ProMinent Sigma / 2 Basic Type SBKa User manual

Piston Metering Pump

Sigma / 2 Basic Type SBKa

Operating instructions

P_SI_0135_SW

Original operating instructions (2006/42/EC)Part no. 984863 BA SI 059 11/13 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!

Technical changes reserved.

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 correct

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 instructions

Table of contents

1Identity code.................................................................................... 4

2 Safety chapter................................................................................. 6

3 Storage, transport and unpacking................................................. 11

4 Overview of equipment and control elements............................... 12

5 Functional description.................................................................... 14

5.1 Drive unit............................................................................... 14

5.2 Liquid End............................................................................. 14

6 Assembly....................................................................................... 15

7Installation..................................................................................... 17

7.1 Installation, hydraulic............................................................. 17

7.2 Installation, electrical............................................................. 20

8 Start up.......................................................................................... 24

9 Maintenance.................................................................................. 26

10 Repairs.......................................................................................... 30

10.1 Cleaning double ball valves................................................ 31

10.2 Changing the piston............................................................ 32

11 Troubleshooting............................................................................. 36

12 Decommissioning.......................................................................... 38

13 Technical data............................................................................... 40

13.1 Performance data................................................................ 40

13.2 Shipping weight................................................................... 41

13.3 Viscosity.............................................................................. 41

13.4 Wetted materials................................................................. 42

13.5 Ambient conditions.............................................................. 42

13.5.1 Ambient temperatures...................................................... 42

13.5.2 Media temperatures......................................................... 42

13.5.3 Air humidity...................................................................... 42

13.6 Motor data........................................................................... 42

13.7 Stroke sensor "Sigma"........................................................ 43

13.8 Relay................................................................................... 43

13.9 Gear oil................................................................................ 44

13.10 Sound pressure level........................................................ 44

13.11 Supplementary information for modified versions............. 44

14 Diagrams for adjusting the capacity.............................................. 45

15 Dimensional drawings................................................................... 46

16 Exploded drawing Sigma piston metering pump........................... 47

17 Sigma/ 2 piston ordering information............................................. 48

18 EC Declaration of Conformity for Machinery................................. 49

19 EC Declaration of Conformity for Machinery Used in Areas at

Risk of Explosion........................................................................... 50

Table of contents

1 Identity code

SBKa Sigma 2 Basic Type

HK Main power end, piston

Type: Capacity

_ _ _ _

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

housing

Dosing head material

SS Stainless steel

Seal material

T PTFE

Displacement body

4 Piston (oxide ceramic)

Dosing head design

0 no valve springs

1 with 2 valve springs, Hastelloy C; 0.1 bar

Hydraulic connector

0 Standard threaded connector (in line with technical data)

Design

0With ProMinent® logo (standard)

1Without ProMinent® logo

M Modified* * order-related design, refer to

order paperwork for pump

features

Electric power supply

_ Connection data - see motor nameplate

1 No motor, with B14 flange, size 71 (DIN)

2 No motor, with C 56 flange (NEMA)

3 No motor, with B 5, size 63 (DIN)

4 No motor, with B 5, size 71 (DIN)

5 No motor, with B14 flange, size 80 (DIN)

Degree of protection

0 IP 55 (standard)

1 Exe design ATEX-T3

2 Exd version ATEX-T4

Stroke sensor

0 No stroke sensor (standard)

2 Pacing relay (reed relay)

3 Stroke sensor (Namur) for haz‐

ardous locations

Stroke length adjustment

0 Manual (standard)

1 With servomotor, 230 V,

50/60 Hz

Identity code

SBKa Sigma 2 Basic Type

2 With servomotor, 115 V,

50/60 Hz

3 With control motor 0...20 mA

230 V, 50/60 Hz

4 With control motor 4...20 mA

230 V, 50/60 Hz

5 With control motor 0...20 mA

115 V, 50/60 Hz

6 With control motor 4...20 mA

115 V, 50/60 Hz

Identity code

2 Safety chapter

CAUTION!

These operating instructions include notes and quotes from

German guidelines relating to the system operator's scope of

responsibility. This information does not discharge the oper‐

ator 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.

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 – hand injuries.

Warning – high-voltage.

Warning – hot surface.

Warning – danger zone.

nOnly use the pump to meter liquid metering chemicals.

nIn potentially explosive atmospheres in zone 1, device category II 2G,

explosion group II C, only operate the pump with the appropriate

nameplate (and the respective EC Declaration of Conformity) for

pumps for use in areas at risk of explosion in compliance with Direc‐

tive 94/9/EC in accordance with the European guidelines. The explo‐

sion group, category and degree of protection specified on the label

should correspond to or be better than the conditions given in the

intended field of application.

nOnly start up the pump after it has been correctly installed and com‐

missioned in accordance with the technical data and specifications

contained in the operating instructions.

Identification of safety notes

Warning signs denoting different types of

danger

Intended use

Safety chapter

nObserve the general limitations with regard to viscosity limits, chem‐

ical resistance and density - see also ProMinent Resistance List (in

the Product Catalogue or at www.prominent.com/en/downloads)!

nAll other uses or modifications are prohibited.

nNever operate pumps without the relevant nameplate (and the respec‐

tive EC Declaration of Conformity) for pumps for use in atmospheres

at risk from explosion in atmospheres potentially at risk from explo‐

sion.

nThe pump is not intended for the metering of gaseous media or solids.

nThe pump is not intended for the metering of flammable feed chemi‐

cals.

nThe pump is not intended to meter explosive substances and mix‐

tures.

nThe pump is not intended for unprotected outside use.

nThe pump is only intended for industrial use.

nThe pump should only be operated by trained and authorised per‐

sonnel.

nObserve the information contained in the operating instructions at the

different phases of the device's service life.

Action Qualification

Storage, transport, unpacking Instructed person

Assembly Technical personnel, service

Planning hydraulic installation Qualified personnel who have a

thorough knowledge of oscillating

diaphragm pumps.

Hydraulic installation Technical personnel, service

Installation, electrical 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 terms:

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/her

technical training, knowledge and experience, as well as knowledge of

pertinent regulations.

Note:

A qualification of equal validity to a technical qualification can also be

gained by several years employment in the relevant work area.

Electrical technician

Electrical technicians are deemed to be people, who are able to complete

work on electrical systems and recognise and avoid possible dangers

independently based on their technical training and experience, as well as

knowledge of pertinent standards and regulations.

Electrical technicians should be specifically trained for the working envi‐

ronment in which they are employed and know the relevant standards and

regulations.

Electrical technicians must comply with the provisions of the applicable

statutory directives on accident prevention.

Instructed person

Qualification of personnel

Safety chapter

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.

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.

WARNING!

– Observe the European Operator Directive 99/92/EC

(ATEX 137), implemented in Germany by the Industrial

Health and Safety Regulation and the German Ordi‐

nance on Hazardous Substances, for the installation and

operation of equipment in areas at risk from explosion.

–Observe the European standards EN 1127-1, EN

60079-10, EN 60079-14, EN 60079-17 and EN

60079-25 and EN 50039 for inherently safe electrical cir‐

cuits. (In Germany these standards are partly imple‐

mented by VDE 0165 and VDE 0118).

– Adhere to the respective national regulations outside of

the EU.

– Ensure that installations in areas at risk from explosion

are checked by a "recognisably trained" skilled opera‐

tive. This applies specifically to intrinsically safe elec‐

trical circuits.

– The following information relates essentially to the

unique characteristics in areas at risk from explosion but

does not replace the standard operating instructions.

– Only clean plastic parts carefully with a damp cloth to

avoid electrostatic charges and sparks.

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.

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 assess‐

ment for the workstations affected.

Safety notes

Safety chapter

CAUTION!

Warning of feed chemical spraying around

Feed chemical can spray out of the hydraulic components 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 unauthor‐

ised 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 materials

when selecting the feed chemical - see the ProMinent

product catalogue or visit www.prominent.com/en/down‐

loads.

CAUTION!

Danger of personnel injury and material damage

The use of untested third party parts can result in personnel

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 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.

WARNING!

– Attach the following safety note to pumps that contain

parts made of electrically non-conductive plastic.

– Ensure that the label is always fitted and legible.

WARNING

Electrostatic charge may

cause an explosion!

Clean plastic parts very

carefully using a damp cloth!

Fig. 2

All isolating protective equipment must be installed for operation:

Safety equipment

Isolating protective equipment

Safety chapter

nDrive front cover

nMotor fan cowling

nTerminal box cover, motor

nProtective cover - see figure.

P_SI_0146_SW

Fig. 3: Protective cover, two-section (*)

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.

Prior to commissioning the system or system component, the system oper‐

ator is obliged to obtain the latest safety data sheet from the supplier for

the chemicals / resources to be used with the system. The operator should

create the legal framework for safe operation of the system or system

component, such as for example the preparation of operating instructions

(operator duties), based on the information provided in the data sheets

concerning health and safety, water and environmental protection and

taking into consideration the actual operating environment on site.

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

at maximum stroke length, maximum stroke rate, maximum back pressure

(water)

Information in the event of an emergency

Safety information relating to the operating

instructions

Sound pressure level

Safety chapter

Table of contents

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