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