Operating instructions Diaphragm Motor-Driven Metering Pump Sigma / 2 Base Type S2Ba P_SI_0074_SW Two sets of operating instructions are required for the safe, correct and proper operation of the metering pumps: The product-specific operating instructions and the "General Operating Instructions for ProMinent® motor-driven metering pumps and hydraulic accessories". Both sets of operating instructions are only valid when read together.
ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 69123 Heidelberg Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-617 email: info@prominent.com Internet: www.prominent.
Supplemental instructions Supplementary information Read the following supplementary information in its entirety! Should you already know this information, you have an even greater need of the Oper‐ ating Instructions. The following are highlighted separately in the document: Fig.
Table of contents Table of contents 1 Identity code S2Ba.......................................................................... 5 2 Safety chapter................................................................................. 7 3 Storage, transport and unpacking................................................. 10 4 Overview of equipment and control elements............................... 12 5 Functional description.................................................................... 14 5.1 5.
Identity code S2Ba 1 Identity code S2Ba S2Ba Sigma 2 basic type H Main power end, diaphragm Type: Power (at 50 Hz) bar l/h*** 16050 10* 50 16090 10* 90 16130 10* 130 07120 7 120 07220 7 220 04350 4 350 Dosing head material PV PVDF SS Stainless steel Seal material T PTFE seal Displacement S Multi-layer safety diaphragm with optical break indicator A Multi-layer safety diaphragm with diaphragm rupture signalling (contact) H Diaphragm for hygienic pump head Dosing head version
Identity code S2Ba S2Ba Sigma 2 basic type M Modified* * order-related version, for pump features see paperwork for order Electric power supply S 3 ph, 230 V/400 V 50/60 Hz M 1 ph AC, 230 V 50 Hz N 1 ph AC, 115 V 60 Hz L 3 ph, 230 V/400 V, 50 Hz, (Exe, Exd) P 3 ph, 265 V/440 V, 60 Hz, (Exe, Exd) R 3 ph, variable speed motor, 230/400 V V(0) Variable speed motor with integrated Frequency converter 1 ph, 230 V, 50/60 Hz Z Speed control complete 1 ph, 230 V, 50/60 Hz (control motor + frequency
Safety chapter 2 Safety chapter Explanation of the safety information Warning signs denoting different types of danger The following signal words are used in these operating instructions to identify different severities of a hazard: Signal word Meaning WARNING Denotes a possibly hazardous 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 hazardous sit‐ uation.
Safety chapter Safety information WARNING! Warning of hazardous or unknown feed chemical Should a hazardous or unknown feed chemical be used, it may escape from the hydraulic components when working on the pump. – – Take appropriate protective measures before working on the pump (protective eyewear, protective gloves, ...). Read the safety data sheet on the feed chemical. Drain and flush the liquid end before working on the pump.
Safety chapter Information in the event of an emergency In the event of an electrical accident, disconnect the mains cable from the mains or press the emergency cut-off switch fitted on the side of the system! If feed chemical escapes, also depressurise the hydraulic system around the pump as necessary. Adhere to the safety data sheet for the feed chemical.
Storage, transport and unpacking 3 Storage, transport and unpacking Safety information WARNING! Only return metering pumps for repair in a cleaned state and with a flushed liquid end - refer to the section on decommis‐ sioning! Only send metering pumps with a filled in Decontamination Declaration form. The Decontamination Declaration consti‐ tutes an integral part of an inspection / repair order.
Storage, transport and unpacking Ambient conditions Data Value Unit Minimum storage and transport tempera‐ ture -10 °C Maximum storage and transport tempera‐ ture +50 °C Maximum air humidity * 95 % rel.
Overview of equipment and control elements 4 Overview of equipment and control elements 1 2 4 3 5 P_SI_0068_SW Fig. 2: Overview of equipment and control elements S2Ba 1 2 3 4 5 Drive motor Drive unit Stroke length adjustment knob Liquid end with relief valve Diaphragm rupture sensor 1 2 P_SI_0088_SW Fig.
Overview of equipment and control elements 75% 0 50 25 75 20 30% 0 0 25 5 5 0 10 P_SI_0095_SW Fig. 4: Adjusting the stroke length n n n 100 % = 4 rotations 25 % = 1 rotation 0.5 % = 1 scale mark on stroke adjustment dial PG9 PG11 1 2 3 P_SI_0036 A B Fig.
Functional description 5 Functional description 5.1 Drive unit The metering pump is an diaphragm pump, the stroke length of which can be adjusted. An electric motor (1) drives the pump. A worm gear (2) steps down its drive rotation A cam (3), in conjunction with the uptake fork (8) converts this into an oscillation movement of the slide rod (4). A return spring (5) presses the uptake fork together with the slide rod positively against the cam thus producing the reciprocal stroke.
Functional description 5.2 Liquid end The diaphragm (2) hermetically shuts off the pump volume of the dosing head (4) towards the outside. The suction valve (1) closes as soon as the diaphragm (2) is moved in to the dosing head (4) and the feed chemical flows through the discharge valve (3) out of the dosing head.
Functional description 1 2 3 4 5 P_SI_0019 Fig. 9: Integral relief valve 1 2 3 4 5 Spring, large Ball Rotary dial Spring, small Hose connection 5.4 Multi-layer safety diaphragm The multi-layer safety diaphragm has the same function as the conven‐ tional double diaphragm system with working and safety diaphragms; how‐ ever it also has the advantage that both diaphragms are joined together in a single unit.
Functional description 1 7 6 5 4 2 3 P_SI_0020_SW Fig.
Assembly 6 Assembly WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Assembly Capacity too low Vibrations can disturb the valves of the liquid end. – The supporting floor must not vibrate. Space requirement CAUTION! Danger from incorrectly operated or inadequately maintained pumps Danger can arise from a poorly accessible pump due to incorrect operation and poor maintenance. A – – A Ensure that the pump is accessible at all times. Adhere to the maintenance intervals.
Installation 7 Installation CAUTION! Danger of personnel injury and material damage The disregard of technical data during installation may lead to personal injuries or damage to property. – Observe the technical data- refer to chapter "Technical Data" and, where applicable, the operating instructions of the accessories. 7.1 Installation, hydraulic WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed.
Installation CAUTION! Warning against the discharge line bursting With a closed discharge line (e.g. due to a clogged discharge line or by closing a valve), the pressure that the metering pump generates can reach several times the permissible pressure of the system or the metering pump. This could lead to lines bursting resulting in dangerous consequences with aggressive or toxic feed chemicals.
Installation CAUTION! Warning of backflow A back pressure valve, spring-loaded injection valve, relief valve, foot valve or a liquid end do not represent absolutely leak-tight closing elements. – For this purpose use a shut-off valve, a solenoid valve or a vacuum breaker. CAUTION! Warning of illegal operation Observe the regulations that apply where the unit is to be installed.
Installation CAUTION! Warning of feed chemical spraying around If no relief valve was connected to the overflow line, the feed chemical sprays out of the hose connection as soon as the relief valve opens. – An overflow line must always be connected to the inte‐ gral relief valve and be fed back to the storage tank or if required by the regulations - into a special storage tank. CAUTION! Danger of cracking Cracking of the PVT liquid end can occur if a metal overflow line is connected to the relief valve.
Installation CAUTION! Warning of unnoticed diaphragm rupture Only above approximately 2 bar system back pressure is a signal generated upon a diaphragm rupture. – Only rely on the diaphragm rupture sensor at back pres‐ sures greater than 2 bar. 7.2 Installation, electrical WARNING! Danger of electric shock Unprofessional installation may lead to electric shocks. – – All cable cores cut to length must be provided with cable end sleeves.
Installation Motor CAUTION! Pump can be damaged The pump can be damaged if the motor drives the pump in the wrong direction. – When connecting the motor, pay attention to the correct direction of rotation indicated by the arrow on the fan cover, as shown in Fig. 21. P_SI_0012_SW Fig. 21: Direction of rotation of motor 1. Install a motor protection switch, as the motors have no fuse. 2. Install an emergency cut-off switch or include the motor in the emer‐ gency cut-off management of the system. 3.
Installation Stroke sensor (identity code specification "Stroke sensor": 3) Connect the stroke sensor to a suitable monitoring device according to the technical data provided with the monitoring device and that of the stroke sensor - see chapter "Technical data". Pacing relay (identity code specification "Stroke sensor": 2) 1. Install the cable which originates from the pacing relay - see the figure in the chapter entitled "Overview of equipment and control elements": Cable A, left.
Start up 8 Start up Safety information WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases. WARNING! Fire danger Only with combustible media: These may start to burn when combined with oxygen.
Start up CAUTION! Possible environmental and material damage In event the red gear bleeding plug is sealed, during opera‐ tion it prevents any pressure compensation between the drive housing and the surroundings. This ensure that oil can be pushed from the drive housing. – Remove the gear bleeding plug before commissioning. Remove the gearbox vent stopper Before start up pull the red gearbox vent stopper off, see chapter "Over‐ view of equipment and control elements".
Start up When operating the integral relief valve close to the opening pressure, a minimal overflow into the overflow line can occur. Eliminating suction problems (only for single ball valves with PTFE ball seat) For suction problems occurring during start up: – – – – Exclude the possibility that there are foreign bodies in the valve. Place the valve on a stable surface. Using a hammer (1) and a brass bar (2), gently tap the PTFE ball seat above the valve ball - see figure below.
Start up Diaphragm rupture sensor CAUTION! Danger resulting from unnoticed diaphragm rupture If the pump has been ordered with an electric diaphragm rup‐ ture sensor, it still has to be installed. – Screw the enclosed diaphragm rupture sensor into the liquid end (no seal necessary). CAUTION! Warning of unnoticed diaphragm rupture Only above approximately 2 bar system back pressure is a signal generated upon a diaphragm rupture.
Maintenance 9 Maintenance Safety information WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Maintenance Third party spare parts for the pumps may lead to problems when pumping. – – Use only original spare parts. Use the correct spare part kits. In case of doubt, refer to the exploded views and ordering information contained in the "Supplementary information CD for ProMinent® pump operating instructions". Standard liquid ends: Interval Maintenance work Personnel After approx. 5,000 oper‐ ating hours Change gear oil - refer to "Changing gear oil" in this chapter.
Maintenance 3. Unscrew the oil drain plug (2) out of the drive housing. 4. Allow the gear oil to run out of the drive. 5. Screw in the oil drain plug (2) with a new seal. Filling with gear oil Prerequisites: Gear oil according to the "Ordering information" chapter is available. 1. Start up the pump. 2. Slowly pour gear oil through the vent screw (1) opening until the oil inspection window (3) is half covered. 3. Allow the pump to run for a further 1... 2 minutes 4. Replace the vent screw (1).
Repairs 10 Repairs Safety information WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Repairs Personnel: n Technical personnel Repairing ball valves CAUTION! Warning of personal injury and material damage Feed chemical may escape from the liquid end, for example, if ball valves not repaired correctly. – – Only use new components which fit your valve - both in terms of shape and chemical resistance! Pay attention to the flow direction of the discharge and suction connectors when fitting the valve. 1. Unscrew the valve from the liquid end. 2.
Repairs 10.2 Replacing the metering diaphragm Third party spare parts for the pumps may lead to problems when pumping. – – Use only original spare parts. Use the correct spare part kits. In case of doubt, refer to the exploded views and ordering information contained in the "Supplementary information CD for ProMinent® pump operating instructions". Personnel: n Technical personnel Requirements: n n n If necessary take protective measures. Observe the safety data sheet for the feed chemical.
Repairs ð If this is still unsuccessful, contact ProMinent-ProMaqua cus‐ tomer service. 12. Place the dosing head with the screws onto the diaphragm - the suction connector must be pointing downwards in the pump's fitting position. 13. Tighten the screws gently to start with. 14. Screw the diaphragm rupture sensor into the dosing head. 15. Start up the pump and adjust the stroke length to 100 %. 16. Stop the pump and tighten the screws crosswise.
Troubleshooting 11 Troubleshooting Safety information WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Troubleshooting Fault description Cause Remedy Personnel The motor is wired incor‐ rectly. 1. Check the mains voltage and mains frequency. Electrician 2. Wire the motor correctly. The mains voltage has failed. Eliminate the cause. Electrician The dosing head screws are no longer tight enough. Tighten the screws crosswise to the specified tightening torque. Technical per‐ sonnel The diaphragm leaks. Replace the diaphragm - refer to the "Repair" chapter.
Decommissioning 12 Decommissioning Decommissioning WARNING! Warning about personal and material damage EX pumps only: When operating in EX areas, certain sub‐ jects must be observed. – The chapter "Important supplements for metering pumps in EX zones" of the "General Operating Instructions on ProMinent ® Motor-Driven Metering Pumps and Hydraulic Accessories" must be observed in all cases.
Decommissioning WARNING! Warning of eye injuries When opening the relief valve, a spring under high tension can jump out. – Wear protective glasses. CAUTION! Danger of damage to the device The device can be damaged by incorrect and improper storage or transportation. – (Temporary) decommissioning Personnel: Take into account the information in the "Storage, Trans‐ port and Unpacking" chapter if the system is decommis‐ sioned for a temporary period. n Technical personnel 1.
Decommissioning 42
Technical data 13 Technical data Only for "M - modified" version: WARNING! Risk of personal injuries Please observe the ”Supplement for modified version“ at the end of the chapter! It replaces and supplements the technical data! 13.1 Performance data S2Ba under 50 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate Suction lift Permissible priming pres‐ sure, suction side Connector size bar l/h ml/stroke Strokes/min m WS bar R"-DN 16050 PVT 10 50 11.
Technical data S2Ba under 60 Hz operation Type Minimum pump capacity at maximum back pres‐ sure Maximum stroke rate Suction lift Permissible priming pressure, suction side Connector size bar psi l/h gph Strokes/ min m WS bar R"-DN 16050 PVT 10 145 60 15.9 87 7 3 1" - 15 16050 SST 16 232 57 15.1 87 7 3 1" - 15 16090 PVT 10 145 106 27.8 158 7 3 1" - 15 16090 SST 16 232 98 26 158 7 3 1" - 15 16130 PVT 10 145 156 41.
Technical data Types Material version Shipping weight kg 07120 ... 04350 13.3 PVT 16 SST 24 Wetted materials Material ver‐ sion Liquid end Suction/dis‐ charge con‐ nector Seals* / ball seat Balls Springs Integral relief valve PVT PVDF PVDF PTFE/PTFE Ceramic / glass ** Hastelloy C PVDF/FPM or EPDM SST Stainless steel 1.4404 Stainless steel 1.4581 PTFE/PTFE Stainless steel 1.
Technical data 13.4.3 Air humidity Air humidity Data Value Unit Maximum air humidity *: 92 % rel. humidity * non-condensing 13.5 Motor data Electrical data Identity code specification Phase, protection Nominal voltage Mains supply fre‐ quency Rated output S 3 ph, IP 55 220-240 V / 380-420 V 50 Hz 0.25kW 250-280 V / 440-480 V 60 Hz 0.25 kW Remarks M 1 ph AC, IP 55 230 V ±5 % 50/60 Hz 0.18 kW N 1 ph AC, IP 55 115 V ±5 % 60 Hz 0.
Technical data 13.6 13.7 13.8 Stroke actuator Voltage Mains supply fre‐ quency Performance 230 V ±10 % 50/60 Hz 11.7 W 115 V ±10 % 60 Hz 11.7 W Voltage Mains supply fre‐ quency Performance 230 V ±10 % 50/60 Hz 6.5 W 115 V ±10 % 60 Hz 6.5 W Stroke control drive Diaphragm rupture sensor Install the sensor according to the chapter "Installation, elec‐ trical". a) Contact (Standard for identity code specification "Displacement body“: A) Contact loading, max.
Technical data 13.9 Cable colour Polarity blue - brown + Stroke sensor "Sigma" Install the sensor according to the chapter "Installation, elec‐ trical". a) Pacing relay (stroke sensor with ...) (Identity code specification "Stroke sensor": 2) For more information, see "Pacing relay" in the "Relay" chapter. b) Namur sensor (identity code specifica‐ tion "Stroke sensor": 3) 5–25 V DC, in accordance with Namur or DIN 60947-5-6, potential-free design.
Technical data 13.12 Sound pressure level Sound pressure level Sound pressure level LpA < 70 dB in accordance with EN ISO 20361:2010-10 at maximum stroke length, maximum stroke rate, maximum back pressure (water) 13.13 Supplementary information for modified versions (With identity code specification "Version": "M" - "modified") Technical data Technical data of pumps in the modified version can deviate from those of the standard pumps. They can be queried by stating the details of the serial number.
EC Declaration of Conformity 14 EC Declaration of Conformity For pumps without explosion protection: EC Declaration of Conformity We hereby declare, ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 - 11 D - 69123 Heidelberg that the following designated product complies with the pertinent fundamental safety and health requirements of the EC Directive in terms of its design and construction and in terms of the version marketed by us.
EC Declaration of Conformity For pumps with explosion protection: The EC Declaration of Conformity, the EC type-examination certificates and the operating instructions for the individual components are also enclosed with the pump.
Decontamination declaration 15 52 Decontamination declaration
