ProMinent EMFa User manual

Metering pump
Evolution mikro, EMFa / EMHa
Operating instructions
These operating instructions form part of combined documentation and, as such, are only valid if used in conjunction with
the other documents.
Target group: trained, qualified personnel, unless otherwise required.
EN
Original operating instructions (2006/42/EC)981089 Version: BA ORL 012 09/21 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 Information
Safety information is identified by pictograms - see Safety Chapter.
Refer to the precise designation of suppliers' components in the "Technical
Data" chapter for ease of finding the relevant information.
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 unit
type and material versions to be clearly identified.
The nameplate stuck on the cover page is identical to the pump supplied
so that there is a clear link between the operating instructions and the
pump.
Supplementary information
Fig. 1: Please read!
Information in supplier instructions
Validity
State the identity code and serial number
EX pumps only
Supplemental directives
2

Table of contents
1Functional description...................................................................... 5
1.1 Overview of equipment / control elements.............................. 6
1.2 Scope of delivery..................................................................... 7
1.2.1 Scope of delivery of the Evolution mikro.............................. 7
1.2.2 Scope of delivery of the Evolution mikro ATEX.................... 7
1.3 Identity code............................................................................ 8
1.4 Product identification of the Evolution mikro - Project ver‐
sion........................................................................................ 11
2 Safety chapter............................................................................... 12
2.1 Labelling of Warning Information.......................................... 12
2.2 User qualification................................................................... 13
2.3 Warning symbols denoting different types of danger............ 13
2.4 Intended use......................................................................... 14
2.5 Misuse................................................................................... 14
2.6 Safety information................................................................. 15
2.7 Safety equipment.................................................................. 18
2.8 Sound pressure level............................................................ 18
3 Storage, transport and unpacking................................................. 19
3.1 Ambient conditions................................................................ 20
4 Assembly....................................................................................... 22
4.1 Space requirement................................................................ 22
4.2 Alignment of the pump and liquid end................................... 22
4.3 Fastening.............................................................................. 23
5 Installation..................................................................................... 24
5.1 Installation, hydraulic............................................................. 24
5.1.1 Basic installation notes....................................................... 26
5.2 Installation, electrical............................................................. 26
5.2.1 Motor, controller, cables..................................................... 26
5.2.2 Controller............................................................................ 27
5.2.3 Diaphragm monitor (optional)............................................. 27
5.2.4 Earthing wires (to be provided on site)............................... 28
5.2.5 Potential equalisation lines (to be provided on site, pre‐
scribed in the area at risk from explosion)......................... 28
5.2.6 Other units.......................................................................... 28
5.2.7 Terminal diagram............................................................... 29
6 Commissioning and operation....................................................... 34
6.1 Pre-commissioning................................................................ 34
6.2 Immediately after commissioning.......................................... 36
6.3 0.5 h ... 1 h after commissioning........................................... 37
6.4 Bleeding the hydraulics......................................................... 37
7 Maintenance.................................................................................. 38
7.1 Inspection.............................................................................. 39
7.2 Maintenance work................................................................. 40
7.3 Changing the hydraulic oil..................................................... 41
7.4 Cleaning valves..................................................................... 42
7.5 Replacing the diaphragm...................................................... 44
7.6 Replacing the safety relief valve........................................... 45
7.7 Replace the motor bearing (ATEX only)............................... 45
8 Repairing the diaphragm monitoring sensor.................................. 50
9Troubleshooting............................................................................. 53
9.1 Mechanical faults.................................................................. 53
9.2 Hydraulic faults...................................................................... 53
Table of contents
3

9.3 Electrical faults...................................................................... 55
10 Decommissioning and disposal..................................................... 56
10.1 Decommissioning................................................................ 56
10.2 Disposal.............................................................................. 57
11 Technical data............................................................................... 58
11.1 Reproducibility..................................................................... 58
11.2 Particle size......................................................................... 58
11.3 Performance data................................................................ 59
11.3.1 Evolution mikro EMFa...................................................... 59
11.3.2 EMHa (metal diaphragm)................................................. 61
11.4 Viscosity.............................................................................. 62
11.5 Weight................................................................................. 62
11.6 Wetted materials................................................................. 63
11.7 Ambient conditions.............................................................. 63
11.7.1 Temperatures................................................................... 63
11.7.2 Air humidity...................................................................... 63
11.7.3 Installation height............................................................. 64
11.8 Housing degree of protection.............................................. 64
11.9 Diaphragm monitoring sensor............................................. 64
11.10 Safety relief valve (Evolution mikro).................................. 65
11.11 Sound pressure level of HA2a / HA3a.............................. 65
11.12 Supplementary information with modified designs............ 66
11.13 Filling volumes.................................................................. 66
11.14 Motor data......................................................................... 67
12 Dimensional drawing, example...................................................... 69
13 Earthing / potential equalisation drawings of the Evolution
mikro.............................................................................................. 70
14 Ordering information...................................................................... 72
14.1 General............................................................................... 72
15 List of other applicable documents................................................ 73
16 Declaration of Conformity.............................................................. 74
17 ATEX Declaration of Conformity.................................................... 75
Table of contents
4

1 Functional description
P_ORL_0070_SW
M.
H.
D.
1
2
3
4
5
6
M Interface to the linear motor
H Hydraulic block
D Dosing head
1 Slide rod
2 Piston
3 Hydraulic block hydraulic oil
4 Diaphragm
5 Delivery chamber of the liquid end
6 Magnet
The “Orlita Evolution mikro” micro-metering pump is a hydraulic diaphragm
metering pump with an electronically controlled linear motor as a direct
drive. “Direct drive” means that the pump does not need a gearbox. The
piston (2) of the liquid end is connected directly to the motor (M).
The pump’s separate electronic controller can vary the stroke and stroke
rate without the need for additional equipment – depending on the pro‐
gramming. Due to the very high dynamics of the linear motor, the con‐
troller can compensate for any disruptive effects caused by the hydraulics
or valves – depending on the programming.
You can find an animated video of the pump showing the operating prin‐
ciple online at
https://www.youtube.com/watch?v=0S54ygsju1Q .
Functional description
5

1.1 Overview of equipment / control elements
P_ORL_0069_SW
1
2
6
7
811
12
10
5
4
3
9
1 Transport protection (in parked position)
2 Vent screw
3 Motor - controller connecting cable
4 Controller C1100 / 1150
5 Motor housing
6 Oil inspection window
7 Pressure relief valve
8 Diaphragm rupture indicator
9 Bleed / post-suction valve
10 Suction valve
11 Liquid end
12 Discharge valve
Functional description
6

1.2 Scope of delivery
1.2.1 Scope of delivery of the Evolution mikro
Pump Cable Controller
By the customer
Control cabinet
Skid
Delivery limit
Version A, B and C
A3428
Fig. 2: Scope of delivery of the Evolution mikro
1 Pump 2 Cable 3 Controller
Evolution mikro Standard:
2 m cable
Standard:
Controller C1100/1150
Standard control: See identity code.
1.2.2 Scope of delivery of the Evolution mikro ATEX
A3429
Pump Cable Controller
ATEX Zone 1 No ATEX
By the customer
Version A, B and C
Delivery limit
Pt1000 temperature signal
Control cabinet
Skid
Temperature
Relay
24 V DC
AC
Power supply
Fig. 3: Scope of delivery of the Evolution mikro ATEX
1 Pump 2 Cable 3 Controller
Evolution mikro Standard:
2 m cable
Standard:
Controller C1100/1150
Transformer
Standard control: See identity code.
Functional description
7

1.3 Identity code
Tab. 1: Identity code ordering system for the Evolution mikro - EMFa / EMHa
EMFa
EMHa
Drive type
V Simplex (vertical)
Piston
003 Piston Ø3
006 Piston Ø6
Stroke rate
030 30 strokes/min
060 60 strokes/min
080 80 strokes/min
100 100 strokes/min
120 120 strokes/min
140 140 strokes/min
160 160 strokes/min
180 180 strokes/min
200 200 strokes/min
Pressure stage
A 10 bar
D 25 bar
E 40 bar
H 64 bar
J 80 bar
K 100 bar
N 160 bar
P 250 bar
Dosing head material
S2 Standard, stainless steel; 1.4404
Valve design
0 Standard
Diaphragm monitor
1 none
2 Visual display
3 Contact manometer
4 Electric pressure switch
Hydraulic connector
0 Standard
Electrical connection
G Standard linear motor with 2-metre cable, 24 V DC
H Standard linear motor with 4-metre cable, 24 V DC
Functional description
8

J Standard linear motor without cable, 24 V DC
K ATEX linear motor with 2-metre cable, 24 V DC
L ATEX linear motor with 4-metre cable, 24 V DC
M ATEX linear motor without cable, 24 V DC
A Standard linear motor with 2-metre cable
B Standard linear motor with 4-metre cable
C Standard linear motor without cable
D ATEX linear motor with 2-metre cable
E ATEX linear motor with 4-metre cable
F ATEX linear motor without cable
Control version
0 Manual (potentiometer provided by the customer)
2 Analogue - 1 parameter (stroke rate)
3 Analogue - 1 parameter (stroke length)
4 Analogue - 2 parameters
5 Analogue - 3 parameters
6 Analogue - fieldbus
Ambient temperature
0 -20 °C…+40 °C
1 -10 °C…+50 °C
3 -10 °C…+55 °C
4 0 °C…+60 °C
Paintwork/pump housing
0A unpainted - aluminium
0S unpainted - stainless steel
1A C3 standard gloss paint RAL 2003 - alu‐
minium
1S C3 standard gloss paint RAL 2003 -
stainless steel
2A C4 outdoor, RAL 2003 - aluminium
2S C4 outdoor, RAL 2003 - stainless steel
Tests
S1 Standard performance test
S2 Standard performance test
including 3.1 certificate
S3 as S1 + 3.1 material certificate
S4 as S2 + 3.1 material certificate
A1 API complete test including 3.1
certificate
A2 API complete test + NPSH
including 3.1 certificate
A3 API complete test + NPIP including
3.1 certificate
Certification
Functional description
9

0 CE
1 CE + ATEX
2 CE + EAC
3 CE + EAC + ATEX
4 CE + UKCA
5 CE + UKCA + ATEX
Documentation*
DE German
EN English
FR French
ES Spanish
RU Russian
Measuring unit
0 bar, l/h
1 psi, gph
2 kPa, l/h
* other languages on request.
Functional description
10

1.4 Product identification of the Evolution mikro - Project version
Tab. 2: Product identification of the Evolution mikro - Project version
Product
range
Power end Liquid end
EMFa Evolution with
PTFE diaphragm
SStandard PPTFE diaphragm
EMHa Evolution mikro
with metal dia‐
phragm
A ATEX
240 Motor size DDouble diaphragm
E Single diaphragm
AL Aluminium housing 66 mm piston
SS Stainless steel
housing
3 3 mm piston
S1 Stainless steel dosing
head
H1 Hastelloy® C dosing head
P1 PVDF dosing head
T1 PTFE dosing head
Exampl
e :
EMFa - S240AL - PD6-S1
Functional description
11

2 Safety chapter
2.1 Labelling of Warning Information
These operating instructions provide information on the technical data and
functions of the product. These operating instructions provide detailed
warning information and are provided as clear step-by-step instructions.
The warning information and notes are categorised according to the fol‐
lowing scheme. A number of different symbols are used to denote different
situations. The symbols shown here serve only as examples.
DANGER!
Nature and source of the danger
Consequence: Fatal or very serious injuries.
Measure to be taken to avoid this danger.
Description of hazard
–Denotes an immediate threatening danger. If the sit‐
uation is disregarded, it will result in fatal or very
serious injuries.
WARNING!
Nature and source of the danger
Possible consequence: Fatal or very serious injuries.
Measure to be taken to avoid this danger.
– Denotes a possibly hazardous situation. If the situa‐
tion is disregarded, it could result in fatal or very
serious injuries.
CAUTION!
Nature and source of the danger
Possible consequence: Slight or minor injuries. Material
damage.
Measure to be taken to avoid this danger.
– Denotes a possibly hazardous situation. If the situa‐
tion is disregarded, it could result in slight or minor
injuries. May also be used as a warning about mate‐
rial damage.
NOTICE!
Nature and source of the danger
Damage to the product or its surroundings.
Measure to be taken to avoid this danger.
– Denotes a possibly damaging situation. If the situa‐
tion is disregarded, the product or an object in its
vicinity could be damaged.
Type of information
Hints on use and additional information.
Source of the information. Additional measures.
– Denotes hints on use and other useful information. It
does not indicate a hazardous or damaging situa‐
tion.
Introduction
Safety chapter
12

2.2 User qualification
WARNING!
Danger of injury with inadequately qualified personnel
The operator of the system / equipment is responsible
for ensuring that the qualifications are fulfilled.
If inadequately qualified personnel work on the unit or
loiter in the hazard zone of the unit, this could result in
dangers that could cause serious injuries and material
damage.
– All work on the unit should therefore only be con‐
ducted by qualified personnel.
–Unqualified personnel should be kept away from the
hazard zone.
The pertinent accident prevention regulations, as well as
all other generally acknowledged safety regulations,
must be adhered to.
Training Definition
Instructed personnel 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.
Trained user A trained user is a person who fulfils the requirements made of an instructed person
and who has also received additional training specific to the system from the manufac‐
turer or another authorised distribution partner.
Trained, qualified personnel A trained, qualified employee is deemed to be a person who is able to assess the tasks
assigned to him and recognize possible hazards based on his training, knowledge and
experience, as well as knowledge of pertinent regulations. A trained, qualified
employee must be able to perform the tasks assigned to him 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 relevant field.
Electrical technician An electrical technician is able to complete work on electrical systems and recognise
and avoid possible dangers independently based on his technical training and experi‐
ence as well as knowledge of pertinent standards and regulations. An electrical techni‐
cian must be able to perform the tasks assigned to him independently with the assis‐
tance of drawing documentation, parts lists, terminal and circuit diagrams. The
electrical technician must be specifically trained for the working environment in which
the electrical technician is employed and be conversant with the relevant standards
and regulations.
Service The Service department refers to service technicians, who have received proven
training and have been authorised by the manufacturer to work on the system.
2.3 Warning symbols denoting different types of danger
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 – falling objects.
Warning signs denoting different types of
danger
Safety chapter
13

Warning signs Type of danger
Warning – hot surface.
Warning – magnetic field.
Warning – danger zone.
2.4 Intended use
nOnly use the pump to meter liquid, sediment-free feed chemicals.
nOnly suitable pumps can be used in areas at risk from explosion.
nOnly start up the pump once it has been correctly installed and started
up in accordance with the technical data and specifications 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)!
nThe pump is not intended for private use.
nOnly allow appropriate personnel to operate the pump,
Ä Chapter 2.2
‘User qualification’ on page 13 .
2.5 Misuse
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 explosive mixtures.
nThe pump is not intended for unprotected use outdoors.
Safety chapter
14

2.6 Safety information
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.
WARNING!
Ignition hazard by exothermic reaction
Certain oils from the intermediate diaphragm chamber
can react exothermically and become hot with certain
feed chemicals.
– Assess the required feed chemical in terms of this
risk.
(Project-specific oil replacement is possible.)
CAUTION!
Refer to the documentation for the bought-in parts.
CAUTION!
Altering the programming can result in different damage
to the unit.
Do not modify the programming.
WARNING!
The motor rotor and also the liquid end both contain a
very strong magnet.
The magnet can interfere with pacemakers and other
electrical equipment.
– Maintain a minimum distance of 250 mm from the
magnet.
WARNING!
The motor rotor contains a very strong magnet.
When removed, the magnet can attract magnetic objects
with great force.
– When removed, store the rotor in a suitable crate or
box etc.
Safety information
Safety chapter
15

CAUTION!
The drive can become very hot.
CAUTION!
Warning of feed chemical spraying around
Feed chemical may spray out of the hydraulic compo‐
nents if they are tampered with 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.
–Ensure that the system is at atmospheric pressure
before commencing any work on hydraulic parts of
the system.
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 ProMinent Resistance List when
selecting the feed chemical - see the ProMinent
Product Catalogue or visit ProMinent.
WARNING!
The inside of the dosing head needs to be constantly
filled with medium in normal mode, and the start-up and
run-down processes have to be designed in such a way
by the operator so that no explosive mixture is produced
inside the dosing head.
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.
Information in the event of an emergency
Safety chapter
16

Basic assumption for assessment of the ignition hazards:
With regard to the ignition hazard assessment, it is assumed that the
inside of the dosing head is constantly filled with medium in normal mode
and also that the start-up and run-down processes are designed in such a
way by the operator that no explosive mixture is produced inside the
dosing head.
The operator must pay attention to the documentation for the bought-in
parts and employ qualified personnel.
Ignition hazard Protective measures to be observed by the customer
Hot surfaces Limitation of the maximum feed chemical temperature to
80 °C (EMFa) / 100 °C (EMHa).
Limit the maximum temperature of the motor to 100 °C;
refer to the documentation on the motor (temperature
relay, power contactor).
Switch off the pump in fault mode (pressure drops).
Mechanically generated sparks Only perform repair and maintenance work, assembly /
disassembly in a clean room without an explosive atmos‐
phere.
Electrical sources of ignition The installation / dismantling / placement of electrical com‐
ponents is only permitted outside of explosive atmos‐
pheres in a “safe non-ATEX” area.
Exothermic reaction, including the self-combustion of dust EMFa only: feed chemicals, which react exothermically
with the oil from the intermediate diaphragm chamber,
have to be considered in terms of the risk.
Dust deposits and other material Regularly and carefully clean the outside of the pump.
Diaphragm damage The operator must switch off the pump safely and as
quickly as possible.
Electrical bought-in parts (motor, controller, motor cable,
diaphragm rupture indicator, ...)
Electrical connection by technical personnel.
Refer to the documentation for the bought-in part.
Summary of relevant ignition hazards and
protective measures put in place for the
Evolution mikro EMFa / EMHa in accord‐
ance with EN ISO 80079-36
Safety chapter
17

2.7 Safety equipment
The labels on the pump housing must be kept legible at all times.
Danger of tipping over
Magnetic field
Hot surface
2.8 Sound pressure level
Sound pressure level LpA < 70 dB according to EN ISO 20361
at maximum stroke length, maximum stroke rate, maximum back pressure
(water)
Labels
Sound pressure level
Safety chapter
18

3 Storage, transport and unpacking
User qualification: trained person / qualified personnel
Ä Chapter 2.2 ‘User qualification’ on page 13
WARNING!
Only return metering pumps for repair in a cleaned state
and with a flushed liquid end - refer to "Decommis‐
sioning!
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
on our homepage.
WARNING!
High centre of gravity
The unsecured pump can easily topple over.
– Only transport the pump horizontally.
WARNING!
The ring bolt can break off
If the pump is connected to other components, do not lift
this assembly by the ring bolt on the top of the pump –
the ring bolt could break off and the unit could drop.
– Only use the ring bolt on the top of the pump to lift
the pump itself.
CAUTION!
The ring bolt seals the housing
The ring bolt protects the inside of the pump from the
ingress of dirt etc. Therefore never remove the ring bolt
without replacing it.
– If the ring bolt presents a problem at the installation
site, use an appropriate plug to permanently seal the
thread.
CAUTION!
Danger for suction valve
The suction valve protrudes a little downwards.
– Pay attention to the position of the suction valve
when transporting the unit.
Storage, transport and unpacking
19

CAUTION!
Danger of environmental and material damage
The unit can be damaged or oil may escape due to
incorrect or improper storage or transportation.
– Therefore only screw the transport protection pin (1)
into the thread in the centre of the plate, Figure A.
–Only transport the unit with the correctly fitted trans‐
port protection pin and the sealing screw, instead of
the vent screw.
B1219
A) B)
1
Fig. 4: Using the transport protection pin (1)
A) Transport position (the rotor is prevented from moving, oil cannot
escape)
B) Parked position (in operation)
1. Place the pump on a pallet - do not stand it upright.
2. Cover the pump with a tarpaulin cover - allowing rear ventilation.
3. Store the pump in a dry, sealed place in line with the prescribed
ambient conditions - refer to the chapter entitled "Technical data".
1. Check whether the transport protection is screwed into the oil filler
opening instead of the vent screw.
2. Apply preservative to the rotor surface of the motor – refer to the
motor manufacturer’s operating instructions.
3. Flush the liquid end with a suitable medium and dry it.
4. Fit the caps to the valves.
1. Replace the PTFE diaphragm and the intermediate webbing.
2. Replace the O-rings and the radial shaft sealing ring.
3. After a total of more than 2 years: change the hydraulic oil.
3.1 Ambient conditions
Tab. 3: Pump, complete
Specification Value
Storage and transport temperatures: -25 ... +60 °C
Storage
Preservation
Stoppage of 1 ... 6 months
Stoppage of more than 6 months
Storage, transport and unpacking
20