ProMinent Sigma/3, S3Cb Operating Instructions Manual
Operating instructions
Diaphragm Motor-Driven Metering Pump
Sigma X Control type — Sigma/ 3 - S3Cb
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.
Original operating instructions (2006/42/EC)Part no. 982514 BA SI 080 07/18 EN
Supplemental directives
Supplementary information
Fig. 1: Please read!
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
Handling instructions
Outcome of the operation guidelines
ð
- see (reference)
Information
This provides important information relating to the cor‐
rect operation of the device or is intended to make your
work easier.
Validity
State the identity code and serial number
Safety notes
Safety notes are identified by pictograms - see Safety Chapter.
At the time of going to press, these operating instructions conformed to the
current EU regulations.
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.
2
Table of contents
Table of contents
Identity code.................................................................................... 5
1
2 Safety Chapter................................................................................. 8
3 Storage, Transport and Unpacking................................................ 12
4 Overview of equipment and control elements............................... 13
4.1 Control elements................................................................... 15
4.2 Key functions......................................................................... 17
5 Functional description.................................................................... 18
5.1 Pump..................................................................................... 18
5.2 Liquid end.............................................................................. 19
5.3 Bleed valve and integrated relief valve ................................ 19
5.4 Multi-layer safety diaphragm................................................. 20
5.5 Operating modes................................................................... 20
5.6 Functions............................................................................... 21
5.7 Options.................................................................................. 22
5.8 Function and fault indicator................................................... 22
5.8.1 LCD screen........................................................................ 22
5.8.2 LED displays...................................................................... 23
5.9 Hierarchy of operating modes, functions and fault sta‐
tuses......................................................................................
6 Assembly....................................................................................... 24
7 Installation..................................................................................... 26
7.1 Installation, hydraulic............................................................. 26
7.1.1 Basic installation notes....................................................... 30
7.2 Installation, electrical............................................................. 31
7.2.1 Control connectors............................................................. 32
7.2.2 HMI operating unit.............................................................. 39
7.2.3 Pump, power supply........................................................... 40
7.2.4 Other units.......................................................................... 41
8 Basic set-up principles................................................................... 42
8.1 Basic principles for setting up the control.............................. 42
8.2 Checking adjustable variables.............................................. 44
8.3 Changing to Setting mode..................................................... 44
9 Set up /
9.1
9.2
9.3
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6
9.3.7
9.4
9.4.1 Timer
9.4.2
9.4.3
9.4.4 Example............................................................................. 59
9.5
9.5.1
9.5.2
9.5.3
‘Menu’
.............................................................................. 45
‘Information’
‘Operating mode’
‘Settings’
‘Operating mode’
‘Metering’
‘Calibration’
‘Inputs/outputs’
‘System’
‘Set time’
‘Date’
‘Timer’
‘Setting the timer’
‘Clear all’
‘Service’
‘Password’
‘Clear counter’
‘Log book’
......................................................................... 45
.................................................................. 45
.............................................................................. 45
............................................................... 46
.......................................................................... 50
....................................................................... 51
.................................................................. 53
............................................................................ 55
........................................................................... 56
................................................................................. 56
.................................................................................. 56
‘activation’
........................................................................... 58
............................................................................... 59
............................................................... 56
.............................................................. 56
......................................................................... 59
................................................................... 59
.......................................................................... 60
23
3
Table of contents
9.5.4
‘Display’
9.5.5
‘HMI logout’
9.5.6
‘Diaphragm part number: XXXXXXX’
9.5.7
‘Spare parts kit part number: XXXXXXX’
9.6
‘Language’
10 Start up.......................................................................................... 62
Operation....................................................................................... 66
11
11.1 Manual operation................................................................ 66
12 Maintenance.................................................................................. 68
13 Carrying out repairs....................................................................... 71
13.1 Cleaning valves................................................................... 71
13.2 Replacing the diaphragm.................................................... 73
14 Troubleshooting............................................................................. 77
14.1 Faults without a fault message............................................ 77
14.2 Fault messages................................................................... 78
14.3 Warning messages............................................................. 79
14.4 All other faults..................................................................... 80
14.5 Log book............................................................................. 80
14.5.1 Warning messages in the log book.................................. 80
14.5.2 Fault messages in the log book....................................... 81
14.5.3 Events in the log book...................................................... 82
15 Decommissioning.......................................................................... 83
16 Technical data............................................................................... 86
16.1 Performance data................................................................ 86
16.2 Viscosity.............................................................................. 87
16.3 Shipping weight................................................................... 87
16.4 Wetted materials................................................................. 87
16.5 Ambient conditions.............................................................. 88
16.5.1 Ambient temperatures...................................................... 88
16.5.2 Media temperatures......................................................... 88
16.5.3 Air humidity...................................................................... 88
16.5.4 Degree of Protection and Safety Requirements............... 89
16.6 Installation height................................................................ 89
16.7 Electrical connection........................................................... 89
16.8 Diaphragm rupture sensor.................................................. 90
16.9 Relay................................................................................... 90
16.10 Gear oil.............................................................................. 91
16.11 Sound pressure level........................................................ 91
17 Dimensional drawings................................................................... 92
Motor data sheets.......................................................................... 95
18
19 Liquid ends for Sigma/ 3................................................................ 96
20 Wear parts for S3Cb.................................................................... 106
20.1 Standard............................................................................ 106
20.2 Physiological safety........................................................... 106
21 Diagrams for adjusting the capacity............................................ 108
22
Declaration of Conformity for Machinery..................................... 109
23 Operating/Set-up overview of the Sigma X Control type............. 110
24 Operating menu of Sigma X Control type, complete................... 111
25 Continuous displays and secondary displays.............................. 115
26 Index............................................................................................ 117
............................................................................. 60
....................................................................... 60
................................ 60
.......................... 61
........................................................................... 61
4
1 Identity code
Sigma X Control type - Sigma/ 3 - S3Cb
Product range
S3Cb
Power end type
H Main power end, diaphragm
Type Capacity
Identity code
_ _ _ _ __Performance data at maximum back pressure and type: refer to nameplate on the pump
Dosing head material
housing
PP Polypropylene
PC PVC
PV PVDF
SS Stainless steel
Seal material
T PTFE
Displacement body
S Multi-layer safety diaphragm with optical rupture indicator
A Multi-layer safety diaphragm with rupture signalling by electrical signal
H Diaphragm for hygienic pump head
Dosing head design
0 without bleed valve, without valve springs
1 without bleed valve, with valve springs
2 with bleed valve, FPM, without valve springs ***
3 with bleed valve, FPM, with valve springs ***
4 with relief valve, FPM, without valve springs ***
5 with relief valve, FPM, with valve springs ***
6 with relief valve, EPDM, without valve springs ***
7 with relief valve, EPDM, with valve springs ***
8 with bleed valve, EPDM, without valve springs ***
9 with bleed valve, EPDM, with valve springs ***
H Hygienic pump head with tri-clamp connectors (max. 10 bar)
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
5
Identity code
Sigma X Control type - Sigma/ 3 - S3Cb
Design
0
with ProMinent® logo
1
without ProMinent®
N Seal according to NEMA 4x
Electric power supply
U 1-phase, 100-240 V, 50/60 Hz
Cable and plug
A 2 m European
B 2 m Swiss
C 2 m Australian
D 2 m USA
Relay
0 no relay
1 Fault indicating relay (230V - 8A)
logo
3 Fault indicating relay + pacing relay (24V
- 100mA)
8 0/4-20 mA analogue output + fault indi‐
cating / pacing relay (24V - 100mA)
Control version
0 Manual + external contact with
PulseControl + timer
1 Manual + external contact with
PulseControl + analogue +
metering profiles
2 Manual + controller + PulseControl
+ analogue + dosing profile +
extreme profile
5 as 1 + timer
6
as 1 + PROFIBUS®
DP interface
(M12 plug)
7 as 1 + CANopen (M12 plug) **
Overload shut-down
0 without overload shut-down
Operating unit (HMI)
0 HMI (0.5 m cable)
4 HMI + 2 m cable
5 HMI + 5 m cable
6 HMI + 10 m cable
X without HMI
Safety options
0 Metering monitor,
dynamic, without
access control
6
Sigma X Control type - Sigma/ 3 - S3Cb
Identity code
1 Metering monitor,
dynamic, with
access control
B HMI with Blue‐
tooth
W HMI with Wi-Fi
Language
DE German
EN English
ES Spanish
FR French
FPM = fluorine rubber
** Pump without HMI control unit
*** Standard with tube nozzle in the bypass. Threaded connection on
request.
7
Safety Chapter
2 Safety Chapter
Identification of safety notes
Warning signs denoting different types of
danger
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.
Intended use
n Only use the pump to meter liquid feed chemicals.
n Only use the pump after it has been correctly installed and started up
in accordance with the technical data and specifications contained in
the operating instructions.
n Only pumps with the identity code option "Multi-layer safety diaphragm
with rupture signalling by electrical signal" are approved for use with
flammable feed chemicals, at back pressures of over 2 bar, software
setting
‘Diaphragm rupture’
priate safety measures.
n Only pumps with the design "F - Physiological safety with regard to
wetted materials" are approved for use with 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 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.
n The pump is not intended for the metering of gaseous media and
solids.
n The pump is not intended for operation in areas at risk from explosion.
n The pump is not intended for unprotected outside use.
n The pump is only intended for industrial use.
n The pump should only be operated by trained and authorised per‐
sonnel, see the following "Qualifications" 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.
-
‘Error’
and if the operator takes appro‐
8
Qualification of personnel
Safety Chapter
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
Operation Instructed person
Maintenance, repair Technical personnel, Service
Decommissioning, disposal Technical personnel, Service
Troubleshooting Technical personnel, electrical
technician, instructed person,
service
Explanation of the table:
Technical personnel
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 tech‐
nical training, knowledge and experience, as well as knowledge of perti‐
nent regulations.
Note:
A qualification of equal validity to a technical qualification can also be
gained by several years of employment in the relevant field of work.
Electrical technician
An electrical technician is able to complete work on electrical systems and
recognise and avoid possible dangers independently based on his tech‐
nical training and experience as well as knowledge of pertinent standards
and regulations.
The electrical technician must be specifically trained for the working envi‐
ronment in which he is employed and be conversant with the relevant
standards and regulations.
The electrical technician must comply with the provisions of the applicable
statutory directives on accident prevention.
Instructed person
An instructed person is deemed to be a person who has been instructed
and, if required, trained in the tasks assigned to him and any possible dan‐
gers that could result from improper behaviour, as well as having been
instructed in the required protective equipment and protective measures.
Service
Customer Service department refers to service technicians, who have
received proven training and have been authorised by ProMinent or Pro‐
Maqua to work on the system.
9
Safety Chapter
Safety information
WARNING!
Warning of hazardous feed chemical
Should a dangerous feed chemical be used: it may
escape from the hydraulic components when working on
the pump, material failure or incorrect handling of the
pump.
– Take appropriate protective measures before
working on the pump (e.g. safety glasses, safety
gloves, ...). Adhere to the material safety data sheet
for the feed chemical.
Drain and flush the liquid end before working on the
–
pump.
WARNING!
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.
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.
10
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.
–
WARNING!
An on/off switch may not be fitted on the pump,
dependent on the identity code and installation.
Safety equipment
Fig. 2: Hot surface
Isolating protective equipment
Information in the event of an emergency
Warning labels
This warning sign is affixed to the motor:
Ensure that the warning sign is always fitted and clearly visible.
All isolating protective equipment must be installed for operation:
n Drive front cover
n Motor fan cowling
n Motor terminal box cover
n Hood
In exactly the same way, plug all relays, modules and options into the
hood - if available.
Only remove them when the operating instructions request you to do so.
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.
Sound pressure level
Sound pressure level LpA < 70 dB according to EN ISO 20361
at maximum stroke length, maximum stroke rate, maximum back pressure
(water)
11
Storage, Transport and Unpacking
3 Storage, Transport and Unpacking
Safety information
WARNING!
Only return the metering pump for repair in a cleaned
state and with a flushed liquid end - refer to the chapter
"Decommissioning"!
Only return metering pumps with a completed Decon‐
tamination Declaration form. The Decontamination Dec‐
laration constitutes an integral part of an inspection /
repair order. A unit can only be inspected or repaired
when a Declaration of Decontamination Form is sub‐
mitted that has been completed correctly and in full by
an authorised and qualified person on behalf of the
pump operator.
The "Decontamination Declaration Form" can be found
at www.prominent.com.
WARNING!
Slings can tear
ProMinent only supplies “non-reusable slings” in accord‐
ance with DIN EN 60005. They can tear with repeated
use.
– Destroy and remove the slings as soon as the pump
has been lifted into its final position.
Scope of delivery
Storage
CAUTION!
Danger of material damage
The device can be damaged by incorrect or improper
storage or transportation!
– The unit should only be stored or transported in a
well packaged state - preferably in its original pack‐
aging.
–
Only transport the unit when the red gear bleeding
plug is pushed in.
– The packaged unit should also only be stored or
transported in accordance with the stipulated
storage conditions.
– The packaged unit should be protected from mois‐
ture and the ingress of chemicals.
Compare the delivery note with the scope of supply:
Personnel:
1. Plug the caps on the valves.
2. Check if the red gear bleeding plug is pushed in.
3. Preferably place the pump standing vertically on a pallet and secure
against falling over.
4. Cover the pump with a tarpaulin cover - allowing rear ventilation.
Technical personnel
n
Store the pump in a dry, sealed place under the ambient conditions
according to chapter "Technical Data".
12
P_SI_0191_SW
1
2
5
6
7
3
4
1
2
P_SI_0088_SW_2
Overview of equipment and control elements
4 Overview of equipment and control elements
Overview of equipment
Control elements
Fig. 3: Overview of Sigma X - S3Cb equipment
1 HMI control unit
2 Frequency converter
3 Drive unit
4 Stroke length adjustment wheel
5 Drive motor
6 Liquid end
7 Diaphragm rupture sensor
Fig. 4: Sigma control elements
1 Bleed valve (optional)
2 Diaphragm rupture sensor (visual)
13
P_SI_0180_SW
3
1
5
4
2
10
9
8
6
7
P_SI_0193_SW
6
7
543
2
1
8
Overview of equipment and control elements
Fig. 5: Control elements for HMI Sigma X Control type
1 LCD screen
2
[Menu]
3
Clickwheel
4
5
6
7 "Bluetooth active” display (blue)
8 Fault indicator (red)
9 Warning indicator (yellow)
10 Operating indicator (green)
key
[Priming]
[STOP/START]
[Back]
key
key
key
Fig. 6: Connector cover control elements
1 Relay and mA-output (option)
2
3 "Diaphragm rupture" socket
4 "External control" terminal
5 "Metering monitor" terminal
Slot for optional module (PROFIBUS®, ...)
14
4.1 Control elements
12012
12000
CONTACT
memory
l/h
CAN
open
hh
B1087
1
3
2
120120
12000
Dosing monitor!
CONTACT
memory
l/h
CAN
open
hh
12000
ANALOGUE
hh
Input signal < 4 mAInput signal < 4 mA
i < 4 mAi < 4 mA
B1088
a)
b)
i < 4 mA!
Pressure display, identifier and fault dis‐
plays on the LCD screen
Overview of equipment and control elements
6 "Level switch" terminal
7 "CAN bus" socket (external)
8 LEDs (as Fig. 5) and CAN bus status LED (external)
not shown Stroke length adjustment wheel
Use this overview to familiarise yourself with the keys
and the other control elements on the pump!
Fig. 7: Construction of continuous display
1 Status bar
2 Continuous display, central area
3 Secondary display
Refer to the chapter entitled "Main displays and secondary displays" in the
Appendix for the different main displays and secondary displays.
The LCD screen supports the operation and adjustment of the pump by
providing different information and identifiers:
Fig. 8: a) Continuous display with warning message; b) Continuous display
with fault message. Explanation of the symbols in the following tables.
The above Figure, Part a) shows that:
n The pump is in operation
n Is in
n A metering monitor is connected
n A log entry has been made
n A warning message for the
n The capacity of 12.0 l/h has been set
n The stroke rate is 12,000 strokes / h
‘Contact’
operating mode with "memory" stroke memory
‘metering monitor’
is pending
15
dia
off
Overview of equipment and control elements
Tab. 1: Identifier and error displays:
Identifier Meaning
The pump is working or waiting for a starting signal.
‘memory’
The pump was manually stopped using the
The pump was remotely stopped (Pause) - via the "External" socket.
The pump was stopped by an error.
Only with cyclical batch metering: the pump is waiting for the next cycle.
Only in
The "Stroke memory" auxiliary function has been set.
The pump is in
The
The pump is in
The
‘CONTACT’
‘Curve è linear’
and
‘BATCH’
‘ANALOGUE’
type of processing is set.
‘ANALOGUE’
operating mode.
operating mode.
‘Curve è Upper side band’
operating modes:
type of processing is set.
[STOP/START]
key.
‘AUX’
The pump is currently pumping at auxiliary capacity and/or auxiliary frequency.
The diaphragm rupture warning system is disabled.
A "Flow Control" metering monitor is connected.
The timer is active.
Only with
Only with
The pump is in the
‘Password’
‘Password’
: the pump software is locked.
: the pump software has been temporarily unlocked.
‘Menu’
(Set up).
Further explanations can be found in the "Trouble‐
shooting" chapter.
16
Overview of equipment and control elements
The pump only shows the metering volume and the
capacity in the calibrated state in l or l/h or in gal or
gal/h.
4.2 Key functions
Key Application In the continuous displays In the menu
[Back]
press - Move back to the previous menu
point (or a continuous display) without saving
press Stop pump, Stop pump,
[STOP/
START]
Start pump Start pump
[Menu]
[Priming]
[Clickwheel]
[Clickwheel]
press Move to the menu Move back to a continuous display
press Priming * Priming *
press Start batch (only in
mode),
Acknowledge errors
turn Switch between the continuous dis‐
plays
‘Batch’
operating
Move to next menu option (or a
continuous display)
Confirm entry and save
Change figure or change selection
* When priming the pump does not run at maximum
stroke rate.
[Priming] is pressed in ‘Stop’ state, then [Priming]
If
has top priority as long as the button is pressed.
Refer to the "Set-up basics" chapter to adjust figures
17
0
s s
a)
180 360 0
b)
180 360
ω ω
P_PL_0009_SW
P_SI_0120_SW
s
t
P_SI_0103_SW
s
t
Functional description
5 Functional description
Pump
5.1
The metering pump is an oscillating diaphragm pump, the stroke length of
which can be adjusted. An electric motor drives it. The slide rod transmits
the stoke motion to the diaphragms.
Illustration of the stroke movement
The stroke movement of the displacement body is continuously detected
and regulated so that the stroke is performed according to a previously set
metering profile - see chapter.
‘Metering’ ‘setting’
.
The following metering profiles are available:
n Normal
n Metering optimised
n Priming optimised
Every metering profile is ineffective below the switchover frequency for Start/Stop mode.
Normal
Fig. 9: Stroke movement at a) maximum stroke length and b) reduced
stroke length.
s Stroke velocity
⍵ Cam rotational angle
+ Discharge stroke
- Suction stroke
Metering optimised
With a metering optimised metering profile, the discharge stroke is elon‐
gated and the suction stroke is executed as quickly as possible. This set‐
ting is for example suitable for those applications that require optimum
mixing ratios and the most continuous chemical mixing possible.
Priming optimised
18
5.2
4
2
1
5
3
13
P_SI_0104_SW
s
t
Functional description
With a priming optimised metering profile, the suction stroke is elongated
as much as possible, which facilitates the precise and problem-free
metering of viscous and gaseous media. Select this setting to minimise the
NPSH value as well.
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. The dis‐
charge valve (3) closes as soon as the diaphragm (2) is moved in the
opposite direction due to the vacuum pressure in the dosing head and
fresh feed chemical flows through the suction valve (1) into the dosing
head. One cycle is thus completed.
Fig. 10: Cross-section through the liquid end
1 Suction valve
2 Diaphragm
3 Discharge valve
4 Dosing head
5 Backplate
13 Safety diaphragm
5.3 Bleed valve and integrated relief valve
Bleed valve
Integral relief valve
Turning the rotary dial (3) on the bleed valve to "open" causes it to open
and the liquid end can be bled. Or it is used as a priming aid for priming
against pressure. The feed chemical flows out through the hose connec‐
tion (5), e.g. into a storage tank.
The integral relief valve operates in the "close" position as a simple,
directly controlled relief valve. As soon as the pressure exceeds the pres‐
sure value, which is preset using the large spring (1), it lifts the ball (2).
The feed chemical flows out through the hose connection (5), e.g. into a
storage tank.
19
1 2
5
3
P_SI_0109
Functional description
The integral relief valve can only protect the motor and the gear, and then
only against impermissible positive pressure that is caused by the
metering pump itself. It cannot protect the system against positive pres‐
sure.
The integral relief valve works as a bleed valve as soon as the rotary dial
(3) is turned to "open": The valve opens and the liquid end can be bled. Or
it is used as a priming aid for priming against pressure.
5.4 Multi-layer safety diaphragm
Fig. 11: Relief valve and integrated relief valve
1 Spring, large
2 Ball
3 Rotary dial
5 Hose connection
With the visual diaphragm rupture sensor, the lowered red cylinder (6)
springs forward beneath the transparent cover (7) so that it then becomes
clearly visible
Fig. 12.
With the electrical diaphragm rupture sensor, a switch is switched. A con‐
nected signalling device must signal the diaphragm rupture.
Fig. 12: Visual diaphragm rupture sensor, triggered and untriggered
The electrical diaphragm rupture sensor is connected to the "diaphragm
rupture indicator" terminal. If a diaphragm ruptures, the red LED "Fault"
display lights up on the pump and the identifier "Error" and
‘dia’
flash on
the LCD screen.
5.5 Operating modes
The operating modes are selected via the
‘Operating mode’
operating modes may not be present depending on the identity code.)
20
menu (some
‘Manual’
unit.
Functional description
operating mode: The stroke rate is set manually on the control
operating mode
‘Batch’
‘Contact’
operating mode
This operating mode provides the option of working with large transfer fac‐
tors (up to 99,999). Metering can be triggered either by pressing the
[Clickwheel]
via a contact or a semiconductor switching element. It is possible to preselect a metering volume (batch) or a number of strokes using the
[Clickwheel]
This operating mode provides the option of controlling the pump externally
by means of potential-free contacts (e.g. by means of a contact water
meter). The "Pulse Control" option enables you to preselect the number of
strokes (a scaling or transfer factor of 0.01 to 99.99) in the
menu.
‘Analogue’
logue current signal via the "External control" terminal. The processing of
the current signal can be preselected using the control unit.
‘BUS’
FIBUS® DP interface). This operating mode provides the option of control‐
ling the pump via BUS – see “Supplementary instructions for Sigma Con‐
trol type SxCb pumps with Can connector” or “Supplementary instructions
for delta® DLTa and Sigma SxCb with PROFIBUS®".
or by a pulse received via the "External control" terminal or
in the
‘Settings’
menu.
‘Settings’
operating mode The stroke rate is controlled using an ana‐
operating mode: (Identity code, control version: CANopen or PRO‐
5.6 Functions
The following functions can be selected using the
"Calibrate" function: The pump can also be operated in a calibrated state
in all operating modes. In this case, the corresponding continuous displays
can then indicate the metering volume or the capacity directly. Calibration
is maintained throughout the stroke rate range. The calibration is also
maintained when the stroke length is altered by up to ±10% scale divi‐
sions.
"Auxiliary frequency" function: Enables a freely selectable and program‐
mable stroke rate to be switched on in the
controlled via the "External control" terminal. This auxiliary frequency has
priority over the operating mode stroke rate settings.
"Flow" function: Stops the pump when the flow is insufficient, provided a
metering monitor is connected. The number of defective strokes, after
which the pump is switched off, can be set in the
The following functions are available as standard:
‘Settings’
‘Settings’
‘Settings’
menu:
menu, which can be
menu.
"Level switch" function: Information about the liquid level in the dosing tank
is reported to the pump control. To do this, a two-stage level switch must
be fitted, which is connected to the "Level switch" terminal.
21
Functional description
"Pause" function:
control" terminal. The "Pause" function only works via the "External con‐
trol" terminal.
The following functions are triggered by a key press:
"Stop" function: The pump can be stopped without disconnecting it from
the mains/power supply by pressing
The pump can be remotely stopped via the "External
[STOP/START]
.
"Priming" function
5.7 Options
Relay option
[]
Priming.
Priming can be triggered by pressing
The pump has several connection possibilities for the following options:
"Output relay" option: In the event of fault signals, warning signals, stop‐
ping of the pump or tripped level switches, the relay connects to complete
an electric circuit (for alarm horns etc.).
The relay can be retrofitted via a knock-out in the drive unit.
The various functions can be adjusted – see "Settings" - "Relays” chap‐
ters.
"Fault indicating relay and semiconductor relay" option:
fault signals, warning signals, stopping of the pump or tripped level
switches, the fault indicating relay connects to complete an electric circuit
(for control panel etc.).
In addition to the fault indicating relay, the pacing relay can be used to
make a contact every stroke.
Other functions can be adjusted – see "Settings" - "Relays” chapters. The
option can be retrofitted via a knock-out in the drive unit.
In the event of
"0/4-20 mA analogue current output and
fault indicating relay” option
5.8
Function and fault indicator
5.8.1 LCD screen
The current output I signal indicates the pump's actual calculated metering
volume.
The "0/4-20 mA analogue current output and fault indicating relay" option
can be retrofitted via a knock-out in the control unit.
The option also always includes a semiconductor relay - see above. Other
functions can be adjusted – see "Settings" - "Relays” chapters.
The operating and fault statuses are indicated by the three or four LED
displays and the
If a fault occurs, the identifier
sage – see “Troubleshooting” chapter
‘Error’
identifier on the LCD screen:
‘Error’
appears and an additional error mes‐
22
5.8.2 LED displays
Pump device LEDs
Functional description
- see "Troubleshooting" chapter
Fault indicator (red)
Warning indicator (yellow)
Operating indicator (green)
CAN bus status LED (external)
The fault indicator lights up if the fluid level in the dosing tank falls below
the second switching point of the level switch (20 mm residual filling level
in the dosing tank).
It also lights up with all other faults - refer to "Troubleshooting" chapter.
The warning indicator lights up if the fluid level in the dosing tank falls
below the first switching point of the level switch.
It also lights up with all other warnings - refer to "Troubleshooting" chapter.
The operating indicator lights up if the pump is ready for operation and
there are no fault or warning alerts. It briefly goes out as soon as the pump
has performed a stroke.
This LED on the power end is the top one in the row of 4 LEDs.
Colour Flash code Cause Conse‐
green lit Bus status
OPERA‐
TIONAL
quence
Normal bus
mode
Remedy
-
green flashing Bus status
PREOPERA‐
TIONAL
red any Bus error no meas‐
5.9 Hierarchy of operating modes, functions and fault statuses
The different operating modes, functions and fault statuses have a dif‐
ferent effect on whether and how the pump reacts.
The following list shows the order:
1. - Priming
2. - Fault, Stop, Pause
3. - Auxiliary frequency (external frequency changer)
4. - Manual, External contact, Batch, External analogue
currently no
measured
value com‐
munication
ured value
transmission
wait briefly.
Disconnect
HMI then
reconnect
Check
whether the
CAN con‐
nection is
faulty.
Notify
Service
Comments:
re 1 - “Priming" can take place in any mode of the pump (providing it is
re 2 - "Fault", "Stop" and "Pause" stop everything apart from "Priming".
re 3 - The "Auxiliary frequency" stroke rate always has priority over the
working).
stroke rate specified by an operating mode listed under 4.
23
h
P_MOZ_0016_SW
A
A
P_MOZ_0018_SW
Assembly
6 Assembly
Base
Compare the dimensions on the dimension sheet with
those of the pump.
WARNING!
Danger of electric shock
If water or other electrically conducting liquids penetrate
into the drive housing, in any other manner than via the
pump's suction connection, an electric shock may occur.
– Position the pump so that it cannot be flooded.
Fig. 13
Space requirement
Fig. 14
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.
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.
Position the pump so that control elements, such as the stroke length
adjustment knob, the indicating dial A or the oil inspection window, are
accessible.
In so doing, ensure there is enough space to carry out an oil change (vent
screws, oil drain plugs, oil trough ...).
If the HMI is mounted remotely from the pump: a clearly marked Stop
mechanism must be installed in the direct vicinity of the pump for emer‐
gencies!
24
1
3
2
f
f
f
P_MOZ_0017_SW
Fig. 15
DNm
m
P_MOZ_0015_SW
Liquid end alignment
Fastening
Assembly
1 Discharge valve
2 Dosing head
3 Suction valve
Ensure there is sufficient free space (f) around the dosing head as well as
the suction and discharge valve so that maintenance and repair work can
be carried out on these components.
Capacity too low
The liquid end valves cannot close correctly if they are
not upright.
–
Ensure that the discharge valve is upright.
Capacity too low
Vibrations can disturb the liquid end valves.
–
Secure the metering pump so that no vibrations can
occur.
Fig. 16
Take the dimensions (m) for the fastening holes from the appropriate
dimensions- or data sheets.
Use appropriate bolts to fix the pump base to the supporting floor.
Mounting the HMI user control
If ordered with the wall mounting, the HMI can be mounted directly on a
wall.
Install the HMI in the immediate vicinity of the pump. If not provided for, fit
a circuit breaker there - refer to the "Installation, electrical" chapter. Ensure
that the system is arranged ergonomically.
When doing so, consider the available cable length.
Prevent tripping hazards.
Refer to the relevant dimensional drawing for the dimensions of the HMI
and fixing holes.
CAUTION!
Warning of faulty operation
– Do not install the HMI and cable too close to devices
and cabling that emit strong electrical interference.
25
Installation
7 Installation
7.1 Installation, hydraulic
CAUTION!
Danger of injury to personnel and material damage
Disregard of technical data during installation may lead
to personal injuries or damage to property.
– Observe the technical data - refer to the "Technical
data" chapter and, where applicable, the operating
instructions for the accessories.
WARNING!
Danger of fire with flammable feed chemicals
– Only metering pumps with the identity code option
"Multi-layer safety diaphragm with rupture signalling
with electrical signal" are permitted to meter flam‐
mable media, with back pressures over 2 bar and if
the operator puts in place the appropriate safety pre‐
cautions.
WARNING!
Warning of feed chemical reactions to water
Feed chemicals that should not come into contact with
water may react to residual water in the liquid end that
may originate from works testing.
– Blow the liquid end dry with compressed air through
the suction connector.
–
Then flush the liquid end with a suitable medium
through the suction connector.
WARNING!
The following measures are beneficial when working
with highly aggressive or hazardous feed chemicals:
– Install a bleed valve with recirculation in the storage
tank.
Install a shut-off valve on the discharge or suction
–
side.
CAUTION!
Warning of feed chemical spraying around
PTFE seals, which have already been used / com‐
pressed, can no longer reliably seal a hydraulic connec‐
tion.
– New, unused PTFE seals must always be used.
26
Installation
CAUTION!
Suction problems are possible
The valves may no longer close properly with feed
chemicals with a particle size of greater than 0.3 mm.
– Install a suitable filter in the suction line.
CAUTION!
Warning of the discharge line rupturing
With a closed discharge line (e.g. from a clogged dis‐
charge line or by closing a valve), the pressure that the
metering pump generates can reach several times more
than the permissible pressure of the system or the
metering pump. This could lead to lines rupturing
resulting in dangerous consequences with aggressive or
hazardous feed chemicals.
– Install a relief valve that limits the pressure of the
pump to the maximum permissible operating pres‐
sure of the system.
CAUTION!
Warning against rupturing of suction or discharge lines
Hose lines with insufficient pressure rating may rupture.
– Only use hose lines with the required pressure
rating.
CAUTION!
Uncontrolled flow of feed chemical
Feed chemical can press through the metering pump in
an uncontrolled manner in the event of excessive pri‐
ming pressure on the suction side of the metering pump.
– Do not exceed the maximum permissible priming
pressure for the metering pump or
Set up the installation properly.
–
CAUTION!
Warning about lines coming loose
If suction, discharge and relief lines are installed incor‐
rectly, they can loosen / disconnect from the pump con‐
nection.
– Only use original hoses with the specified hose
diameter and wall thickness.
Only use clamp rings and hose nozzles that fit the
–
respective hose diameter.
– Always connect the lines without mechanical ten‐
sion.
27
P_SI_0021
P_SI_0022
1
1
2
3
4
5
P_MOZ_0020_SW
1
2
3
P_MOZ_0021_SW
Installation
Fig. 17: Moulded composite seals with
corrugated insert
CAUTION!
Warning of leaks
Leaks can occur on the pump connection depending on
the insert used.
– The pump is supplied with PTFE moulded compo‐
site seals with a flare, which are used for the pump
connectors, which seal the connectors between
grooved pump valves and ProMinent grooved
inserts - see
Ä Further information on page 26
.
– Use an elastomer flat seal in the event that an
unflared insert is used (e.g. third party part) - see
Ä Further information on page 26
Precise metering is only possible when the back
–
.
pressure is maintained above 1 bar at all times.
–
If metering at atmospheric pressure, a back pres‐
sure valve should be used to create a back pressure
of approx. 1.5 bar.
Fig. 18: Elastomer flat seal for a smooth
insert
Fig. 19: Manometer connector options
CAUTION!
Warning of backflow
A back pressure valve, a spring-loaded injection valve, a
relief valve, a foot valve or a liquid end do not represent
absolutely leak-tight closing elements.
– Use a shut-off valve, a solenoid valve or a vacuum
breaker for this purpose.
CAUTION!
To check the pressure conditions in the piping system it
is recommended that connecting options for a manom‐
eter are provided close to the suction and pressure con‐
nector.
1 Manometer socket
2 Discharge line (pipe)
3 Discharge valve
4 Suction valve
5 Suction line (pipe)
CAUTION!
Connect the pipelines to the pump so that no residual
forces act on the pump, e.g. due to the offsetting, weight
or expansion of the line.
Only connect steel or stainless steel piping via a flexible
piping section to a plastic liquid end.
Fig. 20: Steel pipeline at the liquid end
1 Steel piping
2 Flexible pipe section
3 Plastic liquid end
28
Integral relief valve or integral bleeder
valve
Installation
WARNING!
Product can be dangerously contaminated
Only with "Physiologically safety with regard to wetted
materials” version:
If the integral bleed valve or the integral relief valve
opens, the feed chemical comes into contact with phys‐
iologically harmful seals.
– Do not route feed chemical that escapes from the
integral bleed valve or the integral relief valve back
into the process.
CAUTION!
Danger due to incorrect use of the integral relief valve
The integral relief valve can only protect the motor and
the gear, and then only against impermissible positive
pressure that is caused by the metering pump itself. It
cannot protect the system against positive pressure.
– Protect the motor and gear of the system against
positive pressure using other mechanisms.
– Protect the system against illegal positive pressure
using other mechanisms.
CAUTION!
Warning of feed chemical spraying around
If no overflow line is connected to the integral relief valve
or the integral bleeder valve, feed chemical will spray out
of the hose connector as soon as the relief valve opens.
– Always connect an overflow line to the integral relief
valve or the integral bleeder valve and feed it back
into the storage tank or - if required by the regula‐
tions - into a special storage tank.
CAUTION!
Danger of cracking
Cracks on the PVT liquid end can occur if a metal over‐
flow line is connected to the relief valve.
– Never connect a metal overflow line to the relief
valve.
CAUTION!
Danger of the integral relief valve failing
The integral relief valve no longer operates reliably with
feed chemicals that have a viscosity of greater than 200
mPa s.
– Only use the integral relief valve with feed chemicals
that have a viscosity of up to 200 mPa s.
29
P_SI_0023
Installation
Fig. 21: Permissible alignment of the relief
valve
CAUTION!
Warning of leaks
Feed chemical, which remains in the overflow line at the
relief valve or bleeder valve, can attack the valve or
cause it to leak
– Route the overflow line with a continuous slope and
moreover with the hose nozzle pointed downwards see .
If the overflow line is fed into the suction line, the bleed
function is blocked.
Therefore lead the overflow line back into the storage
tank.
When operating the integral relief valve close to the
opening pressure, a minimal overflow into the overflow
line can occur.
Diaphragm rupture sensor
7.1.1 Basic installation notes
Safety notes
CAUTION!
Danger resulting from unnoticed diaphragm rupture
If the pump has been ordered with an electric diaphragm
rupture sensor, it still has to be installed.
– Screw the enclosed diaphragm rupture sensor into
the liquid end.
CAUTION!
Warning of unnoticed diaphragm rupture
Only above approximately 2 bar system back pressure is
a signal generated in the event of the rupture of a dia‐
phragm.
– Only rely on the diaphragm rupture sensor with back
pressures of greater than 2 bar.
Or install a back pressure valve and set it to a min‐
imum of 2 bar – if the installation permits this.
CAUTION!
Danger resulting from rupturing hydraulic components
Hydraulic components can rupture if the maximum per‐
missible operating pressure is exceeded.
– Never allow the metering pump to run against a
closed shut-off device.
With metering pumps without integral relief valve:
–
Install a relief valve in the discharge line.
30
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