ProMinent DULCO flex Control Operating Instructions Manual

Peristaltic metering pump

DULCO flex Control, DFXa

Operating instructions

EN

Original operating instructions (2006/42/EC)Part no. 981953 BA DX 027 07/19 EN

Please carefully read these operating instructions before use. · Do not discard.

The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

Read the following supplementary information in its entirety! Should you

already know this information, you will benefit more from referring to the

operating instructions.

The following are highlighted separately in the document:

n Enumerated lists

Instructions

ð

Outcome of the instructions

Ä ‘State the identity code and serial number’ on page 2

: Links to points

in this chapter

- refer to ... : References to points in this document or another document

[Keys]

‘Menu level 1

è

Menu level 2

è

Menu level ...’

: Menu paths

‘Software interface text’

Information

This provides important information relating to the cor‐

rect operation of the unit or is intended to make your

work easier.

Safety Information

Safety information is identified by pictograms - see "Safety Chapter".

Please state the identity code and serial number, which you can find on

the nameplate or in the menu under

‘Setting / Menu

è

Information’

when

you contact us or order spare parts. This enables the unit type and mate‐

rial versions to be clearly identified.

Supplementary information

Fig. 1: Please read!

State the identity code and serial number

Supplemental directives

2

Table of contents

1

Identity code.................................................................................... 5

2 About this pump............................................................................... 8

3 Safety chapter................................................................................. 9

4 Storage, transport and unpacking................................................. 14

5 Overview of equipment and control elements............................... 15

5.1 Overview of equipment......................................................... 15

5.2 Control elements................................................................... 16

5.2.1 Control elements................................................................ 16

5.2.2 Key functions...................................................................... 18

6 Functional description.................................................................... 20

6.1 Device................................................................................... 20

6.2 Capacity................................................................................ 20

6.3 Operating modes................................................................... 20

6.4 Functions............................................................................... 20

6.5 Relay (options)...................................................................... 21

6.6 LED displays......................................................................... 21

6.7 Hierarchy of operating modes, functions and fault sta‐

tuses......................................................................................

22

7 Assembly....................................................................................... 23

7.1 Changing dosing head alignment.......................................... 23

8 Installation, hydraulic..................................................................... 26

9 Installation, electrical..................................................................... 29

9.1 Supply voltage connector - mains voltage............................ 30

9.2 Description of the terminals................................................... 31

9.2.1 "Config I/O” terminal........................................................... 31

9.2.2 "External control" terminal.................................................. 32

9.2.3 "Level switch" terminal....................................................... 33

9.2.4 "Metering monitor" terminal................................................ 34

9.2.5 "Hose rupture indicator" terminal....................................... 34

9.2.6 Relay.................................................................................. 35

10 Basic set-up principles................................................................... 39

10.1 Basic principles for setting up the control............................ 39

10.2 Checking adjustable variables............................................ 41

10.3 Changing to Setting mode................................................... 41

11 Initial commissioning..................................................................... 42

12 Set up /

‘Menu’

.............................................................................. 45

12.1

‘Information’

....................................................................... 45

12.2

‘Settings’

............................................................................ 45

12.2.1

‘Operating mode’

............................................................. 45

12.2.2 Dosing direction............................................................... 49

12.2.3 Concentration................................................................... 49

12.2.4 Calibrate........................................................................... 54

12.2.5 System............................................................................. 56

12.2.6 Inputs/outputs................................................................... 57

12.2.7

‘Priming time’

.................................................................. 59

12.2.8

‘Set time’

......................................................................... 59

12.2.9

‘Date’

............................................................................... 60

12.3

‘Hose replacement’

............................................................ 60

12.4 Timer................................................................................... 60

12.4.1 Activation / deactivation................................................... 60

12.4.2 Setting the timer............................................................... 61

12.4.3 Clear all............................................................................ 68

Table of contents

3

12.4.4 Examples......................................................................... 68

12.4.5 Timer information............................................................. 72

12.4.6 Typical pitfalls Timer functional faults............................. 72

12.4.7 Brief explanation of selected functions............................. 73

12.5

‘Service’

............................................................................. 76

12.5.1

‘Access protection’

.......................................................... 77

12.5.2

‘Password ’

...................................................................... 78

12.5.3

‘Clear counters’

............................................................... 78

12.5.4

‘Hose’

.............................................................................. 78

12.5.5

‘Error log book’

................................................................ 79

12.5.6

‘Display’

........................................................................... 80

12.5.7

‘Factory setting’

............................................................... 80

12.5.8 Spare parts kit number: XXXXXXX.................................. 80

12.6

‘Language’

......................................................................... 80

13 Operation....................................................................................... 81

13.1 Manual operation................................................................ 81

14 Maintenance.................................................................................. 83

15

Repair............................................................................................ 85

15.1 Replacing pump hose......................................................... 86

15.2 Cleaning hose rupture indicator (option)............................. 88

16 Troubleshooting............................................................................. 89

16.1 Faults without a fault message............................................ 89

16.2 Faults with error message................................................... 89

16.2.1 Fault messages on the LCD screen................................. 89

16.2.2 Warning messages on the LCD screen........................... 91

16.2.3 All other faults.................................................................. 92

16.3 Log book............................................................................. 92

16.3.1 Fault messages in the log book....................................... 92

16.3.2 Warning messages in the log book.................................. 93

16.3.3 Event messages in the log book...................................... 94

16.3.4 Log book entry - detailed view......................................... 94

17 Decommissioning and disposal..................................................... 96

18 Technical data............................................................................... 98

18.1 Performance data................................................................ 98

18.2 Precision............................................................................. 98

18.3 Viscosity.............................................................................. 98

18.4 Material specifications......................................................... 99

18.5 Electrical data...................................................................... 99

18.6 Temperatures...................................................................... 99

18.7 Climate.............................................................................. 100

18.8 Altitude of site ................................................................... 100

18.9 Degree of Protection and Safety Requirements................ 100

18.10 Sound pressure level...................................................... 100

18.11 Suction lance, continuous............................................... 100

19 Dimensional drawings................................................................. 102

20

Declaration of Conformity for Machinery..................................... 103

21 Operating / set-up overview DULCO flex Control........................ 104

22 DULCO flex Control operating menu, overall.............................. 106

23 Continuous displays and secondary displays.............................. 111

24 Installation instructions: Retrofitting Relays ................................ 113

25 Index............................................................................................ 115

Table of contents

4

1 Identity code

Product identification

This identity code serves to identify the product.

Use the identity code from the Product Catalogue for

orders.

Product range DULCO flex Control

DFXa

Regional design

EU Europe

US USA

CN China

Pump type

0730 7 bar, 30 l/h

0530 5 bar, 30 l/h

Hose material / connections / O-rings

SP TPV / PVDF / PTFE

VP PUR / PVDF / PTFE

Seal material

F FDA-compliant (PTFE)

T PTFE

Dosing head orientation (orientation of hydraulic connectors - viewed from behind)

R right

L left

O top

U bottom

Hydraulic connector

0 Standard connector (12x9)

2 8x5 connector

5 12x6 connector, discharge side

7 without connector kit

8 9x5 connector

E DN10 connector, with nozzle

Hose rupture indicator

0 none

1 Optical hose rupture indicator

Design

0 Housing RAL5003 / Hood RAL2003

2 Housing RAL5003 / Hood RAL3001

M modified

Identity code

5

Product range DULCO flex Control

Logo

0 with ProMinent logo

2 without ProMinent logo

Version of power unit

U 100-240 V

Cable and plug

A 2 m, Europe

B 2 m, Switzerland

C 2 m, Australia

D 2 m, USA / 115 V

1 2 m, open end

.. ...

Relay function

0 no relay -

1 1 x changeover contact

230 V AC – 6 A

Fault indicating relay (N/C)

4 1 x N/O 24 V DC – 1 A

1 x N/O 24 V DC – 100

mA

as 1 + pacing relay

C 1 x N/O 24 V DC – 100

mA, and 1 x 4-20 mA

output

As 1 + 4-20 mA output

.. ...

Accessories

0 no accessories

1 with 1/2” injection valve and foot valve

2 as 0 + measuring cup

3 as 1 + measuring cup

Control version

0 Manual + external contact with pulse control

3 Manual + external contact with pulse control +

analog 0/4-20mA

C As 3 + CANopen

E As 3 + PROFINET

R

As 3 + PROFIBUS

®

M12 plug

M As 3 + Modbus RTU

Communication

0 none

W with Wi-Fi

B Bluetooth

Language

DE German

Identity code

6

Product range DULCO flex Control

EN English

ES Spanish

FR French

... ...

Identity code

7

2 About this pump

Pumps in the DULCO flex Control product range are microprocessor-con‐

trolled peristaltic metering pumps with the following characteristics:

n simple adjustment of the capacity directly in l/h or in gph

n flow reversal possible

n simpler hose replacement supported by software

n only the medium comes into contact with the hose

n CIP-compatible - when pump is running

n direct input of the required final concentration with volume-propor‐

tional metering tasks in concentration mode

n external control via potential-free contacts with pulse step-up and

step-down

n external control via 0/4-20 mA standard signal, scalable

n integrated 1-week/1-month timer

n connection to process control systems via a BUS interface, such as

PROFINET, Modbus RTU or CAN bus

n DULCOnneX-compatible

About this pump

8

3 Safety chapter

The following signal words are used in these operating instructions to

denote different severities of danger:

Signal word Meaning

WARNING Denotes a possibly dangerous sit‐

uation. If this is disregarded, you

are in a life-threatening situation

and this can result in serious inju‐

ries.

CAUTION Denotes a possibly dangerous sit‐

uation. If this is disregarded, it

could result in slight or minor inju‐

ries or material damage.

The following warning signs are used in these operating instructions to

denote different types of danger:

Warning signs Type of danger

Warning – automatic start-up.

Warning – hand injuries.

Warning – high-voltage.

Warning – danger zone.

n Only use the pump to meter liquid feed chemicals.

n The pump may only be started up after it has been correctly installed

and started up in accordance with the technical data and specifica‐

tions contained in the operating instructions.

n Observe the general limitations with regard to viscosity limits, chem‐

ical resistance and density - see also ProMinent resistance list in the

Product Catalogue or at www.prominent.com! Use the "Chemical

Resistance List DFXa" available at www.prominent.com for the pump

hose.

n All other uses or modifications are prohibited.

n The pump is not intended for the metering of gaseous media and

solids.

n The pump is not intended to meter flammable media.

n The pump is not intended for the metering of explosive media.

n The pump is not intended for use outdoors without appropriate protec‐

tive measures.

n The pump should only be operated by trained and authorised per‐

sonnel - see the following "Qualifications" table.

n You have a duty to observe the information contained in the operating

instructions during the different phases of the device's service life.

Identification of safety notes

Warning signs denoting different types of

danger

Intended use

Safety chapter

9

WARNING!

Warning about personal and material damage

The pump can start to pump, as soon as it is connected

to the mains voltage.

– Install an emergency cut-off switch in the pump

power supply line or integrate the pump in the emer‐

gency cut-off management of the system.

WARNING!

Warning of personal injury and material damage

The pump can start pumping as soon as it has cooled

down after the error

‘temperature’

.

– Take this into account with the pump and your

installation.

WARNING!

Danger of electric shock

A mains voltage may exist inside the pump housing.

– If the pump housing has been damaged, you must

disconnect it from the mains immediately. It may

only be returned to service after an authorised

repair.

WARNING!

Warning of hazardous feed chemical

Should a dangerous feed chemical be used: it may

escape from the hydraulic components when working on

the pump, material failure or incorrect handling of the

pump.

– Take appropriate protective measures before

working on the pump (e.g. safety glasses, safety

gloves, ...). Adhere to the material safety data sheet

for the feed chemical.

–

Drain and flush the liquid end before working on the

pump.

WARNING!

Fire danger

The pumping of flammable media is prohibited.

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.

Safety information

Safety chapter

10

CAUTION!

Warning of feed chemical spraying around

Feed chemical can spray out of the hydraulic compo‐

nents if they are manipulated or opened due to pressure

in the liquid end and adjacent parts of the system.

– Disconnect the pump from the mains power supply

and ensure that it cannot be switched on again by

unauthorised persons.

–

Depressurise the system before commencing any

work on hydraulic parts.

CAUTION!

Warning of body parts being drawn in

The rotor running in the liquid end may draw in and trap

body parts.

– Do not reach into the running rotor.

–

Only take off bearing cover once prompted to do so

by the operating instructions or operating software.

CAUTION!

Warning of feed chemical spraying around

An unsuitable feed chemical can damage the parts of

the pump that come into contact with the chemical.

– Take into account the resistance of the wetted mate‐

rials and the ProMinent Resistance List when

selecting the feed chemical - see the ProMinent

Product Catalogue or visit ProMinent.

CAUTION!

Warning of feed chemical spraying around

An unsuitable feed chemical may cause premature wear

to the pump hose.

– Observe the pump hose's resistance and "Chemical

Resistance List DFXa" available at www.promi‐

nent.com when selecting the feed chemical.

CAUTION!

Danger of injury to personnel and material damage

The use of untested third party components can result in

injury to personnel and material damage.

– Only fit parts to metering pumps that have been

tested and recommended by ProMinent.

CAUTION!

Danger from incorrectly operated or inadequately main‐

tained pumps

Danger can arise from a poorly accessible pump due to

incorrect operation and poor maintenance.

– Ensure that the pump is accessible at all times.

–

Adhere to the maintenance intervals.

Safety chapter

11

CAUTION!

Warning against illegal operation

Observe the regulations that apply where the device is

installed.

n Cover for the slot for relays and optional modules - see the chapter

entitled "Overview of Equipment and Control Elements"

n Bearing cover for liquid end - see "Overview of equipment and control

elements” chapter

Customers should only remove the cover for the slot for relays and

optional modules and/or a relay or optional module in line with the supple‐

mentary instructions for the relays and optional modules.

Customers should only remove the bearing cover for the liquid end in

accordance with the "Repair" chapter.

Only the ProMinent service department is authorised to open the housing

and hood (housing the control elements).

Adhesive labels

WARNING!

– A warning sign indicating "Warning of injury to

hands" is stuck on the pump and warns of rotating

parts and the risk of being drawn into the liquid end.

–

Ensure that the label is always fitted and legible.

In an emergency, either disconnect the mains plug, press

[Start/Stop]

or press the Emergency Stop switch installed on the customer's side or

disconnect the pump from the mains/power supply in line with the Emer‐

gency Stop management guidelines for your system.

If feed chemical escapes, also ensure that the pump's hydraulic environ‐

ment is at atmospheric pressure. Adhere to the material safety data sheet

for the feed chemical.

Task Qualification

Storage, transport, unpacking Instructed person

Assembly Technical personnel, service

Planning the hydraulic installation Technical personnel who have a thorough knowledge of peristaltic

pumps

Hydraulic installation Technical personnel, service

Electrical installation Electrical technician

Initial commissioning Technical personnel, service

Operation Instructed person

Maintenance, repair Technical personnel, service

Decommissioning, disposal Technical personnel, service

Troubleshooting Technical personnel, electrical technician, instructed person, service

Explanation of the table:

Technical personnel

Isolating protective equipment

Other protective equipment

Information in the event of an emergency

Qualification of personnel

Safety chapter

12

Technical personnel are deemed to be people who are able to assess the

tasks assigned to them and recognise possible dangers based on their

technical training, knowledge and experience, as well as knowledge of

pertinent regulations.

Note:

A qualification of equal validity to a technical qualification can also be

gained by several years of employment in the relevant field of work.

Electrical technician

An electrical technician is able to complete work on electrical systems and

recognise and avoid possible dangers independently based on his or her

technical training and experience as well as knowledge of pertinent stand‐

ards and regulations.

The electrical technician must be specifically trained for the working envi‐

ronment in which he or she is employed and be conversant with the rele‐

vant standards and regulations.

The electrical technician must comply with the provisions of the applicable

statutory directives on accident prevention.

Instructed person

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 dan‐

gers that could result from improper behaviour, as well as having been

instructed in the required protective equipment and protective measures.

Service

The service department refers to service technicians, who have received

proven training and have been authorised by ProMinent to work on the

device / system.

Sound pressure level LpA < 70 dB according to EN ISO 20361

at maximum feed rate and maximum back pressure (water)

Sound pressure level

Safety chapter

13

4 Storage, transport and unpacking

User qualification: Instructed person - see

Ä ‘Qualification of personnel’

on page 12

WARNING!

Only return metering pumps for repair in a cleaned state

and with a flushed liquid end - refer to "Decommis‐

sioning!

Only return metering pumps with a completed Decon‐

tamination Declaration form. The Decontamination Dec‐

laration constitutes an integral part of an inspection /

repair order. A unit can only be inspected or repaired

when a Declaration of Decontamination Form is sub‐

mitted that has been completed correctly and in full by

an authorised and qualified person on behalf of the

pump operator.

The "Decontamination Declaration Form" can be found

on our homepage.

CAUTION!

Danger of material damage

The device can be damaged by incorrect or improper

storage or transportation!

– The unit should only be stored or transported in a

well packaged state - preferably in its original pack‐

aging.

–

The packaged unit should also only be stored or

transported in accordance with the stipulated

storage conditions.

– The packaged unit should be protected from mois‐

ture and the ingress of chemicals.

Ambient conditions - see "Technical Data" chapter.

Storage period of pump hose non-condensing, max.: 2 years

Compare the delivery note with the scope of delivery:

n Metering pump with mains cable

n Pump hose

n Rotor half

n Connector kit for hose/pipe connection (option)

n Product-specific operating instructions with EU Declaration of Con‐

formity

n Optional accessories

Safety information

Ambient conditions

Storage period, max.

Scope of delivery

Storage, transport and unpacking

14

5 Overview of equipment and control elements

5.1

Overview of equipment

1

P_G_0103_SW

2 3

Fig. 2: Overview of equipment DFXa, complete

1 Control unit

2 Drive unit

3 Liquid end

P DX 0177 SW

1

2

3

4

5

Fig. 3: Liquid end DFXa

1 Dosing head

2 Pressure connector (delivery status)

3 Suction connector (delivery status)

4 Star screws

5 Bearing cover

Overview of equipment and control elements

15

5.2 Control elements

a)

b)

P_G_0105_SW

12 14

15

13

10

11

3

1

5

4

2

9

8

7

6

Fig. 4

1 LCD screen

2

[Menu]

key

3

Clickwheel

4

[Priming]

key

5

[STOP/START]

key

6

[Back]

key

7 Fault indicator (red)

8 Warning indicator (yellow)

9 Operating indicator (green)

10 "Config I/O” terminal

11 "Hose rupture indicator" terminal

12 "External control" terminal

13 "Metering monitor" terminal (no function)

14 "Level switch" terminal

15 Slot for relays and optional modules

5.2.1 Control elements

Use this overview to familiarise yourself with the keys

and other control elements on the pump!

Control elements, overview

Overview of equipment and control elements

16

10.0

10.0 mA

ANALOG

4..20mA

l/h

B1150

1

3

2

AUX

Fig. 5: Structure of continuous display

1 Status bar

2 Continuous display, central area

3 Secondary display

Refer to the chapter entitled "Main displays and secondary displays" in the

Appendix for the different main displays and secondary displays.

The LCD screen supports the operation and adjustment of the pump using

various information and identifiers:

30.0

Level

MANUAL

l/h

Service: 600 h

MANUAL

Level error!

B1151

a)

b)

Level

602371

Fig. 6: a) Continuous display with warning message; b) Continuous display

with fault message. Explanation of the symbols in the following tables.

The above Figure, Part a) shows that:

n the pump is in operation

n is in

‘Manual’

operating mode

n a

‘level’

warning message is pending

n the capacity of 30.0 l/h has been set

n the pump has performed 602371 revolutions to date

Tab. 1: Identifiers and error displays:

Identifier Meaning

The pump is working or waiting for a starting signal.

The pump was manually stopped using the

[STOP/START]

key.

The pump was remotely stopped (Pause) - via the "External" terminal.

The pump was stopped by an error.

Only with cyclical batch metering: the pump is waiting for the next cycle.

Identifier and fault displays on the LCD

screen

Overview of equipment and control elements

17

Identifier Meaning

Only with

‘Access protection’

: the pump software is locked.

‘AUX’

The pump is currently pumping at auxiliary capacity.

‘memory’

Only in

‘CONTACT’

and

‘BATCH’

operating modes:

the auxiliary function "Memory" has been set.

The pump is in

‘ANALOG’

operating mode.

The

‘Curve

è

linear’

type of processing is set.

The pump is in

‘ANALOG’

operating mode.

The

‘Curve

è

Upper side band’

type of processing is set.

A hose rupture indicator is connected.

The pump is in the

‘Menu’

(Set up).

Further explanations can be found in the "Trouble‐

shooting" chapter.

The pump only shows the metering volume and the

capacity in the calibrated state in l or l/h or in gal or gal/h

(US gallons).

5.2.2 Key functions

Key Application In the continuous displays In the menu

[Back]

press - Go back to the previous menu

item (or a continuous display) -

without saving

[STOP/

START]

press Stop pump, Stop pump,

Start pump Start pump

[Menu]

press Go to the menu Go back to a continuous display

[Priming]

press Priming * Priming *

[Clickwheel]

press Start batch (only in

‘Batch’

operating

mode),

Acknowledge errors

Go to next menu item (or a contin‐

uous display)

Confirm entry and save

[Clickwheel]

turn Switch between the continuous dis‐

plays

Change figure or change selection

Overview of equipment and control elements

18

* When priming the pump does not run at maximum

number of revolutions.

If

[Priming] is pressed in ‘Stop’ state, then [Priming]

has top priority as long as the button is pressed.

Refer to the "Set-up basics" chapter for how to adjust fig‐

ures

Overview of equipment and control elements

19

6 Functional description

6.1

Device

An electric motor drives a rotor. Rollers are fitted to the ends of the rotors,

which press the pump hose against the inner curvature of the dosing

head. The peristaltic pump operates by the rollers driving the feed chem‐

ical through the pump hose. The feed chemical is primed by the pump

hose automatically returning to its initial position.

6.2 Capacity

The capacity that has been set regulates the pump itself.

6.3 Operating modes

Operating modes are selected via the "Operating modes" menu.

Refer to the "Hierarchy of Operating Modes, Functions and Fault Statuses"

for the order of the various operating modes, functions and fault statuses.

‘Manual’

operating mode permits you to operate the pump manually.

This operating mode provides the option of controlling the pump externally

by means of potential-free contacts (e.g. by means of a contact water

meter). “Pulse Control” can be used to preselect the metering volume in

the

‘Settings’

menu.

This operating mode provides the option of working with large metering

volumes. Metering can be triggered either by pressing the

[Clickwheel]

or

by a pulse received via the "External control" terminal via a contact or a

semiconductor switching element. It is possible to pre-select a metering

volume (batch) and a metering time using the

[Clickwheel]

in the

‘Settings’

menu.

The capacity is controlled using an analogue current signal via the

"External control" terminal. Processing of the current signal can be prese‐

lected using the control unit.

6.4 Functions

Refer to the "Hierarchy of Operating Modes, Functions and Fault Statuses"

for the order of the various operating modes, functions and fault statuses.

The following functions can be selected using the

‘Settings’

menu:

"Manual" operating mode

"Contact" operating mode

"Batch" operating mode

"Analog" operating mode

Functional description

20

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