ProMinent Orlita Evolution User manual

Hydraulic diaphragm liquid ends with PTFE dia‐
phragm
Orlita® Evolution
Operating instructions
Serial no. .............................
These operating instructions form part of an operating manual and are only valid if used in conjunction with the documents
in this operating manual.
EN
983747 BA ORL 007 06/16 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.

Table of contents
1Safety.................................................................................... 3
2 Storage, Transport and Unpacking..................................... 10
2.1 Safety information....................................................... 10
2.2 Transport.................................................................... 10
2.3 Storage....................................................................... 13
2.4 Preservation................................................................ 13
3 Functional Description of Liquid End Components............. 15
4Installation, Hydraulic.......................................................... 16
4.1 Basic installation notes............................................... 19
5 Installation, Electrical.......................................................... 21
6 Start Up............................................................................... 22
7 Maintenance....................................................................... 23
7.1 Inspections and Maintenance Points.......................... 25
7.2 Cleaning...................................................................... 28
7.3 Material Required / Equipment / Oil Change Require‐
ments.......................................................................... 28
7.4 Changing the hydraulic oil.......................................... 29
7.5 Changing Gear Oil in a Power End/Drive................... 33
8 Repairs................................................................................ 35
8.1 Dismantling the Diaphragm........................................ 35
8.2 Installing the Diaphragm............................................. 37
8.3 Dismantling the suction valve and discharge valve.... 40
8.4 Assembling the suction valve and discharge valve.... 42
8.5 Dismantling the Bleed Valve (356)............................. 43
8.6 Installing the Bleed Valve (356).................................. 43
8.7 Dismantling the Pressure Relief Valve (358).............. 44
8.8 Installing the Pressure Relief Valve (358)................... 44
9 Rectifying Faults on the Hydraulic Liquid Ends................... 45
10 Decommissioning and Disposal.......................................... 49
10.1 Decommissioning..................................................... 49
10.2 Disposal.................................................................... 50
11 Index................................................................................... 52
Table of contents
2

1 Safety
WARNING!
Observe the safety chapter and safety information in
the other documents, particularly in the "Operating
Instructions for the Drive Unit Orlita® Evolution".
Note the information on the "Technical Data Sheet" for
the pump.
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
disregarded, you are in a life-threatening situation
and this can result in serious injuries.
CAUTION Denotes a possibly hazardous situation. If this is
disregarded, it could result in slight or minor inju‐
ries or material damage.
The following warning signs are used in these operating instruc‐
tions to denote different types of danger:
Warning signs Type of danger
Warning – high-voltage.
Warning – hot surface.
Warning – danger zone.
nOnly use the hydraulic liquid end to meter or pump liquid feed
chemicals.
nOnly use the hydraulic liquid end after it has been correctly
installed and started up in accordance with the technical data
and specifications contained in the operating instructions.
nThe hydraulic liquid end is intended for metering flammable
media if the relevant information is observed.
nObserve the general limitations with regard to viscosity limits,
chemical resistance and density - see also the ProMinent
Resistance List (in the Product Catalogue or at www.promi‐
nent.com)!
nAll other uses or modifications are prohibited.
nNever use the hydraulic liquid end to meter media containing
sediment.
nNever use the hydraulic liquid end to meter explosive media
and explosive mixtures.
nNever use the hydraulic liquid end to meter radioactive media.
Explanation of the safety information
Warning signs denoting different
types of danger
Intended Use
Safety
3

nNever use the hydraulic liquid end to meter media that reacts
exothermically with hydraulic oil.
nThe ATEX design is not intended for the metering of electrically
non-conductive media (conductivity less than 50 pS/m).
nDo not expose the ATEX design to ionising radiation, electro‐
magnetic high frequency radiation within the range of 104 ...
3x1015 Hz or ultrasound without putting in place measures in
line with EN 1127-1.
nOnly allow trained and authorised personnel to operate the
pump - see the following table.
nYou have a responsibility to adhere to the information con‐
tained 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
Transport technical personnel
Storage, unpacking Instructed person
Assembly Technical personnel, Service
Planning the hydraulic installation Qualified personnel who have a thorough knowledge of oscillating
metering pumps
In areas at risk from explosion: ATEX qualified person, ATEX elec‐
trical technician
Hydraulic installation Technical personnel, Service
Electrical Installation Electrical technician,
In areas at risk from explosion: ATEX electrical technician
Start Up technical personnel
In areas 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
In areas at risk from explosion: ATEX qualified person, ATEX elec‐
trical technician
Decommissioning, disposal Technical personnel, Service
Troubleshooting Qualified person, electrical technician, instructed person, service -
depending on the requirement
In areas at risk from explosion: ATEX electrical technician; checking
of the electrical installation: recognised competent person
Explanation of the table:
technical personnel
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 technical training, knowledge and experience, as well
as knowledge of pertinent regulations.
Qualification of personnel
Safety
4

Qualified personnel who open the hydraulic components of the
pump have to be able to recognise sealing surfaces so that they do
not become scratched.
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 sys‐
tems and recognise and avoid possible dangers independently
based on his technical training and experience, as well as knowl‐
edge of pertinent standards and regulations.
The electrical technician should be specifically trained for the
working environment in which he is employed and be conversant
with the relevant standards and regulations.
Make sure that the electrical technician complies with the provi‐
sions 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.
Electrical technician with knowledge of ATEX explosion protection
The electrical 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 electrical technician with an additional explo‐
sion protection qualification can work on electrical systems and
independently recognise and avoid possible dangers based on his
technical training and experience.
The electrical technician with an additional explosion protection
qualification is familiar with all the standards and regulations appli‐
cable to explosion protection, in particular, but not however exclu‐
sively, with all parts of EN 60079 [Electrical equipment for areas at
risk of a gas explosion].
The electrical technician with an additional explosion protection
qualification must comply with the provisions of the applicable stat‐
utory 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 experi‐
ence of safety technology.
Make sure that the person is familiar with the relevant body of
standards and regulations and has worked in the area for at least
one year. The person needs to have opportunities for an exchange
of experience.
Specific requirements are placed on competent persons who per‐
form tests on repaired devices/parts. They have to be recognised
by the responsible authorities (e.g. district council) in this respect.
Instructed person
Safety
5

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.
Service
The Service department 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 opera‐
tor'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 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 areas at risk from explosion
– Note the relevant regulations for the installation
and operation of equipment in areas at risk from
explosion.
– Note the regulations governing intrinsically safe
power circuits.
– Adhere to the respective national regulations out‐
side of the EU.
– Ensure that installations in areas at risk from explo‐
sion are checked by a "recognised competent"
person. This applies specifically to intrinsically safe
power circuits.
– Only clean the pump outside of / in the absence of
explosive atmospheres.
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.
Safety Information
Safety
6

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 pro‐
vided 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 sub‐
stance 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 associ‐
ated 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 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.
–Depressurise the system before commencing any
work on hydraulic parts.
CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical can damage the wetted
parts of the pump.
– Take into account the resistance of the wetted
materials when selecting the feed chemical - see
the ProMinent Product Catalogue or visit our
homepage.
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
7

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.
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
responsibility 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 pro‐
tection, and taking into consideration the actual operating environ‐
ment 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).
When using the hydraulic liquid end, all these parts have to be per‐
manently fixed in place.
Protective equipment May only be removed by*:
Turret cover Technical personnel, Service
Liquid end oil inspection window Technical personnel, 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. Make sure
that all protective equipment is refitted during operation.
Safety equipment May only be removed by*:
Oil inspection window via bleed valve Technical personnel, Service
Only in areas at risk from explosion: Vent screw with
filter
Qualified employee, electrical technician, ATEX
electrical technician, Service
Diaphragm rupture indicator Qualified employee, electrical technician, ATEX
electrical technician, Service
Information in the event of an emer‐
gency
Safety information for operating
instructions
Safety equipment
Fixed, isolating protective equipment
Additional safety equipment
Safety
8

Safety equipment May only be removed by*:
"Hot surface" label -
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. Make sure
that all protective equipment is refitted during operation.
Small amounts of hydraulic oil can evaporate out of the vent
screws. We recommend that you slightly ventilate the installation
site.
Hydraulic oil or feed chemical can escape from the hydraulic end in
the event of specific faults, damage, neglected maintenance,
during commissioning and during maintenance and repair work.
Other emissions
Safety
9

2 Storage, Transport and Unpacking
2.1 Safety information
WARNING!
Only return the metering pump for repair in a cleaned
state and with a flushed liquid end - refer to the
chapter "Decommissioning"!
Only return metering pumps with a completed Decon‐
tamination Declaration form. The Decontamination
Declaration constitutes an integral part of an inspec‐
tion / 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
transported in accordance with the stipulated
storage conditions.
– The packaged unit should be protected from mois‐
ture and the ingress of chemicals.
CAUTION!
Danger of environmental damage
The pumps are supplied filled with oil.
– When transporting, take care that no oil escapes.
2.2 Transport
WARNING!
Only lift the pump as shown in
Ä further information on page 10 or .
Only remove the pump from the crane hook once it is
firmly connected to the base.
Replace the vent screws with the sealing stoppers.
Storage, Transport and Unpacking
10

Weight - refer to the "Evolution Data Sheet".
A. B.
C. D.
P_PZ_0018_SW
Fig. 1: Position of slings EF1a and EF2a
A. Single pump with motor
B. Single pump without motor
C. Single pump with motor
D. Single pump without motor
Storage, Transport and Unpacking
11

A. B.
C. D.
P_PZ_0013_SW.svg
Fig. 2: Position of slings EF3a and EF4a
A. Single pump with motor
B. Single pump without motor
C. Single pump with motor
D. Single pump without motor
Storage, Transport and Unpacking
12

2.3 Storage
CAUTION!
If the pump has been stored for longer than 1 month,
then it also has to be preserved - see .
Preferably bolt the pump to the pallet supplied and prevent it
from toppling over.
Parameter Value
Constant storage and transport
temperature:
+1 … +50 °C
relative air humidity, non-con‐
densing:
> 95 %
Other requirements governing the storage location:
ndry
nwell ventilated
nvibration-free
nprotected against direct sunlight
2.4 Preservation
nIncrease the oil level in the drive unit to the upper edge of the
oil inspection window - but only to the upper edge!
Do not replace the vent screw with a stopper screw (tempera‐
ture-related pressure equalisation required).
nIncrease the oil level in the turrets only to the lower edge of the
cast reinforcing stays - only to the lower edge! - see
Do not replace the vent screw by a stopper screw (tempera‐
ture-related pressure equalisation required).
nFully clean and dry the dosing heads.
nSeal the valve connections with blank flanges, blanking plugs
or other suitable covers.
nDismantle the bleed valves and store in hydraulic oil.
nWith dismantled bleed valves: Move the stroke adjustment
mechanism 1x monthly from the smallest to the largest stroke
length and back again.
nWith dismantled bleed valves and 100% stroke length: Move
the motor shaft 1x monthly 25 revolutions - refer to the con‐
necting flange for the direction of rotation.
Ambient conditions
Stoppage of between 1 and 6 months
Storage, Transport and Unpacking
13

Fig. 3: Preservation oil level in the turrets
nDismantle the motor and store in accordance with the manu‐
facturer's instructions.
nSeal the pump motor flange.
nAfter 2 years: Change the oil on the drive unit and hydraulics.
Oil level - see
Ä ‘ Stoppage of between 1 and 6 months’
on page 13 .
nAfter 2 years: Replace the diaphragms and mesh.
nThe oil change intervals are not extended by the stoppage
time.
nLower the oil level of the drive unit and the turrets to the oper‐
ating level. Otherwise there will be no thermal cut-off with over‐
pressure operation!
nSpread assembly paste on the threads of the bleed valves
before screwing in - risk of corrosion!
nCheck that the sealing rings on the screw shaft, slide rod and
threaded shaft are working properly. Replace the sealing rings
if necessary.
Stoppage of more than 6 months
When re-commissioning
Storage, Transport and Unpacking
14

3 Functional Description of Liquid End Components
At each piston stroke, a bleed valve in the hydraulic end pumps a
small amount of hydraulic oil with isolated gas bubbles from the
discharge chamber into the hydraulic oil storage chamber, thereby
bleeding the discharge chamber.
With unacceptably high pressures, the pressure relief valve (358)
protects the metering pump Evolution from overloading. It does not
protect the system.
The diaphragm position control with supplementary leakage func‐
tion makes sure that the diaphragm returns again and again to the
neutral position.
The supplementary leakage function constantly supplements leaks
of hydraulic oil at the piston and bleed valve, thereby maintaining
the amount of hydraulic oil in the pressure chamber.
Bleed valve (356)
Pressure relief valve (358)
Diaphragm position control with sup‐
plementary leakage function
Functional Description of Liquid End Components
15

4 Installation, Hydraulic
WARNING!
ATEX pumps in areas at risk from explosion
– Metering pumps in areas at risk from explosion are
provided, as a matter of course, with an appro‐
priate 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
triggered by overloading.)
WARNING!
ATEX pumps in areas at risk from explosion
Static electricity can cause ignition sparks.
– Consider potential equalisation before you
approach any pump equipment that could be at a
different electrical potential (such as pipes or tools)
WARNING!
Danger of fire with flammable feed chemicals
– Combustible media may only be transported using
stainless steel dosing heads.
–Metering pumps can be used for metering flam‐
mable media, but fundamentally only those
designed with an ATEX diaphragm rupture sensor
and a discharge-side flow control, which both stop
the pump as soon as a diaphragm rupture or no
flow is detected.
– During filling and draining of the liquid end, an
expert must ensure that feed chemical does not
come into contact with oxygen.
– If necessary, the operator must implement further
measures.
WARNING!
The diaphragm rupture sensor can fail
If the back pressure for the diaphragm rupture sensor
is too low, it cannot trigger.
– Note the minimum necessary back pressure for the
diaphragm rupture sensor in its operating instruc‐
tions.
Installation, Hydraulic
16

WARNING!
The following measures are an advantage when
working with highly aggressive or hazardous feed
chemicals:
– Install a bleed valve with recirculation in the
storage tank.
–Install an additional shut-off valve on the discharge
or suction ends.
CAUTION!
Warning of backflow
A back pressure valve or a spring-loaded injection
valve do not represent absolutely leak-tight closing ele‐
ments.
– For this purpose use a shut-off valve, a solenoid
valve or a vacuum breaker.
CAUTION!
Warning of the discharge line rupturing
With a closed discharge line (e.g. due to a clogged dis‐
charge line or by closing a valve), the pressure that the
metering pump generates can reach several times
more than the permissible pressure of the system or
the metering pump. This could lead to lines bursting
resulting in dangerous consequences with aggressive
or hazardous feed chemicals.
– Install a relief valve that limits the pressure of the
pump to the maximum permissible operating pres‐
sure of the system.
CAUTION!
Warning of the discharge line rupturing
The pressure peaks can damage the pump and
system especially with single and double pumps.
– Check whether a pulsation damper needs to be
used.
CAUTION!
Warning of the discharge line rupturing
Lines with insufficient pressure rating can rupture.
– Only use lines with the required pressure rating.
CAUTION!
Uncontrolled flow of feed chemical
Feed chemical can press through a stopped metering
pump if there is back pressure.
– Use an injection valve or a vacuum breaker.
Installation, Hydraulic
17

CAUTION!
Uncontrolled flow of feed chemical
Feed chemical can press through the metering pump
in an uncontrolled manner in the event of excessive
priming pressure on the suction side of the metering
pump.
– Do not exceed the maximum permissible priming
pressure for the metering pump.
–Ensure that the back pressure is at least 1.5 bar
higher than the priming pressure.
– Set up the installation properly.
CAUTION!
Warning about lines coming loose
Unprofessionally installed suction and discharge lines
can work themselves loose from the pump connection.
– Always connect the lines without mechanical ten‐
sion.
CAUTION!
Danger due to incorrect use of the pressure relief valve
The pressure relief valve can only protect the motor
and the gear, and then only against impermissible
excess pressure caused by the metering pump itself. It
cannot protect the system from excess pressure.
– Use other mechanisms to protect the motor and
gear from impermissible excess pressure from the
system.
–Use other mechanisms to protect the system from
impermissible excess pressure.
CAUTION!
The diaphragm may be damaged
The diaphragm can be damaged by insufficient priming
pressure.
– Make sure that the priming pressure is a minimum
of 0.7 bar (absolute).
CAUTION!
Suction problems are possible
The metering diaphragms close extremely quickly with
feed chemicals with particles and impurities.
– Install a suitable filter in the suction line - see table
below.
Installation, Hydraulic
18

Recommended maximum mesh width of the filter
Nominal width of valve Maximum mesh width of filter
[mm]
6 0.1
10 0.15
16 0.2
20 0.25
25 0.25
32 0.3
40 0.3
50 0.3
65 0.3
A discharge-side flow control can help to avoid prob‐
lems.
–
Precise metering is only possible when the back
pressure is maintained above 1 bar at all times.
– If metering at atmospheric pressure, a back pres‐
sure valve should be used to create a back pres‐
sure of approx. 1.5 bar.
4.1 Basic installation notes
CAUTION!
Danger resulting from rupturing hydraulic components
Hydraulic components can rupture if the maximum per‐
missible operating pressure is exceeded.
– Never allow the metering pump to run against a
closed shut-off device.
–With metering pumps without integral relief valve:
Install a relief valve in the discharge line.
CAUTION!
Hazardous feed chemicals can escape
With hazardous feed chemicals: Hazardous feed
chemical can leak out when using conventional
bleeding procedures with metering pumps.
– Install a bleed line with a return into the storage
tank.
Shorten the return line so that it does not dip into the feed
chemical in the storage tank.
Safety notes
Installation, Hydraulic
19

P_MOZ_0043_SW
2
1
A) B)
*
PD
1
2
Fig. 4: (A) standard installation, (B) with pulsation damper
1 Main line
2 Storage tank
Symbol Explanation Symbol Explanation
Metering pump Foot valve with filter meshes
Injection valve Level switch
Multifunctional valve Manometer
Legend for hydraulic diagram
Installation, Hydraulic
20