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8-1000-282EV Rev. 01


8-1000-282Ev rev. 1

Operating Instructions Manual ProMinent? gamma/ L Solenoid Dosing Pump

GALA

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Please enter ident code of the device here

Please read the operating instructions through completely before commissioning this equipment! Do not discard! Any part which has been subject to misuse is excluded from the warranty!

Part No. 987604

ProMinent Dosiertechnik GmbH ? 69123 Heidelberg ? Germany

BA G 021 11/02 GB

ProMinent

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Printing

Printing: Operating Instructions ProMinent? gamma/ L ? ProMinent Dosiertechnik GmbH, 1999

Address: ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 69123 Heidelberg Postfach 101760 69007 Heidelberg Germany info@prominent.de www.prominent.de

Subject to technical alteration.

Please fold out this page!

ProMinent?

Control elements and key functions

Control elements: overview 8 9 10
1 2 3 4 5 6 7 8 9 10 LCD display Stroke length adjusting knob UP key P key DOWN key STOP/START key i key Fault indicator (red) Warning indicator (yellow) Operating indicator (green)

1 2 3 4 7 6 5

11 “Dosing monitor” terminal 12 “External control” terminal 13 “Float switch” terminal

11

12

13

Key functions
In continuous display mode (operating) STOP/START key
STOP
START

In settings mode (settings)

Press briefly

Stop pump, start pump

Stop pump, start pump

P key

P
Press briefly Press for Press for Press for Press for i key 2s 3s 10 s 15 s Start batch (in “batch” operating mode only), Cancel error Change to settings mode --Display software version Load factory settings (calibration) Confirm entry- jump to next menu option or continuous display --Jump to continuous display -----

i
Press x1 Press x2 Arrow keys UP and DOWN Toggle between continuous displays --Toggle between “change individual digits” and change a figure" For “change individual digits”: jumps to first digit

Press x1 (until “Set” appears) Press simultaneously

Change directly alterable values Prime

Select other settings, change individual digit or figure ---

ProMinent?

Operating-/Settings Diagram
Continuous display
Start/stop pump
STOP
START

1 = Lock (CODE 1) 2 = Lock (CODE 2)

2

Change directly alterable values

Prime Start batch (in"batch" operating mode only) Cancel error Check adjustable values

P P

i
Analog

p. 27
P
2s

mode mode mode mode
Batch Contact Manual

1
Analog Manual Contact Batch

mode
p. 16

P

P

no e n code
p. 23
P

P

code1 code2

P

0 9
Analog
Set

P

0 9

P

0 9

P

0 9

P

o 20 4 20

mA

P

set

P
Set

a alg n
p. 16

P

Analog
Set

Analog
mA Set

----P

Analog
Set

curve

P

Analog
Set

Analog
Set

Analog
Set

i10

Analog
mA Set

P
mA Set

i1 0 i1 9

Analog
mA Set

P
mA Set

i1 0 i1 9

mA

P
mA

Analog
Set

i11

Analog

Analog

Analog
Set

f10 f11 i20 i22

Analog
Freq. Set

P
Freq. Set

f1 0 f1 9 i2 0 i2 9

Analog
Freq. Set

P
Freq. Set

f1 0 f1 9 i2 0 i2 9

Freq.

P
Freq.

Analog
Set

Analog

Analog

Analog
Set

Analog
mA Set

Analog
mA Set

mA

P
mA Set

P
mA Set

P
mA

Analog
Set

Analog

Analog

Analog
Set

f20 f21

Analog
Freq. Set

P
Freq. Set

f2 0 f2 9

Analog
Freq. Set

P
Freq. Set

f2 0 f2 9

Analog
Freq. Set

P
Freq. Set

eroff er o n

P

Analog
Set

Analog

Analog

Analog

Mem Set

Set

c tct n
p. 19

P
Mem Set

off o n 0 9

Contact

P

Contact

Mem Set

Contact

Mem Set

P
Contact
Mem Set

0

Contact

Mem Set

P
Mem Set

0

Contact

Mem Set

Contact

P
Mem Set

0

P

Mem Set

9

Contact

9 0 9 0 9

Contact

Contact

9
Batch

Mem Set

0 6

Batch
Mem

Batch
Mem

*

Set

*

Set

P
Batch
Mem

P
Batch
Mem

0 9 0 9

*

P
Batch

Mem Set

*

Set

*

Set

*

Batch
Mem

Batch

Mem Set

*

Set

*

P
Batch
Mem

P
Batch

Mem

Mem Set

Set

batch
p. 20

P
Mem Set

off o n

Batch

Set

*

Set

*

P
Batch

i
Mem Set

00001 15420

Batch
L

P
Batch
L

Mem Set

Calib Set

off o n

P

Set

cal ib
p. 21

P
Calib Set Calib Set

P

Calib Set

start

P
Calib Set

0 200 0 9 u it n u it n

N

P
N

Calib Set

0 6 0 9 p 1 p4
Aux

Calib L Set

P
Calib L Set

0 9 0 9

Calib L Set

L

P
Calib L Set

P
L

Calib Set

Calib Set

Calib L Set

L

Set

L

P
Calib L Set

P
L Set

P
gal

Calib Set

Set

Set

press
p. 22

P
Set

P

Aux
Freq. Set

Aux
Freq. Set

Set

Set

aux
p. 22

P
Set

0
Aux

P
Freq. Set

0
Aux

P
Aux
Freq. Set

0 9

Freq.

P
Freq.

1

9

Flow Set

off o n

P

Set

flow
p. 23

P
Flow Set

Flow Set

P
Flow Set

0 1

Flow Set

P
Flow Set

0 9

Flow Set

P
Flow Set

0 9

P

clear
p. 23

N L

P

Continuous display
Operating mode "Manual" Operating mode "Contact" with memory and tansfer factor 5
Stop Contact
Freq.

Continuous display

Operating mode "Analog" 0-20 mA

Operating mode "Batch" with memory and tansfer factor 5
Stop Batch
Freq.

Stop Analog Stop Manual
Freq.

Stroke rate

&
i
Stop Manual
L /h

Freq.

&
i i

&

&

i

Feed rate

Stop Analog

%#
i
Stop Manual Contact
N N

L /h

%#
Stop Stop

i

Total stroke number

Stop Analog

Batch
N

!#$
i
Stop Manual Contact
L L

N

!#$
i
Stop

!#$
i

!#$
i
Stop

i

Stop Analog

Batch
L

Total litres (feed quantity)

 !$&
i
Stop
Mem

L

 !$& ANJ
Contact

 !$&
i

 !$&
i
Stop
Mem

i

"External" display

Stop Analog

ANJ

ANJ
i

Batch

i

Signal current

Stop Analog



mA

i
Stop
Mem

Strokes remaining

Batch

#
i
Stop
Mem

*N

Batch
L

Batch size/ Litres remaining


i
Stop
Mem

*

Factor

Contact

#
i
Stop Manual Stop
%

*

Stop Contact

Stop Analog

Batch

Stroke length

$#
i

%

$#

i

$#

%

i

$#
"Mem" appears only when "memory" function activated

%

i

= UP and/or DOWN arrow keys, directly alterable values

Table of Contents

Table of Contents
Identcode General User Important 1 About This Pump ......................................................................................................................................................................... 2 Safety .................................................................................................................................................................................................... 3 Storage, Transport and Unpacking ............................................................................................................................ 4 Device Overview and Control elements ................................................................................................................ 4.1 4.2 Device overview ................................................................................................................................................................ Control elements ............................................................................................................................................................. 1 1 2 2 2 3 3 6 6 6 6 8 9

5 Function Description ............................................................................................................................................................... 6 Assembly and Installation ................................................................................................................................................... 6.1 6.2 Assembling dosing pump ........................................................................................................................................ Assembling tubing ........................................................................................................................................................ 6.2.1 6.2.2 6.3 6.4 Installation for non-self bleeding pumps ................................................................................. Installation of self-bleeding pumps ..............................................................................................

Electrical Installation ....................................................................................................................................................

Retrofitting relays ........................................................................................................................................................... 12

7 Settings ............................................................................................................................................................................................... 14 7.1 7.2 7.3 7.4 Check adjustable values ............................................................................................................................................ 15 Change to settings mode ......................................................................................................................................... 15 Select operating mode (MODE menu) ............................................................................................................. 16 Settings for operating mode (SET menu) .................................................................................................... 16 7.4.1 7.4.2 7.4.3 7.4.4 7.5 7.5.1 7.5.2 7.5.3 7.5.4 7.6 7.7 Settings for “manual” operating mode ....................................................................................... 16 Settings for “analogue” operating mode (ANALG menu) ............................................ 16 Settings for “contact” operating mode (CONTCT menu) ............................................ 18 Settings for “batch” operating mode (BATCH menu) ..................................................... 20 Settings for “calibration” function (CALIB menu) ............................................................. 21 Settings for the “pressure levels” function (PRESS menu) ........................................ 22 Settings for “auxiliary frequency” function (AUX menu) .............................................. 22 Settings for the “flow” function (FLOW menu) .................................................................... 23

Settings for programmable functions (SET menu) ............................................................................... 21

Setting code (CODE menu) ..................................................................................................................................... 23 Cancel total stroke number or total litres (CLEAR window) ......................................................... 23

8 Commissioning ............................................................................................................................................................................. 24 8.1 8.2 Precision dosing settings ........................................................................................................................................ 25 Diagrams for setting feed capacity
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9 Operating ........................................................................................................................................................................................... 26 9.1 9.2 Manual operation ............................................................................................................................................................ 26 Remote control ................................................................................................................................................................. 27

10 Maintenance ................................................................................................................................................................................... 28 11 Repairs ................................................................................................................................................................................................ 28 12 Troubleshooting
...........................................................................................................................................................................

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13 Decommissioning and Disposal ................................................................................................................................... 35

ProMinent?

Table of Contents

14 Technical Data .............................................................................................................................................................................. 36 14.1 Performance data and weights ............................................................................................................................ 36 14.2 Dosing reproducibility ................................................................................................................................................. 37 14.3 Viscosity ................................................................................................................................................................................. 37 14.4 Materials Data for Liquid ends ............................................................................................................................. 37 14.5 Electrical Data ..................................................................................................................................................................... 37 14.6 Ambient conditions ...................................................................................................................................................... 38 14.7 Enclosure rating and safety class ...................................................................................................................... 38 14.8 Compatibility ...................................................................................................................................................................... 38 15 Accessories ..................................................................................................................................................................................... 39 Appendix ............................................................................................................................................................................................. 40 gamma/ L Dimensions .............................................................................................................................................................. 40 Exploded diagrams of liquid ends ................................................................................................................................... 44 Feed rate settings diagrams ................................................................................................................................................. 62 EC Declaration of Conformity ............................................................................................................................................ 68 Customer Specification Form ............................................................................................................................................. 69 Guarantee Form ............................................................................................................................................................................. 70 Safety Declaration Form .......................................................................................................................................................... 71

ProMinent?

Identcode
Identcode
Please enter the identity code on the device label into the grey box below

GALA

Series gamma/ L, version a
Type 1000 1601 1602 1005 0708 0413 0220 1605 1008 0713 0420 0232 Capacity bar l/h 10 0.74 16 1.1 16 2.1 10 4.4 7 7.1 4 12.3 2 19.0 16 4.1 10 6.8 7 11.0 4 17.1 2 32.0

Solenoid ? 70/M70

Solenoid ? 85/M85

Material version: PPE Polypropylene/EPDM PPB Polypropylene/FPM (Viton?) PCE PVC/EPDM PCB PVC/FPM (Viton?) NPE Acrylic glass/EPDM NPB Acrylic glass/FPM (Viton?) PVT PVDF/PTFE TTT PTFE/PTFE SST Stainless steel 1.4571/PTFE Liquid end version: 0 Non-bleed, no valve spring, for NP, TT and SS only 1 Non-bleed, with valve spring, for NP, TT and SS only 2 Bleed function, no valve spring for PP, PC, NP, not type 0232 3 Bleed function, no valve spring for PP, PC, NP, not type 0232 4 No-vent with valve springs for highly viscous media 9 Self bleed function, for PP, NP, not for type 1000 and 0232 Hydraulic connection: 0 Standard connector as indicated in technical data 5 12/6 hose connector, pressure side only 9 10/4 hose connector, pressure side only Version: 0 With ProMinent? logo Power supply: U 100 - 230 V, ±10 %, 50/60 Hz M 12...24 V DC (only M 70) N 24 V DC (only M 85) P 24 V AC Cabel and plug: A 2 m Euro B 2 m Swiss C 2 m Australian D 2 m USA 1 2 m open end Relay: 0 No relay 1 Fault indicating relay, (N/C) changeover relay 3 Fault indicating relay, (N/O) changeover relay 4 As 1 + pacing relay, (1 input each) 5 As 3 + pacing relay, (1 input each) Accessories: 0 No accessories 1 Foot and dosing valve,, 2 m PVC suction tube, 5 m PE discharge tubing, PP, PC, and NP only 2 As 0 + calibrating cylinder 3 As 1 + calibrating cylinder Control variants: 0 Manual + external 1:1 1 Manual + external with pulse control 2 Manual + external 1:1 with analogue current 3 Manual + external with pulse control + analogue current 4 as 0 + timer 5 as 3 + timer P as 3 + Profibus? Access code: 0 No access code 1 Access code Dosing monitoring: 0 Pulse input 1 Input for continuous contact Pause/level: 0 Pause N/C level N/C
Viton? (FPM) is a registered trademark of DuPont Dow Elastomers.

GALA

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ProMinent?

General User Guidelines

General User Guidelines
Please read through the following user Guidelines. Familiarity with these points ensures optimum use of the operating instructions. On the fold-out page after the title page you will find the overviews “control elements and key functions” and “operating/settings diagrams”. You will find it useful to open out the “control elements and key functions” overview as you read this instructions manual. Key points in the text are indicated as follows: ? S Enumerated points Hints

Working Guidelines:

Important Guidelines are intended to make your work easier.
Safety Guidelines:

Warning
Describes a potentially dangerous situation. Could result in loss of life or serious injury if preventative measures are not taken.

Caution
Describes a potentially dangerous situation. Could result in lesser injuries or damage to property if preventative measures are not taken.

Notice
Describes a potentially threatening situation. Could result in damage to property if preventative measures are not taken.

The name plate affixed to the title page is identical to that on the gamma/ L pump supplied. This facilitates matching the correct operating instructions manual to the correct pump. Please quote the identity code and the serial number, which you will find on the name plate, in any subsequent correspondence or when ordering spare parts. This will ensure accurate identification of the pump type and material version.

ProMinent?

About this pump / Safety

1

About This Pump

The pumps in the ProMinent? gamma/ L pump series are microprocessor controlled solenoid dosing pumps with the following special features: ? The feed rate can be displayed in l/h and/or gal/h (calibrated), or in strokes/min. ? The stroke rate is continuously adjustable and is displayed in the LCD display. ? Stroke rate adjustment is digitally accurate and is displayed in the LCD display. ? The rated pressure of the gamma/ L can be adapted to individual systems. ? Two pumps can be controlled in different ways via the same standard signal. ? Large, illuminated LCD display The hydraulic parts of the gamma/ L are identical to those of the Beta ?.

2
Correct use

Safety

The gamma/ L must be used for liquids only! The gamma/ L may be used only in compliance with the technical data and specifications given in the operating instructions! It is forbidden to use the gamma/ L for any other purpose, or to modify it in any way! The gamma/ L is not suitable for dosing gases or solids! The gamma/ L must be used by trained and authorised personnel only!

Safety Guidelines

WARNING ?
As soon as the gamma/ L is connected to the electricity supply it may commence pumping! Avoid leakage of hazardous chemicals in this case! If this should occur, then press the STOP/START key or disconnect the gamma/ L from the power supply immediately! The gamma/ L cannot be switched to a current-free status! In the event of an electrical accident, disconnect cable from the mains power supply! Disconnect cable from the mains power supply before commencing work on the gamma/ L! Always depressurise liquid end before commencing work on the gamma/ L! Empty and rinse out the liquid end before commencing work on the gamma/ L after use with hazardous or unknown chemicals! Pumps for radioactive materials may not be returned to ProMinent after use!

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CAUTION ?
It is not permitted to assemble and install ProMinent? dosing pumps with non-original parts unless these have been checked and recommended by ProMinent. It can result in harm to persons and property for which no liability will be accepted! When dosing aggressive materials, check the resistance of the pump materials (see ProMinent? resistance list in the product catalogue!) If another liquid end size is installed the pump must be reprogrammed on factory premises! Observe applicable national directives during installation!

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Sound intensity level

The sound intensity level is < 70 dB (A) at maximum stroke, maximum stroke rate, maximum back pressure (water) in accordance with: DIN EN ISO 3744 (Reproducibility 2 Determining Sound Intensity Level) PR DIN EN 12639 (Metering Pump Noise Measurement) DIN 45635-24 (Machine Noise Measurement)

ProMinent?

Page 1

Storage, Transport and Unpacking / Device Overview and Control elements

3

Storage, Transport and Unpacking

Transport and store the gamma/ L in the original packaging! Protect the packed gamma/ L from moisture and the effects of chemicals! Environmental conditions for storage and transport: Storage and transport temperature: -10 bis +50 °C Humidity: < 92 % relative humidity Check that the delivery is complete: Delivery range ? ? ? Dosing pump with mains lead Operating instructions manual with EU conformity declaration Accessories if applicable

4

Device Overview and Control elements

When reading this section it is helpful to fold out the overview “Control elements and key functions”!

4.1

Device overview

1

2

3

1 2 3

Control unit Power end Liquid end

Fig. 01

3.1 a d b f g c

3.2 a e b d c

a b c d e f g

Backplate Liquid end Suction valve Discharge valve Bleed valve Coarse/fine bleed valve Bypass hose nozzle

Fig. 02

Fig. 03

Page 2

ProMinent?

Device Overview and Control elements / Function Description

4.2

Control elements

Please acquaint yourself with the gamma/ L control elements with the help of the “control elements and key functions” overview! Indicators The LCD display supports the operation and setting of the gamma/ L with a range of indicators:

Stop Aux Pause Error Auto
Mem Calib Flow Set

The indicators are interpreted as follows: Symbol for P key: Close symbol: Stop: Pause: Aux: Error: Auto: The gamma/ L is in settings mode. In a continuous display: lock (if code has been set). In settings mode: indicates access to code menu. The gamma/ L has been stopped using the STOP/START key. The gamma/ L has been stopped using the “pause” function (external). The gamma/ L is pumping at the auxiliary frequency. In AUX menu: the gamma/ L is in the AUX menu. A fault has occurred and the pump has been stopped. The gamma/ L is in “Auto“ operating mode. Depending on the Identcode this means that the gamma/ L can be controlled using PROFIBUS? or the timer (as a comparison see the relevant supplementary instructions). An additional “memory” function has been set in the “contact” and “batch” operating modes. In CNTCT or BATCH menus (“mem” flashes): the memory function can be set The gamma/ L is in the CALIB menu. In a continuous display (“calib” flashes”): Deviation in stroke length of more than 10 degrees (e.g. a stroke length of 40 % when set at less than 30 % or greater than 50 %) from the value at the time of calibration. The gamma/ L is in the FLOW menu. The gamma/ L is in the SET menu. The number of strokes reached is above the maximum value (99999) that can be shown in the LCD display

Mem:

Calib:

Flow: Set: Command symbol:

IMPORTANT
The pump gamma/ L only displays the metering output in l or l/h or in gal or gal/h when calibrated.

5
Function principle

Function Description

Dosing takes place as follows: the dosing diaphragm is forced into the liquid end; the pressure in the liquid end causes the suction valve to close and the chemical flows out of the liquid end through the discharge valve. The dosing diaphragm is then forced back out of the liquid end. The vacuum in the liquid end causes the discharge valve to close and fresh chemical flows into the suction valve in the liquid end. This concludes one operating cycle. The dosing diaphragm is driven by an electronically controlled electrical solenoid.

Feed rate

The feed rate is determined by the stroke length and the stroke rate. The stroke length is set between 0 - 100 % using the stroke length adjusting knob. Optimum dosing reproducibility is achieved by setting the stroke length to between 30 - 100 % (SEK type: 50 - 100 %)! The stroke rate is set using the arrow keys (not in “analogue” operating mode) to between 0 - 180 strokes/min.

ProMinent?

Page 3

Function Description

Self-bleed function

Pumps with self-bleed function (= SEK types) can operate a prime action even when the discharge tubing is closed, discharging existing air through a bypass valve. These pumps can release gas even during operation, irrespective of the actual operating pressure. An in-built pressure maintenance valve allows accurate dosing even in depressurised states. Operating modes are selected using the MODE menu (depending upon identity code, some operating modes may be absent). “Analog” operating mode: (Identity code, control variant: analogue current) The stroke rate is controlled via an analogue electrical signal via the “external control” terminal. Signal processing is pre-selected at the controller. “Manual” operating mode: (Identity code, control variant: manual, standard function) The stroke rate is controlled manually via the controller. “Contact” operating mode: (Identity code, control variant: external 1:1 / external with pulse control) This operating mode offers the opportunity to make fine adjustments with small increase/ decrease factors. Dosing can be activated by a pulse via the “external control” terminal or by a semiconductor element. With the “pulse control” option it is possible to pre-set a feed quantity (batch) or number of strokes (factor 0.01 to 99.99) via the control unit. “Batch” operating function: (identity code, control variant, external 1:1 / external with pulse control) This operating mode offers the option of working with larger transfer factors (up to 65535). Metering can be triggered by pressing the P key or a pulse from the “external control” terminal via a contact or semiconductor element. A batching quantity or number of strokes can be preselected via the control unit. Operating mode ?PROFIBUS?“: (ident code, control variant: profibus?) This operating mode offers the possibility to control the pump via PROFIBUS? (see “supplemental instructions for ProMinent gamma/ L and ProMinent Sigma versions with “PROFIBUS?”).

.

Operating modes

Functions

The following functions can be selected using the SET menu: “Calibrate” function: The gamma/ L can be operated in all operating modes including in calibrating mode. The corresponding continuous displays can show the actual feed quantity or the feed rate. Calibration is maintained within the stroke frequency range 0 - 180 strokes/min. Calibration is also maintained when a stroke frequency is altered up to ±10 %. “Pressure level” function: It is possible to set different pressure levels. “Auxiliary frequency” function: It is possible to set a stroke rate in the SET menu, which may be activated via the “external control” terminal. This auxiliary frequency overrides all other pre-set stroke rate frequencies. “Flow” function: Stops the gamma/ L when the flow is insufficient. In the SET menu, the number of failed strokes is entered after which the pump will be turned off. The following functions are available as standard: “Float switch” function: Information on the liquid level in the feed chemical container is transmitted to the gamma/ L. This option requires the installation of a 2-stage float switch. This is connected to the “float switch” terminal. “Pause” function: The gamma/ L can be stopped by remote control via the “external control” terminal. The “pause” function operates only via the “external control” terminal.

Page 4

ProMinent?

Function Description

The following functions are activated by keystrokes: “Stop” function: The gamma/ L can be stopped by pressing the STOP/START key without disconnecting from the mains power supply. “Prime” function: Priming (short term feed at maximum frequency) is activated by pressing both arrow keys at the same time (in “Stoke rate” permanent display). Optional relay The gamma/ L has two connection options. “Fault indicating relay” option: In the event of fault signals, warning signals or float switch activation signals, connects an electrical circuit to trigger alarm sirens etc. The relay is retrofitted via an aperture in the power end. “Fault indicating and pacing relay” option: Along with the fault indicating relay, the pacing relay produces a contact for every stroke. The relay is retrofitted via an aperture in the power end. Function and error indicators LCD indicator LED indicator

The operating and error status is shown via the three LEDs and the “error” indicator on the LCD (see also section 12): If a fault occurs “error” will appear along with an additional fault warning. Operating indicator (green) This indicator is lit as long as the gamma/ L is operating correctly. It stops briefly with each stroke. Warning indicator (yellow) This warning light appears if the gamma/ L electronics detect a situation that could lead to a fault, e.g. “liquid levels low 1st stage”. Warning indicator (red) This warning light appears if a fault occurs, e.g. “liquid levels low 2nd stage”.

Hierarchy of operating modes, functions and fault statuses
The different operating modes, functions and fault statuses each have a differing effect on whether and how the gamma/ L functions. These effects are given below: 1. 2. 3. 4. to: 1. 2. 3. “Prime” can take place in the permanent “Stoke rate” display in any pump mode (as long as it is operational). “Fault”, “stop” and “pause” stop all system parts up to “prime”. The stroke frequency of the “auxiliary frequency“ always has precedence over the stroke frequency, which is set by an operating mode listed under 4. Prime Fault, stop, pause Auxiliary frequency Manual, analogue, contact, batch

ProMinent?

Page 5

Assembly and Installation

6

Assembly and Installation
WARNING ? ?
The gamma/ L series dosing pumps must be commissioned exactly as described in the operating instructions manual! It is not permitted to assemble and install ProMinent? dosing pumps with non-original parts unless these have been checked and recommended by ProMinent. Always depressurise tubing before working on the dosing pump. Empty and rinse out the liquid end! Never allow the dosing pump to operate when an discharge tube stop tap is closed! It may burst! Remove all water from liquid end before commissioning or rinse with a suitable cleaning agent if using chemicals that should not come into contact with water! Before unscrewing the control unit disconnect the mains lead from the power supply! Observe applicable national directives during installation!

? ? ?

? ?

6.1

Assembling dosing pump

NOTICE ? ? ?
Assembling dosing pump The gamma/ L should be fixed in such a way as to prevent vibration! Suction and discharge valve must be upright (bleed valve in self-bleed liquid ends)! Ensure free access for operation and maintenance!

The base of the dosing pump must be mounted on a firm, horizontal surface.

6.2 6.2.1

Assembling tubing Installation for non-self bleeding pumps
CAUTION ? ?
Tubing must be free from stress and kinks when fitted! When dosing extremely aggressive or hazardous chemicals it is advisable to install a bleed valve that feeds back to the container and isolation valves on the prime and discharge sides. In order to ensure connections are fast, use correctly sized clamping rings and nozzle unions! Use only original hoses with specified dimensions and wall-thicknesses! Do not exceed maximum permissible priming pressure (see section 14)! It is imperative that the maximum permissible operating pressure is not exceeded (see section 14 and plant documentation)!

? ? ? ?

IMPORTANT
The tubing should be attached in such a way as to allow lateral detachment of the gamma/ L and the liquid end if necessary!

Page 6

ProMinent?

Assembly and Installation

PP, PC, NP, TT versions

Assembling tubing to plastic valves (see fig. 04) S S S S S S S Cut hose ends straight across Push union nut (2) and clamping ring (3) onto hose (1) Push the hose end (1) over the nozzle (4) to the stop. Widen if necessary Make sure that the O-ring (5) is sitting correctly in the valve (6) Place the hose (1) with the nozzle (4) onto the valve (6) Clamp the hose connector: Tighten the union nut (2) while pressing in the hose (1) Retighten the hose connector: Pull the tubing (1) connected to the liquid end briefly and then retighten the union nut (2) Hose Union nut Clamping ring Nozzle O-ring Valve

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5

1 2 3 4 5

Tube Union nut ring Rear clamping Front clamping ring Valve

Fig. 04

Fig. 05

SS Version

Assembling stainless steel tube connectors to stainless steel valves (see fig. 05) S S S Push union nut (2) and clamping rings (3, 4) onto tube (1) leaving approx. 10 mm distance between them Push tube (1) up to the stop in the valve (5) Tighten union nut (2)

SS Version

Assembling tubing to stainless steel valves

NOTICE
Assemble only PE or PTFE tubing to stainless steel valves! S Insert an additional support (stainless steel) into PE or PTFE tubing

Installing suction tubing

NOTICE
Do not exceed maximum permissible priming pressure on the prime side (see section 14)!

IMPORTANT
? ? ? ? Make suction tubing as short as possible. Suction tubing should be rising in order to prevent air bubbles forming! As far as possible use swept bends for bends rather than right angle bends! Measure the length and cross section to ensure that the vacuum created by the priming action does not reach the vaporising pressure of the feed chemical! In extreme cases excess vacuum on the priming side can cause breaks in the liquid column or incomplete return stroke! Please note: “actual suction lift (in m) x density of the dosing medium (in g/cm?) = max. suction lift” (in m WS)

? Assembly of foot valve S

Cut the free suction end so that the foot valve hangs just above the container base; for chemicals with impurities or sedimentation at the bottom, the foot valve should be positioned well above this layer. Page 7

ProMinent?

Assembly and Installation

Installing pressure tubing

NOTICE ?
The discharge tubing should be laid in such a way as to ensure that the pressure surge of the discharge stroke does not exceed the maximum operating pressure. As overload protection for the discharge tubing, it is advisable to fit a relief valve feeding back into the chemical supply container, e.g. a ProMinent? multifunction valve. Check that the length and cross section of the tubing are correct!

?

6.2.2

Installation of self-bleeding pumps
CAUTION ? ?
Observe all installation and safety guidelines for standard pumps! Do not exceed tubing cross section, priming lift, priming pressure or viscosity of feed chemical!

In addition to the suction and discharge tubing, a bypass tube should be connected. This is attached to the bleed valve on the upper side of the liquid end (red packing, see fig. 06).

IMPORTANT
The discharge valve is located on the front of the liquid end in the SEK type!

Installation of by-pass tubing

IMPORTANT
When the suction side is primed, at least equal pressure must exist in the bypass tubing! The pump can operate when the bypass is primed and the suction side is depressurised. S S S Place the tube onto the bypass nozzle and/or bleed valve of the self-bleed function liquid end (recommended: flexible 6x4 PVC hose) Push the free end of the tube back into the dosing container Cut the bypass tube so that it does not enter the feed chemical.

Bleed valve for the bypass tube to the supply container, 6/4 mm

Discharge valve for discharge tubing to injection point, 6/4 - 12/9 mm

Suction valve for suction tubing in supply container, 6/4 - 12/9 mm

Fig. 06

Page 8

ProMinent?

Assembly and Installation

6.3

Electrical installation

WARNING ?
? ? Installation must be carried out by a trained engineer! Disconnect gamma/ L from mains power supply during installation! Risk of electric shock – This pump is supplied with a grounding conductor and grounding-type attachment plug. To reduce the risk of electric shock, be certain that it is connected only to a properly grounding-type receptacle. Observe applicable national directives when installing the dosing pumps! When connecting with parallel inductive power consumers a switch contact must be fitted, e.g. relay or contactor!

? ?

NOTICE
The universal signal cable, the external/connecting cable and the liquid level monitoring cable should never be shortened to less than 1.20 m, otherwise the cable identification system will fail. Connection to mains power supply Parallel connection to inductive power consumers

Connect the gamma/ L to the mains power supply using the mains lead

If the gamma/ L is connected to the mains in parallel with inductive power consumers (e.g. solenoid valve, motor) they must be electrically isolated. This will avoid damage caused by induction and voltage surges when switching off. S S Fit individual contacts for the gamma/ L and supply power via auxiliary contactor or relay. If this is not possible, then: Connect a varistor in parallel (order number 710912) or an RC circuit, 0.22 ?F/220 ? (order number 710802).

Power element (in base of pump)

2 5
N L1 PE

4 3 1

Fig. 07

1 2 3 4 5

Mains terminal Relay circuit terminal Fuse Solenoid earth lead terminal Solenoid terminal

“External control” terminal

The “external control” terminal is a five pin in-built terminal. It is compatible with the two and four core cables used previously. The “auxiliary frequency” function is only available with a five core cable.

ProMinent?

Page 9

Assembly and Installation

gamma/ L configuration

Electrical interface for “external contact” - “pause” - “auxiliary frequency”: ? ? ? ? ? Voltage when contacts open: Input resistance: Control: or: Maximum pulse frequency: Required pulse duration: approx. 5 V 10 k? voltage free contact (load: 0.5 mA at 5 V), Semiconductor switch (residual voltage < 0.7 V) 25 pulses/s ≥ 20 ms

Electrical interface for “external analogue": ? ? Input load resistance: Maximum current at input: approx. 120 ? 50 mA

gamma/ L configuration

2

1

Pin Pin 1 Pin 2 Pin 3 Pin 4 Pin 5

Function Pause External contact External analogue Earth Auxiliary frequency

2 core cable Jumped at pin 4 Brown – White –

4 core cable Brown White Blue Black –

5 core cable Brown White Blue Black Grey

3 4
Fig. 08

5

Plug configuration “Pause” function

1

2

The gamma/ L is not operating when ? The cable is connected and pins 1 and 4 are free. The gamma/ L is operating when ? The cable is connected and pins 1 and 4 are connected. ? There is no cable connected (pin 1 is free).

3 5
Fig. 09

4

“Contact” und “Batch” operating modes One or more discharge strokes are triggered when pin 2 and pin 4 are connected to one another for at least 20 ms. Otherwise, pin 1 and pin 4 must be connected. “Analogue” operating mode The stroke frequency of the gamma/ L is controlled via an electrical signal. The electrical signal is applied between pins 3 and 4. Otherwise, pin 1 and pin 4 must be connected. “Auxiliary frequency” function The gamma/ L runs at a pre-set stroke rate when pin 5 and pin 4 are connected to one another. Otherwise, pin 1 and pin 4 must be connected. The factory setting for this function is 180 strokes.

IMPORTANT
For function and operating mode hierarchy, see section 5!

Page 10

ProMinent?

Assembly and Installation

Connecting two gamma/ L pumps in series Connect two gamma/ L pumps in series as follows if you wish to control both via one electrical signal in the “analog” operating mode (see section 7.4.2):

+

power source



blue brown black gray white

blue brown black gray white

Fig. 10

“Float switch” terminal gamma/ L configuration

Optional fitting of a 2-stage float switch with prior warning and limit switch capacity.

Electrical interface:

3

? ? ?

Voltage when contacts open: Input resistance: Controller: or:

approx. +5 V 10 k? voltage free contact (load: 0.5 mA at + 5V), semiconductor switch (residual voltage < 0.7 V)

1

2

Fig. 11

Plug configuration Function 3 core cable Earth Minimum prior warning Minimum limit switch black blue brown

3

Pin 1 Pin 2 Pin 3

2

1

Fig. 12

“Dosing monitor” terminal gamma/ L configuration

Optional connection of dosing monitor.

Electrical interface:

2

1

? ? ?

Voltage when contacts open: Input resistance: Controller:

approx. +5 V 10 k? voltage free contact (load: 0.5 mA at +5 V)

3

4

Fig. 13

Plug configuration Function 4 core cable Power supply (5V) Encoding Response Earth brown white blue black

1

2

Pin 1 Pin 2 Pin 3 Pin 4

4

3

Fig. 14

ProMinent?

Page 11

Assembly and Installation

Relay “Fault indicating relay” output A fault indicating relay may be ordered optionally. It is used as the signal output when a pump fault has been detected and to indicate the prior warning signal “liquid level low, stage 1” and the fault signal “liquid level low, stage 2”. Allocation of signal types to “N/O” and “N/C” relay states is selected on the basis of the identity code descriptors. The relay can be retrofitted and is ready to operate after inserting the relay component (see section 6.4). The gamma/ L is delivered ex works with default settings for a N/C relay. If an alternative switch function is required the gamma/ L can be reprogrammed at ProMinent. Electrical interface “Fault indicating relay and pacing relay” output ? ? Contact load: Operating life: 250 V/2 A 50/60 Hz > 200.000 switch cycles

A fault indicating relay and pacing relay output may be ordered optionally. The pacing relay output is electrically isolated via an optical coupler with a semiconductor switch. The second switch is a relay as for the “fault indicating relay” variant. The fault indicating / pacing relay can be retrofitted (see section 6.4). The gamma/ L is delivered ex works with default settings for a N/C fault indicating relay and a N/O pacing relay. If an alternative switch function is required the gamma/ L can be reprogrammed at ProMinent (not necessary for PROFIBUS? or Timer version).

Electrical interface

For semiconductor switch ? ? ? ? Residual voltage: Maximum voltage: Maximum current: Pacing relay pulse duration: < 0,4 Volt at IC = 1 mA < 100 mA 24 V/DC approx. 100 ms

For relay output ? ? Contact load: 24 V/100 mA 50/60 Hz Operating life: > 200.000 switch cycles

Relay cable contact configuration “Fault indicating relay” option VDE cable white green brown “Fault indicating relay and pacing relay” option VDE cable yellow green white brown CSA cable white red black Contact NO (normally open) C (common) NO (normally open) C (common) Contact NO (normally open) NC (normally closed) C (common) Relay Fault indicating relay Fault indicating relay Pacing relay Pacing relay

6.4

Retrofitting relays

Delivery range: 1 1 1 Press-out relay opening relay circuit set with 2 screw fasteners relay cable set with socket seal

WARNING
Disconnect gamma/ L from the mains power supply and rinse liquid end before commencing work (see section 13)!

NOTICE
When preparing the opening, ensure that the punch is not forced through the entire pump base! Pump circuits may become damaged.

Page 12

ProMinent?

Assembly and Installation

S S S S

Place the gamma/ L on a firm surface with the relay opening press-out section at the top (see fig. 15:a) Place a punch (dia. 8-15 mm) in the centre of the relay opening press-out section , and strike briefly and sharply with a hammer (approx. 250 g) If necessary clean up the edges of the opening Remove the pressed out section from the gamma/ L

a

a

Fig. 15

Fig. 16

Inserting the relay component S S

S S S

Hold the relay component with your right hand gripping the left and right hand edges of the relay cover, and tilt the front end slightly to the left (see fig. 17) Push the relay component through the relay opening, holding the upper corner of the lower edge against the guide rail on the pump base, until the contact of the relay component has reached the controller contact. (See fig. 18: test: can you still move the end of the circuit back and forth?) Gently push the relay component right into the opening. Screw the relay cover firmly onto the housing using the screws provided. Insert the relay cable plug seal into the relay cover and screw on the plug (see fig. 19)

The gamma/ L is delivered ex works with default settings for a N/C fault indicating relay and a N/O pacing relay. If an alternative switch function is required the gamma/ L can be reprogrammed at ProMinent (not necessary for PROFIBUS? or Timer version).

b

Fig. 17

Fig. 18

Fig. 19 Page 13

ProMinent?

Settings

7

Settings
IMPORTANT
? Open out the fold-out page following the title page fully! There you will find the overviews “control elements and key functions” and “operating/settings diagram”. If no keys are pressed within a period of 1 minute, the gamma/ L will return to a continuous display.

?

Basic information for setting up the gamma/ L
= Settings option = flashes

Set

FHAII
P
3s

P
Set

F
P
3s

P

continuous display

Confirm entries Exit menu option without confirming

Press the P key briefly; you will automatically move to the next menu option or to a continuous display. Press the P key for 3 s: The entry is cancelled and you will return to a continuous display.

#"!
i
1x

#"!
P

#"!
i
2x

#"!
Incremental change Iof a value Press the i key 1x; you can toggle between altering the digits of a value (“change individual digits” = standard) or incremental alteration of a value (“change a figure”). Press UP or DOWN arrow key; The flashing digit or figure will start to increase or decrease incrementally. For “change individual digits”: confirm each digit using the P key. When the last digit has been confirmed you will automatically move to the next menu option or to a continuous display. For “change a figure”; press the P key 1x; you will simultaneously move to the next menu option or to a continuous display. Correct wrongly set digits Press the i key 2x; you will go back to the first digit. Change adjustable values Confirm adjustable values

Page 14

ProMinent?

Settings

7.1

Check adjustable values

Before setting up the gamma/ L you can check the current settings of adjustable values. Press the i key (“i” as in “info”) when the gamma/ L is in continuous display mode (There is no P key symbol in the LCD display): Each time you press the i key you will see a different continuous display. The number of continuous displays depends upon the identity code, the selected operating mode and the connected accessories (see overview “continuous displays”).

7.2

Change to settings mode

If you hold down the P key for 2 seconds in any continuous display, the gamma/ L will change to the settings mode. If CODE 1 is set, the code must be entered after pressing the P key. The following menu options appear first in the settings mode (see also overview “operating/ settings diagram”): ? ? ? ? MODE menu CODE menu (optional) SET menu CLEAR window

In order to adapt the gamma/ L to your process requirements you must: 1. 2. Select the operating mode in the MODE menu Adjust settings to this operating mode in the SET menu

1. MODE menu

CODE menu Continuous display
2s

P

2. SET menu

CLEAR window

ProMinent?

Page 15

Settings

7.3

Select operating mode (MODE menu)

The following operating modes are selected via the MODE menu (depending upon identity code, some operating modes may be absent): ? ? ? ? Manual: for operation by hand (Identity code, control variant: manual, standard option) Analogue: for electronic control (Identity code, control variant: analogue current) Contact: for contact operation (Identity code, control variant: external 1:1 / external with pulse control) Batch: for batch operation (Identity code, control variant: external with pulse control)

Analog Manual Contact Batch

mode

P

Analog

mode

P

Continuous display

7.4

Settings for operating mode (SET menu)

In the SET menu you can adjust various settings depending upon the selected operating mode. The following programmable function settings menus appear in all operating modes: ? ? ? ? Calibrate (CALIB menu) Pressure levels (PRESS menu) Auxiliary frequency (AUX menu) Flow (FLOW menu, available only if flow monitor is connected)

See also section 7.5! Further settings menus depend upon the selected operating mode.

7.4.1

Settings for “manual” operating mode

There are no other settings menus in the overall SET menu for the “manual” operating mode apart from those described in 7.5.

7.4.2

Settings for “analogue” operating mode (ANALG menu)

In addition to those settings menus described in 7.5, there is an additional ANALG menu in the overall SET menu for the “analogue” operating mode. The stroke rate is controlled by an analogue electrical signal via the “external control” terminal. You can select three signal-processing methods: ? 0 - 20 mA: at 0 mA the gamma/ L does not operate at 20 mA the gamma/ L operates at 180 strokes/min. Between these two extremes the stroke rate is proportional to the electrical signal.

set
Continuous display

P
Set

analg

P

Analog
Set

o 20

mA

P

Page 16

ProMinent?

Settings

?

4 - 20 mA: at 4 mA the gamma/ L does not operate at 20 mA the gamma/ L operates at 180 strokes/min. Between these two extremes the stroke rate is proportional to the electrical signal. For signals of below 3.8 mA a fault will be detected and the gamma/ L will stop (e.g. cable break). Curve: In the “curve” processing mode you can programme the gamma/ L ratios. There are 3 options available: ? ? ? = straight line = lower band = upper band

?

set

P
Set

analg i1o40
mA

P

Analog
Set

curve f1o60 er on
Freq.

P

Analog
Set

P

Analog
Set

P

Analog
Set

P

Analog
Set

i2160

mA

P

Analog
Set

f2120

Freq.

P

Analog
Set

P

Continuous display

Straight line: The following symbol appears in the LCD display: . You can enter any stroke frequency ratio for the gamma/ L in proportion to the electrical signal. You must enter two points P1 (I1, F1) and P2 (I2, F2). F1 is the stroke rate at which the pump should operate at current I1: the straight line and the ratio are fixed accordingly:

Fmax

F2 P1

P2

F1

0

I1

I2

20

I [mA]

Fig. 20

IMPORTANT
Draw a diagram like the one above - with values for (I1, F1) and (I2, F2) - in order to set the gamma/ L to your required stroke rate!

ProMinent?

Page 17

Settings

Lower/upper band: This processing mode allows you to control a pump via an electrical signal as shown in the diagrams below. You may also control two pumps for different feed chemicals from a single signal (e.g. one acid pump and one alkali pump from a pH sensor signal). The pumps must be connected electrically in series (see wiring plan in section 6.3).

Lower band e.g. Alkali pump

Upper band e.g. acid pump

Fmax F1 P1

Fmax F2 P2 P2

F2

F1

P1

0

I1

I2

20

I [mA]

0

I1

I2

20

I [mA]

Fig. 21

Fig. 22

Lower band: appears in the LCD display. The gamma/ L will operate below I1 at F1. The symbol Above I2, the gamma/ L ceases to operate. Between I1 and I2 the stroke rate is between F1 and F2, proportional to the signal current. Upper band: The signal appears in the LCD display. The gamma/ L will cease to operate below I1. Above I2, the gamma/ L will operate at F2. Between I1 and I2 the stroke rate between is F1 and F2, proportional to the signal current. The smallest processable difference between I1 and I2 is 4 mA. Error processing In the “ER” (error) menu option you can activate an error processing function for the “curve” mode. An error message appears for signals below 3.8 mA and the gamma/ L stops.

7.4.3

Settings for “contact” operating mode (CONTCT menu)

In addition to those settings menus described in 7.5, there is an additional CONTCT in the overall SET menu for the “contact” operating mode. The operating mode “contact” allows you to activate a single stroke or a series of strokes. The strokes can be activated by a pulse or via the “external control” terminal. This operating mode is intended to transfer input pulses into a reduction (break) or small increase in strokes.

NOTICE
? When switching to another operating mode the factor is reset to “1”.

The following versions are available: ? ? Contact - identity code: external 1:1 Contact - identity code: external with pulse control

Page 18

ProMinent?

Settings

Contact – identity code: external 1:1 In the “contact - identity code: external 1:1” version the gamma/ L makes precisely 1 stroke per pulse (identity code: external 1:1). No entry possible. Contact – identity code: external with pulse control In the “contact - identity code: external with external pulse control” you can enter the number of pulses after which a stroke should be carried out. “Contact - identity code: external with external pulse control” is intended for small dosing quantities.

set
Continuous display

P
Set

cntct

P

Mem Set

on

Contact

P

Mem Set

0120
Contact

P

The number of strokes per pulse depends upon the factor, which you can enter. This allows you to vary to a certain extent the input pulses by a factor of 1.01 to 99.99 and/or reduce by a factor of 0.01 to 0.99: “Number of strokes activated = factor x number of input pulses” Examples Increase Factor 1 2 25 99,99 1.50 1.25 1 0.50 0.10 0.01 0.25 0.40 0.75 Pulse (sequential) 1 1 1 1 1 1 1 2 10 100 4 2.5 (3 / 2) 1.33 (2 / 1 / 1) Stroke number (sequential) 1 2 25 99,99 1.5 (1 / 2) 1.25 (1 / 1 / 1 / 2) 1 1 1 1 1 (1 / 1) (1 / 1 / 1)

Reduction

Explanation of increase At a factor of 1 At a factor of 2 At a factor of 25 Explanation of decrease At a factor of 1 At a factor of 0.5 At a factor of 0.1 At a factor of 0.75 After 1 pulse, 1 stroke is activated After 2 pulses, 1 stroke is activated After 10 pulses, 1 stroke is activated After 2 pulses, 1 stroke is activated, then after 1 pulse, 1 stroke is activated, then after 2 pulses, 1 stroke is activated etc. For every 1 pulse, 1 stroke is activated For every 1 pulse, 2 strokes are activated For every 1 pulse, 25 strokes are activated

IMPORTANT
If a remainder occurs when the factor is processed, the gamma/ L counts up the remainder values. When the sum reaches or exceeds “1” the gamma/ L will activate a stroke. This ensures that the stroke number corresponds exactly to the factor throughout the dosing operation.

ProMinent?

Page 19

Settings

The number of input pulses which have not been processed are stored by the gamma/ L in the stroke memory. When the STOP/START key is pressed or the “pause” function is activated, the stroke memory is deleted (this can be avoided using the “memory” extension function, see below). The “contact - identity code: external with pulse control” version allows optimum adaptation of the gamma/ L, in conjunction with e.g. water contact meters, to any process. “Memory” extension function The “memory” extension function can be optionally activated (“mem” appears in the LCD display). When “Memory“ is activated, the gamma/ L adds up the unused excess strokes, up to the stroke memory’s maximum capacity of 65535 strokes. If the maximum capacity is exceeded the pump will malfunction.

7.4.4

Settings for “batch” operating mode (BATCH menu)

In addition to those settings menus described in 7.5, there is an additional BATCH menu in the overall SET menu for the “batch” operating mode.

set
Continuous display

P
Set

batch

P

Mem Set

on

Batch

P

Mem Set

15420

Batch
L

P

The “batch” operating mode is a variant of the “contact” operating mode (see 7.4.3). You can pre-select a stroke number (no breaks, whole numbers only from 1 to 65535) as well as a feed quantity (batch). To switch between entries for “stroke number” and “feed quantity” press the i key 1x in the corresponding menu option (see also overview “operating/settings diagram”, fold-out page). The “batch” operating mode is intended for large dosing quantities. Metering is activated by pressing the P key or via a pulse from the "external control" terminal. The number of input pulses which have not been processed are stored by the gamma/ L in the stroke memory. The stroke memory is limited to the batch size if “Memory“ is not activated (with “Memory“ this is 65535 strokes). You can clear it by changing to a different operating mode. “Memory” extension function The “memory” extension function can be optionally activated (“mem” appears in the LCD display). When “Memory“ is activated, the gamma/ L adds up the unused excess strokes, up to the stroke memory’s maximum capacity of 65535 strokes. If the maximum capacity is exceeded the pump will malfunction.

Page 20

ProMinent?

Settings

7.5

Settings for programmable functions (SET menu)

The following programmable function settings menus appear in all operating modes: ? ? ? ? Calibrate (CALIB menu) Pressure levels (PRESS menu) Auxiliary frequency (AUX menu) Flow (FLOW menu, available only if flow monitor is connected)

7.5.1

Settings for “calibration” function (CALIB menu)

set
Daueranzeige

P
Set

cal ib
200
N

P

Calib Set

on
L

P

Calib Set

start un it
L

P

Calib Set

P

Calib Set

04232

P
Set

P

The gamma/ L can also run in calibration mode. The corresponding continuous displays show the current dosing quantities or the feed rate. Calibration is maintained when a stroke rate is altered up to ±10 degrees (where the stroke length is set at 40 %, the range is 30-50 %). If the stroke rate is altered more than ±10 degrees the yellow warning light is lit, the continuous display flashes and the flashing message “calib” appears.

IMPORTANT
? ? Do not go below 30 % stroke length (SEK type: 50 %). This will significantly affect accuracy of calibration. Calibration becomes increasingly accurate the more strokes made by the gamma/ L during calibration (recommended: at least 200 strokes).

WARNING
? If using a hazardous feed chemical, the following setting instructions ensure adequate safety precautions have been taken!

Calibration

S S S S S S

Insert the suction tube into a measuring cylinder containing the feed chemical - the discharge tubing must also be correctly installed (operating pressure, …!) Suck up the feed chemical (press both arrow keys at the same time) when the suction tube is empty Note the liquid level in the measuring cylinder and the stroke length Select the CALIB menu and go the first menu option using the P key Select “ON” using an arrow key and change to the next menu option using the P key To commence calibration, press the P key. The gamma/ L starts to pump and displays the number of strokes (“STOP” appears at regular intervals) (the gamma/ L works at the stroke frequency set under “MANUAL“ ). After a sufficient number of strokes, stop the gamma/ L with the P key Calculate the dosed quantity (difference between the original quantity and the quantity remaining) Enter this quantity in the next menu and then go to the next menu option using the P key Select the unit (“L” or “gal”) in the “UNIT” menu with an arrow key

S S S S

The gamma/ L is calibrated. The corresponding continuous displays show the calibrated values. The total stroke number and total litres are set during calibration to “0”. The gamma/ L is in the STOP state.

ProMinent?

Page 21

Settings

7.5.2

Settings for the “pressure levels” function (PRESS menu)

IAJ
Continuous display

P
Set

FHAII

P
Set

F

P

The programmable function “pressure levels” is used to reduce the rated pressure of the gamma/ L.

CAUTION
? ? ? The rated pressure can be considerably exceeded at stroke lengths of below 100 %! The rated pressure relates to a stroke length of 100 %. If another liquid end size is installed the pump must be reprogrammed on factory premises! Select as large a rated pressure as required and as small as possible! This will increase system safety (reduces the risk of the tubing bursting when blocked)! This also protects the diaphragm and saves electricity.

IMPORTANT
If installing another liquid end size the pump must be reprogrammed on factory premises. The following rated pressures can be selected for these liquid end sizes (rated pressure in bar):

Liquid end size 1601, 1602, 1605 1000, 1005, 1008 0708, 0713

Pressure level 1 4 4 4

Pressure level 2 7 7 7

Pressure level 3 10 10

Pressure level 4 16

No adjustments can be made for pump types 0413, 0420, 0220, 0232.

7.5.3

Settings for “auxiliary frequency” function (AUX menu)

IAJ
Continuous display

P
Set

=KN

P
Set

&#
Aux

Freq.

P

The programmable function “auxiliary frequency” allows switching to a different stroke frequency, which can be set in the AUX menu. It can be activated via the “external control” terminal. When the auxiliary frequency is activated, “aux” appears in the LCD display. This auxiliary frequency overrides the current stroke frequency set for the selected operating mode.

Page 22

ProMinent?

Settings

7.5.4

Settings for the “flow” function (FLOW menu)

set
Continuous display

P
Set

flow

P

Flow Set

on

P

Flow Set

008

P

The flow menu only appears when a dosing monitor is connected to the “dosing monitor” terminal. This dosing monitor registers each discharge stroke of the gamma/ L at the discharge connector and transmits it back to the gamma/ L. If this response transmission is serially omitted for a period set in the FLOW menu (due to failure or below-minimum dosing) the gamma/ L stops.

7.6

Setting code (CODE menu)

The code menu is used to select whether you want to prevent access to parts of the settings options.

code
Continuous display

P

code1

P

5432

P

In the first menu option you can choose CODE 1 or CODE 2 (both use the same number). ? Select CODE 1 to prevent access to the settings mode (? in the overview “operating/ settings diagram”, fold-out page). In the next menu option, enter the number you wish to use as the code. Select CODE 2 to prevent access to the settings options for directly alterable values in the continuous displays (? in the overview “operating/settings diagram”, fold-out page). In the next menu option, enter the number you wish to use as the code. Select NONE to remove a pre-set security lock.

?

?

7.7

Cancel total stroke number or total litres (CLEAR window)

In the CLEAR window you can delete the stored total stroke number and simultaneously the total litres (= set to “0”). You may then press the P key briefly to exit this window. The values displayed are counted incrementally from the point of commissioning the pump, or from the last delete action.

clear
Continuous display

N L

P

ProMinent?

Page 23

Commissioning

8

Commissioning
WARNING ? ?
Protect yourself from contact with hazardous feed chemicals! Remove all water from liquid end before commissioning or rinse out with a suitable material if using chemicals that should not come into contact with water! (Proceed as described below. The liquid end may contain water left over from factory testing.) After long periods out of commission the gamma/ L is not guaranteed to meter absolutely reliably, as feed chemicals in the valves and diaphragm can crystallise! Check valves and diaphragm regularly (see section 10)! Check the seals of the pump connections and connectors. Check whether coarse or fine bleed vent is closed (see also fine bleed function).

?

? ?

IMPORTANT
? ? Set stroke length only while pump is running! The gamma/ L should prime at 100 % stroke length as the suction lift is dependent upon lift volume when the liquid end is empty. If the gamma/ L is required to prime at less than 100 % stroke length, and fails to do so, then select a correspondingly smaller suction lift. SEK type: priming capacity is diminished if discharge takes place against pressure! Retighten screws in liquid end after 24 hours (see section 10)!

? ? Removing water from liquid end

When using with chemicals that should not come into contact with water: S S S Turn the pump so that the discharge connector is pointing downwards. Allow water to run out of the liquid end. Rinse the suction connector from above with a suitable material.

Filling liquid end

WARNING
Protect yourself from contact with hazardous feed chemicals! For liquid ends without coarse/fine bleed function: S S Connect suction tubing, but not discharge tubing, to liquid end Switch on the gamma/ L and allow to run at maximum stroke length and stroke rate, until the liquid end is full and free from air bubbles (a little feed chemical will seep out of the discharge valve) Switch off the gamma/ L Connect discharge tubing to liquid end

S S

The gamma/ L is ready to operate. For liquid ends with coarse/fine bleed function: S S S S Connect suction and discharge tubing to liquid end Connect bypass tubing Open the bleed valve by rotating the knob on the top anticlockwise. Opens access to the bypass tubing for coarse bleed function. Switch on the gamma/ L and allow to run at maximum stroke length and stroke rate, until the liquid end is full and free from air bubbles (the feed chemical is visible in the bypass and discharge tubing) Close the bleed valve (turn clockwise) Switch off the gamma/ L

S S

The gamma/ L is ready to operate.

Page 24

ProMinent?

Commissioning

IMPORTANT
? For gaseous chemicals there must be a continuous partial flow back to the supply container. The return flow quantity should be approx. 20 % of the feed quantity. The feed chemicals should be non-viscous and free from suspended particles. The bypass tubing should end above the liquid level in the supply container. The fine bleed valve then acts as a vacuum breaker which prevents the possibility of a vacuum in the discharge tubing causing the container to be emptied.

? ?

Fine bleed function When metering slightly gaseous chemicals the liquid end can be continuously de-aerated via the fine bleed vent, if a coarse/fine bleed vent is present. Open fine bleed vent (see fig. 23): S S Pull off the cap (a) from the coarse/fine bleed vent (b). Turn the screw (c) in the coarse/fine bleed vent approx. 1 turn anticlockwise with a screwdriver.

b 2.

c

1.

a

Fig. 23

For self-bleed dosing pumps (SEK type):

IMPORTANT
On this liquid end the discharge connector is horizontal - the bleed valve is at the top! (The bleed connector is identified on delivery with a red collar!) S S S Connect the suction and discharge tubing to the liquid end Connect the bypass tubing to the liquid end Switch on the gamma/ L and allow to run at maximum stroke length and stroke rate until the liquid end is full and free from air bubbles (the feed chemical is visible in the bypass and discharge tubing) Switch off the gamma/ L

S

The gamma/ L is ready to operate.

8.1

Precision dosing settings
IMPORTANT
? ? ? For highly viscous and gaseous chemicals select a large stroke length and a low stroke rate! For good mixing action, select a low stroke length and high stroke rate! For precision dosing, set stroke length higher than 30 % (SEK type: higher than 50 %)!

ProMinent?

Page 25

Commissioning / Operating

8.2
General S S S S

Diagrams for setting feed capacity

Open out the page showing the diagram of your pump type (see appendix). Calculate the correction factor. Mark the operating pressure for your application in the diagram “correction factor depending upon operating pressure”. Trace a line from this value vertically up to the curve and then horizontally left. Read off the correction factor. Divide the required feed rate by the correction factor determined as above. Mark this value (l/h) on the “l/h” axis in the diagram “feed rate depending upon stroke length and stroke rate”. Trace a line horizontally from this value to the left. Trace a line from the intersection with the straight line for the adjustable stroke frequencies vertically downwards to the “stroke length” axis. Set the gamma/ L to one of the stroke frequencies determined in this way, and the corresponding stroke length.

S

S

The measurements for determining the feed rate for the following diagrams were carried out using water and the correction factor was determined at a 70 % stroke length. Distribution of the feed rate across all material versions: -5 to +15 %.

9

Operating

This section describes all operating options available to you when the gamma/ L is in continuous display mode (no P key symbol in the LCD display).

IMPORTANT
? Open out the fold-out page following the title page fully! There you will find the overviews “control elements and key functions” and “operating/settings diagram”. Look at the overview “continuous displays”. This page shows you which displays are available in which operating mode, and which values are directly alterable in the corresponding continuous displays.

?

9.1
Set stroke length

Manual operation

Stroke length is continually adjustable within a range of 0 - 100 %. The recommended stroke length range, which will practically guarantee technical reproducibility, is 30 - 100 % (SEK type: 50 - 100 %). The following operating options are available via the different keys (see also figure on the next page): To stop gamma/ L: press STOP/START key. To start gamma/ L: press STOP/START key. Press the P key briefly in “batch” operating mode. Press the P key for 15 s to load factory calibration settings! Current settings will be deleted. WeIf you press the P key for 2 s in any continuous display the gamma/ L will change to settings mode (see section 7). If CODE 1 is set, the code must be entered after pressing the P key. Each time you press the i key you will see a different continuous display. The number of continuous displays depends upon the identity code, the selected operating mode and the connected accessories. To change a value (see below) directly in the corresponding continuous display, press one of the arrow keys until “set” appears in the LCD display. The delay has been programmed in to prevent inadvertent changing of values. If CODE 2 has been set, this code must be entered after pressing the arrow key. Directly alterable values are as follows:

Stop/Start gamma/ L Start batch Load factory settings Change to settings mode

Check adjustable values

Change directly alterable values

Page 26

ProMinent?

Operating

Stroke rate Feed rate Factor

In “manual”, “contact” and “batch” operating modes: The stroke rate can be altered in the “stroke rate” display. In “manual” operating mode The feed rate can be altered in the “feed rate” display. The factor is the number of strokes activated by an external pulse or a press of the P key (in “batch” mode only). In “batch” operating mode: You can alter the factor from the “remaining strokes” display. The gamma/ L returns to the original continuous display a few seconds after the factor has been reset.

Batch size

In “batch” operating mode: The batch size can by changed from the “batch size/remaining litres” display. The gamma/ L returns to the original continuous display a few seconds after the batch size has been reset. The “priming” function is activated by pressing both arrow keys at the same time in “Stroke rate” permanent display. Error messages are cancelled by pressing the P key briefly. Press on the P key for 10 seconds to display the programme versions. Example: “V 1052“ + X 1010“. Release the key on “LOAD 3“ immediately. Continuous display

Priming Cancel error Display programme versions

STOP
START

Stopp/start pump

2

Change directly alterable values

Prime

P P

Start batch (in "batch" operating mode only)

Cancel error

i
P
2s

Check adjustable values

1
1 = Security lock (CODE 1)

Settings mode

2 = Security lock (CODE 2)

9.2

Remote control

It is possible to control the gamma/ L remotely via a signal cable or PROFIBUS ? (see section 6.3 and section 7, "Supplementary Instructions for ProMinent? gamma/ L and ProMinent? Sigma versions with PROFIBUS?" and plant documentation).

ProMinent?

Page 27

Maintenance / Repairs

10
Maintenance intervals Maintenance actions ? ?

Maintenance
Every quarter, when subject to normal usage (continuous operation - approx. 30 % ) Shorter intervals when subject to heavier usage (e.g. continuous operation)

Standard liquid ends: S Check the diaphragm for damage (see section 11) S Check chemical seepage at vent hole S Check that the discharge tubing is connected firmly to the liquid end S Check that discharge and suction valves are firmly fixed S Check that the liquid end is generally watertight (especially vent hole! See fig. 24) S Check for correct feed: run the gamma/ L run for a short period (press both arrow keys together) S Check electrical connections for wear S Check that liquid end screws are fastened tightly (on coarse/fine bleeding versions, first remove knob and cover Screw fastening torque: Liquid end dia. 70 mm: Liquid end dia. 90 mm and dia. 100 mm: 2,5 to 3 Nm 4,5 to 5 Nm

IMPORTANT
? ? ? ? ? For PP liquid end, check fastening torque every quarter! Check that the bypass tubing is connected firmly to the liquid end Check that the bleed valve is firmly fixed in place Examine the discharge and bypass tubing for kinks Check that the coarse/fine bleed function is working correctly

Additionally, for liquid ends with coarse/fine bleed function and SEK type:

Fig. 24

Vent hole

11

Repairs
IMPORTANT
Repair work that may be carried out by authorised personnel only, or on factory premises: ? ? Replacement of damaged mains cables Replacement of fuses and electronic controller.

Please contact your nearest ProMinent branch or representative! When sending the pump for repair make sure it is clean and that the liquid end has been thoroughly rinsed out (see section 13)! If, despite careful emptying and cleaning, safety precautions are still required for handling the gamma/ L, the necessary information must be entered in the safety declaration! The safety declaration is a component of the inspection/repair order. An inspection or repair can only be carried out when a safety declaration has been correctly and completely filled out by an authorised and qualified member of staff from the company operating the pump. A form is included in the appendix.

Page 28

ProMinent?

Repairs

WARNING
Pumps used for radioactive materials cannot be returned to ProMinent after use! They will not be accepted by ProMinent! Repairs: These should only be carried out by qualified personnel (in accordance with Safety section): ? Cleaning the valve ? Changing the diaphragm

WARNING
? ? Always take suitable precautions when using hazardous chemicals! Ensure equipment is de-pressurised

Cleaning the discharge valve (PP, PC, NP) for types 1000, 1005, 1605, 1601, 1602

IMPORTANT
? ? ? S S S S S S S S S S S
Fig. 25

Discharge and suction valves are different! Dismantle one after the other to avoid confusion. Only use new parts, which fit your valve (in shape and chemical resistance)! The pump must be reset after replacing a valve.

Loosen the hose. Unscrew the discharge valve from the liquid end and rinse thoroughly. Remove the O-ring from the liquid end with a small screw driver. Insert an Allen key or similar into the smaller hole of the pressure connector and push out the valve inserts. Remove the valve seats with a small screwdriver and allow the valve balls to drop out. Clean all parts Drop the valve balls into the valve seats and push on the valve inserts Press the valve seats into the pressure connector with their smaller hole in the direction of the flow (see direction of arrows on the fluting on the pressure connector) Insert the O-ring into the liquid end Screw the valve in as far as it will go Secure the hose

Cleaning the suction valve (PP, PC, NP) for types 1000, 1005, 1605, 1601, 1602 Dismantling, cleaning and reassembly of the suction valve is practically the same as for a discharge valve. Notice however that: ? ? ? ? both valve inserts are actually identical an additional spacer is found under the valve inserts in the liquid end a shaped seal is used instead of an O-ring the flow direction of the suction connection is reversed as for the pressure connector.

Fig. 26

ProMinent?

Page 29

Repairs

Cleaning the discharge valve (PP, PC, NP) for types 0708, 1008, 0220, 0420, 0413, 0713, 0232

IMPORTANT
? ? ? S Discharge and suction valves are different! Dismantle one after the other to avoid confusion! Only use new parts, which fit your valve (in shape and chemical resistance)! The pump must be reset after replacing a valve.

Loosen the hose. Unscrew the discharge valve from the liquid end and rinse thoroughly. Remove the O-ring (12) and the shaped seal (11) from the liquid end with a small screwdriver. Insert an Allen key or similar into the smaller hole of the pressure connector (1) and push out the valve inserts (2, 6). Separate the two valve inserts (2, 6) and let the valve ball (3) drop out. Remove the valve seat (10) from the “valve insert” (6) and let the valve ball (7) drop out. Remove the washers (4, 8) and the O-rings (5, 9) from the “valve insert” (8) and the valve cap (10) with a small screwdriver. Clean all parts. Put one of the washers (4, 8) and one of the O-rings (5, 9) into the “valve insert” (6) and the valve cap (10) respectively. Place the valve balls (3, 7) onto the washers (4, 8) in the “valve insert” and the valve cap (10) respectively. Push the valve cap (10) onto the “valve insert” (6) until it engages. Push the valve insert (2) onto the “valve insert” (6) until it engages. Insert both valve inserts into the pressure connector (1), (check that the directions of the arrows on the fluting of the pressure connector (1) and on the valve inserts (2, 6) are the same!) Insert the O-ring (12) and the shaped seal (11) into the liquid end. Screw the valve in as far as it will go. Secure the hose.

1

S S S

2 3 4 5 6 7 8 9 10 11 12
Fig. 27

S S S S S S S S S S S S

Cleaning the suction valve (PP, PC, NP) for types 0708, 1008, 0220, 0420, 0413, 0713, 0232 Dismantling, cleaning and reassembling of a suction valve is practically the same as for a discharge valve. Please ensure, however, that: ? ? ? the shaped seal is placed in the suction connector only the O-ring is inserted into the liquid end and not the shaped seal the flow direction for the suction connector is reversed as for the pressure connector

Fig. 28

Page 30

ProMinent?

Repairs

Change diaphragm

WARNING
? ? S S S S S S Always take suitable precautions when using hazardous chemicals! Ensure that the equipment is de-pressurised!

Empty the liquid end (turn the unit upside down and let the feed chemical run out, rinse with a suitable material: rinse the liquid end thoroughly after use with hazardous materials!). When gamma/ L is running set the stroke length to 0 % (the drive axis is then set). Switch off the gamma/ L. Unscrew the hydraulic connectors from the discharge and suction side. For versions with coarse/fine bleed function: firstly pull out the coarse/fine bleed (knob), then lift off the cover from the liquid end using a screwdriver. Remove the screws (1).

For pump types 0220, 0232 and 0420 see the following page (4 holes on the diaphragm rim)! Supply unit types, except 0220, 0232 and 0420

S S

Loosen the liquid end (2) and the top plate (4) from the pump housing (6) (loosen only!). Hold the housing (6) in one hand and with the other, clamp the diaphragm (3) between the liquid end (2) and the top plate (4); release the diaphragm (3) from the drive spindle with a light anticlockwise turn of the liquid end (2) and top plate (4). Unscrew the diaphragm (3) completely from the drive spindle. Remove the top plate (4) from the housing (6). Check the condition of the safety diaphragm (5) and replace if necessary. Push the safety diaphragm (5) only as far onto the drive axis until it lies flat on the pump housing (6) – no further! Screw the new diaphragm (3) carefully up to the stop on the drive axis – this must be exact to ensure correct metering! Screw the diaphragm (3) tight once more. Position the top plate (4) on the pump housing (6).

S S S S S S S

NOTICE
? ? The leakage hole must point downwards when the pump is fully assembled (see fig. 24). Position the top plate (4) correctly on the pump housing (6). Do not distort the top plate on the pump housing, otherwise the safety diaphragm (5) will not fit.

S S

Lay the diaphragm (3) into the top plate (4). Hold the top plate (4) and screw the diaphragm (3) in a clockwise direction until it is firmly in position (you will feel the resistance of the return spring).

NOTICE
? ? Do not overtighten the diaphragm (3) (particularly on type 1601). The top plate (4) must remain in position to prevent the safety diaphragm (5) from distorting.

S S S

Place the liquid end (2) with the screws (1) on the diaphragm (3) and the top plate (4) (the priming connector must point downwards once the pump is fully assembled). Screw on screws (1) lightly and tighten (starting torque, see below). For versions with coarse/fine bleed function, ensure that the liquid end cover engages in the liquid end, then push the coarse/fine bleed vent (knob) into the liquid end.

ProMinent?

Page 31

Repairs

1

2

3

4

5

6

Fig. 29

1 Screws 2 Liquid end 3 Diaphragm

4 Top plate 5 Safety diaphragm 6 Pump housing

IMPORTANT
? ? Check the screw torques after 24 hours in operation For PP liquid ends check the screw torques again after three months.

Screw torques: Liquid end ? 70 mm: 2,5 to 3 Nm Liquid end ? 90 mm and ? 100 mm: 4,5 to 5 Nm Liquid ends - types 0220, 0232 and 0420 S Remove the metering head (2) with the screw (1) from the pump (see fig. 30). Only type 0232: Remove the screws of the set disk (4) below the diaphragm (3). Remount the metering head (2) with the screws (1). Hold the housing (6) in one hand and with the other hand, clamp the diaphragm (3) between the liquid end (2) and the top plate (4); release the diaphragm (3) from the drive spindle with a light anti-clockwise turn of the liquid end (2) and top plate (4). Remove the liquid end (2) with screws (1) from of the diaphragm and unscrew completely from the drive spindle. Remove the top plate (4) from the housing (6). Check the condition of the safety diaphragm (5) and replace it necessary. Push the safety diaphragm (5) only as far onto the drive axis until it lies flat on the pump housing (6) – no further! Screw the new diaphragm (3) carefully up to the stop on the drive axis – this must be exact to ensure correct metering! Check that the holes in the diaphragm are aligned with those in the pump housing. If not, start the pump and set the stroke length to 100 %. When the pump is running, turn the diaphragm (3) slowly in a clockwise direction until the four holes in the diaphragm are flush with those on the pump housing (6). Hold the diaphragm (3) in this position, set the stroke length to 0 % and stop the pump. Screw the diaphragm (3) tight once more. Position the top plate (4) on the pump housing (6). Only type 0232: Mount the set disk (4) with the screws.

S

S S S S S S S S S S S S

Page 32

ProMinent?

Troubleshooting

12

Troubleshooting
WARNING
? ? Always take suitable precautions when using hazardous chemicals! Ensure the equipment is de-pressurised before working on the pump!

gamma/ L does not prime despite full stroke and bleed function Cause Remedy Crystalline deposits on the ball seat because valves have dried out S S Remove the suction sleeve from the chemical supply container and rinse out the liquid end thoroughly If still unsuccessful, dismantle valves and clean (see section 10)

Fluid is seeping from the top plate Cause Remedy The liquid end is not sealed against the pump diaphragm S S Tighten screws in the liquid end (see section 10) If unsuccessful, replace the diaphragm (see section 11)

Green LED indicator (operating display) is not lit Cause Remedy Incorrect or no mains voltage S Use the recommended mains voltage as given in the voltage specification on the nameplate

Error Messages
Red LED display is lit, “Error” appears and “MINIM” flashes in the display Cause Remedy Fluid level in the chemical storage tank has reached “liquid level low, stage 2” S Fill the chemical supply container

Red LED display is lit, “Error” appears and “ANALG” flashes in the display Cause Remedy gamma/ L is in “analogue” operating mode, a fault routine has been programmed in the ANALG menu and the operating current has fallen below 3.8 mA S S Remedy low operating current Switch fault routine “OFF” (see Section 7.4.2.)

Red LED display is lit, “Error” appears and “CNTCT” flashes in the display Cause gamma/ L is in “contact” or “batch” operating mode and the extended function “memory” has been set. In addition a very large factor has been entered, too many contacts have been input or the Pkey has been pressed too often, resulting in an overflow of the stroke memory. S S Press the P-key, saved data will be deleted Change gamma/ L set up

Remedy

Red LED display is lit, “Error” appears and “FLOW” flashes in the display Cause Remedy Cause Remedy Dosing monitor not properly connected S S S S Connect dosing monitor properly Press P-key Press P-key Investigate the cause and remedy

Dosing monitor has reported more defective strokes than have been set in the FLOW menu

Red LED display is lit, “Error” appears and “Mem” flashes in the display Cause Remedy Stroke memory full S S Remove cause Press P-key (Consider the consequences this will have on your process)

All other Errors Please contact your ProMinent branch or representative! Page 34

ProMinent?

Troubleshooting / Decommissioning and Disposal

Fault Signals
Yellow LED display is lit Cause Remedy Liquid level in chemical storage tank has reached “liquid level low, stage 1” S Fill chemical storage tank

Yellow LED Display is lit and “calib” flashes Cause Remedy The pump is calibrated and the stroke length deviates by more than ±10 % from the value at the time of calibration. S Reset the stroke length or calibrate the pump again to the desired stroke length

13
Decommissioning

Decommissioning and Disposal
WARNING
? ? ? When decommissioning the gamma/ L the housing and, in particular, the liquid end must be thoroughly cleaned to remove chemicals and dirt! Always take suitable precautions when using hazardous chemicals! Ensure that the equipment is de-pressurised!

S S S

Disconnect the gamma/ L from the power supply Empty the liquid end by turning the gamma/ L upside down and allow the feed chemical to pour out Rinse the liquid end with a suitable material, thoroughly rinse the liquid end after use with hazardous materials!

If decommissioning is only temporary, maintain the correct storage conditions: Storage temperature: Air humidity: -10 to +50 °C < 92 % relative humidity

Disposal

NOTICE
Electronic waste is classified as special waste! Please observe all locally applicable directives!

ProMinent?

Page 35

Technical Data

14
14.1
gamma/ L
Liquid end type

Technical Data
Performance data and weights
at 180 strokes/minute and 100 % stroke length
Max. feed rate at maximum operating pressure bar 1000 1601 1602 1005 0708 0413 0220 1605 1008 0713 0420 0232 10 16 16 10 7 4 2 16 10 7 4 2 l/h 0.74 1.1 2.1 4.4 7.1 12.3 19.0 4. 1 6.8 11.0 17.1 32.0 ml/str. 0.09 0.10 0.19 0,41 0.66 1.14 1.76 0.38 0.63 1.02 1.58 2.96 Ma. feed rate at medium operating pressure bar 5 8 8 5 3.5 2 1 8 5 3.5 2 1 l/h 0.82 1. 4 2.5 5.0 8.4 14.2 20.9 4. 9 8.3 13.1 19.1 36.2 ml/str. 0.076 0.13 0.24 0.46 0.78 1.31 1.94 0.45 0.76 1.21 1.77 3.35 Connector size outer ? x inner ? mm 6x4 6x4 6x4 8x5**** 8x5 8x5 12x9 8x5**** 8x5 8x5 12x9 12x9 Suction lift* Priming lift** Admiss. priming pressure bar 8 8 5.5 3 2 1.5 1 3 2 1.5 1 0.8 Ship. Wt1

m Wg 6 6 6 5 4 3 2 4 3 3 3 2

m Wg 1.8 2 2 3 2 2 2 3 3 3 3 2

approx. kg 2.9 / 3.6 2.9 / 3.6 2.9 / 3.6 3.1 / 4.5 3.1 / 4.5 3.1 / 4.5 3.1 / 4.5 4.5 / 5.9 4.5 / 5.9 4.5 / 5.9 5.5 / 8.6 5.5 / 8.6

gamma/ L with self-degassing liquid end ***
Liquid end type Max. feed rate at maximum operating pressure bar 1601 1602 1005 0708 0413 0220 1605 1008 0713 0420 16 16 10 7 4 2 16 10 7 4 l/h 0.59 1.4 3.6 6.6 10.8 16.2 3.3 6.3 10.5 15.6 ml/str. 0.055 0.13 0.33 0.61 1.00 1.50 0.31 0.58 0.97 1.44 Max. feed rate at medium operating pressure bar 8 8 5 3.5 2 1 8 5 3.5 2 l/h 0.78 1.74 4.0 7.5 12.6 18.0 3.8 7.5 12.3 17.4 ml/str. 0.072 0.16 0.37 0.69 1.17 1.67 0.35 0.69 1.14 1.61

at 180 strokes/minute and 100 % stroke length
Connector size outer ? x inner ? mm 6x4 6x4 8x5 8x5 8x5 12x9 8x5 8x5 8x5 12x9 Suction lift* Priming lift** Admiss. priming pressure bar 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Ship. Wt ?

m Wg – – – – – – – – – –

m Wg 1.8 2.1 2.7 2 2.5 2 3.0 3.0 2.5 2.5

approx. kg 2.9 2.9 3.1 3.1 3.1 3.1 4.5 4.5 4.5 4.5

* ** *** ****
1 2

Lift when suction line and liquid end are full Priming lift with clean and wetted valves, priming lift at 100% stroke length and free flow or opened bleed valve The feed rate values are for minimum feed rates, based on water For material versions SST : 6 x 4 mm For material versions PPE, PPB, PCE, PCB, NPE, NPB, TTT/SST For material versions PPE, PPB, NPE, NPB

Page 36

ProMinent?

Technical Data

14.2

Dosing reproducibility

Standard Liquid ends Dosing precision Reproducibility -5 to +10 % at max. stroke length and max. operating pressure for all materials. ±2 % at constant conditions and minimum 30 % stroke length. Self-degassing liquid ends Since self-degassing liquid ends are filled with air bubbles when in contact with gaseous chemicals and when in operation, no dosing reproducibility values can be given. The recommended minimum stroke length with self-degassing liquid ends is 50 %.

14.3

Viscosity

The liquid ends are designed for liquids up to a maximum viscosity of ? 200 mPas for standard liquid ends ? 500 mPas for valves with springs ? 50 mPas for self-degassing liquid ends

14.4

Materials Data Liquid ends
Version PPE PPB PCE PCB NPE NPB TTT SST Liquid end PP PP PVC PVC Acrylic glass Acrylic glass PTFE with carbon Stainless steel 1.4571 Valves PP PP PVC PVC PVC PVC PTFE with carbon Stainless steel 1.4571 Seals EPDM FPM (Viton?) EPDM FPM (Viton?) EPDM FPM (Viton?) PTFE PTFE Balls Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic

Viton? (FPM) is a registered trade mark of DuPont Dow Elastomers.

Pump Housing Cover Electronics Polyphenylene ether (PPE with glass fibre) Polycarbonate Electronic components

14.5

Electrical Data

Version: 100 - 230 V ±10 %, 50/60 Hz
Variants 100 - 230 V/AC Power rating: Rated current: Switch on peak current: Fuse: gamma/ L M70 17 W 0.7 A 15 A (for approx.1 ms) 0.8 AT gamma/ L M85 22 W 1A 15 A (for approx. 1 ms) 0.8 AT

Note

Fuses must display VDE, UL and CSA certification, e.g. type 19195 from Wickmann in accordance with IEC publication 127 - 2/3 Page 37

ProMinent?

Technical Data

14.6
Temperatures

Ambient conditions
-10 to +50 °C -10 to +35 °C -10 to +45 °C (drive and control)

Storage and transport temperatures: Feed chemical temperature: Ambient temperature when in operation:

Maximum ambient temperatures for liquid ends depending on material type:

Max. ambient temperature Long-term at max. operating pressure: Short-term (max. 15 min) at max. 2 bar:

PPE, PPB 50 °C 100 °C

PCE, PCB 45 °C* 60 °C

NPE, NPB 45 °C 60 °C

TTT 50 °C 120 °C

SST 50 °C 120 °C

*

Under extreme conditions such as maximum dosing temperatures, maximum stroke frequency and maximum operating pressure, leakage can occur on the liquid end at an ambient temperature of 35 °C. 92 % relative humidity, not condensing FW 24 in accordance with DIN 50016

Climate

Permissible air humidity: Moist and fluctuating air conditions:

14.7
Enclosure Rating Safety Requirements

Enclosure rating and safety class

Contact and moisture enclosure rating: IP 65 in accordance with IEC 529, EN 60529, DIN VDE 0470 Part 1 Safety Class 1 - Mains connection with earth lead

14.8

Compatibility

The hydraulic parts of the gamma/ L are identical to those of the Beta?. The following components and accessories for pumps from the product ranges Beta?, CONCEPT, gamma-Classic and gamma are all compatible: ? ? ? ? ? ? ? ? ? gamma/Vario signal cable; 2-, 4- and 5 core for “external” function 2 stage float switch (gamma/Vario) Discharge tubing diameters Standard gamma connector set gamma wall bracket Chemical feed containers and mounting plates Total height (distance between suction and discharge connector) Distance between the connectors and locating holes on the pumps Accessories such as pressure back pressure valve, multifunctional valve, dosing monitor and rinsing equipment

Page 38

ProMinent?

Accessories

15

Accessories
CAUTION
The fitting and installing of ProMinent? dosing pumps using parts from other suppliers which have not been tested and recommended by ProMinent is inadmissible and can result in harm to personnel and equipment, for which no liability will be accepted.

Level switch 2-stage with 2 m connection cable Fault indicating relay To signal faults Fault indicating and pacing relay For timing other equipment and for indicating faults. Signal cable Universal signal cable: External contact cable: Foot valves With suction filter and non-return valve for connection at the end of the suction tubing. Discharge valve With spring-loaded non-return valve for dosing into open or closed systems and for connecting discharge tubing. Discharge lances For dosing into large pipes and to prevent blockage when dosing crystallising substances. Back pressure valves For precision dosing when operating pressure is low or as a relief valve. Accumulator without diaphragm For reducing pulsation, e.g. with long dosing lines. Dosing monitors For monitoring dosing. After pre-set number of failed strokes the error message displays and the dosing pump switches off. Suction lances With foot valve and float switch for disposable drums or chemical feed containers Chemical feed container To contain 35 to 1000 litres with lockable screw top and necessary accessories. Manual/electronic stirrers For mixing and batching of feed solutions. Bracket For stable pump mounting. 5 core / 2.5 and 10 m 2 core / 2.5 and 10 m

ProMinent?

Page 39

gamma/ L Dimensions

PPE, PPB material versions

12 (not for 0232)

in e

nt ?

F

Pr oM

E

101

160

80 102 96 147

15 36 K L

Fig. 31

Measurements in mm
gamma/ L M70 1000 - 1602 E F K L M 23 186 71 106 ? 70 1005 13 193 71 105 ? 90 0708 - 0413 15 191 74 108 ? 90 0220 15 191 76 110 ? 90 1605 13 193 71 105 ? 90 gamma/ L M85 1008 - 0713 15 191 74 108 ? 90 0420 15 191 76 110 ? 90 0232 5 197 76 91 ? 110

PCE, PCB material versions

M 13,8 F

ProMinent?
101 160

E

15 36 96 147 K L

80 102 Fig. 32

Measurements in mm
gamma/ L M70 1000 - 1601 E F K L M 25 177 77 105 62 (? 70) 1602 23 179 77 105 66 (? 70) 1005 16 188 74 102 ? 90 0708 13 189 74 102 ? 90 0413 - 0220 15 189 76 104 ? 90 1605 16 188 74 102 ? 90 gamma/ L M85 1008 13 189 74 102 ? 90 0713 - 0420 15 189 76 104 ? 90 0232 5 199 76 105 ? 110

Page 40

ProMinent?

M

Exploded diagrams of liquid ends

Liquid end 0708 (1008) - 0220 (0420) PP with coarse/fine bleed

Connector kit 8/5 PPE Connector kit 12/9 PPE Connector kit 8/5 PPB Connector kit 12/9 PPB

817153 817151 817167 817168

*
4 valve balls 1 seal set 1 seal set 404281 1001776 1001774 Diaphragm 0708 1000248 Diaphragm 0413 1000249 Diaphragm 0220 1000250 Discharge valve set Discharge valve set PPE PPB 1001441 1001440

EPDM FPM

*

Spare parts kits for: Type 0708 (1008) 0413 (0713) 0220 (0420) 0708 (1008) 0413 (0713) 0220 (0420) Material PPE PPE PPE PPB PPB PPB Order No. 1001648 1001649 1001650 1001656 1001657 1001658

Suction valve set Suction valve set

PPE PPB

1001437 1001436

Connector kit

The listed items are included in the spare parts kit. * Customer accessories Subject to technical alterations.
60_07-104_00_19-04_2

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Stroke rate [%] Feed rate [l/h] 16 GALa 0413 at medium operating pressure Stroke rate [%]

Feed rate [l/h]

GALa 0708 at medium operating pressure

9 100 14
180 strokes/min 162 strokes/min 144 strokes/min

8 90

100

180 strokes/min

162 strokes/min

7 80 12
108 strokes/min 90 strokes/min 126 strokes/min

144 strokes/min

90

126 strokes/min

108 strokes/min

80

6 70
72 strokes/min

90 strokes/min

72 strokes/min

Feed rate settings diagrams

10
54 strokes/min

54 strokes/min

70

5
18 strokes/min

36 strokes/min

60 8 50

36 strokes/min

18 strokes/min

60

4 40 6

50

3 30 4 20

40

30

2 20 2 10 10

1

0 60% 0% 70% 80% 90% 100% 0

0%

10%

20%

30%

40%

50%

10%

20%

30%

40%

50%

60%
Stroke length

70%

80%

90%

100%

Stroke length

Correction factor

Correction factor

1,2

1,2 1 0,8 0,6 0,4 0,2 6 7 0 1 1,5 3 4 2 Operating pressure

1

0,8

0,6

0,4

0,2

0

1

2

3,5

4

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Operating pressure


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