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General Operating Instructions
®
ProMinent
Motor-Driven Metering Pumps
and Hydraulic Accessories
Sigma
Vario
alpha
Hydro
Meta
Makro/ 5
Makro TZ
Two sets of operating instructions are necessary to ensure safe operation of the metering pumps corresponding to their
intended purpose: The product-specific operating instructions (e.g. for Sigma) and the general operating instructions
®
for ProMinent
motor-driven metering pumps.
Both are only applicable in conjunction with each other.
Please completely read through these operating instructions first! Do not discard!
The warranty shall be invalidated by damage caused by operating errors!
Part No. 987702
ProMinent Dosiertechnik GmbH · 69123 Heidelberg · Germany
BA MOZ 015 05/06 GB
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Table of Contents
Troubleshooting
Related Manuals for ProMinent Hydro Series
Summarization of Contents
User Information
Understanding Manual Conventions
Explains symbols like NOTE, WARNING, CAUTION, IMPORTANT for guidance within the manual.
Application of Metering Pumps
Application Scope
Defines the sole purpose of metering liquid media and prohibits other uses or modifications.
Safety Notes
General Safety Warnings
Highlights critical safety advice, including emergency shutdown and radioactive media handling.
Cautionary Safety Notes
Advises against blocking access and emphasizes trained personnel for maintenance.
Important Safety Considerations
Warns about property damage from errors and the need for safety devices like overflow valves.
Mounting Guidelines
Important Mounting Precautions
Mount pump upright on a stable base and ensure vibration-free installation.
Pump and Valve Positioning
Install pump at a convenient level with vertical valves (head valve up, intake valve down).
Ensuring Clearances for Maintenance
Maintain adequate clearance around the liquid end and valves for easy removal.
Hydraulic Installation Procedures
Explosion-Proof Pump Safety Compliance
Emphasizes adherence to section 9 for explosion-proof pump installations.
Installation Directives and Pressure Monitoring
Follow national directives and consider manometer connections for pressure verification.
Connecting Pipes Without Stress
Connect pipes without stress on the pump, using flexible adapters for dissimilar materials.
Intake Side Installation Notes
Preventing Intake Line Emptiness
Install foot valve at the end of the intake line when the pump is above the liquid level.
Impurity Retention Measures
Implement impurity retention, like a dirt trap, to prevent pump and system faults.
Intake for Gas-Emitting Media
Install the pump with the inlet on the intake side for gas-emitting media.
Siphon Line for High-Level Tanks
Use a siphon line for high-level tanks without base connections, observing acceleration pressures.
Delivery Side Installation Notes
Overpressure Protection Measures
Install overflow valves to prevent damage if pump head pressure exceeds limits.
Overflow Line Routing and Connection
Route overflow lines to the supply tank or runoff channel under atmospheric pressure.
Preventing Unwanted Mixing
Ensure return flow from the main line is cut off to avoid mixing in the metering line.
Pulsation Dampening Requirements
Dampen pulsation for smooth flow or reduced acceleration forces to prevent damage.
Incorrect Pump Installation Practices
Air Pocket Prevention in Intake Line
Avoid air pockets in the intake line; ensure proper bleeding.
Effective Pulsation Damper Arrangement
Correct arrangement of pulsation damper and pressure retention valve is crucial.
Avoiding Siphon Effects
Prevent siphon effects in the intake line.
Managing Intake Side Pressure
Avoid excessively high admission pressure on the intake side.
Special Installation Considerations
Preventing Delivery/Intake Pressure Overload
Avoid overloading by positive pressure difference between delivery and intake sides.
Ensuring Stable Intake Pressure
Maintain constant intake pressure to prevent irregular pump flow.
Advanced Installation Practices
Avoiding Siphon in Vacuum Metering
Install control valves to prevent siphon effects when metering into a vacuum.
Pump Head Flushing for Suspensions
Flush pump head for suspensions to prevent deposit formation.
Flushing Procedure Safety
Switch off the pump before flushing and adhere to maximum flushing pressure.
Electrical Installation and Motor Setup
Explosion-Proof Pump Electrical Safety
Emphasizes adherence to section 9 for explosion-proof pump electrical installations.
Motor Connection and Protection
Connect motors according to VDE, check ratings, and provide adequate motor protection.
Wet Room/Open Installation Practices
Arrange terminal boxes downwards and seal cable entries properly in wet environments.
Three-Phase AC Motor Wiring
Details wiring for three-phase squirrel-cage motors in low and high voltage configurations.
Motor Types and Connections
Pole-Changing Motor Speeds
Wiring diagrams for pole-changing motors to achieve different speeds.
AC Network Motor Operation
Operating three-phase AC motors on the alternating current network with a running capacitor.
Electronic Speed Control Motors
Connecting motors via electronic control devices like frequency converters.
Separate Cooling Fan Power
Motors with separate cooling fans require an independent power supply.
Stroke Length Adjustment Drive Operation
Stroke length adjustment drives must only be operated when the pump is running.
Pump Start-Up Procedure
Explosion-Proof Pump Start-Up Safety
Emphasizes adherence to section 9 for explosion-proof pump start-up.
Pre-Start Up Checks
Verify drive motor, additional equipment, lines, and safety valves before starting.
Delivery Side Bleeding Process
Step-by-step guide to bleeding the delivery side of the pump for operation.
Post-Start Up Checks
Vent air vessels, check gas pressure, and follow frequency converter instructions.
Maintenance and Troubleshooting
Explosion-Proof Pump Maintenance Safety
Emphasizes adherence to section 9 for explosion-proof pump maintenance.
General Maintenance Recommendations
Refer to specific instructions, clean pumps before shipping for repair.
Diaphragm and Packing Maintenance
Procedures for diaphragm failure and high leakage from piston liquid ends.
Troubleshooting: Intake Issues
Addresses no pump intake, causes like high suction head, and remedies.
Troubleshooting: Metering Failures
Addresses no metering when running, causes like stroke setting, and remedies.
Troubleshooting: Leaks and Capacity Loss
Addresses liquid from leakage openings and loss of metering capacity due to wear.
Ex-Zone Operation Considerations
Regulatory Compliance for Ex-Zones
Operation in explosion-risk areas requires specific approvals and conformity.
Ex-Zone Safety Directives
Adherence to European (ATEX) and national directives for ex-zone installations and operation.
Ex-Zone Safety Equipment Precautions
Special care for plastic components during cleaning to prevent electrostatic discharge.
Ex-Zone Component Certification
EU declaration of conformity, design inspection reports, and manuals are essential.
Ex-Zone Assembly Notes
No specific assembly notes are provided for ex-zone installations.
Ex-Zone Hydraulic Installation Safety
Ex-Zone Relief Valve Requirement
Ex-zone pumps must have safety relief valves to prevent overheating.
Temperature Class T3/T4 for Piston Pumps
Piston pumps are T3; T4 requires additional controllers for dry running protection.
Temperature Class T4 for Diaphragm Pumps
Hydraulic diaphragm pumps need diaphragm-rupture and flow controllers for T4.
Lowest Temperature Class Determines Application
The pump's application is limited by its component with the lowest temperature class.
Combustible Media Material Requirements
Combustible media mandates stainless steel or conductive PTFE dosing heads.
Piston Pump Restrictions with Combustible Media
Piston pumps are unsuitable for combustible media; extra safety measures are needed if used.
Mechanically Linked Diaphragm Pumps Ex 'i'
Ex 'i' construction requires diaphragm-rupture indicator for mechanically linked diaphragm pumps.
Ex-Zone Installation Verification
Installations in ex-zones must be verified by a "recognised qualified" person.
Supervised Start-Up for Combustible Media
Starting and draining combustible media requires supervision by a qualified person.
Ex-Zone Electrical Installation and Commissioning
Intrinsically Safe Circuit Requirements
Accessories like switches must connect to intrinsically safe electrical circuits in ex-zones.
Electrical Component Safety Assurance
Ensure electrical component safety via conformity declarations for the entire connection.
Approved Ex-Zone Electrical Components
Use approved motor protection, mains switches, and fuses per manufacturer specifications.
Macro-Hydraulic Switch Ex-Zone Usage
Switches for diaphragm rupture/pressure sensors are suitable for Category II 2G gas explosion risk.
Intrinsically Safe Switch Connections
Switches must connect to intrinsically safe circuits, identified by blue cables.
Ex 'e' Motor Protection
Ex 'e' motors require approved protection against overload and overheating.
Qualified Personnel for Ex Motor Installation
Ex motors must be installed and checked by a "recognised qualified" person.
Commissioning Combustible Media
Commissioning combustible media requires supervision by an appropriately qualified person.
Material Selection for Combustible Media
Use stainless steel or conductive PTFE dosing heads for combustible media.
Ex-Zone Maintenance Procedures
Routine Checks for Pump Operation
Perform regular checks for leaks, noise, temperature, and odors for general operation.
Lubricant Level and Leak Checks
Check lubricant levels and for leaks; locate and fix leaks immediately to prevent overheating.
Relief Valve Function in Ex-Zones
Ensure relief valve operation prevents gear overload and overheating in explosion-risk areas.
Electrostatic Discharge Prevention
Prevent electrostatic charge during cleaning of plastic components via careful friction.
Supervised Start-Up/Drain for Combustible Media
Start up and drain combustible media solely under the supervision of a qualified person.
Replacement of Worn Parts
Expendable parts, such as bearings, must be replaced upon visible signs of unacceptable wear.
Use of Original Spare Parts
It is mandatory to use original spare parts for all replacements.
Ex-Zone Repair and Inspection Standards
Inspections and repairs must adhere to DIN EN IEC 60079-17 by qualified personnel.
Ex-Zone Troubleshooting and Repair
Routine Checks for Pump Health
Conduct regular checks for leaks, noise, temperatures, and odors for optimal operation.
Lubricant Management and Leak Repair
Monitor lubricant levels and promptly address any leaks to prevent overheating.
Static Charge Prevention During Cleaning
Avoid creating electrostatic charge by minimizing friction when cleaning plastic components.
Combustible Media Handling Supervision
Start up and drain combustible media only under the supervision of an appropriately qualified person.
Wear Assessment and Part Replacement
Replace expendable parts like bearings when they show signs of unacceptable wear.
Adherence to Spare Parts Policy
Replacements must strictly be original spare parts.
Ex-Zone Repair and Inspection Expertise
Repairs and inspections require compliance with DIN EN IEC 60079-17 and experienced personnel.
Pump Repair Supervision
Start up and drain combustible media only under qualified person's supervision during repair.
Ex-Zone Decommissioning
Supervised Decommissioning of Combustible Media
Start up and drain combustible media only under the supervision of an appropriately qualified person.
Hydraulic Accessory Overview
Importance of System Accessories
Proper selection of hydraulic and electrical accessories is crucial for metering system performance.
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