ProMinent Hydro 2 Series User manual

Metering pumps
Hydro/ 2 and Hydro/ 3
Operating instructions
P_HY_0004_SW
EN
Original operating instructions (2006/42/EC)984721 BA HY 018 05/19 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 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
1Identity code.................................................................................... 5
2 Safety chapter............................................................................... 10
2.1 Safety information for ATEX designs.................................... 15
2.2 Explanation of the ATEX label.............................................. 26
3 Storage, transport and unpacking................................................. 29
4Overview of equipment / control elements.................................... 31
5 Functional description.................................................................... 32
6 Assembly....................................................................................... 33
7 Installation..................................................................................... 37
7.1 Installation, hydraulic............................................................. 37
7.1.1 Basic installation notes....................................................... 40
7.2 Installation, electrical............................................................. 42
8 Start up and operation................................................................... 48
8.1 Bleeding the liquid end.......................................................... 51
8.2 Calibrate the stroke control drive (optional).......................... 52
9 Maintenance.................................................................................. 53
10 Repair............................................................................................ 59
10.1 Cleaning valves................................................................... 60
10.2 Replacing the diaphragm.................................................... 62
10.3 Repairing the diaphragm rupture sensor............................. 64
10.4 Calibrating the dosing rate.................................................. 66
10.5 Replacing power end bearings............................................ 68
11 Troubleshooting............................................................................. 69
12 Decommissioning and disposal..................................................... 73
12.1 Decommissioning................................................................ 73
12.2 Disposal.............................................................................. 74
13 Technical data............................................................................... 76
13.1 Performance data................................................................ 77
13.2 Metering reproducibility....................................................... 80
13.3 Viscosity.............................................................................. 81
13.4 Weight................................................................................. 81
13.5 Wetted materials................................................................. 81
13.6 Ambient conditions.............................................................. 82
13.6.1 Temperatures................................................................... 82
13.6.2 Air humidity...................................................................... 83
13.6.3 Installation height............................................................. 83
13.7 Housing degree of protection.............................................. 83
13.8 Motor data........................................................................... 83
13.9 Diaphragm rupture sensor.................................................. 85
13.10 Safety relief valve (HP2 and HP3).................................... 86
13.11 Stroke sensor.................................................................... 86
13.12 Heating cartridge............................................................... 86
13.13 Protection temperature limiter (ATEX only)....................... 87
13.14 Filling volumes.................................................................. 87
13.14.1 Hydraulic oil.................................................................... 87
13.15 Sound pressure level HP2a / Hp3a................................... 87
13.16 Supplement for modified versions..................................... 87
14 Dimensional drawings................................................................... 89
15 Earthing drawing.......................................................................... 102
16 Diagrams for setting the metering capacity................................. 103
Table of contents
3

17 Ordering information.................................................................... 105
17.1 Exploded view drawing..................................................... 105
17.2 Spare parts kits................................................................. 105
17.3 Diaphragms....................................................................... 107
17.4 General............................................................................. 107
18 EU Declaration of Incorporation for Machines HP2..................... 109
19 EU Declaration of Incorporation for Machines HP3..................... 110
20 EC Declaration of Conformity for HP2 Machines........................ 111
21 EC Declaration of Conformity for HP3 Machines........................ 112
22 EC Declaration of Incorporation for ATEX HP2 Machines.......... 113
23 EC Declaration of Incorporation for ATEX HP3 Machines.......... 114
24 EC Declaration of Conformity for ATEX HP2 Machines.............. 115
25 EC Declaration of Conformity for ATEX HP3 Machines.............. 116
Table of contents
4

1 Identity code
HP2a Hydro/ 2, version a
Power end type
H Main power end
D Main power end, double head version
E Main power end for add-on power end
F Main power end double head version for add-on power end
A Add-on power end
B Add-on power end double head version
Typ
e *
Capacity
_ _ _
_ _ _
Performance data at maximum back pressure and type: refer to nameplate on the pump housing
Dosing head material
SS Stainless steel
PV PVDF
HC Hastelloy C
TT PTFE + carbon
Seal material
T PTFE
Displacement body
0 Standard multi-layer safety diaphragm with rupture signalling
Dosing head design
0 no valve spring (standard)
1 with valve spring
D Double ball valve (only for SST and HCT)
H HV version for (only for 025019 ... 025060)
Hydraulic connector
0 Standard threaded connector (in line with technical data)
E with DIN ISO flange
F with ANSI flange
Design
0with ProMinent® logo (standard)
1without ProMinent® logo
M modified* * order-related design, refer to order paperwork
for pump features
Electric power supply
S 3-phase, 230 V/400 V 50/60 Hz, 0.37 kW
L 3-phase, 230 V/400 V, 50 Hz, (Exe, Exde), 0.37 kW
P 3-phase, 265 V/440 V, 60 Hz, (Exe, Exde), 0.37 kW
R 3-phase variable speed stroke control motor, 230/400 V, 0.37
kW
Identity code
5

HP2a Hydro/ 2, version a
V(0) Variable stroke control motor with integrated frequency con‐
verter 1-phase, 230 V, 50/60 Hz
V(2) Variable stroke control motor with integrated frequency con‐
verter (Exd)
Z Speed control complete 1-phase, 230 V, 50/60 Hz (stroke con‐
trol motor + frequency converter)
1 without motor, with flange 200/80
3 without motor, with flange 160/71
4 without motor, with 56C flange (NEMA)
0 Add-on power end
Degree of protection
0 IP 55 (standard) ISO class F
1 Exe design ATEX-T3 **
2 Exde design ATEX-T4 **
A ATEX power end **
Stroke sensor
0 no stroke sensor (standard)
1 Stroke sensor (suitable for use in areas at risk from
explosion)
Stroke length adjustment
0 manual (standard)
1 with servomotor, 230 V, 50/60 Hz
2 with servomotor, 115 V, 60 Hz
A with stroke control motor 0...20 mA 230 V, 50/60
Hz
B with stroke control motor 4...20 mA 230 V, 50/60
Hz
C with stroke control motor 0...20 mA 115 V, 60 Hz
D with stroke control motor 4...20 mA 115 V, 60 Hz
Hydraulic oil
0 Standard
1 Food approval for oil
2 Low temperature to -25 ℃
3 Low temperature Zone 2
Tab. 1: * Type, power (at 50 Hz)
Type Capacity Type Capacity Type Capacity
bar l/h bar l/h bar l/h
100003 10013064007 6417025019 25119
100006 10016064015 64115 025040 25140
100007 10017064018 64118 025048 25148
Identity code
6

Type Capacity Type Capacity Type Capacity
bar l/h bar l/h bar l/h
100009 10019064022 64122 025060 25160
100010 100110 064025 64125 025068 25168
1 Maximum back pressure for TTT material version: 16 bar!
Maximum back pressure for PVT material version: 25 bar!
** ATEX specification - refer to the nameplate on the pump, corresponding
EU Declaration of Conformity for ATEX Machinery and
Ä Chapter 2.2
‘Explanation of the ATEX label’ on page 26
Identity code
7

HP3a Hydro/ 3, version a
Power end type
H Main power end
D Main power end, double head version
E Main power end for add-on power end
F Main power end double head version for add-on power end
A Add-on power end
B Add-on power end double head version
Type Capacity
_ _ _ _ _
_
Performance data at maximum back pressure and type: refer to the nameplate on the
pump
Dosing head material
SS Stainless steel
PV PVDF
H
C
Hastelloy C
TT PTFE + carbon
Seal material
T PTFE
Displacement body
0 Standard multi-layer safety diaphragm with rupture signalling
Dosing head design
0 no valve spring (standard)
1 with valve spring
D Double ball valve (for 100010 ... 100035, 064019 ... 064060 and SST /
HTC)
H HV version (for 064019 ... 064068, 025048 ... 025170)
Hydraulic connector
0 Standard threaded connector (in line with technical data)
E with DIN ISO flange
F with ANSI flange
Design
0with ProMinent® logo (standard)
1without ProMinent® logo
M modified* * order-related design, refer to order paper‐
work for pump features
Electric power supply
_ Connection data - see motor nameplate
1 without motor, with flange 200/80
3 without motor, with flange 160/71
4 without motor, with 56C flange (NEMA)
0 Add-on power end
Degree of protection
Identity code
8

HP3a Hydro/ 3, version a
0 IP 55 (standard) ISO class F
1 Exe design ATEX-T3 **
2 Exde design ATEX-T4 **
A ATEX power end
Stroke sensor
0 no stroke sensor (standard)
1 Stroke sensor (suitable for use in areas at risk
from explosion)
Stroke length adjustment
0 manual (standard)
1 with servomotor, 230 V, 50/60 Hz
2 with servomotor, 115 V, 60 Hz
A with stroke control motor 0...20 mA 230 V,
50/60 Hz
B with stroke control motor 4...20 mA 230 V,
50/60 Hz
C with stroke control motor 0...20 mA 115 V,
60 Hz
D with stroke control motor 4...20 mA 115 V,
60 Hz
Hydraulic oil
0 Standard
1 Food approval for oil
2 Low temperature to -25 ℃
3 Low temperature Zone 2
Tab. 2: * Type, power (at 50 Hz)
Type Capacity Type Capacity Type Capacity
bar l/h bar l/h bar l/h
100010 100110 064019 64119 025048 25148
100021 100121 064040 64140 025100 251100
100025 100125 064048 64148 025120 251120
100031 100131 064060 64160 025150 251150
100035 100135 064068 64168 025170 251170
1 Maximum back pressure for TTT material version: 16 bar!
Maximum back pressure for PVT material version: 25 bar!
** ATEX specification - refer to the nameplate on the pump, corresponding
EU Declaration of Conformity for ATEX Machinery and
Ä Chapter 2.2
‘Explanation of the ATEX label’ on page 26
Identity code
9

2 Safety chapter
The following signal words are used in these operating instructions to
identify different severities of a hazard:
Signal word Meaning
WARNING Denotes a possibly hazardous situation. If this is disre‐
garded, you are in a life-threatening situation and this
can result in serious injuries.
CAUTION Denotes a possibly hazardous situation. If this is disre‐
garded, it could result in slight or minor injuries or mate‐
rial 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 – flammable substances.
Warning – hot surface.
Warning – danger zone.
nOnly use the pump to meter liquid feed chemicals.
nThe pump is only approved for use with flammable feed chemicals if it
has the identity code option "Standard multi-layer safety diaphragm
with rupture signalling", is operated at back pressures of over 2 bar
with metal liquid ends and if the operator implements appropriate
safety measures.
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. When working at temper‐
atures arising using a heating cartridge, bear in mind their effect.
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.
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.
nThe pump is only intended for industrial use.
nOnly allow trained and authorised personnel to operate the pump -
see the following table.
Explanation of the safety information
Warning signs denoting different types of
danger
Intended use
Safety chapter
10

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.
Task Qualification
Storage, transport, unpacking Instructed person
Assembly Technical personnel, service
Planning the hydraulic installation Qualified personnel who have a
thorough knowledge of oscillating
metering 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.
Electrical technician with knowledge of ATEX explosion protection
An electrical technician with an additional explosion protection qualification
should be specifically trained for the field of work in which he is employed
and be familiar with the relevant standards and regulations. An electrical
technician with an additional explosion protection qualification can work on
electrical systems and independently recognise and avoid possible dan‐
gers based on his technical training and experience.
The electrical technician with an additional explosion protection qualifica‐
tion is familiar with all the standards and regulations applicable to explo‐
sion protection, in particular, but not however exclusively, with all parts of
EN 60079 [Electrical equipment for areas at risk of a gas explosion].
An electrical technician with an additional explosion protection qualification
must comply with the provisions of the applicable statutory directives on
accident prevention.
Qualification of personnel
Safety chapter
11

Recognised competent person
To carry out explosion hazard inspections the competent person must
have:
nCompleted a relevant course of study or
nHave a comparable technical qualification or
nAnother technical qualification combined with long-term experience of
safety technology.
Make sure that the person is familiar with the relevant body of standards
and regulations and has worked in the field for at least one year. The
person needs to have opportunities for an exchange of experiences.
Specific requirements are placed on competent persons who perform tests
on repaired devices/parts. They must be recognised by the responsible
authorities (e.g. district council) in this respect.
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.
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
Service refers to service technicians, who have received proven training
and have been authorised by ProMinent to work on the system.
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.
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
12

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.
CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic compo‐
nents 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
unauthorised 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 mate‐
rials and the ProMinent Resistance List when
selecting the feed chemical - see the ProMinent
Product Catalogue or visit ProMinent.
WARNING!
Danger of injury to personnel and material damage
The pump must only be opened at those points required
to be opened by these operating instructions.
It may only be opened in other positions upon receipt of
written authorisation from the ProMinent head office,
Heidelberg.
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in per‐
sonnel injuries and material damage.
– Only fit parts to metering pumps, which have been
tested and recommended by ProMinent.
Safety chapter
13

CAUTION!
Danger from incorrectly operated or inadequately main‐
tained 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.
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, it is the respon‐
sibility of the system operator to obtain the latest safety data sheet for the
chemicals / equipment to be used with the system from the supplier.
Based on the information provided in the data sheets concerning health
and safety, water and environmental protection, and taking into considera‐
tion the actual operating environment on site, it is the responsibility of the
operator to create the legal framework for the safe operation of the system
or system component, such as for example the preparation of operating
instructions (operator's duties).
Secure all these parts in their place when using the pump.
Protective equipment May only be removed by*:
Motor terminal box cover Electrical technician, Service
Flange cover, side Service
Protective cowling over the motor
fan
Service
Only with additional equipment:
Their corresponding parts
Technical personnel, Service
* Only if required by the operating instructions and if the mains cable
remains disconnected from the mains voltage.
The operator must be able to:
nPerform a risk assessment
nProduce and attach a nameplate
nIssue a Declaration of Conformity
nAdapt the operating instructions, if necessary
nInstall the motor correctly
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 for operating instruc‐
tions
Safety equipment
Fixed, isolating protective equipment
Requirements if the motor is being
installed independently
Sound pressure level
Safety chapter
14

2.1 Safety information for ATEX designs
This chapter lists all safety information for ATEX designs. Safety informa‐
tion is listed again at the relevant points in these operating instructions.
This safety information is supplementary to or replaces the safety informa‐
tion for non-ATEX designs. If the safety information for ATEX designs con‐
tradicts the other safety information, then the safety information in this
chapter applies to ATEX designs.
nOnly operate the pump in premises at risk from explosion in an ATEX
designs in accordance with the applicable guidelines.
nDo not expose the ATEX design to any sources of ionising radiation or
electromagnetic high frequency radiation in the range 104 ... 3x1015 Hz
or laser radiation or ultrasound or lightning without putting in place
measures in line with EN 80079-38.
nThe ATEX design is not intended for the metering of electrically non-
conductive media (conductivity less than 50 pS/m).
nThe ATEX design may not meter media, which tend to produce exo‐
thermic reactions or self-ignite (examples of exothermic reactions:
pyrophoric substances with air, alkali metal with water, decomposition
of organic peroxides, polymerisation reactions), without taking effec‐
tive measures in accordance with EN 80079-38.
Task Qualification
Planning the hydraulic installation ATEX qualified person, ATEX elec‐
trical technician
Electrical installation ATEX electrical technician
Start up Skilled ATEX technician;
Checking the electrical installation:
Recognised competent person
Maintenance, repair ATEX qualified person, ATEX elec‐
trical technician
Troubleshooting Qualified ATEX technician or ATEX
electrical technician - depending on
the fault;
Checking the electrical installation:
Recognised competent person
Explanation of the table:
Recognised competent person
To carry out explosion hazard inspections the competent person must
have:
nCompleted a relevant course of study or
nHave a comparable technical qualification or
nAnother technical qualification combined with long-term experience of
safety technology.
Make sure that the person is familiar with the relevant body of standards
and regulations and has worked in the field for at least one year. The
person needs to have opportunities for an exchange of experiences.
Specific requirements are placed on competent persons who perform tests
on repaired devices/parts. They have to be recognised by the responsible
authorities (e.g. district council) in this respect.
Skilled technician with knowledge of ATEX explosion protection
Intended use
Qualification of personnel
Safety chapter
15

The skilled technician with an additional explosion protection qualification
should be specifically trained for the work area in which he is employed
and be familiar with the relevant standards and regulations. The skilled
technician with an additional explosion protection qualification can work on
equipment and systems in areas protected from explosion and independ‐
ently recognise and avoid possible dangers based on his technical training
and experience.
The skilled technician with an additional explosion protection qualification
is familiar with all the standards and regulations applicable to explosion
protection.
The skilled technician with an additional explosion protection qualification
must comply with the provisions of the applicable statutory directives on
accident prevention.
Electrical technician with knowledge of ATEX explosion protection
An electrical technician with an additional explosion protection qualification
should be specifically trained for the field of work in which he is employed
and be familiar with the relevant standards and regulations. An electrical
technician with an additional explosion protection qualification can work on
electrical systems and independently recognise and avoid possible dan‐
gers based on his technical training and experience.
The electrical technician with an additional explosion protection qualifica‐
tion is familiar with all the standards and regulations applicable to explo‐
sion protection.
An electrical technician with an additional explosion protection qualification
must comply with the provisions of the applicable statutory directives on
accident prevention.
Recognised competent person
To carry out explosion hazard inspections the competent person must
have:
nCompleted a relevant course of study or
nHave a comparable technical qualification or
nAnother technical qualification combined with long-term experience of
safety technology.
Make sure that the person is familiar with the relevant body of standards
and regulations and has worked in the field for at least one year. The
person needs to have opportunities for an exchange of experiences.
Specific requirements are placed on competent persons who perform tests
on repaired devices/parts. They must be recognised by the responsible
authorities (e.g. district council) in this respect.
Ignition hazard Protective measures to be observed by the customer
Excessive surface pressure Limitation of the maximum temperature of the feed chem‐
ical
Pump running hot Customer must monitor and maintain the pump in accord‐
ance with the “Maintenance” chapter.
Customer must monitor the capacity.
Customer must fit a relief valve on the discharge side.
Mechanically generated sparks from the mechanism with
low oil
Customer must monitor and maintain the pump in accord‐
ance with the “Maintenance” chapter.
Mechanically generated sparks from a faulty valve for the
feed chemical
Customer must monitor the capacity.
Electrical stray current in the event of a short circuit Customer must earth the pump and maintain the earthing
of the individual components.
Summary of relevant ignition hazards and
protective measures put in place for the
Hydro in accordance with EN ISO
80079-36
Safety chapter
16

Ignition hazard Protective measures to be observed by the customer
Electrical stray current in the event of a lightning strike Customer must implement suitable protective measures
outdoors.
Static electricity Customer must earth the earthing points and maintain the
potential equalisation cables of the individual components.
Customer must pay attention to potential equalisation
when dismantling.
Paint should not be applied too thickly.
Only with plastic dosing heads: Only use feed chemicals
with conductivities above 50 pS/m.
Customer must wire the diaphragm rupture indicator in
such a way that it immediately stops the pump.
Electromagnetic waves (also lasers), ionising radiation
and ultra-sound 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 Flammable feed chemicals: 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.
Feed chemicals that undergo an exothermic reaction with
hydraulic oil: Customer must wire the diaphragm rupture
indicator in such a way that it immediately stops the pump.
Deposits of dust Regularly clean the outside of the pump with a damp
cloth.
Flammable feed chemicals 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 a motor protection 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 with bought-in Rotex coupling Refer to the documentation for the coupling (maintenance,
alignment if necessary, ...).
Ignition hazard caused by bought-in heating cartridge with
protective temperature limiter
Refer to the documentation for the heating cartridge and
the protective temperature limiter (electrical installation,
maintenance, ...).
Do not reprogram the protective temperature limiter.
Ignition hazard caused by bought-in proximity switch
NJ1.5-8GM-N (stroke sensor, diaphragm rupture indicator)
Refer to the documentation for the proximity switch (elec‐
trical installation, maintenance, ...).
Safety chapter
17

WARNING!
Only use ATEX pumps in areas at risk from explosion
– Observe the European Operator Directive, imple‐
mented in Germany by the Industrial Health and
Safety Regulation, and the German Ordinance on
Hazardous Substances, for the installation and ope‐
ration of equipment in areas at risk from explosion.
–Observe the European standards governing intrinsi‐
cally safe power circuits. (In Germany these stand‐
ards are partly implemented by VDE.)
– Adhere to the respective national regulations outside
of the EU.
– Ensure that installations in areas at risk of explosion
are checked by a "recognised competent" person.
This applies specifically to intrinsically safe power
circuits.
– The following information relates essentially to spe‐
cifics in areas at risk from explosion and does not
replace the standard operating instructions.
– Only clean plastic parts carefully with a damp cloth
to avoid electrostatic charges and sparks.
WARNING!
Motor may overheat
If the necessary cooling air supply is not guaranteed, the
motor may overheat. In an area at risk from explosion, it
could trigger an explosion.
– Maintain sufficient clearance between the air intake
opening and the walls. The distance should be
greater than 1/4 of the diameter of the air intake
opening.
– The fan must not suck in the exhaust air from other
devices.
WARNING!
ATEX pumps in areas at risk from explosion
– Metering pumps in areas at risk of explosion are
provided, as a matter of course, with an appropriate
safety relief valve on the outlet side of the metering
pump (which is used to protect against excessive
heating due to overloading and impact sparks
caused by the breakage of power end parts trig‐
gered by overloading.)
–Likewise a temperature monitor or a pressure side
flow control is to be fitting to metering pumps with
hydraulic diaphragm control for T4. (Protection
against impermissible heating up in the event of
continuous operation by the internal relief valve).
– Should the various components have differing tem‐
perature classes, scope for using the complete
pump depends on the component with the lowest
temperature class.
– Hydraulic diaphragm pumps are highly suitable,
although the design with Ex "i" diaphragm rupture
sensor and a pressure-side flow control is required.
– Ensure that installations in areas at risk of explosion
are checked by a "recognised competent" person.
– Please note the relevant national regulations during
installation!
Safety information
Safety chapter
18

WARNING!
ATEX pumps and flammable media
The ignition temperature is reduced significantly below
the ignition temperature at atmospheric pressure due to
compression with the discharge stroke of the possibly
ignitable vapour-air mixture.
– Do not allow it to run dry. Take appropriate protec‐
tive measures.
–Immediately switch off the pump in the event of a
diaphragm rupture.
WARNING!
Risk of fire with flammable feed chemicals
– Combustible media may only be transported using
stainless steel or Hastelloy C dosing heads.
– Metering pumps can be used for metering combus‐
tible media, however as a matter of principle only of
a design including ATEX diaphragm rupture sensors
and a pressure-side flow control.
– During filling and draining of the liquid end, an
expert must ensure that feed chemical does not
come into contact with air.
– If necessary, the operator must implement further
measures.
WARNING!
ATEX pumps in areas at risk from explosion
– Make sure that a suitably competent person checks
whether the appropriate installation information from
the "Installation " chapter has been implemented
correctly.
–Make sure that a "recognised competent person"
checks the electrical installation and in particular the
intrinsically safe power circuits.
– Set the opening pressure of the relief valve at a
maximum of no more than 1.5 times the rated pres‐
sure of the pump.
WARNING!
ATEX pumps in areas at risk from explosion
If feed chemicals are metered, which tend to produce
exothermic reactions or self-ignite (examples of exo‐
thermic reactions: pyrophoric substances with air, alkali
metal with water, decomposition of organic peroxides,
polymerisation reactions), they can lead to high tempera‐
tures and ignition.
– Put in place measures in accordance with EN
80079-38.
WARNING!
ATEX pumps in areas at risk from explosion
If abrasive media are being metered, they will escape as
soon as all layers of the diaphragm have eroded
through.
– Wire the electrical diaphragm rupture indicator to
stop the pump in the event of a diaphragm rupture.
Safety chapter
19

WARNING!
ATEX pumps in areas at risk from explosion
– Electrically wire all electrical units cleanly and per‐
manently to an electrically clean earthing point, -
e.g. with an earthing bar on your system.
–Electrically connect the electrical units fitted with a
potential equalisation cable to each other, cleanly
and permanently, to an electrically clean potential
equalisation point - e.g. with a potential equalisation
bar on your system.
– Note the enclosed documentation for the individual
electrical components.
WARNING!
ATEX pumps in areas at risk from explosion
– Use a suitable motor protection switch to protect
power end motors. Use motor protection approved
for this application with Ex"e" motors. (Protection
against warming caused by overloading)
– Provide a time-delay residual current device.
– Observe the enclosed operating instructions for the
Ex motor.
WARNING!
The following applies in areas at risk from explosion:
– Note the details of the type examination certificate
PTB 00 ATEX 2048 X for the Namur sensor
NJ1.5-8GM-N as well.
WARNING!
ATEX pumps in areas at risk from explosion
– Make sure that a suitably competent person checks
whether the appropriate installation information from
the "Installation " chapter has been implemented
correctly.
–Make sure that a "recognised competent person"
checks the electrical installation and in particular the
intrinsically safe power circuits.
– Set the opening pressure of the relief valve to a
maximum of no more than 1.5 times the nominal
pressure of the pump.
Safety chapter
20