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