ProMinent Sigma 1 Basic User manual

Diaphragm motor-driven metering pump
Sigma/ 1 Basic type S1Ba
Operating instructions
P_SI_0039
EN
Original operating instructions (2006/42/EC)Part no. 985911 BA SI 084 12/18 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 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.
Supplementary information
Fig. 1: Please read!
Validity
State the identity code and serial number
Supplemental directives
2

Table of contents
1Identity code.................................................................................... 5
2 Safety chapter................................................................................. 7
2.1 Safety information for ATEX designs.................................... 13
2.2 Explanation of the ATEX label.............................................. 21
3 Storage, Transport and Unpacking................................................ 24
4Overview of equipment and control elements............................... 25
5 Functional description.................................................................... 27
5.1 Pump..................................................................................... 27
5.2 Liquid end.............................................................................. 27
5.3 Integral relief valve................................................................ 27
5.4 Multi-layer safety diaphragm................................................. 28
6 Assembly....................................................................................... 29
7 Installation, hydraulic..................................................................... 32
7.1 Basic installation notes.......................................................... 36
8 Installation, electrical..................................................................... 37
9 Start up.......................................................................................... 44
10 During operation............................................................................ 48
11 Maintenance.................................................................................. 49
12 Carrying out repairs....................................................................... 53
12.1 Cleaning valves................................................................... 54
12.2 Replacing the diaphragm.................................................... 55
13 Troubleshooting............................................................................. 59
14 Decommissioning.......................................................................... 62
15 Technical data............................................................................... 65
15.1 Performance data................................................................ 65
15.2 Shipping weight................................................................... 66
15.3 Wetted materials................................................................. 67
15.4 Ambient conditions.............................................................. 67
15.4.1 Ambient temperatures...................................................... 67
15.4.2 Media temperatures......................................................... 67
15.4.3 Air humidity...................................................................... 68
15.5 Installation height................................................................ 68
15.6 Motor data........................................................................... 68
15.7 Stroke actuator.................................................................... 69
15.8 Stroke control drive............................................................. 69
15.9 Diaphragm rupture sensor.................................................. 69
15.10 Stroke sensor "Sigma"...................................................... 70
15.11 Relay................................................................................. 71
15.12 Sound pressure level........................................................ 71
15.13 Supplementary information for modified versions............. 71
16 Diagrams for adjusting the capacity.............................................. 72
17 Dimensional drawings................................................................... 74
18 Potential equalisation drawings for Sigma Basic Type.................. 80
19 Motor data sheet standard motor.................................................. 81
20 Exploded drawings Sigma/ 1......................................................... 82
21 Wear parts for Sigma/ 1................................................................. 91
21.1 Standard.............................................................................. 91
21.2 Physiological safety............................................................. 92
22 Declaration of Conformity for Machinery....................................... 94
Table of contents
3

23 Declaration of Incorporation for Machinery.................................... 95
24 Declaration of Conformity for Machinery ATEX............................. 96
25 Declaration of Conformity for ATEX Machinery............................. 97
26 Index.............................................................................................. 98
Table of contents
4

1 Identity code
S1Ba Sigma 1 Basic Type
H Main power end, diaphragm
Type: Capacity
_ _ _ _
_ _
Performance data at maximum back pressure and type: refer to nameplate on the pump
housing
Dosing head material
PV PVDF
SS Stainless steel
TT PTFE + carbon
Seal material
T PTFE seal
Displacement body
S Multi-layer safety diaphragm with optical rupture indicator
A Multi-layer safety diaphragm with diaphragm rupture signalling (contact)
H Diaphragm for hygienic pump head
Dosing head design
0 no valve springs
1 with 2 valve springs, Hastelloy C; 0.1 bar
4 ** with relief valve, FPM seal, no valve springs
5 ** with relief valve, FPM seal, with valve springs
6 ** with relief valve, EPDM seal, no valve spring
7 ** with relief valve, EPDM seal, with valve springs
H Hygienic pump head with tri-clamp connectors (max. 10 bar)
Hydraulic connector
0 Standard threaded connector (in line with technical data)
1 Union nut and PVC insert
2 Union nut and PP insert
3 Union nut and PVDF insert
4 Union nut and SS insert
7 Union nut and PVDF hose nozzle
8 Union nut and SS hose nozzle
9 Union nut and SS welding sleeve
Design
0with ProMinent® logo (standard)
1without ProMinent® logo
F Physiological safety with
regard to wetted mate‐
rials
FDA No. 21 CFR §177.1550
(PTFE)
FDA No. 21 CFR §177.2510
(PVDF)
M Modified* * order-related design, refer to
order paperwork for pump
features
Identity code
5

S1Ba Sigma 1 Basic Type
5 Left liquid end
Electric power supply
_ Connection data - see motor nameplate
G Without gear motor
2 No motor, with C 42 flange (NEMA)
3 No motor, with B 5, size 56 (DIN)
Degree of protection
0 IP 55 (standard)
1 Exe design ATEX-T3 ***
2 Exd design ATEX-T4 ***
G Without gear motor
A ATEX design of power end
Stroke sensor
0 No stroke sensor (standard)
2 Pacing relay (reed relay)
3 Stroke sensor (Namur) for areas at
risk from explosion
Stroke length adjustment
0 Manual (standard)
1 With servomotor, 230 V,
50/60 Hz
2 With servomotor, 115 V,
50/60 Hz
3 With stroke control motor
0...20 mA 230 V, 50/60 Hz
4 With stroke control motor
4...20 mA 230 V, 50/60 Hz
5 With stroke control motor
0...20 mA 115 V, 50/60 Hz
6 With stroke control motor
4...20 mA 115 V, 50/60 Hz
FPM = fluorine rubber
** Standard with tube nozzle in the bypass. Threaded connection on
request.
*** ATEX specification - refer to the EU Declaration of Conformity for
Machinery EX
Identity code
6

2 Safety chapter
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.
The following signal words are used in these operating instructions to
denote different severities of danger:
Signal word Meaning
WARNING Denotes a possibly dangerous sit‐
uation. If this is disregarded, you
are in a life-threatening situation
and this can result in serious inju‐
ries.
CAUTION Denotes a possibly dangerous sit‐
uation. 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 instructions to
denote different types of danger:
Warning signs Type of danger
Warning – high-voltage.
Warning – danger zone.
nOnly use the pump to meter liquid feed chemicals.
nOnly pumps with the identity code option "Multi-layer safety diaphragm
with visual rupture display" and "Multi-layer safety diaphragm with rup‐
ture signalling (contact)" are approved for use with flammable feed
chemicals with electrically conductive dosing heads, at back pres‐
sures of over 2 bar and only if the operator takes appropriate safety
measures.
nOnly pumps with the design "F - Physiologically safe with regard to
wetted materials" are approved for use in physiologically harmless
applications.
nOnly “H - Hygienic head” design pumps may be used for applications
in accordance with the hygienic requirements of the EHEDG
(www.ededg.org).
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.
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.
Identification of safety notes
Warning signs denoting different types of
danger
Intended use
Safety chapter
7

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 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.
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.
nATEX designs only: Refer to the chapter "
Ä Chapter 2.1 ‘Safety infor‐
mation for ATEX designs’ on page 13 ".
Task Qualification
Storage, transport, unpacking Instructed person
Assembly Technical personnel, service
Planning the hydraulic installation Qualified personnel who have a
thorough knowledge of oscillating
diaphragm 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.
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.
Qualification of personnel
Safety chapter
8

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
The Service department refers to service technicians, who have received
proven training and have been authorised by ProMinent to work on the
system.
Ignition hazard Protective measures to be observed by the customer
Excessive surface pressure Limitation of the maximum temperature of the feed chem‐
ical
Too low ambient temperature Limitation of the minimum ambient temperature
Pump running hot The customer must monitor and maintain the pump in
accordance with the “Maintenance” chapter.
The customer must fit a relief valve on the discharge side.
Mechanically generated sparks from the mechanism with
low oil
The customer must monitor and maintain the pump in
accordance with the “Maintenance” chapter.
Mechanically generated sparks from a faulty valve The customer must monitor the capacity.
Electrical stray current in the event of a short circuit The customer must earth the pump and maintain the
earthing of the individual components.
Electrical stray current in the event of a lightning strike The customer must put in place suitable protective meas‐
ures outdoors.
Static electricity The customer must earth the earthing points and maintain
the potential equalisation cables of the individual compo‐
nents.
The customer must pay attention to potential equalisation
when dismantling.
Paint should not be applied too thickly.
Only clean plastic parts with a damp cloth.
Provide a temperature monitor on the dosing head with
feed chemical with critical friction properties.
The customer must wire the diaphragm rupture indicator in
such a way that it immediately stops the pump.
Electromagnetic waves (also lasers), ionising radiation
and ultrasound 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 Feed chemical with electrical conductivity of < 50 pS/m,
which could form a combustible mixture: 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.
Deposits of dust Regularly clean the outside of the pump with a damp
cloth.
Summary of relevant ignition hazards and
protective measures put in place for the
Sigma in accordance with EN ISO
80079-36
Safety chapter
9

Ignition hazard Protective measures to be observed by the customer
Flammable feed chemicals Only material version SS or TT is permitted to pump flam‐
mable feed chemicals.
Do not allow it to run dry.
The operator must install suitable protective measures, for
example a flow meter.
The 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 means of a motor protec‐
tion 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 caused by bought-in proximity switch
NJ1.5-8GM-N (stroke sensor)
Refer to the documentation for the proximity switch (elec‐
trical installation, maintenance, ...).
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
10