Operating instructions Diaphragm Metering Pump Makro TZ, TZMb P_MA_0022_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® motor-driven metering pumps and hydraulic accessories". Both sets of operating instructions are only valid when read together.
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.
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.
Table of contents Table of contents 1 Identity code.................................................................................... 5 2 About this pump............................................................................... 7 3 Safety chapter................................................................................. 8 4 Storage, transport and unpacking................................................. 13 5 Overview of equipment, control elements.....................................
Identity code 1 TZMb Identity code Makro/ 5 diaphragm metering pump Power end type H Main power end D Main power end, doubled A Add-on power end B Add-on power end doubled Type * 120260, 070430, 040840 120340, 070570, 041100 120430, 070720, 041400 120510, 070860, 041670 120650, 071070, 042100 Material dosing head ** PC PVC PP Polypropylene TT PTFE + 25 % carbon SS Stainless steel Material of seals / diaphragm T PTFE Displacement body material T Multi-layer safety diaphragm with ru
Identity code TZMb Makro/ 5 diaphragm metering pump S 3 ph, 230 V/400 V 50/60 Hz (WBS) L 3 ph, 230 V/400 V, 60 Hz, (Exe, Exd) P 3 ph, 230 V/400 V 50 Hz (Exe, Exd) R 4 pole, variable speed motor, 230/400 V V(0) Motor with integral frequency converter V(2) Motor with integral frequency converter (Exd) Z Speed controller compl.
About this pump 2 About this pump All pumps The Makro TZ diaphragm metering pump is fitted as standard with a 0.75 kW wide range AC motor. The stroke length can be adjusted between 0...10 mm. The acrylic resin painted cast housing can be combined with up to 16 liquid end sizes and 5 gear reduction ratios (integrated in the spur geared motor). The liquid ends are available in various material combina‐ tions which can be matched to the feed chemicals being metered.
Safety chapter 3 Safety chapter Identification of safety notes 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.
Safety chapter n n n n n The pump is not intended for the metering of gaseous media or solids. The pump is not intended for unprotected outside use. The pump is only approved to meter flammable liquids, if the operator takes appropriate safety measures. The pump should only be operated by trained and authorised per‐ sonnel, see also Ä ‘Qualification of personnel’ on page 9.
Safety chapter 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.
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 materials which will come into contact with the chemical when selecting the feed chemical - see the ProMinent product catalogue or under www.prominent.com. CAUTION! Danger of personnel injury and material damage The use of untested third party parts can result in personnel injuries and material damage.
Safety chapter 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) 12
Storage, transport and unpacking 4 Storage, transport and unpacking Safety notes 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 metering pumps for repair in a cleaned state and with a flushed liquid end - refer to the section on decommis‐ sioning! Only send metering pumps with a filled in Decontamination Declaration form.
Storage, transport and unpacking Store the pump in a dry, sealed place in the following ambient conditions. Ambient conditions Data Minimum storage and transport tempera‐ ture -10 °C Maximum storage and transport tempera‐ ture +50 °C Maximum air humidity * * non-condensing 14 Value Unit 95 % rel.
Overview of equipment, control elements 5 Overview of equipment, control elements Power end, single head 1 2 3 4 P_MA_0023_SW C A 5 Fig. 3: Side view (here TZMb H) A C 1 2 3 4 5 Drive Liquid end Vent screw Stroke length adjustment wheel Oil inspection window Motor Oil drainage screw Power end, double head 1 2 3 4 P_MA_0024_SW C A 5 C Fig.
Overview of equipment, control elements Liquid end 6 1 2 3 P_MA_0025_SW 4 Fig.
Functional description 6 Functional description Power end functional description The metering pump MAKRO TZ is an oscillating, continuously adjustable diaphragm pump. It is driven by an AC standard motor, the power end rotation of which is stepped down by a worm gear (1), transmitted via an adjustable cam (2), a connecting rod (3) and the slide rod (4) and hence converted into an oscillating movement - see .
Functional description 1 2 3 5 4 P_MA_0029_SW Fig. 7: Cross-section through the liquid end 1 2 3 4 5 Diaphragm rupture warning system func‐ tional description Discharge valve Metering diaphragm Dosing head Suction valve Diaphragm rupture signaller The diaphragm rupture warning system monitors the leak-tightness of the multi-layer diaphragm. Together with the diaphragm rupture sensor and downstream analysis electronics, the multi-layer diaphragm forms the dia‐ phragm rupture warning system.
Functional description 1 2 3 4 4 P_MA_0030_SW Fig.
Assembly 7 Assembly Safety notes WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Assembly WARNING! The pump can break through the supporting floor or slide off it – The supporting floor must be horizontal, smooth and per‐ manently load-bearing. Capacity too low Vibrations can disturb the valves of the liquid end. – The supporting floor must not vibrate. Space requirement CAUTION! Danger from incorrectly operated or inadequately maintained pumps Danger can arise from a poorly accessible pump due to incorrect operation and poor maintenance.
Assembly m DN Take the dimensions (m) for the fastening holes from the appropriate dimensional drawings or data sheets. Fasten the pump base to the supporting floor using suitable screws. m P_MOZ_0015_SW Fig. 12 Instruction Screw the pump to a support surface with 4 sufficiently strong screws through the 4 holes in the frame. Nothing more need be fitted to the pump itself: the pump is filled with gear oil and completely assembled on a frame.
Installation 8 Installation CAUTION! Danger of personnel injury and material damage The disregard of technical data during installation may lead to personal injuries or damage to property. – Observe the technical data- refer to chapter "Technical Data" and, where applicable, the operating instructions of the accessories. 8.1 Installation, hydraulic WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed.
Installation CAUTION! Suction problems possible For feed chemicals with a particle size greater than 0.3 mm, the valves may no longer close properly. – Install a suitable filter in the suction line. CAUTION! Warning against the discharge line bursting With a closed discharge line (e.g. due to a clogged discharge line or by closing a valve), the pressure that the metering pump generates can reach several times the permissible pressure of the system or the metering pump.
Installation 8.2 Installation, electrical WARNING! Danger of electric shock Unprofessional installation may lead to electric shocks. – – All cable cores cut to length must be provided with cable end sleeves. The Installation, electrical of the device may only be undertaken by technically trained personnel.
Installation Personnel: n Electrician What requires electrical installation? n n n n n n n motor External fan (option) Stroke control drive (Option) Stroke adjusting drive (Option) Diaphragm rupture sensor Stroke sensor (Option) Frequency converter (option) motor CAUTION! Pump can be damaged The pump can be damaged if the motor drives the pump in the wrong direction.
Installation The external fan requires an independent mains connection. Stroke sensor (Option) Connect the stroke sensor to a suitable monitoring device according to the details in the chapter "Technical Data". Also observe its tech‐ nical data. Other units Install the other units according to their documentation.
Start up 9 Start up Safety notes WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Start up Eliminating suction problems (only for single ball valves with PTFE ball seat) For suction problems occurring during start up: – – – – Exclude the possibility that there are foreign bodies in the valve. Place the valve on a stable surface. Using a hammer (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. Fig.
Start up Correctly adjusting the pump: n n n n Select as large a stroke length as possible for viscous feed chemicals. Select as large a stroke length as possible for outgassing feed chemi‐ cals. Select as high a stroke rate as possible for good mixing. For precise metering using quantity-proportional metering, do not set the stroke length to less than 30 %. The pump can now be released for operation.
During use 10 During use WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Maintenance 11 Maintenance Safety notes WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Maintenance Maintenance work Under heavy loading (e.g. continuous operation) shorter maintenance intervals are recommended than those given. Place a spare parts kit in stock ready for maintenance work. Order numbers are contained on the CD.
Maintenance Under heavy loading (e.g. continuous operation): Shorter intervals. ** under normal loading. With very unfavourable metering parameters: Shorter intervals. Changing the gear oil WARNING! Risk of burns due to hot gear oil The gear oil may become very hot when the pump is heavily loaded – When draining oil, avoid contact with the oil running out. Gear oil Gear oil Supplied quantity Mobilgear 634 VG 460 Part no. 1.0 l 1004542 Gear oil filling volumes Types Volume, approx. All 3.
Maintenance 1. Start up the pump. 2. Slowly pour gear oil through the vent screw (1) opening until the upper oil inspection window (3) is nearly covered. 3. Allow the pump to run for a further 1... 2 minutes. 4. Replace the vent screw (1).
Repairs 12 Repairs Safety notes WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Repairs 12.1 Replacing the membrane WARNING! Observe the safety instructions at the beginning of the chapter. 1. Flush the suction line, discharge lines and liquid end (activate flushing equipment or immerse suction lance in a suitable medium and pump for a while (consider the effect of the medium on your system first!)) or proceed, as described below. 2. Set the stroke length to 0 % stroke with the pump running. 3. Switch off the pump. 4. Secure the pump to prevent it being switched back on. 5.
Repairs 1 2 P_MA_0039_SW 3 4 Fig. 19: Cross-section through the diaphragm rupture warning system 1 2 3 4 5 Safety piston Spring Bushing O-ring Expandable point multi-layer diaphragm 8. Undo the safety screw and remove the protective cover (5) from the backplate (6). 9. Unscrew the diaphragm rupture signaller from the dosing head. 10. Unscrew the bushing (3) from the dosing head. 11. Take the safety piston (1) with the spring (2) out of the dosing head. 12.
Repairs – – 12.2 Check the tightening torque of the screws after 24-hours' operation. With PP dosing heads, recheck the tightening torque again after three months. Repair the diaphragm rupture sensor 12.2.1 30 V version 30 V version Check diaphragm rupture sensor 1 2 1. When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head. 2. Check for electrical continuity: 3. Using a blunt insulating probe (Ø 2 ...
Repairs 12.2.2 EX Version EX Version Check diaphragm rupture sensor 1 2 1. When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head. 2. Check that the monitor does not indicate a diaphragm rupture: 3. Using a blunt insulating probe (Ø 2 ... 3 mm, no sharp edges), press into the channel of the diaphragm rupture sensor. 3 3a 4 5 6 ð The monitor device must indicate a diaphragm rupture. 4. Release the pin again.
Repairs 12.3 Valve repair Unsuitable spare parts for the valves may lead to problems for the pumps. – – Only use new components that are especially adapted to fit your valve (both in terms of shape and chemical resistance). Use the correct spare part kits. In case of doubt, refer to the exploded views and ordering information contained in the "Supplementary information CD for ProMinent® pump operating instructions".
Repairs 1. Slide into the valve body (1) one after another: n n n n n n n 1 2 3 4 * n n 5 2.
Repairs 1 2 3 4 5 1 2 Seal Valve body Valve ball Valve seat Valve cap 3 4 5 P_MAK_0054_SW Fig. 23: Cross-section through the single ball valve 12.3.3 Plate valves Do not scratch the finely machined sealing surfaces on the valve plates (5) and valve inserts (6). 1 2 1 2 3 4 5 Compression spring Valve body Valve plate Valve insert Valve body bushing 3 4 5 P_MA_0040_SW Fig. 24: Cross-section through the plate valve 1. Screw the valve cap (7) on to the suction side - see Fig. 24. 2.
Repairs 6. Place the compression spring (3) inside the valve body (4). V Position the compression spring with the end (see figure: arrow N, at the bottom) as shown on one of the lugs in the valve body. Otherwise the valve plate may knock when in opera‐ tion. 7. Insert the valve plate (5) and the valve insert (6). 8. Screw on the valve cap (7). Pay attention to the flow direction of the discharge and suc‐ tion connectors when fitting the valve. N P_MAK_0056_SW Fig.
Troubleshooting 13 Troubleshooting Safety notes WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. WARNING! Fire danger Only with combustible media: These may start to burn when combined with oxygen.
Troubleshooting WARNING! Risk of injury from the fan impeller The fan impeller beneath motor's fan cowling can cause severe injuries while it is turning. – The pump must only be connected to the mains voltage with the fan cowling closed. 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.
Decommissioning and disposal 14 14.1 Decommissioning and disposal Decommissioning WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Decommissioning and 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. – – 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.
Decommissioning and disposal 14.2 Disposal Personnel: n Technical personnel CAUTION! Environmental hazard due to gear oil The pump contains gear oil, which can cause damage to the environment. – – Drain the gear oil from the pump.
Technical data 15 Technical data Only for "M - modified" version: WARNING! Risk of personal injuries Please observe the ”Supplement for modified version“ at the end of the chapter! It replaces and supplements the technical data! 15.
Technical data Main pumps with motor 1800 rpm under 60 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate Suction lift Connector size Shipping weight* psi l/h gph Strokes/min m WS G-DN kg 120260 174 309 81.8 86 4 1 1/2 - 25 46/54 120340 174 414 109.5 115 4 1 1/2 - 25 46/54 120430 174 518 137 144 4 1 1/2 - 25 46/54 120510 174 622 164.5 173 4 1 1/2 - 25 46/54 120650 174 – – – 4 1 1/2 - 25 46/54 70430 100 511 135 86 3.
Technical data * at maximum stroke length and maximum back pressure 15.3 Viscosity The liquid ends are generally suitable for the following viscosity ranges: Version Range no valve springs Unit 0 ... 200 mPas with valve springs 200 ... 500 mPas with appropriately laid out installation with appropriately laid out installation and advice from ProMinent 500 ... 1000 mPas > 1000 mPas * Only when the installation is correctly adjusted 15.
Technical data 15.5 15.5.1 Ambient conditions Temperatures Pump, compl. PC liquid end Data Value Unit Storage and transport temperature -10 ... +50 °C Ambient temperature in operation (drive + motor): -10 ... +40 °C Data Max. temperature long-term at max. oper‐ ating pressure 45 °C Max. temperature for 15 min at max. 2 bar 60 °C Minimum temperature PP liquid end TT liquid end SST liquid end 15.5.2 Value Unit Data -10 °C Value Unit Max. temperature long-term at max.
Technical data 15.6 Housing degree of protection Data Value Protection against contact and humidity* IP 55 *according to DIN VDE 470 (EN IEC 60529) 15.7 Stroke sensor (option), intrinsically safe Stroke sensor (option), intrinsically safe Install the sensor according to the chapter "Installation, elec‐ trical". Namur sensor (Specified for EX zones) 5–25 V DC, in accordance with Namur or DIN 19234, potential-free design.
Technical data – – Namur sensor (Specified for EX zones) For safety reasons we recommend connecting to a pro‐ tective low voltage, e.g. in accordance with EN 60335-1 (SELV ). The cable can be poled as required. 5–25 V DC, in accordance with Namur or DIN 19234, potential-free design. Data Value Unit Rated voltage * 8 VDC Power consumption - active surface uncovered > 3 mA Power consumption - active surface cov‐ ered < 1 mA Rated switching distance 1.
Technical data Identity code specification Phase, protection Rated voltage Mains supply fre‐ quency Rated output Remarks V0 1 ph, IP 55 400 V ±10 % 50/60 Hz 1.1 kW Variable speed motor with inte‐ grated frequency converter V2 3 ph, II2GEEX‐ dIICT4 400 V ±10 % 50/60 Hz 1.5 kW EX variable speed motor with integrated fre‐ quency converter. Motor data sheets can be requested for more information. 15.10 Filling volumes 15.10.
Technical data Spare parts With a modified version, it is absolutely necessary to specify the details of the serial number requesting and ordering the spare and replacement parts.
Motor data sheet 16 Motor data sheet Motor Datenblatt / Motor data sheet / Fiche technique pour moteur Bestell Nr. order no. / no. de commade 1039212 ATB Mat.Nr. 570330 Leistungsfaktor 0,77 motor type power factor 0,78 type du moteur facteur de puissance Motor- Typ NF80/4H-13+E2 Hersteller producer / producteur Wirkungsgrad 73% type of machine efficiency 76% désignation rendement Maschinenart 3-Ph.
EC Declaration of Conformity 17 EC Declaration of Conformity For pumps without explosion protection: - 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.
EC Declaration of Conformity For pumps with explosion protection: The EC Declaration of Conformity for pumps for potentially explosive atmospheres is enclosed with the pump. The EC Declaration of Conformity, the EC type-test reports and the oper‐ ating instructions for the individual components are also enclosed with the pump.
Index 18 Index A Modified......................................................................... 56 Accuracy....................................................................... 51 motor....................................................................... 26, 56 Air humidity................................................................... 53 Motor data sheet........................................................... 58 Ambient conditions......................................................