ProMinent Evolution E1Sa User manual

Metering pump
Evolution E1Sa
Operating instructions
A3500
These operating instructions form part of combined documentation and, as such, are only valid if used in conjunction with
the combined documentation.
Target group: trained, qualified personnel, unless otherwise required.
EN
Original operating instructions (2006/42/EC)999638 Version: BA ORL 014 07/23 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.

In order to make it easier to read, this document uses the male form in
grammatical structures but with an implied neutral sense. The document is
always aimed equally at women, men and gender-neutral persons. We
kindly ask readers for their understanding in this simplification of the text.
Please read the supplementary information in its entirety.
Information
This provides important information relating to the cor‐
rect operation of the unit or is intended to make your
work easier.
Warning information
Warning information includes detailed descriptions of the hazardous situa‐
tion, see Ä Chapter 3.1 ‘Labelling of Warning Information’ on page 17 .
The following symbols are used to highlight instructions, links, lists, results
and other elements in this document:
Tab. 1: More symbols
Symbol Description
Action, step by step.
⇨Outcome of an action.
Links to elements or sections of these instructions or other applicable documents.
nList without set order.
[Button] Display element (e.g. indicators).
Operating element (e.g. button, switch).
‘Display/GUI’ Screen elements (e.g. buttons, assignment of function keys).
CODE Presentation of software elements and/or texts.
General non-discriminatory approach
Supplementary information
Supplemental directives
2

Table of contents
1 Function........................................................................................... 5
1.1 Functional description............................................................. 5
1.2 Field of application.................................................................. 5
1.3 Accessories............................................................................. 5
1.4 Overview of equipment........................................................... 6
1.5 Liquid end................................................................................ 7
1.6 Diaphragm monitor.................................................................. 8
1.7 Nameplate............................................................................... 9
1.7.1 Nameplate data.................................................................... 9
1.7.2 ATEX nameplate data.......................................................... 9
1.8 Dimensional drawing............................................................. 10
1.8.1 Dimensional drawing, example.......................................... 10
1.8.2 Dimensional drawing with stroke control motor.................. 11
1.8.3 Dimensional drawing with actuator/horizontal.................... 12
1.8.4 Dimensional drawing with actuator/vertical........................ 13
2 Identity code.................................................................................. 14
2.1 Explanation of the ATEX label.............................................. 16
3 Safety chapter............................................................................... 17
3.1 Labelling of Warning Information.......................................... 17
3.2 User qualification................................................................... 18
3.3 Warning symbols denoting different types of danger............ 19
3.4 Intended use......................................................................... 19
3.5 Misuse................................................................................... 19
3.6 Safety information................................................................. 19
3.7 Emissions.............................................................................. 21
4 Storage and transport.................................................................... 22
4.1 Ambient conditions................................................................ 22
4.2 Transport............................................................................... 23
4.2.1 Pump without base plate.................................................... 23
5 Assembly....................................................................................... 25
5.1 Motor number........................................................................ 26
5.2 Space requirement................................................................ 26
5.3 Alignment of the liquid end.................................................... 27
5.4 Fastening.............................................................................. 27
6 Installation..................................................................................... 28
6.1 Pipework forces and torque.................................................. 28
6.2 Installation, hydraulic............................................................. 29
6.2.1 Suction lift........................................................................... 30
6.2.2 Diaphragm monitoring sensor............................................ 30
6.2.3 Basic installation notes....................................................... 31
6.3 Installation, electrical............................................................. 32
6.4 Earthing / potential equalisation............................................ 34
7 Start up.......................................................................................... 35
7.1 Check-list.............................................................................. 35
7.2 Venting the hydraulics........................................................... 36
7.2.1 Venting the hydraulics with an adjustable stroke length.... 36
7.2.2 Venting the hydraulics with a fixed stroke drive................. 37
7.3 Calibrate the stroke control drive (optional).......................... 37
8 Operation....................................................................................... 38
9 Diaphragm package...................................................................... 39
9.1 Material versions................................................................... 39
9.2 Lubricant, diaphragm rupture warning system...................... 39
Table of contents
3

9.3 Replacing the diaphragm...................................................... 39
9.3.1 A diaphragm rupture can remain unnoticed....................... 39
9.3.2 Drain the hydraulic oil from the hydraulic end.................... 39
9.3.3 Replacing the diaphragm................................................... 40
9.3.4 Tightening torque for screws.............................................. 41
9.3.5 Filling hydraulic oil into the hydraulic end........................... 41
10 Maintenance.................................................................................. 43
10.1 Inspection............................................................................ 44
10.2 Maintenance work............................................................... 44
10.2.1 Case-specific.................................................................... 44
10.2.2 Annually........................................................................... 45
10.3 Changing and topping up hydraulic oil................................ 45
10.3.1 Changing the hydraulic oil................................................ 45
10.3.2 Filling with hydraulic oil.................................................... 46
10.4 Cleaning.............................................................................. 46
10.5 Cleaning valves................................................................... 47
10.5.1 Cleaning a discharge valve (double ball)......................... 47
10.5.2 Assembling the discharge valve....................................... 47
10.5.3 Cleaning a suction valve (double ball)............................. 48
10.6 Using moulded composite seals......................................... 48
10.7 Replacing the safety relief valve......................................... 48
10.8 Repairing the diaphragm monitoring sensor....................... 49
11 Rectifying functional faults............................................................. 52
11.1 Mechanical faults................................................................ 52
11.2 Hydraulic faults.................................................................... 53
11.3 Electrical faults.................................................................... 54
12 Temporary decommissioning........................................................ 55
12.1 Preservation........................................................................ 55
13 Decommissioning and disposal..................................................... 57
13.1 Decommissioning................................................................ 57
13.2 Disposal.............................................................................. 57
14 Technical data............................................................................... 58
14.1 Particle size......................................................................... 58
14.2 Performance data................................................................ 58
14.3 Dosing precision, reproducibility and linearity..................... 58
14.4 Weight................................................................................. 59
14.5 Ambient conditions.............................................................. 59
14.6 Housing degree of protection.............................................. 59
14.7 Diaphragm monitoring sensor............................................. 59
14.7.1 Contact............................................................................. 60
14.7.2 NAMUR sensor, specified for areas at risk from explo‐
sion................................................................................... 61
14.8 Pressure stage.................................................................... 61
14.9 Safety relief valve................................................................ 61
14.10 Sound pressure level........................................................ 62
14.11 Supplementary information with modified designs............ 62
14.12 Filling volumes.................................................................. 62
14.13 Motor data......................................................................... 62
15 Spare parts and equipment........................................................... 63
15.1 General............................................................................... 63
15.1.1 Wear parts........................................................................ 63
15.1.2 Hydraulic oil...................................................................... 63
16 Declaration of Conformity.............................................................. 64
17 ATEX Declaration of Conformity.................................................... 65
Table of contents
4

1 Function
1.1 Functional description
The pump is an oscillating-action process metering pump with a PTFE
two-layer safety diaphragm. An electric motor drives the pump. The drive
unit generates the oscillating force-stroke needed for the displacement
process from the rotational movement of the motor. The displacement
body driven by the drive unit converts the force-stroke movement into
hydraulic energy. The metering flow is determined by the continuously
adjustable stroke length and the volume of the displacement body.
1.2 Field of application
These process metering pumps are typically used in the following indus‐
trial sectors:
nOil, gas, petrochemical,
nChemical industry,
nPharmaceuticals,
nFood and beverage industry.
1.3 Accessories
List of possible accessories:
nHeating unit
nCooling unit
nElectrical diaphragm rupture warning system
nStroke counter
nSpeed control/Frequency converter operation
nActuator/control drive-controlled stroke adjustment
Function
5

1.4 Overview of equipment
This pump consists of the following main assemblies:
A3526
16
1
15
14
13
12
11
10 9
8
7
6
45
3
2
Fig. 1: Overview of the main assemblies
1 Evolution 1 S (abbreviated to Evo1 S)
2 Motor
3 Motor base
4 Stroke adjustment
5 Stroke adjustment, manual
6 Stroke adjustment, by actuator
7 Multiple pump
8 Multiple pump, base
9 Multiple pump, connection kit
10 Base
11 Lubrication oil
12 Liquid end
13 Liquid end, relief valve
14 Liquid end, piston and socket
15 Stroke sensor
16 Drive unit
The basic construction of a pump is always identical. As a minimum, a
complete pump consists of:
nA drive unit, which can be attached to the top or side of the motor.
nA motor
nManual plastic or stainless steel stroke adjuster or
Actuator-controlled stroke adjuster
with a fixed stroke drive
nOne/multiple liquid end(s) for diverse applications
Motor base as a connection for the drive
nA base and, if need be,
nOne/multiple connecting set(s) to combine two drive units,
A cover.
Function
6

1.5 Liquid end
A3841
1.
Fig. 2: Liquid end of the PTFE multi-layer diaphragm (1)
The heart of the liquid end is a PTFE multi-layer diaphragm (1). The PTFE
multi-layer diaphragm hermetically seals the delivery chamber of the
dosing head and causes displacement in the dosing head at each pump
stroke. The suction valve and the discharge valve provide the feed in con‐
junction with the movement of the diaphragm. The diaphragm is tightly
stretched between the dosing head and a diaphragm mounting plate.
The multi-layer diaphragm prevents feed chemical from mixing with
hydraulic oil in the event of a diaphragm rupture.
If the diaphragm is hydraulically actuated - it is not attached to the piston -
then it always works in balance with the pressure and is therefore well
suited to high feed pressures. The return to the starting position after a
stroke is guaranteed by an in-built diaphragm return spring.
The diaphragm is designed as a multi-layer diaphragm. The diaphragm
anchor and a film of liquid join the sandwiched diaphragm layers together.
Function
7

1.6 Diaphragm monitor
A3839
1.
Fig. 3: The diaphragm monitoring interface (1), shown here with the visual
display screwed in
The diaphragm monitor monitors the multi-layer diaphragm for leaks and
faults. The central slot of the multi-layer diaphragm features a drainage
net. The drainage net is connected to the diaphragm monitoring sensor by
a channel in the dosing head. If one of the outer diaphragm layers rup‐
tures, feed chemical or hydraulic oil reaches the diaphragm monitoring
sensor through the drainage layer. The diaphragm monitoring sensor gen‐
erates a signal.
B1316
Fig. 4: Visual display
Visual display
Function
8

1.7 Nameplate
1.7.1 Nameplate data
Ser.Nr.
p rtd
p max
A3529
p test
DBV
Typ
987654321
XXX bar
XXX bar
XXX bar
XXX bar
Baujahr
Q rtd
Q max
Temp.
Hubzahl
2022
XXX l/h
XXX l/h
-20 ... +40 °C
XXX 1/min
*******************************************
ProMinent GmbH, Im Schuhmachergewann 5 - 11
69123 Heidelberg, Germany
Fig. 5: Nameplate data (example), explanation
Type Identity code - see above
p rtd Maximum pressure, as ordered
p max Maximum pressure
p test Maximum pressure in the test
DBV Opening pressure of the pressure relief valve
Q rtd Maximum dosing rate, as ordered
Q max Maximum dosing rate
Temp. Ambient temperature, range
Stroke rate Stroke rate, maximum, in strokes per minute
1.7.2 ATEX nameplate data
Ser.Nr.
p rtd
p max
A3531
p test
DBV
Typ
987654321
XXX bar
XXX bar
XXX bar
XXX bar
Baujahr
Q rtd
Q max
Temp.
Hubzahl
2022
XXX l/h
XXX l/h
-20 ... +40 °C
XXX 1/min
********************************************************
ProMinent GmbH, Im Schuhmachergewann 5 - 11
69123 Heidelberg, Germany
II 2G Ex h IIC T4 Gb X
Fig. 6: ATEX nameplate data (example)
Type Identity code - see above
p rtd Maximum pressure, as ordered
p max Maximum pressure
p test Maximum pressure in the test
DBV Opening pressure of the pressure relief valve
Q rtd Maximum dosing rate, as ordered
Q max Maximum dosing rate
Temp. Ambient temperature, range
Stroke rate Stroke rate, maximum, in strokes per minute
ATEX specification - refer to the nameplate on your pump, the corre‐
sponding EU Declaration of Conformity for ATEX Machinery and .
Function
9

1.8 Dimensional drawing
1.8.1 Dimensional drawing, example
Dimensional drawing, example
nPlease use the dimensional drawing enclosed with the documentation
for the dimensions for your specific pump.
nAll dimensions are in mm.
40523784
A3505
Fig. 7: Dimensional drawing
Function
10

1.8.2 Dimensional drawing with stroke control motor
40523784
A3840
Fig. 8: Dimensional drawing with stroke control motor
Function
11

1.8.3 Dimensional drawing with actuator/horizontal
A3847
40523784
Fig. 9: Dimensional drawing with actuator/horizontal
Function
12

1.8.4 Dimensional drawing with actuator/vertical
A3848
40583784
Fig. 10: Dimensional drawing with actuator/vertical
Function
13

2 Identity code
Tab. 2: ES1a
Drive type
V Simplex (vertical)
X Drive (without liquid end)
Piston
006 Piston Ø6
008 Piston Ø8
010 Piston Ø10
013 Piston Ø13
022 Piston Ø22
030 Piston Ø30
Stroke rate
50 Hz operation 60 Hz operation
093 93 strokes/min. @ 50 Hz 113 113 strokes/min. @ 60 Hz
175 175 strokes/min. @ 50 Hz 170 170 strokes/min. @ 60 Hz
194 194 strokes/min. @ 50 Hz
Pressure stage
A 260 bar
B 163 bar
D 51 bar
E 30 bar
X Drive (without liquid end)
Material
S2 Standard stainless steel; stainless steel - DIN EN
S3 Standard stainless steel; stainless steel - AISI
XX Drive (without liquid end)
Valve design
0 Standard 7 Plate valve with spring
4 Ball valve 8 Conical valve
5 Ball valve with spring 9 Conical valve with spring
6 Double ball valve X Drive (without liquid end)
Diaphragm monitor
2 Visual display
1 Without diaphragm monitor
3 Contact manometer
4 Electrical pressure switch
X Drive (without liquid end)
Hydraulic connector
0 Standard
E DIN flange
Identity code
14

F ANSI flange
N NPT connector
X Drive (without liquid end)
Electrical connection
S 3-phase, 230/400 V, 50/60 Hz
T 3-phase, 230/400 V, 50/60 Hz, with PTC
L 3-phase, 230/400 V, 50 Hz, (EXDE) T4
Q 3-phase, 265/460 V, 60 Hz, (EXDE) T4
V Controllable motor with integrated frequency converter
A PM China - 3-phase, 380 V, 50 Hz
B PM China - 3-phase, variable motor, 220 ... 380 V, 1:5
C PM China - 3-phase, EXDIICT4,220/380 V, 50 Hz
D PM China - 3-phase, EXDIIBT4, 220/380 V, 50 Hz
1 Without motor, with 160/71 flange
2 Without motor, with 200/90 flange
3 Without motor, with NEMA 56/143 flange
4 Without motor, with 160/71 ATEX flange
5 Without motor, with 200/90 ATEX flange
6 Without motor, with NEMA 56/143 ATEX flange
X Without motor, without flange
Stroke length adjustment
0 Standard stroke length adjustment
Temperature (ambient)
0 -20 °C … +40 °C
1 -10 °C … +50 °C
Paintwork
0P C3 standard textured paint - RAL2003
1P C3 standard gloss paint - RAL2003
2P C4 Outdoor - RAL2003
3P C5 Offshore - RAL2003
XX Drive without paintwork but with rust protection
Tests
S1 Standard quality inspection
S2 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 material cer‐
tificate
A2 As A1 + NPSH
A3 As A1 + NPIP
XX Drive (without liquid end)
Identity code
15

Approval
0 CE
1 CE + ATEX
2 CE + EAC
3 CE + EAC+ ATEX
4 CE + UCKA
5 CE + UCKA + ATEX
X Drive (without liquid end)
Documentation *
DE German
EN English
XX Drive (without liquid end)
M0 modified
Unit of measure
0 bar, l/h
1 psi, gph
2 kPa, l/h
X Drive (without liquid end)
* other languages on request.
2.1 Explanation of the ATEX label
Explanation of the pump’s ATEX label in accordance with Directive 2014/34/EU / Standards EN ISO 80079-36, -37
Unit group
II No mines or associated underground systems, which can be endangered by firedamp - Unit for use in other areas
at risk from explosion
Other parameters
3G Ex h (Example)
Explosion group
IIC for explosion group IIC gas - refer to your explosion protection document.
IIB for explosion group IIB gas - refer to your explosion protection document.
Temperature class
T3 for temperature class T3 gas - refer to your explosion protection document.
T4 for temperature class T4 gas - refer to your explosion protection document.
Equipment protection level (EPL)
Gb high EPL
use possible in zones 1 and 2 - refer to your explosion protection document.
Gc normal EPL
use possible in zone 2 - refer to your explosion protection document.
Suffix X
X Special conditions - refer to the Declarations of Conformity and EC-type
examination certificates
Identity code
16

3 Safety chapter
3.1 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
17

3.2 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.
Safety chapter
18

3.3 Warning symbols denoting different types of danger
The following warning symbols are used in these operating instructions to
denote different types of danger:
Warning symbol Type of danger
Warning of a dangerous area.
Warning of hazardous electrical voltage.
Warning of hot surfaces.
3.4 Intended use
nOnly use the pump to meter liquid, sediment-free feed chemicals.
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)!
nOnly suitable pumps can be used in areas at risk of explosion.
nThe pump is not intended for operation in private areas.
nOnly allow appropriate personnel to operate the pump, see
Ä Chapter
3.2 ‘User qualification’ on page 18 .
nYou have a responsibility to observe the information contained in the
operating instructions for the auxiliary equipment at the different
phases of its respective service life.
3.5 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.
3.6 Safety information
The surface of the pump can take on the temperature of the media. Note
this when considering the safety of the pump.
Warning symbols denoting different types
of danger
Safety chapter
19

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
If damaged, the oil from the intermediate diaphragm
chamber can react exothermically with the feed chemical
and become hot, e.g. by a diaphragm rupture.
– Assess your feed chemical in terms of this risk.
The type of oil can be replaced for a specific project.
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.
INFORMATION: Refer to the documentation for the bought-in parts.
The standard version is intended for installation up to a height of 1,000 m
above sea level. Above 1,000 m, among other things, cavitation in the oil
or the decreasing cooling ability of the air can affect the function and
safety of the pump.
Safety information
Installation height
Safety chapter
20