Operating instructions Panel-mounted metering system DULCODOS Panel, type DSWa EN A1837 Please enter the identity code of your unit here: DSWa Please carefully read these operating instructions before use. Do not discard. The operator shall be liable for any damage caused by installation or operating errors. The latest version of the operating instructions are available on our homepage. 986762 Original Operating Instructions (2006/42/EC) BA DST 008 12/16 EN
Supplemental directives General non-discriminatory approach In order to make it easier to read, this document uses the male form in grammatical structures but with an implied neutral sense. It is aimed equally at both men and women. We kindly ask female readers for their understanding in this simplification of the text. Supplementary information Please read the supplementary information in its entirety. Information This provides important information relating to the correct operation of the unit or is intended to make your work easier. Warning information Warning information includes detailed descriptions of the hazardous situation, see Ä Chapter 3.2 Labelling of Warning Information on page 13. The following symbols are used to highlight instructions, links, lists, results and other elements in this document: More symbols Symbol Description Action, step by step. Outcome of an action. Links to elements or sections of these instructions or other applicable documents. List without set order. [Button] Display element (e.g. indicators). Operating element (e.g. button, switch). Display /GUI Screen elements (e.g. buttons, assignment of function keys). CODE Presentation of software elements and/or texts. 2
Table of contents Table of contents 1 DSWa identity code... 4 1.1 Identity code ordering system, Beta and gamma/ L, DN 10.. 4 1.2 Identity code ordering system, Sigma/ 1, DN 10... 6 1.3 Identity code ordering system, Sigma/ 1, DN 15... 7 1.4 Identity code ordering system, Sigma/ 2, DN 15... 8 1.5 Identity code ordering system, Sigma/ 2, DN 20... 9 1.6 Identity code ordering system, Sigma/ 3, DN 25... 10 1.7 Identity code ordering system, Sigma/ 3, DN 32... 11 2 About this Product... 12 3 Safety and Responsibility... 13 3.1 Users' qualifications... 13 3.2 Labelling of Warning Information... 13 3.3 General safety notes... 15 3.4 Intended use... 17 4 Storage and Transport... 18 5 Overview of equipment... 19 5.1 Overview of equipment, options... 19 5.2 Overview of equipment, operating elements... 20 6 Assembly and installation... 21 7 Start up... 23 7.1 Option: Vacuum cylinder, vacuum pump... 23 7.2 Option: Pulsation damping... 24 7.3 Adjusting the operating pressure of the system using the back pressure valve... 24 7.4 Adjusting the relief valve... 24 7.5 Calibration... 25 7.6 Vacuum cylinder... 25 8 Maintenance and repair... 27 9 Decommissioning and Disposal... 28 9.1 Disposal of Used Parts... 29 10 Technical data... 30 11 EU Declaration of Conformity for Machinery... 33 12 Index... 34 3
DSWa identity code 1 DSWa identity code 1.1 Identity code ordering system, Beta and gamma/ L, DN 10 DSWa Assembly frame with pipework for installation of a metering pump (order metering pump separately) B410 B510 GL10 for Beta, DN 10 (BT4b 1000-0220: 0.74-19 l/h) for Beta, DN 10 (BT5b 1605-0232: 4.1-32 l/h) for gamma/ L, DN 10 (GALa 1000-0232: 0.74-32 l/h) Extension for installation of a standby pump (order standby pump separately) 1 with extension for standby pump (same type as the metering pump) Pipework material PC PP PVC PP Material of seals/diaphragm E A EPDM FKM Vacuum cylinder 1 with vacuum cylinder Vacuum pump 1 with vacuum pump Pulsation damper 1 with pulsation damper (including back pressure valve) Manometer 1 with manometer and diaphragm seal Overflow device 0 with multifunctional valve (for 1 pump of type: 1000-1605) 1 with multifunctional valve (for 1 pump of type: 0708-0232) 2 with back pressure valve (for 1 pump) 3 with multifunctional valve (for 2 pumps of type: 1000-1605) 4 with multifunctional valve (for 2 pumps of type: 0708-0232) 5 with back pressure valves (for 2 pumps) Terminal box 0 without terminal box 1 with terminal box for 1 pump 2 with terminal box for 2 pumps 4
DSWa identity code DSWa Assembly frame with pipework for installation of a metering pump (order metering pump separately) 3 with terminal box + main switch for 1 pump 4 with terminal box + 2 main switches for 2 pumps Leakage sensor in collecting pan 0 without leakage sensor 1 with leakage sensor Suction / discharge side connecting parts 0 with adhesive /welding sleeves 1 with hose nozzles 6x4 2 with hose nozzles 8x5 3 with hose nozzles 12x6 4 with hose nozzles 12x9 5 with hose nozzles DN 10 Information - Pump* e.g.: BT4b 1005 PPE 300AA000 * Please enter the identity code of the selected pump 5
DSWa identity code 1.2 Identity code ordering system, Sigma/ 1, DN 10 DSWa Assembly frame with pipework for installation of a metering pump (order metering pump separately) S110 Sigma/ 1, DN 10 (S1Cb/S1Ba 12017-07065: 20-65 l/h) Extension for installation of a standby pump (order standby pump separately) 1 with extension for standby pump (same type as the metering pump) Pipework material PC PVC PP PP Material of seals/diaphragm E EPDM A FKM Vacuum cylinder 2 with vacuum cylinder Vacuum pump 1 with vacuum pump Pulsation damper 2 with pulsation damper (including back pressure valve) Manometer 1 with manometer and diaphragm seal Overflow device 6 with overflow device Terminal box 0 without terminal box 1 with terminal box for 1 pump 2 with terminal box for 2 pumps 3 with terminal box + main switch for 1 pump 4 with terminal box + 2 main switches for 2 pumps Leakage sensor in collecting pan 0 without leakage sensor 1 with leakage sensor Suction / discharge side connecting parts 0 with adhesive / welding sleeves 6 with hose nozzles DN 10 Information - Pump* e.g.:s1ba H12017 PVT0110M000 * Please enter the identity code of the selected pump: 6
DSWa identity code 1.3 Identity code ordering system, Sigma/ 1, DN 15 DSWa Assembly frame with pipework for installation of a metering pump (order metering pump separately) S115 Sigma/ 1, DN 15 (S1Cb/S1Ba 07042-04120: 50-120 l/h) Extension for installation of a standby pump (order standby pump separately) 3 with extension for standby pump (same type as the metering pump) Pipework material PC PVC PP PP Material of seals/diaphragm E EPDM A FKM Vacuum cylinder 3 with vacuum cylinder Vacuum pump 1 with vacuum pump Pulsation damper 3 with pulsation damper (including back pressure valve) Manometer 1 with manometer and diaphragm seal Overflow device 6 with overflow device Terminal box 0 without terminal box 1 with terminal box for 1 pump 2 with terminal box for 2 pumps 3 with terminal box + main switch for 1 pump 4 with terminal box + 2 main switches for 2 pumps Leakage sensor in collecting pan 0 without leakage sensor 1 with leakage sensor Suction / discharge side connecting parts 0 with adhesive /welding sleeves 7 with hose nozzles DN 15 Information - Pump* e.g.: S1Ba H07042 PVT0110M000 * Please enter the identity code of the selected pump: 7
DSWa identity code 1.4 Identity code ordering system, Sigma/ 2, DN 15 DSWa Assembly frame with pipework for installation of a metering pump (order metering pump separately) S215 Sigma/ 2, DN 15 (S2Cb/S2Ba 16050-16130: 60-130 l/h) Extension for installation of a standby pump (order standby pump separately) 4 with extension for standby pump (same type as the metering pump) Pipework material PC PVC PP PP Material of seals/diaphragm E EPDM A FKM Vacuum cylinder 4 with vacuum cylinder Vacuum pump 1 with vacuum pump Pulsation damper 4 with pulsation damper (incl. back pressure valve) Manometer 1 with manometer and diaphragm seal Overflow device 6 with overflow device Terminal box 0 without terminal box 1 with terminal box for 1 pump 2 with terminal box for 2 pumps 3 with terminal box + main switch for 1 pump 4 with terminal box + 2 main switches for 2 pumps Leakage sensor in collecting pan 0 without leakage sensor 1 with leakage sensor Suction / discharge side connecting parts 0 with adhesive /welding sleeves 8 with hose nozzles DN 15 Information - Pump* e.g.: S2Ba HM16050 PVT0110M000 * Please enter the identity code of the selected pump: 8
DSWa identity code 1.5 Identity code ordering system, Sigma/ 2, DN 20 DSWa Assembly frame with pipework for installation of a metering pump (order metering pump separately) S220 Sigma/ 2, DN 20 (S2Cb/S2Ba 07120-04350: 120-350 l/h) Extension for installation of a standby pump (order standby pump separately) 5 with extension for standby pump (same type as the metering pump) Pipework material PC PVC PP PP Material of seals/diaphragm E EPDM A FKM Vacuum cylinder 5 with vacuum cylinder Vacuum pump 1 with vacuum pump Pulsation damper 5 with pulsation damper (incl. back pressure valve) Manometer 1 with manometer and diaphragm seal Overflow device 6 with overflow device Terminal box 0 without terminal box 1 with terminal box for 1 pump 2 with terminal box for 2 pumps 3 with terminal box + main switch for 1 pump 4 with terminal box + 2 main switches for 2 pumps Leakage sensor in collecting pan 0 without leakage sensor 1 with leakage sensor Suction / discharge side connecting parts 0 with adhesive /welding sleeves 9 with hose nozzles DN 20 Information - Pump* e.g.: S2Ba HM07120 PVT0110M000 * Please enter the identity code of the selected pump: 9
DSWa identity code 1.6 Identity code ordering system, Sigma/ 3, DN 25 DSWa Assembly frame with pipework for installation of a metering pump (order metering pump separately) S325 Sigma/ 3, DN 25 (S3Cb 120145-120330: 174-324 l/h) Extension for installation of a standby pump (order standby pump separately) 6 with extension for standby pump (same type as the metering pump) Pipework material PC PVC PP PP Material of seals/diaphragm E EPDM A FKM Vacuum cylinder 6 with vacuum cylinder Vacuum pump 1 with vacuum pump Pulsation damper 6 with pulsation damper (incl. back pressure valve) Manometer 1 with manometer and diaphragm seal Overflow device 6 with overflow device Terminal box 0 without terminal box 1 with terminal box for 1 pump 2 with terminal box for 2 pumps 3 with terminal box + main switch for 1 pump 4 with terminal box + 2 main switches for 2 pumps Leakage sensor in collecting pan 0 without leakage sensor 1 with leakage sensor Suction / discharge side connecting parts 0 with adhesive /welding sleeves A with hose nozzles DN 25 Information - Pump* e.g.: S3Ba H120145 PVT0110M000 * Please enter the identity code of the selected pump: 10
DSWa identity code 1.7 Identity code ordering system, Sigma/ 3, DN 32 DSWa Assembly frame with pipework for installation of a metering pump (order metering pump separately) S332 Sigma/ 3, DN 32 (S3Cb 070410-041030: 492-1000 l/h) Extension for installation of a standby pump (order standby pump separately) 7 with extension for standby pump (same type as the metering pump) Pipework material PC PVC PP PP Material of seals/diaphragm E EPDM A FKM Vacuum cylinder 7 with vacuum cylinder Vacuum pump 1 with vacuum pump Pulsation damper 7 with pulsation damper (incl. back pressure valve) Manometer 1 with manometer and diaphragm seal Overflow device 6 with overflow device Terminal box 0 without terminal box 1 with terminal box for 1 pump 2 with terminal box for 2 pumps 3 with terminal box + main switch for 1 pump 4 with terminal box + 2 main switches for 2 pumps Leakage sensor in collecting pan 0 without leakage sensor 1 with leakage sensor Suction / discharge side connecting parts 0 with adhesive /welding sleeves B with hose nozzles DN 32 Information - Pump* e.g.: S3Ba H070410 PVT0110M000 * Please enter the identity code of the selected pump: 11
About this Product 2 About this Product The DULCODOS DSWA metering system offers the following models for metering tasks: Metering of biocides and inhibitors in cooling water Metering of lyes and acids for ph regulation Metering of coagulants (iron-iii-chloride) for waste water treatment Metering of detergents (CIP (cleaning in place) systems and bottle washing machines) Panel-mounted metering systems can be selected and ordered with the help of an identity code system. First of all, select and order the metering and standby pump using the separate pump identity code. The metering system consists of a stable wall mounting plate with integral collecting pan. Feed chemicals that escape are collected in this collecting pan. An integral leakage sensor reports when feed chemical is present in the collecting pan. 12
Safety and Responsibility 3 Safety and Responsibility 3.1 Users' qualifications WARNING! Danger of injury with inadequately qualified personnel! The operator of the plant / device is responsible for ensuring that the qualifications are fulfilled. If inadequately qualified personnel work on the unit or loiter in the hazard zone of the unit, this could result in dangers that could cause serious injuries and material damage. All work on the unit should therefore only be conducted by qualified personnel. Unqualified personnel should be kept away from the hazard zone Training Instructed personnel Trained user Trained qualified personnel Electrician Customer Service department Definition An instructed person is deemed to be a person who has been instructed and, if required, trained in the tasks assigned to him/her and possible dangers that could result from improper behaviour, as well as having been instructed in the required protective equipment and protective measures. A trained user is a person who fulfils the requirements made of an instructed person and who has also received additional training specific to the system from ProMinent or another authorised distribution partner. A qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognize possible hazards based on his/her training, knowledge and experience, as well as knowledge of pertinent regulations. The assessment of a person's technical training can also be based on several years of work in the relevant field. Electricians are deemed to be people, who are able to complete work on electrical systems and recognize and avoid possible hazards independently based on his/her technical training and experience, as well as knowledge of pertinent standards and regulations. Electricians should be specifically trained for the working environment in which the are employed and know the relevant standards and regulations. Electricians must comply with the provisions of the applicable statutory directives on accident prevention. Customer Service department refers to service technicians, who have received proven training and have been authorised by ProMinent to work on the system. Note for the system operator The pertinent accident prevention regulations, as well as all other generally acknowledged safety regulations, must be adhered to! 3.2 Labelling of Warning Information Introduction These operating instructions provide information on the technical data and functions of the product. These operating instructions provide detailed warning information and are provided as clear step-by-step instructions. The warning information and notes are categorised according to the following scheme. A number of different symbols are used to denote different situations. The symbols shown here serve only as examples. 13
Safety and Responsibility DANGER! Nature and source of the danger Consequence: Fatal or very serious injuries. Measure to be taken to avoid this danger. Description of hazard Denotes an immediate threatening danger. If the situation is disregarded, it will result in fatal or very serious injuries. WARNING! Nature and source of the danger Possible consequence: Fatal or very serious injuries. Measure to be taken to avoid this danger. Denotes a possibly hazardous situation. If the situation is disregarded, it could result in fatal or very serious injuries. CAUTION! Nature and source of the danger Possible consequence: Slight or minor injuries. Material damage. Measure to be taken to avoid this danger. Denotes a possibly hazardous situation. If the situation is disregarded, it could result in slight or minor injuries. May also be used as a warning about material damage. NOTICE! Nature and source of the danger Damage to the product or its surroundings. Measure to be taken to avoid this danger. Denotes a possibly damaging situation. If the situation is disregarded, the product or an object in its vicinity could be damaged. Type of information Hints on use and additional information. Source of the information. Additional measures. Denotes hints on use and other useful information. It does not indicate a hazardous or damaging situation. 14
Safety and Responsibility 3.3 General safety notes WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries. Please ensure when handling hazardous substances that you have read the latest safety data sheets provided by the manufacture of the hazardous substance. The actions required are described in the safety data sheet. Check the safety data sheet regularly and replace, if necessary, as the hazard potential of a substance can be re-evaluated at any time based on new findings. The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date, as well as for producing an associated hazard assessment for the workstations affected. WARNING! Live parts Possible consequence: Fatal or very serious injuries Measure: Disconnect the mains plug prior to opening the housing De-energise damaged, defective or manipulated units by disconnecting the mains plug Immediately disconnect the pump from the mains/ power supply if the pump housing has been damaged. Only start up the pump again after it has been repaired by authorised personnel. WARNING! Operating error / Unauthorised access Possible consequence: Fatal or very serious injuries. Measure: Ensure that there can be no unauthorised access to the device Ensure that the device is only operated by adequately qualified and technically expert personnel Please also observe the operating instructions for controllers and fittings and any other units, such as sensors, sample water pumps... The operator is responsible for ensuring that personnel are qualified WARNING! Use of the unit in areas at risk from explosion Possible consequence: Fatal or very serious injuries. Operating the unit in areas at risk from explosion. The unit is not approved to pump media at risk from explosion. 15
Safety and Responsibility WARNING! Pumping flammable media Possible consequence: Fatal or very serious injuries. Take appropriate safety precautions when pumping flammable media. Observe the safety data sheet for the medium. CAUTION! Securing the unit Only operate the unit when fixed to a wall or similar. CAUTION! Caution: feed chemical spraying around The metering pump can generate a multiple of its rated pressure. Hydraulic parts can burst if a discharge line is blocked. Fit a relief valve in the discharge line. CAUTION! Caution: backflow Metering pumps are not absolutely leak-tight shut-off devices. Use a shut-off valve, a solenoid valve or a vacuum breaker as an absolutely leak-tight shut-off device. CAUTION! Personnel injury and material damage / Unit starts immediately The pump can start to pump as soon as it is connected to mains voltage. Only connect the device to the mains voltage when all installation work has been completed and the pumped chemicals can no longer escape in an uncontrolled manner. Install an emergency cut-off switch in the pump power supply line or integrate the pump in the emergency cutoff management of the system. CAUTION! Contact with chemicals De-pressurise, drain and rinse the hydraulic part of the unit before working on it. Flushing connections Both flushing connections can always remain closed in normal mode. 16
Safety and Responsibility Information in the event of an emergency In the event of an electrical accident, disconnect the mains cable from the mains/power supply or press the emergency cut-off switch fitted on the side of the system. If feed chemical is escaping, switch off the pump by pressing [Stop/Start]. If necessary ensure that the hydraulic system around the pump is at atmospheric pressure. Adhere to the safety data sheet for the feed chemical. 3.4 Intended use Intended use Only use the DSWa metering system to meter liquid metering chemicals in hydraulic systems. The DSWa metering system is not intended to meter gaseous or solid media. Only use the unit in accordance with the technical data and specifications provided in these operating instructions and in the operating instructions for the individual components (such as sensors, fittings, calibration devices, metering pumps etc.). Do not operate the system under conditions other than those described in the technical data! Only allow adequately qualified and technically expert personnel to operate the metering system. All other uses or modifications are prohibited. 17
Storage and Transport 4 Storage and Transport Ambient conditions for storage and transport CAUTION! Prior to storage or transport, ensure that the system is free from feed chemical and water Flush out the media carrying parts including the hoses using clean pure water Store and transport the system in its original packaging. Also protect the packaged systems against damp, exposure to chemicals and mechanical effects Please also observe the operating instructions for fittings and other units, such as sensors, filters, metering pumps... Storage temperature: 0... 55 C air humidity: < 95% relative air humidity, non-condensing Humidity: None. Rain and condensation not permitted. Other: No dust, no direct sunlight. NOTICE! If the system is stored as an assembly with other components, then the storage and transport conditions should be appropriate for the component with the least resistance to external influences. 18
Overview of equipment 5 Overview of equipment 5.1 Overview of equipment, options 10 12 8 7 8 7 6 1 5 9 9 2 12 11 A1838 Fig. 1: Overview of equipment of panel-mounted metering systems (with all options) 1 Assembly frame with pipework for installation of a metering pump 2 Extension for installation of a standby pump (same type as the metering pump) 3 Pipework material 4 Seal material 5 Vacuum cylinder 6 Vacuum pump 7 Pulsation damper (pulsation damper and back pressure valve) 8 Manometer with diaphragm seal 9 Overflow device (back pressure valve and multifunctional valve) 10 Terminal box 11 Leakage sensor 12 Connectors for the suction and discharge side 19
Overview of equipment 5.2 Overview of equipment, operating elements h i k l n f a q 1 e 1 e 2 q 2 m 1 m 2 p b c d 1 d 2 g A1839 Fig. 2: Operating elements for panel-mounted metering systems (with all options) a Bleed valve on the vacuum cylinder b Stopcock for the vacuum cylinder c Stopcock in the suction line d 1, d 2 Stopcocks upstream of the metering pumps (only fitted with versions with 2 pumps) e 1, e 2 Stopcocks downstream of the metering pumps (only fitted with versions with 2 pumps) f Flushing connector, outlet (simultaneously bleed connector) g Flushing connector, inlet h Stopcock in the discharge line i Back pressure valve k Manometer for system pressure l Pulsation damper m Relief valve n Vacuum pump p Connector for overflow device q 1, q 2 Manometer connector (only for "Start up") The pump's operating elements are described in the operating instructions for the pump. 20
Assembly and installation 6 Assembly and installation Indoors or protective covering The unit is only intended for use indoors. When using outdoors, provide a protective housing to offer protection against the weather and the sun's rays. User qualification, mechanical and hydraulic installation: trained qualified personnel, see Ä Chapter 3.1 Users' qualifications on page 13 User qualification, electrical installation: Electrical technician, see Ä Chapter 3.1 Users' qualifications on page 13 Installation, mechanical WARNING! Live parts! Bear in mind any concealed installations when drilling holes to fix the metering system in place. Drain any water from the metering system and other components supplied before fitting if feed chemicals will be used that should not come into contact with water! Fit the metering system perpendicular and upright on a wall or a stable mounting system. When doing so, bear in mind the load-bearing capacity of the wall or the mounting system Ensure that the metering system is freely accessible. Secure the metering system with hanger bolts as close as possible to the point of injection. Select the mounting height so that all operating elements are easily accessible. 10 mm 1 2 3 4 A0924 Fig. 3: Hanger bolt 1. Rawlplug (design dependent on substrate and according to stipulations of the rawlplug manufacturer) 2. Hanger bolt 3. U-washer 4. Hexagonal nut 21
Assembly and installation Installation, hydraulic Note the maximum allowable pressures, also depending on the temperature. Otherwise parts of the metering system could rupture. Provide for a suitable discharge option for flushing medium and for bleeding at the outlet of the flushing connector (f). The suction line should always rise. This is the only way of ensuring that any air bubbles rise up to the pump and can then escape through the outlet of the flushing connector (f). Installation, electrical Electrically connect the metering pumps in line with the operating instructions for the metering pumps. Electrical data for leakage sensor: Switching voltage: 48 V Switching current: 0.5 A Switch output: 10 W / 12 VA Type of contact: NC 22
Start up 7 Start up h i k l n f a q 1 e 1 e 2 q 2 m 1 m 2 p b c d 1 d 2 g A1839 Fig. 4: Operating elements for panel-mounted metering systems (with all options) a Bleed valve on the vacuum cylinder b Stopcock for the vacuum cylinder c Stopcock in the suction line d 1, d 2 Stopcocks upstream of the metering pumps (only fitted with versions with 2 pumps) e 1, e 2 Stopcocks downstream of the metering pumps (only fitted with versions with 2 pumps) f Flushing connector, outlet (simultaneously bleed connector) g Flushing connector, inlet h Stopcock in the discharge line i Back pressure valve k Manometer for system pressure l Pulsation damper m Relief valve n Vacuum pump p Connector for overflow device q 1, q 2 Manometer connector (only for "Start up") 7.1 Option: Vacuum cylinder, vacuum pump Priming: You can prime and calibrate the metering pump with the aid of the vacuum cylinder and vacuum pump options. You can also use the vacuum cylinder to reduced pressure losses in he suction line and as a bleed vessel in the event of gaseous feed chemicals. Fully fill the metering system's suction line with feed chemical and remove any air bubbles from the system when priming. 1. To fill the suction line, connect the vacuum pump (n) to the vent valve (a) on the vacuum cylinder 2. Open the following stopcocks when the metering pump is stopped: Bleed valve on the vacuum cylinder (a) Stopcock to the vacuum cylinder (b) Stopcock in the suction line (c) Stopcock upstream of the metering pump used (d) (only fitted with versions with 2 pumps) Stopcock downstream of the metering pump used (e) (only fitted with versions with 2 pumps) Bleed valve on the flushing connector (f) 23
Start up 3. Use the vacuum pump to pump until some feed chemical has risen in the vacuum cylinder. Do not allow the feed chemical to rise above the vacuum cylinder into the vacuum pump 4. Close the damper on the vacuum cylinder (a) 5. Allow the metering pump to work until the feed chemical rises in the discharge line 6. Using the standby pump: Fill this metering pump with feed chemical as well, following the instructions for priming 7. Close the following ball valves: Stopcock to the vacuum cylinder (b) Bleed valve on the flushing connector (f) ð This brings priming to a close. 7.2 Option: Pulsation damping Adjusting pulsation damping: The pulsation damping option includes a pulsation damper (l) and a back pressure valve (i). You need to adjust the pulsation damper and the back pressure valve to obtain optimum pulsation damping. Use a conventional air pump to increase the priming pressure of the pulsation damper (l) to around 60 to 80% of the system's subsequent average operating pressure with the metering pump stopped. First use the air pump to set a pressure which is around 2 bar higher, as the pressure will drop by around 2 bar when the air pump is removed. Press the pin in the automatic valve to finely adjust the pressure. 7.3 Adjusting the operating pressure of the system using the back pressure valve Adjusting the operating pressure of the system using the back pressure valve: 1. Fully open the back pressure valve (I), by turning the adjusting screw all the way to the left 2. Start the metering pump: the needle on the manometer on the pulsation damper (I) oscillates at the same rhythm as the metering strokes 3. Slowly increase the operating pressure on the back pressure valve (I), by turning the adjusting screw to the right until the operating pressure you need is reached. ð Read off the operating pressure on the manometer (k) (optional). Leak test: Check the metering system and all connectors for leak-tightness. 7.4 Adjusting the relief valve Adjusting the relief valve: Adjust the relief valve so that the maximum permissible operating pressure of all parts of the metering system and the downstream parts of the system is not exceeded. Ensure that a manometer is fitted to the manometer connector on the relief valve during adjustment. 1. Fully open the relief valve (m), by turning the adjusting screw all the way to the left 2. Close the stopcock in the discharge line (h) and observe the operating pressure on the manometer 24
Start up 3. Start the metering pump 4. Slowly increase the operating pressure on the back pressure valve (I), by turning the adjusting screw to the right until the maximum permissible operating pressure of the weakest component on the discharge side is reached ð This operating pressure is the pressure when the relief valve opens. 7.5 Calibration Calibration: Calibration determines the capacity (litres/hour) of the metering pump. Calibrate a metering pump by metering out of the vacuum cylinder. 1. To fill the vacuum cylinder, connect the vacuum pump (n) to the vacuum cylinder (a). 2. Stop the metering pump 3. Open the following ball valves: 4. Bleed valve on the vacuum cylinder (a) Stopcock to the vacuum cylinder (b) Stopcock upstream of the metering pump used (d) (only fitted with versions with 2 pumps) Stopcock downstream of the metering pump used (e) (only fitted with versions with 2 pumps) Stopcock in the suction line (c) Stopcock in the discharge line (h) Do not allow the feed chemical to rise above the vacuum cylinder into the vacuum pump. Use the vacuum pump to pump until the feed chemical in the vacuum cylinder has risen only as far as the first scale marking on the scale and no further. 5. Close the stopcock in the suction line (c) 6. Note the liquid level in the vacuum cylinder 7. Allow the metering pump to run for a specified time and then stop the metering pump (refer to the operating instructions for the metering pump) 8. Read off the volume metered on the scale of the vacuum cylinder. 9. With metering pumps with a calibration menu, you can enter the value for the metered volume directly in the metering pump's calibration menu, see the operating instructions for the relevant ProMinent metering pump. With other metering pumps you can now calculate the capacity. 10. Open the stopcock in the suction line (c) 11. Close the damper on the vacuum cylinder (a) 12. Close the stopcock to the vacuum cylinder (b) 7.6 Vacuum cylinder Use the vacuum cylinder to reduce pressure losses in the suction line. 25
Start up Generate an air cushion in the vacuum cylinder: There should always be an air cushion in the vacuum cylinder. 1. Open the stopcock to the vacuum cylinder (b) 2. Open the bleed valve on the vacuum cylinder (a) 3. Allow the metering pump to run until no more feed chemical can be seen in the vacuum cylinder. You can speed up the process, if necessary, by briefly closing the stopcock in the suction line (c). 4. Close the damper on the vacuum cylinder (a) Fill the vacuum cylinder: Use the vacuum cylinder as a bleed vessel: There should always be feed chemical in the vacuum cylinder. There should always be an air cushion in the vacuum cylinder. 1. To fill the vacuum cylinder, connect the vacuum pump (n) to the vacuum cylinder (a). 2. Stop the metering pump 3. Open the following ball valves: 4. Bleed valve on the vacuum cylinder (a) Stopcock to the vacuum cylinder (b) Stopcock in the suction line (c) Do not allow the feed chemical to rise above the vacuum cylinder into the vacuum pump. Use the vacuum pump to pump until the feed chemical in the vacuum cylinder has risen only as far as the first scale marking on the scale and no further. 5. Close the damper on the vacuum cylinder (a) 26
Maintenance and repair 8 Maintenance and repair User qualification: trained qualified personnel, see Ä Chapter 3.1 Users' qualifications on page 13 Maintenance interval for pulsation damper and vacuum cylinder: Maintain at regular intervals depending on the feed chemical, installation and operating conditions. Also read the operating instructions for the individual components used. Regularly check the pulsation damper as follows: Check that the threaded connections are tight. Check that the pulsation damper is leak-tight Function Regularly check the vacuum cylinder as follows: Check that the threaded connections are tight. Check that the vacuum cylinder is leak-tight Function 27
Decommissioning and Disposal 9 Decommissioning and Disposal User qualification: instructed user, see Ä Chapter 3.1 Users' qualifications on page 13 WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries. Please ensure when handling hazardous substances that you have read the latest safety data sheets provided by the manufacture of the hazardous substance. The actions required are described in the safety data sheet. Check the safety data sheet regularly and replace, if necessary, as the hazard potential of a substance can be re-evaluated at any time based on new findings. The system operator is responsible for ensuring that these safety data sheets are available and that they are kept up to date, as well as for producing an associated hazard assessment for the workstations affected. During decommissioning, de-energise the mains cable and ensure that it cannot be switched on again. Thoroughly clean the unit of chemicals and dirt when decommissioning the unit! 1. Disconnect the device from the mains power supply. 2. De-pressurise the pulsation damper (l). 3. De-pressurise the back pressure valve (I) and the relief valves (m). 4. De-pressurise the multifunctional valve (m). 5. Drain the metering system and thoroughly rinse it with a suitable medium. 6. Also read the operating instructions for the individual components used. Maintain the storage conditions in the event of temporary decommissioning. 28
Decommissioning and Disposal 9.1 Disposal of Used Parts User qualification: instructed user, see Ä Chapter 3.1 Users' qualifications on page 13 NOTICE! Regulations governing the disposal of used parts Note the national regulations and legal standards that currently apply in your country The manufacturer will take back decontaminated used units providing they are covered by adequate postage. Decontaminate the unit before returning it for repair. To do so, remove all traces of hazardous substances. Refer to the Material Safety Data Sheet for your feed chemical. A current Declaration of Decontamination is available to download on the ProMinent website. 29
Technical data 10 Technical data You will find the technical data for the metering pump and the other units (back pressure valve, multifunctional valve, pulsation damper etc.) in the product-specific operating instructions. Storage and transport temperature of the metering station: 0... 50 C Maximum air humidity *: 95% rel. humidity Maximum permissible operating pressure: 10 bar at 25 C (feed chemical) 6 bar at 40 C (feed chemical) Electrical data for leakage sensor: Switching voltage: 48 V Switching current: 0.5 A Switch output: 10 W / 12 VA Type of contact: NC 30
Technical data DSWa with one pump: Type B410 B510 GL10 S110 S115 Pumps Beta 4 Beta 5 gamma/ L Sigma/ 1 Sigma/ 1 Nominal width of pipework Nominal width of flushing connector Nominal width of relief valve return line Dimensions (HxWxD) in mm DN 10 DN 10 DN 10 DN 10 DN 15 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 1200x800x300 1200x800x300 1200x800x300 1400x900x450 1400x900x450 Pulsation damper PDS 80 G PDS 80 G PDS 80 G PDS 80 G PDS 250 Volume of vacuum cylinder 0.5 l 0.5 l 0.5 l 0.5 l 1 l Max. capacity 19 l/h 32 l/h 32 l/h 65 l/h 120 l/h Max. operating pressure (25 C) Max. operating pressure (40 C) 10 bar 10 bar 10 bar 10 bar 10 bar 6 bar 6 bar 6 bar 6 bar 6 bar Type S215 S220 S325 S332 Pumps Sigma/ 2 Sigma/ 2 Sigma/ 3 Sigma/ 3 Nominal width of pipework Nominal width of flushing connector Nominal width of relief valve return line Dimensions (HxWxD) in mm DN 15 DN 20 DN 25 DN 32 DN 10 DN 15 DN 20 DN 25 DN 10 DN 15 DN 20 DN 25 1400x900x450 1400x900x450 1600x900x500 1600x900x500 Pulsation damper PDS 250 G PDS 750 G PDS 750 G PDS 2500 Volume of vacuum cylinder 1 l 2.5 l 2.5 l 5.0 l Max. capacity 130 l/h 350 l/h 324 l/h 1000 l/h Max. operating pressure (25 C) Max. operating pressure (40 C) 10 bar 10 bar 10 bar 8* / 10 bar 6 bar 6 bar 6 bar 6 bar * with pulsation damper option 31
Technical data DSWa with 2 pumps: Type B410 B510 GL10 S110 S115 Pumps Beta 4 Beta 5 gamma/ L Sigma/ 1 Sigma/ 1 Nominal width of pipework Nominal width of flushing connector Connector for relief valve return line Dimensions (HxWxD) in mm DN 10 DN 10 DN 10 DN 10 DN 15 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 DN 10 1400x1000x300 1400x1000x300 1400x1000x300 1600x1200x450 1600x1200x450 Pulsation damper PDS 80 G PDS 80 G PDS 80 G PDS 80 G PDS 250 G Volume of vacuum cylinder 0.5 l 0.5 l 0.5 l 0.5 l 1 l Max. capacity 19 l/h 32 l/h 32 l/h 65 l/h 120 l/h Max. operating pressure (25 C) Max. operating pressure (40 C) 10 bar 10 bar 10 bar 10 bar 10 bar 6 bar 6 bar 6 bar 6 bar 6 bar Type S215 S220 S325 S332 Pumps Sigma/ 2 Sigma/ 2 Sigma/ 3 Sigma/ 3 Nominal width of the pipework Nominal width of flushing connector Connector for relief valve return line Dimensions (HxWxD) in mm DN 15 DN 20 DN 25 DN 32 DN 10 DN 15 DN 20 DN 25 DN 10 DN 15 DN 20 DN 25 1600x1200x450 1600x1200x450 1600x1200x500 1600x1200x500 Pulsation damper PDS 250 G PDS 750 G PDS 750 G PDS 2500 Volume of vacuum cylinder 1 l 2.5 l 2.5 l 5.0 l Max. capacity 130 l/h 350 l/h 324 l/h 1000 l/h Max. operating pressure (25 C) Max. operating pressure (40 C) 10 bar 10 bar 10 bar 8* / 10 bar 6 bar 6 bar 6 bar 6 bar * with pulsation damper option 32
EU Declaration of Conformity for Machinery 11 EU Declaration of Conformity for Machinery In accordance with DIRECTIVE 2006/42/EC OF THE EUROPEAN PAR LIAMENT AND OF THE COUNCIL, Appendix I, BASIC HEALTH AND SAFETY REQUIREMENTS, section 1.7.4.2. C. We, ProMinent GmbH Im Schuhmachergewann 5-11 D - 69123 Heidelberg, Germany, hereby declare that the product specified in the following, complies with the relevant basic health and safety requirements of the EU Directive, on the basis of its functional concept and design and in the version distributed by us. Any modification to the product not approved by us will invalidate this declaration. Extract from the EU Declaration of Conformity Designation of the product: Product type: Serial number: Relevant EU directives: Harmonised standards applied, in particular: DULCODOS Panel DSWa see nameplate on the device EC Machinery Directive (2006/42/EC) Compliance with the protection targets of the Low Voltage Directive 2014/35/EU according to Appendix I, No. 1.5.1 of the Machinery Directive 2006/42/EC EMC Directive (2014/30/EU) EN ISO 12100:2010 EN 809:1998 + A1:2009 + AC:2010 EN 61000-6-2:2005 + AC:2005 EN 61000-6-4:2007 + A1:2011 Place/Date: Heidelberg / 20.04.2016 You will find the EU Declaration of Conformity to download on our homepage. 33
Index 12 Index A Action, step by step... 2 Applied harmonised standards... 33 C Collecting pan... 12 Concealed installations... 21 D Designation of the product...33 E Electrical data for leakage sensor... 22 EU Declaration of Conformity for Machinery...33 G General information on installation and assembly... 21 General non-discriminatory approach... 2 H Hanger bolts... 21 I Indoors...21 Information in the event of an emergency... 17 Installation...21 Installation, electrical... 22 L Leakage sensor... 12 Links to elements or sections of these instructions or other applicable documents...2 Live parts... 15 Question: How should I dispose of the unit?...28 Question: How should I electrically install the unit?... 22 Question: How should the suction line be routed?... 22 Question: Is the unit approved for areas at risk from explosion?... 15 Question: What ambient conditions need to be taken into consideration?... 18 Question: What components make up the unit?... 19 Question: What operating elements does the unit have?... 20 Question: Where do I find the safety information?... 15 R Relevant EU directives... 33 S Securing the unit... 16 Serial number... 33 Storage...18 Suction line... 22 T Transport... 18 U Use of the unit in areas at risk from explosion...15 Users' qualifications... 13 W Wall mounting plate... 12 Warning information... 13 M Maximum permissible operating pressure... 30 More symbols... 2 Mounting system... 21 N Non-discriminatory approach... 2 O Operating elements... 20 Operating error / Unauthorised access... 15 P Protective housing... 21 Pumping flammable media... 16 Q Question: How can I store and transport the product? 18 34
35
ProMinent GmbH Im Schuhmachergewann 5-11 69123 Heidelberg, Germany Germany Telephone: ++49 6221 842-0 Fax: ++49 6221 842-419 Email: info@prominent.com Internet: www.prominent.com 986762, 2, en_gb 2016