ProMinent Hydro/4 HP4a Bedienungsanleitung

Metering pump

Hydro/ 4, HP4a

Operating instructions

Original operating instructions (2006/42/EC)984728 BA HY 019 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 Information

Safety information is identified by pictograms - see Safety Chapter.

Refer to the precise designation of suppliers' components in the "Technical

Data" chapter for ease of finding the relevant information.

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 unit

type and material versions to be clearly identified.

The nameplate stuck on the cover page is identical to the pump supplied

so that there is a clear link between the operating instructions and the

pump.

Supplementary information

Fig. 1: Please read!

Information in supplier instructions

Validity

State the identity code and serial number

EX pumps only

Supplemental directives

Table of contents

1Identity code.................................................................................... 5

2 Safety chapter................................................................................. 8

2.1 Safety information for ATEX designs.................................... 13

2.2 Explanation of the ATEX label.............................................. 25

3 Storage, transport and unpacking................................................. 28

4Overview of device / control elements........................................... 30

5 Functional description.................................................................... 31

6 Assembly....................................................................................... 32

7 Installation..................................................................................... 36

7.1 Installation, hydraulic............................................................. 36

7.1.1 Basic installation notes....................................................... 40

7.2 Installation, Electrical............................................................ 41

8 Start up and operation................................................................... 48

8.1 Bleeding the liquid end.......................................................... 51

8.2 Calibrate the stroke control drive (optional).......................... 52

9 Maintenance.................................................................................. 53

10 Repair............................................................................................ 59

10.1 Replacing the diaphragm.................................................... 60

10.2 Repairing the diaphragm rupture sensor............................. 64

10.3 Calibrating the dosing rate.................................................. 66

10.4 Replacing power end bearings............................................ 67

11 Troubleshooting............................................................................. 68

12 Decommissioning and disposal..................................................... 72

12.1 Decommissioning................................................................ 72

12.2 Disposal.............................................................................. 73

13 Technical data............................................................................... 75

13.1 Performance data................................................................ 75

13.2 Metering reproducibility....................................................... 76

13.3 Viscosity.............................................................................. 77

13.4 Weight................................................................................. 77

13.5 Wetted materials................................................................. 77

13.6 Ambient conditions.............................................................. 77

13.6.1 Temperatures................................................................... 77

13.6.2 Air humidity...................................................................... 79

13.6.3 Installation height............................................................. 79

13.7 Housing degree of protection.............................................. 80

13.8 Motor data........................................................................... 80

13.9 Diaphragm rupture sensor.................................................. 81

13.10 Pressure limitation valve (HP4)......................................... 82

13.11 Pressure switch (for signalling an overpressure).............. 82

13.12 Stroke sensor.................................................................... 82

13.13 Heating cartridge............................................................... 83

13.14 Filling volumes.................................................................. 83

13.14.1 Hydraulic oil.................................................................... 83

13.15 Sound pressure level HP4a.............................................. 83

13.16 Supplement for modified versions..................................... 84

14 Ordering information...................................................................... 85

14.1 Exploded view drawing....................................................... 85

14.2 Spare parts kits................................................................... 85

14.3 Diaphragms......................................................................... 87

14.4 Pressure relief valves.......................................................... 87

Table of contents

14.5 Pressure switch................................................................... 87

14.6 General............................................................................... 87

15 Dimensional drawings................................................................... 89

16 Earthing drawing.......................................................................... 102

17 EU Declaration of Conformity for Machinery............................... 103

18 EU Declaration of Incorporation for Machinery............................ 104

19 EU Declaration of Conformity for Machines ATEX HP4 without

heating cartridge.......................................................................... 105

20 EU Declaration of Conformity for Machines ATEX HP4 with

heating cartridge.......................................................................... 106

21 EC Declaration of Incorporation for Machines ATEX HP4 without

heating cartridge.......................................................................... 107

22 EC Declaration of Incorporation for Machines ATEX HP4 with

heating cartridge.......................................................................... 108

23 Diagrams for adjusting the capacity............................................ 109

Table of contents

1 Identity code

HP4a Hydro/ 4, version a

Power end type

H Main power end

D Main power end, double-head version

E Main power end for add-on power end

F Main power end, double-head version for add-on power end

A Duplex/Triplex add-on power end

B Add-on power end, double-head version

T Triplex main power end

V Triplex add-on power end

Capacity

_ _

Performance data at maximum back pressure and type: refer to nameplate on the pump housing

Dosing head material

SS Stainless steel

PV PVDF

HC Hastelloy C

PC PVC

PP PP

TT PTFE + 25% carbon

Seal material

T PTFE

Displacement body

0 Standard multi-layer safety diaphragm with rupture signalling

Dosing head design

0 no valve spring (standard)

1 With valve spring

Hydraulic connector

0 Standard threaded connector (in line with technical data)

E With DIN ISO flange

F With ANSI flange

Design

0with ProMinent® logo (standard)

1without ProMinent® logo

2with ProMinent® logo, with mechanical overpressure display

3with ProMinent® logo, with electrical overpressure display

M modified* ** order-related design, refer to order paperwork for

pump features

Electric power supply

Identity code

HP4a Hydro/ 4, version a

S 3-phase, 230 V/400 V 50/60 Hz, 1.1 kW

L 3-phase, 230 V/400 V, 50 Hz, (Exe, Exde), 1.1 kW

P 3-phase, 265 V/440 V, 60 Hz, (Exe, Exde), 1.1 kW

R 3-phase variable speed stroke control motor, 230/400 V, 1.5 kW

V(0) Variable speed motor with integrated Frequency converter 1-phase,

230 V, 50/60 Hz

V(2) Variable speed motor with integrated frequency converter (Exd)

Z Speed control complete 1-phase, 230 V, 50/60 Hz

1 No motor, with flange 250/100

3 No motor, with flange 200/90

4 no motor, with NEMA flange

0 Add-on power end

Degree of protection

0 IP 55 (standard) ISO class F

1 Exe design ATEX-T3 **

2 Exde design ATEX-T4 **

A ATEX power end **

Stroke sensor

0 No stroke sensor (standard)

1 Stroke sensor (suitable for use in areas at risk from explo‐

sion)

Stroke length adjustment

0 Manual (standard)

K Manual outdoor, SS

1 With servomotor, 230 V, 50/60 Hz

2 With servomotor, 115 V, 60 Hz

A With stroke control motor 0...20 mA 230 V, 50/60 Hz

B With stroke control motor 4...20 mA 230 V, 50/60 Hz

C With control motor 0...20 mA 115 V, 60 Hz

D With control motor 4...20 mA 115 V, 60 Hz

Hydraulic oil

0 Standard

1 Food approval for oil

2 Low temperature to -25 ℃

3 Low temperature Zone 2

* Maximum back pressure for TTT, PPT and PCT material versions: 10

bar!

Identity code

Tab. 1: * Type, power (at 50 Hz)

Type Capacity Type Capacity Type Capacity Type Capacity

bar l/h bar l/h bar l/h bar l/h

250130 251130 160210 161210 100330 10 330 070465 7 465

250190 251190 160300 161300 100480 10 480 070670 7 670

250250 251250 160400 161400 100635 10 635 070890 7 890

250350 251350 160400 161550 100800 10 880 071230 7 1230

250400 251400 160625 161625 101000 10 1000 071400 7 1400

1 Maximum back pressure for TTT, PPT and PCT material versions: 10

bar!

** ATEX specification - refer to the nameplate on the pump, corresponding

EU Declaration of Conformity for ATEX Machinery and

Ä Chapter 2.2

‘Explanation of the ATEX label’ on page 25

Identity code

2 Safety chapter

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 disre‐

garded, you are in a life-threatening situation and this

can result in serious injuries.

CAUTION Denotes a possibly hazardous situation. If this is disre‐

garded, it could result in slight or minor injuries or mate‐

rial 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 – flammable substances.

Warning – hot surface.

Warning – danger zone.

nOnly use the pump to meter liquid feed chemicals.

nThe pump is only approved for use with flammable feed chemicals if it

has the identity code option "Multi-layer safety diaphragm with visual

rupture display", is operated at back pressures of over 2 bar with

metal liquid ends and if the operator implements appropriate safety

measures.

nThe pump may only be used after it has been correctly installed and

started up in accordance with the technical data and specifications

contained in the operating instructions. When working at temperatures

arising using a heating cartridge, bear in mind their effect.

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.

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 explosive 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.

Explanation of the safety information

Warning signs denoting different types of

danger

Intended use

Safety chapter

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.

Task Qualification

Storage, transport, unpacking Instructed person

Assembly Technical personnel, service

Planning the hydraulic installation Qualified personnel who have a

thorough knowledge of oscillating

metering 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 recognize 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.

Electrical technician with knowledge of ATEX explosion protection

An electrical technician with an additional explosion protection qualification

should be specifically trained for the field of work in which he is employed

and be familiar with the relevant standards and regulations. An electrical

technician with an additional explosion protection qualification can work on

electrical systems and independently recognise and avoid possible dan‐

gers based on his technical training and experience.

The electrical technician with an additional explosion protection qualifica‐

tion is familiar with all the standards and regulations applicable to explo‐

sion protection, in particular, but not however exclusively, with all parts of

EN 60079 [Electrical equipment for areas at risk of a gas explosion].

An electrical technician with an additional explosion protection qualification

must comply with the provisions of the applicable statutory directives on

accident prevention.

Qualification of personnel

Safety chapter

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 experience of

safety technology.

Make sure that the person is familiar with the relevant body of standards

and regulations and has worked in the field for at least one year. The

person needs to have opportunities for an exchange of experiences.

Specific requirements are placed on competent persons who perform tests

on repaired devices/parts. They have to be recognised by the responsible

authorities (e.g. district council) in this respect.

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.

Trained user

A trained user is a person who fulfils the requirements made 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.

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.

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

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