ProMinent Sigma 1 Basic User manual

Diaphragm motor-driven metering pump

Sigma/ 1 Basic type S1Ba

Operating instructions

P_SI_0039

Original operating instructions (2006/42/EC)Part no. 985911 BA SI 084 12/18 EN

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

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

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

Read the following supplementary information in its entirety! Should you

already know this information, you will benefit more from referring to the

operating instructions.

The following are highlighted separately in the document:

nEnumerated lists

Operating guidelines

ðOutcome of the operating guidelines

- see (reference)

Information

This provides important information relating to the cor‐

rect operation of the unit or is intended to make your

work easier.

Safety notes

Safety notes are identified by pictograms - see Safety Chapter.

These operating instructions conform to current EU regulations applicable

at the time of publication.

Please state identity code and serial number, which you can find on the

nameplate when you contact us or order spare parts. This enables the

device type and material versions to be clearly identified.

Supplementary information

Fig. 1: Please read!

Validity

State the identity code and serial number

Supplemental directives

Table of contents

1Identity code.................................................................................... 5

2 Safety chapter................................................................................. 7

2.1 Safety information for ATEX designs.................................... 13

2.2 Explanation of the ATEX label.............................................. 21

3 Storage, Transport and Unpacking................................................ 24

4Overview of equipment and control elements............................... 25

5 Functional description.................................................................... 27

5.1 Pump..................................................................................... 27

5.2 Liquid end.............................................................................. 27

5.3 Integral relief valve................................................................ 27

5.4 Multi-layer safety diaphragm................................................. 28

6 Assembly....................................................................................... 29

7 Installation, hydraulic..................................................................... 32

7.1 Basic installation notes.......................................................... 36

8 Installation, electrical..................................................................... 37

9 Start up.......................................................................................... 44

10 During operation............................................................................ 48

11 Maintenance.................................................................................. 49

12 Carrying out repairs....................................................................... 53

12.1 Cleaning valves................................................................... 54

12.2 Replacing the diaphragm.................................................... 55

13 Troubleshooting............................................................................. 59

14 Decommissioning.......................................................................... 62

15 Technical data............................................................................... 65

15.1 Performance data................................................................ 65

15.2 Shipping weight................................................................... 66

15.3 Wetted materials................................................................. 67

15.4 Ambient conditions.............................................................. 67

15.4.1 Ambient temperatures...................................................... 67

15.4.2 Media temperatures......................................................... 67

15.4.3 Air humidity...................................................................... 68

15.5 Installation height................................................................ 68

15.6 Motor data........................................................................... 68

15.7 Stroke actuator.................................................................... 69

15.8 Stroke control drive............................................................. 69

15.9 Diaphragm rupture sensor.................................................. 69

15.10 Stroke sensor "Sigma"...................................................... 70

15.11 Relay................................................................................. 71

15.12 Sound pressure level........................................................ 71

15.13 Supplementary information for modified versions............. 71

16 Diagrams for adjusting the capacity.............................................. 72

17 Dimensional drawings................................................................... 74

18 Potential equalisation drawings for Sigma Basic Type.................. 80

19 Motor data sheet standard motor.................................................. 81

20 Exploded drawings Sigma/ 1......................................................... 82

21 Wear parts for Sigma/ 1................................................................. 91

21.1 Standard.............................................................................. 91

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

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

Table of contents

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

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

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

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

Table of contents

1 Identity code

S1Ba Sigma 1 Basic Type

H Main power end, diaphragm

Type: Capacity

_ _ _ _

_ _

Performance data at maximum back pressure and type: refer to nameplate on the pump

housing

Dosing head material

PV PVDF

SS Stainless steel

TT PTFE + carbon

Seal material

T PTFE seal

Displacement body

S Multi-layer safety diaphragm with optical rupture indicator

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

H Diaphragm for hygienic pump head

Dosing head design

0 no valve springs

1 with 2 valve springs, Hastelloy C; 0.1 bar

4 ** with relief valve, FPM seal, no valve springs

5 ** with relief valve, FPM seal, with valve springs

6 ** with relief valve, EPDM seal, no valve spring

7 ** with relief valve, EPDM seal, 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

Design

0with ProMinent® logo (standard)

1without ProMinent® logo

F Physiological safety with

regard to wetted mate‐

rials

FDA No. 21 CFR §177.1550

(PTFE)

FDA No. 21 CFR §177.2510

(PVDF)

M Modified* * order-related design, refer to

order paperwork for pump

features

Identity code

S1Ba Sigma 1 Basic Type

5 Left liquid end

Electric power supply

_ Connection data - see motor nameplate

G Without gear motor

2 No motor, with C 42 flange (NEMA)

3 No motor, with B 5, size 56 (DIN)

Degree of protection

0 IP 55 (standard)

1 Exe design ATEX-T3 ***

2 Exd design ATEX-T4 ***

G Without gear motor

A ATEX design of power end

Stroke sensor

0 No stroke sensor (standard)

2 Pacing relay (reed relay)

3 Stroke sensor (Namur) for areas at

risk from explosion

Stroke length adjustment

0 Manual (standard)

1 With servomotor, 230 V,

50/60 Hz

2 With servomotor, 115 V,

50/60 Hz

3 With stroke control motor

0...20 mA 230 V, 50/60 Hz

4 With stroke control motor

4...20 mA 230 V, 50/60 Hz

5 With stroke control motor

0...20 mA 115 V, 50/60 Hz

6 With stroke control motor

4...20 mA 115 V, 50/60 Hz

FPM = fluorine rubber

** Standard with tube nozzle in the bypass. Threaded connection on

request.

*** ATEX specification - refer to the EU Declaration of Conformity for

Machinery EX

Identity code

2 Safety chapter

CAUTION!

These operating instructions include notes and extracts

from German regulations relating to the operator's scope

of responsibility. This information does not discharge the

operator from his responsibility as an operator and is

intended only to remind him or make him aware of spe‐

cific problem areas. This information does not lay claim

to being complete, nor applicable to every country and

every type of application, nor to being unconditionally

up-to-date.

The following signal words are used in these operating instructions to

denote different severities of danger:

Signal word Meaning

WARNING Denotes a possibly dangerous sit‐

uation. If this is disregarded, you

are in a life-threatening situation

and this can result in serious inju‐

ries.

CAUTION Denotes a possibly dangerous sit‐

uation. If this is disregarded, it

could result in slight or minor inju‐

ries or material damage.

The following warning signs are used in these operating instructions to

denote different types of danger:

Warning signs Type of danger

Warning – high-voltage.

Warning – danger zone.

nOnly use the pump to meter liquid feed chemicals.

nOnly pumps with the identity code option "Multi-layer safety diaphragm

with visual rupture display" and "Multi-layer safety diaphragm with rup‐

ture signalling (contact)" are approved for use with flammable feed

chemicals with electrically conductive dosing heads, at back pres‐

sures of over 2 bar and only if the operator takes appropriate safety

measures.

nOnly pumps with the design "F - Physiologically safe with regard to

wetted materials" are approved for use in physiologically harmless

applications.

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

in accordance with the hygienic requirements of the EHEDG

(www.ededg.org).

nThe pump may only be started up after it has been correctly installed

and started up in accordance with the technical data and specifica‐

tions contained in the operating instructions.

nObserve 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)!

nAll other uses or modifications are prohibited.

Identification of safety notes

Warning signs denoting different types of

danger

Intended use

Safety chapter

nThe pump is not intended for the metering of gaseous media and

solids.

nThe pump is not intended for the metering of explosive substances

and mixtures.

nThe pump is not intended for unprotected use outdoors.

nThe pump is only intended for industrial use.

nOnly allow trained and authorised personnel to operate the pump -

see the following table.

nYou have a responsibility to adhere to the information contained 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.

nATEX designs only: Refer to the chapter "

Ä Chapter 2.1 ‘Safety infor‐

mation for ATEX designs’ on page 13

Task Qualification

Storage, transport, unpacking Instructed person

Assembly Technical personnel, service

Planning the hydraulic installation Qualified personnel who have a

thorough knowledge of oscillating

diaphragm pumps

Hydraulic installation Technical personnel, service

Electrical installation Electrical technician

Start up Technical personnel

Operation Instructed person

Maintenance, repair Technical personnel, service

Decommissioning, disposal Technical personnel, service

Troubleshooting Qualified person, electrical techni‐

cian, instructed person, service -

depending on the requirement

Explanation of the table:

Trained, qualified personnel

A trained, qualified employee is deemed to be a person who is able to

assess the tasks assigned to him and recognise possible hazards based

on his training, knowledge and experience, as well as knowledge of perti‐

nent regulations. A trained, qualified employee must be able to perform

the tasks assigned to him/her independently with the assistance of

drawing documentation and parts lists. The assessment of a person's

technical training can also be based on several years of work in the rele‐

vant field.

Electrical technician

An electrical technician is able to complete work on electrical systems and

recognise and avoid possible dangers independently based on his tech‐

nical training and experience as well as knowledge of pertinent standards

and regulations. An electrical technician must be able to perform the tasks

assigned to him/her independently with the assistance of drawing docu‐

mentation, parts lists, terminal and circuit diagrams. The electrical techni‐

cian must be specifically trained for the working environment in which the

electrical technician is employed and be conversant with the relevant

standards and regulations.

Instructed person

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

and, if required, trained in the tasks assigned to him/her and possible dan‐

gers that could result from improper behaviour, as well as having been

instructed in the required protective equipment and protective measures.

Qualification of personnel

Safety chapter

Trained user

A trained user is a person who fulfils the requirements demanded of an

instructed person and who has also received additional training specific to

the system from ProMinent or another authorised distribution partner.

Service

The Service department refers to service technicians, who have received

proven training and have been authorised by ProMinent to work on the

system.

Ignition hazard Protective measures to be observed by the customer

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

ical

Too low ambient temperature Limitation of the minimum ambient temperature

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

accordance with the “Maintenance” chapter.

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

Mechanically generated sparks from the mechanism with

low oil

The customer must monitor and maintain the pump in

accordance with the “Maintenance” chapter.

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

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

earthing of the individual components.

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

ures outdoors.

Static electricity The customer must earth the earthing points and maintain

the potential equalisation cables of the individual compo‐

nents.

The customer must pay attention to potential equalisation

when dismantling.

Paint should not be applied too thickly.

Only clean plastic parts with a damp cloth.

Provide a temperature monitor on the dosing head with

feed chemical with critical friction properties.

The customer must wire the diaphragm rupture indicator in

such a way that it immediately stops the pump.

Electromagnetic waves (also lasers), ionising radiation

and ultrasound have an impact on the pump

The customer must put in place measures in accordance

with EN 1127-1, if need be.

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

which could form a combustible mixture: Do not allow the

unit to run dry – even when filling and emptying the liquid

end.

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

have a tendency towards exothermic reactions or self-

combustion. Put in place measures in accordance with EN

1127-1, if need be.

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

cloth.

Summary of relevant ignition hazards and

protective measures put in place for the

Sigma in accordance with EN ISO

80079-36

Safety chapter

Ignition hazard Protective measures to be observed by the customer

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

mable feed chemicals.

Do not allow it to run dry.

The operator must install suitable protective measures, for

example a flow meter.

The customer must wire the diaphragm rupture indicator in

such a way that it immediately stops the pump.

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

Comply with the monitoring intervals.

The insulation resistance needs to be greater then 5

MOhm.

Provide a time-delay residual current device.

Provide overload protection by means of a motor protec‐

tion switch or an equivalent protective device.

Observe the minimum spacing between the air inlet on the

fan hood and any obstacles.

Avoid deposits of dust more then 5 mm deep.

Connect the earth wire.

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

Ignition hazard with bought-in actuator or control drive

components

Refer to the documentation for the actuator.

Wait 3 minutes after switching off before opening the

housing.

Ignition hazard caused by bought-in proximity switch

NJ1.5-8GM-N (stroke sensor)

Refer to the documentation for the proximity switch (elec‐

trical installation, maintenance, ...).

WARNING!

Warning of hazardous feed chemical

Should a dangerous feed chemical be used: it may

escape from the hydraulic components when working on

the pump, material failure or incorrect handling of the

pump.

– Take appropriate protective measures before

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

gloves, ...). Adhere to the material safety data sheet

for the feed chemical.

–Drain and flush the liquid end before working on the

pump.

Safety information

Safety chapter

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