ProMinent Sigma / 2 Basic Type SBKa User manual

Piston Metering Pump
Sigma / 2 Basic Type SBKa
Operating instructions
P_SI_0135_SW
Original operating instructions (2006/42/EC)Part no. 984863 BA SI 059 11/13 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.
Supplementary information
Fig. 1: Please read!
Validity
State the identity code and serial number
Supplemental instructions
2

Table of contents
1Identity code.................................................................................... 4
2 Safety chapter................................................................................. 6
3 Storage, transport and unpacking................................................. 11
4 Overview of equipment and control elements............................... 12
5 Functional description.................................................................... 14
5.1 Drive unit............................................................................... 14
5.2 Liquid End............................................................................. 14
6 Assembly....................................................................................... 15
7Installation..................................................................................... 17
7.1 Installation, hydraulic............................................................. 17
7.2 Installation, electrical............................................................. 20
8 Start up.......................................................................................... 24
9 Maintenance.................................................................................. 26
10 Repairs.......................................................................................... 30
10.1 Cleaning double ball valves................................................ 31
10.2 Changing the piston............................................................ 32
11 Troubleshooting............................................................................. 36
12 Decommissioning.......................................................................... 38
13 Technical data............................................................................... 40
13.1 Performance data................................................................ 40
13.2 Shipping weight................................................................... 41
13.3 Viscosity.............................................................................. 41
13.4 Wetted materials................................................................. 42
13.5 Ambient conditions.............................................................. 42
13.5.1 Ambient temperatures...................................................... 42
13.5.2 Media temperatures......................................................... 42
13.5.3 Air humidity...................................................................... 42
13.6 Motor data........................................................................... 42
13.7 Stroke sensor "Sigma"........................................................ 43
13.8 Relay................................................................................... 43
13.9 Gear oil................................................................................ 44
13.10 Sound pressure level........................................................ 44
13.11 Supplementary information for modified versions............. 44
14 Diagrams for adjusting the capacity.............................................. 45
15 Dimensional drawings................................................................... 46
16 Exploded drawing Sigma piston metering pump........................... 47
17 Sigma/ 2 piston ordering information............................................. 48
18 EC Declaration of Conformity for Machinery................................. 49
19 EC Declaration of Conformity for Machinery Used in Areas at
Risk of Explosion........................................................................... 50
Table of contents
3

1 Identity code
SBKa Sigma 2 Basic Type
HK Main power end, piston
Type: Capacity
_ _ _ _
_
Performance data at maximum back pressure and type: refer to nameplate on the pump
housing
Dosing head material
SS Stainless steel
Seal material
T PTFE
Displacement body
4 Piston (oxide ceramic)
Dosing head design
0 no valve springs
1 with 2 valve springs, Hastelloy C; 0.1 bar
Hydraulic connector
0 Standard threaded connector (in line with technical data)
Design
0With ProMinent® logo (standard)
1Without ProMinent® logo
M Modified* * order-related design, refer to
order paperwork for pump
features
Electric power supply
_ Connection data - see motor nameplate
1 No motor, with B14 flange, size 71 (DIN)
2 No motor, with C 56 flange (NEMA)
3 No motor, with B 5, size 63 (DIN)
4 No motor, with B 5, size 71 (DIN)
5 No motor, with B14 flange, size 80 (DIN)
Degree of protection
0 IP 55 (standard)
1 Exe design ATEX-T3
2 Exd version ATEX-T4
Stroke sensor
0 No stroke sensor (standard)
2 Pacing relay (reed relay)
3 Stroke sensor (Namur) for haz‐
ardous locations
Stroke length adjustment
0 Manual (standard)
1 With servomotor, 230 V,
50/60 Hz
Identity code
4

SBKa Sigma 2 Basic Type
2 With servomotor, 115 V,
50/60 Hz
3 With control motor 0...20 mA
230 V, 50/60 Hz
4 With control motor 4...20 mA
230 V, 50/60 Hz
5 With control motor 0...20 mA
115 V, 50/60 Hz
6 With control motor 4...20 mA
115 V, 50/60 Hz
Identity code
5

2 Safety chapter
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.
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 – hand injuries.
Warning – high-voltage.
Warning – hot surface.
Warning – danger zone.
nOnly use the pump to meter liquid metering chemicals.
nIn potentially explosive atmospheres in zone 1, device category II 2G,
explosion group II C, only operate the pump with the appropriate
nameplate (and the respective EC Declaration of Conformity) for
pumps for use in areas at risk of explosion in compliance with Direc‐
tive 94/9/EC in accordance with the European guidelines. The explo‐
sion 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.
nOnly start up the pump after it has been correctly installed and com‐
missioned in accordance with the technical data and specifications
contained in the operating instructions.
Identification of safety notes
Warning signs denoting different types of
danger
Intended use
Safety chapter
6

nObserve the general limitations with regard to viscosity limits, chem‐
ical resistance and density - see also ProMinent Resistance List (in
the Product Catalogue or at www.prominent.com/en/downloads)!
nAll other uses or modifications are prohibited.
nNever operate pumps without the relevant nameplate (and the respec‐
tive EC Declaration of Conformity) for pumps for use in atmospheres
at risk from explosion in atmospheres potentially at risk from explo‐
sion.
nThe pump is not intended for the metering of gaseous media or solids.
nThe pump is not intended for the metering of flammable feed chemi‐
cals.
nThe pump is not intended to meter explosive substances and mix‐
tures.
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.
nObserve the information contained in the operating instructions at the
different phases of the device's service life.
Action Qualification
Storage, transport, unpacking Instructed person
Assembly Technical personnel, service
Planning hydraulic installation Qualified personnel who have a
thorough knowledge of oscillating
diaphragm pumps.
Hydraulic installation Technical personnel, service
Installation, electrical Electrical technician
Operation Instructed person
Maintenance, repair Technical personnel, service
Decommissioning, disposal Technical personnel, service
Troubleshooting Technical personnel, electrical
technician, instructed person,
service
Explanation of the terms:
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/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 employment in the relevant work area.
Electrical technician
Electrical technicians are deemed to be people, who are able to complete
work on electrical systems and recognise and avoid possible dangers
independently based on their technical training and experience, as well as
knowledge of pertinent standards and regulations.
Electrical technicians should be specifically trained for the working envi‐
ronment in which they are employed and know the relevant standards and
regulations.
Electrical technicians must comply with the provisions of the applicable
statutory directives on accident prevention.
Instructed person
Qualification of personnel
Safety chapter
7

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.
WARNING!
– 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 "recognisably trained" skilled opera‐
tive. This applies specifically to intrinsically safe elec‐
trical 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 notes
Safety chapter
8

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/en/down‐
loads.
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.
WARNING!
– Attach the following safety note to pumps that contain
parts made of electrically non-conductive 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
All isolating protective equipment must be installed for operation:
Safety equipment
Isolating protective equipment
Safety chapter
9

nDrive front cover
nMotor fan cowling
nTerminal box cover, motor
nProtective cover - see figure.
P_SI_0146_SW
Fig. 3: Protective cover, two-section (*)
Only remove them when the operating instructions request you to do so.
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.
Sound pressure level LpA < 70 dB according to EN ISO 20361
at maximum stroke length, maximum stroke rate, maximum back pressure
(water)
Information in the event of an emergency
Safety information relating to the operating
instructions
Sound pressure level
Safety chapter
10

3 Storage, transport and unpacking
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/en/downloads.
WARNING!
Slings can tear
ProMinent only supplies non-reusable slings. These can tear
with repeated use.
– Only use the slings once.
CAUTION!
Danger of material damage
The device can be damaged by 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 when the red gear bleeding plug
is pushed in.
– 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.
Compare the delivery note with the scope of supply:
Personnel: nTechnical personnel
1. Plug the caps on the valves.
2. Check if the red gear bleeding plug is pushed in.
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 notes
Scope of supply
Storage
Storage, transport and unpacking
11

4 Overview of equipment and control elements
P_SI_0140_SW
1
2
4
5
3
Fig. 4: Overview of equipment and control elements SBKa
1 Liquid end
2 Drive motor
3 Gear bleeding plug
4 Drive unit
5 Stroke length adjustment knob
75 % 50 %
Fig. 5: Adjusting the stroke length
n100 % = 10 rotations
n10 % = 1 rotation
n0.2 % = 1 scale mark on stroke adjustment dial
Overview of equipment and control elements
12

PG11
PG9
1 23
A B
P_SI_0036
Fig. 6: Front cover for version with pacing relay
A Pacing relay cable
B Supply voltage cable for pacing relay PCB
Overview of equipment and control elements
13

5 Functional description
5.1 Drive unit
The metering pump is an oscillating diaphragm pump, the stroke length of
which can be adjusted. An electric motor drives the pump.
5.2 Liquid End
The heart of the liquid end is a highly resistant piston (4) made from
coated stainless steel. The suction valve (1) closes as soon as the piston
(4) is moved in to the dosing head and the feed chemical flows through the
discharge valve (3) out of the dosing head. As soon as the piston moves in
the opposite direction, the discharge valve (3) closes due to the negative
pressure in the dosing head and fresh feed chemical flows through the
suction valve (1) into the dosing head.
Use the flushing collar (6) to flush the sealing surface of the piston.
P_SI_0144_SW
3
2
7
4
6
5
1
Fig. 7: Cross-section through the liquid end
1 Suction valve
2 Dosing head
3 Discharge valve
4 Piston
5 Packing collar
6 Flushing collar
7 Flushing connector
Functional description
14

6 Assembly
Compare the dimensions on the dimension sheet and pump.
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.
Capacity too low
Vibrations can disrupt the liquid end valves.
– The supporting floor must not vibrate.
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.
Position the pump so that control elements such as the stroke length
adjustment knob or the indicating dial A are easily accessible.
1 Discharge 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.
Base
h
P_MOZ_0016_SW
Fig. 8
Space requirement
A
A
P_MOZ_0018_SW
Fig. 9
1
3
2
f
f
f
P_MOZ_0017_SW
Fig. 10
Assembly
15

Capacity too low
The liquid end valves cannot close correctly if they are not
upright.
– Ensure that the discharge valve is upright.
Capacity too low
Vibrations can disrupt the liquid end valves.
– Secure the metering pump so that no vibrations can
occur.
Take the dimensions (m) for the fastening holes from the appropriate
dimensional drawings or data sheets.
Fix the pump base to the base with suitable screws.
Liquid end alignment
Fastening
DNm
m
P_MOZ_0015_SW
Fig. 11
Assembly
16

7 Installation
CAUTION!
Danger of injury to personnel and material damage
Disregarding the technical data when installing may lead to
personal injuries or damage to property.
– Observe the technical data- refer to chapter "Technical
Data" and, where applicable, the operating instructions
of the accessories.
7.1 Installation, hydraulic
WARNING!
EX pumps in areas at risk from explosion
– Metering pumps in areas at risk from explosion are as a
matter of course provided with a suitable safety relief
valve on the outlet side of the metering pump (which is
used to protect against excessive heating due to over‐
loading and impact sparks caused by the breakage of
power end parts triggered by overloading).
–Piston metering pumps are designed for applications in
temperature class T3. Pumps are suitable for T4 with an
additional flow control on the outlet side (to protect it
from excess temperature following running dry) or a suit‐
able temperature monitor.
– In the event of differing temperature classes amongst
the diverse components, operation of the complete
pumps should be based on the component with the
lowest temperature class.
– Ensure that installations in areas at risk from explosion
are checked by a "recognisably trained" skilled opera‐
tive.
– Please note the relevant national regulations during
installation!
WARNING!
Warning of feed chemical reactions to water
Feed chemicals that should not come into contact with water
may react to residual water in the liquid end that may origi‐
nate from works testing.
– Blow the liquid end dry with compressed air through the
suction connector.
– Then flush the liquid end with a suitable medium through
the suction connector.
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.
Installation
17

CAUTION!
Warning of feed chemical spraying around
PTFE seals, which have already been used / compressed,
can no longer reliably seal a hydraulic connection.
– New, unused PTFE seals must always be used.
CAUTION!
Suction problems possible
The valves may no longer close properly using feed chemi‐
cals with a particle size of greater than 0.3 mm.
– Install a suitable filter in the suction line.
CAUTION!
Warning against the discharge line bursting
With a closed discharge line (e.g. due to a clogged discharge
line or by closing a valve), the pressure that the metering
pump generates can reach several times the permissible
pressure of the system or the metering pump. This could
lead to lines bursting, resulting in dangerous consequences
with aggressive or toxic feed chemicals.
– Install a relief valve that limits the pressure of the pump
to the maximum permissible operating pressure of the
system.
CAUTION!
Uncontrolled flow of feed chemical
Feed chemicals can leak through a stopped metering pump if
there is back pressure.
– Use an injection valve or a vacuum breaker.
CAUTION!
Uncontrolled flow of feed chemical
Feed chemical can leak through the metering pump in an
uncontrolled manner in the event of excessive priming pres‐
sure on the suction side of the metering pump.
– Do not exceed the maximum permissible priming pres‐
sure for the metering pump.
– Configure the installation correctly for this purpose.
CAUTION!
Warning of backflow
Liquid ends, foot valves, back pressure valves, relief valves
or spring-loaded injection valves do not constitute absolutely
leak-tight sealing elements.
– Use a shut-off valve, a solenoid valve or a vacuum
breaker for this purpose.
Installation
18

P_MAZ_0001_SW
2
1
Fig. 12: Standard installation
1 Main line
2 Storage tank
Symbol Explanation Symbol Explanation
Injection valve
Multifunctional valve Manometer
Relief valve (alterna‐
tively a multifunction
valve can be used)
Metering pump
Level switch Foot valve with filter
meshes
CAUTION!
If you do not connect any flushing equipment, then you must
ensure that no dust and no foreign bodies can enter through
the top hose nozzles!
Otherwise this may result in damage to the liquid end. For
example, fit a sealing stopper (order no. 359585).
The leakage liquid is drained off via the flushing collar and a hose nozzle,
without other parts of the liquid end coming into contact with the medium.
1. Connect a hose to the lower hose nozzle.
2. Route the hose into a collection vessel for the leakage liquid.
CAUTION!
– A flushing equipment must be connected when using
very aggressive or toxic media or when using media with
a poor lubricating effect.
–The flushing agent must be compatible with the feed
chemical and the wetted materials of the liquid end.
– The flushing medium pressure must not exceed 0.5 bar.
Connect the flushing equipment to the hose nozzles via two hoses.
Standard installation
Symbols for the components
Route the leakage liquid drainage line
Connecting the flushing equipment
Installation
19

7.2 Installation, electrical
WARNING!
EX pump in area at risk from explosion
– Potential-free switches can be evaluated as simple elec‐
trical devices (EN 60079-14 or EN 50020).
–Only connect potential-free as well as non-isolating low
voltage switch accessories, such as diaphragm rupture
indicators, stroke frequency instruments etc., to an
intrinsically safe power circuit in areas at risk from explo‐
sion.
– If several electrical components are connected together,
test and confirm the technical safety of the entire con‐
nected system. This can either be in the form of a decla‐
ration of conformity from the supplier (ProMinent) for the
entire unit or, with the supply of individual components,
with the operator's explosion protection document.
– Only motor protection switches, mains switches and
fuses permitted for use in areas at risk from explosion in
line with the manufacturer's information may be used as
electrical components in areas at risk from explosion.
– Note the enclosed documentation for the individual elec‐
trical components.
WARNING!
Danger of electric shock
Unprofessional installation may lead to electric shocks.
– Cable end sleeves must be crimped onto all cut-to-
length cable conductors.
–Only technically trained personnel are authorised to
undertake the electrical installation of the device.
WARNING!
Danger of electric shock
In the event of an electrical accident, it must be possible to
quickly disconnect the pump, and any electrical ancillaries
which may possibly be present, from the mains.
– Install an emergency cut-off switch in the mains supply
line to the pump and any electrical ancillaries which may
be present or
–Integrate the pump and electrical ancillaries which may
be present in the emergency cut-off management of the
system and inform personnel of the isolating option.
WARNING!
Danger of electric shock
This pump is equipped with a protective earth conductor, to
reduce the risk arising from an electric shock.
– Connect the PE conductor to "earth" with a clean and
permanent electrical connection.
Installation
20