ProMinent Orlita Evolution User manual

Hydraulic diaphragm liquid ends with PTFE dia‐

phragm

Orlita® Evolution

Operating instructions

Serial no. .............................

These operating instructions form part of an operating manual and are only valid if used in conjunction with the documents

in this operating manual.

983747 BA ORL 007 06/16 EN

Please carefully read these operating instructions before use. · Do not discard.

The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

Table of contents

1Safety.................................................................................... 3

2 Storage, Transport and Unpacking..................................... 10

2.1 Safety information....................................................... 10

2.2 Transport.................................................................... 10

2.3 Storage....................................................................... 13

2.4 Preservation................................................................ 13

3 Functional Description of Liquid End Components............. 15

4Installation, Hydraulic.......................................................... 16

4.1 Basic installation notes............................................... 19

5 Installation, Electrical.......................................................... 21

6 Start Up............................................................................... 22

7 Maintenance....................................................................... 23

7.1 Inspections and Maintenance Points.......................... 25

7.2 Cleaning...................................................................... 28

7.3 Material Required / Equipment / Oil Change Require‐

ments.......................................................................... 28

7.4 Changing the hydraulic oil.......................................... 29

7.5 Changing Gear Oil in a Power End/Drive................... 33

8 Repairs................................................................................ 35

8.1 Dismantling the Diaphragm........................................ 35

8.2 Installing the Diaphragm............................................. 37

8.3 Dismantling the suction valve and discharge valve.... 40

8.4 Assembling the suction valve and discharge valve.... 42

8.5 Dismantling the Bleed Valve (356)............................. 43

8.6 Installing the Bleed Valve (356).................................. 43

8.7 Dismantling the Pressure Relief Valve (358).............. 44

8.8 Installing the Pressure Relief Valve (358)................... 44

9 Rectifying Faults on the Hydraulic Liquid Ends................... 45

10 Decommissioning and Disposal.......................................... 49

10.1 Decommissioning..................................................... 49

10.2 Disposal.................................................................... 50

11 Index................................................................................... 52

Table of contents

1 Safety

WARNING!

Observe the safety chapter and safety information in

the other documents, particularly in the "Operating

Instructions for the Drive Unit Orlita® Evolution".

Note the information on the "Technical Data Sheet" for

the pump.

The following signal words are used in these operating instructions

to identify different severities of a hazard:

Signal word Meaning

WARNING Denotes a possibly hazardous situation. If this is

disregarded, you are in a life-threatening situation

and this can result in serious injuries.

CAUTION Denotes a possibly hazardous situation. If this is

disregarded, it could result in slight or minor inju‐

ries or material damage.

The following warning signs are used in these operating instruc‐

tions to denote different types of danger:

Warning signs Type of danger

Warning – high-voltage.

Warning – hot surface.

Warning – danger zone.

nOnly use the hydraulic liquid end to meter or pump liquid feed

chemicals.

nOnly use the hydraulic liquid end after it has been correctly

installed and started up in accordance with the technical data

and specifications contained in the operating instructions.

nThe hydraulic liquid end is intended for metering flammable

media if the relevant information is observed.

nObserve the general limitations with regard to viscosity limits,

chemical resistance and density - see also the ProMinent

Resistance List (in the Product Catalogue or at www.promi‐

nent.com)!

nAll other uses or modifications are prohibited.

nNever use the hydraulic liquid end to meter media containing

sediment.

nNever use the hydraulic liquid end to meter explosive media

and explosive mixtures.

nNever use the hydraulic liquid end to meter radioactive media.

Explanation of the safety information

Warning signs denoting different

types of danger

Intended Use

Safety

nNever use the hydraulic liquid end to meter media that reacts

exothermically with hydraulic oil.

nThe ATEX design is not intended for the metering of electrically

non-conductive media (conductivity less than 50 pS/m).

nDo not expose the ATEX design to ionising radiation, electro‐

magnetic high frequency radiation within the range of 104 ...

3x1015 Hz or ultrasound without putting in place measures in

line with EN 1127-1.

nOnly allow trained and authorised personnel to operate the

pump - see the following table.

nYou have a responsibility to adhere to the information con‐

tained in the operating instructions at the different phases of

the unit's service life.

nYou have a responsibility to observe the information contained

in the operating instructions for the auxiliary equipment at the

different phases of their respective service lives.

Task Qualification

Transport technical personnel

Storage, unpacking Instructed person

Assembly Technical personnel, Service

Planning the hydraulic installation Qualified personnel who have a thorough knowledge of oscillating

metering pumps

In areas at risk from explosion: ATEX qualified person, ATEX elec‐

trical technician

Hydraulic installation Technical personnel, Service

Electrical Installation Electrical technician,

In areas at risk from explosion: ATEX electrical technician

Start Up technical personnel

In areas at risk from explosion: Qualified personnel with ATEX

training; checking of the electrical installation: recognised competent

person

Operation Instructed person

Maintenance, repair Technical personnel, Service

In areas at risk from explosion: ATEX qualified person, ATEX elec‐

trical technician

Decommissioning, disposal Technical personnel, Service

Troubleshooting Qualified person, electrical technician, instructed person, service -

depending on the requirement

In areas at risk from explosion: ATEX electrical technician; checking

of the electrical installation: recognised competent person

Explanation of the table:

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 technical training, knowledge and experience, as well

as knowledge of pertinent regulations.

Qualification of personnel

Safety

Qualified personnel who open the hydraulic components of the

pump have to be able to recognise sealing surfaces so that they do

not become scratched.

Note:

A qualification of equal validity to a technical qualification can also

be gained by several years of employment in the relevant field of

work.

Electrical technician

An electrical technician is able to complete work on electrical sys‐

tems and recognise and avoid possible dangers independently

based on his technical training and experience, as well as knowl‐

edge of pertinent standards and regulations.

The electrical technician should be specifically trained for the

working environment in which he is employed and be conversant

with the relevant standards and regulations.

Make sure that the electrical technician complies with the provi‐

sions of the applicable statutory directives on accident prevention.

A qualification of equal validity to a technical qualification can also

be gained by several years of employment in the relevant field of

work.

Electrical technician with knowledge of ATEX explosion protection

The electrical technician with an additional explosion protection

qualification should be specifically trained for the work area in

which he is employed and be familiar with the relevant standards

and regulations. The electrical technician with an additional explo‐

sion protection qualification can work on electrical systems and

independently recognise and avoid possible dangers based on his

technical training and experience.

The electrical technician with an additional explosion protection

qualification is familiar with all the standards and regulations appli‐

cable to explosion protection, in particular, but not however exclu‐

sively, with all parts of EN 60079 [Electrical equipment for areas at

risk of a gas explosion].

The electrical technician with an additional explosion protection

qualification must comply with the provisions of the applicable stat‐

utory directives on accident prevention.

Recognised competent person

To carry out explosion hazard inspections the competent person

must have:

nCompleted a relevant course of study or

nHave a comparable technical qualification or

nAnother technical qualification combined with long-term experi‐

ence of safety technology.

Make sure that the person is familiar with the relevant body of

standards and regulations and has worked in the area for at least

one year. The person needs to have opportunities for an exchange

of experience.

Specific requirements are placed on competent persons who per‐

form tests on repaired devices/parts. They have to be recognised

by the responsible authorities (e.g. district council) in this respect.

Instructed person

Safety

An instructed person is deemed to be a person who has been

instructed and, if required, trained in the tasks assigned to him and

possible dangers that could result from improper behaviour, as well

as having been instructed in the required protective equipment and

protective measures.

Service

The Service department refers to service technicians, who have

received proven training and have been authorised by ProMinent

to work on the system.

CAUTION!

These operating instructions include notes and

extracts from German regulations relating to the opera‐

tor's scope of responsibility. This information does not

discharge the operator from his responsibility as an

operator and is intended only to remind him or make

him aware of specific problem areas. This information

does not lay claim to being complete, nor applicable to

every country and every type of application, nor to

being unconditionally up-to-date.

WARNING!

Only use ATEX pumps in areas at risk from explosion

– Note the relevant regulations for the installation

and operation of equipment in areas at risk from

explosion.

– Note the regulations governing intrinsically safe

power circuits.

– Adhere to the respective national regulations out‐

side of the EU.

– Ensure that installations in areas at risk from explo‐

sion are checked by a "recognised competent"

person. This applies specifically to intrinsically safe

power circuits.

– Only clean the pump outside of / in the absence of

explosive atmospheres.

WARNING!

Warning of dangerous or unknown feed chemical

Should a dangerous or unknown feed chemical be

used: It may escape from the hydraulic components

when working on the pump.

– Take appropriate protective measures before

working on the pump (e.g. safety glasses, safety

gloves, ...). Observe the safety data sheet for the

feed chemical.

–Drain and flush the liquid end before working on

the pump.

Safety Information

Safety

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 pro‐

vided 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 sub‐

stance 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 associ‐

ated 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 pres‐

sure in the liquid end and adjacent parts of the system.

– Disconnect the pump from the mains power supply

and ensure that it cannot be switched on again by

unauthorised persons.

–Depressurise the system before commencing any

work on hydraulic parts.

CAUTION!

Warning of feed chemical spraying around

An unsuitable feed chemical can damage the wetted

parts of the pump.

– Take into account the resistance of the wetted

materials when selecting the feed chemical - see

the ProMinent Product Catalogue or visit our

homepage.

WARNING!

Danger of injury to personnel and material damage

The pump must only be opened at those points

required to be opened by these operating instructions.

It may only be opened in other positions upon receipt

of written authorisation from the ProMinent head office,

Heidelberg.

CAUTION!

Danger of personnel injury and material damage

The use of untested third party parts can result in per‐

sonnel injuries and material damage.

– Only fit parts to metering pumps, which have been

tested and recommended by ProMinent.

Safety

CAUTION!

Danger from incorrectly operated or inadequately

maintained pumps

Danger can arise from a poorly accessible pump due

to incorrect operation and poor maintenance.

– Ensure that the pump is accessible at all times.

–Adhere to the maintenance intervals.

In the event of an electrical accident, disconnect the mains cable

from the mains or press the emergency cut-off switch fitted on the

side of the system!

If feed chemical escapes, also depressurise the hydraulic system

around the pump as necessary. Adhere to the safety data sheet for

the feed chemical.

Prior to commissioning the system or system component, it is the

responsibility of the system operator to obtain the latest safety data

sheet for the chemicals / equipment to be used with the system

from the supplier. Based on the information provided in the data

sheets concerning health and safety, water and environmental pro‐

tection, and taking into consideration the actual operating environ‐

ment on site, it is the responsibility of the operator to create the

legal framework for the safe operation of the system or system

component, such as for example the preparation of operating

instructions (operator's duties).

When using the hydraulic liquid end, all these parts have to be per‐

manently fixed in place.

Protective equipment May only be removed by*:

Turret cover Technical personnel, Service

Liquid end oil inspection window Technical personnel, Service

Only with additional equipment: Their corresponding

parts

Technical personnel, Service

* Only if required by the operating instructions and if the mains

cable remains disconnected from the mains voltage. Make sure

that all protective equipment is refitted during operation.

Safety equipment May only be removed by*:

Oil inspection window via bleed valve Technical personnel, Service

Only in areas at risk from explosion: Vent screw with

filter

Qualified employee, electrical technician, ATEX

electrical technician, Service

Diaphragm rupture indicator Qualified employee, electrical technician, ATEX

electrical technician, Service

Information in the event of an emer‐

gency

Safety information for operating

instructions

Safety equipment

Fixed, isolating protective equipment

Additional safety equipment

Safety

Safety equipment May only be removed by*:

"Hot surface" label -

Only with additional equipment: Their corresponding

parts

Technical personnel, Service

* Only if required by the operating instructions and if the mains

cable remains disconnected from the mains voltage. Make sure

that all protective equipment is refitted during operation.

Small amounts of hydraulic oil can evaporate out of the vent

screws. We recommend that you slightly ventilate the installation

site.

Hydraulic oil or feed chemical can escape from the hydraulic end in

the event of specific faults, damage, neglected maintenance,

during commissioning and during maintenance and repair work.

Other emissions

Safety

2 Storage, Transport and Unpacking

2.1 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

Declaration constitutes an integral part of an inspec‐

tion / repair order. A unit can only be inspected or

repaired when a Declaration of Decontamination Form

is submitted 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.

CAUTION!

Danger of environmental and material damage

The unit can be damaged or oil may escape due to

incorrect or improper storage or transportation!

– The unit should only be stored or transported in a

well packaged state - preferably in its original

packaging.

–Only transport the unit with the locking screw - not

the bleed plug - fitted to the oil filling opening.

– 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.

CAUTION!

Danger of environmental damage

The pumps are supplied filled with oil.

– When transporting, take care that no oil escapes.

2.2 Transport

WARNING!

Only lift the pump as shown in

Ä further information on page 10

or .

Only remove the pump from the crane hook once it is

firmly connected to the base.

Replace the vent screws with the sealing stoppers.

Storage, Transport and Unpacking

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