ProMinent Sigma/ 2 Control S2Cb Operating Instructions Manual
Operating instructions
Diaphragm Motor-driven Metering Pump
Sigma/ 2 Control type S2Cb
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. 985454 BA SI 073 03/17 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 Key functions......................................................................... 15
4.2 LCD screen identifiers........................................................... 15
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
5.9 LCD screen........................................................................... 23
5.10 LED Displays....................................................................... 23
5.11 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 Setting........................................................................................... 42
8.1 Basic Principles for Setting up the Control............................ 42
8.2 Checking adjustable values / error messages...................... 42
8.3 Changing to set up mode...................................................... 43
8.4 Selecting the operating mode (Menu "Mode")...................... 44
8.5 Operating mode settings (menu "Settings").......................... 44
8.5.1 "Manual" operating mode settings..................................... 45
8.5.2 "Batch" mode settings ....................................................... 45
8.5.3 "Contact" operating mode settings..................................... 46
8.5.4 "Analog" operating mode settings...................................... 49
8.6 Programmable function settings ("Settings" menu ).............. 52
8.6.1 “Auxiliary frequency” function settings (AUX menu)........... 52
8.6.2 Settings for the “Calibration” function (CALIBRATION
menu).................................................................................
8.6.3 Settings for the “Metering” function (DOSING menu)........ 54
8.6.4 Settings for the “Dosing monitor” function (DOSING
MONITOR menu)............................................................... 56
8.6.5 Settings for the “Relay” function (RELAY menu)................ 57
8.6.6 Settings for the “Analog output” function (ANALOG
OUTPUT menu)................................................................. 58
8.6.7 Settings for the “Diaphragm break” function (DIA‐
PHRAGM BREAK menu)................................................... 59
8.6.8 Settings in the "System" menu" (SYSTEM menu)............. 59
8.7 Service (SERVICE menu)..................................................... 59
8.7.1 Clear counters (CLEAR COUNTERS menu)..................... 60
8.7.2 Adjusting the Display (DISPLAY menu)............................. 60
23
53
3
Table of contents
8.7.3 HMI logout.......................................................................... 60
8.7.4 Security (SECURITY menu)............................................... 61
8.8 Information about the pump (INFORMATION menu)............ 62
8.9 Set language (LANGUAGE menu)........................................ 62
9 Start Up......................................................................................... 64
10
Operation....................................................................................... 67
10.1 Manual................................................................................ 67
10.2 Remote operation................................................................ 69
11 Maintenance.................................................................................. 70
Carrying out repairs....................................................................... 73
12
12.1 Cleaning valves................................................................... 73
12.2 Replacing the diaphragm.................................................... 75
13 Troubleshooting............................................................................. 79
13.1 Faults without a fault message............................................ 79
13.2 Fault messages................................................................... 80
13.3 Warning messages............................................................. 81
13.4 All Other Faults................................................................... 82
14 Decommissioning.......................................................................... 83
15 Technical data............................................................................... 86
15.1 Performance data................................................................ 86
15.2 Viscosity.............................................................................. 87
15.3 Shipping weight................................................................... 87
15.4 Wetted materials................................................................. 87
15.5 Ambient conditions.............................................................. 87
15.5.1 Ambient temperatures...................................................... 87
15.5.2 Media temperatures......................................................... 88
15.5.3 Air humidity...................................................................... 88
15.5.4 Degree of Protection and Safety Requirements............... 88
15.6 Installation height................................................................ 88
15.7 Electrical connection........................................................... 89
15.8 Diaphragm rupture sensor.................................................. 89
15.9 Relay................................................................................... 90
15.10 Gear oil.............................................................................. 90
15.11 Sound pressure level........................................................ 90
16 Design Documents........................................................................ 91
Declaration of Conformity for Machinery....................................... 92
17
18 Operating / adjustment overview................................................... 93
19 Continuous displays...................................................................... 94
20 Index.............................................................................................. 96
4
1 Identity Code
S2Cb Sigma 2, Control Type, Version b
Product range
S2Cb
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
PV PVDF
SS Stainless steel
Seal material
T PTFE
Displacement body
Ste
Multi-layer safety diaphragm with optical rupture indicator
ckk
opf,
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, without valve springs
3 with bleed valve, 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 tube nozzle
8 Union nut and SS tube nozzle
9 Union nut and SS welding sleeve
Design
5
Identity Code
S2Cb Sigma 2, Control Type, Version b
0
With ProMinent®
1
Without ProMinent® logo
logo
F Physiological safety with
regard to wetted materials
Electric power supply
U 1 ph, 100-230 V ± 10%, 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)
3 Fault indicating relay + pacing relay (24V
- 100mA)
8 0/4-20 mA analogue output + fault indi‐
cating / pacing relay (24V - 100mA)
Control version
FDA No. 21 CFR §177.1550
(PTFE)
FDA No. 21 CFR §177.2510
(PVDF)
0 Manual + external contact with
pulse control
1 Manual + external contact with
pulse control + analog + dosing
profiles
5 as 1 + timer
6
as 1 + PROFIBUS®-DP interface
(M12 plug)
7 as 1 + CANopen (M12 plug) **
Overload switch-off
0 without overload switch-off
1 with overload switch-off
Operating unit (HMI)
Ste
HMI (0.5 m cable)
ckk
opf,
1 HMI + 2 m cable
2 HMI + 5 m cable
3 HMI + 10 m cable
X without HMI
Safety options
0 Dosing monitor,
dynamic, without
access control
6
S2Cb Sigma 2, Control Type, Version b
Identity Code
1 Dosing monitor,
dynamic, with
access control
Language
EN German
EN English
ES Spanish
FR French
FPM = fluorine rubber
** Pump without HMI control unit
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 the metering of flammable feed chemi‐
cals.
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 [ERROR: Missing definition for variable
"Hersteller"!] Resistance List when selecting the
feed chemical - see the [ERROR: Missing definition
for variable "Hersteller"!] Product Catalogue or visit
[ERROR: Missing definition for variable "Hers‐
teller"!].
10
Safety Chapter
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 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.
Isolating protective equipment
Information in the event of an emergency
Sound pressure level
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 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_0125_SW
1
2
5
6
7
3
4
1
2
P_SI_0088_SW
Overview of equipment and control elements
4 Overview of equipment and control elements
Overview of Equipment
Control elements
Fig. 2: Overview of equipment S2Cb
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. 3: Sigma control elements
1 Bleed valve or relief valve (dependent on identity code)
2 Diaphragm rupture sensor (visual)
13
2
1
5
10
8
9
6
7
3
4
P_SI_0105_SW
P_SI_0106_SW_2
6
7
543
2
1
8
Overview of equipment and control elements
Fig. 4: HMI control elements
1 LCD screen
2 Fault indicator (red)
3 Warning indicator (yellow)
4 Operating indicator (green)
5
[i]
key / Cursor to right
6
[ESC]
7
8
9
10
key
[START/STOP]
[DOWN]
[P / OK]
[UP]
key
key
key
key
Fig. 5: Connector cover control elements
1 Relay and mA-output (option)
2
3 "Diaphragm rupture" terminal
4 "External control" terminal
5 "Dosing monitor" terminal
6 "Level Switch" terminal
7 "CAN-bus" port (external)
8 LEDs (as Fig. 4) and status LED CAN bus (external)
not shown Stroke length adjustment wheel
Optional module slot (timer, PROFIBUS®)
14
10548
Manual
180
/min
Stop
Aux
B0412
Overview of equipment and control elements
4.1 Key functions
Key Application In continuous displays (operation) In adjustment mode (set up)
[STOP/START]
start pump start pump
[P / OK]
Pressed for 2 s Change to adjustment mode -
[ i / >]
1x long press Change from the continuous dis‐
Pressed briefly Stop pump, Stop pump,
Pressed briefly Start batch (only in
ating mode),
Acknowledge errors
1x short press Change between the continuous
displays
Change between the secondary
displays
plays to the secondary displays
„Batch“
oper‐
Confirm entry - jump to next menu
option or to continuous display
Change between "Changing indi‐
vidual numbers" and "Changing a
number"
Change to the next digit
[UP], [DOWN]
Simultaneous long
[ESC]
Pressed for 2s - Jumps to a continuous display
Pressed briefly Change directly changeable varia‐
bles
Priming -
press
Pressed briefly - Jumps back one menu level
Select another setting, change
individual number or number.
Exit the setting menu without
saving
4.2 LCD screen identifiers
The LCD screen supports the operation and adjustment of the pump using
different identifiers:
The identifiers and information in the various fields of the LCD screen
have different meanings:
15
1 2 3 4 5
6
9
10
7
8
B0413
Overview of equipment and control elements
1 Operating main display
2 Source indicator for stop
3 Auxiliary operation / Diaphragm break sensor deactivated
4 Module option
5 Mode
6 Main display
7 Secondary display
8 Display type (number of pages)
9 Other identifiers, error source indicator
10 Continuous display identifier (" i " as "Info")
The identifiers have the following meanings:
Field no. Icon Name Meaning
1 Stop The pump is stopped. Cause see field 2.
1 Priming The pump is currently priming (both
2
2
2
2 CAN
open
2 Profi
bus
3 Auxiliary The pump is currently pumping with the auxiliary fre‐
3
Manual The pump was stopped manually.
External signal The pump was externally stopped by the Pause contact.
Timer The pump was stopped via the timer.
CANopen The pump was stopped via the external CAN bus.
PROFIBUS
Diaphragm rupture A diaphragm rupture sensor is connected, but deacti‐
®
pressed).
The pump was externally stopped by the PROFIBUS®.
quency as the stroke rate.
During this time, the pump is in
mode.
vated.
[arrow keys]
„Manual“
operating
4 Timer The "Timer" option is active.
4 CAN
4 Profi
CANopen The "CANopen" option is active.
open
PROFIBUS
bus
®
The "PROFIBUS®" option is active.
16
mm
0..200..20
4..204..20
Overview of equipment and control elements
Field no. Icon Name Meaning
5 MANUAL
5 CONTACT
5 BATCH
5 ANALOG
9
9 Stroke length adjust‐
9 Flow control A flow control is connected.
9
9
9
9
„Manual“ „Manual“
„Contact“ „Contact“
„Batch“ „Batch“
„Analog“ „Analog“
Error A fault exists.
ment
Memory The pump is in operating mode
0...20 mA The pump is in operating mode
4...20 mA The pump is in operating mode
Linear The pump is in operating mode
Deviation in the stroke length from the value set at the
time of the last locking of the setting menu.
the auxiliary function "Memory" is set.
cessing type
cessing type
The processing type
operating mode
operating mode
operating mode
operating mode
„0...20“
„4...20“
is set.
is set.
„Curve“-„Linear“
„Contact“
„Analog“
„Analog“
„Analog“
is set.
or
„Batch“
. The pro‐
. The pro‐
.
and
9 Upper sideband The pump is in operating mode
The processing type
9
10
10 Security Security lock (if a code was set).
Lower sideband The pump is in operating mode
Continuous display A continuous display appears on the LCD screen.
cessing type
For identifiers which appear in response to errors, see
the "Troubleshooting" chapter.
„Curve“-„Lower sideband“
„Curve“-„Upper sideband“
„Analog“
„Analog“
.
is set.
. The pro‐
is set.
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 the pump. The slide rod
transmits the stoke motion to the diaphragms.
Illustration of the stroke movement
The stroke movement of the displacement body is continuously measured
and regulated so that the stroke is executed according to a previously set
dosing profile, see chapter
„Metering“ „setting“
.
The following dosing profiles are available:
n Normal
n Discharge opti.
n Suction opti.
Every metering profile is ineffective below the switchover frequency for Start/Stop mode.
Normal
Fig. 6: Stroke movement at a) maximum stroke length and b) reduced
stroke length.
s Stroke velocity
⍵ Cam rotational angle
+ Discharge stroke
- Suction stroke
Discharge opti.
With a discharge optimised dosing profile, the discharge stroke is elon‐
gated, the suction stroke is executed as quickly as possible. This setting is
for example suitable for those applications that require optimum mixing
ratios and as continuous as possible chemical mixing.
Suction opti.
18
5.2
4
2
1
5
3
13
P_SI_0104_SW
s
t
Functional Description
With a suction optimised dosing profile, the suction stroke is elongated as
much as possible, which makes possible a precise and problem-free
dosing 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. 7: 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. 8: 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. 9.
With the electrical diaphragm rupture sensor, a switch is switched. A con‐
nected signalling device must signal the diaphragm rupture.
Fig. 9: 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
„Mode“
the identity code, some operating modes may not be present):
20
menu (dependent on
Functional Description
„Analog“
current signal via the "External control" terminal The processing of the cur‐
rent signal can be preselected via the control unit.
operating mode The stroke rate is controlled using an analog
„Manual“
unit.
„Contact“
making fine adjustments using small scaling or transfer factors. Metering
can be triggered either by a pulse received via the "External control" ter‐
minal or through a contact or a semiconductor switching element. A
metering quantity (batch) or a number of strokes (scaling or transfer factor
0.01 to 100.00) can be pre-selected via the control unit using the
„Factor“
„Batch“
working with large transfer factors (up to 99,999). The metering can be
triggered either by pressing the
"External control" terminal or through a contact or a semiconductor
switching element. It is possible to pre-select a metering quantity (batch)
or a number of strokes via the control unit.
„BUS“
FIBUS® DP interface). This operating mode provides the option of control‐
ling the pump via BUS (see “Supplementary instructions for ProMinent
delta and Sigma with PROFIBUS®".
operating mode The stroke rate is set manually via the control
operating mode: This operating mode provides the option of
setting.
operating mode: This operating mode provides the option of
[P]
key or by a pulse received via the
operating mode (Identity code, control variant: CANopen or PRO‐
5.6 Functions
The following function can be ordered via the identity code:
Booster pump (optional): The pump can issue an electronic warning and
switch off if a tolerance range is exceeded. The overload switch-off is to
protect the pump, not the system. In the event of overloading, the pump
signals an error via the LED displays, the LCD screen (
„blockade“
The following functions can be selected using the
"Calibrate" function: The pump can also be operated in the 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.
) and - if fitted – the fault indicating relay.
„Settings“
„p+“
or
„Settings“
menu:
menu, which can be
"Flow" function: Stops the pump when the flow is insufficient, provided a
dosing 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:
21
„Settings“
menu.
Functional Description
"Level switch" function: Information about the liquid/powder level in the
chemical feed container is reported to the pump control. To do so, a twostage level switch must be fitted; it is connected to the "Level switch" ter‐
minal.
5.7 Options
Relay option
"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
"Priming" function: Priming (short-term transport at maximum frequency)
can be triggered by simultaneous pressing of the two arrow keys.
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" - "Relay".
The pump can be remotely stopped via the "External
[STOP/START]
key.
Option "0/4-20 mA analog current output
and fault indicating relay"
5.8
Function and fault indicator
"Fault indicating and semiconductor relay" option In the event of fault sig‐
nals, 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" - "Relay". The option can
be retrofitted via a knock-out in the drive unit.
The current output I signal indicates the pump's actual calculated metering
volume.
The option "0/4-20 mA analog current output and fault indicating relay" can
be retrofitted via a knock-out in the control unit.
Additionally the option always provides a semiconductor relay, see above.
Other functions can be adjusted, see "Settings" - "Relay".
The operating and fault statuses are indicated by the three LED indicators
and the
shooting" chapter.
„Error“
identifier on the LCD screen, see also the "Trouble‐
22
5.9 LCD screen
5.10 LED Displays
Functional Description
„Error“
If a fault occurs, the identifier
sage.
CANopen status display (green): The CANopen status indicator shows the
status of the CANopen bus.
appears and an additional error mes‐
Colour Flash code Cause Conse‐
green illuminated Bus status
OPERA‐
TIONAL
green flashing Bus status
PREOPERA‐
TIONAL
red any Bus error no meas‐
Contact customer service in the event of all other flash codes.
Fault indicator (red): The fault indicator illuminates if a fault occurs e.g.
liquid level low 2nd stage".
Warning indicator (yellow): The warning indicator illuminates if the pump
electronics detect a condition which may lead to a fault, e.g. "liquid level
low 1st stage".
Operating indicator (green):
the pump is correctly connected to the operating voltage. The operating
indicator goes out briefly with every stroke.
The operating indicator illuminates provided
quence
Normal bus
mode
currently no
measured
value com‐
munication
ured value
transmission
Remedy
-
wait briefly.
Disconnect
HMI then
reconnect
Check
whether the
CAN con‐
nection is
faulty.
Notify
Service
5.11 Hierarchy of operating modes, functions and fault statuses
The different operating modes, functions and fault statuses have a dif‐
ferent effect on if and how the pump reacts.
The following list shows the order:
1. - Priming
2. - Fault, Stop, Pause
3. - Auxiliary frequency (external frequency changeover)
4. - Manual, external contact, batch, external analog
Comments:
re 1 - "Priming" can take place in any mode of the pump (providing it is
functioning).
re 2 - "Fault", "Stop" and "Pause" stop everything apart from "Priming".
re 3 - The "Auxiliary frequency" stroke rate always has priority over the
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
Refer to the correct dimensional drawings on our web‐
site www.prominent.com for assistance.
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. 10
Space requirement
WARNING!
The pump can break through the base or slide off it
– Ensure that the base is horizontal, flat and perma‐
nently load-bearing.
CAUTION!
If your Sigma S2Cb is to be installed in place of a Sigma
S2Ca, a base plate order no. 1044841 is possibly
needed to lift the liquid end.
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.
Fig. 11
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 ...).
24
1
3
2
f
f
f
P_MOZ_0017_SW
Fig. 12
DNm
m
P_MOZ_0015_SW
Liquid end alignment
Assembly
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!
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.
Fastening
Fig. 13
Capacity too low
Vibrations can disturb the liquid end valves.
–
Secure the metering pump so that no vibrations can
occur.
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
The disregard of technical data during installation may
lead to personal injuries or damage to property.
– Observe the technical data- refer to chapter "Tech‐
nical Data" and, where applicable, the operating
instructions of 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 takes appropriate safety precautions.
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 an advantage when working
with highly aggressive or hazardous feed chemicals:
– Install a bleed valve with recirculation in the storage
tank.
Install an additional shut-off valve on the discharge
–
or suction ends.
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.
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.
26
P_SI_0021
Installation
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 bursting
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 bursting of the suction or discharge
lines
Hose lines with insufficient pressure rating may burst.
– Only use hose lines with the required pressure
rating.
Fig. 14: Moulded composite seals with
corrugated insert
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.
–
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.
CAUTION!
Warning against 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
connections. They seal the connections between
grooved pump valves and the grooved inserts from
ProMinent - see
Ä Further information on page 26
– In the event that an unflared insert is used (e.g. third
party part), an elastomer flat seal must be used see
Ä Further information on page 26
.
.
27
P_SI_0022
1
1
2
3
4
5
P_MOZ_0020_SW
1
2
3
P_MOZ_0021_SW
Installation
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. 15: Elastomer flat seal for a smooth
insert
Fig. 16: Manometer connecting options
CAUTION!
Warning of backflow
A back pressure valve, spring-loaded injection valve,
relief valve, foot valve or a liquid end do not represent
absolutely leak-tight closing elements.
– 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 are provided
for a manometer 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. 17: Steel pipeline at the liquid end
Integral relief valve or integral bleeder
valve
1 Steel piping
2 Flexible pipe section
3 Plastic liquid end
WARNING!
Product can be dangerously contaminated
Only with the design "Physiologically safety with regard
to wetted materials".
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.
28
P_SI_0023
Installation
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
Cracking of 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 having a viscosity of greater than 200
mPa s.
– Only use the integral relief valve with feed chemicals
having a viscosity up to 200 mPa s.
CAUTION!
Warning against 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 tube nozzle pointed downwards see .
Fig. 18: Permissible alignment of the relief
valve
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.
29
Installation
Diaphragm rupture sensor
When operating the integral relief valve close to the
opening pressure, a minimal overflow into the overflow
line can occur.
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 upon a diaphragm rupture.
– Only rely on the diaphragm rupture sensor at back
pressures greater than 2 bar.
7.1.1 Basic installation notes
Safety notes
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.
CAUTION!
Hazardous feed chemicals can escape
With hazardous feed chemicals: Hazardous feed chem‐
ical can leak out when using conventional bleeding pro‐
cedures with metering pumps.
– Install a bleed line with a return into the storage
tank.
Shorten the return line so that it does not dip into the feed chemical
in the storage tank.
30
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