ProMinent Hydro/4 User manual

Metering pump
Hydro/ 4, HP4a
Operating instructions
Original Operating Instructions (2006/42/EC)984728 BA HY 013 03/14 EN
Please carefully read these operating instructions before use! · Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
Technical changes reserved.

Read the following supplementary information in its entirety! Should you
already know this information, you will benefit more from referring to the
operating instructions.
The following are highlighted separately in the document:
nEnumerated lists
Operating guidelines
ðOutcome of the operating guidelines
- see (reference)
Information
This provides important information relating to the correct
operation of the unit or is intended to make your work easier.
Safety notes
Safety notes are identified by pictograms - see Safety Chapter.
These operating instructions conform to current EU regulations applicable
at the time of publication.
Please state identity code and serial number, which you can find on the
nameplate when you contact us or order spare parts. This enables the
device type and material versions to be clearly identified.
The nameplate stuck on the cover page is identical with the pump supplied
so that a clear assignment is given between the operating instructions and
the pump.
Supplementary information
Fig. 1: Please read!
Validity
State the identity code and serial number
EX pumps only
Supplemental instructions
2

Table of contents
1 Identity code.................................................................................... 5
2Safety chapter................................................................................. 7
3 Storage, transport and unpacking................................................. 14
4 Overview of device / control elements........................................... 16
5 Functional description.................................................................... 17
6 Assembly....................................................................................... 18
7 Installation..................................................................................... 22
7.1 Installation, hydraulic............................................................. 22
7.1.1 Basic installation notes....................................................... 25
7.2 Installation, Electrical............................................................ 27
8 Start up ......................................................................................... 34
8.1 Bleeding the liquid end.......................................................... 37
8.2 Calibrate the stroke control drive (Option)............................ 38
9 Maintenance.................................................................................. 39
10 Repairs.......................................................................................... 44
10.1 Replacing the diaphragm.................................................... 45
10.2 Repair the diaphragm rupture sensor................................. 49
10.3 Calibrating the dosing rate.................................................. 51
11 Troubleshooting............................................................................. 53
12 Decommissioning and Disposal.................................................... 56
12.1 Decommissioning................................................................ 56
12.2 Disposal.............................................................................. 57
13 Technical data............................................................................... 59
13.1 Performance data................................................................ 59
13.2 Dosing precision.................................................................. 61
13.2.1 Reproducibility.................................................................. 61
13.3 Viscosity.............................................................................. 61
13.4 Weight................................................................................. 61
13.5 Wetted materials................................................................. 62
13.6 Ambient conditions.............................................................. 62
13.6.1 Temperatures................................................................... 62
13.6.2 Air humidity...................................................................... 64
13.7 Housing degree of protection.............................................. 64
13.8 Motor data........................................................................... 65
13.9 Diaphragm rupture sensor.................................................. 65
13.10 Pressure limitation valve (HP4)......................................... 66
13.11 Pressure switch (for signalling an overpressure).............. 66
13.12 Stroke sensor.................................................................... 67
13.13 Heating cartridge............................................................... 68
13.14 Protective temperature limiter........................................... 68
13.15 Gear oil.............................................................................. 68
13.16 Sound pressure level HP4a.............................................. 68
13.17 Supplement for modified versions..................................... 69
14 Ordering Information...................................................................... 70
14.1 Exploded view of the drawing............................................. 70
14.2 Spare parts kits................................................................... 70
14.3 Diaphragms......................................................................... 72
14.4 Pressure relief valves.......................................................... 72
14.5 Pressure switch................................................................... 72
14.6 General............................................................................... 73
15 Dimensions sheets........................................................................ 74
Table of contents
3

16 EC Declaration of Conformity for Machinery................................. 87
Table of contents
4

1 Identity code
HP4a Hydro/ 4, 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 *
Dosing head material
SS Stainless steel
PV PVDF
HC Hastelloy C
PC
T
PVC
Seal material
T PTFE
Displacement
0 Standard multi-layer safety diaphragm with rupture signalling
Dosing head version
0 No valve spring (standard)
1 With valve spring
Hydraulic connector
0 Standard threaded connector (in line with technical data)
E With DIN ISO flange
F With ANSI flange
Version
0With ProMinent® logo (standard)
1Without ProMinent® logo
M Modified* * order-related version, for pump features see order
paperwork
Electric power supply
S 3 ph, 230 V/400 V 50/60 Hz, 1.1 kW
L 3 ph, 230 V/400 V, 50 Hz, (Exe, Exde), 1.1 kW
P 3 ph, 265 V/440 V, 60 Hz, (Exe, Exde), 1.1 kW
R 3 ph, variable speed motor, 230/400 V, 1.5 kW
V(0) Variable speed motor with integrated Frequency converter 1 ph,
230 V, 50/60 Hz
V(2) Variable speed motor with integrated Frequency converter (Exd)
Z Speed control complete 1 ph, 230 V, 50/60 Hz (control motor + fre‐
quency converter)
Identity code
5

HP4a Hydro/ 4, version a
3 No motor, with B 5 flange, size 80 (DIN)
4 No motor, with C 56 flange (NEMA)
0 Add-on power end
Degree of protection
0 IP 55 (Standard) ISO class F
1 Exe version ATEX-T3
2 Exde version ATEX-T4
A ATEX power end
Stroke sensor
0 No stroke sensor (standard)
1 Stroke sensor (EX zone capable)
Stroke length adjustment
0 Manual (standard)
1 With servomotor, 230 V, 50/60 Hz
2 With servomotor, 115 V, 60 Hz
A With control motor 0...20 mA 230 V, 50/60 Hz
B With control motor 4...20 mA 230 V, 50/60 Hz
C With control motor 0...20 mA 115 V, 60 Hz
D With control motor 4...20 mA 115 V, 60 Hz
Hydraulic oil
0 Standard
1 Food approval for oil
2 Low temperature to -25 ℃
* Type, power (at 50 Hz)
Type Performance Type Performance Type Performance Type Performance
bar l/h bar l/h bar l/h bar l/h
250130 25 130 160210 16 210 025019 10 330 070465 7 465
250190 25 190 160300 16 300 025040 10 480 070670 7 670
250250 25 250 160400 16 400 025048 10 635 070890 7 890
250350 25 350 160400 16 550 025060 10 880 071230 7 1230
250400 25 400 160625 16 625 025068 10 1000 071400 7 1400
Identity code
6

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.
nIn potentially explosive atmospheres only operate the pump with the
appropriate nameplate for pumps for use in areas at risk of explosion
in compliance with Directive 94/9/EC in accordance with the European
guidelines.
The explosion group, category and degree of protection specified on
the label should correspond to or be better than the conditions given
in the intended field of application.
nThe pump is only approved for use with flammable feed chemicals if it
has the identity code option "Multi-layer safety diaphragm with visual
rupture display", is operated at back pressures over 2 bar with metal
liquid ends and if the operator implements appropriate safety meas‐
ures.
nOnly use the pump after it has been correctly installed and started up
in accordance with the technical data and specifications contained in
the operating instructions. When working at temperatures 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.
Explanation of the safety information
Warning signs denoting different types of
danger
Intended use
Safety chapter
7

nPumps without the relevant nameplate (and the respective EC Decla‐
ration of Conformity) for pumps for potentially explosive atmospheres
must never be operated in potentially explosive atmospheres.
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 ATEX version is not intended for the metering of electrically non-
conductive media (conductivity less than 50 pS/m).
nThe ATEX version must not be exposed to any ionising radiation,
electromagnetic high frequency radiation in the range 104 ... 3x1015 Hz
or ultrasound without measures according to EN 1127-1.
nThe pump is not intended for unprotected outside use.
nThe pump is only intended for industrial use.
nThe pump should only be operated by trained and authorised per‐
sonnel, see the following table.
nYou are obliged to observe the information contained in the operating
instructions at the different phases of the device's service life.
nYou are obliged to observe the information contained in the operating
instructions of the accessory devices at the different phases of their
respective service lives.
Task Qualification
Storage, transport, unpacking Instructed person
Assembly Technical personnel, service
Planning hydraulic installation Qualified personnel who have a
thorough knowledge of metering
pumps.
In the area at risk from explosion:
ATEX qualified person, ATEX elec‐
trical technician
Hydraulic installation Technical personnel, service
Installation, electrical Electrical technician,
In the area at risk from explosion:
ATEX electrical technician
Start up Qualified personnel
In the area at risk from explosion:
Qualified personnel with ATEX
training; checking of the electrical
installation: recognised competent
person
Operation Instructed person
Maintenance, repair Technical personnel, service
Decommissioning, disposal Technical personnel, service
Troubleshooting Qualified person, electrical techni‐
cian, instructed person, customer
service - dependent on the require‐
ment
In the area at risk from explosion:
ATEX electrical technician;
checking of the electrical installa‐
tion: recognised competent person
Explanation of the table:
Qualified personnel
Qualification of personnel
Safety chapter
8

A qualified employee is deemed to be a person who is able to assess the
tasks assigned to him and recognise possible dangers based on his/her
technical training, knowledge and experience, as well as knowledge of
pertinent regulations.
Note:
A qualification of equal validity to a technical qualification can also be
gained by several years of employment in the relevant field of work.
Electrical technician
An electrical technician is able to complete work on electrical systems and
recognise and avoid possible dangers independently based on their tech‐
nical training and experience, as well as knowledge of pertinent standards
and regulations.
The electrical technician should be specifically trained for the working
environment in which they are employed and know the relevant standards
and regulations.
An electrical technician must comply with the provisions of the applicable
statutory directives on accident prevention.
A qualification of equal validity to a technical qualification can also be
gained by several years of employment in the relevant field of work.
ATEX explosion protection electrical technician
The electrical technician with an additional explosion protection qualifica‐
tion should be specifically trained for the work area in which they are
employed and know the relevant standards and regulations. The electrical
technician with an additional explosion protection qualification can work on
electrical systems and independently recognise and avoid possible dan‐
gers based on their 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].
The electrical technician with an additional explosion protection qualifica‐
tion 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
na comparable technical qualification or
nanother technical qualification combined with long-term experience of
safety technology.
The person must be knowledgeable in respect of the relevant body of
standards and regulations and have worked in the area for at least one
year. Participation in options for exchanging experience is required.
Particular requirements are made in respect of competent persons who
carry out tests on repaired devices/parts. They must be recognised in this
respect by the responsible authorities (e.g. the district council).
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.
Service
Customer Service department refers to service technicians, who have
received proven training and have been authorised by ProMinent or Pro‐
Maqua to work on the system.
Safety chapter
9

CAUTION!
These operating instructions include notes and quotes from
German guidelines relating to the system operator's scope of
responsibility. This information does not discharge the oper‐
ator from his responsibility as an operator and is intended
only to remind him or make him aware of specific problem
areas. This information does not lay claim to being complete,
nor applicable to every country and every type of application,
nor to being unconditionally up-to-date.
WARNING!
Only use ATEX pumps in the area at risk from explosion
– Observe the European Operator Directive 99/92/EC
(ATEX 137), implemented in Germany by the Industrial
Health and Safety Regulation and the German Ordi‐
nance on Hazardous Substances, for the installation and
operation of equipment in areas at risk from explosion.
– Observe the European standards EN 1127-1, EN
60079-10, EN 60079-14, EN 60079-17 and EN
60079-25 and EN 50039 for inherently safe electrical cir‐
cuits. (In Germany these standards are partly imple‐
mented by VDE 0165 and VDE 0118).
– Adhere to the respective national regulations outside of
the EU.
– Ensure that installations in areas at risk from explosion
are checked by a "recognised competent" person. This
applies specifically to intrinsically safe circuits.
– The following information relates essentially to the
unique characteristics in areas at risk from explosion but
does not replace the standard operating instructions.
– Only clean plastic parts carefully with a damp cloth to
avoid electrostatic charges and sparks.
WARNING!
Warning of dangerous or unknown feed chemical
Should a dangerous or unknown feed chemical be used: It
may escape from the hydraulic components when working
on the pump.
– Take appropriate protective measures before working on
the pump (e.g. safety glasses, safety gloves, ...).
Observe the safety data sheet for the feed chemical.
– Drain and flush the liquid end before working on the
pump.
WARNING!
Danger from hazardous substances!
Possible consequence: Fatal or very serious injuries.
Please ensure when handling hazardous substances that
you have read the latest safety data sheets provided by the
manufacture of the hazardous substance. The actions
required are described in the safety data sheet. Check the
safety data sheet regularly and replace, if necessary, as the
hazard potential of a substance can be re-evaluated at any
time based on new findings.
The system operator is responsible for ensuring that these
safety data sheets are available and that they are kept up to
date, as well as for producing an associated hazard assess‐
ment for the workstations affected.
Safety information
Safety chapter
10

CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic components if
they are manipulated or opened due to pressure in the liquid
end and adjacent parts of the system.
– Disconnect the pump from the mains power supply and
ensure that it cannot be switched on again by unauthor‐
ised persons.
– Depressurise the system before commencing any work
on hydraulic parts.
CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical can damage the parts of the
pump that come into contact with the chemical.
– Take into account the resistance of the wetted materials
when selecting the feed chemical - see the ProMinent
product catalogue or visit www.prominent.com.
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, Heidel‐
berg.
WARNING!
Adjusted pressure switches fail
– The switching point of the 42 V pressure switch must not
be changed.
– The ATEX pressure switch must not be reprogrammed.
It could result in overheating of the pump.
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in personnel
injuries and material damage.
– Only fit parts to metering pumps, which have been
tested and recommended by ProMinent.
CAUTION!
Danger from incorrectly operated or inadequately maintained
pumps
Danger can arise from a poorly accessible pump due to
incorrect operation and poor maintenance.
– Ensure that the pump is accessible at all times.
– Adhere to the maintenance intervals.
Safety chapter
11

In the event of an electrical accident, disconnect the mains cable from the
mains or press the emergency cut-off switch fitted on the side of the
system!
If feed chemical escapes, also depressurise the hydraulic system around
the pump as necessary. Adhere to the safety data sheet for the feed
chemical.
Prior to commissioning the system or system component, the system oper‐
ator is obliged to obtain the latest safety data sheet from the supplier for
the chemicals / resources to be used with the system. The operator should
create the legal framework for safe operation of the system or system
component, such as for example the preparation of operating instructions
(operator duties), based on the information provided in the data sheets
concerning health and safety, water and environmental protection and
taking into consideration the actual operating environment on site.
During use of the pump all such parts should be secured in their position.
Protective equipment May only be removed by*:
Protective cowling above the motor
fan
Service
Terminal box cover, motor Electrical technician, ATEX elec‐
trical technician, customer service
Flange cover, side Service
Only with add-on power end: Motor
connection cover
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.
WARNING!
– The following safety note must be stuck to pumps that
contain parts made of electrically non-conducting plastic.
–Ensure that the label is always fitted and legible.
WARNING
Electrostatic charge may
cause an explosion!
Clean plastic parts very
carefully using a damp cloth!
Fig. 2: @
The operator must be able to:
nfor ATEX motors: perform an ignition hazard assessment
nperform a risk assessment
ncreate and attach a nameplate
ncreate an EC Declaration of Conformity
nadapt the operating instructions, if necessary
ncorrectly install the motor
Information in the event of an emergency
Safety information relating to the operating
instructions
Safety equipment
Fixed, isolating protective equipment
Other safety equipment - ATEX
Requirements, if the motor is being
installed independently
Safety chapter
12

Sound pressure level LpA < 75 dB according to EN ISO 20361
at maximum stroke length, maximum stroke rate, maximum back pressure
(water)
Sound pressure level
Safety chapter
13

3 Storage, transport and unpacking
WARNING!
The transporting of pumps which have been used with radio‐
active feed chemicals is forbidden!
They will also not be accepted by ProMinent!
WARNING!
Only return the metering pump for repair in a cleaned state
and with a flushed liquid end - refer to the chapter "Decom‐
missioning"!
Only return metering pumps with a completed Decontamina‐
tion Declaration form. The Decontamination Declaration con‐
stitutes an integral part of an inspection / repair order. A unit
can only be inspected or repaired when a Declaration of
Decontamination Form is submitted 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 at
www.prominent.com.
CAUTION!
Danger of environmental and material damage
The unit can be damaged or oil may escape due to incorrect
or improper storage or transportation!
– The unit should only be stored or transported in a well
packaged state - preferably in its original packaging.
– Only transport the unit with the locking screw - not the
bleed plug - fitted to the oil filling opening.
–The packaged unit should also only be stored or trans‐
ported in accordance with the stipulated storage condi‐
tions.
– The packaged unit should be protected from moisture
and the ingress of chemicals.
CAUTION!
Danger of environmental damage
Pumps with a liquid end are supplied filled with oil.
– When transporting, take care that no oil can escape.
Personnel: nTechnical personnel
1. Plug the caps on the valves.
2. Check whether the sealing screw is in place on the oil filler neck.
3. Preferably place the pump standing vertically on a pallet and secure
against falling over.
4. Cover the pump with a tarpaulin cover - allowing rear ventilation.
Store the pump in a dry, sealed place under the ambient conditions
according to chapter "Technical Data".
Safety information
Storage
Storage, transport and unpacking
14

- refer to "Technical Data" chapter.Ambient conditions
Storage, transport and unpacking
15

4 Overview of device / control elements
A
A B B B C C C
21
2
21
1
4
56 7 P_HY_0043_SW
4
558 6
9
33
9
Fig. 3: Single head and double head version, Hydro/ 4
A Power end
B Hydraulic end
C Liquid End
1 Stroke adjustment dial
2 Bleed valve
3 Oil inspection window
4 Gear bleeding plug
5 Oil drain stopper
6 Oil drainage plug
7 Stroke sensor (optional)
8 Diaphragm rupture sensor
P_HY_0042_SW
1
4
5
3
2
Fig. 4: Liquid end Hydro/ 4
1 Discharge valve
2 Diaphragm mounting plate
3 Diaphragm rupture sensor
4 Suction valve
5 Dosing head
Overview of device / control elements
16

5 Functional description
The metering pump is an oscillating diaphragm pump, the stroke length of
which can be adjusted.
The hydraulic end has a bleed valve (2), a fixed pressure limitation valve
(3) and optionally an overpressure signaller (1). The bleed valve (2) con‐
tinuously bleeds the hydraulic end. The pressure limitation valve (3) pro‐
vides protection for the pump power end and the diaphragm if the liquid
feed pressure becomes too high. If the discharge side of the liquid end is
blocked, the pressure limitation valve (3) opens at a pre-set pressure and
allows the hydraulic oil to flow into the power end housing.
This does not guarantee protection of the system against overpressure! A
relief valve should nevertheless be fitted in the case of the ATEX pump!
Above a heightened overpressure, the overpressure signaller (1) switches.
1
3
2
P_HY_0034_SW
Fig. 5: Overview of hydraulic end HP4
Pump
Hydraulic end
Functional description
17

6 Assembly
–
Compare the dimensions on the dimensions sheet and
pump.
1. Select a suitable motor - it must correspond to the data of one of the
motors from the table "Motor data" - see Chapter "Technical data"
WARNING!
In an area at risk from explosion, EX applies to
selected equipment and methods!
2. Fit the motor correctly on the flange (qualified personnel).
Observe the clutch operating instructions!
WARNING!
In an area at risk from explosion, EX applies to
selected equipment and methods!
With a dog clutch: The claw on the motor shaft must be fixed at the
correct height, see Fig.
Ä ‘Motor installation - for versions without a
motor’ on page 18
3. As you have converted an "incomplete machine" into a complete
machine, you must perform a conformity assessment, risk assess‐
ment, create an EC Declaration of Conformity, fit a company name‐
plate, ... .For ATEX pumps: additionally perform an ignition hazard
assessment
4. Complete the pump documentation / operating instructions.
Motor installation - for versions without a
motor
Assembly
18

QQ
P_HY_0060_SW
Fig. 6: Correct heigh of the clutch claw on the motor shaft
Size Motor flange Q
143 / 145TC 2-1/8"
53.975
100 B5 / 250 60
WARNING!
Danger of electric shock
If water or other electrically conducting liquids penetrate into
the drive housing, in any other manner than via the pump's
suction connection, an electric shock may occur.
– Position the pump so that it cannot be flooded.
WARNING!
The pump can break through the base or slide off it
– Ensure that the base is horizontal, smooth and perma‐
nently load-bearing.
Dosing rate too low
Vibrations can disrupt the liquid end valves.
– The supporting floor must not vibrate.
Supporting floor
h
P_MOZ_0016_SW
Fig. 7
Assembly
19

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.
CAUTION!
Danger from incorrectly operated or inadequately maintained
pumps
Danger can arise from a poorly accessible pump due to
incorrect operation and poor maintenance.
– Ensure that the pump is accessible at all times.
– Adhere to the maintenance intervals.
WARNING!
Risk of burns with hot feed chemicals
If hot feed chemicals can heat the liquid ends above the per‐
missible surface temperatures, persons can suffer burns
from them.
– Avoid contact.
– If necessary, mount a guard plate.
Install the pump so that control elements, such as the stroke length adjust‐
ment knob, the indicating dial A or the oil inspection window, are acces‐
sible.
In so doing, ensure there is enough space to carry out an oil change (vent
screws, oil drainage plugs, oil trough ...).
1Discharge valve
2 Dosing head
3 Suction valve
Ensure that there is sufficient free space (f) around the dosing head, as
well as the suction and discharge valve, so that maintenance and repair
work can easily be carried out on these components.
Dosing rate too low
The liquid end valves cannot close correctly if they are not
upright.
– Ensure that the discharge valve is upright.
Space requirement
A
A
P_MOZ_0018_SW
Fig. 8
1
3
2
f
f
f
P_MOZ_0017_SW
Fig. 9
Liquid end alignment
Assembly
20