ProMinent Makro TZ, Operating Instructions Manual

Page 1: ...structions 2006 42 EC Part No 985741 BA MA 021 01 20 EN Please carefully read these operating instructions before use Do not discard The operator shall be liable for any damage caused by installation...

Page 2: ...the precise designation of suppliers components in the Technical Data chapter for ease of finding the relevant informa tion These operating instructions conform to current EU regulations applicable at...

Page 3: ...nsor 61 10 3 Valve repair 64 10 3 1 Double ball valves 64 10 3 2 Plate valves 65 10 4 Replacing power end bearings 66 11 Troubleshooting 67 12 Decommissioning and disposal 70 12 1 Decommissioning 70 1...

Page 4: ...for adjusting the capacity 87 18 Spare parts 91 18 1 Spare parts 91 18 2 Other material 92 18 2 1 Gear oil 92 19 Declaration of Conformity for Machinery 93 20 Declaration of Incorporation 94 21 ATEX...

Page 5: ...fety diaphragm with rupture signalling Dosing head design 0 without valve spring 1 with valve spring Hydraulic connector 0 Standard connection 1 Union nut and PVC insert 2 Union nut and PP insert 3 Un...

Page 6: ...d Degree of protection 0 IP 55 standard ISO class F 1 Exe design ATEX T3 2 Exd design ATEX T4 A ATEX design of power end Stroke sensor 0 without stroke sensor 1 Stroke sensor Namur intrinsically safe...

Page 7: ...r flammable feed chemicals if the operator takes appropriate safety measures n The pump may only be started up after it has been correctly installed and started up in accordance with the technical dat...

Page 8: ...ed person service depending on the requirement Explanation of the table Trained qualified personnel A trained qualified employee is deemed to be a person who is able to assess the tasks assigned to hi...

Page 9: ...ve a comparable technical qualification or n another technical qualification combined with long term experi ence of safety technology Make sure that the person is familiar with the relevant body of st...

Page 10: ...d before working on the pump WARNING Danger from hazardous substances Possible consequence Fatal or very serious inju ries Please ensure when handling hazardous sub stances that you have read the late...

Page 11: ...connect the pump from the mains power supply and ensure that it cannot be switched on again by unauthorised persons Depressurise the system before commencing any work on hydraulic parts CAUTION Warnin...

Page 12: ...al escapes also depressurise the hydraulic system around the pump as necessary Adhere to the safety data sheet for the feed chemical Prior to commissioning the system or system component it is the res...

Page 13: ...cover side Service 4 Protective cover diaphragm and plunger design only Technical per sonnel Service Only with additional equipment Their cor responding parts Technical per sonnel Service Only if req...

Page 14: ...EX designs contradicts the other safety information then the safety information in this chapter applies to ATEX designs n Only operate an ATEX design pump in premises at risk from explosion in accorda...

Page 15: ...skilled technician with an additional explosion protection qualification can work on equipment and systems in areas pro tected from explosion and independently recognise and avoid pos sible dangers ba...

Page 16: ...he indi vidual components The customer must pay attention to potential equali sation when dismantling Paint should not be applied too thickly Dosing heads made of electrically non conductive materials...

Page 17: ...y Ignition hazard caused by bought in proximity switch NJ1 5 8GM N stroke sensor Refer to the documentation for the proximity switch electrical installation WARNING ATEX pumps in areas at risk from ex...

Page 18: ...s in accordance with EN 80079 38 WARNING ATEX pumps in areas at risk from explosion Electrically connect the electrical units listed on the earthing diagram in the appendix cleanly and permanently to...

Page 19: ...ke sure that a suitably competent person checks whether the appropriate installation information from the Installation chapter has been implemented correctly Make sure that a recognised competent pers...

Page 20: ...al such as pipes or tools Replace wear parts such as bearings when there is an identifiable incidence of unaccept able wear Appropriate diagnostic equipment for bearing damage is recommended for the p...

Page 21: ...ling is OK the maintenance interval can be increased to 4000 hours If the coupling is not clearly OK Call ProMinent Service Technical per sonnel After 20 000 operating hours or 26 000 operating hours...

Page 22: ...e colour Polarity blue brown WARNING The following safety information must be affixed to pumps that include parts made of electrically non conducting plastic Ensure that the label is always fitted and...

Page 23: ...ion hazard assessment 5 Complete the pump documentation operating instructions In areas at risk from explosion only the following combinations of identity code variants are permitted Identity code spe...

Page 24: ...plosion protection document IIB for explosion group IIB gas refer to your explosion protection document Temperature class T3 for Temperature class T3 gas refer to your explosion protection document T4...

Page 25: ...mparable gas refer to the material safety data sheet for the gas or your explosion protection document The pump in the example could also be suitable for gases that require only Explosion group IIA an...

Page 26: ...plosion groups and temperature classes on page 25 shows the following the pump can be used for all gases of Explosion group IIC and Temperature class T4 refer to your explosion protection document The...

Page 27: ...age or transportation The unit should only be stored or transported in a well packaged state preferably in its original packaging Only transport the unit with the locking screw not the bleed plug fitt...

Page 28: ...length adjustment wheel 3 Oil inspection window 4 Motor 5 Oil drainage screw 1 2 3 4 C C A 5 P_MA_0024_SW Fig 5 Side view here TZMb D A Drive C Liquid end 1 Vent screw 2 Stroke length adjustment wheel...

Page 29: ..._MA_0025_SW Fig 6 View of the liquid end 1 Discharge valve 2 Dosing head 3 Diaphragm rupture sensor 4 Suction valve 5 Tube nozzle for leakage 6 Protective cover Liquid end Overview of equipment contro...

Page 30: ...5 Functional description The metering pump is an oscillating diaphragm pump the stroke length of which can be adjusted An electric motor drives it Pump Functional description 30...

Page 31: ...pling The claw on the motor shaft must be fixed at the correct height see corresponding figure and table 3 As you have converted an incomplete machine into a com plete machine you must perform a confo...

Page 32: ...can heat the liquid ends above the permissible surface temperatures per sons can suffer burns from them Consider attaching a Hot surface label to the liquid end or fitting a guard plate Position the p...

Page 33: ...e dimensional or data sheets Use appropriate screws to fix the pump base to the supporting floor Using 4 sufficiently strong screws screw the pump to the support surface through the 4 holes in the fra...

Page 34: ...er of fire with flammable feed chemicals Flammable media may only be pumped using metering heads made of stainless steel Has telloy C PRFE with carbon or PP with carbon Metering pumps can be used for...

Page 35: ...le size of greater than 0 3 mm Install a suitable filter in the suction line CAUTION Warning of the discharge line rupturing With a closed discharge line e g from a clogged discharge line or by closin...

Page 36: ...ctive hose diameter Always connect the lines without mechanical tension Only connect steel piping via a flexible piping section to a plastic valve body see the fol lowing figure 1 2 3 P_MOZ_0021_SW Fi...

Page 37: ...is a signal generated in the event of the rup ture of a diaphragm Only rely on the diaphragm rupture indicator with back pressures of greater than 2 bar Or install a back pressure valve and set it to...

Page 38: ...nto the storage tank Shorten the return line so that it does not dip into the feed chemical in the storage tank P_MOZ_0043_SW 2 1 A B PD 1 2 Fig 12 A standard installation B with pulsation damper 1 Ma...

Page 39: ...or and a discharge side flow control must both stop the pump as soon as a diaphragm rupture or no flow is detected WARNING Danger of electric shock In the event of an electrical accident it must be po...

Page 40: ...change the Motor voltage and Cycle fre quency parameters with motor designs with inte gral frequency converter The parameters on delivery from ProMinent do not correspond to the motor manufacturer s f...

Page 41: ...l box CAUTION The motor can be damaged Provide appropriate motor protection devices e g motor protection switch with thermal overcurrent trip to protect the motor from overloading Fuses do not provide...

Page 42: ...ominent com Motor data sheets can be requested for all other motors With motors other than those with identity code specifications S M or N Pay special attention to the operating instructions for the...

Page 43: ...ever allow the diaphragm to rupture fully if damage can be caused by hydraulic oil mixing with the feed chemical The diaphragm rupture sensor must switch off the pump immediately Only restart the pump...

Page 44: ...e sure that the monitoring feed equipment installed by the customer is capable of evaluating the current variations of the Namur sensor to indicate a stroke WARNING The following applies in areas at r...

Page 45: ...Install the other units in line with their documentation Other units Installation 45...

Page 46: ...hazard with flammable media Only with flammable media They can be ignited by oxygen The pump may not work if there is a mixture of feed chemical with oxygen in the liquid end A specialist may need to...

Page 47: ...upture Only above approximately 2 bar system back pres sure is a signal generated in the event of the rup ture of a diaphragm Only rely on the diaphragm rupture sensor with back pressures of greater t...

Page 48: ...n the pump is idle check whether the pump oil level almost covers the oil inspection window This indicates that the pump has not lost oil and consequently been damaged When commissioning the unit chec...

Page 49: ...ng correctly on the pump and connected to a clean potential equalisation point 8 1 Bleeding the liquid end Requirements Depressurise the suction and discharge lines With dangerous feed chemicals take...

Page 50: ...1 and a brass bar 2 gently tap the PTFE ball seat above the valve ball see figure below Then with the valve in a damp condition allow it to prime 8 2 Calibrate the stroke control drive optional The st...

Page 51: ...n cleaning plastic components ensure that no electrostatic charges are generated by excessive friction Prevent serious deposits of dust on the motor Consider potential equalisation before you approach...

Page 52: ...o the mains voltage with the fan cowling closed CAUTION Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic com ponents if they are manipulated or opened due to press...

Page 53: ...d than those given Third party spare parts for the pumps may result in problems when pumping Only use original spare parts Use the correct spare parts kits In the event of doubt refer to the exploded...

Page 54: ...flow is correct Allow the pump to prime briefly Technical personnel Check the leak tightness of the entire liquid end particularly around the leakage hole With critical applications check or replace...

Page 55: ...instructions for the motor Technical personnel Under normal loading approx 30 of continuous operation Under heavy loading e g continuous operation Shorter intervals under normal loading With very unfa...

Page 56: ...new seal 1 3 2 P_MA_0037_SW Fig 17 Oil change 1 Vent screw 2 Oil drainage plug 3 Oil inspection window Filling with gear oil 1 Start the pump 2 Slowly pour gear oil through the vent screw 1 opening u...

Page 57: ...is a mixture of feed chemical with oxygen in the liquid end A specialist may need to take appropriate actions using inert gas WARNING It is mandatory that you read the safety information and specifica...

Page 58: ...it cannot be switched on again by unauthorised persons Depressurise the system before commencing any work on hydraulic parts 10 1 Replacing the diaphragm CAUTION A diaphragm rupture may remain unnoti...

Page 59: ...that have been wetted by the medium in a trough with a suitable medium for flushing be sure to rinse hazardous media thoroughly 6 Unscrew the hydraulic connectors on the discharge and suc tion side 1...

Page 60: ...plate 13 Remove the dosing head 1 with the screws from the turret 8 14 Unscrew the diaphragm 2 from the slide rod 6 and remove 15 Clean the sealing surfaces 16 Smear a little screw locking paste onto...

Page 61: ...ety screw Check the tightening torque of the screws after 24 hour operation With PP dosing heads check the tightening torque again after three months 10 2 Repairing the diaphragm rupture sensor WARNIN...

Page 62: ...the diaphragm rupture sensor from the power supply 2 When changing the diaphragm unscrew the diaphragm rup ture sensor from the dosing head 3 Grasp the upper section 2 of the diaphragm rupture sensor...

Page 63: ...changing the diaphragm unscrew the diaphragm rup ture sensor from the dosing head 3 Grasp the top part 2 of the diaphragm rupture sensor Do not tamper with the lacquer protected nut 4 Hold the body 5...

Page 64: ...note of the orientation of the valve seats 3 The valve seats 3 are used as a ball seat on the fine machined side and as a ball cage and spring guide on the other side The fine machined side must poin...

Page 65: ...t 3 must be aligned in the other direc tion The fine machined side must point in the direction of flow with all valve seats 3 10 3 2 Plate valves Do not scratch the finely machined sealing sur faces o...

Page 66: ...may knock when in operation 7 Insert the valve plate 5 and the valve insert 6 8 Screw on the valve cap 7 Note the flow direction of the discharge and suc tion connectors when fitting the valve 10 4 R...

Page 67: ...s replacements WARNING ATEX pumps in areas at risk from explosion Static electricity can cause ignition sparks Consider potential equalisation before you approach any pump equipment that could be at a...

Page 68: ...al box CAUTION Only motors with a frequency converter The motor can be damaged The input current limiter could be damaged if a motor with an integrated frequency converter is restarted within 3 minute...

Page 69: ...equency 2 Wire the motor correctly Electrician Electrical technician with additional explosion protection qualification The mains voltage has failed Eliminate the cause Electrician Electrical technici...

Page 70: ...anger from chemical residue 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 i...

Page 71: ...from the mains power supply 2 Depressurise and bleed the hydraulic system around the pump 3 Flush the liquid end with a suitable medium observe the material safety data sheet Flush the dosing head tho...

Page 72: ...idelines currently appli cable in your country In accordance with the European Directive 2012 19 EU on waste electrical and electronic equipment this device features the symbol showing a waste bin wit...

Page 73: ...7 1070 99 180 3 5 2 32 50 64 40840 4 840 194 72 3 2 1 4 40 56 80 41100 4 1100 194 96 3 2 1 4 40 56 80 41400 4 1400 194 120 3 2 1 4 40 56 80 41670 4 1670 194 144 3 2 1 4 40 56 80 42100 4 2100 194 180 3...

Page 74: ...54 115 3 2 1 4 40 56 80 41400 58 1676 443 144 3 2 1 4 40 56 80 41670 58 2014 532 173 3 2 1 4 40 56 80 42100 58 3 2 1 4 40 56 80 Material version PP PC TT max 145 psi Material versions PPT PCT TTT SST...

Page 75: ...laid out installa tion 500 1000 mPas with appropriately laid out installa tion and advice from ProMinent over 1000 mPas Only when the installation is correctly adjusted 13 4 Wetted materials Tab 4 wi...

Page 76: ...lar to PTFE 13 5 Ambient conditions 13 5 1 Temperatures Data Value Unit Storage and transport temperature 10 50 C Data Value Unit ATEX ambient temperature during operation 10 40 C Ambient temperature...

Page 77: ...p 90 C Minimum temperature 10 C Data Value Unit Max temperature long term at max operating pressure 90 C Max temperature for 15 min at max 2 bar 120 C Minimum temperature 10 C 13 5 2 Air humidity Data...

Page 78: ...0 75 kW R 3 phase IP 55 230 V 400 V 50 60 Hz 1 5 kW with PTC speed adjustment range 1 20 with external fan 1 phase 230 V 50 60Hz V0 1 phase IP 55 230 V 50 60 Hz 1 1 kW Variable speed motor with inte g...

Page 79: ...le on request 13 9 Stroke sensor optional intrinsically safe Install the sensor according to the chapter Instal lation electrical Refer to its documentation Sensor name NJ1 5 8GM N 5 25 V DC in accord...

Page 80: ...lation electrical Refer to its documentation Sensor name NJ1 5 8GM N 5 25 V DC in accordance with Namur or DIN 19234 potential free design Data Value Unit Rated voltage 8 VDC Power consumption active...

Page 81: ...ement for modified versions With Identcode specification Version M modified Technical data of pumps in the modified version can deviate from those of the standard pumps They can be queried by stating...

Page 82: ...f Makro TZ in mm Type 120260 120340 120430 120510 120650 120260 120340 120430 120510 120650 070430 070570 070720 070860 071070 070430 070570 070720 070860 071070 040840 041100 041400 041670 42100 0408...

Page 83: ...Makro TZ in mm Type 120260 120340 120430 120510 120650 120260 120340 120430 120510 120650 070430 070570 070720 070860 071070 070430 070570 070720 070860 071070 040840 041100 041400 041670 42100 04084...

Page 84: ..._ _8_ _ _ 160 90 _ _ _9_ _ _ 200 90 A 167 120 160 200 B 149 3 100 130 165 C 114 3 80 110 130 D 15 87 19 24 24 E 4 4 4 4 F 48 76 37 46 5 46 5 G 11 6 6 9 M10 H 193 181 191 191 Coupling type M24 Bowex M2...

Page 85: ...ge fois ATEX Nr Umgebungstemperatur ambient temperature temp rature ambiante Ex Schutzklasse Schaltung ex protective system connection branchement Drehzahlregelbereich speed ajustment range Anmerkung...

Page 86: ...Potential equalisation of motor Potential equalisation line of Pos no 1 at 3 P_MA_0044_SW 40115855_2 2 1 2 2 3 4 1 Fig 29 Earthing equipotential bonding drawing 2 Makro TZ TZMb 1 Potential equalisatio...

Page 87: ...430 120340 120260 C l h C l h C l h C l h 0 5 4 2 3 6 7 1 500 0 1100 1200 1000 900 800 700 600 300 400 100 200 p bar 071070 070860 070720 070570 070430 0 20 40 60 10 30 50 80 70 90 100 500 0 1100 1200...

Page 88: ...70 90 100 1000 500 0 1500 2000 s 042100 041670 041400 041100 040840 C l h C l h Fig 31 Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis...

Page 89: ...120260 C l h C l h C l h C l h 0 20 40 60 10 30 50 80 70 90 100 500 0 1000 900 800 700 600 300 400 100 200 s 070860 070720 070570 070430 0 1 3 5 6 7 4 2 500 0 1000 900 800 700 600 300 400 100 200 p b...

Page 90: ...70 90 100 1000 500 0 1500 2000 s 041670 041400 041100 040840 C l h C l h Fig 33 Metering capacity C at medium back pressure according to the stroke length s or metering capacity C on the basis of bac...

Page 91: ...lve seat valve seat bushing Tab 12 For 12 10 bar types 120260 120340 120430 120510 120650 FM 650 DN 25 Order no PP 1025166 P 1025164 T 1025172 S 1022896 S without valve assemblies 1022895 Tab 13 For 7...

Page 92: ...120650 Liquid end type Order no FM 650 1022887 Tab 16 For 7 bar types 070430 070570 070720 070860 071070 Liquid end type Order no FM 1070 1022900 Tab 17 For 4 bar types 040840 041100 041400 041670 04...

Page 93: ...Metering pump product range Makro TZ Product type TZMb _ _ _ _ _ _ _ _ _ _ _ _ _ _ 0 _ _ _ TZHa _ _ _ _ _ _ _ _ _ _ _ _ _ _ 0 _ _ _ TZKa _ _ _ _ _ _ _ _ _ _ _ _ _ _ 0 _ _ _ with the characteristics R...

Page 94: ...ump without motor product range Makro TZ Product type TZMb_ _ _ _ _ _ _ _ _ _ _ _ _ _ 0_ _ _ TZHa_ _ _ _ _ _ _ _ _ _ _ _ _ _ 0_ _ _ TZKa_ _ _ _ _ _ _ _ _ _ _ _ _ _ 0_ _ _ with the characteristics 4 or...

Page 95: ...4 34 EC Product type TZMb_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 0 TZHa_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ TZKa_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 0 with characteristics L or P or V and 1 or 2 0 or 3 Serial number se...

Page 96: ...19 With regard to Special conditions refer also to the chapter enti tled Safety information for ATEX designs You can download the Declaration of Conformity from www promi nent com ATEX Declaration of...

Page 97: ...pe TZMb_ _ _ _ _ _ _ _ _ _ _ _ _ _ A_ _ 0 TZHa_ _ _ _ _ _ _ _ _ _ _ _ _ _ A_ _ TZKa_ _ _ _ _ _ _ _ _ _ _ _ _ _ A_ _ 0 with characteristics 4 or 7 or 8 or 9 or 0 0 or 3 Serial number see nameplate on t...

Page 98: ...Date 22 07 2019 You can download the Declaration of Incorporation at www promi nent com ATEX Declaration of Incorporation 98...

Page 99: ...99...

Page 100: ...985741 5 en_GB 2022 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...