filter time constants: 1 second Tab. 14: Pause input: Input Specification Value Contact input Input resistance: 15 kΩ against +5 V Max.

  • Page 61: Ordering Information For Spare Parts/Accessories

    Ordering information for spare parts/accessories Ordering address for spare parts and accessories: The current address for ordering spare parts and accessories can be found on the manufacturer's homepage www.prominent.com. Fig. 23: Pump hose for DF4a Tab. 19: Pump hoses for DF4a...

  • Page 62: Declaration Of Conformity For Machinery

    In accordance with DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL, Appendix I, BASIC HEALTH AND SAFETY REQUIREMENTS, section 1.7.4.2. C. ProMinent GmbH Im Schuhmachergewann 5 - 11 D - 69123 Heidelberg, Germany, hereby declare that the product specified in the following, complies...

  • Page 63: Overview Of Setting Parameters

    Overview of setting parameters Overview of setting parameters Application as chemical pump Parameter Meaning Setting range Factory setting ‘DOS’ Capacity 7.5 ml/h* ... 99.80 l/h* 0.30 l/h AUX_1 / AUX_2 Manual capacity change 7.5 ml/h* ... 1.50 l/h* 0.75 l/h / 1.25 l/h ‘MANUAL’...
  • Page 64 Overview of setting parameters Parameter Meaning Setting range Factory setting ‘TUBE TYPE’ Hose dimensions 0.5 l/h, (dependent on identity code) 1.5 l/h, 6.0 l/h, 12.0 l/h ‘CONCENTRAT.’ Concentration 0.01 ppm ... 9999 ppm 40.0 ppm ‘MASS PERCENT’ Mass percent 0.1 ... 100.0% 100.0% ‘DENSITY’...
  • Page 65 Overview of setting parameters Application as flocculant pump and active carbon pump Parameter Meaning Setting range Factory setting ‘CONC’ Metering concentration 0.01 ml/m³ ... 99.9 ml/m³ 1.5 ml/m³ ‘FLOW’ Circulation capacity 0(1) m³/h – 999 m³/h 200 m³/h ‘DOS’ Capacity 7.5 ml/h* ...
  • Page 66 Overview of setting parameters Parameter Meaning Setting range Factory setting ‘REV.RUN COUNT’ Service interval counter 0 ... 32767 ‘REV. TESTMODE’ Test operation for reverse OFF, ON mode ‘ENTER CODE’ Enter access code 0000 ... 9999 1111 ‘ACCESS LEVEL’ Level access protection NONE, NONE LOCK MENU,...

  • Page 67: Index

    Index Index COUNTER ......44 Access code ......47 Access level .
  • Page 68 Index LIMIT ........43 Relevant EC directives: ....62 Links to elements or sections of these instruc‐...
  • Page 72 ProMinent GmbH Im Schuhmachergewann 5 - 11 69123 Heidelberg, Germany Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-419 Email: info@prominent.com Internet: www.prominent.com 986513, 3, en_GB © 2021...

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