ProMinent Sigma 3 Basic User manual

Diaphragm motor-driven metering pump

Sigma/ 3 Basic type S3Ba

Operating instructions

P_SI_0075_SW

Original operating instructions (2006/42/EC)Part no. 985905 BA SI 089 01/19 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

1.1 Explanation of the ATEX label................................................ 6

2 Safety chapter................................................................................. 9

2.1 Safety information for ATEX designs.................................... 15

2.2 Explanation of the ATEX label.............................................. 23

3 Storage, Transport and Unpacking................................................ 26

4Overview of equipment and control elements............................... 27

5 Functional description.................................................................... 29

5.1 Pump..................................................................................... 29

5.2 Liquid end.............................................................................. 29

5.3 Integral relief valve................................................................ 29

5.4 Multi-layer safety diaphragm................................................. 30

6 Assembly....................................................................................... 31

7 Installation, hydraulic..................................................................... 34

7.1 Basic installation notes.......................................................... 38

8 Installation, electrical..................................................................... 39

9 Start up.......................................................................................... 46

10 During operation............................................................................ 50

11 Maintenance.................................................................................. 51

12 Carrying out repairs....................................................................... 56

12.1 Cleaning valves................................................................... 57

12.2 Replacing the diaphragm.................................................... 58

13 Troubleshooting............................................................................. 62

14 Decommissioning.......................................................................... 65

15 Technical data............................................................................... 68

15.1 Performance data................................................................ 68

15.2 Shipping weight................................................................... 69

15.3 Wetted materials................................................................. 70

15.4 Ambient conditions.............................................................. 70

15.4.1 Ambient temperatures...................................................... 70

15.4.2 Media temperatures......................................................... 70

15.4.3 Air humidity...................................................................... 71

15.5 Installation height................................................................ 71

15.6 Motor data........................................................................... 72

15.7 Stroke actuator.................................................................... 73

15.8 Stroke control drive............................................................. 73

15.9 Diaphragm rupture sensor.................................................. 73

15.10 Stroke sensor "Sigma"...................................................... 74

15.11 Relay................................................................................. 74

15.12 Gear oil.............................................................................. 75

15.13 Sound pressure level........................................................ 75

15.14 Supplementary information for modified versions............. 75

16 Diagrams for setting the metering capacity................................... 76

17 Dimensional drawings................................................................... 77

18 Potential equalisation drawings for Sigma Basic Type.................. 82

19 Motor data sheet standard motor.................................................. 84

20 Exploded drawings of Sigma/ 3..................................................... 85

21 Wear parts of Sigma/ 3.................................................................. 92

21.1 Standard.............................................................................. 92

Table of contents

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

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

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

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

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

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

Table of contents

1 Identity code

S3Ba Sigma 3 Basic type

H Main power end, diaphragm

Type: Capacity

_ _ _ _

_ _

Performance data at maximum back pressure: see nameplate on pump housing

Dosing head material

PP Polypropylene

PC PVC

PV PVDF

TT PTFE + carbon

SS Stainless steel

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 head (on request)

Dosing head design

0 no valve springs

1 with 2 valve springs, Hastelloy C; 0.1 bar (standard with DN 32)

4 with relief valve, FPM seal, no valve springs

5 with relief valve, FPM seal, with valve springs (standard with DN 32)

6 with relief valve, EPDM seal, no valve spring

7 with relief valve, EPM seal, with valve spring (standard with DN 32)

H Hygienic head with tri-clamp connectors (max. 10 bar) (on request)

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

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)

Identity code

S3Ba Sigma 3 Basic type

M modified* * order-related design, refer to

order paperwork for pump

features

Electric power supply

_ Connection data - see motor nameplate

1 no motor, with B 5 flange, size 80 (DIN)

2 no motor, with C 56 flange (NEMA)

3 no motor, with B 5, size 71 (DIN)

Degree of protection

0 IP 55 (standard)

1 Exe design ATEX-T3 ***

2 Exd design ATEX-T4 ***

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, 2 Connection data - refer to

nameplate on servomotor

3 - 6 Connection data - refer to

nameplate on stroke control

motor

*** ATEX specification - refer to the nameplate on the pump, corre‐

sponding EU Declaration of Conformity for ATEX Machinery and

Ä Chapter 1.1 ‘Explanation of the ATEX label’ on page 6

FPM = fluorine rubber

1.1 Explanation of the ATEX label

in accordance with Directive 2014/34/EU and standards EN ISO

80079-36, -37

Unit group

II Units for use in areas with a potentially explosive atmosphere – excluding mines

Unit category

2 High level of safety – use possible in zones 1 and 2

3 Normal level of safety – use possible in zone 2

Identity code

Type of explosive atmosphere

G Mix of air and gases, vapours or mist

Areas at risk of explosion label

Ex in accordance with EN ISO 80079-36, -37

Type of protection

h non-electrical device

Explosion group

IIC Group IIC gas - refer, for example, to

Ä Tab. 1 ‘Divi‐

sion of gases into explosion groups and temperature

classes’ on page 7

IIB Group IIB gas - for example

Ä Tab. 1 ‘Division of

gases into explosion groups and temperature classes’

on page 7

Temperature class

T3 Max. surface temperature: 200 °C

T4 Max. surface temperature: 135 °C

Equipment protection level (EPL)

Gb high EPL in normal operation and in

the event of expected errors (corre‐

sponds to category “2G”.)

Gc normal EPL in normal operation (corre‐

sponds to category “3G”.)

Suffix X

X Special conditions - refer to the

Declarations of Conformity and

EC-type examination certifi‐

cates

Tab. 1: Division of gases into explosion groups and temperature classes

T4 T3 T2 T1

IIC - - Acethylene Hydrogen

IIB Ethyl ether - Ethylene Mains gas (coal gas)

IIA Acetaldehyde Benzine,

Diesel fuel,

Aircraft fuel,

Heating oils,

n-hexane

Ethyl alcohol,

n-butane,

n-butyl alcohol

Acetone,

Ammonia,

Benzene (pure),

Acetic acid,

Ethane,

Ethyl acetate,

Carbon oxide,

Methanol,

Propane,

Toluene

Identity code

You should always consider the explosion group AND

temperature class together:

You are safe in areas at risk from explosion with all the

gases listed in the table with equipment approved for

explosion group IIC and temperature class T4.

Equipment approved for explosion group IIB can also be

used for explosion group IIA – not for explosion group

IIC.

Equipment approved for temperature class T3 can also

be used for temperature classes T2 to T1 – not for tem‐

perature class T4.

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 15

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

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