Page 1
Drive unit
Orlita® Evolution
Operating instructions
These operating instructions form part of an operating manual and are only valid if used in conjunction with the documents
in this operating manual.
EN
983748 BA ORL 008 06/16 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.
Page 2
Table of contents
1
Safety.................................................................................... 3
2 Functional Description of the Drive Unit................................ 9
3 Assembly............................................................................ 10
4 Installation, Electrical.......................................................... 15
5 Start Up and Operation....................................................... 20
5.1 Tests Prior to Start Up of the Pump............................ 22
5.2 Testing Directly After the Pump has Started Up......... 24
5.3 Testing 0.5 to 1 Hour After the Pump has Started...... 25
5.4 Bleeding the Diaphragm Holder.................................. 25
6 Maintenance....................................................................... 26
7
Carrying out repairs............................................................ 27
8 Remedying Faults on the Drive Unit................................... 28
9 Decommissioning and Disposal.......................................... 30
10 Index................................................................................... 31
Table of contents
2
Page 3
1 Safety
WARNING!
Observe the safety chapter and safety information in
the other documents.
Note the information on the "Technical Data Sheet" for
the pump.
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 situation. If this is
disregarded, you are in a life-threatening situation
and this can result in serious injuries.
CAUTION Denotes a possibly hazardous situation. 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 instruc‐
tions to denote different types of danger:
Warning signs Type of danger
Warning – high-voltage.
Warning – hot surface.
Warning – danger zone.
n Only operate the pump in premises at risk from explosion with
the appropriate nameplate for pumps for use in areas at risk of
explosion in accordance with the European guidelines.
Ensure that the explosion group, category and degree of pro‐
tection specified on the label corresponds to or is superior to
the conditions prevalent in the intended application.
n Only use the pump after it has been correctly installed and
started up in accordance with the technical data and specifica‐
tions contained in the operating manual.
n The pump is intended for use in dry, ventilated rooms with a
non-aggressive atmosphere.
The pump has to have a different design for other environ‐
ments, such as outdoors, areas at risk from explosion, drilling
rigs etc... .
n All other uses or modifications are prohibited.
Explanation of the safety information
Warning signs denoting different
types of danger
Intended use
Safety
3
Page 4
n Never operate pumps in premises at risk from explosion
without the relevant nameplate (and the respective EC Decla‐
ration of Conformity) for pumps for use in areas at risk from
explosion.
n Do not expose the ATEX design to ionising radiation, electro‐
magnetic high frequency radiation within the range of 104 ...
3x1015 Hz or ultrasound without putting in place measures in
line with EN 1127-1.
n The pump is not suitable for portable operation.
n The pump is only intended for industrial use.
n Only allow trained and authorised personnel to operate the
pump - see the following table.
n This pump is designed to be operated in an upright position by
an adult who does not suffer from impaired vision.
n You have a responsibility to adhere to the information con‐
tained in the operating instructions at the different phases of
the unit's service life.
n You have a responsibility to observe the information contained
in the operating instructions for the auxiliary equipment at the
different phases of their respective service lives.
Task Qualification
Transport Qualified personnel
Storage, unpacking Instructed person
Assembly Technical personnel, Service
Planning the hydraulic installation Qualified personnel who have a thorough knowledge of oscillating
metering pumps
In areas at risk from explosion: ATEX qualified person, ATEX
electrical technician
Hydraulic installation Technical personnel, Service
Installation, electrical Electrical technician,
In areas at risk from explosion: ATEX electrical technician
Start up Qualified personnel
In areas at risk from explosion: Qualified personnel with ATEX
training; checking of the electrical installation: recognised compe‐
tent person
Operation Instructed person
Maintenance, repair Technical personnel, Service
In areas at risk from explosion: ATEX qualified person, ATEX
electrical technician
Decommissioning, disposal Technical personnel, Service
Troubleshooting Qualified person, electrical technician, instructed person, service
- depending on the requirement
In areas at risk from explosion: ATEX electrical technician;
checking of the electrical installation: recognised competent
person
Explanation of the table:
Qualified personnel
Qualification of personnel
Safety
4
Page 5
A qualified employee is deemed to be a person who is able to
assess the tasks assigned to him and recognise possible dangers
based on his technical training, knowledge and experience, as well
as knowledge of pertinent regulations.
Qualified personnel who open the hydraulic components of the
pump have to be able to recognise sealing surfaces so that they do
not become scratched.
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 sys‐
tems and recognise and avoid possible dangers independently
based on his technical training and experience, as well as knowl‐
edge of pertinent standards and regulations.
The electrical technician should be specifically trained for the
working environment in which he is employed and be conversant
with the relevant standards and regulations.
Make sure that the electrical technician complies with the provi‐
sions of the applicable statutory directives on accident prevention.
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 with knowledge of ATEX explosion protection
The electrical technician with an additional explosion protection
qualification should be specifically trained for the work area in
which he is employed and be familiar with the relevant standards
and regulations. The electrical technician with an additional explo‐
sion protection qualification can work on electrical systems and
independently recognise and avoid possible dangers based on his
technical training and experience.
The electrical technician with an additional explosion protection
qualification is familiar with all the standards and regulations appli‐
cable to explosion protection, in particular, but not however exclu‐
sively, with all parts of EN 60079 [Electrical equipment for areas at
risk of a gas explosion].
The electrical technician with an additional explosion protection
qualification must comply with the provisions of the applicable stat‐
utory directives on accident prevention.
Recognised competent person
To carry out explosion hazard inspections the competent person
must have:
n Completed a relevant course of study or
n Have a comparable technical qualification or
n Another technical qualification combined with long-term experi‐
ence of safety technology.
Make sure that the person is familiar with the relevant body of
standards and regulations and has worked in the area for at least
one year. The person needs to have opportunities for an exchange
of experience.
Specific requirements are placed on competent persons who per‐
form tests on repaired devices/parts. They have to be recognised
by the responsible authorities (e.g. district council) in this respect.
Instructed person
Safety
5
Page 6
An instructed person is deemed to be a person who has been
instructed and, if required, trained in the tasks assigned to him and
possible dangers 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 system.
CAUTION!
These operating instructions include notes and
extracts from German regulations relating to the opera‐
tor's scope of responsibility. This information does not
discharge the operator from his responsibility as an
operator and is intended only to remind him or make
him aware of specific problem areas. This information
does not lay claim to being complete, nor applicable to
every country and every type of application, nor to
being unconditionally up-to-date.
WARNING!
Only use ATEX pumps in areas at risk from explosion
– Note the relevant regulations for the installation
and operation of equipment in areas at risk from
explosion.
– Observe the guidelines for intrinsically safe power
circuits.
– Adhere to the respective national regulations out‐
side of the EU.
– Ensure that installations in areas at risk from explo‐
sion are checked by a "recognised competent"
person. This applies specifically to intrinsically safe
power circuits.
– Only clean the pump outside of / in the absence of
explosive atmospheres.
WARNING!
Danger of injury to personnel and material damage
The pump must only be opened at those points
required to be opened by these operating instructions.
It may only be opened in other positions upon receipt
of written authorisation from the ProMinent head office,
Heidelberg.
WARNING!
Danger of slippage on the pump
Danger of injury from slipping.
– Never climb on the pump.
Safety information
Safety
6
Page 7
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in per‐
sonnel injuries and material damage.
– Only fit parts to metering pumps, which have been
tested and recommended by ProMinent.
CAUTION!
Danger from incorrectly operated or inadequately
maintained 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.
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.
Prior to commissioning the system or system component, it is the
responsibility of the system operator to obtain the latest safety data
sheet for the chemicals / equipment to be used with the system
from the supplier. Based on the information provided in the data
sheets concerning health and safety, water and environmental pro‐
tection, and taking into consideration the actual operating environ‐
ment on site, it is the responsibility of the operator to create the
legal framework for the safe operation of the system or system
component, such as for example the preparation of operating
instructions (operator's duties).
Secure all these parts in their place when using the pump.
Protective equipment May only be removed by*:
Protective cowling over the motor fan Service
Motor terminal box cover Electrical technician, ATEX electrical technician,
Service
Drive unit cover Technical personnel, Service
Only with multiple pumps: Connecting flange for
drive units
Technical personnel, Service
Other units and ancillary equipment: Their corre‐
sponding parts
Technical personnel, Service
Information in the event of an emer‐
gency
Safety information for operating
instructions
Safety equipment
Fixed, isolating protective equipment
Safety
7
Page 8
* Only if required by the operating instructions and if the mains
cable remains disconnected from the mains voltage. Make sure
that all protective equipment is refitted during operation.
Safety equipment May only be removed by*:
Only in areas at risk from explosion: Vent screw with
filter
Qualified employee, electrical technician, ATEX
electrical technician, Service
"Hot surface" label -
Earthing lines from motor and third-party electrical
parts
Electrical technician, ATEX electrical technician,
Service
Only with multiple pumps: Potential equalisation
lines between the drive units and base plate
Electrical technician, ATEX electrical technician,
Service
Other units and ancillary equipment: Their corre‐
sponding parts
Technical personnel, Service
* Only if required by the operating instructions and if the mains
cable remains disconnected from the mains voltage. Make sure
that all protective equipment is refitted during operation.
The operator must be able to:
n Perform a risk assessment
n Produce and attach a nameplate
n Issue an EC Declaration of Conformity
n Adapt the operating instructions, if necessary
n Correctly install the motor
n With ATEX motors: perform an ignition hazard assessment
Sound pressure level at maximum stroke length, maximum stroke
rate, maximum back pressure (water) - see "Evolution Data Sheet".
Small amounts of gear oil can evaporate out of the vent screws.
We recommend that you slightly ventilate the installation site.
Gear oil can escape from the pump in the event of specific faults,
damage, neglected maintenance, during commissioning and during
maintenance and repair work.
Additional safety equipment
Requirements, if the motor is installed
independently
Sound pressure level
Other emissions
Safety
8
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2 Functional Description of the Drive Unit
The stroke length of a drive unit can be set via its stroke adjust‐
ment wheel or an actuator (optional) or control drive (optional).
The pump's stroke rate can be changed by a frequency converter
(optional) if required.
One or more add-on drive units can be attached to the main drive
unit using 1 connecting set with a claw coupling.
General
Add-on drive unit
Functional Description of the Drive Unit
9
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3 Assembly
WARNING!
Danger of toppling over
The centre of gravity of the single pump with standing
motor is relatively high.
– Only remove the pump from the crane hook once it
is firmly connected to the base.
–
Compare the dimensions on the dimension sheet
with those of the pump.
1. Select a suitable motor - make sure that it corresponds to the
data from the "Motor data" table.
WARNING!
This is EX-relevant in areas at risk from explo‐
sion!
2. Fit the motor correctly on the flange (qualified personnel).
Observe the coupling operating instructions!
WARNING!
This is EX-relevant in areas at risk from explo‐
sion!
With a claw coupling: Make sure that the claw on the motor
shaft is fixed at the correct height – see Fig. Fig. 1.
3. ATEX pumps only: Ensure that there is also potential equali‐
sation between the motor and drive unit.
4. As you have converted an "incomplete machine" into a com‐
plete machine, you must:
n Perform an assessment of conformity
n Perform a risk assessment
n Produce an EC Declaration of Conformity
n Fit your own nameplate
n With ATEX pumps: additionally perform an ignition
hazard assessment.
n Complete the pump documentation / operating instruc‐
tions.
n ...
Motor installation - with designs
without a motor
Assembly
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QQ
P_HY_0060_SW
Fig. 1: Correct heigh of the clutch claw on the motor shaft
EF1a
Motor Motor flange Rotex Q
1.1 kW F200 24 1a 40
0.75 kW F200 24 1a 40
0.55 kW F160 19 1b 41
0.35 kW F160 19 1b 41
EF2a
Motor Motor flange Rotex Q
1.5 kW F200 24 1a 40
1.1 kW F200 24 1a 40
0.75 kW F200 24 1a 40
0.55 kW F200 24 1a 40
EF3a
Motor Motor flange Rotex Q
2.2/3.0 kW F250 38 59
2.2/3.0 kW F250 28 68
0.75 kW F200 28 67
1.1/1.5 kW F250 28 67
Assembly
11
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EF4a
Motor Motor flange Rotex Q
11 / 15 kW F350 42 1b 89.5
5.5 / 7.5 kW F300 42 Typ 1 65.5
2.2 / 3.0 / 4.0 kW F250 38 1b 72.5
WARNING!
The pump can break through the base or slide off it
– Ensure that the base is horizontal, flat and perma‐
nently load-bearing.
Capacity too low
Vibrations can disturb the liquid end valves.
–
Do not allow the base to vibrate.
WARNING!
Motor may overheat
If the necessary cooling air supply is not guaranteed,
the motor may overheat. In an area at risk from explo‐
sion, it could trigger an explosion.
– Maintain sufficient clearance between the air
intake opening and the walls. The distance should
be greater than 1/4 of the diameter of the air intake
opening.
–
The fan must not suck in the exhaust air from other
devices.
WARNING!
Danger with high pressure
Feed chemicals at pressures above 100 bar can seri‐
ously injure people standing nearby in the event of a
discharge-side leak - particularly if energy stores, such
as pulsation dampers, are used.
– Use appropriate guard panels to shield the dis‐
charge-side components if necessary.
Base
h
P_MOZ_0016_SW
Fig. 2
Space requirement
Assembly
12
Page 13
CAUTION!
Danger from incorrectly operated or inadequately
maintained 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.
WARNING!
Risk of injury from feed chemical at extreme tempera‐
tures
People could be injured if feed chemical at extreme
temperatures can heat up or cool down the liquid ends
above or below the permitted surface temperatures.
– Avoid contact with the unit.
–
If necessary, mount a guard plate.
Position the pump so that control elements, such as the oil inspec‐
tion windows, are easily accessible.
Make sure that there is sufficient room to carry out an oil change or
perform other maintenance work and repairs.
1 Discharge valve
2 Dosing head
3 Suction valve
Ensure there is sufficient free space (f) around the dosing head
and hydraulic end so that maintenance and repair work can be car‐
ried out easily on these components.
Capacity too low
Vibrations can disturb the liquid end valves.
–
Secure the metering pump so that no vibrations
can occur.
1. Take the dimensions of the fastening holes - refer to the
appropriate dimensional drawings or data sheets.
2. Use screws (strength class 8.8) to fix the pump base to the
foundation.
Pumptype Screw size
EF1a M12
EF2a M12
EF3a M12
EF4a M16
1
3
2
f
f
f
P_MOZ_0017_SW
Fig. 3
Fastening
Assembly
13
Page 14
Protect the pump from lightening.
Install a guard if the pump is exposed to direct sunlight or another
heat source.
Lightning protection
Direct sunlight
Assembly
14
Page 15
4 Installation, Electrical
CAUTION!
Danger of injury to personnel and material damage
Disregarding the technical data when installing can
lead to personal injuries or damage to property.
– Refer to the Technical Data - see the "Evolution
Data Sheet" chapter and the operating instructions
for the other components.
WARNING!
ATEX pumps in areas at risk from explosion
– Only connect potential-free as well as non-isolating
low voltage switch accessories, such as diaphragm
rupture indicators, stroke rate instruments etc., to
an intrinsically safe power circuit in areas at risk
from explosion.
– Only use motor protection switches, mains
switches and fuses permitted for use in areas at
risk from explosion in line with the manufacturer's
information, as electrical components in areas at
risk from explosion.
– Electrically wire all electrical units cleanly and per‐
manently to an electrically clean earthing point, e.g. with an earthing bar on your system.
– Electrically wire the earthing point on the pump
cleanly and permanently to an electrically clean
potential equalisation point - e.g. with a potential
equalisation bar on your system.
– Note the enclosed documentation for the individual
electrical components.
– Please note the relevant national regulations
during installation!
WARNING!
ATEX pumps in areas at risk from explosion
Static electricity can cause ignition sparks.
– Consider potential equalisation before you
approach any pump equipment that could be at a
different electrical potential (such as pipes or tools)
WARNING!
Danger of fire with flammable feed chemicals
– The ATEX diaphragm rupture sensor and a dis‐
charge-side flow control must both stop the pump
as soon as a diaphragm rupture or no flow is
detected.
Installation, Electrical
15
Page 16
WARNING!
Danger of electric shock
Unprofessional installation may lead to electric shocks.
– Crimp cable end sleeves onto all shortened cable
cores.
–
Only allow technically trained personnel to under‐
take the electrical installation of the device.
WARNING!
Danger of electric shock
In the event of an electrical accident, it must be pos‐
sible to quickly disconnect the pump, and any electrical
ancillaries which may possibly be present, from the
mains.
– Install an emergency cut-off switch in the mains
supply line to the pump and any electrical ancilla‐
ries which may be present or
–
Integrate the pump and electrical ancillaries which
may be present in the emergency cut-off manage‐
ment of the system and inform personnel of the
isolating option.
WARNING!
Danger of electric shock
This pump is equipped with a protective earth con‐
ductor, to reduce the risk arising from an electric
shock.
– Connect the PE conductor to "earth" with a clean
and permanent electrical connection.
WARNING!
Danger of electric shock
A mains voltage may exist inside the motor or elec‐
trical ancillaries.
– If the housing of the motor or electrical ancillaries
has been damaged, you must disconnect it from
the mains immediately. The pump must only be
returned to service after an authorised repair.
What requires electrical installation?:
n Motor
n External fan (optional)
n A frequency converter (bought-in part) if necessary
n Electric diaphragm rupture sensor (optional)
n Diagnostic equipment for bearing damage (bought-in part) if
necessary
n Stroke sensor (optional)
n Earthing wires (to be provided on site)
n Potential equalisation line (to be provided on site)
Installation, Electrical
16
Page 17
WARNING!
ATEX pumps in areas at risk from explosion
– Use a suitable motor protection switch to protect
power end motors. Use motor protection approved
for this application with Ex"e" motors. (Protection
against warming caused by overloading)
–
Provide a time-delay residual current device.
– Ensure that motors are only installed and checked
by a "recognised competent" person in areas at
risk from explosion.
– Cleanly earth the motor via the mains cable.
– Observe the enclosed operating instructions for the
Ex motor, especially the maintenance plan.
CAUTION!
The motor can be damaged
Provide appropriate motor protection devices (e.g.
motor protection switch with thermal overcurrent trip)
to protect the motor against overloading. Fuses do not
provide motor protection.
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 - refer to the "Start Up"
chapter.
Use an electrical isolating device in the mains supply
cable, such as a mains switch, to switch off the pump
independently of the entire installation (e.g. for
repairs).
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
system's emergency cut-off management scheme.
3. Connect the motor to the power supply.
–
Key motor data can be found on the nameplate.
–
The terminal wiring diagram is located in the ter‐
minal box.
CAUTION!
Provide a separate power supply for the external fan
with motors with external fan.
Motor
External fan (optional)
Installation, Electrical
17
Page 18
Connect the motor as per the wiring diagram for the controller, if it
is controlled by an electronic control unit (such as direct current
motors by a frequency converter).
WARNING!
Danger of electric shock
In event of a defect, there is a risk of electric shock
when conductive feed chemicals are present.
– For safety reasons we recommend connecting to
protective low voltage, e.g. in accordance with EN
60335-1 (SELV ).
WARNING!
Risk of fire after a diaphragm rupture
With seriously oxidising feed chemicals: Make sure
that the electric diaphragm rupture sensor switches off
the pump immediately after a diaphragm rupture.
– Connect the pump and the diaphragm rupture
sensor to a control so that the pump stops immedi‐
ately in the event of a diaphragm rupture.
CAUTION!
Danger resulting from unnoticed diaphragm rupture
All pumps ordered with an electric diaphragm rupture
sensor need to be electrically installed.
– Electrically wire the enclosed diaphragm rupture
sensor to a suitable monitoring device.
CAUTION!
Additional damage with a ruptured diaphragm
Never allow the diaphragm to rupture fully if damage
can be caused by hydraulic oil mixing with the feed
chemical.
– The diaphragm rupture sensor must switch off the
pump immediately.
Only restart the pump once the diaphragm has
been replaced.
Refer to the operating instructions for the diaphragm rupture
sensor.
Connect the stroke sensor to a suitable monitoring device in
line with the details in the "Technical Data" chapter - also
refer to their technical data!
Make sure that the monitoring/feed equipment installed by
the customer is capable of evaluating the current variations
of the Namur sensor to indicate a diaphragm rupture!
Frequency converter (to be provided
on site)
Electric diaphragm rupture sensor
(optional)
Stroke sensor (optional)
Installation, Electrical
18
Page 19
WARNING!
In areas at risk from explosion:
– Note the details of the type examination certificate
PTB 00 ATEX 2048 X for the Namur sensor
NJ1.5-8GM-N.
CAUTION!
Danger from unnoticed bearing damage
If the pump is intended for operation with diagnostic
equipment for bearing damage (e.g. for areas area at
risk from explosion), then it also has to be electrically
installed.
– Electrically connect the diagnostic equipment for
bearing damage to a suitable monitoring device.
CAUTION!
The pump's earthing concept is not suitable for active
cathodic corrosion protection with external current.
Wire the earthing lines of all electrical components for the supplied
installation cleanly and permanently to an electrically clean
earthing point, e.g. with an earthing bar on site - see earthing dia‐
grams in the appendix.
Connect the partial potential equalisation points of the pump, motor
and, if necessary further units, which are not connected electrically
cleanly to the pump, electrically cleanly via potential equalisation
lines - see dimensional drawing. Electrically wire an additional
potential equalisation cable from the potential equalisation cables
from this system cleanly and permanently to an electrically clean
potential equalisation point, e.g. to a potential equalisation bar on
site.
Install the other units in line with their documentation.
Diagnostic equipment for bearing
damage (provided on site)
Earthing lines
Potential equalisation lines (manda‐
tory with ATEX)
Other units
Installation, Electrical
19
Page 20
5 Start Up and Operation
WARNING!
ATEX pumps in areas at risk from explosion
– Make sure that a suitably competent person
checks whether the appropriate installation infor‐
mation from the "Installation " chapter has been
implemented correctly.
–
Make sure that a "recognised competent person"
checks the electrical installation and in particular
the intrinsically safe power circuits.
– Set the opening pressure of the relief valve to a
maximum of no more than 1.5 times the nominal
pressure of the pump.
WARNING!
ATEX pumps in areas at risk from explosion
Static electricity can cause ignition sparks.
– Consider potential equalisation before you
approach any pump equipment that could be at a
different electrical potential (such as pipes or tools)
WARNING!
Danger of fire with flammable feed chemicals
– Combustible media may only be transported using
stainless steel dosing heads.
–
The ATEX diaphragm rupture sensor and a dis‐
charge-side flow control must both stop the pump
as soon as a diaphragm rupture or no flow is
detected.
– During filling and draining of the liquid end, an
expert must ensure that feed chemical does not
come into contact with oxygen.
– If necessary, the operator must implement further
measures.
WARNING!
Hot surface
In event the power end motor is loaded excessively, its
surface may become very hot.
– Avoid contact.
–
If necessary, mount a guard plate.
Safety Information
Start Up and Operation
20
Page 21
WARNING!
Risk of burns with hot feed chemicals
If hot feed chemicals can heat the liquid ends above
the permissible surface temperatures, persons can
suffer burns from them.
– Consider attaching a "Hot surface" label to the
liquid end or ...
–
fitting a guard plate.
WARNING!
Danger with high pressure
Feed chemicals at pressures above 100 bar can seri‐
ously injure people standing nearby in the event of a
discharge-side leak - particularly if energy stores, such
as pulsation dampers, are used.
– Wear protective goggles and protective clothing if
no protective panels are fitted.
WARNING!
Only with frequency control unit: Danger of electric
shock
There is still the risk of an electric shock on conducting
parts of the frequency control unit (e.g. frequency con‐
verter), the motor and the cables even after the mains
voltage has been switched off.
– Once switched off, allow the device to stand for as
long as is required in the operating instructions for
the frequency control unit and only then open the
terminal box.
WARNING!
Observe other operating instructions
Observe the safety information in the other operating
instructions.
CAUTION!
Do not permit the maximum permissible priming pres‐
sure on the suction side to be more than 10% of the
maximum allowable operating pressure. Otherwise the
pump will wear out quickly.
CAUTION!
Use the clamp lever to fix the manual adjustment
wheel following every adjustment of the stroke length.
Start Up and Operation
21
Page 22
CAUTION!
Prior to commissioning, check that the power end
motor and corresponding ancillary equipment is con‐
nected in compliance with the regulations!
CAUTION!
Adhere to the instructions in the frequency converter
operating instructions when using pumps with speed
control
CAUTION!
Danger of material damage
Note all information on the "Evolution data sheet".
Note all information in the operating instructions and
on the data sheets.
CAUTION!
Feed chemical can escape unnoticed
Feed chemical can escape unnoticed if the electric dia‐
phragm rupture sensor does not stop the pump or no
alarm is triggered.
– Trigger the electric diaphragm rupture sensor - see
"Operating Instructions for Electric Diaphragm
Rupture Sensor..." and thus check the reaction of
the monitoring unit and/or the pump.
CAUTION!
Only restart the pump once the diaphragm has been
replaced after a diaphragm rupture if damage can be
caused by hydraulic oil mixing with the feed chemical.
CAUTION!
Never adjust the pressure relief valve.
5.1 Tests Prior to Start Up of the Pump
Check whether the gear oil covers up to a quarter to three-quarters
of the oil inspection window (020).
Check whether the oil level in the turrets lies between the marks
and the end of the dipstick.
Observe the technical data
Testing the electric diaphragm rupture
sensor (option)
Pressure relief valve
Checking the oil levels and oil quali‐
ties
Start Up and Operation
22
Page 23
Check whether water is in the dosing head - if it would interfere.
Check whether the accessories supplied loose are correctly
assembled and installed. Use the operating instructions for the
loosely fitted accessories.
Check whether the safety equipment is correctly assembled and
working properly.
Check whether the entire electrical installation is correctly installed
and in accordance with local regulations. Also potential equalisa‐
tion and earthing lines.
Check whether the supply voltage from the drive motor,
actuator ...is correct.
Check whether the system is protected from overpressure.
Only in areas at risk from explosion: Set the opening pressure of
the (on site) relief valve downstream of the pressure manifold to a
maximum of 1.5 times the nominal pressure of the pump.
Check whether the suction line and discharge line are free from
tension and connected tightly.
Replace the closing screws on the oil filler neck with the vent
screws supplied.
Slight oil marks on the pump do not indicate leaks with
a new product.
Remove any oil stains and note their position.
Set the stroke length to start at 0 mm.
Check whether all obstacles have been removed in the suction and
discharge manifold and that the shut-off valves are open.
Check whether the actuator is working correctly over the entire
stroke length. This is also the case with drive units that are not
working.
Is the clamp of the stroke adjustment wheel working?
EF3a and EF4a only:
Check whether the scale bushing with the round scale is correctly
fitted.
Checking for water
Checking for accessories supplied
loose
Checking the safety equipment
Checking the electrical installation
Checking the supply voltage
Adjusting the relief valve (on site)
Checking the suction line and dis‐
charge line
Installing the vent screws with filter
Setting the stroke length to 0 mm
Checking the flow in discharge and
suction lines
Checking the stroke length adjust‐
ment
Checking the scale bushing
Start Up and Operation
23
Page 24
5.2 Testing Directly After the Pump has Started Up
With the pump running, check whether bubbles are rising in the oil
inspection window (336) above the bleed valve in the diaphragm
holder (300) - no foam!
Check whether liquids are escaping at any point.
Ensure that the back pressure on the discharge side is perma‐
nently above 1.5 bar (2.5 bar absolute).
Check whether the ratio of stroke length / metering frequency is
appropriate to the process.
Set the stroke length to prime to the maximum value on the scale.
WARNING!
Risk of injury from the fan impeller
The fan impeller beneath motor's fan cowling can
cause severe injuries while it is turning.
– The pump must only be connected to the mains
voltage with the fan cowling closed.
With upright motors:
Check whether the drive motor is rotating correcting – refer to the
arrow on the motor flange.
1. Unscrew the screw from the control opening on the motor
flange.
2. Push a long thin piece of cardboard a little way into the
opening with the motor running.
3. Remove the cardboard from the opening.
ð
The bend of the cardboard shows the direction of rota‐
tion.
With multiple pumps:
Check whether the drive shaft is rotating correctly - refer to the
arrow on the connecting flange between the drive units.
1. Unscrew the drive unit cover when the motor is at a standstill.
2. Carefully place a long thin piece of cardboard onto the end of
the shaft with the motor running.
WARNING!
Risk of injury
Never touch the end of the shaft with your fin‐
gers.
ð
The cardboard indicates the direction of rotation.
3. When the motor is stopped: Screw the drive unit cover onto
the drive unit.
Checking the hydraulic oil flow
Checking for leaks
Setting the back pressure
Checking the stroke length / metering
rate
Setting the stroke length to the max‐
imum value on the scale
Checking the direction of rotation
Start Up and Operation
24
Page 25
5.3 Testing 0.5 to 1 Hour After the Pump has Started
With the pump running, check whether oil is rising in the oil inspec‐
tion window (336) above the bleed valve (356) in the diaphragm
holder (300) - a few bubbles are permitted.
Check whether liquids are escaping at any point.
With the pump idle, check whether the drive unit oil level slightly
covers a quarter to three-quarters of the oil inspection window
(020).
With the pump idle and the stroke length 0 mm, check whether the
oil level in the turrets lies between the marks and the end of the
dipstick - screw in the vent screw with the measuring dipstick to do
so.
5.4
Bleeding the Diaphragm Holder
Bleed the hydraulics once to start up:
1. Set a stroke length of 0 mm.
2. Unscrew the oil inspection window (336) and the bleed valve
(356) from the diaphragm holder (300).
3. Re-fit the oil inspection window (336).
4. Start up the pump at a low speed.
5. Slowly increase the speed until hydraulic oil flows into the
feed of the bleed valve (356).
The hydraulic system is adequately bled when only isolated
air bubbles rise from the feed of the bleed valve (356) within
1 minute.
6. Re-fit the bleed valve (356) with the pump stopped.
Checking the hydraulic oil flow
Checking for leaks
Checking the oil levels and oil quali‐
ties
Start Up and Operation
25
Page 26
6 Maintenance
- refer to the "Operating Instructions for the Liquid Ends Orlita
®
Evolution"
Maintenance
26
Page 27
7 Carrying out repairs
- refer to the "Operating Instructions for the Liquid Ends Orlita
®
Evolution"
Carrying out repairs
27
Page 28
8 Remedying Faults on the Drive Unit
WARNING!
ATEX pumps in areas at risk from explosion
Immediately stop the pump in the event of leakages,
unusual noises, high temperatures, unusual smells,
vibrations and rectify the cause.
WARNING!
Danger of an electric shock
Personnel working on electrical parts can be electro‐
cuted if all electrical lines carrying current have not
been disconnected.
– Disconnect the supply cable before working on the
motor and prevent it from being reconnected acci‐
dentally.
–
Any separately driven fans, servo motors, speed
controllers or diaphragm rupture sensors fitted
should also be disconnected.
– Check that the supply cables are de-energised.
WARNING!
Risk of injury from the fan impeller
The fan impeller beneath motor's fan cowling can
cause severe injuries while it is turning.
– The pump must only be connected to the mains
voltage with the fan cowling closed.
CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic compo‐
nents if they are manipulated or opened due to pres‐
sure 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.
Rectify functional faults on the liquid ends and boughtin parts as per their operating instructions.
Remedying Faults on the Drive Unit
28
Page 29
Electrical faults
Description of fault Cause Remedy Personnel
Drive unit does not rotate Faulty or missing contact
to power supply
Check the power supply
connector
Electrical technician,
ATEX electrical techni‐
cian
Drive motor rotates in the
wrong direction
The phases have been
swapped
Swap the phases Electrical technician,
ATEX electrical techni‐
cian
Various sensors do not
react
Incorrect installation,
faulty contacts, faulty
sensor
Correct installation, if
necessary, check con‐
tacts and repair if
required, replace sensor
Electrical technician,
ATEX electrical techni‐
cian
Mechanical faults
Description of fault Cause Remedy Personnel
Gear motor makes loud
noises
Bearing damage on the
motor shaft
Replace bearings or
motor
Service
Overload Monitor the process
parameters
Qualified employee
Monitor the process
parameters, makes loud
noises
Too great axial play in
the cam shaft bearing
Tighten / monitor adjust‐
ment nuts
Service
Overload Monitor the process
parameters
Qualified employee
Mechanics sluggish Too little axial play in the
cam shaft bearing (tight)
Monitor the adjustment
nut
Service
A piston is too tight in its
socket
n Loosen the hydraulic
end screws
n Press the hydraulic
end manually
upwards and
n Re-tighten the
screws
Qualified employee
No stroke movement
despite motor running
Check mechanical com‐
ponents for breakage
Replace defective com‐
ponents
Service
Remedying Faults on the Drive Unit
29
Page 30
9 Decommissioning and Disposal
- refer to the "Operating Instructions for the Liquid Ends Orlita
®
Evolution"
Decommissioning and Disposal
30
Page 31
10 Index
A
Add-on drive unit ..........................9
Assembling the motor independently ........8,
10
Assembly ..............................10
B
Base ..................................12
C
Carrying out repairs ....................27, 30
Claw coupling ...........................10
D
Diaphragm holder ........................25
Diaphragm rupture sensor ...............18, 22
Direct sunlight ...........................14
Direction of rotation ....................17, 24
E
Earthing lines ...........................19
Electrical faults ..........................29
Emergency ..............................7
Emissions ...............................8
Explanation of the safety information ..........3
External fan .............................17
F
Fastening ..............................13
Frequency converter ......................18
Functional description ......................9
H
Hydraulic oil flow .........................24
I
Information in the event of an emergency .......7
Installation, Electrical .....................15
Intended use .............................3
L
Lightning protection .......................14
M
Maintenance ............................26
Mechanical faults ........................29
Motor ..................................17
O
Oil level ................................22
Operation ..............................20
P
Potential equalisation cables ................19
Pressure relief valve ......................22
Protective equipment ......................7
Q
Qualification of personnel ...................4
S
Safety ..................................3
Safety equipment .........................7
Sound pressure level ......................8
Space requirement .......................12
Start Up ................................20
Stroke sensor ...........................18
T
Troubleshooting .........................28
V
Vent screw .............................23
W
Warning sign .............................3
Index
31
Page 32
Heidelberg, 3, en_GB
© 2015
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
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