Manual: Delta Manual English

ProMinen
t
Operating instructions
Solenoid Metering Pump
delta® DLTa
with controlled optoDrive® solenoid drive
P_DE_0002_SW
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® Solenoid Metering Pumps".
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!
Technical changes reserved.
Part no. 986691
Original Operating Instructions (2006/42/EC)
BA DE 019 07/11 EN
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
986692, 2, en_GB
© 2009
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Supplemental instructions
Supplementary information
Read the following supplementary information in its entirety! Should you
already know this information, you have an even greater need of the Oper‐
ating Instructions.
The following are highlighted separately in the document:
Fig. 1: Please read!
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Enumerated lists
Instructions
ð Outcome of the instructions
Information
This provides important information relating to the correct
operation of the device or is intended to make your work
easier.
Safety information
Safety information is identified by pictograms - see Safety Chapter.
User information
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® Sole‐
noid Metering Pumps".
Both sets of operating instructions are only valid when read together.
Please read these operating instructions carefully before use! Do not dis‐
card!
State the identity code and serial number
Please state identity code and serial number, which you can find on the
nameplate when you contact us or order spare parts. This enables the
device type and material versions to be clearly identified.
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.
3
Table of contents
Table of contents
1
Identity code.................................................................................... 6
2
About this pump............................................................................... 9
3
Safety chapter............................................................................... 10
4
Storage, transport and unpacking................................................. 14
5
Device overview and control elements.......................................... 16
5.1 Device overview....................................................................
5.2 Control elements...................................................................
5.2.1 Key functions......................................................................
5.2.2 Stroke length adjustment knob...........................................
5.2.3 Identifiers............................................................................
6
Functional description.................................................................... 21
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
7
16
17
17
18
18
Liquid End.............................................................................
Drive unit...............................................................................
Capacity................................................................................
Operating modes...................................................................
Functions...............................................................................
Relay (options)......................................................................
Functional and fault Indicator................................................
LCD display...........................................................................
LED indicators.......................................................................
Hierarchy of operating modes, functions and fault sta‐
tuses....................................................................................
21
21
21
22
22
23
23
24
24
24
Hydraulic installation...................................................................... 25
7.1 Install hose lines.................................................................... 26
7.1.1 Installation for metering pumps without bleed valve.......... 26
7.1.2 Installation for metering pumps with bleed valve............... 28
8
Electrical installation...................................................................... 30
8.1 Supply voltage connection....................................................
8.2 Description of the jacks.........................................................
8.2.1 "External control" terminal..................................................
8.2.2 "Level Switch" terminal.......................................................
8.2.3 "Dosing monitor" terminal...................................................
8.2.4 "Diaphragm rupture sensor" jack.......................................
8.3 Relay.....................................................................................
8.3.1 "Fault indicating relay" output (identity code 1 + 3 or 6 +
7)........................................................................................
8.3.2 Output for other relays (identity code 4 + 5, 8 + 9, A + B)..
8.3.3 Output "Current output plus relay" (identity code C + D +
E)........................................................................................
9
34
35
35
Adjustment..................................................................................... 37
9.1 Basic principles of control adjustment...................................
9.2 Checking adjustable variables..............................................
9.3 Changing to adjustment mode..............................................
9.4 Selecting the operating mode (Menu "Operation")................
9.5 Operating mode settings (menu "Settings")..........................
9.5.1 "Manual" operating mode settings.....................................
9.5.2 Settings for the “Batch” operating mode (BATCH menu)...
9.5.3 "Contact" operating mode settings.....................................
9.5.4 "Analog" operating mode settings......................................
9.6 Programmable function settings ("Settings" menu )..............
9.6.1 Settings for the “Auxiliary rate” function (AUX menu)........
9.6.2 Settings for the “Flow” function (FLOW menu)...................
9.6.3 Settings for the “Calibrate” function (CALIBRATE menu). .
4
31
32
32
33
33
33
34
37
37
38
39
39
41
41
42
44
46
47
47
47
Table of contents
9.6.4
9.6.5
9.6.6
9.6.7
Settings for the “Metering” function (DOSING menu)........
Settings for the "Bleeding" function)...................................
Settings for the “Relay” function (RELAY menu)................
Settings for the “Analog output” function (ANALOG
OUTPUT menu).................................................................
9.6.8 Settings in the "System" menu" (SYSTEM menu).............
9.7 Set code (SECURITY menu)................................................
9.8 Delete total number of strokes or total litres (CLEAR menu)
9.9 Set language (LANGUAGE menu)........................................
10
48
52
54
55
56
57
58
58
Operation....................................................................................... 59
10.1 Manual................................................................................ 59
10.2 Remote operation................................................................ 61
11
Maintenance.................................................................................. 62
12
Repairs.......................................................................................... 64
12.1 Cleaning valves................................................................... 64
12.2 Replacing the metering diaphragm..................................... 65
12.3 Cleaning the diaphragm rupture indicator........................... 68
13
Troubleshooting............................................................................. 69
13.1
13.2
13.3
13.4
13.5
Faults without a fault alert...................................................
Fault alerts..........................................................................
Fault alerts / warning alerts.................................................
Warning Alerts.....................................................................
All Other Faults...................................................................
69
69
70
71
71
14
Decommissioning.......................................................................... 72
15
Technical data............................................................................... 74
15.1 Performance data................................................................
15.2 Accuracy.............................................................................
15.2.1 Standard liquid ends........................................................
15.3 Viscosity..............................................................................
15.4 Material data.......................................................................
15.5 Electrical data......................................................................
15.6 Temperatures......................................................................
15.7 Climate................................................................................
15.8 Protection class and Safety Requirements.........................
15.9 Compatibility........................................................................
15.10 Weight...............................................................................
15.11 Sound pressure level........................................................
74
74
74
75
75
75
76
76
76
76
77
77
16
EC Declaration of Conformity........................................................ 78
17
Operating menu overview.............................................................. 79
18
Continuous displays...................................................................... 81
19
Index.............................................................................................. 83
5
Identity code
1
Identity code
Product range delta® , version a
DLTa
Type
Performance
bar
l/h
2508
25
7.5
1608
16
7.8
1612
16
11.3
1020
10
19.1
0730
7
29.2
0450
4
49.0
0280
2
75.0
Material of dosing head/valves
TT
PTFE/PTFE
SS
Stainless steel 1.4404/1.4404
PV
PVDF/PVDF
NP
Clear acrylic/PVDF. With the self-bleeding version (SEK): Clear acrylic/PVC
Material of seals/diaphragm
T
PTFE/PTFE coated
S
Diaphragm additionally with FPM coating for media containing silicate
B
FPM-B/PTFE coated, only for PP and NP self-bleeding (SEK)
E
EPDM/PTFE coated, only for PP and NP self-bleeding (SEK)
Dosing head version
0
Without bleed valve, without valve spring
1
Without bleed valve, with valve spring
2
With bleed valve, without valve spring
3
With bleed valve, with valve spring
4
HV version for media of higher viscosity
Hydraulic connection
0
Standard connection in line with technical data
5
Connection for 12/6 tube, suction side standard
Diaphragm rupture reporter
0
Without diaphragm rupture reporter
1
Diaphragm rupture reporter
Version
0
With ProMinent logo
Electrical connection
U
Universal control 100-230 V ±10 %, 50/60 Hz
Cable and plug
6
A
2 m European
B
2 m Swiss
C
2 m Australian
Identity code
Product range delta® , version a
D
2 m USA
...
...
Relay
0
No relay
1
Fault indicating
relay N/C
1 x changeover con‐
tact 230 V – 8 A
3
Fault indicating
relay magnetic
1 x changeover con‐
tact 230 V – 8 A
4
As 1 + pacing relay 2 x N/O 24 V – 100
mA
5
As 3 + pacing relay 2 x N/O 24 V – 100
mA
A
Cut-off and
warning relays N/C
2 x N/O 24 V – 100
mA
C
As 1 + 4-20 mA
mA output
1 x N/O 24 V – 100
mA
F
With automatic
bleed valve
not for pump type
2508
...
...
Accessories
0
No accessories
1
With foot and injection valve, 2 m
suction line, 5 m metering line
2
As 0 + measuring cup
3
As 1 + measuring cup
Control versions
0
Manual + external contact
with pulse control
3
Manual + external contact
with pulse control + analog
0/4-20mA
4
As 0 +14-day process timer
5
As 3 +14-day process timer
C
CANopen
R
As 3 + PROFIBUS® inter‐
face, M12
Access code
0
No access code
1
With access code
Language
DE
German
EN
English
FR
French
ES
Spanish
...
...
7
Identity code
Product range delta® , version a
Pause / level
0
8
Pause N/
C, level
N/C
About this pump
2
About this pump
Properties of the device
The solenoid metering pumps belonging to the delta® product range with
controlled optoDrive® solenoid drive are microprocessor-controlled sole‐
noid metering pumps with the following characteristics:
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Continuous or pulsing operation
Adaptation of the pump to the feed chemical
Detection of blocked points of injection, broken metering lines and
trapped air or gas bubbles in the dosing head by the integral injection
point monitor optoGuard.
Output range 7.5 l/h, 25 - 2 bar
Stroke length continuously adjustable between 0 - 100 % (recom‐
mended 30 - 100 %)
Material versions PVDF and stainless steel
Patented coarse/fine adjustment
Diaphragm rupture detection and signalling (optional)
Adjustment and display of the feed rate, either as strokes/min or l/h
via the keyboard
Large illuminated graphic display
External activation via potential-free contacts with optional pulse stepup and step-down
Option of external activation by standard signal 0/4-20 mA
Interface for PROFIBUS®or CANopen (optional)
14-day process timer* for time- and event-dependent metering tasks
Connection for 2-stage level switch
3 LED display for operation, warning and fault messages in plain text
Concentration input for volume-proportional metering
Automatic bleed
Pump type 2508 with 7.5 l/h at 25 bar
Material version NP for pump types 2508, 1612, 1608, 1020 and 0730
9
Safety chapter
3
Safety chapter
Explanation of the safety information
Warning signs denoting different types of
danger
The following signal words are used in these operating instructions to
denote different severities of danger:
Signal word
Meaning
WARNING
Denotes a possibly dangerous sit‐
uation. If this is disregarded, you
are in a life-threatening situation
and this can result in serious inju‐
ries.
CAUTION
Denotes a possibly dangerous sit‐
uation. If this is disregarded, it
could result in slight or minor inju‐
ries or material damage.
The following warning signs are used in these operating instructions to
denote different types of danger:
Warning signs
Type of danger
Warning – automatic start-up.
Warning – high-voltage.
Warning – danger zone.
Correct and proper use
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10
The pump may only be used to dose liquid metering chemicals.
The pump may only be started up after it has been correctly installed
and commissioned in accordance with the technical data and specifi‐
cations contained in the operating instructions.
Observe the general limitations with regard to viscosity limits, chem‐
ical resistance and density - see also ProMinent resistance list (In the
product equipment catalogue or at www.prominent.com)!
Any other uses or modifications are prohibited.
The pump is not intended for the metering of gaseous media or solids.
The pump is not intended for the metering of explosive media.
The pump is not intended for operation in hazardous locations.
The pump is not intended for exterior applications without use of suit‐
able protective equipment.
The pump should only be operated by trained and authorised per‐
sonnel, see the following "Qualifications" table.
You are obliged to observe the information contained in the operating
instructions at the different phases of the device's service life.
Safety chapter
Safety information
WARNING!
Warning about personal and material damage
The pump can start to pump, as soon as it is connected to
the mains voltage.
–
Install an emergency cut-off switch in the pump power
supply line or integrate the pump in the emergency cutoff management of the system.
WARNING!
Danger of electric shock
A mains voltage may exist inside the pump housing.
–
If the pump housing has been damaged, you must dis‐
connect it from the mains immediately. It may only be
returned to service after an authorised repair.
WARNING!
Fire danger
Combustible media may only be transported using stainless
steel dosing heads. In exceptional cases where this is not
possible, PTFE with carbon can be used, whereby our TT_
versions are manufactured from this conducting plastic.
Here, the operator is urged to take special care due to the
low mechanical strength.
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, protective gloves, ...).
Read the safety data sheet on the feed chemical.
Drain and flush the liquid end before working on the
pump.
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‐
ised persons.
Depressurise the system before commencing any work
on hydraulic parts.
11
Safety chapter
CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical can damage the parts of the
pump contacted by the chemical.
–
Take into account the resistance of the material con‐
tacted by the chemical when selecting the feed chemical
- refer to the ProMinent ® resistance list in the product
equipment catalogue or at www.prominent.com.
CAUTION!
Warning of feed chemical spraying around
The metering pump can generate a multiple of its rated pres‐
sure. If a discharge line is blocked, hydraulic parts may burst.
–
Correctly install a back pressure valve in the discharge
line behind the metering pump.
CAUTION!
Danger of personal and material damage
The use of untested third party parts can result in damage to
personnel and material damage.
–
Only fit parts to dosing pumps, which have been tested
and recommended by ProMinent.
CAUTION!
Danger from incorrectly operated or inadequately maintained
pumps
Danger can arise from a poorly accessible pump due to
incorrect operation and poor maintenance.
–
–
Ensure that the pump is accessible at all times.
Adhere to the maintenance intervals.
CAUTION!
Danger from incorrect metering
Should a different liquid end size be fitted, this will change
the metering behaviour of the pump.
–
Have the pump reprogrammed in the works.
CAUTION!
Warning of illegal operation
Observe the regulations that apply where the unit is to be
installed.
Information in the event of an emergency
In the event of an electrical accident, disconnect the mains cable from the
mains or press the emergency cut-off switch fitted on the side of the
system!
If feed chemical exits, switch off the pump by pressing the [Stop/Start] key.
If necessary depressurise the hydraulic system around the pump. Observe
the safety data sheet for the feed chemical.
12
Safety chapter
Qualification of personnel
Activity
Qualification level
Storage, transport, unpacking
Instructed personnel
Installation, installation of hydraulic
system
Technical personnel
Installation, electrical
Electrical technician
Operation
Instructed personnel
Maintenance, repair
Technical personnel
Decommissioning, disposal
Technical personnel
Troubleshooting
Technical personnel, electrical
technician, instructed personnel
Explanation of the terms:
Qualified 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.
Note:
A qualification of equal validity to a technical qualification can also gained
by several years employment in the relevant work area.
Electrical technician
Electrical technicians are deemed to be people, who are able to complete
work on electrical systems and recognize and avoid possible dangers
independently based on their technical training and experience, as well as
knowledge of pertinent standards and regulations.
Electrical technicians should be specifically trained for the working envi‐
ronment in which the are employed and know the relevant standards and
regulations.
Electrical technicians must comply with the provisions of the applicable
statutory directives on accident prevention.
Instructed personnel
An instructed person is deemed to be a person who has been instructed
and, if required, trained in the tasks assigned to him/her and possible dan‐
gers that could result from improper behaviour, as well as having been
instructed in the required protective equipment and protective measures.
Customer Service department
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.
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)
13
Storage, transport and unpacking
4
Storage, transport and unpacking
Safety information
WARNING!
The pump can tip over when lifting
The pump can tip over when lifting, as the centre of gravity of
the pump is quite a distance from the liquid end.
–
Grip the pump quite close to the liquid end.
Safety information
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 the metering pump for repair in a cleaned state
and with a flushed liquid end - refer to the section on decom‐
missioning!
Only send metering pumps with a filled in Decontamination
Declaration form. The Decontamination Declaration consti‐
tutes an integral part of an inspection / repair order. A unit
can only be inspected or repaired if a Decontamination Dec‐
laration is submitted that has been completed correctly and
in full by an authorised and qualified person on behalf of the
pump operator.
The "Decontamination Declaration" form can be found in the
General Operating Instructions or under
www.prominent.com.
CAUTION!
Danger of material damage
The device can be damaged by incorrect or improper storage
or transportation!
–
–
–
Personnel:
Ambient conditions
14
The unit should only be stored or transported in a well
packaged state - preferably in its original packaging.
The packaged unit should also only be stored or trans‐
ported in accordance with the stipulated storage condi‐
tions.
The packaged unit should be protected from moisture
and the ingress of chemicals.
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Technical personnel
Data
Value Unit
Minimum storage and transport tempera‐
ture
-10 °C
Maximum storage and transport tempera‐
ture
+50 °C
Storage, transport and unpacking
Data
Air humidity
Value Unit
< 95 % rel.
humidity*
* non-condensing
Scope of supply
Compare the delivery note with the scope of supply:
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Metering pump with mains power cable
Connector kit for hose/pipe connection
Product-specific operating instructions with EC Declaration of Con‐
formity
CD with order information, exploded diagrams and data sheets
Optional accessories if ordered
Relay cable, as necessary
15
Device overview and control elements
5
Device overview and control elements
5.1 Device overview
1
2
3
P_DE_0027_SW
Fig. 2
1
2
3
Control unit
Drive Unit
Liquid end
a
b
c
d
e
f
g
P_DE_0019_SW
Fig. 3
a
b
c
d
e
f
g
16
Discharge valve
End disc
Dosing head
Bleed valve
Bypass hose nozzle
Diaphragm rupture sensor
Suction valve
Device overview and control elements
5.2 Control elements
a)
b)
1
10
9
8
2
7
3
4
5
6
P_DE_0017_SW
11 12 13 14
15
16
Fig. 4: a) Displays and keys, b) Electrical control connections
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
LCD display
Stroke length adjustment knob
Key [UP]
Key [P]
Key [DOWN]
Key [STOP/START]
Key [i]
Operating indicator (green)
Warning indicator (yellow)
Fault indicator (red)
"External control" jack
"Dosing monitor" jack
"Level Switch" jack
"Diaphragm rupture reporter" jack
Optional module slot (timer, PROFIBUS®, CAN-Bus)
Relay and mA-output (option)
5.2.1 Key functions
Key
Application
In continuous displays (operation)
In adjustment mode (set up)
Pressed briefly
Stop pump,
Stop pump,
start pump
start pump
Pressed briefly
Start batch (only in “ Batch” operating
mode), acknowledge fault
Confirm entry - jump to next menu
point or to continuous display
Pressed for 2 s
Change to adjustment mode
-
Pressed for 3 s
-
Jump to continuous display
STOP
START
[STOP/
START]
P
[P]
i
B0098
17
Device overview and control elements
Key
Application
In continuous displays (operation)
In adjustment mode (set up)
[i]
Pressed 1x
Change between the continuous dis‐
plays
Change between "Changing indi‐
vidual numbers" and "Changing a
number"
Pressed 2x
-
Under "Changing individual num‐
bers": jump to the first number
Press and hold
Change to the secondary display
-
Individually pressed
(until double arrow
appears)
Changing directly changeable varia‐
bles
Select another setting, change
individual number or number.
Pressed simultaneously
Suction (in continuous display "Stroke
rate")
[UP], [DOWN]
At the top end of a selection,
effect similar to an ESC key.
-
5.2.2 Stroke length adjustment knob
The stroke length can be adjusted using the stroke length adjustment knob
and with it the volume per stroke.
5.2.3 Identifiers
The LCD screen supports the operation and adjustment of the pump with
different identifiers:
P
cal
Stop
Aux
Analog
200
/min
10548
Fig. 5
The identifiers have the following meanings:
Symbol
Additional
symbol
P
Name
Meaning
Priming:
The pump is currently priming (both arrow keys pressed).
Symbol for P-key:
The pump is in adjustment mode.
Lock symbol:
Lock (if a code was set. Flashes).
Double arrow symbol: The value in the continuous display can be changed with
the arrow keys.
i
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Info symbol:
It is possible to change between continuous displays.
Stop:
The pump was stopped using the [STOP/START] key
(i.e. manually).
Device overview and control elements
Symbol
Additional
symbol
Name
Meaning
Pause:
The pump was externally stopped by the Pause contact.
Aux:
The pump is currently pumping with the auxiliary rate as
the stroke rate.
During this time, the pump is in operating mode
“Manual.”
Fault:
A fault has occurred, which has stopped the system.
Stroke length:
The pump is set to “Dosing” “slow” and this metering
mode is also active (less than 61 stroke/min). Below 30
strokes/min the operating indicator flashes during opera‐
tion and illuminates for slightly longer at the end of each
stroke.
The symbol relates to the symbol, which is located
beneath the stroke adjustment dial.
Stroke length adjust‐
ment:
Deviation in the stroke length from the value set at the
time of the last locking of the adjustment menu.
Diaphragm rupture:
The diaphragm is broken. The message appears as a
warning or fault, dependent upon the setting.
The symbol represents a section through the membrane.
Air lock:
There is air in the liquid end. The message appears as a
warning or fault, dependent upon the setting.
The symbol represents a liquid end with air bubbles in it.
Level:
The "Warning" level in the storage tank was undershot. If
the symbol flashes, the level has fallen below the "Fault"
level in the storage tank and the pump stops.
Flow:
A flow control is connected. Together with a call sign, the
symbol indicates problems with the flow.
Contact:
The pump is in operating mode “Contact” .
The symbol closes every time a contact signal is gener‐
ated.
Contact signal:
The pump is in operating mode “Batch” .
The symbol flashes every time a contact signal is gener‐
ated.
p+
Overpressure moni‐
toring:
A constriction or a closed shut-off valve on the discharge
side allows the pressure to increase above the maximum
permissible operating pressure. The message appears
as a warning or fault, dependent upon the setting.
p-
Low pressure:
There is a leak or a burst or torn line on the discharge
side. The message appears as a warning or fault,
dependent upon the setting.
Memory:
The pump is in operating mode “Contact” or “Batch” : the
auxiliary function "Memory" has been set.
0..20
0...20 mA:
The pump is in operating mode “Analog” . The pro‐
cessing type “0...20” is set.
4..20
4...20 mA:
The pump is in operating mode “Analog” . The pro‐
cessing type “4...20” is set.
i<4
i less than 4 mA:
Problems with the standard signal at the standard signal
input e.g. broken cable.
m
19
Device overview and control elements
Symbol
i > 23
Additional
symbol
Name
Meaning
i greater than 23 mA:
The standard signal at the standard signal input indicates
a fault with the connected unit.
Line:
The pump is in operating mode “Analog” .
The processing type “Curve” - “Line” is set.
Upper sideband:
The pump is in operating mode “Analog” .
The processing type “Curve” - “Upper sideband” is set.
Lower sideband:
The pump is in operating mode “Analog” . The pro‐
cessing type “Curve” - “Lower sideband” is set.
The pump only shows the metering volume and the capacity
in the calibrated state in l or l/h or in gal or gal/h.
20
Functional description
6
Functional description
6.1 Liquid End
The dosing process is performed as follows: The diaphragm is pressed
into the dosing head; the pressure in the dosing head closes the suction
valve and the feed chemical flows through the discharge valve out of the
dosing head. The diaphragm is now drawn out of the dosing head; the dis‐
charge valve closes due to the negative pressure in the dosing head and
fresh feed chemical flows through the suction valve into the dosing head.
One cycle is completed.
6.2 Drive unit
The displacement body is driven by an electromagnet, which is controlled
by an electronic control.
optoDrive® drive technology
p
a)
The optoDrive® drive technology means the variation over time of the
metering flow can be precisely matched to the requirements of the partic‐
ular application. Hence the user can, dependent on requirements, set a
slow discharge stroke for nearly continuous metering or a quick stroke e.g.
for quick clocked filling processes. In both operating modes it is possible,
to selectively also slow the suction stroke, see figure. In this way, it is pos‐
sible to prevent the main cause for imprecise metering with high viscosity
feed chemicals, namely the incomplete filling of the liquid end. For the
case of gaseous feed chemicals, the slow suction stroke prevents cavita‐
tion and consequently increases metering accuracy. Oscillations in the
back pressure in the metering line, which could lead to undesirable varia‐
tions in the metering volume, are automatically compensated for by the
drive. Consequently, a dosing precision is attained, which otherwise could
only be achieved using a complex control circuit.
p
t
b)
Pressure
Time
t
P_DE_0006_SW
Fig. 6: Metering types: a) pulsing, b)
nearly continuous
The integral injection point monitoring of the hydraulic metering parame‐
ters, optoGuard® is integrated in the drive. It automatically detects blocked
points of injection or broken metering lines. Consequently, dependent on
the hydraulic installation situation, separate relief valves and pressure sen‐
sors need not be used, and no uncontrolled metering through a broken
line occurs. It also detects air or gases (airlock) trapped in the liquid end.
This prevents metering of incorrect quantities and thus increases process
reliability. The relevant messages are shown on the pump's display. The
system operator can determine, depending on the type of fault, whether a
message is to be sent to the process control system via the fault signal
relay and whether metering is automatically stopped.
6.3 Capacity
The capacity is determined by the stroke length and rate.
21
Functional description
The stroke length is adjusted by the stroke length adjustment knob within
a range of 0 ... 100 %. A stroke length of between 30 ... 100 %) is recom‐
mended to achieve the specified reproducibility.
The stroke rate can be set using the arrow keys (not in "Analog" operating
mode) in the range 0 - 200 strokes/min (200 strokes/min ≜12,000 strokes/
h). The "Stroke rate (strokes / min)" continuous display shows decimal
places if a stroke frequency is set in the "Stroke rate (strokes / h)" contin‐
uous display, which cannot be divided by 60 without a remainder.
Data
Recommended stroke length
Value Unit
30 ... 100 %
The stroke speed can be set in the "Dosing" menu.
6.4 Operating modes
Operating modes are selected via the "Operating modes" menu.
"Manual" operating mode
The stroke rate is set manually via the control unit.
"Batch" operating mode
This operating mode provides the option of working with large transfer fac‐
tors (up to 65535). Metering can be triggered by pressing the button [P] or
by a pulse received via the "External control" jack through a contact or a
semiconductor switching element. A metering volume (batch) or a number
of strokes can be selected in the “Settings” menu using the [arrow keys] .
Operating mode "Contact"
This operating mode offers the option of activating the pump externally by
means of potential-free contacts (e.g. by means of a contact water gauge).
The number of strokes (reducing or transfer factor 0.01 to 99.99) can be
pre-selected in the “Settings” menu using the [arrow keys] .
"Analog" operating mode
The stroke rate is controlled using an analog current signal via the
"External control" jack. Processing of the current signal can be preselected
via the control unit.
6.5 Functions
The following functions can be selected vin the menu “Settings” :
"Calibrate" function
The stroke rate is controlled using an analog current signal via the
"External control" jack. Processing of the current signal can be preselected
via the control unit.
The pump can also be operated in the calibrated state in all operating
modes. The corresponding continuous displays can then either display the
metering volume or the capacity (in the 2nd level continuous display). The
calibration remains valid over the entire stroke rate range and over a
stroke length range from 0 - 100 %.
"Auxiliary rate" function
This enables switching to an adjustable stroke rate which can be fixed in
the “Settings” menu via the "External control" jack. This auxiliary fre‐
quency has priority over the operating mode stroke rate settings .
"Flow" function
This monitors the flow in "pulsing" dosing mode after every individual
stroke, if a dosing monitor is connected. The number of sequential faulty
strokes above which it is to be stopped, can be set in the “Settings” menu.
22
Functional description
The following functions are available as standard:
"Level switch" function
Information about the liquid/powder level in the feed chemical container is
reported to the pump. To do so, a two-stage level switch must be fitted; it
is connected to the "Level switch" jack.
"Pause" function
The pump can be remotely stopped via the "External control" jack.
The following functions are triggered by a key press:
"Stop" function
The pump can be stopped by pressing the key [STOP/START] , without
disconnecting it from the power supply.
"Priming" function
Priming (short-term transport at maximum frequency) can be triggered by
simultaneous pressing of the two [arrow keys].
6.6 Relay (options)
The pump has several connection options for:
"Fault indicating relay" option
The relay can, in the event of fault or warming alerts or messages (e.g.
“Warning level” ), close a connected electric circuit (e.g. for an alarm
horn).
The relay can be retrofitted through a knock-out opening in the pump foot refer to "Retrofitting relays".
"Fault indicating and pacing relay" option
This combined relay can generate a contact with each stroke via its pacing
relay in addition to its function as a fault indicating relay.
The relay can be retrofitted through a knock-out opening in the pump foot refer to "Retrofitting relays".
"Automatic bleed" option
The function "Bleeding" is used for controlled bleeding of the liquid end, if
the pump is provided with the option "Automatic bleed". The "Automatic
bleed" option can be retrofitted, i.a. via a knock-out in the control unit.
There are two versions:
n
n
"mA output" option
version with only 1 relay - to control the bleed valve.
Version with only 2 relays - one relay to control the bleed valve and
one relay free for other uses.
The I signal of the current output signals the currently calculated pump
metering volume. The option "mA output" can be retrofitted via a knock-out
in the control unit.
The option additionally always provides a fault indicating relay or a pacing
relay.
6.7 Functional and fault Indicator
The operating and fault statuses are indicated by the three LED indicators
and the "Fault" identifier of the LCD screen, see also the "Troubleshooting"
chapter.
23
Functional description
6.8 LCD display
If a fault occurs, the identifier "Fault" appears as well an additional, explan‐
atory symbol.
6.9 LED indicators
Fault indicator (red)
The fault indicator lights up if the liquid level in the chemical feed container
falls below the second switching point of the level switch (20 mm residual
filling level in the chemical feed container).
This LED flashes in the event of an undefined operating mode.
Warning indicator (yellow)
The warning indicator lights up if the fluid level in the chemical feed con‐
tainer falls below the first switching point of the level switch.
Operating indicator (green)
The operating indicator lights up if the pump is ready for operation and
there are no fault or warning alerts. It goes out quickly as soon as the
pump has performed a stroke. It starts to flash as soon as the stroke rate
falls below 30 strokes / min.
6.10
Hierarchy of operating modes, functions and fault statuses
The different operating modes, functions and fault statuses have a dif‐
ferent effect on if and how the pump reacts.
The following list shows the order:
1. - Priming
2. - Fault, Stop, Pause
3. - Auxiliary rate
4. - Manual, Analog, Contact, Batch
Comments:
re 1 - "Priming" can take place in any mode of the pump (providing it is
functioning).
re 2 - "Fault", "Stop" and "Pause" stop everything apart from "Priming".
re 3 - The stroke rate of "Auxiliary rate" always has priority over the
stroke rate specified by an operating mode or priority 4.
24
Hydraulic installation
7
Hydraulic installation
Safety information
CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical can damage the parts of the
pump contacted by the chemical.
–
Take into account the resistance of the material con‐
tacted by the chemical when selecting the feed chemical
- refer to the ProMinent ® resistance list in the product
equipment catalogue or at www.prominent.com.
CAUTION!
Warning of feed chemical spraying around
Pumps which are not fully installed hydraulically can eject
feed chemicals from the outlet openings of the discharge
valves as soon as they are connected to the mains.
–
–
The pump must first be hydraulically installed and then
electrically.
In the event that you have failed to do so, press the
[STOP/START] button or press the emergency-stop
switch.
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‐
ised persons.
Depressurise the system before commencing any work
on hydraulic parts.
CAUTION!
Danger from rupturing hydraulic components
Peak loads during the dosing stroke can cause the maximum
permissible operating pressure of the system and pump to
be exceeded.
–
The discharge lines are to be properly designed.
CAUTION!
Danger of personal and material damage
The use of untested third party parts can result in damage to
personnel and material damage.
–
Only fit parts to dosing pumps, which have been tested
and recommended by ProMinent.
CAUTION!
Warning of illegal operation
Observe the regulations that apply where the unit is to be
installed.
25
Hydraulic installation
7.1 Install hose lines
7.1.1 Installation for metering pumps without bleed valve
Safety information
CAUTION!
Warning of feed chemical spraying around
If the pipes are improperly installed, they can come lose or
burst.
–
–
–
Route all hose lines so they are free from mechanical
stresses and kinks.
Only use original hoses with the specified hose dimen‐
sions and wall thicknesses.
To ensure high durability of the connections, only use
clamp rings and hose nozzles that are intended for the
hose diameter in question.
CAUTION!
Danger resulting from rupturing hydraulic components
Hydraulic components can rupture if the maximum permis‐
sible operating pressure is exceeded.
–
–
–
Always maintain the maximum permissible operating
pressure of all hydraulic components - please refer to
the product specific operating instructions and system
documentation.
Never allow the metering pump to run against a closed
shut-off device.
Install a relief valve.
CAUTION!
Hazardous feed chemicals can escape
Hazardous or extremely aggressive feed chemicals can leak
out when using conventional bleeding procedures with
metering pumps.
–
Install a bleed line with recirculation into the storage
tank.
CAUTION!
Hazardous feed chemicals can escape
Hazardous or extremely aggressive feed chemicals can leak
out in the event that the metering pump is removed from the
installation.
–
Shut-off valves must be installed on the metering pump's
pressure and discharge sides.
CAUTION!
Uncontrolled flowing feed chemicals
Feed chemicals can leak through a stopped metering pump
in the event of back pressure.
–
26
For this purpose, use an injection valve or vacuum
breaker.
Hydraulic installation
CAUTION!
Uncontrolled flowing feed chemicals
Feed chemicals can leak through the metering pump in an
uncontrolled manner in the event of excessive priming pres‐
sure.
–
The maximum priming pressure for the metering pump
may not be exceeded - please refer to the product-spe‐
cific operating instructions.
The pipes are to be aligned in such a way as the metering
pump and the liquid end can be removed from the side, if
necessary.
Install hose lines - design PP, NP, PV, TT
1.
Cut off the ends of the hoses at right angles.
2.
Pull the union nut (2) and clamp ring (3) over the hose (1) - see
figure .
3.
Push the hose end (1) up to the stop over the nozzle (4). Widen it, if
necessary.
Ensure that the O-ring and flat seal (5) is properly
fitted to the valve (6).
Used PTFE seals may never be re-used. An installa‐
tion sealed in this way will not be watertight.
The reason for this is that this type of seal is perma‐
nently distorted when subjected to pressure.
In order to enable it to be distinguished from the
EPDM flat seal, the FPM flat seal design PV has a dot.
4.
Place the hose (1) with the nozzle (4) onto the valve (6).
5.
Clamp the hose connector: Screw the union nut (2) tight while
simultaneously pressing on the hose (1).
6.
Re-tighten the hose connector: Pull on the hose (1) briefly, which is
fastened to the dosing head, and tighten up the union nut (2) once
more.
27
Hydraulic installation
1
2
3
4
5
6
1
2
3
4
Hose
Union nut
Clamp ring
Nozzle
O-ring and flat seal
Valve
5
6
P_MAZ_0021_SW
Fig. 7: Designs PP, NP, PV, TT
Installing stainless steel pipe - design SS
1.
Pull the union nut (2) and clamp rings (3, 4) over the pipe (1) with
approx. 10 mm overhang - see .
2.
Insert the pipe (1) up to the stop in the valve (5).
3.
Tighten the union nut (2).
1
2
3
4
5
1
2
3
Pipe
Union nut
Rear clamp ring
Front clamp ring
Valve
4
5
P_MAZ_0022_SW
Fig. 8: Design SS
Installing hose lines - design SS
CAUTION!
Warning of feed chemical spraying around
Connections can come free in the event that hose lines are
installed incorrectly on stainless steel valves.
–
–
Only use PE or PTFE hose lines.
In addition, insert a stainless steel support insert into the
hose line.
7.1.2 Installation for metering pumps with bleed valve
Safety information
CAUTION!
– All of the installation and safety notes for metering
pumps without bleed valves also apply.
Installation of the return line
28
A return line is connected in addition to the suction and discharge lines.
1.
Fasten the tube line to the return line tube nozzle or to the liquid end
bleed valve. PVC hose, soft, 6x4 mm is recommended for this.
2.
Feed the free end of the return line back to the storage tank.
Hydraulic installation
3.
Shorten the return line hose so that it cannot submerge into the feed
chemical in the storage tank.
29
Electrical installation
8
Electrical installation
WARNING!
Danger of electric shock
A mains voltage may exist inside the device.
–
Before any work, disconnect the device's mains cable
from the mains.
WARNING!
Risk of electric shock
This pump is supplied with a grounding conductor and a
grounding-type attachment plug.
–
To reduce the risk of electric shock, ensure that it is con‐
nected only to a proper grounding-type receptacle.
WARNING!
Risk of electric shock
In the event of an electrical accident, the pump must be
quickly disconnected from the mains.
–
–
Install an emergency cut-off switch in the pump power
supply line or
Integrate the pump in the emergency cut-off manage‐
ment of the system and inform personnel of the isolating
option.
WARNING!
Danger of electric shock
Incompletely installed electrical options can allow moisture
into the inside of the housing.
–
Knock-out openings in the pump housing must be
equipped with matching modules or be sealed in a leaktight manner.
WARNING!
Danger of electric shock
A mains voltage may exist inside the pump housing.
–
If the pump housing has been damaged, you must dis‐
connect it from the mains immediately. It may only be
returned to service after an authorised repair.
CAUTION!
Risk of short circuiting caused by moist pins
No moisture must reach the pins of the PROFIBUS® jack.
–
30
A suitable PROFIBUS® plug or protective cap must be
screwed onto the PROFIBUS® jack.
Electrical installation
CAUTION!
Material damage possible due to power surges
Should the pump be connected to the mains power supply in
parallel to inductive consumers (such as solenoid valves,
motors), inductive power surges can damage the controller
when it is switched off.
–
Personnel:
Provide the pump with its own contacts and supply with
voltage via a contactor relay or relay.
n
Electrician
Install the pump technically correctly and in accordance with the
operating instructions and applicable regulations.
8.1 Supply voltage connection
WARNING!
Unexpected startup is possible
As soon as the pump is connected to the mains, the pump
may start pumping and consequently feed chemical may
escape.
–
–
Prevent dangerous feed chemicals from escaping.
If you have not successfully prevented this, immediately
press the [STOP/START] key or disconnect the pump
from mains, e.g. via an emergency cu-off switch.
CAUTION!
If the pump is integrated into a system: The system must be
designed so that potential hazardous situations are avoided
by pumps starting up automatically subsequent to unin‐
tended power interruptions.
Connect the pump to the mains power supply using the mains cable.
Parallel connection to inductive con‐
sumers
Should the pump be connected to the mains in parallel to inductive con‐
sumers (e.g. solenoid valves, motor), the pump must be electrically iso‐
lated when these consumers are switched off.
n
n
Interference suppression aids
Supply the pumps with voltage via a contactor relay or relay using
separate contacts for the pump.
If this is not possible then connect a varistor (part no. 710912) or an
RC member, 0.22 µF / 220 Ω in parallel.
Product
Part no.
Varistor:
710912
RC Gate, 0.22 µF / 220 Ω:
710802
31
Electrical installation
8.2 Description of the jacks
8.2.1 "External control" terminal
The "external control" jack is a five-pin panel jack. It is compatible with
two- and four-conductor cables.
The "Auxiliary rate" function can only be used with a five conductor cable.
Electrical interface for pin 1 "Pause" - pin 2 "External contact" - pin 5 "Aux‐
iliary rate"
2
1
Data
Value Unit
Voltage with open contacts
3
4
5
P_BE_0014_SW
Fig. 9: Pump pin assignments
1
2
3
5
4
P_BE_0015_SW
Fig. 10: Cable conductor assignments
5 V
Input resistance
10 kΩ
Max. pulse frequency
25 pulse/s
Minimum pulse duration
20 ms
Control via:
n
n
potential-free connection contact (load: 0.5 mA at 5 V) or
Semiconductor switch (residual voltage < 0.7 V)
Pin
Function
5-conductor
cable
2-conductor
cable
1
Pause
brown
bridged at pin 4
2
External contact
white
brown
3
-
blue
-
4
Earth / GND
black
white
5
Auxiliary rate
grey
-
Refer to the functional description for the hierarchy of func‐
tions and operating modes.
"Pause" function
The pump does not work if:
n
the cable is connected and pin 1 and pin 4 are open.
The pump works if:
n
n
"External contact" operating mode
The pump performs one or more strokes if:
n
"Auxiliary rate" operating mode:
Pin 2 and pin 4 are connected to each other for at least 20 ms. At the
same time, pin 1 and pin 4 must also be connected to each other.
The pump works at a preset stroke rate if:
n
32
the cable is connected and pin 1 and pin 4 are connected.
no cable is connected.
Pin 5 and pin 4 are connected to each other. At the same time, pin 1
and pin 4 must also be connected to each other. The auxiliary rate is
factory-preset to the maximum stroke rate.
Electrical installation
8.2.2 "Level Switch" terminal
A 2-stage level switch with pre-warning and limit stop can be connected.
Electrical interface
3
Data
Value Unit
Voltage with open contacts
5 V
Input resistance
10 kΩ
Control via:
1
2
P_BE_0016_SW
n
n
potential-free connection contact (load: 0.5 mA at 5 V) or
Semiconductor switch (residual voltage < 0.7 V)
Fig. 11: Pump pin assignments
3
2
Pin
Function
3-conductor cable
1
Earth / GND
black
2
Minimum pre-warning
blue
3
Minimum limit stop
brown
1
P_BE_0017_SW
Fig. 12: Cable conductor assignments
8.2.3 "Dosing monitor" terminal
There is a connecting option for a dosing monitor.
Electrical interface
2
1
Data
Value Unit
Voltage with open contacts
5 V
Input resistance
10 kΩ
Control via:
3
4
n
potential-free connection contact (load: 0.5 mA at 5 V) or
P_DE_0009_SW
Fig. 13: Pump pin assignments
1
4
2
3
Pin
Function
4-conductor cable
1
Power supply (5 V)
brown
2
Coding
white
3
Feedback
blue
4
Earth / GND
black
P_DE_0010_SW
Fig. 14: Cable conductor assignments
8.2.4 "Diaphragm rupture sensor" jack
There is a connecting option for a diaphragm rupture sensor.
Electrical interface
33
Electrical installation
3
Data
2
Value Unit
Voltage with open contacts
5 V
Input resistance
10 kΩ
Control via:
4
1
n
potential-free connection contact (load: 0.5 mA at 5 V) or
P_DE_0011_SW
Fig. 15: Pump pin assignments
2
3
4
1
Pin
Function
4-conductor cable
1
Power supply (5 V)
brown
2
Coding
white
3
Feedback
blue
4
Earth / GND
black
P_DE_0012_SW
Fig. 16: Cable conductor assignments
8.3 Relay
8.3.1 "Fault indicating relay" output (identity code 1 + 3 or 6 + 7)
A fault indicating relay can be ordered as an option - refer to ordering
information in the appendix. It is used to emit a signal when there is a fault
with the pump and for the "Liquid level low, 1st stage" warning alert and
"Liquid level low, 2nd stage".
A cut-off relay works when there are fault alerts from the pump and in the
event of the "Liquid level low 2nd stage" alert.
The fault indicating relay can be retrofitted and is operational once
attached to the relay board - refer to "Retrofitting Relays" supplementary
operating instructions.
The behaviour is programmed ex factory. If another switching function is
required, the pump can be reprogrammed in the “Relay” menu.
The relay can be retrofitted and operates once it is plugged into the relay
board.
Electrical interface
2
Data
3
1
Value Unit
Maximum contact load at 230 V and 50/60
Hz:
Minimum mechanical lifespan:
8 A
200 000 Switching
operations
4
P_SI_0010_SW
Fig. 17: Pump pin assignments
Identity code 1 + 3 or 6 + 7
P_SI_0043
Fig. 18: Cable conductor assignments
34
To pin
VDE cable
Contact
CSA cable
1
white
NO (normally open)
white
2
green
NC (normally closed)
red
4
brown
C (common)
black
Electrical installation
8.3.2 Output for other relays (identity code 4 + 5, 8 + 9, A + B)
A fault indicating and a pacing relay can optionally be ordered - refer to
ordering information in the appendix. The pacing output is electrically-iso‐
lated by means of an optocoupler with a semiconductor switch. The
second switch is a relay.
The behaviour is programmed ex factory. If another switching function is
required, the pump can be reprogrammed in the “Relay” menu.
The fault indicating/pacing relay can be retrofitted and is operational once
attached to the relay board - refer to "Retrofitting Relays" supplementary
operating instructions.
Electrical interface
2
for fault indicating relay output:
3
1
4
Data
Value Unit
Maximum contact load at 24 V and 50/60
Hz:
Minimum mechanical lifespan:
20,000,000 Switching
operations
P_SI_0010_SW
Fig. 19: Pump pin assignments
2 A
for semiconductor switch pacing relay:
Data
Value Unit
Residual voltage max. at Ioff max = 1 µA
0.4 V
Maximum current
100 mA
Maximum voltage
24 VDC
Pacing pulse duration, approx.
100 ms
Identity code 4 + 5, 8 + 9, A + B
P_SI_0044
Fig. 20: Cable conductor assignments
To pin
VDE cable
Contact
Relay
1
yellow
NO (normally open)
Other relay
4
green
C (common)
Other relay
3
white
NO (normally open)
Pacing relay
2
brown
C (common)
Pacing relay
8.3.3 Output "Current output plus relay" (identity code C + D + E)
A relay combined with a current output can be optionally ordered. The
relay switches either as a fault indicating relay when there is a fault with
the pump and with "Liquid level low, 1st stage" warning alert and "Liquid
level low 2nd stage" fault alert or is used as a pacing relay.
The behaviour is programmed ex factory. If another switching function is
required, the pump can be reprogrammed in the “Relay” menu.
In the “ANALOG OUTPUT” menu, the variable to be signalled by the cur‐
rent output can be selected.
The current output plus relay can be retrofitted and operates once it is
plugged into the board.
35
Electrical installation
Electrical interface
2
for current output
3
1
4
Data
Value Unit
Open circuit voltage:
8 V
Current range:
4 ... 20 mA
Ripple, max.:
P_SI_0010_SW
Fig. 21: Pump pin assignments
80 μA ss
Ripple, max.:
250 Ω
for semiconductor switch ("relay"):
Data
Value Unit
Residual voltage max. at Ioff max = 1 µA
0.4 V
Maximum current
100 mA
Maximum voltage
24 VDC
Pacing pulse duration, approx.
100 ms
Identity code C + D + E
To pin
VDE cable
Contact
Relay
1
yellow
"+"
Current
output
4
green
"-"
Current
output
3
white
NC (normally closed) or
Relay
P_SI_0044
Fig. 22: Cable conductor assignments
NO (normally open)
2
36
brown
C (common)
Relay
Adjustment
9
Adjustment
Please read the overviews in the appendix, "Control ele‐
ments and key functions" and "Operating/setting dia‐
gram" for supplementary information.
If no key is pressed for a 1 minute duration, the pump
returns to a continuous display.
–
–
9.1 Basic principles of control adjustment
= adjustment option
= flashes
P
P
Continuous
display
Confirming an entry
P
Batch
Settings
Batch
Concentration
Auxiliar
Calibration
3s
P
Batch
Auxiliar
100
/min
P
P
3s
Quickly press key [P].
The display simultaneously changes to the next selection, to the next
menu point or into a continuous display.
Quitting a menu point without confirming it
Press the [UP] key in the top menu selection, if no entry has been started
(flashing beam).
You will jump back to the previous menu point or menu, at most back to
the main menu.
Jumping back to a continuous display
Press and hold the [P] key for 3 seconds.
Entry is cancelled and you jump back to a continuous display.
Changing adjustable variables
Press the arrow keys [UP] or [DOWN].
In this way the number between the flashing bars counts upwards or
downwards.
Confirming adjustable variables
Under "Changing a number": press key [P] 1x.
The display simultaneously changes to the next selection, to the next
menu point or into a continuous display.
9.2 Checking adjustable variables
Continuous displays
Before you adjust the pump, you can check the actual settings of the
adjustable variables:
Press the key [i] ("i" for "Info"), if the pump is displaying a contin‐
uous display (The display does not contain the symbol for the [P]
key).
ð Each time you press the [i] key, you see another continuous
display, an "i" can be seen at the top left.
37
Adjustment
The number of continuous displays depends on the identity
code, the selected operating mode and the connected addi‐
tional devices, see overview "Continuous displays" in the
appendix.
Secondary displays
The lowest line of the Info displays (2nd level continuous display) various
information, which cannot, however, be adjusted here, see overview "Sec‐
ondary displays" in the appendix...
If you are in a continuous display, you can access the bottom line of the
info displays by:
1.
pressing key [i], provided that the top left double arrow is not visible.
2.
Keep key [i] pressed down until a small arrow appears and glides
into the bottom line of the LCD display.
3.
As soon as it has reached it, quickly release the [i] key and immedi‐
ately page through the info displays in the bottom line by quickly
pressing the [i] key.
9.3 Changing to adjustment mode
If the [P] key is pressed for 2 seconds in a continuous display, the pump
changes to adjustment mode. If [Lock menu] or “Lock all” have been set
under “Security” (top left lock symbol), the [P] key must be pressed and
then the access code entered ([arrow keys]!).
The following menus can be initially chosen in adjustment mode - see also
the overview "Operating/setting diagram":
n
n
n
n
n
Menu
Menu
Menu
Menu
Menu
“Operation”
“Settings”
“Security” (option)
“Delete”
“Language”
To adapt the pump to your process requirements, you must:
38
1.
Select the operating mode in the “Operation” menu.
2.
Carry out the adjustment for this operating mode under the
“Settings” menu.
Adjustment
1.
Menu
Mode
2.
Menu
Settings
Continuous
display
2s
P
P
Analog
Main
Mode
Settings
Security
Clear
P
Menu
Security
Menu
Clear
Menu
Language
9.4 Selecting the operating mode (Menu "Operation")
In the “Operation” menu (dependent on the identity code, some operating
modes may not be present) the following operating modes can be
selected:
n
n
n
n
“Manual” : for manual operation
“Batch” : for batch operation
“Contact” : for contact operation
“Analog” : for current control
P
0..20
P
Analog
Main
Mode
Settings
Security
Clear
P
0..20
Analog
Mode
Manual
Batch
Contact
Analog
P
Continuous
display
9.5 Operating mode settings (menu "Settings")
Various settings can be adjusted in the “Settings” menu dependent on the
selected operating mode.
Setting menus are available in all operating modes for the following pro‐
grammable functions:
n
n
n
n
n
“Concentration”
“Auxiliary rate”
“Calibration”
“Metering”
“System”
39
Adjustment
For further details, see Ä Chapter 9.6 “Programmable function settings
("Settings" menu )” on page 46
As to whether or not a further setting menu is available, depends on the
selected operating mode and the connected devices or modules.
Continuous
display
Analog
Main
Mode
Settings
Security
Clear
Menu
Settings
Menu
Operating mode**
Menu
Timer*
Menu
Profibus*
Menu
Concentration
Menu
Auxiliar
Menu
Flow*
Menu
Calibration
Menu
Dosing
Submenu
Settings
Submenu
Airlock
Submenu
Low pressure
Menu
Bleeding*
Submenu
High pressure
Menu
Relay*
Menu
Analog Out*
Menu
System
Submenu
Unit
Submenu
Diaphragma
Submenu
Info
Submenu
Change head?
Fig. 23: "Settings" menu branch
40
Adjustment
9.5.1 "Manual" operating mode settings
Alongside the setting menu, which are described in more detail in
Ä Chapter 9.6 “Programmable function settings ("Settings" menu )”
on page 46, in “Manual” operating mode in the “Settings” menu there is
no further setting menu available.
9.5.2 Settings for the “Batch” operating mode (BATCH menu)
Alongside the setting menus, which are described in more detail in
Ä Chapter 9.6 “Programmable function settings ("Settings" menu )”
on page 46, in “Batch” operating mode in the “Settings” menu, the
“BATCH” menu is also available.
P
P
Batch
Main
Mode
Settings
Security
Clear
P
P
Batch
Settings
Batch
Concentration
Auxiliar
Calibration
P
P
Batch
Batch
Memory
Factor
off
4
P
Batch
Batch
Memory
Factor
off
P
4
Continuous
display
The operating mode “Batch” is one variant of the “Contact” operating
mode - see the following chapter. Here also, you can select a number of
strokes (no fractions, only integers from 1 to 65535).
Operating mode “Batch” is intended for large metering quantities.
Metering can be triggered by pressing the [P] key or via an pulse received
via the "External Control" jack.
The number of received pulses, which could not yet be processed, is
stored by the pump in the stroke memory.
CAUTION!
When changing over from the "Manual" operating mode to
the "Batch" operating mode, the pump maintains the stroke
rate.
The stroke rate can also be set in “Contact” operating mode.
It should normally be set to 200 strokes / min.
In operation, the batch size can be changed more easily by
using “Batch size” in the continuous display:
"Memory" function extension
1.
Using the [i] key, select the "Batch size" continuous display (dis‐
plays an “↑L” after the number).
2.
Hold down an [arrow key] until the variable is flanked by two
flashing bars.
3.
Change the batch size as required using the [arrow keys].
Additionally, you can activate the "Memory" function extension (Identifier
"m"). When "Memory" is activated, the pump adds up the remaining
strokes , which could not be processed, up to the maximum capacity of the
stroke memory of 65,535 strokes. If this maximum capacity is exceeded,
the pump goes into fault mode.
41
Adjustment
9.5.3 "Contact" operating mode settings
Alongside the setting menus, which are described in more detail in
Ä Chapter 9.6 “Programmable function settings ("Settings" menu )”
on page 46, in “Contact” operating mode in the “Settings” menu, the
“Contact” menu is also available.
“Contact” operating mode allows you to trigger individual strokes or a
stroke series.
You can trigger the strokes via a pulse sent via the "External control" jack.
The purpose of this operating mode is to convert the incoming pulses with
a reduction (bridge) or small step-up into strokes.
CAUTION!
When changing over from “Manual” operating mode to
“Contact” operating mode, the pump maintains the stroke
rate.
The stroke rate can also be set in “Contact” operating mode.
It should normally be set to 200 strokes / min.
P
P
Contact
Main
Mode
Settings
Security
Clear
P
Contact
Settings
Contact
Concentration
Auxiliar
Calibration
P
P
Contact
Contact
Stroke memory off
Stroke memory on
P
P
Contact
Stroke memory on
Factor: 1.25 stroke/cont.
P
Continuous
display
The number of strokes per pulse depends on the factor which you input.
By use of the factor you can multiply incoming pulses by a factor between
1.01 and 99.99 or reduce them by a factor of 0.01 to 0.99.
Number of strokes executed = factor x number of
incoming pulses
42
Adjustment
Example table
Factor
Pulse (sequence)
Number of strokes
(sequence)
1
1
1
2
1
2
25
1
25
99.99
1
99.99
1.50
1
1.50 (1 / 2)
1.25
1
1.25 (1 / 1 / 1 / 2)
1
1
1
0.50
2
1
0.10
10
1
0.01
100
1
0.25
4
1
0.40
2.5 (3 / 2)
(1 / 1)
0.75
1.33 (2 / 1 / 1)
(1 / 1 / 1)
Step-up*
Reduction**
* Explanation of the conversion ratio
With a factor of 1,
... 1 stroke is executed per 1 pulse.
With a factor of 2,
... 2 strokes are executed per 1 pulse.
With a factor of 25,
... 25 strokes are executed per 1 pulse.
** Explanation of reduction
With a factor of 1,
... 1 stroke is executed per 1 pulse.
With a factor of 0.5,
...1 stroke is executed after 2 pulses.
With a factor of 0.1,
...1 stroke is executed after 10 pulses.
With a factor of 0.75,
...1 stroke is executed once after 2 pulses,
then 1 stroke is executed after 1 pulse two times,
and then again 1 stroke after 2 pulses etc.
If a remainder is obtained when dividing by the factor, then
the device adds the remainders together. As soon as this
sum reaches or exceeds "1", the pump executes an addi‐
tional stroke. Therefore on average during the metering ope‐
ration, the resultant number of strokes precisely matches the
factor.
Non-processed pulses
The number of received pulses, which could not yet be processed, is
stored by the pump in the stroke memory. When the [STOP/START] key is
pressed or the "Pause" function is activated, the stroke memory is deleted.
You can avoid this with the "Memory" function extension:
43
Adjustment
"Memory" function extension
Additionally, you can activate the "Memory" function extension (Identifier
"m"). When "Memory" is activated, the pump adds up the remaining
strokes , which could not be processed, up to the maximum capacity of the
stroke memory of 65,535 strokes. If this maximum capacity is exceeded,
the pump goes into fault mode.
Contact water meter
With "Pulse control" you can optimally adapt the pump to the relevant
process, for example in conjunction with contact water meters.
9.5.4 "Analog" operating mode settings
Alongside the setting menus, which are described in more detail in
Ä Chapter 9.6 “Programmable function settings ("Settings" menu )”
on page 46, in “Analog” operating mode in the “Settings” menu, the
“ANALOG” menu is also available. The stroke rate is controlled using an
analog current signal via the "External control" jack. The continuous dis‐
play "Signal current" of the 2nd level indicates the incoming current.
You can select three types of current signal processing:
“0 - 20 mA”
“4 - 20 mA”
“Curve”
n
n
n
0 - 20 mA
At 0 mA the pump is stationary At 20 mA the pump works at the maximum stroke rate.
Between these values, the stroke rate is proportional to the current signal.
P
0..20
P
Analog
Main
Mode
Settings
Security
Clear
P
0..20
Analog
Settings
Analog
Concentration
Auxiliar
Calibration
P
P
0..20
Analog
Analog
0..20mA
4..20mA
Curve
P
Continuous
display
4 - 20 mA
At 4 mA the pump is stationary At 20 mA the pump works at the maximum stroke rate.
Between these values, the stroke rate is proportional to the current signal.
For current signals less than 3.8 mA a fault message appears and the
pump stops (e.g. if a cable has broken).
The maximum stroke rate can only be reduced under pro‐
cessing type “Curve” , not under processing types "0 .. 20"
and "4 .. 20".
P
0..20
Continuous
display
44
P
Analog
Main
Mode
Settings
Security
Clear
P
0..20
Analog
Settings
Analog
Concentration
Auxiliar
Calibration
P
P
0..20
Analog
Analog
0..20mA
4..20mA
Curve
P
Adjustment
In the processing type “Curve” you can freely program the pump behav‐
iour.
Curve
There are three options:
n
n
n
Linear
Lower sideband
Upper sideband
The following applies to all three options:
The smallest processable difference between I1 and I2 is 4
mA (ll I1-I2 ll ≥4 mA).
P
0..20
P
Analog
Main
Mode
Settings
Security
Clear
P
0..20
Analog
Settings
Analog
Concentration
Auxiliar
Calibration
P
P
Analog
Analog
0..20mA
4..20mA
Curve
P
0..20
P
0..20
Analog
Curve
Straight
top side band
bottom Sideband
P
P
P
0..20
P
Analog
top side band
I1=
04.0mA
F1=
060 stroke/min
I2=
20.0mA
F2=
100 stroke/min
P
0..20
P
Analog
top side band
I1=
04.0mA
F1=
060 stroke/min
I2=
20.0mA
F2=
100 stroke/min
P
Analog
top side band
Errorswitch: On
P
0..20
Continuous
display
Linear
The "Linear" symbol appears in the LCD display. You can enter any stroke
rate- behaviour of the pump proportional to the current signal. For this pur‐
pose, enter any two points P1 (I1, F1) and P2 (I2, F2) (F1 is the stroke rate
at which the pump is to operate at current I1, F2 is the stroke rate at which
the pump is to operate at current I2...); this defines a straight line and thus
the behaviour is specified:
Fmax
P2
F2
P1
F1
0
I1
I2
20
I [mA]
B0088
Fig. 24: Rate(frequency)-Current Diagram for Linear control
Plot a diagram similar to the one above - with values for (I1,
F1) and (I2, F2) – so that you can set the pump as desired!
Fault processing
Under the menu option “Alarm message” (fault) your can activate a fault
processing sequence for the “Curve” processing type. For current signals
below 3.8 mA, a fault message appears and the pump stops.
45
Adjustment
Lower sideband
Using this processing type, you can control a metering pump using the
current signal as shown in the diagram below.
However, you can also control two metering pumps for different feed
chemicals via a current signal (e.g. one acid pump and one alkali pump
using the signal of a pH sensor). To do this, you must connect the pumps
electrically in series, - see the wiring diagram in Ä Chapter 8 “Electrical
installation” on page 30.
The "Lower sideband" symbol appears in the LCD display. Below I1, the
pump works at a rate of F1 - above I2 it stops. Between I1 and I2 the
stroke rate varies between F1 and F2 in proportion to the signal current.
a)
b)
Fmax
Fmax
P1
F1
P2
F2
P2
F2
P1
F1
0
I1
I2
20
I [mA]
0
I1
I2
20
I [mA]
B0089
Fig. 25: Frequency-current diagram for a) Lower sideband, b) Upper sideband
Upper sideband
Using this processing type, you can control a metering pump using the
current signal as shown in the diagram above.
However, you can also control two metering pumps for different feed
chemicals via a current signal (e.g. one acid pump and one alkali pump
using the signal of a pH sensor). To do this, you must connect the pumps
electrically in series, - see the wiring diagram in Ä Chapter 8 “Electrical
installation” on page 30.
The "Upper sideband" symbol appears in the LCD display. Below I1, the
pump is stationary - above I2 the pump works at rate F2. Between I1 and
I2 the stroke rate varies between F1 and F2 in proportion to the signal cur‐
rent.
9.6 Programmable function settings ("Settings" menu )
Setting menus are available in all operating modes in the menu "SET‐
TINGS" for the following programmable functions:
n
n
n
n
n
n
n
46
Concentration (menu “CONCENTRATION” )
Auxiliary rate (menu “AUX” )
Flow (menu “FLOW” ) (only available if a dosing monitor is connected)
Calibrate (menu “CALIBRATE” )
Metering (menu “METERING” )
Relay (menu “RELAY” ) (only available if a relay is fitted)
System (menu “SYSTEM” )
Adjustment
9.6.1 Settings for the “Auxiliary rate” function (AUX menu)
P
P
Batch
Main
Mode
Settings
Security
Clear
P
P
Batch
Settings
Batch
Concentration
Auxiliar
Calibration
P
Batch
Auxiliar
100
P
/min
Continuous
display
The programmable function "Auxiliary rate" facilitates the switchover to an
auxiliary stroke rate, which can be fixed in the “AUX” menu. It can be acti‐
vated via the "External control" jack. If the auxiliary rate applies, then the
identifier "Aux" appears in the LCD display.
This auxiliary rate has priority over the stroke rate, which is specified by
the currently selected operating mode - see also the chapter "Function
description" - "Hierarchy of operating modes".
9.6.2 Settings for the “Flow” function (FLOW menu)
The menu “FLOW” only appears if a dosing monitor is connected to the
"Dosing monitor" jack. The dosing monitor records the individual pressure
surges of the pump at the discharge connector during pulsed metering
( “Metering” “fast” , menu “METERING” ) and immediately reports it back
to the pump. In the event that this feedback message remains missing in a
sequence as often as set in the menu “FLOW” under “Tolerance” (due to
a failure or too low a metering level), then this function stops the pump.
The last menu option provides the choice, of whether this case should
lead to a “Fault” or a “Warning” .
The function “Flow” can be deactivated for the “AUX” operating mode
(auxiliary rate).
9.6.3 Settings for the “Calibrate” function (CALIBRATE menu)
P
P
Batch
Main
Mode
Settings
Security
Clear
P
P
Batch
Settings
Batch
Concentration
Auxiliar
Flow
P
P
P
Batch
Flow
Off
On
P
Batch
Flow
Tolerance: 8
by Auxiliary: off
P
Batch
Flow
Tolerance: 8
by Auxiliary: off
P
P
Batch
Flow
Warning
Error
P
Continuous
display
The pump can also be operated in the calibrated state. In this case, the
corresponding continuous displays then indicate the metering volume or
the capacity directly.
47
Adjustment
Accuracy of the calibration
The calibration will not be accurate, if these conditions are
not adhered to:
–
–
do not allow the stroke length to fall below 30 %
The pump should execute at least 200 strokes.
Calibration
WARNING!
If the feed chemical is dangerous, take appropriate safety
precautions when executing the following calibration instruc‐
tions. Observe the safety data sheet for the feed chemical!
1.
Lead the suction hose into a measuring cylinder containing the feed
chemical - the discharge hose must be installed in a permanent
manner (operating pressure, ...!).
2.
Prime using the feed chemical (simultaneously press the two
[arrow keys]), should the suction hose be empty.
3.
Record the level in the measuring cylinder.
4.
Using the [i] key scroll through the continuous display and check
whether litres or gallons are selected.
5.
If the incorrect volume units are selected, select the “SYSTEM”
menu and the then the “UNITS” sub-menu.
6.
Using the [arrow keys], select the correct units and confirm by
pressing the [P] key.
7.
Select the “CALIBRATE” menu and then use the [P] key to change
to the first menu option.
8.
Use the [DOWN] key to select “Start calib.” .
9.
To start the calibration, press the [P] key: The next menu option,
“Stop calib.” . appears, the pump starts to pump and indicates the
stroke rate (the pump works at the stroke rate, which is set under
“MANUAL” ).
10.
After a reasonable number of strokes (e.g. 200), stop the pump by
pressing the [P] key.
11.
Determine the required metering volume (difference initial volume residual volume).
12.
Enter this volume in the menu option which appears and then press
the key [P] - the pump changes to continuous display.
ð The pump is calibrated.
The corresponding continuous displays indicate the calibrated
values.
9.6.4 Settings for the “Metering” function (DOSING menu)
The "Metering" menu branches into the following sub-menus:
1 - “Settings” (metering)
2 - “Air lock”
3 - “Low pressure”
4 - “High pressure”
48
Adjustment
The last menu option of "Settings" offers the following functions:
n
n
9.6.4.1
Pressure (ratings)
Compensation
Settings in the sub-menu ″Settings″ (metering)
P
P
Batch
Main
Mode
Settings
Security
Clear
P
P
Batch
Settings
Auxiliar
Calibration
Dosing
Relay
P
Batch
Dosing
Settings
Airlock
Low Pressure
Press. Monitor
P
Batch
Settings
:slow
:fast
P
P
- Discharge stroke-
P
P
Batch
Settings
:normal
:HV1
:HV2
:HV3
P
Batch
Settings
Pressure 1
Compensation: off
Monitoring:
off
P
- Suction stroke Continuous
display
In the sub-menu “Settings” (metering), you can precisely match the pump
metering flow over time against the requirements of the particular applica‐
tion.
Discharge stroke
Hence the user can, dependent on requirements, set a fast discharge
stroke ( “Metering” - “fast” ) for pulsed metering e.g. for quick clocked
filling processes ( a) ) or a slow discharge stroke ( “Metering” - “slow” ) for
quasi-continuous metering, e.g. for processes requiring good mixing ( b) ).
p
a)
b)
t
P_DE_0006_SW
Fig. 26
–
–
–
–
During quasi-continuous metering for high accuracy set
as large as possible a stroke length.
The slowing of the discharge stroke only becomes
noticeable at lower stroke rates.
At maximum stroke rate, “slow” is identical to “fast” !
Slowing of the suction stroke leads to a lower capacity.
49
Adjustment
In both metering modes it is possible, to selectively also slow the suction
stroke. For the case of volatile feed chemicals, the slow suction stroke pre‐
vents cavitation and consequently increases metering precision ( b) and
c) ). In this way, it is possible to prevent the main cause for imprecise
metering with high viscosity feed chemicals, namely the incomplete filling
of the liquid end.
Suction stroke
Discharge
stroke"fast"
Discharge
stroke"slow"
p
t
a) Suction
stroke"normal"
t
b) Suction
stroke"HV1"
t
c) Suction
stroke"HV3"
P_DE_0006_SW
Fig. 27: Pulsed and quasi-continuous Mode with:
a)
b)
c)
normal suction stroke
slightly slowed suction stroke
maximally slowed suction stroke
The metering behaviour of the pump can be matched to the viscosity of
the feed chemical.
Viscosity in mPa
"Dosing" setting
Suction stroke
slowing
Max. stroke rate
Remarks
0...50
"normal"
none
200
50...200
"HV1"
slight
160
200...500
"HV2"
medium
120
for valves with springs
500...1000
"HV3"
Maximum
80
for valves with springs
For the adjustment for slowing the suction stroke dependent upon the feed
chemical viscosity - see the "Adjustment" chapter.
Should "Settings" - "Intelligent" have been selected, a further menu option
with the following functions appears:
n
n
Pressure ratings
“Pressure” (ratings)
“Compensation”
Using the "Pressure ratings" function, you can reduce the pump rated
pressure.
The threshold of the permanently active overpressure monitoring falls
simultaneously with the pressure rating (reacts at approx. 30 … 50 %
exceeding of the rated pressure, also pressure rating).
50
Adjustment
CAUTION!
If another liquid end size is fitted, then the pump must be
converted to the corresponding type - see "Set‐
tings"-"System"-"Change head?".
CAUTION!
Warning of bursting lines
If a line becomes blocked, it could burst.
–
Select the pump rated pressure only as large as neces‐
sary and as small as possible. This reduces the risk of
bursting lines.
You can select the following rated pressures for these liquid end sizes via
the pressure ratings:
Pressure rating/
1
2
3
4
Size of liquid end
[bar]
[bar]
[bar]
[bar]
2508
4
7
10
25
1608
4
7
10
16
1612
4
7
10
16
1020
4
7
10
-
0730
4
7
-
-
0450
4
-
-
-
0280
2
-
-
-
Compensation
Using the "Compensation" programmable function, you can minimise the
influence of back pressure oscillations and thus achieve a high metering
precision.
Under difficult hydraulic conditions, it can be better to switch
off the "Compensation" function.
9.6.4.2
Settings in the "Air lock" sub-menu
Should a message appear, this may mean that there is air in the liquid end
(if “Warning” or “Fault” was selected in the “Air lock” sub-menu). Then
either no suction has taken place or there are gas bubbles in the liquid
end. These may have been sucked in or created by outgassing or cavita‐
tion.
9.6.4.3
″Low Pressure″ sub-menu settings
Should a message appear, then, owing to a lack of back pressure, the
delta® has established that there is possibly a leak, a burst line or a line
ripped off on the pressure side (if “Warning” or “Error” has been selected
in the “No pressure” sub-menu).
51
Adjustment
The “No pressure” function can only function if the liquid end
has been filled free from bubbles.
9.6.4.4
″High Pressure″ sub-menu settings
If an alert appears, then the pump has identified a possible blockage or
closed shut-off valve on the discharge side, owing to the back pressure
being too high (if “Warning” or “Fault” has been set in the “High
Pressure” sub-menu).
9.6.5 Settings for the "Bleeding" function)
P
0..20
P
Analog
Settings
Dosing
Bleeding
Relay 2
System
P
0..20
P
Analog
Bleeding
Off
Airlock
Periodic
Both
P
Analog
Bleeding
Period: 10 min
0..20
P
Analog
Bleeding
Dose time:
if Pause:
P
10 s
off
P
0..20
Continuous
display
The menu “BLEEDING” only appears, if a bleed module is plugged in.
The module is also immediately recognised when the pump is running and
the function is inserted in the operating menu (plug and play). The function
"Bleeding" is used for controlled bleeding of the liquid end, if the pump has
the option "Bleed module" (can be retrofitted).
There are two versions of the bleed module with different effects on the
operating menu:
n
n
Version with only 1 relay - to control the bleed valve. The menu
“BLEEDING” replaces the “RELAY” menu.
Version with 2 relays - one relay to control the bleed valve and one
relay free for other uses. For this version, the additional menu
“RELAY 2” appears under the menu “BLEEDING” .
The "Bleeding" function can be triggered in three ways:
1 - Only through the internal signal "Bleeding" from the pump drive unit.
2 - Only through the control unit - periodically for the set duration (both
adjustable).
3 - If one of the two events occurs.
52
Adjustment
Detailed explanation:
1 - If “Air lock” has been selected in the menu, the internal signal "Air
lock" triggers the bleed procedure.
If the signal appears again within 8 minutes of the bleed procedure
being carried out, the control unit repeats the bleed procedure up to a
maximum 3x. However if the signals still appear, then a fault alert is
generated, which must be acknowledged via the “STOP/START”
key. In the event of an “Air lock” there is no option for a direct fault or
warning alert upon receipt of the "Air lock" signal. Also the corre‐
sponding menu branch in the menu “METERING” is hidden. The
signal is only available for the "Bleeding" function.
2 - If “Periodic” was selected in the menu, then the control unit periodi‐
cally triggers the bleed procedure with the adjustable period (10 ...
1440 min = 24 h) and the adjustable duration ( “Dose time” : 0 ... 300 s
= 5 min).
Triggering always occurs at the start of a period. Triggering also
occurs if started using the “STOP/START” key or a mains voltage is
applied arising from a bleed procedure. If under the menu the function
“Upon pause” , is set to “on” , the bleed procedure also takes place
during pauses.
3 - If “Both” has been selected in the menu, either the internal signal "Air
lock" or the control unit triggers the bleed procedure. If one trigger
occurs, while the other has already triggered a bleed procedure, this
results in two sequential bleed procedures.
Sequence of the bleed procedure (auto‐
matic):
1.
The pump control stops the running normal metering operation - the
"Stop" symbol appears on the LCD screen.
2.
After 1 s, it opens the bleed valve of the liquid end (via the bleed
relay and the solenoid valve).
3.
1 s later, the pump starts to run at its maximum possible stroke rate
(as during priming) - the symbol "Air lock" appears on the LCD
screen instead of the "Stop" symbol.
4.
The pump runs in this way for the total set time.
5.
Once the set time has elapsed, the pump stops, the symbol "Stop"
appears on the LCD screen again.
6.
After 1 s the pump control closes the liquid end bleed valve.
7.
After 1 s the "Stop" symbol disappears and the pump recommences
normal operation.
If the pump was in the "Stop" state upon triggering (Key “STOP/START” ,
pause, fault), the start of the bleed procedure is delayed - until this state is
cleared.
If the pump is placed in the "Stop" state during the bleed procedure, the
pump control jumps immediately to phases 5 and 6. (see above) This defi‐
nitely cancels the bleed procedure. As soon as the "Stop" state is cleared,
the bleed procedure starts from the beginning.
53
Adjustment
9.6.6 Settings for the “Relay” function (RELAY menu)
P
P
Batch
Main
Mode
Settings
Security
Clear
P
Batch
Settings
Dosing
Relay
Analog Out
System
P
P
P
Batch
Relay 1
Error
Warning
Warning+Error
Pulse
Batch
Relay
Relay 1
Relay 2
P
P
P
Batch
Relay 1
energizing
releasing
P
Continuous
display
Using the "Relay" programmable function, you can match the pump relays
to your requirements.
You can reprogram the relays using the "Relay" function in an almost
limited way. Exception: The two 8 A fault indicating relays (under identity
code: 1 and 2) and the 8 A cut-off relays (under identity code: 6 and 7) can
only be reprogrammed from “NO” to “NC” and vice versa.
Allocations for the relay combinations
Identity code specification
Relay type
"Relay 1"
"Relay 2"
(Mechanical relay)
Semiconductor relay)
4+5
Fault indicating relay and
pacing relay
Fault indicating relay
Pacing relay
8+9
Cut-off relay and pacing
relay
Cut-off relay
Pacing relay
A+B
Cut-off relay and warning
relay
Cut-off relay
Warning relay
You can set whether the respective relay is to switch due to a triggering
event from the timer, upon a warning alert, a fault alert or a pump stroke:
Selectable behaviour types
Setting in the “Relay” menu
Effect
Warning
The relay switches upon a warning alert (yellow LED*).
Fault
The relay switches upon a fault alert (red LED*).
Warning + fault
The relay switches upon a warning alert (yellow LED*) or a fault alert (red LED*).
Pacing relay
The relay switches every stroke.
Option
The relay has the option of which module was plugged in (e.g. timer).
Warn. + Fault + Stop
The relay switches upon a warning alert (yellow LED*) or a fault alert (red LED*)
or a stop (key “STOP/START” or pause).
* see "Troubleshooting" chapter
You can also indicate how the respective relay should behave as soon as
it switches. You can change this via the setting “NO” / “NC.”
54
Adjustment
The setting option for the "Relay" function only exists if a
relay is present.
The following table summarises once more the behaviour of the deliver‐
able relay types according to the identity code in the as-delivered condi‐
tion:
Relay type behaviour according to identity code
Relay type
Behaviour
Warning indicating relay
... switches upon a warning alert (yellow LED*).
Fault indicating relay
... switches upon a warning alert (yellow LED*) and / or a fault alert (red
LED*).
Cut-off relay
... switches upon a fault alert (red LED*).
Pacing relay
... switches with every pump stroke.
* see "Troubleshooting" chapter
9.6.7 Settings for the “Analog output” function (ANALOG OUTPUT menu)
P
P
Batch
Main
Mode
Settings
Security
Clear
P
P
Batch
Settings
Dosing
Relay
Analog Out
System
P
P
Batch
Analog Out
0..20mA
4..20mA
Batch
0..20mA
/h
l/h x
Capacity
P
P
only under "Capacity"
P
Batch
Capacity
12 l/h at 20 mA
P
Continuous
display
Using the "Analog output" programmable function, you can match the
pump current output signal to your requirements.
The signal I of the current output signal one of the three following varia‐
bles:
n
n
n
n
Strokes /h
Litre / h x stroke length (= current, calculated capacity)
Performance (= capacity, value adjustable at 20 mA)
In the "Stop" or "Pause" states (either because of a fault or operation) or
"Pause" the current output emits a current of 4 mA.
The signal for the current, calculated capacity "Litre / h *" is calculated by
the pump according to the following formula (here for the range 4-20 mA):
I(4...20) = 16 x (f/fmax) x (L/100) + 4
with
55
Adjustment
l
- Output current in mA
f
- Stroke rate in strokes/min
L
- Stroke length in %
fmax - Maximum stroke rate in strokes/min
In the “Contact” and “Batch” operating modes, f is the stroke rate which is
set in the "Stroke rate" continuous display.
9.6.8 Settings in the "System" menu" (SYSTEM menu)
Menu
Settings
P
Menu
System
P
Submenu
Unit
Submenu
Diaphragma
Submenu
Change head?
Submenu
Info
Continuous
display
The "System" menu branches into the following sub-menus:
n
n
n
n
9.6.8.1
Unit
Diaphragm
Info
Change head?
Settings in the sub-menu ″Units″
In the “Units” sub-menu, you can select whether the pump uses litres or
gallons (US).
9.6.8.2
Settings in the sub-menu ″Diaphragm″
In the “Diaphragm” sub-menu you can select whether the pump generates
a warning or fault alert upon a diaphragm rupture.
9.6.8.3
"Info" sub-menu
In the "Info" sub-menu you can read off the following identification num‐
bers:
n
n
n
n
n
n
n
n
n
56
Identity code ID
Serial number SN
Software control SW
Hardware control HW
Software drive AS
Hardware drive AH
Name module-option (e.g. proTIME)
Software option OS
Hardware option OH
Adjustment
9.6.8.4
Sub-menu "Change head?"
CAUTION!
– Should a different liquid end size be fitted, then the
pump must be reprogrammed in the sub-menu “Change
head?” .
– For demonstration purposes or if operating without feed
chemical, reprogram the pump to “Without head” .
9.7 Set code (SECURITY menu)
P
P
Batch
Main
Mode
Settings
Security
Clear
P
Batch
Security
none
Lock Menu
Lock all
P
P
Batch
Lock Menu
Code: 2793
P
Continuous
display
In the “SECURITY” menu, you can enter whether you want to block sec‐
tions of the adjustment options.
In the first menu option, you can either set “None” or “Lock menu” or
“Lock all” (both locks use the same code.):
n
n
n
Select “None” , to clear a security lock.
Select “Lock menu” to lock the adjustment mode (point ① in the over‐
view "Operating/setting diagram", in the appendix). In the next menu
option, enter the number you want to use as the code.
Select “Lock all” to lock the adjustment option for the directly adjust‐
able variables in the continuous displays and to lock the stroke length
(point ② in the overview "Operating/setting diagram", in the appendix),
in addition to the adjustment mode. In the next menu option, enter the
number you want to use as the code.
If a lock is set, a padlock appears in the continuous display.
If you have set “Lock all” , a padlock will appear after 1 minute in the top
left corner and the specified areas are locked, if no key has been pressed
in the meantime.
If you have set “Lock menu” , the operating menu will be locked after 1
minute, if no key has been pressed in the meantime.
Test
To test whether the menu is locked, press the [P] key for 2 s.
If you try to change into a locked area, a key appears in the LCD display
and the padlock flashes.
Overriding the lock
To override the lock, enter the code using the [arrow keys].
Changing the stroke length variable
In the stroke adjustment dial has been turned, the padlock flashes, the
pump stops and a fault alert and key appear. If you enter the code, the
pump continues metering and the fault alert clears.
57
Adjustment
9.8 Delete total number of strokes or total litres (CLEAR menu)
P
P
Batch
Main
Mode
Settings
Security
Clear
P
Batch
Clear
none
Counter
Quantity
Count+Quantity
P
Continuous
display
In the “DELETE” menu, you can either delete the stored total number of
strokes or the total litres or both together (= reset to "0"):
n
n
n
n
“None”
“Counter” (total number of strokes)
“Quantity” (total litres)
“all” (both)
To do this quit the menu by quickly pressing the key [P] key.
The variables have increased since commissioning of the pump, the last
calibration or the last deletion.
9.9 Set language (LANGUAGE menu)
P
P
Batch
Main
Settings
Security
Clear
Language
P
Batch
Language
english
english (us)
deutsch
francais
P
Continuous
display
In the “LANGUAGE” menu, you can select the desired operating lan‐
guage.
The selection “English (US)” also changes the decimal comma to a dec‐
imal point in the displays.
58
Operation
10
Operation
WARNING!
Danger of electric shock
Incompletely installed electrical options can allow moisture
into the inside of the housing.
–
Knock-out openings in the pump housing must be
equipped with matching modules or be sealed in a leaktight manner.
WARNING!
Danger of electric shock
A mains voltage may exist inside the pump housing.
–
If the pump housing has been damaged, you must dis‐
connect it from the mains immediately. It may only be
returned to service after an authorised repair.
This chapter describes all the operating options available to you if the
pump is displaying a continuous display - the display does not contain the
symbol for the [P] key.
–
–
10.1
For supplementary information, see the overviews "Con‐
trol elements and key functions" in the chapter "Device
overview and control elements" and "Operating/setting
diagram" in the appendix.
Also take note of the overview "Continuous displays" in
the appendix. It shows which continuous displays are
available in which operating mode and which variables
are directly changeable in the relevant continuous dis‐
play.
Manual
Personnel:
Adjusting the stroke length
n
Instructed personnel
The stroke length is adjusted by the stroke length adjustment knob within
a range of 0 ... 100 %. A stroke length of between 30 ... 100 %) is recom‐
mended to achieve the specified reproducibility.
The following operating options are available via the keys - see the next
figure:
Stop/start pump
Stop the pump: Press the [STOP/START] key.
Start the pump: press the [STOP/START] key again.
Start batch
In “Batch” operating mode: briefly press key [P].
Changing to adjustment mode
If the [P] key is pressed for 2 seconds in a continuous display, the delta®
changes to adjustment mode - see chapter "Adjustment".
If an access code was set in the "Security" menu for “Lock menu” , then
after pressing the [P] key the access code must first be entered.
59
Operation
Checking adjustable variables
After every press of the [i] key, a different continuous display is shown.
The number of continuous displays depends on the identity code, the
selected operating mode and the connected additional devices.
Changing directly changeable variables
To change a variable, see below, directly in the corresponding continuous
display, press and hold one of the [arrow keys] (approx. 1/2 s) until the
identifier "Double arrow" appears and the variable is flanked by two
flashing lines. The delay has been programmed in to prevent variables
from being unintentionally changed.
If an access code was set in the "Security" menu for “Lock all” , then after
pressing the [P] key the access code must first be entered.
The directly changeable variables are in detail:
stroke rate
In operating modes “Manual” , “Contact” and “Batch” :
You can change the stroke rate in the "Stroke rate" continuous display.
To change a precisely previously set feed rate (possibly
specified in litres), there is an option of changing it via the
stroke rate. As the stroke rate is digitally processed, there is
no tolerance.
Changing using the stroke length interferes with the mechan‐
ical tolerance.
Capacity
In “Manual” operating mode:
You can change the capacity in the "Capacity" continuous display.
Factor
The factor is the number of strokes which are triggered upon an external
pulse or by pressing key [P] (only in “Batch” operating mode.
Priming
Simultaneous pressing of the two [arrow keys] triggers the "Priming" func‐
tion (in the "Stroke rate" continuous display).
Fault acknowledgement
Fault displays are acknowledged by brief pressing of the [P] key.
60
Operation
Continuous
display
STOP
Pump stop/start
START
Change directly alterable variables
2
2
P
P
i
P
Priming
Start batch (only in "Batch" operating mode)
Acknowledge error
Check adjustable variables
2s
1
1 = Security lock ("Lock Menu")
Adjustment
mode
2 = Security lock ("Lock all")
Fig. 28: Operating options with a locked operating menu
10.2
Remote operation
There is an option to control the pump remotely via a signal cable - refer to
your system documentation and to the "Electrical Installation" chapter.
61
Maintenance
11
Maintenance
WARNING!
It is mandatory that you read the safety information and
specifications in the "Storage, Transport and Unpacking"
chapter prior to shipping the pump.
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‐
ised persons.
Depressurise the system before commencing any work
on hydraulic parts.
Standard liquid ends:
Interval
Maintenance work
Quarterly*
n
n
n
n
n
n
n
Personnel
Check the diaphragm for damage - refer to the "Overhaul" chapter.
Check that the dosing lines are fixed firmly to the liquid end.
Check that the suction valve and discharge valve are tight.
Check the tightness of the entire liquid end - particularly around the
leakage hole, see the following figure.
Check that the flow is correct: Allow the pump to prime briefly - quickly
press both [arrow keys] simultaneously.
Check that the electrical connections are intact and check the pump
housing.
Check that the dosing head screws are tight
Technical personnel
* under normal loading (approx. 30 % of continuous operation)
Under heavy loading (e.g. continuous operation): Shorter intervals.
P_BE_0012_SW
Fig. 29: Leakage hole
62
Maintenance
Liquid ends with bleed valve:
Interval
Maintenance work
Personnel
Quarterly*
In addition:
Technical personnel
n
n
n
n
Check that the return line is fixed firmly to the liquid end.
Check that the bleed valve is tight.
Check the discharge and return line for kinks.
Check that the bleed valve is operating correctly.
* under normal loading (approx. 30 % of continuous operation)
Under heavy loading (e.g. continuous operation): Shorter intervals.
Tightening torque
Data
Tightening torque for screws:
Value Unit
4.5 ... 5.0 Nm
63
Repairs
12
Repairs
Safety information
WARNING!
Danger of an electric shock
Unauthorised repairs inside the pump can result in an elec‐
tric shock.
For this reason repairs inside the pump may only be per‐
formed by a ProMinent branch or representative, in particular
the following:
–
–
–
Replacement of damaged mains connection lines
Replacement of fuses
Replacement of electronic control
WARNING!
It is mandatory that you read the safety information and
specifications in the "Storage, Transport and Unpacking"
chapter prior to shipping the pump.
WARNING!
Contact with the feed chemical
Parts that come into contact with the feed chemical are
uncovered and handled during overhaul work.
–
Protect yourself against the feed chemical in case it is
hazardous. Read the safety data sheet on the feed
chemical.
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‐
ised persons.
Depressurise the system before commencing any work
on hydraulic parts.
The exploded views on the CD should be referred to when
working on the unit.
12.1
Cleaning valves
Personnel:
n
Technical personnel
Warning of faulty operation
The exploded views on the CD should be referred to when
working on the unit.
64
Repairs
Cleaning a discharge valve for types
0730, 1020, 1612, 1608, 2508
Cleaning a suction valve for types 0730,
1020, 1612, 1608, 2508
Warning of faulty operation
– Discharge and suction valves differ from each other!
Only take them apart one after each other, so that you
do not confuse the components!
– Only use new components which fit your valve - both in
terms of shape and chemical resistance!
– Readjust the pump after replacing a valve!
– Using an Allen key or similar, insert it into the smaller
hole of the discharge connector and push the valve
inserts out of it.
A suction valve is constructed in almost the same way as a discharge
valve.
Please note, however, that:
n
n
n
n
Cleaning a discharge valve for types
0280, 0450
Cleaning a suction valve for types 0280,
0450
the two valve inserts are identical here
There is an additional spacer between the valve inserts.
There is a shaped seal in the dosing head instead of an O-ring.
The flow direction of the suction connector is the opposite of that of
the discharge connector.
Warning of faulty operation
– Discharge and suction valves differ from each other!
Only take them apart one after each other, so that you
do not confuse the components!
– Only use new components which fit your valve - both in
terms of shape and chemical resistance!
– On the PVT material version, the ball seat is integrated
in the dosing head and so has to be cleaned separately!
– On the PVT material version, the discharge valve is a
double ball valve!
– Using an Allen key or similar, insert it into the smaller
hole of the discharge connector and push the valve
inserts out of it.
A suction valve is constructed in almost the same way as a discharge
valve.
Please note, however, that:
n
12.2
The flow direction of the suction connector is the opposite of that of
the discharge connector.
Replacing the metering diaphragm
WARNING!
A few cubic centimetres of feed chemical may have accumu‐
lated behind the metering diaphragm in the backplate fol‐
lowing a leak - depending on the design!
–
Take this feed chemical into consideration when you are
planning a repair - especially if it is hazardous!
65
Repairs
Personnel:
n
n
n
n
Technical personnel
If necessary take protective measures.
Observe the safety data sheet for the feed chemical.
Depressurise the system.
1.
Empty the liquid end (turn the liquid end upside down and allow the
feed chemical to run out; flush out with a suitable medium; flush the
liquid end thoroughly when using hazardous feed chemicals!)
2.
Turn the stroke adjustment dial up to the stop below 0 % stroke
length if the pump is running (the drive axle is then difficult to turn).
3.
Switch off the pump.
4.
Unscrew the hydraulic connectors on the discharge and suction
side.
5.
For types with coarse/fine bleed valve: Firstly remove the coarse/
fine bleed valve (knob), then lift off the cover of the liquid end with a
screwdriver.
1
2
3
4
5
6
P_DE_0041_SW
Fig. 30: Partially exploded view of liquid end
1
2
3
4
5
6
66
Screws
Dosing head
Diaphragm
Backplate
Safety diaphragm
Pump housing
6.
Remove the screws (1).
7.
Take the dosing head (2) plus screws (1) off from the pump - see
figure Fig. 30
8.
Replace the dosing head (2) and screws - the screws (1) should still
extend into the holes in the diaphragm (3), but not into the pump
housing!
9.
Hold the pump housing (6) with one hand and clamp the diaphragm
(3) with the other hand between the dosing head (2) and the back‐
plate (4).
10.
Loosen the diaphragm (3) from the drive axle with a gentle back‐
wards turn of the dosing head (2), diaphragm (3) and backplate (4)
in an anticlockwise direction.
11.
Pull the dosing head (2) with the screws (1) out of the diaphragm (3)
and completely unscrew this from the drive axle.
12.
Remove the backplate (4) from the pump housing (6).
13.
Check the condition of the safety diaphragm (5) and replace if nec‐
essary.
14.
Push the safety diaphragm (5) onto the drive axle only until it lies
flush with the pump housing (6) and no further!
Repairs
15.
Tentatively screw the new diaphragm (3) onto the drive axle up to
the stop - this must be successful, otherwise the pump will subse‐
quently not meter correctly!
16.
Check whether the diaphragm holes align correctly with the pump
housing.
17.
If not, start the pump and adjust the stroke length to 100 %.
18.
With the pump running, slowly turn the diaphragm (3) in the clock‐
wise direction until the 4 diaphragm holes align correctly with the
pump housing (6). Do not turn anticlockwise!
19.
Clamp the diaphragm (3) in this position, adjust the stroke length to
0 % and stop the pump.
20.
Unscrew the diaphragm (3) again.
21.
Place the backplate (4) onto the pump housing (6).
CAUTION!
– The leakage hole must point downwards in the
subsequent fitting position of the pump - see
figure in the "Maintenance" chapter!
– Place the backplate (4) immediately into the cor‐
rect position on the pump housing (6)! Do not twist
the backplate on the pump housing so that the
safety diaphragm (5) becomes warped!
22.
Place the diaphragm (3) into the backplate (4).
CAUTION!
– Do not overtighten the diaphragm (3) in the fol‐
lowing step!
– The backplate (4) must remain in its position so
that the safety diaphragm does not become
warped!
23.
Hold the backplate (4) firmly and screw the diaphragm (3) in a clock‐
wise direction until it is sitting tightly (the twisting resistance of the
return spring can be felt).
24.
Place the dosing head (2) with the screws (1) onto the diaphragm
(3) and the backplate (4) - the suction connector must be pointing
downwards in the pumps subsequent fitting position.
25.
Gently tighten the screws (1) and then tighten in a diagonal pattern.
See below for tightening torque.
26.
For types with coarse/fine bleed valve: Allow the cover of the liquid
end to rest in the dosing head, then press the knob of the bleed
valve into the coarse/fine bleed valve.
Check the tightening torque of the screws after 24hours of operation!
Tightening torques
Data
Tightening torques for dosing head
screws:
Value Unit
4.5 ... 5.0 Nm
67
Repairs
12.3
Cleaning the diaphragm rupture indicator
WARNING!
Warning of unnoticed escaping of feed chemical
After triggering of the diaphragm rupture indicator, any feed
chemical residues can be blocked.
–
Personnel:
After triggering of the diaphragm rupture indicator, clean
and test.
n
Technical personnel
1.
First replace the liquid end diaphragm - see above!
2.
Unscrew the diaphragm rupture indicator using a 15mm open ended
spanner.
3.
Clean the diaphragm rupture indicator with suitable liquid - if pos‐
sible using water (polysulphone material).
4.
Test the connected diaphragm rupture indicator: Immerse the for‐
ward hemisphere completely in water, a diaphragm rupture must be
indicated in the continuous display.
ð The continuous display indicates a diaphragm rupture.
5.
Thoroughly dry the diaphragm rupture indicator.
ð The continuous display no longer indicates a diaphragm rup‐
ture.
6.
68
Screw the clean and dry diaphragm rupture indicator hand-tight and
liquid tight into the hole - without using tools
Troubleshooting
13
Troubleshooting
Safety information
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, protective gloves, ...).
Read the safety data sheet on the feed chemical.
Drain and flush the liquid end before working on the
pump.
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.
–
–
13.1
Disconnect the pump from the mains power supply and
ensure that it cannot be switched on again by unauthor‐
ised persons.
Depressurise the system before commencing any work
on hydraulic parts.
Faults without a fault alert
Fault description
Cause
Remedy
Personnel
Pump does not prime in
spite of full stroke motion
and bleeding
Minor crystalline deposits
on the ball seat due to the
valves drying out
Take suction tube out of the storage container
and thoroughly flush out the liquid end
Technical
personnel
Major crystalline deposits
on the ball seat due to the
valves drying out
Dismantle the valves and clean them - refer to
the "Overhaul" chapter.
Technical
personnel
The screws in the dosing
head are too loose
Tighten the screws in the dosing head in a
diagonal pattern - refer to the "Repairs"
chapter for tightening torque.
The diaphragm is not tight
Replace the diaphragm - refer to the "Over‐
haul" chapter.
Fluid is escaping from the
end disc
Technical
personnel
If a diaphragm rupture has been indicated,
clean the diaphragm rupture reporter, refer to
the "Overhaul" chapter.
Green LED indicator
(operating indicator) does
not light up
13.2
The wrong mains voltage
Connect the pump correctly to the specified
or no mains voltage is con‐ mains voltage - according to the specification
nected
on the nameplate.
Electrician
Fault alerts
Fault description
Cause
Remedy
Personnel
The red LED indicator illuminates, the "Level"
symbol
flashes in the LCD display, the
"Fault" and "Stop" symbols are also displayed
and the pump stops.
The liquid level in the
storage tank has
reached "liquid level low
2nd stage".
Fill the storage tank
Technical
personnel
69
Troubleshooting
Fault description
Cause
Remedy
Personnel
The red LED indicator illuminates, the symbol
"i < 4 mA" i < 4 flashes in the LCD display, the
"Fault" and "Stop" symbols are also displayed
and the pump stops.
The pump is in "Analog"
operating mode, a fault
behaviour has been pro‐
grammed in the
ANALOG menu and the
control current has fallen
below 4 mA.
Clear the cause of the low
control current or
Technical
personnel
The red LED indicator illuminates, the symbol
"i > 23 mA" i > 23 flashes in the LCD display,
the "Fault" and "Stop" symbols are also dis‐
played and the pump stops.
The pump is in "Analog"
operating mode, a fault
behaviour has been pro‐
grammed in the
ANALOG menu and the
control current has risen
above 23 mA.
Clear the cause of the high
control current or
The red LED indicator illuminates, the sym‐
The stroke memory has
bols "m" and "External"
flashes in the LCD overflown.
display, the "Fault" and "Stop" symbols are
also displayed and the pump stops.
The red LED indicator illuminates, the "Tem‐
perature " symbol flashes in the LCD display,
the "Fault" and "Stop" symbols are also dis‐
played and the pump stops.
The pump is overloaded.
switch the programming of the
fault behaviour to "OFF" - see
chapter "Settings for 'Analog'
operating mode".
switch the programming of the
fault behaviour to "OFF" - see
chapter "Settings for 'Analog'
operating mode".
Rectify the cause, then
press the[P] key (think of the
consequences for the
process!).
Rectify the cause, then
C
press the[P] key (think of the
consequences for the
process!).
F
The red LED indicator illuminates, the "Stroke
length adjustment" symbol
flashes in
the LCD display, the "Fault" and "Stop" sym‐
bols are also displayed and the pump stops.
13.3
Technical
personnel
The temperature is too
high.
Rectify the cause, then
The stroke adjustment
dial was rotated while
the menu was locked.
Turn the stroke adjustment
dial back or enter the code.
press the[P] key (think of the
consequences for the
process!).
Technical
personnel
Technical
personnel
Technical
personnel
Technical
personnel
Fault alerts / warning alerts
At issue here are error alerts, which dependent on the setting in the setting
menu are displayed as fault alerts or warning alerts.
Fault description
Cause
Remedy
Personnel
Either the yellow LED indicator illuminates and
the "Flow" symbol
flashes in the LCD display,
or, together with the red LED indicator, the sym‐
bols for "Fault" and "Stop" also appear and the
pump stops.
The dosing monitor
is not correctly con‐
nected.
Connect the dosing monitor cor‐
rectly and
Electrician
The dosing monitor
reported too few
strokes, more that
set in the FLOW
menu.
press the[P] key.
Either the yellow LED indicator illuminates and
the "Diaphragm" symbol flashes in the LCD dis‐
play, or, together with the red LED indicator, the
symbols for "Fault" and "Stop" also appear and
the pump stops.
The diaphragm is
broken.
Replace the diaphragm and
clean the diaphragm rupture
reporter, refer to the "Overhaul"
chapter.
Technical
personnel
Either the yellow LED indicator illuminates and
the "Air lock" symbol flashes in the LCD dis‐
play, or, together with the red LED indicator, the
symbols for "Fault" and "Stop" also appear and
the pump stops.
Gas bubbles in the
liquid end (leaks,
gaseous medium,
cavitation).
If the red LED indicator illumi‐
nates, press the[P] key, think of
the consequences for the
process!
Technical
personnel
70
press the[P] key.
Investigate and clear the cause
Bleed the liquid end and rectify
the cause. Seal the system or
slow the suction stroke.
Technical
personnel
Troubleshooting
Fault description
Cause
Remedy
Personnel
Either the yellow LED indicator illuminates and
the "p+" symbol p+flashes in the LCD display,
or, together with the red LED indicator, the sym‐
bols for "Fault" and "Stop" also appear and the
pump stops.
A constriction or a
closed shut-off
valve on the dis‐
charge side.
If the red LED indicator illumi‐
nates, press the[P] key, think of
the consequences for the
process!
Technical
personnel
There is a leak or a
Either the yellow LED indicator illuminates and
the "p-" symbol p -flashes in the LCD display, or, burst or torn line on
together with the red LED indicator, the symbols the discharge side.
for "Fault" and "Stop" also appear and the pump
stops.
13.4
Open the shut-off valve or rectify
the constriction.
If the red LED indicator illumi‐
nates, press the[P] key, think of
the consequences for the
process!
Technical
personnel
Rectify the leak or clear the
cause.
Warning Alerts
Fault description
Cause
Remedy
Personnel
The yellow LED indicator illuminates, the
"Level" symbol
appears flashing in the
LCD display.
The liquid level in the storage
tank has reached "liquid level
low 1st stage".
Fill the storage
tank
Instructed per‐
sonnel
13.5
All Other Faults
Please contact the responsible ProMinent subsidiary or representative!
71
Decommissioning
14
Decommissioning
Decommissioning
WARNING!
Danger from chemical residues
There is normally chemical residue in the liquid end and on
the housing after operation. This chemical residue could be
hazardous to people.
–
–
It is mandatory that the safety information relating to the
"Storage, transport and unpacking" chapter is read
before shipping or transporting the unit.
Thoroughly clean the liquid end and the housing of
chemicals and dirt. Adhere to the safety data sheet for
the feed chemical.
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, protective gloves, ...).
Read the safety data sheet on the feed chemical.
Drain and flush the liquid end before working on the
pump.
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‐
ised persons.
Depressurise the system before commencing any work
on hydraulic parts.
Danger of damage to the device
Take into account the information in the "Storage, Transport
and Unpacking" chapter if the system is decommissioned for
a temporary period.
Personnel:
72
n
Technical personnel
1.
Disconnect the pump from the mains power supply.
2.
Empty the liquid end by turning the pump upside down and allowing
the feed chemical to run out.
3.
Flush the liquid end with a suitable medium; flush the dosing head
thoroughly when using hazardous feed chemicals!
Decommissioning
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.
–
–
Personnel:
Disconnect the pump from the mains power supply and
ensure that it cannot be switched on again by unauthor‐
ised persons.
Depressurise the system before commencing any work
on hydraulic parts.
n
Technical personnel
CAUTION!
Environmental hazard due to electronic waste
There are electronic components in the pump, which can
have a toxic effect on the environment.
–
–
Separate the electronic components from the remaining
parts.
Note the pertinent regulations currently applicable in
your country!
73
Technical data
15
15.1
Technical data
Performance data
delta®
operating at 200 strokes/minute and
100 % stroke length
Liquid end type Minimum pump capacity
Minimum pump capacity
at maximum counter pressure
at medium counter pressure
bar
l/h
ml/stroke
bar
l/h
ml/stroke
2508
25
7.5
0.62
12.5
8.0
0.67
1608
16
7.8
0.62
8
8.2
0.69
1612
16
11.3
0.94
8
12.2
1.02
1020
10
19.1
1.59
5
19.2
1.6
0730
7
29.2
2.43
3.5
29.4
2.45
0450
4
49.0
4.08
2
51.5
4.29
0280
2
75.0
6.25
1
75.6
6.3
Stroke rate
Connector
size
Suction lift*
Priming lift**
Permissible
priming pres‐
sure suction
side
Weight
outsideÆ x
insideÆ
Liquid end type
Strokes/min
mm
m WS
m WS
bar
kg
200
8x4 1
5
3.5 / 3.0 1
8
10 / 11 1
2508
200
8x5
5
3.5 / 3.0 1
8
10 / 11 1
1608
200
8x5
5
3.0 / 2.5 1
8
10 / 11 1
1612
200
12x9
5
3.5 / 3.0 1
5
10 / 11 1
1020
200
12x9
4
4.0 / 3.5 1
3
10 / 11 1
0730
200
DN 10
3
2.5 / 2.5 1
2
10 / 11 1
0450
200
DN 10
2
3.0 / 3.0 1
1
10 / 11 1
0280
*
- Suction lift with a filled suction line and filled liquid end.
** - Priming lift with clean and moist valves. Priming lift at 100 % stroke
length and free outlet or opened bleed valve.
1
15.2
15.2.1
- For the SST material version there is a 6 mm connector size
Accuracy
Standard liquid ends
Data
Product scatter
Metering reproducibility
*
Value Unit
-5 ... 10 % *
±2 % **
- with max. stroke length and max. operating pressure for all material
versions
** - under constant conditions and at least 30 % stroke length
74
Technical data
The delta® ensures uniform conditions provided the stroke velocities are
correctly adjusted and, if "Compensation" is set to "on" (see Chapter
"Dosing").
15.3
Viscosity
The metering behaviour of the pump can be matched to the viscosity of
the feed chemical.
Viscosity in mPa
"Dosing" setting
Suction stroke
slowing
Max. stroke rate
Remarks
0...50
"normal"
none
200
50...200
"HV1"
slight
160
200...500
"HV2"
medium
120
for valves with springs
500...1000
"HV3"
Maximum
80
for valves with springs
For the adjustment for slowing the suction stroke dependent upon the feed
chemical viscosity - see the "Adjustment" chapter.
15.4
Material data
Liquid ends
Version
Dosing head
Suction/discharge
connector
Seals
Valve balls
NP
Clear acrylic
PVDF
PTFE
Ceramic
PV
PVDF
PVDF
PTFE
Ceramic
SS
Stainless steel 1.4404 Stainless steel 1.4404 PTFE
Ceramic
Version
Housing
Hood
Transparent cover
Electronics
All
Polyphenyl ether
(PPE with fibreglass)
Polyphenyl ether
(PPE with fibreglass)
Polycarbonate
Electronic compo‐
nents
Pump
15.5
Electrical data
Version: 100 - 230 V ±10 %, 50/60 Hz
Data
Power rating, approx.
Nominal current, approx.
Switch on peak current, (within approx.
50 ms falling
Fuse
Value Unit
73 W
0.90 ... 0.55 A
8 ... 4 A
1.6 AT
Fuses must have VDE, UL and CSA approvals. e.g. Series SPT, 1.6 A
supplied by Schurter Order no. 0001.2506 according to IEC Publ. 127 2/3.
75
Technical data
15.6
Temperatures
Pump, compl.
Liquid end, long-term*
Data
Value Unit
Storage and transport temperature
–10 ... +50 °C
Ambient temperature in operation (drive
and control):
–10 ... +45 °C
Data
Value Unit
Liquid end temperature
-10 ... +45 °C
* long term at max. operating pressure, dependent on ambient and feed
chemical temperatures
Liquid end, short-term*
Material version
Value
Unit
NP_
60
°C
PVT
120
°C
SST
120
°C
* Temp. max., for 15 min at max. 2 bar, dependent on the ambient and
feed chemical temperatures
15.7
Climate
Data
Maximum air humidity *:
Value Unit
95 % rel.
humidity
* non-condensing
Exposure in a humid and alternating climate:
FW 24 according to DIN 50016
15.8
Protection class and Safety Requirements
Degree of protection
Protection against contact and humidity:
IP 65 in accordance with IEC 529, EN 60529, DIN VDE 0470 Part 1
Safety requirements
Degree of protection:
1 - mains power connection with protective earth conductor
15.9
Compatibility
Some hydraulic parts of the delta® are identical to those of the Beta® and
gamma/ L.
There is greatest compatibility with pumps of the Beta® and gamma series
for the following components and accessories:
n
n
n
76
Control wire gamma/Vario 2-, 4- and 5-wire for the "External" function
Level switch 2-stage (gamma / Vario / Beta®)
Metering line cross-sections
Technical data
n
n
n
n
Standard gamma connector kit
Chemical feed container
Overall height (distance between the suction and discharge con‐
nector)
Same use of accessories, such as back pressure valves, multifunc‐
tional valves, dosing monitor and flushing assembly
15.10 Weight
Material version
Weight
kg
SST
11
PVT
10
NP_
10
15.11 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)
77
EC Declaration of Conformity
16
EC Declaration of Conformity
- Original -
EC Declaration of Conformity for Machinery
We,
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.
This declaration loses its validity in the event of a modification to the product not agreed with us.
78
Description of the product:
Metering pump, delta series
Product
type:
DLTA....
Serial no.:
Please refer to type plate on
the device
Pertinent
EC Directives:
EC - Machinery Directive (2006/42/EC)
EC EMC Directive (2004/108/EC)
The safety objectives of the Low voltage Directive 2006/95/EC
are complied with
in accordance with Appendix I, No. 1.5.1
of the Machinery Directive 2006/42/EC
Harmonised standards applied, in
particular:
EN ISO 12100, EN 809,
EN 60335-1, EN 60529, EN 60335-2-41,
EN 61000-3-2, EN 61000-6-1/2/3/4
Technical documents have been
compiled by documentation
specialists:
Norbert Berger
Im Schuhmachergewann 5-11
DE-69123 Heidelberg
Date / manufacturer's signature:
06.07.2011
Details of the signatory:
Joachim Schall, Head of Development
Operating menu overview
17
Operating menu overview
Continuous
display
STOP
Pump stop/start
START
2
Change directly alterable variables
Priming
P
P
i
P
Start batch (only in "Batch" operating mode)
Acknowledge error
Check adjustable variables
2s
1
P
Analog
Main
Mode
Settings
Security
Clear
P
Menu
Mode
Menu
Settings
P
Menu
Operating mode
Menu
Auxiliar
Menu
Flow
Menu
Calibration
Menu
Dosing
Menu
Analog Out
Menu
System
P
Submenu
Unit
Submenu
Diaphragma
Submenu
Info
79
Operating menu overview
Menu
Security
Menu
Clear
Menu
Language
80
86500
/h
Manual
%
Manual
0.220
86500
80.00
86500
/min
Manual
/h
Manual
200
86500
12000
Op. mode "Manual"
= with the arrow keys [Up] and [Down] directly alterable variables
Concentration
Factor
Display "External"
Capacity
Stroke rate
(Strokes/min)
Stroke rate
(Strokes/h)
Continuous
display
Batch
Batch
%
0.220
86500
Contact
%
Contact
86500
86500
/min
Contact
/h
Contact
200
86500
12000
Op. mode "Contact" with
Memory and transfer factor 5
Identifier "m" only, should function extension "Stroke memory" be activated.
86500
0.220
Batch
86500
5*
86500
86500
/min
Batch
/h
Batch
200
86500
12000
Op. mode "Batch" with
Memory and transfer factor 5
0..20
0..20
0..20
0..20
86500
/h
Analog
%
Analog
0.220
86500
80.00
86500
/min
Analog
/h
Analog
200
86500
12000
Op. mode "Analog"
18
Continuous display
Continuous displays
Continuous displays
81
82
slow,
Op. mode "Manual"
4
1
1
slow,
4
1
1, 2
2
Op. mode "Batch" with
Memory and transfer factor 5
1 = only after running through the CALIBRATION menu - also after every change of operating mode
2 = only with function extension "Memory"
3 = only with current output
4 = only after running through the CONCENTRATION menu - also after every change of operating mode
Concentration
Dosing mode
Signal current
(at the input)
Stroke length
Total litres
(Dosing amount)
Total strokes
Batch size
Remaining litres
Remaining strokes
Factor
Capacity
Stroke rate
(Strokes/min)
Stroke rate
(Strokes/h)
Auxiliary
display
slow,
4
1
Op. mode "Contact" with
Memory and transfer factor 5
Auxiliary displays in the continuous display
slow,
Op. mode "Analog"
4
3
1
1
Continuous displays
Index
19
Index
"
Diaphragm rupture sensor...................................... 16, 33
"Diaphragm rupture reporter" jack................................. 17
Discharge stroke..................................................... 21, 49
"Dosing monitor" jack.................................................... 17
Discharge valve............................................................. 16
"External control" jack................................................... 17
Disposal........................................................................ 73
"External control" terminal............................................. 32
Dosing head.................................................................. 16
"Level Switch" jack........................................................ 17
Dosing monitor.............................................................. 33
1, 2, 3 ...
E
4 - 20 mA....................................................................... 44
Emergency.................................................................... 12
A
Emptying the liquid end................................................. 72
Adjustment, chapter...................................................... 37
End disc........................................................................ 16
Adjustment mode.......................................................... 38
Explanation of the safety information............................ 10
AH................................................................................. 56
External contact...................................................... 24, 32
Airlock..................................................................... 21, 51
External frequency changeover.................................... 24
Air lock.......................................................................... 51
F
Analog..................................................................... 22, 44
Factor...................................................................... 41, 42
Analog output................................................................ 55
Fault.............................................................................. 24
AS................................................................................. 56
Fault indicating and pacing relay option........................ 23
Automatic bleeding........................................................ 23
Fault indicating relay......................................... 23, 34, 35
AUX............................................................................... 47
Fault indicator (red)................................................. 17, 24
Auxiliary rate......................................... 22, 23, 24, 32, 47
Fault processing............................................................ 45
B
Fault statuses................................................................ 24
Back pressure oscillations............................................. 51
Flow......................................................................... 22, 47
Basic principles of control adjustment........................... 37
Functional description................................................... 21
Batch....................................................................... 22, 41
Functions....................................................................... 24
Bleeding.................................................................. 28, 52
Function settings........................................................... 46
Bleed valve.................................................................... 16
G
Bus................................................................................ 17
Gallon............................................................................ 56
Bypass hose nozzle...................................................... 16
Gaseous feed chemicals............................................... 50
C
H
Calibrate........................................................................ 22
Hardware control HW.................................................... 56
Calibration..................................................................... 47
Hardware drive AH........................................................ 56
Capacity........................................................................ 21
Hardware option OH..................................................... 56
Cavitation...................................................................... 50
Hierarchy of operating modes....................................... 24
Change head?............................................................... 57
High pressure................................................................ 52
Checking adjustable variables...................................... 37
HW................................................................................ 56
CLEAR.......................................................................... 58
I
Code.............................................................................. 57
ID................................................................................... 56
Compensation............................................................... 51
Identity code.................................................................... 6
Contact.................................................................... 22, 42
Identity code ID............................................................. 56
Contacter relay.............................................................. 31
Inductive consumers..................................................... 31
Contact water meter...................................................... 44
Info................................................................................ 56
Continuous displays...................................................... 37
Information in the event of an emergency..................... 12
Control elements........................................................... 17
Installation, electrical..................................................... 30
Correct and proper use................................................. 10
Installation, hydraulic..................................................... 25
Current output............................................................... 35
Install hose lines............................................................ 26
Curve............................................................................. 44
IP................................................................................... 76
D
K
Decommissioning.......................................................... 72
Keys.............................................................................. 17
Degree of protection...................................................... 76
L
Device overview............................................................ 16
Language...................................................................... 58
Diaphragm..................................................................... 56
LCD display................................................................... 17
83
Index
Leakage hole................................................................. 62
Remote operation.......................................................... 61
Level switch................................................. 23, 24, 33, 34
Reproducibility............................................................... 21
Linear............................................................................ 45
Return line............................................................... 26, 28
Litre............................................................................... 56
S
Low pressure................................................................. 51
Safety chapter............................................................... 10
M
Safety declaration form................................................. 14
Mains Cable.................................................................. 31
Safety requirements...................................................... 76
Maintenance.................................................................. 62
Scope of supply............................................................. 15
Manual.............................................................. 22, 24, 41
Secondary displays....................................................... 38
Manual operation.......................................................... 59
SECURITY.................................................................... 57
mA Output..................................................................... 23
Semiconductor switch................................................... 35
Memory................................................................... 41, 42
Serial number SN.......................................................... 56
Metering precision......................................................... 51
Sideband....................................................................... 46
Metering pumps with bleed valve.................................. 28
Slot for optional module ............................................... 17
Metering pumps without self-bleeding........................... 26
Slowing.......................................................................... 50
Metering settings........................................................... 49
SN................................................................................. 56
N
Software control SW..................................................... 56
Name module-option..................................................... 56
Software drive AS......................................................... 56
O
Software option OS....................................................... 56
OH................................................................................. 56
Sound pressure level.............................................. 13, 77
Operating indicator (green)..................................... 17, 24
Stop......................................................................... 23, 24
Operating modes..................................................... 22, 24
Storage.......................................................................... 14
Operating mode selection............................................. 39
Stroke length................................................................. 21
Operating mode settings............................................... 39
Stroke length adjustment knob...................................... 17
Operation................................................................ 39, 59
Stroke rate..................................................................... 21
optoDrive....................................................................... 21
Stroke velocity............................................................... 21
optoGuard..................................................................... 21
Suction stroke......................................................... 21, 50
OS................................................................................. 56
Suction valve................................................................. 16
Overpressure................................................................ 21
Supply Voltage.............................................................. 31
P
SW................................................................................ 56
Pacing relay.................................................................. 35
System.......................................................................... 56
Parallel connection........................................................ 31
T
Pause................................................................ 23, 24, 32
Test (function)............................................................... 24
Pressure........................................................................ 50
Total litres...................................................................... 58
Pressure rating.............................................................. 50
Total number of strokes................................................ 58
Priming.......................................................................... 24
Transport....................................................................... 14
Protection against contact and humidity....................... 76
U
Protection class............................................................. 76
Unit................................................................................ 56
Pulse control................................................................. 44
Unpacking..................................................................... 14
Q
V
Qualification of personnel.............................................. 13
Varistor.......................................................................... 31
R
Viscosity........................................................................ 50
Radioactive................................................................... 14
W
Rated pressure.............................................................. 50
Warning alert................................................................. 34
RC member................................................................... 31
Warning indicator (yellow)....................................... 17, 24
Relay........................................................... 17, 23, 34, 54
Warning sign................................................................. 10
Relay behaviour............................................................ 54
84
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