ProMinent Sigma 3, S3Ba, Sigma/ 1 Basic S1Ba Basic Operating Instructions Manual

Diaphragm motor-driven metering pump Sigma/ 3 Basic type S3Ba

Operating instructions

P_SI_0075_SW

Original operating instructions (2006/42/EC)Part no. 985905 BA SI 089 01/19 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

Operating guidelines

Outcome of the operating guidelines

- see (reference)

Information

This provides important information relating to the cor‐ rect operation of the unit or is intended to make your work easier.

Safety notes

Safety notes are identified by pictograms - see Safety Chapter.

These operating instructions conform to current EU regulations applicable at the time of publication.

Please state identity code and serial number, which you can find on the nameplate when you contact us or order spare parts. This enables the device type and material versions to be clearly identified.

Supplementary information

Fig. 1: Please read!

Validity

State the identity code and serial number

Supplemental directives

Table of contents

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

1.1 Explanation of the ATEX label................................................ 6

2 Safety chapter................................................................................. 9

2.1 Safety information for ATEX designs.................................... 15

2.2 Explanation of the ATEX label.............................................. 23

3 Storage, Transport and Unpacking................................................ 26

Overview of equipment and control elements............................... 27

5 Functional description.................................................................... 29

5.1 Pump..................................................................................... 29

5.2 Liquid end.............................................................................. 29

5.3 Integral relief valve................................................................ 29

5.4 Multi-layer safety diaphragm................................................. 30

6 Assembly....................................................................................... 31

7 Installation, hydraulic..................................................................... 34

7.1 Basic installation notes.......................................................... 38

8 Installation, electrical..................................................................... 39

9 Start up.......................................................................................... 46

10 During operation............................................................................ 50

11 Maintenance.................................................................................. 51

12 Carrying out repairs....................................................................... 56

12.1 Cleaning valves................................................................... 57

12.2 Replacing the diaphragm.................................................... 58

13 Troubleshooting............................................................................. 62

Decommissioning.......................................................................... 65

15 Technical data............................................................................... 68

15.1 Performance data................................................................ 68

15.2 Shipping weight................................................................... 69

15.3 Wetted materials................................................................. 70

15.4 Ambient conditions.............................................................. 70

15.4.1 Ambient temperatures...................................................... 70

15.4.2 Media temperatures......................................................... 70

15.4.3 Air humidity...................................................................... 71

15.5 Installation height................................................................ 71

15.6 Motor data........................................................................... 72

15.7 Stroke actuator.................................................................... 73

15.8 Stroke control drive............................................................. 73

15.9 Diaphragm rupture sensor.................................................. 73

15.10 Stroke sensor "Sigma"...................................................... 74

15.11 Relay................................................................................. 74

15.12 Gear oil.............................................................................. 75

15.13 Sound pressure level........................................................ 75

15.14 Supplementary information for modified versions............. 75

16 Diagrams for setting the metering capacity................................... 76

Dimensional drawings................................................................... 77

18 Potential equalisation drawings for Sigma Basic Type.................. 82

19 Motor data sheet standard motor.................................................. 84

20 Exploded drawings of Sigma/ 3..................................................... 85

21 Wear parts of Sigma/ 3.................................................................. 92

21.1 Standard.............................................................................. 92

Table of contents

21.2 Physiological safety............................................................. 92

22 Declaration of Conformity for Machinery....................................... 94

Declaration of Incorporation for Machinery.................................... 95

24 Declaration of Conformity for ATEX Machinery............................. 96

25 Declaration of Conformity for ATEX Machinery............................. 97

26 Index.............................................................................................. 98

Table of contents

1 Identity code

S3Ba Sigma 3 Basic type

H Main power end, diaphragm

Type: Capacity

_ _ _ _ _ _

Performance data at maximum back pressure: see nameplate on pump housing

Dosing head material

PP Polypropylene

PC PVC

PV PVDF

TT PTFE + carbon

SS Stainless steel

Seal material

T PTFE seal

Displacement body

S Multi-layer safety diaphragm with optical rupture indicator

A Multi-layer safety diaphragm with diaphragm rupture signalling (contact)

H Diaphragm for hygienic head (on request)

Dosing head design

0 no valve springs

1 with 2 valve springs, Hastelloy C; 0.1 bar (standard with DN 32)

4 with relief valve, FPM seal, no valve springs

5 with relief valve, FPM seal, with valve springs (standard with DN 32)

6 with relief valve, EPDM seal, no valve spring

7 with relief valve, EPM seal, with valve spring (standard with DN 32)

H Hygienic head with tri-clamp connectors (max. 10 bar) (on request)

Hydraulic connector

0 Standard threaded connector (in line with technical data)

1 Union nut and PVC insert

2 Union nut and PP insert

3 Union nut and PVDF insert

4 Union nut and SS insert

7 Union nut and PVDF hose nozzle

8 Union nut and SS hose nozzle

9 Union nut and SS welding sleeve

Design

with ProMinent® logo

without ProMinent®

logo

F Physiological safety with

regard to wetted mate‐ rials

FDA No. 21 CFR §177.1550 (PTFE)

FDA No. 21 CFR §177.2510 (PVDF)

Identity code

S3Ba Sigma 3 Basic type

M modified* * order-related design, refer to

order paperwork for pump features

Electric power supply

_ Connection data - see motor nameplate

1 no motor, with B 5 flange, size 80 (DIN)

2 no motor, with C 56 flange (NEMA)

3 no motor, with B 5, size 71 (DIN)

Degree of protection

0 IP 55 (standard)

1 Exe design ATEX-T3 ***

2 Exd design ATEX-T4 ***

Stroke sensor

0 no stroke sensor (standard)

2 pacing relay (reed relay)

3 stroke sensor (Namur) for areas at

risk from explosion

Stroke length adjustment

0 manual (standard)

1, 2 Connection data - refer to

nameplate on servomotor

3 - 6 Connection data - refer to

nameplate on stroke control motor

*** ATEX specification - refer to the nameplate on the pump, corre‐ sponding EU Declaration of Conformity for ATEX Machinery and

Ä Chapter 1.1 ‘Explanation of the ATEX label’ on page 6

FPM = fluorine rubber

1.1 Explanation of the ATEX label

in accordance with Directive 2014/34/EU and standards EN ISO 80079-36, -37

Unit group

II Units for use in areas with a potentially explosive atmosphere – excluding mines

Unit category

2 High level of safety – use possible in zones 1 and 2

3 Normal level of safety – use possible in zone 2

Identity code

Type of explosive atmosphere

G Mix of air and gases, vapours or mist

Areas at risk of explosion label

Ex in accordance with EN ISO 80079-36, -37

Type of protection

h non-electrical device

Explosion group

IIC

Group IIC gas - refer, for example, to

Ä Tab. 1 ‘Divi‐

sion of gases into explosion groups and temperature classes’ on page 7

IIB

Group IIB gas - for example

Ä Tab. 1 ‘Division of

gases into explosion groups and temperature classes’ on page 7

Temperature class

T3 Max. surface temperature: 200 °C

T4 Max. surface temperature: 135 °C

Equipment protection level (EPL)

Gb high EPL in normal operation and in

the event of expected errors (corre‐ sponds to category “2G”.)

Gc normal EPL in normal operation (corre‐

sponds to category “3G”.)

Suffix X

X Special conditions - refer to the

Declarations of Conformity and EC-type examination certifi‐ cates

Tab. 1: Division of gases into explosion groups and temperature classes

T4 T3 T2 T1

IIC - - Acethylene Hydrogen

IIB Ethyl ether - Ethylene Mains gas (coal gas)

IIA Acetaldehyde Benzine,

Diesel fuel,

Aircraft fuel,

Heating oils,

n-hexane

Ethyl alcohol,

n-butane,

n-butyl alcohol

Acetone,

Ammonia,

Benzene (pure),

Acetic acid,

Ethane,

Ethyl acetate,

Carbon oxide,

Methanol,

Propane,

Toluene

Identity code

You should always consider the explosion group AND temperature class together:

You are safe in areas at risk from explosion with all the gases listed in the table with equipment approved for explosion group IIC and temperature class T4.

Equipment approved for explosion group IIB can also be used for explosion group IIA – not for explosion group IIC.

Equipment approved for temperature class T3 can also be used for temperature classes T2 to T1 – not for tem‐ perature class T4.

Identity code

2 Safety chapter

CAUTION! These operating instructions include notes and extracts

from German regulations relating to the operator'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 spe‐ cific 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.

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 – high-voltage.

Warning – danger zone.

n Only use the pump to meter liquid feed chemicals. n Only pumps with the identity code option "Multi-layer safety diaphragm

with visual rupture display" and "Multi-layer safety diaphragm with rup‐ ture signalling (contact)" are approved for use with flammable feed chemicals with electrically conductive dosing heads, at back pres‐ sures of over 2 bar and only if the operator takes appropriate safety measures.

n Only pumps with the design "F - Physiologically safe with regard to

wetted materials" are approved for use in physiologically harmless applications.

n Only “H - Hygienic head” design pumps may be used for applications

in accordance with the hygienic requirements of the EHEDG (www.ededg.org).

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 the ProMinent Resistance List (in the Product Catalogue or at www.prominent.com)!

n All other uses or modifications are prohibited.

Identification of safety notes

Warning signs denoting different types of danger

Intended use

Safety chapter

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

solids.

n The pump is not intended for the metering of explosive substances

and mixtures.

n The pump is not intended for unprotected use outdoors. 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 You have a responsibility to adhere to the information contained 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.

n ATEX designs only: Refer to the chapter "

Ä Chapter 2.1 ‘Safety infor‐

mation for ATEX designs’ on page 15

Task Qualification

Storage, transport, unpacking Instructed person

Assembly Technical personnel, service

Planning the hydraulic installation Qualified personnel who have a

thorough knowledge of oscillating diaphragm pumps

Hydraulic installation Technical personnel, service

Electrical installation Electrical technician

Start up Technical personnel

Operation Instructed person

Maintenance, repair Technical personnel, service

Decommissioning, disposal Technical personnel, service

Troubleshooting Qualified person, electrical techni‐

cian, instructed person, service depending on the requirement

Explanation of the table:

Trained, qualified personnel

A trained, qualified employee is deemed to be a person who is able to assess the tasks assigned to him and recognise possible hazards based on his training, knowledge and experience, as well as knowledge of perti‐ nent regulations. A trained, qualified employee must be able to perform the tasks assigned to him/her independently with the assistance of drawing documentation and parts lists. The assessment of a person's technical training can also be based on several years of work in the rele‐ vant field.

Electrical technician

An electrical technician is able to complete work on electrical systems and recognise and avoid possible dangers independently based on his tech‐ nical training and experience as well as knowledge of pertinent standards and regulations. An electrical technician must be able to perform the tasks assigned to him/her independently with the assistance of drawing docu‐ mentation, parts lists, terminal and circuit diagrams. The electrical techni‐ cian must be specifically trained for the working environment in which the electrical technician is employed and be conversant with the relevant standards and regulations.

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.

Qualification of personnel

Safety chapter

Trained user

A trained user is a person who fulfils the requirements demanded of an instructed person and who has also received additional training specific to the system from ProMinent or another authorised distribution partner.

Service

The Service department refers to service technicians, who have received proven training and have been authorised by ProMinent to work on the system.

Ignition hazard Protective measures to be observed by the customer

Excessive surface pressure Limitation of the maximum temperature of the feed chem‐

ical

Too low ambient temperature Limitation of the minimum ambient temperature

Pump running hot The customer must monitor and maintain the pump in

accordance with the “Maintenance” chapter.

The customer must fit a relief valve on the discharge side.

Mechanically generated sparks from the mechanism with low oil

The customer must monitor and maintain the pump in accordance with the “Maintenance” chapter.

Mechanically generated sparks from a faulty valve The customer must monitor the capacity.

Electrical stray current in the event of a short circuit The customer must earth the pump and maintain the

earthing of the individual components.

Electrical stray current in the event of a lightning strike The customer must put in place suitable protective meas‐

ures outdoors.

Static electricity The customer must earth the earthing points and maintain

the potential equalisation cables of the individual compo‐ nents.

The customer must pay attention to potential equalisation when dismantling.

Paint should not be applied too thickly.

Only clean plastic parts with a damp cloth.

Provide a temperature monitor on the dosing head with feed chemical with critical friction properties.

The customer must wire the diaphragm rupture indicator in such a way that it immediately stops the pump.

Electromagnetic waves (also lasers), ionising radiation and ultrasound have an impact on the pump

The customer must put in place measures in accordance with EN 1127-1, if need be.

Adiabatic compression and shock waves Feed chemical with electrical conductivity of < 50 pS/m,

which could form a combustible mixture: Do not allow the unit to run dry – even when filling and emptying the liquid end.

Exothermic reaction, including the self-combustion of dust The pump is not suitable for use with substances that

have a tendency towards exothermic reactions or selfcombustion. Put in place measures in accordance with EN 1127-1, if need be.

Deposits of dust Regularly clean the outside of the pump with a damp

cloth.

Summary of relevant ignition hazards and protective measures put in place for the Sigma in accordance with EN ISO 80079-36

Safety chapter

Ignition hazard Protective measures to be observed by the customer

Flammable feed chemicals Only material version SS or TT is permitted to pump flam‐

mable feed chemicals.

Do not allow it to run dry.

The operator must install suitable protective measures, for example a flow meter.

The customer must wire the diaphragm rupture indicator in such a way that it immediately stops the pump.

Ignition hazard with bought-in motor components Refer to the documentation for the motor.

Comply with the monitoring intervals.

The insulation resistance needs to be greater then 5 MOhm.

Provide a time-delay residual current device.

Provide overload protection by means of a motor protec‐ tion switch or an equivalent protective device.

Observe the minimum spacing between the air inlet on the fan hood and any obstacles.

Avoid deposits of dust more then 5 mm deep.

Connect the earth wire.

Max. installation height: 1,000 m.a.s.l.

Ignition hazard with bought-in actuator or control drive components

Refer to the documentation for the actuator.

Wait 3 minutes after switching off before opening the housing.

Ignition hazard caused by bought-in proximity switch NJ1.5-8GM-N (stroke sensor)

Refer to the documentation for the proximity switch (elec‐ trical installation, maintenance, ...).

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.

Safety information

Safety chapter

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.

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 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.

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.

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.

Safety chapter

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.

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 respon‐ sibility 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 protection, and taking into considera‐ tion the actual operating environment 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).

All isolating protective equipment must be installed for operation:

Protective equipment May only be removed by*:

Motor terminal box cover Electrical technician, ATEX elec‐

trical technician, Service

Protective cowling over the motor fan

Service

Power end front cover Service

* Only if required by the operating instructions and if the mains cable remains disconnected from the mains voltage.

The operator must be able to:

n Perform a risk assessment n Produce and attach a nameplate n Issue a Declaration of Conformity n Adapt the operating instructions, if necessary n Install the motor correctly

1. Select a suitable motor - it must correspond to the data for one of the motors from the "Motor data" table - see Chapter "Technical data"

2. Fit the motor correctly on the flange (qualified personnel).

Information in the event of an emergency

Safety information for operating instruc‐ tions

Safety equipment

Isolating protective equipment

Requirements if the motor is being installed independently

Install the motor - with designs without motor

Safety chapter

3. As you have converted an "incomplete machine" into a complete machine, you must perform a conformity assessment, risk assess‐ ment, create a Declaration of Conformity, fit a company name‐

plate, ... .

4. Complete the pump documentation / operating instructions.

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

at maximum stroke length, maximum stroke rate, maximum back pressure (water)

2.1

Safety information for ATEX designs

This chapter lists all safety information for ATEX designs. Safety informa‐ tion is listed again at the relevant points in these operating instructions.

This safety information is supplementary to or replaces the safety informa‐ tion for non-ATEX designs. If the safety information for ATEX designs con‐ tradicts the other safety information, then the safety information in this chapter applies to ATEX designs.

n Only operate an ATEX design pump in premises at risk from explosion

in accordance with the applicable guidelines.

n Do not expose the ATEX design to any sources of ionising radiation or

electromagnetic high frequency radiation in the range 104 ... 3x1015 Hz or laser radiation or ultrasound or lightning without putting in place measures in line with EN 80079-38.

n Do not allow the ATEX design to meter media, which tends to produce

exothermic reactions or self-ignite (examples of exothermic reactions: pyrophoric substances with air, alkali metal with water, decomposition of organic peroxides, polymerisation reactions), without taking effec‐ tive measures in accordance with EN 80079-38.

Task Qualification

Planning the hydraulic installation ATEX qualified person, ATEX elec‐

trical technician

Electrical installation ATEX electrical technician

Start up Skilled ATEX technician;

Checking the electrical installation: Recognised competent person

Maintenance, repair ATEX qualified person, ATEX elec‐

trical technician

Troubleshooting Qualified ATEX technician or ATEX

electrical technician - depending on the fault;

Checking the electrical installation: Recognised competent person

Explanation of the table:

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 experience of

safety technology.

Sound pressure level

Intended use

Qualification of personnel

Safety chapter

Make sure that the person is familiar with the relevant body of standards and regulations and has worked in the field for at least one year. The person needs to have opportunities for an exchange of experiences.

Specific requirements are placed on competent persons who perform tests on repaired devices/parts. They must be recognised by the responsible authorities (e.g. district council) in this respect.

Skilled technician with knowledge of ATEX explosion protection

The skilled 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 skilled technician with an additional explosion protection qualification can work on equipment and systems in areas protected from explosion and independ‐ ently recognise and avoid possible dangers based on his technical training and experience.

The skilled technician with an additional explosion protection qualification is familiar with all the standards and regulations applicable to explosion protection.

The skilled technician with an additional explosion protection qualification must comply with the provisions of the applicable statutory directives on accident prevention.

Electrical technician with knowledge of ATEX explosion protection

An electrical technician with an additional explosion protection qualification should be specifically trained for the field of work in which he is employed and be familiar with the relevant standards and regulations. An electrical technician with an additional explosion protection qualification can work on electrical systems and independently recognise and avoid possible dan‐ gers based on his technical training and experience.

The electrical technician with an additional explosion protection qualifica‐ tion is familiar with all the standards and regulations applicable to explo‐ sion protection.

An electrical technician with an additional explosion protection qualification must comply with the provisions of the applicable statutory 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 experience of

safety technology.

Specific requirements are placed on competent persons who perform tests on repaired devices/parts. They must be recognised by the responsible authorities (e.g. district council) in this respect.

Ignition hazard Protective measures to be observed by the customer

Excessive surface pressure Limitation of the maximum temperature of the feed chem‐

ical

Too low ambient temperature Limitation of the minimum ambient temperature

Pump running hot The customer must monitor and maintain the pump in

accordance with the “Maintenance” chapter.

The customer must fit a relief valve on the discharge side.

Summary of relevant ignition hazards and protective measures put in place for the Sigma in accordance with EN ISO 80079-36

Safety chapter