ProMinent DULCO flex DFCa Operating Instructions Manual
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ProMinent DULCO flex DFCa Operating Instructions Manual

ProMinent DULCO flex DFCa Operating Instructions Manual

Peristaltic pump
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Operating instructions
DULCO
flex DFCa
®
Peristaltic Pump
EN
A0374
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. 986227
Original Operating Instructions (2006/42/EC)
BA DX 021 12/15 EN

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Summary of Contents for ProMinent DULCO flex DFCa

  • Page 1 Operating instructions DULCO flex DFCa ® Peristaltic Pump A0374 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.
  • Page 2 Supplemental instructions 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 Introduction................4 1.1 Explanation of the safety information......4 1.2 Users' qualifications............5 1.3 Identity Code for DULCO ® flex DFCa 030..... 7 1.4 Identity Code for DULCO ® flex DFCa 040..... 9 1.5 Identity Code for DULCO ®...

  • Page 4: Introduction

    Introduction Introduction These operating instructions provide information on the technical data and functions of the DULCO ® flex peristaltic pump product range DFCa. 1.1 Explanation of the safety information Introduction These operating instructions provide information on the technical data and functions of the product. These operating instructions pro‐ vide detailed safety information and are provided as clear step-by- step instructions.

  • Page 5: Users' Qualifications

    A trained user is a person who fulfils the requirements made of an instructed person and who has also received additional training specific to the system from ProMinent or another authorised distribution partner. Trained qualified per‐ A qualified employee is deemed to be a person who is able to assess the...
  • Page 6 Customer Service depart‐ Customer Service department refers to service technicians, who have ment received proven training and have been authorised by ProMinent to work on the system. Note for the system operator The pertinent accident prevention regulations, as well...

  • Page 7: Flex Dfca 030

    Introduction 1.3 Identity Code for DULCO ® flex DFCa 030 Identity code DFCa DULCO ® flex DFCa 030 Type 030 DFCa 030, 0.433 l/revolution Power end/drive Pump without power end/drive Reduction gear system / 3 x 230 / 400 VAC 0.25 kW, 18 rpm, 468 l/h, 4 bar 0.37 kW, 29 rpm, 753 l/h, 4 bar 0.55 kW, 38 rpm, 987 l/h, 4 bar...
  • Page 8 Introduction Identity code DFCa DULCO flex DFCa 030 ® Base plate, stainless steel Portable unit + lacquered steel base plate Portable unit + stainless steel base plate Leakage sensor without leakage sensor with leakage sensor with leakage sensor and relay output Rotor Rotor with 2 rollers Batch control...

  • Page 9: Flex Dfca 040

    Introduction 1.4 Identity Code for DULCO ® flex DFCa 040 Identity code DFCa DULCO ® flex DFCa 040 Type DFCa 040, 0.86 l/revolution Power end/drive Pump without power end/drive Reduction gear system / 3 x 230 / 400 VAC 0.55 kW, 18 rpm, 928 l/h, 4 bar 0.55 kW, 29 rpm, 1495 l/h, 4 bar 0.75 kW, 38 rpm, 1960 l/h, 4 bar 1.10 kW, 54 rpm, 2786 l/h, 2 bar...
  • Page 10 Introduction Identity code DFCa DULCO flex DFCa 040 ® Portable unit + lacquered steel base plate Portable unit + stainless steel base plate Leakage sensor without leakage sensor with leakage sensor with leakage sensor and relay output Rotor Rotor with 2 rollers Batch control No batch control With batch control...

  • Page 11: Flex Dfca 050

    Introduction 1.5 Identity Code for DULCO ® flex DFCa 050 Identity code DFCa DULCO ® flex DFCa 050 Type DFCa 050, 1.47 l/revolution Power end/drive Pump without power end/drive Reduction gear system / 3 x 230 / 400 VAC 0.55 kW, 14 rpm, 1235 l/h, 4 bar 0.75 kW, 21 rpm, 1852 l/h, 4 bar 1.10 kW, 30 rpm, 2646 l/h, 4 bar 1.50 kW, 38 rpm, 3352 l/h, 4 bar...
  • Page 12 Introduction Identity code DFCa DULCO flex DFCa 050 ® Base plate, stainless steel Portable unit + lacquered steel base plate Portable unit + stainless steel base plate Leakage sensor without leakage sensor with leakage sensor with leakage sensor and relay output Rotor Rotor with 2 rollers Batch control...

  • Page 13: Flex Dfca 060

    Introduction 1.6 Identity Code for DULCO ® flex DFCa 060 Identity code DFCa DULCO ® flex DFCa 060 Type DFCa 060, 3.16 l/revolution Power end/drive Pump without power end/drive Reduction gear system / 3 x 230 / 400 VAC 2.20 kW, 18 rpm, 3.4 m /h, 4 bar 2.20 kW, 22 rpm, 4.2 m /h, 4 bar...
  • Page 14 Introduction Identity code DFCa DULCO flex DFCa 060 ® Base plate, stainless steel Portable unit + lacquered steel base plate Portable unit + stainless steel base plate Leakage sensor without leakage sensor with leakage sensor with leakage sensor and relay output Rotor Rotor with 2 rollers Batch control...

  • Page 15: Flex Dfca 070

    Introduction 1.7 Identity Code for DULCO ® flex DFCa 070 Identity code DFCa DULCO ® flex DFCa 070 Type DFCa 070, 6.72 l/revolution Power end/drive Pump without power end/drive Reduction gear system / 3 x 230 / 400 VAC 2.20 kW, 13 rpm, 5.2 m /h, 4 bar 3.0 kW, 22 rpm, 8.9 m /h, 4 bar...
  • Page 16 Introduction Identity code DFCa DULCO flex DFCa 070 ® Portable unit + lacquered steel base plate Portable unit + stainless steel base plate Leakage sensor without leakage sensor with leakage sensor with leakage sensor and relay output Rotor Rotor with 2 rollers Batch control No batch control Special version...

  • Page 17: Safety And Responsibility

    Safety and responsibility Safety and responsibility 2.1 General safety information WARNING! Live parts Possible consequence: Fatal or very serious injuries – Measure: The device must be disconnected from the power supply before it is opened – Isolate damaged, faulty or manipulated devices from the mains in order to de-energise.
  • Page 18 Safety and responsibility WARNING! Correct and proper use Possible consequence: Fatal or very serious injuries – The unit is not intended to convey or regulate gas‐ eous or solid media – Do not exceed the rated pressure, speed or tem‐ perature for the pump –...
  • Page 19 Safety and responsibility CAUTION! Environmental influences Possible consequence: Material damage right through to destruction of the unit – The device is not suitable for outdoor operation – Take suitable measures to protect the device from environmental influences such as: – UV rays –...

  • Page 20: Functional Description

    Functional description Functional description Brief functional description The package contents supplied with the DULCOflex DFCa is ® selectable via the identcode. The DULCOflex DFCa is a displacement pump. The feed chem‐ ® ical is transported by the rotor squeezing the hose in the direction of flow.

  • Page 21: Overview Of The Device

    Functional description 3.2 Overview of the Device P_DX_0017_SW Fig. 1: Diagram of functional principle Housing Rollers Rotor Hose...

  • Page 22: Transport, Storage, Assembly And Installation

    Transport, storage, assembly and Installation Transport, storage, assembly and Installation User qualification, transport and storage: trained user, see Ä Chapter 1.2 ‘Users' qualifications’ on page 5 User qualification, installation: trained qualified personnel, see Ä Chapter 1.2 ‘Users' qualifications’ on page 5 User qualification, electrical installation: Electrical technician, Ä...

  • Page 23: Ambient Conditions

    Transport, storage, assembly and Installation 4.3.1 Ambient conditions NOTICE! Ambient conditions Possible consequence: Damage to property and increased wear and tear Install in the following order. If the pump is to be installed outdoors, protect it against sunlight and the influences of the weather.

  • Page 24: Alignment Of The Discharge Side

    Transport, storage, assembly and Installation 4.3.3 Alignment of the discharge side The discharge line is to be kept as straight and short as possible, in order to avoid performance reduction. The diameter must correspond to the rated diameter of the pump hose.
  • Page 25 Transport, storage, assembly and Installation P_DX_0021_SW Fig. 3: Squeezing the hose Normal shape of hose Insufficient squeezing (medium backflowing in Excessive squeezing (increased wear and tear the cavity will destroy the hose within a short on the pump and hose) period of time) Perfect squeezing The spacer plates are factory-fitted.
  • Page 26 Transport, storage, assembly and Installation 0-19 20-39 40-59 60-79 80-99 * Delivery state DFCa 040 / Number of spacer plates of 1.0 mm thickness (except Norprene ® 0-19 20-39 40-59 60-79 80-99 2.0* * Delivery state DFCa 050 / Number of spacer plates of 1.0 mm thickness: 0-19 20-39 40-59...

  • Page 27: Performance Curves

    Transport, storage, assembly and Installation DFCa 070 / Number of spacer plates of 1.0 mm thickness: 0-19 20-39 40-59 60-79 80-99 4.0 * * Delivery state 4.3.5 Performance curves NOTICE! Maximum pressure under continuous operation The dotted line indicates the limit for maximum pres‐ sure under continuous operation A0369 Fig.
  • Page 28 Transport, storage, assembly and Installation 4400 l /h 3960 3520 3080 2640 2200 1760 1320 1/min 8 bar 4 bar 2 bar A0370 Fig. 5: DFCa 040 A0371 Fig. 6: DFCa 050...
  • Page 29 Transport, storage, assembly and Installation A0372 Fig. 7: DFCa 060 1/min A0373 Fig. 8: DFCa 070...

  • Page 30: Commissioning

    Commissioning Commissioning Ä Chapter User qualification, commissioning: trained user, see 1.2 ‘Users' qualifications’ on page 5 5.1 Testing prior to commissioning the pump The following tests are to be carried out: Ensure that the pump has not been damaged during transpor‐ tation or storage.

  • Page 31: Operation Of The Peristaltic Pump

    Operation of the peristaltic pump Operation of the peristaltic pump User qualification, operation: instructed persons, see Ä Chapter 1.2 ‘Users' qualifications’ on page 5 The peristaltic pump is to be fully integrated into the customer's designated plant and is then controlled by this plant. It is not pos‐ sible to operate the pump directly.

  • Page 32: Maintenance, Repair, Malfunctions, Disposal And Spare Parts

    Maintenance, repair, malfunctions, disposal and spare parts Maintenance, repair, malfunctions, disposal and spare parts User qualification, maintenance and disposal: instructed per‐ Ä Chapter 1.2 ‘Users' qualifications’ on page 5 sonnel, see User qualification, repair and troubleshooting: trained user, see Ä Chapter 1.2 ‘Users' qualifications’ on page 5 WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries.

  • Page 33: Troubleshooting

    Maintenance, repair, malfunctions, disposal and spare parts Remove the pump hose to be exchanged Dismantle the hydraulic connections from both pump hose ends Exchanging the pump hoses - installa‐ Clean the interior surfaces of the pump housing tion Lubricate the internal surfaces of the pump housing at the contact surfaces to the pump hose Check the rollers.
  • Page 34 Maintenance, repair, malfunctions, disposal and spare parts Problem Possible cause Solution Air introduction in the suction con‐ Check connections and accesso‐ nections ries for air tightness Vibrations on pumps and pipelines The pipes are not correctly fas‐ Fasten pipes correctly (e.g. wall tened brackets) Pump speed too high...

  • Page 35: Disposal Of Used Parts

    Note the national regulations and legal standards that currently apply in your country Remove and dispose of the pump hose on site before returning the pump to ProMinent Dosiertechnik GmbH, Heidelberg/Germany. ProMinent GmbH, Heidelberg//Germany will take back clean used parts.

  • Page 36: Spare Parts

    Maintenance, repair, malfunctions, disposal and spare parts 7.5 Spare parts A0364 Fig. 9: Exploded view of spare parts for DFCa 30 DFCa 030 see Fig. 9 Item Description Quantity Reference Part number Pump housing 107.00.01 Ball bearing housing 107.00.03 Rotor shaft 107.00.04 Rotor 107.00.05...
  • Page 37 Maintenance, repair, malfunctions, disposal and spare parts DFCa 030 see Fig. 9 Item Description Quantity Reference Part number Connector TRI-CLAMP 107.00.36 Connector DIN DN32 VA 107.00.37 Connector ANSI DN32 VA 107.00.38 Connector PP 1 1/4" BSP 107.00.39 Pump hose NR 107.00.18 1037183 Pump hose NR-A...
  • Page 38 Maintenance, repair, malfunctions, disposal and spare parts A0365 Fig. 10: Exploded view of spare parts for DFCa 40 DFCa 040 see Fig. 10 Item Description Quantity Reference Part number Pump housing 106.00.01 Ball bearing housing 106.00.03 Rotor shaft 106.00.04 Rotor 106.00.05 Roller holder 106.00.06...
  • Page 39 Maintenance, repair, malfunctions, disposal and spare parts DFCa 040 see Fig. 10 Item Description Quantity Reference Part number Connector VA 1 1/2" NPT 106.00.34 Connector DIN 11851 NW40 106.00.35 Connector TRI-CLAMP 106.00.36 Connector DIN DN40 VA 106.00.37 Connector ANSI DN40 VA 106.00.38 Connector PP 1 1/2"...
  • Page 40 Maintenance, repair, malfunctions, disposal and spare parts 22 26 15 13 27 24 9 A0366 Fig. 11: Exploded view of spare parts for DFCa 050 DFCa 050 see Fig. 11 Item Description Quantity Reference Part number Pump housing 108.01.01 Ball bearing housing 108.00.02 Rotor shaft 108.00.03...
  • Page 41 Maintenance, repair, malfunctions, disposal and spare parts DFCa 050 see Fig. 11 Item Description Quantity Reference Part number Connector PP DN40 108.00.16 Connector ANSI PP DN40 108.00.17 Connector PVDF DN40 108.00.18 Connector ANSI PVDF DN40 108.00.19 Connector DIN 11851 NW50 108.00.15 Connector TRI-CLAMP 108.00.40...
  • Page 42 Maintenance, repair, malfunctions, disposal and spare parts 2 2 8 8 2 2 6 6 29 18 2 2 4 4 31 12 12 13 36 38 35 37 A0367 Fig. 12: Exploded view of spare parts for DFCa 060 DFCa 060 see Fig.
  • Page 43 Maintenance, repair, malfunctions, disposal and spare parts DFCa 060 see Fig. 12 Item Description Quantity Reference Part number Roller 110.01.11 Adapter, rotor 110.01.12 Front cover 110.00.13 Front cover, polycarbonate 110.00.14 Pressure flange, standard 110.01.15 Clamp ring 110.01.16 Connector DIN, flange, DN50, VA 110.01.17 Connector ANSI, flange, VA, 2"...
  • Page 44 Maintenance, repair, malfunctions, disposal and spare parts DFCa 060 see Fig. 12 Item Description Quantity Reference Part number Safety collar 110.00.29 Seal 110.00.30 Seal 110.00.31 O-ring 110.00.33 Lifting lug 110.00.34 Discharge screw 107.00.41 Valves 110.00.53 Stud bolts, short 107.00.46 Stud bolts, long 107.00.47 Knurled nut, blank 102.00.26...
  • Page 45 Maintenance, repair, malfunctions, disposal and spare parts DFCa 070 see Fig. 13 Item Description Quantity Reference Part number Rotor shaft 111.00.04 Rotor 112.01.02 Roller holder 112.01.03 Spacer plate 112.00.04 Headless screw 112.00.05 Roller shaft 112.00.06 Roller 112.01.07 Front cover 112.00.40 Front cover, polycarbonate 112.00.41 Pressure flange, standard...
  • Page 46 Maintenance, repair, malfunctions, disposal and spare parts DFCa 070 see Fig. 13 Item Description Quantity Reference Part number Seal 111.00.31 Seal 112.00.28 Lifting lug 112.00.29 Discharge screw 112.00.30 Additional spacer 112.00.31 Adapter, rotor 112.01.32 O-ring, front cover 112.00.35 Lubricant Item Description Quantity Reference Part number...

  • Page 47: Dfca Technical Data

    DFCa technical data DFCa technical data Type Feed rate P max. Flow rate Rollers/ Hose Solids Weight Con‐ shoes nector DFCa in l/U in bar at max. interior max. without pressure Shoes drive ⌀ in mm ⌀ in mm in l/h in kg 0.43 Rollers...

  • Page 48: Dimensions Dfca 040

    DFCa technical data G 471 mm K 262 mm H 305 mm 75 mm 160 mm M 1 1/4" 100 mm Dependent on selected drive 8.2 Dimensions DFCa 040 A0376 Fig. 15: Dimensions DFCa 040 A 135 mm H 385 mm 170 mm 130 mm D 70 mm...

  • Page 49: Dimensions Dfca 050

    DFCa technical data 8.3 Dimensions DFCa 050 A0377 Fig. 16: Dimensions DFCa 050 A 151 mm H 453 mm 200 mm 159 mm D 79 mm K 412 mm E 645 mm 115 mm 415 mm Dependent on selected drive G 633 mm...

  • Page 50: Dimensions Dfca 060

    DFCa technical data 8.4 Dimensions DFCa 060 A0378 Fig. 17: Dimensions DFCa 060 A 215 mm H 500 mm 25 mm 210 mm D 111 mm K 510 mm E 805 mm 25 mm 740 mm Dependent on selected drive G 735 mm...

  • Page 51: Dimensions Dfca 070

    DFCa technical data 8.5 Dimensions DFCa 070 A0379 Fig. 18: Dimensions DFCa 070 A 215 mm H 790 mm 40 mm 240 mm D 250 mm K 784 mm E 1124 mm 40 mm 1065 mm Dependent on selected drive G 1100 mm...

  • Page 52: Dfca Technical Appendices

    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, hereby declare that the product specified in the following, complies...

  • Page 53: Index

    Index Index Action, step by step ......2 Links to elements or sections of these instruc‐ Applied harmonised standards ....52 tions or other applicable documents .
  • Page 56 ProMinent GmbH Im Schuhmachergewann 5 - 11 69123 Heidelberg Telephone: +49 6221 842-0 Fax: +49 6221 842-419 Email: info@prominent.com Internet: www.prominent.com 986227, 3, en_GB © 2015...

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