ProMinent DULCODOS universal mini, Assembly And Operating Instructions Manual

Page 1: ...N Original operating instructions 2006 42 EC 982011 Version BA DST 012 02 19 EN Please carefully read these operating instructions before use Do not discard The operator shall be liable for any damage caused by installation or operating errors The latest version of the operating instructions are available on our homepage ...

Page 2: ...des detailed descriptions of the haz ardous situation see Ä Chapter 2 2 Labelling of Warning Informa tion on page 14 The following symbols are used to highlight instructions links lists results and other elements in this document Tab 1 More symbols Symbol Description Action step by step Outcome of an action Links to elements or sections of these instructions or other applicable documents n List wi...

Page 3: ... Protective Equipment PPE 25 5 3 Commissioning Test Run 25 5 4 Connecting the Chemical Tank for Commissioning 26 6 Operation of the Metering System 27 7 Maintenance and Troubleshooting 28 7 1 Maintenance 29 7 2 Troubleshooting 31 8 Decommissioning and disposal 33 8 1 Disposal of used parts 34 9 Technical data 35 10 Drawings 37 10 1 Metering system 1 pump 1 point of injection 37 10 2 Metering syste...

Page 4: ...r from hazardous substances Possible consequence Fatal or very serious inju ries Please ensure when handling hazardous sub stances that you have read the latest safety data sheets provided by the manufacture of the haz ardous substance The actions required are described in the safety data sheet Check the safety data sheet regularly and replace if neces sary as the hazard potential of a substance c...

Page 5: ...P white 1000x680x410 mm HxWxD for B E C PP white 850x880x410 mm HxWxD for C F Design 00 with ProMinent logo 01 without ProMinent logo Pulsation damper 0 none 1 1 x pulsation damper PVC EPDM 2 1 x pulsation damper PP FKM 3 2 x pulsation damper PVC EPDM 4 2 x pulsation dampers PP FKM Hydraulic connectors 0 Insert 1 Hose nipple 6x4 2 Hose nipple 8x5 3 Hose nipple 12x9 4 Pressure hose nozzle DN10 5 Pr...

Page 6: ...T4b 0220 PVT 12x9 Beta 5 51 10 bar 6 80 l h BT5b 1008 PVT 8x5 52 7 bar 11 0 l h BT5b 0713 PVT 8x5 53 4 bar 17 10 l h BT5b 0420 PVT 12x9 54 2 bar 32 00 l h BT5b 0232 NPE 12x9 delta D1 16 bar 11 3 l h DLTa 1612 PVT 8x5 D2 10 bar 19 1 l h DLTa 1020 PVT 12x9 D3 7 bar 29 2 l h DLTa 0730 PVT 12x9 D4 4 bar 49 0 l h DLTa 0450 PVT DN10 D5 2 bar 75 0 l h DLTa 0280 PVT DN10 gamma X X1 16 bar 3 6 l h GMXa 160...

Page 7: ...3 l h DLTa 1612 PVT 8x5 D2 10 bar 19 1 l h DLTa 1020 PVT 12x9 D3 7 bar 29 2 l h DLTa 0730 PVT 12x9 D4 4 bar 49 0 l h DLTa 0450 PVT N10 D5 2 bar 75 0 l h DLTa 0280 PVT DN10 gamma X X1 16 bar 3 6 l h GMXa 1604 PVT 6x4 X2 7 bar 7 6 l h GMXa 0708 PVT 8x5 X3 10 bar 9 0 l h GMXa 1009 PVT 8x5 X4 4 bar 13 5 l h GMXa 0414 PVT 8x5 X5 7 bar 14 5 l h GMXa 0715 PVT 8x5 X6 2 bar 19 7 l h GMXa 0220 PVT 12x9 X7 4...

Page 8: ...DSUa DULCODOS universal mini Certification 01 CE certification About this product 8 ...

Page 9: ...e Dimension Material Quan tity Part number 1 Assembly frame 600x850x400 PP 1 2 Metering pump To be selected by the customer 1 3 Pulsation damper Hidracar U001 0 09 litres PVC U 1 1057944 4 Manometer MDM902 d25 G1 4 PVC U 1 1030362 5 DHV DHV U DN10 PVC U 1 1037765 6 Back pressure valve DHV U DN10 PVC U 1 1037765 7 Vacuum pump Hubinont MI8121 1 1031565 8 Vacuum cylinder DN10 PVC U 1 1025699 9 Ball v...

Page 10: ...410 180 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A C B 46 A2701 Fig 3 Metering system 2 pumps 1 point of injection A Feed B Outlet C Drain Not shown Connecting parts for flushing pipe DN10 2 no Name Material type Dimension Material Quan tity Part number 1 Assembly frame 700x1000x400 PP 1 2 Metering pump To be selected by the customer 2 3 Pulsation damper Hidracar U001 0 09 litres PVC U 1 1057944 4 Manomet...

Page 11: ...tch PP1 PE 1 142086 11 Splash guard PVC glass 1 12 Terminal box 180x110x90 mm 1 1036995 13 3 way ball valve 543 DN10 PVC U 2 1043568 14 Non return valve 360 ND10 PVC U 2 1 5 Metering system 2 pumps 2 points of injection 900 880 10 10 850 63 40 52 127 46 110 150 412 300 460 290 A C B B 1 2 3 4 5 6 7 8 9 10 11 12 13 A2702 Fig 4 Metering system 2 pumps 2 points of injection A Feed B Outlet C Drain No...

Page 12: ... Manometer MDM902 d25 G1 4 PVC U 2 1030362 5 DHV DHV U DN10 PVC U 2 1037765 6 Back pressure valve DHV U DN10 PVC U 2 1037765 7 Vacuum pump Hubinont MI8121 1 1031565 8 Vacuum cylinder DN10 PVC U 1 1025699 9 Ball valve 546 DN10 PVC U 3 1024538 10 Level switch PP1 PE 1 142086 11 Splash guard PVC glass 1 12 Terminal box 180x110x90 mm 1 1036995 13 3 way ball valve 543 DN10 PVC U 3 1043568 About this pr...

Page 13: ...r another authorised distribution partner Trained qualified per sonnel A trained qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognize possible hazards based on his training knowledge and experience as well as knowledge of pertinent regula tions A trained qualified employee must be able to perform the tasks assigned to him independently with the ...

Page 14: ...in fatal or very serious injuries WARNING Nature and source of the danger Possible consequence Fatal or very serious inju ries Measure to be taken to avoid this danger Denotes a possibly hazardous situation If the situation is disregarded it could result in fatal or very serious injuries CAUTION Nature and source of the danger Possible consequence Slight or minor injuries Material damage Measure t...

Page 15: ...eet regularly and replace if neces sary as the hazard potential of a substance can be re evaluated at any time based on new findings The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date as well as for producing an associated hazard assessment for the worksta tions affected WARNING Live parts Possible consequence Fatal or very...

Page 16: ...at risk from explosion Possible consequence Fatal or very serious inju ries Operating the unit in areas at risk from explosion The unit is not approved to pump media at risk from explosion WARNING Pumping flammable media Possible consequence Fatal or very serious inju ries Take appropriate safety precautions when pumping flammable media Observe the safety data sheet for the medium CAUTION Securing...

Page 17: ... power supply line or integrate the pump in the emergency cut off management of the system CAUTION Contact with chemicals De pressurise drain and rinse the hydraulic part of the unit before working on it Flushing connections Both flushing connections can always remain closed in normal mode In the event of an electrical accident disconnect the mains cable from the mains power supply or press the em...

Page 18: ...se operating instructions and in the operating instructions for the individual components such as sensors fittings calibration devices metering pumps etc The metering system is designed for installation indoors Operation outdoors is not permitted Do not operate the metering system under condi tions other than those described in the technical data Only allow technically expert personnel to operate ...

Page 19: ...he metering system is free from hazardous feed chemicals Immediately check the goods on receipt of delivery Identify any damage caused by transportation as well as missing parts or incor rect delivery Immediately notify us of defects in writing upon receipt of the goods Only transport the metering system standing and secured with ten sioning straps Only transport the metering system on a pallet Th...

Page 20: ...ta Only allow adequately qualified and technically expert personnel to operate the metering system All other uses or modifications are prohibited 1 Only fix the metering system on the feet intended for this pur pose or as a wall panel on the wall 2 Ensure that the fixing surface is level e g DIN 18202 3 Tighten all connectors threaded connectors flange connec tors 1 When installing the metering sy...

Page 21: ...rent devices RCD providing they can be installed sensibly and professionally within the electrical installation Please adhere to all national standards and regulations 1 The transition point for the electrical system is a terminal box attached on the wall mounting plate with a master switch to which all signals and the power supply to the pumps and the power supply to the controller are connected ...

Page 22: ...ing hole Ø15 mm n 1 x stainless steel bracket 1190x600x100 mm LxHxW n 4 x M8 fixing bolts bracket mounting frame A2353 Fig 6 Installation with stainless steel bracket 4 4 Installation on the wall n 4 x M8 bolts A2704 Fig 7 Installation on the wall Assembly and installation 22 ...

Page 23: ... pumps 1 point of injection n Connect the level switch to the active pump Model 2 pumps 2 points of injection n Connect the level switch to the terminal box n Empty signal prompt by a higher level control by the cus tomer n The pumps are switched off possibly by the Pause input by the customer Assembly and installation 23 ...

Page 24: ...ble consequence Fatal or very serious inju ries Please ensure when handling hazardous sub stances that you have read the latest safety data sheets provided by the manufacture of the haz ardous substance The actions required are described in the safety data sheet Check the safety data sheet regularly and replace if neces sary as the hazard potential of a substance can be re evaluated at any time ba...

Page 25: ...stem 5 3 Commissioning Test Run Faults during the test run Should you identify a fault during the test run first remedy this fault Only approve the metering system after a further test run with distilled water providing this test run is fault free Details on the set up of the individual components can be found in the corresponding operating instructions for the respective components Start up the r...

Page 26: ...the latest safety data sheets provided by the manufacture of the haz ardous substance The actions required are described in the safety data sheet Check the safety data sheet regularly and replace if neces sary as the hazard potential of a substance can be re evaluated at any time based on new findings The system operator is responsible for ensuring that these safety data sheets are available and t...

Page 27: ...d replace if neces sary as the hazard potential of a substance can be re evaluated at any time based on new findings The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date as well as for producing an associated hazard assessment for the worksta tions affected During operation perform daily checks to ensure the proper condi tion...

Page 28: ...rom electrical power Possible consequence Fatal or very serious inju ries Measure Make sure that the mains power supply is disconnected during all maintenance and repair work Regularly check the continuity of the earth line by taking measurements Carry out all work in line with the applicable national and international statutory regulations laws and standards The system operator is responsible for...

Page 29: ...etering system n Remove deposits of dust and soiling n Check the capacities n Check the charging pressure of the pulsation damper bladder damper pay particular attention to the filling medium n Check the settings of the back pressure and relief valves especially when changing the capacity n Check and maintain the metering pumps in line with the corre sponding operating instructions n Check any flo...

Page 30: ... the operating instruc tions for the pump Back pressure relief valves Functional test diaphragm replacement Annually or in the event of a fault Metering system operating instructions Multifunctional valve oper ating instructions Functional test Weekly inspection Metering system operating instructions Drip tray Visual inspection for leak tightness and damage Weekly inspection Metering system operat...

Page 31: ...cuation tank not closed Close fitting and if required re evac uate the suction line Tank and or priming lift too high Use priming aid Empty alert and or low flow contact trig gered Top up chemicals into the storage tank make sure that the level sensor is immersed in the medium Ball jammed stuck in the metering pump suction or discharge valve Dismantle clean and if required replace valve Ball disso...

Page 32: ...alfunctioning Check the contacts for corrosion and secure fixing Display on the pressure manometer pulsates Pulsation damper pre load is incorrect Check the setting of the pulsation damper Retrofit pulsation damper if neces sary Discharge line displays strong vibrations or starts pulsating Pressure peaks too high Check the setting of the pulsation damper Retrofit pulsation damper if neces sary Suc...

Page 33: ...ergise the mains cable and ensure that it cannot be switched on again Thoroughly clean the metering system of chemi cals and dirt when decommissioning it If the metering system is idle for a long period of time thoroughly rinse clean and then drain all pipework fittings metering pump and all other wetted parts If possible dry flush the pipework with compressed air Compressed air can pressurise res...

Page 34: ...r To do so remove all traces of hazardous substances Refer to the Material Safety Data Sheet for your feed chemical A current Declaration of Decontamination is available to download on the ProMinent website In accordance with the European Directive 2012 19 EU on waste electrical and electronic equipment this device features the symbol showing a waste bin with a line through it The device must not ...

Page 35: ... pressure level 70 dB A 70 dB A Max operating pressure 25 C 10 bar 10 bar Max operating pressure 40 C 6 bar 6 bar Pulsation damper Inline 50 ml Inline 50 ml Volume of vacuum cylinder 0 5 l 0 5 l Metering pump 1 BT4a BT5a DLTa GMXa BT4a BT5a DLTa GMXa Metering pump 2 BT4a BT5a DLTa GMXa Maximum capacity 75 l h 2 bar 75 l h 2 bar Nominal width of pipework DN 10 DN 10 Nominal width of flushing connec...

Page 36: ...nsing Sound pressure level 70 dB A Max operating pressure 25 C 10 bar Max operating pressure 40 C 6 bar Pulsation damper Inline 50 ml Volume of vacuum cylinder 0 5 l Metering pump 1 BT4a BT5a DLTa GMXa Metering pump 2 BT4a BT5a DLTa GMXa Maximum capacity 2 x 75 l h 2 bar Nominal width of pipework DN 10 Nominal width of flushing connector DN 10 Nominal width of return line DN 10 Output 6x4 8x5 12x9...

Page 37: ...rawings 10 1 Metering system 1 pump 1 point of injection 600 1 2 13 4 5 6 7 8 13 10 11 410 10 580 10 320 300 12 9 63 40 127 52 850 110 150 A2708 Fig 8 Metering system 1 pump 1 point of injection Drawings 37 ...

Page 38: ...ing system 2 pumps 1 point of injection 700 10 680 10 1000 63 40 110 150 52 126 410 300 90 210 360 410 180 1 2 3 4 5 6 7 8 9 10 11 12 13 14 46 A2709 Fig 9 Metering system 2 pumps 1 point of injection Drawings 38 ...

Page 39: ...10 3 Metering system 2 pumps 2 points of injection Fig 10 Metering system 2 pumps 2 points of injection Drawings 39 ...

Page 40: ...nd for flow diagrams Symbols Process line symbols Ball valve Main process line Back pressure valve Pulsation damper Calibration pot Pressure display Metering pump A2428 Test valve Fig 11 Legend for flow diagrams Flow diagram of DSUa mini PID 40 ...

Page 41: ...11 2 Flow diagram of DSUa mini 1 PID A2705 Fig 12 Flow diagram of DSUa mini 1 PID Flow diagram of DSUa mini PID 41 ...

Page 42: ...11 3 Flow diagram of DSUa mini 2 PID A2706 Fig 13 Flow diagram of DSUa mini 2 PID Flow diagram of DSUa mini PID 42 ...

Page 43: ...11 4 Flow diagram of DSUa mini 3 PID A2707 Fig 14 Flow diagram of DSUa mini 3 PID Flow diagram of DSUa mini PID 43 ...

Page 44: ...12 Electrical wiring diagram 12 1 Electrical Wiring Diagram 1062129 1 Pump A2443 Fig 15 BT4b BT5b Electrical wiring diagram 44 ...

Page 45: ...A2444 Fig 16 DLTa GMXa Electrical wiring diagram 45 ...

Page 46: ...12 2 Electrical wiring diagram 2 pumps A2711 Fig 17 Electrical wiring diagram 2 pumps Electrical wiring diagram 46 ...

Page 47: ...A2712 Fig 18 Electrical wiring diagram 2 pumps Electrical wiring diagram 47 ...

Page 48: ...lidate this declaration Tab 3 Extract from the Declaration of Conformity Designation of the product Panel mounted metering system DULCODOS universal Product type DSUa Serial number see nameplate on the device Relevant EC directives EC Machinery Directive 2006 42 EC EMC Directive 2014 30 EU Compliance with the protection targets of the Low Voltage Directive 2006 95 EC according to Appendix I No 1 5...

Page 49: ...ns or other applicable documents 2 Live parts 15 M More symbols 2 N Nameplate 4 Noise level 24 Non discriminatory approach 2 O Operating error Unauthorised access 16 P Personal protective equipment PPE 25 Prerequisite for commissioning 24 Pumping flammable media 16 Q Question How should I dispose of the device 33 Question Is the unit approved for areas at risk from explosion 16 Question Where do I...

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Page 52: ...982011 1 en_GB 2019 ProMinent GmbH Im Schuhmachergewann 5 11 69123 Heidelberg Germany Telephone 49 6221 842 0 Fax 49 6221 842 419 Email info prominent com Internet www prominent com ...