Operating instructions Diaphragm Motor-Driven Metering Pump Sigma/ Control Type S1Ca PK_2_001 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 Part no 985902 Original Operating Instructions (2006/42/EC) BA SI 038 05/11 EN ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5-11 69123 Heidelberg Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-617 email: info@prominent.com Internet: www.prominent.com 3245432324324, 1, en_GB © 2011 Table of contents Table of contents Identity code S1Ca Safety chapter Storage, transport and unpacking 11 Overview of equipment and control elements 13 Functional description 15 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 Drive unit Liquid end Integral relief valve Multi-layer safety diaphragm Operating modes Functions Options Function and fault Indicator LCD screen LED indicators Hierarchy of operating modes, functions and fault sta‐ tuses 15 16 16 17 18 19 19 20 20 20 20 Assembly 21 Installation 23 7.1 Installation, hydraulic 7.2 Installation, electrical 7.2.1 Control connectors 7.2.2 Pump, power supply 7.2.3 Other units Adjustment 37 8.1 Basic principles of pump adjustment 8.2 Checking adjustable values 8.3 Changing to adjustment mode 8.4 Operating mode selection (MODE menu) 8.5 Operating mode settings (SET menu) 8.5.1 "Manual" operating mode settings 8.5.2 "Analog" operating mode settings (ANALG menu) 8.5.3 "Contact" operating mode settings (CNTCT menu) 8.5.4 "Batch" operating mode settings (BATCH menu) 8.6 Programmable function settings (SET menu ) 8.6.1 “Calibrate” function settings (CALIB menu) 8.6.2 “Auxiliary frequency” function settings (AUX menu) 8.6.3 “Flow” function settings (FLOW menu) 8.7 Setting the code (CODE menu) 8.8 Deleting the total number of strokes or total litres (CLEAR window) 23 27 27 36 36 37 38 38 39 40 40 40 43 45 45 46 47 47 47 48 Operation 49 9.1 Manual operation 49 9.2 Remote operation 51 10 Maintenance 52 11 Repairs 54 11.1 Cleaning valves 54 11.2 Replacing the metering diaphragm 56 12 Troubleshooting 60 12.1 Faults without a fault alert 60 12.2 Faults with error message 61 12.2.1 Fault alerts 61 Table of contents 12.2.2 Warning Alerts 62 12.3 All Other Faults 62 13 Decommissioning 63 14 Technical data 65 14.1 Performance data 14.2 Shipping weight 14.3 Wetted materials 14.4 Ambient conditions 14.4.1 Ambient temperatures 14.4.2 Media temperatures 14.4.3 Air humidity 14.4.4 Degree of Protection and Safety Requirements 14.5 Electrical connection 14.6 Diaphragm rupture sensor 14.7 Relay 14.8 Sound pressure level 65 65 66 66 66 66 67 67 67 68 68 69 15 EC Declaration of Conformity 70 16 Decontamination declaration 71 17 Operating / adjustment overview 72 18 Continuous displays 74 19 Index 75 Identity code S1Ca Identity code S1Ca S1Ca Sigma 1, Control Type, Version a Product range S1C a Drive types H Main power end, diaphragm Type Performance bar l/h 12017 10* 20 12035 10* 42 10050 10 50 10022 10 26 10044 10 53 07065 65 07042 50 04084 101 04120 120 Dosing head material PV PVDF SS Stainless steel Seal material T PTFE Displacement S Multi-layer safety diaphragm with optical break indicator A Multi-layer safety diaphragm with rupture signalling with “pump stops” func‐ tion B Multi-layer safety diaphragm with rupture signalling with “pump emits alarm” function H Diaphragm for hygienic pump head (upon request) Dosing head version no valve springs with valve springs, Hastelloy C; 0.1 bar (standard for DN 32) 4** with relief valve, FPM seal, no valve spring 5** with relief valve, FPM seal with valve springs (standard for DN 32) 6** with relief valve, EPDM seal, no valve springs 7** with relief valve, EPM seal, with valve springs (standard for DN 32) H Hygienic pump head with tri-clamp connectors (max 10 bar) (upon request) Hydraulic connector Standard threaded connector (in line with technical data) Union nut and PVC insert Identity code S1Ca S1Ca Sigma 1, Control Type, Version a Union nut and PP insert Union nut and PVDF insert Union nut and SS insert Union nut and PVDF hose nozzle Union nut and SS hose nozzle Union nut and stainless steel welding sleeve Version With ProMinent® Logo Without ProMinent® Logo Electric power supply U ph, 100-230 V, ±10 %, 50/60 Hz Cable and plug A m European B m Swiss C m Australian D m USA Relay No relay Fault indicating relay N/C 1x changeover contact 230 V- A Fault indicating relay magnetic 1x changeover contact 230 V- A as + pacing relay 2x N/O 24 V 100 mA as + pacing relay 2x N/O 24 V 100 mA A Cut-off and warning relays N/C 2x N/ O 24 V - 100 mA C 4-20 mA output = stroke length x-fre‐ quency, 1x fault indicating relay N/O 24 V - 100 mA F Power relay N/C 1x changeover contact 230 V- A Control versions Manual + external with pulse control Man + external + pulse con‐ trol + analog as + process timer as + process timer R*** As + PROFIBUS® interface, M12 C*** As + CANopen Access code Identity code S1Ca S1Ca Sigma 1, Control Type, Version a no access code with access code As + message in the event of a manual stop As + message in the event of a manual stop Dosing monitor Input with pulse evaluation Stroke length adjustment Manual C Manual + calibration FPM = fluorine rubber * for SST = 12 bar ** Standard with tube nozzle in the bypass Threaded connection on request *** With the options PROFIBUS® and CANopen no relay can be selected Safety chapter Safety chapter Explanation of the safety information Warning signs denoting different types of danger 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 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 hazardous 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 Correct and proper use n n n n n n n n n n n The pump may only be used to dose liquid metering chemicals Only SST design pumps may be used with combustible feed chemi‐ cals The pump may only be started up after it has been correctly installed and commissioned in accordance with the technical data and specifi‐ cations contained in the operating instructions The general limitations with regard to viscosity limits, chemical resist‐ ance and density must be observed - see also ProMinent resistance list (In the product catalogue or at www.prominent.com)! Any other uses or modifications are prohibited The pump is not intended for the metering of gaseous media or solids The pump is not intended for operation in hazardous locations The pump is not intended for exterior applications without use of suit‐ able protective equipment The pump should only be operated by trained and authorised per‐ sonnel, see the following "Qualifications" table You are obliged to observe the information contained in the operating instructions at the different phases of the device's service life Safety chapter Safety information WARNING! Warning of hazardous or unknown feed chemical Should a hazardous 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 (protective eyewear, protective gloves, ) Read the safety data sheet on the feed chemical Drain and flush the liquid end before working on the pump 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 contacted by the chemical – Take into account the resistance of the material con‐ tacted by the chemical when selecting the feed chemical - refer to the ProMinent ® resistance list in the product equipment catalogue or at www.prominent.com CAUTION! Danger of personal and material damage The use of untested third party parts can result in damage to personnel and material damage – Only fit parts to dosing 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 CAUTION! Warning of illegal operation Observe the regulations that apply where the unit is to be installed Safety chapter Information in the event of an emergency 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 Qualification of personnel Activity Qualification level Storage, transport, unpacking Instructed person Assembly, installation of hydraulic system 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 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 recognize 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 the 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 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 Customer Service department 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 Sound pressure level Sound pressure level LpA < 70 dB in accordance with EN ISO 20361:2010-10 at maximum stroke length, maximum stroke rate, maximum back pressure (water) 10 Troubleshooting Fault description Cause Remedy The red LED indicator illuminates, on the dis‐ play, the identifiers “Error” and “MEM” flash Stroke memory overflow has occurred Eliminate cause 12.2.2 Press [P] key - bear in mind the consequences for your process Warning Alerts Fault description Cause Remedy Green LED indicator illuminates The liquid level in the storage tank has reached "liquid level low 1st stage" Fill storage tank Green LED indicator illuminates and the identifier “Calib” flashes The pump is calibrated and the stroke length varies by Reset the stroke length or more than ±10 scale divisions from the value at the recalibrate the pump at the time of the calibration desired stroke length 12.3 All Other Faults Please contact the responsible ProMinent branch or representative! 62 Decommissioning 13 Decommissioning Decommissioning WARNING! Danger of an electric shock When working on the motor or electrical auxiliary equipment, there is a danger of an electric shock – – Before working on the motor, take note of the safety instructions in its operating instructions! Should external fans, servomotors or other auxiliary equipment be installed, these should also be discon‐ nected and checked that they are voltage free WARNING! Danger from chemical residues There is normally chemical residue in the liquid end and on the housing after operation This chemical residue could be hazardous to people – – It is mandatory that the safety information relating to the "Storage, Transport and Unpacking" chapter is read before shipping or transporting the unit Thoroughly clean the liquid end and the housing of chemicals and dirt Adhere to the safety data sheet for the feed chemical WARNING! Warning of hazardous or unknown feed chemical Should a hazardous 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 (protective eyewear, protective gloves, ) Read the safety data sheet on the feed chemical Drain and flush the liquid end before working on the pump 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 WARNING! Warning of eye injuries When opening the relief valve, a spring under high tension can jump out – Wear protective glasses 63 Decommissioning CAUTION! Danger of damage to the device The device can be damaged by incorrect and improper storage or transportation – (Temporary) decommissioning Personnel: Take into account the information in the "Storage, Trans‐ port and Unpacking" chapter if the system is decommis‐ sioned for a temporary period n Technical personnel Disconnect the pump from the mains power supply Depressurise and bleed the hydraulic system around the pump Empty the liquid end by turning the pump upside down and allowing the feed chemical to run out Flush the liquid end with a suitable medium - Observe the safety data sheet! Flush the dosing head thoroughly when using haz‐ ardous feed chemicals! Possible additional work - see chapter "Storage, Transport and Unpacking" Disposal Personnel: n Technical personnel CAUTION! Environmental hazard due to incorrect disposal – Note the local guidelines currently applicable in your country, particularly in regard to electronic waste! 64 Technical data 14 14.1 Technical data Performance data S1Ca Type Minimum pump capacity at maximum back pressure Maximum stroke rate Suction lift Permis‐ sible pri‐ ming pres‐ sure, suction side Connector size bar psi l/h gph Strokes/ ml/stroke m WS bar R"-DN 12017 PVT 12 174 20 88 3.9 3/4" - 10 12017 SST 12 174 20 88 3.9 3/4" - 10 12035 PVT 12 174 42 11 172 4.1 3/4" - 10 12035 SST 12 174 42 11 172 4.1 3/4" - 10 10050 PVT 10 145 49 13 200 4.1 3/4" - 10 10050 SST 10 145 49 13 200 4.1 3/4" - 10 10022 PVT 10 145 26 88 5.1 3/4" - 10 10022 SST 10 145 26 88 5.1 3/4" - 10 10044 PVT 10 145 53 14 172 5.1 3/4" - 10 10044 SST 10 145 53 14 172 5.1 3/4" - 10 07065 PVT 102 63 17 200 5.3 3/4" - 10 07065 SST 102 63 17 200 5.3 3/4" - 10 07042 PVT 102 50 13 88 9.6 1" - 15 07042 SST 102 50 13 88 9.6 1" - 15 04084 PVT 58 101 27 172 9.8 1" - 15 04084 SST 58 101 27 172 9.8 1" - 15 04120 PVT 58 117 31 200 9.8 1" - 15 04120 SST 58 117 31 200 9.8 1" - 15 All figures refer to water at 20 °C The suction lift applies to filled suction line and filled liquid end - when installed correctly Accuracies Data Value Unit Reproducibility ±2 % * * - when installed correctly, under constant conditions, at least 30 % stroke length and water at 20 °C 14.2 Shipping weight Types Material version Shipping weight kg 12017 07065 PVT 8.0 SST 11.0 65 Technical data Types Material version Shipping weight kg 07042 04129 14.3 PVT 8.5 SST 12.5 Wetted materials Material ver‐ sion Liquid end Suction/dis‐ charge con‐ nector Seals* / ball seat Balls Springs Integral relief valve PVT PVDF PVDF PTFE/PTFE Ceramic Hastelloy C PVDF / FPM or EPDM SST Stainless steel 1.4404 Stainless steel 1.4581 PTFE/PTFE Stainless steel 1.4404 Hastelloy C Stainless steel / FPM or EPDM * Metering diaphragm is PTFE coated 14.4 14.4.1 Ambient conditions Ambient temperatures Pump, compl 14.4.2 Value Unit Storage and transport temperature -10 +50 °C Ambient temperature in operation (drive + motor): -10 +40 °C Media temperatures PVT liquid end SST liquid end 66 Data Data Value Unit Max temperature long-term at max oper‐ ating pressure 65 °C Max temperature for 15 at max bar 100 °C Minimum temperature -10 °C Data Value Unit Max temperature long-term at max oper‐ ating pressure 90 °C Max temperature for 15 at max bar 120 °C Minimum temperature -10 °C Technical data 14.4.3 Air humidity Air humidity Data Value Unit Maximum air humidity *: 95 % rel humidity * non-condensing 14.4.4 Degree of Protection and Safety Requirements Degree of protection Protection against contact and humidity: IP 55 in accordance with IEC 529, EN 60529, DIN VDE 0470 Part Safety requirements Degree of protection: - Mains power connection with protective earth conductor 14.5 Electrical connection The electrical data not relate to the motor, but the pump, which is connected as a whole unit For the motor electrical data use the motor data sheet 1018455, 1018432, 1018433 in the appendix Electrical data S1Ca pump Identity code specification "power supply" - "U": 100 - 230 V ± 10 %, 50/60 Hz Electrical data at 100 V Data Value Unit Nominal power 130 W Nominal current 2.2 A Peak current during operation A Switch on peak current, (for approx 100 ms) A Electrical data at 230 V Data Value Unit Nominal power 130 W Nominal current 1.2 A Peak current during operation Switch on peak current, (for approx 100 ms) A 16 A Fuses Fuse Value Part no Fuse, internal 3.15 AT - (1.5 kV) 732414 67 Technical data Only use the original fuses from ProMinent! It is not sufficient to use a fuse with the above fuse rating 14.6 Diaphragm rupture sensor b) Reed switch (identity code specification "Stroke sensor": 2) Pin Allocation (white 4.5 V 24 V, max 10 mA (brown) OUT, open collector, 24 V, 20 mA (green) GND Data Value Unit Pulse width (low)* ≥4 ms * depending on the gear and mains frequency The polarity is unimportant b) Namur sensor (identity code specifica‐ tion "Stroke sensor": 3) 5–25 V DC, in accordance with Namur or DIN 60947-5-6, potential-free design Data Value Unit Nominal voltage * VDC Power consumption - active surface uncovered > mA Power consumption - active surface cov‐ ered < mA Rated switching distance 1.5 mm * Ri ~ kΩ 14.7 Cable colour Polarity blue - brown + Relay The technical data for the relay are contained in the chapter "Installation, electrical" 68 Technical data 14.8 Sound pressure level Sound pressure level Sound pressure level LpA < 70 dB in accordance with EN ISO 20361:2010-10 at maximum stroke length, maximum stroke rate, maximum back pressure (water) 69 EC Declaration of Conformity 15 EC Declaration of Conformity For pumps without explosion protection: EC Declaration of Conformity We hereby declare, ProMinent Dosiertechnik GmbH Im Schuhmachergewann - 11 D - 69123 Heidelberg that the following designated product complies with the pertinent fundamental safety and health requirements of the EC Directive in terms of its design and construction and in terms of the version marketed by us This declaration loses its validity in the event of a modification to the product not agreed with us 70 Description of the product: Metering pump, series Sigma Product type: S1Ba / S1Ca Serial no.: refer to nameplate on the device Pertinent EC Directives: EC Machinery Directive (2006/42/EC) EC Low Voltage Directive (2006/95/EC) EC EMC Directive (2004/108/EC) Applied harmonised standards in particular: EN ISO 12100-1, EN ISO 12100-2, EN 809, EN 60335-1, EN 60335-2-41, EN 60529, EN 61000-3-2, EN 61000-6-2 technical documents have been compiled by: Norbert Berger Im Schuhmachergewann 5-11 DE-69123 Heidelberg Date / Manufacturer - Signature : 04.01.2010 Details of the signatory: Joachim Schall, Head of Research and Development Decontamination declaration 16 Decontamination declaration 71 Operating / adjustment overview 17 Operating / adjustment overview Continuous display Stop/start pump = Lock (CODE 1) = Lock (CODE 2) Change directly changeable variables Prime Start batch (only in "Batch" operating mode) Acknowledge errors Check adjustable values P_SI_0040_SW 72 Operating / adjustment overview Calib Set Set Set P Set Set Calib Set Set Set P_SI_0039_SW 73 Continuous displays 18 Continuous displays Continuous displays Continuous display Operating mode "Analog" 20 mA "Manual" operating mode Operating mode "Contact" with memory and transfer factor "Batch" operating mode with memory Stroke rate Capacity Total number of strokes Total litres (metering quantity) "External" display Signal current Remaining strokes Batch size / Remaining litres Factor Stroke length B0100 = values which can be changed directly using the UP or DOWN arrow keys 74 B0101 B0102 B0103 Identifier "Mem" only in the event that function extension "Memory" is activated Index 19 Index " Discharge valve 16 "Analog" operating mode settings 40 Disposal 64 "Batch" operating mode settings 45 Dosing head 16 "Contact" operating mode settings 43 Dosing monitor 47 "External control" terminal 32 Drive motor 13 "Manual" operating mode settings 40 Drive unit 13, 15 1, 2, E - 20 mA 40 Electrical data 67 A Emergency 10 Accuracy 65 Emptying the liquid end 64 Adjustment 37 Explanation of the safety information Adjustment mode 38 External contact 20, 32 Air humidity 67 External frequency changeover 20 Ambient conditions 66 F Analog 18, 40 Factor 43 Assembly 21 Fault 20 Auxiliary frequency 19, 47 Fault indicating relay 19, 28, 29 Auxiliary rate 20, 32 Fault indicator 20 AUX menu 47 Fault processing 43 B Fault statuses 20 Basic principles of pump adjustment 37 Flow 19 Batch 18, 45 FLOW menu 47 BUS 18 Function 46, 47 C Functional description 15 CALIB menu 46 Function display 20 Calibration 19, 46 Functions 19, 20, 45 Capacity 65 H Changing a number 37 Hierarchy of operating modes 20 Changing individual numbers 37 I Changing to adjustment mode 38 Incorrectly set digits 38 check 38 Incremental changing of a value 37 Checking adjustable values 38 Information in the event of an emergency 10 Cleaning valves 54 Installation 23 CLEAR window 48 Integral relief valve 25 Climate 67 IP 67 Code setting 47 L Confirming an entry 37 Leakage hole 53 Connector size 65 Level switch 19 CONTACT 18, 43 Line 41 Control elements 13 Liquid end 13, 16 Correct 38 Lock 47 Correct and proper use Lower sideband 41, 42 Curve 40 M D Maintenance 52 Decommissioning 63 Manual 18, 20, 40 Decontamination declaration 11 Material 66 Degree of protection 67 Memory 45 delete 45, 48 MODE menu 19, 39 Deleting the total number of strokes or total litres 48 N Diaphragm 16 Namur sensor 68 Diaphragm rupture sensor 13, 68 75 Index O S Operating indicator 20 Safety chapter Operating mode 40, 43, 45 Safety requirements 67 Operating modes 18, 20 Scope of supply 11 Operating mode selection 39 SET menu 40, 45 Operating mode settings 40 Shipping weight 65 Options 19 Sound pressure level 10, 69 Output relay 30 Step-up 44 Overview of equipment 13 Stop 19, 20 P Storage 11 Pacing relay 19, 29 Storage and transport temperature 66 Pause 19, 20, 32 Stroke length adjustment wheel 13 Power relay 19 Suction lift 65 Power supply 36 Suction valve 16 Priming 19, 20 T Programmable function settings 45 Temperatures 66 Protect 47 Total litres 48 Protection against contact and humidity 67 Transport 11 Pump capacity 65 U Q Unpacking 11 Qualification of personnel 10 Upper sideband 41, 42 Quitting a menu point without confirming it 37 W R Warning indicator 20 Radioactive 11 Warning sign Reduction 44 Weight 65 Reed switch 68 Wetted materials 66 Relief valve 13, 25 “ Repairs 54 “Auxiliary frequency” function settings 47 Replacing the Diaphragm 56 “Calibrate” function settings 46 Replacing the metering diaphragm 56 “Flow” function settings 47 Reproducibility 65 76 ... Number of strokes (sequence) 1 2 25 25 99.99 99.99 1. 50 1. 50 (1 / 2) 1. 25 1. 25 (1 / / / 2) 1 0.50 0.50 10 0.50 10 0 0.50 0.50 2.5 (3 / 2) (1 / 1) 0.50 1. 33 (2 / / 1) (1 / / 1) Explanation of step-up... Main power end, diaphragm Type Performance bar l/h 12 017 10 * 20 12 035 10 * 42 10 050 10 50 10 022 10 26 10 044 10 53 07065 65 07042 50 04084 10 1 0 412 0 12 0 Dosing head material PV PVDF SS Stainless steel... 49 9 .1 Manual operation 49 9.2 Remote operation 51 10 Maintenance 52 11 Repairs 54 11 .1 Cleaning valves 54 11 .2 Replacing the metering diaphragm