ProMinent Hydro/4 HP4a Operating Instructions Manual Download Page 1

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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.

Summary of Contents for Hydro/4 HP4a

Page 1: ...ns 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 err...

Page 2: ...o 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 a...

Page 3: ...s 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...

Page 4: ...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 fo...

Page 5: ...erial 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...

Page 6: ...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...

Page 7: ...0250 251 250 160400 161 400 100635 10 635 070890 7 890 250350 251 350 160400 161 550 100800 10 880 071230 7 1230 250400 251 400 160625 161 625 101000 10 1000 071400 7 1400 1 Maximum back pressure for...

Page 8: ...erated at back pressures of over 2 bar with metal liquid ends and if the operator implements appropriate safety measures n The pump may only be used after it has been correctly installed and started u...

Page 9: ...e 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 e...

Page 10: ...equirements 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 r...

Page 11: ...nd adjacent parts of the system Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthorised persons Depressurise the system before commencing any wor...

Page 12: ...m the supplier Based on the information provided in the data sheets concerning health and safety water and environmental protection and taking into considera tion the actual operating environment on s...

Page 13: ...ed for the metering of electrically non conductive media conductivity less than 50 pS m n The ATEX design may not meter media which tend to produce exo thermic reactions or self ignite examples of exo...

Page 14: ...lations 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 tra...

Page 15: ...uding 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...

Page 16: ...on Observe the European standards governing intrinsi cally safe power circuits In Germany these stand ards are partly implemented by VDE Adhere to the respective national regulations outside of the EU...

Page 17: ...a recognised competent person Please note the relevant national regulations during installation WARNING Adjusted pressure switches fail The switching point of the 42 V pressure switch must not be cha...

Page 18: ...k from explosion If abrasive media are being metered they will escape as soon as all layers of the diaphragm have eroded through Wire the electrical diaphragm rupture indicator to stop the pump in the...

Page 19: ...ke sure that a suitably competent person checks whether the appropriate installation information from the Installation chapter has been implemented correctly Make sure that a recognised competent pers...

Page 20: ...harge before working on the pump Have wear parts such as bearings replaced by ProMinent Service when there is an identifiable inci dence of unacceptable wear Check whether the potential equalisation l...

Page 21: ...tion active surface uncovered 3 mA Power consumption active surface cov ered 1 mA Rated switching distance 1 5 mm Ri 1 k Cable colour Polarity blue brown Install the sensor according to the chapter In...

Page 22: ...t of their serviceability and replace if necessary Refer to its documentation Type eBR6000 Tab 3 Product identification Code Property e electronic device B label for temperature limiter R Controller 6...

Page 23: ...protective temperature limiter for external damage or corrosion to the housing and connecting parts Immediately have damaged parts rectified with genuine spare parts by the manufacturer After 20 000 o...

Page 24: ...EX electrical technician Service only with ATEX version with add on power end Coupling flange inspection cover Service only with ATEX version without motor Motor connection inspec tion cover Service O...

Page 25: ...of a unit in a Decla ration of Conformity for ATEX Machines or a Declaration of Incorporation for ATEX Machines then special conditions apply for the safe operation of the equipment in areas at risk f...

Page 26: ...of expected errors corre sponds to category 2G Gc normal EPL in normal operation corre sponds to category 3G Suffix X X Special conditions refer to the Declarations of Conformity and EC type examinati...

Page 27: ...sted in the table with equipment approved for explosion group IIC and temperature class T4 Equipment approved for explosion group IIB can also be used for explosion group IIA not for explosion group I...

Page 28: ...ARNING Slings can tear ProMinent only supplies non reusable slings in accord ance with DIN EN 60005 They can tear with repeated use Destroy and remove the slings as soon as the pump has been lifted in...

Page 29: ...y 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 ambien...

Page 30: ...nd C Liquid End 1 Stroke adjustment dial 2 Bleed valve 3 Oil inspection window 4 Gear bleeding plug 5 Oil drain stopper 6 Oil drainage plug 7 Stroke sensor optional 8 Diaphragm rupture sensor P_HY_004...

Page 31: ...ower end and the diaphragm if the liquid feed pressure becomes too high If the discharge side of the liquid end is blocked the pressure limitation valve 3 opens at a pre set pressure and allows the hy...

Page 32: ...tructions WARNING EX is relevant in areas at risk from explosion With a claw coupling The claw on the motor shaft must be fixed at the correct height see corresponding figure and table 3 As you have c...

Page 33: ...lly 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 Th...

Page 34: ...can heat the liquid ends above the permissible surface temperatures persons can suffer burns from them Consider attaching a Hot surface label to the liquid end or fitting a guard plate Position the pu...

Page 35: ...1 Take the dimensions m for the fastening holes from the appro priate dimensional or data sheets 2 Fix the pump base to the supporting floor with sufficient strong screws With externally mounted pumps...

Page 36: ...he event of continuous operation by the internal relief valve In the event of differing temperature classes amongst the diverse components operation of the complete pumps should be based on the compon...

Page 37: ...this purpose use a shut off valve a solenoid valve or a vacuum breaker CAUTION Suction problems possible The valves may no longer close properly with feed chemicals with a particle size of greater tha...

Page 38: ...ess Only use clamp rings and hose nozzles that fit the respective hose diameter Always connect the lines without mechanical ten sion Only connect steel piping via a flexible piping sec tion to a plast...

Page 39: ...ther mechanisms Precise metering is only possible when the back pressure is maintained above 1 bar at all times If metering at atmospheric pressure a back pres sure valve should be used to create a ba...

Page 40: ...With hazardous feed chemicals Hazardous feed chem ical can leak out when using conventional bleeding pro cedures with metering pumps Install a bleed line with a return into the storage tank Shorten th...

Page 41: ...lly clean earthing point e g with an earthing bar on your system Electrically connect the electrical units fitted with a potential equalisation cable to each other cleanly and permanently to an electr...

Page 42: ...or identity code option n Over pressure signalling identity code option n Heating cartridge identity code option n Protective temperature limiter identity code option n Earthing wires to be installed...

Page 43: ...d be damaged After switching off allow the device to stand for at least 3 minutes before restarting If the motor is controlled via a control take this into consideration at the control CAUTION Pump ca...

Page 44: ...onnect the motors in accordance with the enclosed wiring diagram or as per the wiring diagram fixed to the inside of the housing CAUTION Only operate stroke length actuators control drives when the pu...

Page 45: ...a Diaphragm rupture sensor with switch contact The cable can be connected as required b Namur sensor inherently safe The monitor power supply installed by the customer must be able to eval uate the cu...

Page 46: ...42 V diaphragm pressure switch The cable can be connected as required a Overpressure sensor ATEX pressure switch precise type EDS 4448 0060 P AN3 004 The type code is also restated in the Technical Da...

Page 47: ...to the supplied power supply or the protective temperature limiter for ATEX Connect the electrical components of the entire installation supplied cleanly and permanently to an electrically clean eart...

Page 48: ...y not work if there is a mixture of feed chemical with oxygen in the liquid end A specialist may need to take appropriate actions using inert gas WARNING Hot surface In event the power end motor is lo...

Page 49: ...s voltage being switched off After switching off allow the device to stand for at least 3 minutes before restarting CAUTION Feed chemical could escape Check suction and discharge lines and liquid end...

Page 50: ...valve When commissioning the unit check whether the drive motor is rotating correctly check this against the arrow on the motor housing or the dia gram in the chapter entitled Electrical Installation...

Page 51: ...no more than 1 5 times the rated pump pressure Check the heating action of the heating cartridge and the effectiveness of the protective temperature limiter No overheating must occur especially in the...

Page 52: ...n problems occurring during start up Exclude the possibility that there are foreign bodies in the valve Place the valve on a stable surface Using a hammer 1 and a brass bar 2 gently tap the PTFE ball...

Page 53: ...by excessive friction Always earth the discharge line and the suction line against the pump to prevent electrostatic charge before working on the pump Have wear parts such as bearings replaced by ProM...

Page 54: ...commencing any work on hydraulic parts 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 materia...

Page 55: ...loded views and ordering information in the appendix Check the pump installation for n Leaks n Abnormal noises or squeaks n Abnormal temperatures n Abnormal odours n Abnormal vibrations n Other anomal...

Page 56: ...personnel Check that the diaphragm rupture sensor is firmly seated Technical personnel Check whether the overpressure signalling triggers when an over pressure exists Technical personnel Check the se...

Page 57: ...ours Follow the motor manufacturer s recommendations see operating instructions for the motor Under normal loading approx 30 of continuous operation Under heavy loading e g continuous operation Shorte...

Page 58: ...vent stopper 3 until the oil inspection window 3 is 1 3 covered 3 Start the pump 4 Allow the pump to run slowly for a further 1 2 minutes 5 Top up with hydraulic oil if necessary 6 Screw the bleed val...

Page 59: ...ead the safety information and specifications in the Storage Transport and Unpacking chapter prior to shipping the pump CAUTION Warning of feed chemical spraying around Feed chemical can spray out of...

Page 60: ...ic oil and the hydraulic end may become very hot when the pump is exposed to heavy loading Allow the pump to cool before starting work WARNING ATEX pumps in areas at risk from explosion The ATEX press...

Page 61: ...1 Turn the stroke adjustment dial 2 more than 100 to the stop 2 Remove the vent screw 3 3 Place an oil trough under the hydraulic end 4 Unscrew the oil drainage stopper 4 out of the hydraulic end 5 Al...

Page 62: ...diaphragm diaphragm anchor combination from the diaphragm mounting plate 2 12 Clean all parts completely especially the wetted parts see Fig 19 13 Place the new diaphragm diaphragm anchor combination...

Page 63: ...c oil in the hydraulic end For the double head versions perform the following work simultaneously on both dosing heads 1 Set the stroke adjustment dial 1 to 100 and open the safety relief valve 2 tigh...

Page 64: ...peat the test several times 6 If everything is working correctly screw the diaphragm rupture sensor into the dosing head with a new seal 1 7 If not go to the next section Replace separating diaphragm...

Page 65: ...1 Disconnect the diaphragm rupture sensor from the monitor 2 When changing the diaphragm unscrew the diaphragm rupture sensor from the dosing head 3 Grasp the top part 2 of the diaphragm rupture sens...

Page 66: ...NG ATEX pump only Take suitable precautions in poten tially explosive atmospheres regarding the feed chemical in the open measuring cylinder see handling instruc tions below The dosing rate can only b...

Page 67: ...sing rate using the stroke adjustment dial and repeat steps 7 to 10 until the required value is reached 13 Turn the indicating dial 1 only until the 100 marking is precisely above the indicating slot...

Page 68: ...rvice life cannot be calculated with lubri cated bearings Only use genuine spare parts as replacements Carry out inspections and repair in in compliance with DIN EN IEC 60079 17 and ensure that they a...

Page 69: ...ty gloves Adhere to the material safety data sheet for the feed chemical Drain and flush the liquid end before working on the pump WARNING Risk of injury from the fan impeller The fan impeller beneath...

Page 70: ...edy Personnel Pump fails to pressurise or does not prime in despite full stroke motion and bleeding The valves are dirty or worn Repair the valves see chapter entitled Repair Technical per sonnel The...

Page 71: ...sensor has triggered The operating dia phragm has ruptured n Replace multi layer diaphragm imme diately see Diaphragm change in the chapter Repair n Replace separating diaphragm of the diaphragm ruptu...

Page 72: ...he housing after operation This chemical residue could be hazardous to people It is mandatory that the safety information in the Storage transport and unpacking chapter is read before shipping or tran...

Page 73: ...ical personnel 1 Disconnect the pump from the mains 2 Depressurise and bleed the hydraulic system around the pump 3 Flush the liquid end with a suitable medium observe the material safety data sheet F...

Page 74: ...from the pump Note the local guidelines currently applicable in your country CAUTION Note the local guidelines generally currently applicable in your country In accordance with the European Directive...

Page 75: ...25 160400 16 400 50 136 3 m 1 bar G1 1 2 DN25 160550 16 550 50 188 3 m 1 bar G1 1 2 DN25 160625 16 625 50 214 3 m 1 bar G1 1 2 DN25 100330 10 330 78 71 3 m 1 bar G 2 DN32 100480 10 480 78 103 3 m 1 ba...

Page 76: ...2 124 3 m 1 bar G 2 DN32 100635 10 145 760 200 8 164 3 m 1 bar G 2 DN32 100880 10 145 1050 277 4 225 3 m 1 bar G 2 DN32 70465 6 102 560 147 9 86 3 m 1 bar G2 1 4 DN 40 70670 6 102 805 212 7 124 3 m 1...

Page 77: ...all valves From DN 32 DN 40 plate valves Material ver sion Liquid end Suction pres sure con nector Seals Valve seats Valve balls Valve plates valve spring SST Stainless steel 1 4404 Stainless steel 1...

Page 78: ...mperature 10 C Data Value Unit Max temperature long term at max oper ating pressure 65 C Minimum temperature Standard 10 C Minimum temperature Low temperature Zone 2 20 C Data Value Unit Max temperatu...

Page 79: ...e Standard 10 C Minimum temperature Low temperature Zone 2 20 C Data Value Unit Max temperature long term at max oper ating pressure 90 C Max temperature for 15 min at max 2 bar 120 C Minimum temperat...

Page 80: ...ol range 1 5 R 3 phase IP 55 230 V 400 V 50 60 Hz 1 5 kW with PTC speed adjustment range 1 20 with external fan 1 phase 230 V 50 60Hz Z 3 phase IP 55 230 V 400 V 50 60 Hz 1 5 kW Speed control complete...

Page 81: ...t voltage Maximum current 30 V DC 1 A The contact is an opener The contact is an potential free For safety reasons we recommend connecting to a protective low voltage e g in accordance with EN 60335 1...

Page 82: ...The contact is an opener For safety reasons we recommend connecting to a protective low voltage e g in accordance with EN 60335 1 SELV The cable can be connected as required 13 12 Stroke sensor Instal...

Page 83: ...il Supplied amount of oil Type Single head ver sion Double head version HP 4 approx 5 5 l approx 6 1 l 7 0 l Use Manufacturer Name Viscosity class Order no Standard Mobil Mobilube 1 SHC 75W 90 1006010...

Page 84: ...s They can be queried by stating the details of the serial number The motor data sheets for the modified version are valid They may deviate from the standard motor data sheets With a modified version...

Page 85: ...re connection assy 4 Suction connection assy 5 Diaphragm Reinforce plate only with PVT 14 2 Spare parts kits The spare part kits include the replacement parts for the liquid ends Standard delivery for...

Page 86: ...863 SST 1040824 SST with valve 1040825 HCT 1040861 HCT with valve 1040862 for types 100330 100480 100635 100880 101000 for liquid end Material version Order no FMH 1000 DN 32 PVT 1043776 PVT with valv...

Page 87: ...230 071400 1044850 for liquid end Pump type Order no FMH 400 250130 250190 250250 250350 250400 1040874 FMH 625 160210 160300 160400 160550 160625 1040875 FMH 1000 100330 100480 100635 100880 101000 1...

Page 88: ...comparative hydraulic oil 1 L Required amount of oil Supplied amount of oil Type Single head ver sion Double head version HP 4 approx 5 5 l approx 6 1 l 7 0 l Seal for Order no Oil drainage stopper c...

Page 89: ...50 160625 100330 100480 100635 100880 101000 070465 070670 070890 071230 071400 A SS HC 548 553 583 593 A PV TT 558 563 596 605 B SS HC PV 287 288 316 322 C SS HC PV 235 235 255 255 D SS HC PV 458 458...

Page 90: ...160400 160550 160625 100330 100480 100635 100880 101000 070465 070670 070890 071230 071400 A SS HC 770 780 841 861 A PV TT 780 790 854 873 B SS HC PV 287 288 316 322 C SS HC PV 235 235 255 255 D SS HC...

Page 91: ...0210 160300 160400 160550 160625 100330 100480 100635 100880 101000 070465 070670 070890 071230 071400 A SS HC 604 609 639 649 A PV TT 614 619 652 661 B SS HC PV 67 68 96 102 C SS HC PV 15 15 35 35 D...

Page 92: ...550 160625 100330 100480 100635 100880 101000 070465 070670 070890 071230 071400 A SS HC 770 780 841 861 A PV TT 780 790 854 873 B SS HC PV 287 288 316 322 C SS HC PV 235 235 255 255 D SS HC PV 590 59...

Page 93: ...Standard motor Exe motor Exde motor Motor with fre quency con verter Exde frequency converter motor Motor control lable K 604 565 663 914 696 605 Dimensional drawings 93...

Page 94: ...P_HY_0052_SW 61_02 101_00_33 7Ax05_B5 Fig 28 Diagram is not strictly binding Hydro HP4 dimensions sheet HP4a tri plex pump Dimensional drawings 94...

Page 95: ...96 102 C SS HC PV 15 15 35 35 D SS HC PV 521 521 534 534 E SS HC 90 95 106 116 E PV TT 100 105 119 128 F SS HC PV 170 198 226 249 G SS HC PV 66 51 31 2 H SS HC PV 256 284 324 382 J SS HC PV DN25 G1 1...

Page 96: ...9 Diagram is not strictly binding P_HY_0054_SW 61_02 101_00_33 7Ax05_B6b Fig 30 Diagram is not strictly binding Hydro HP4 dimensions sheet HP4a with ATEX FC Hydro HP4 dimensions sheet HP4a without mot...

Page 97: ...33 11 0 875 22 23 2 1 8 53 975 0 197 5 3 16 4 7625 0 964 24 49 14 21 361 100 B5 250 250 215 180 H7 15 28 60 5 8 31 3 367 P_HY_0058_SW 61_02 101_00_33 7Ax05_B6c Fig 31 Diagram is not strictly binding H...

Page 98: ...287 288 316 322 C SS HC PV 235 235 255 255 D SS HC PV 458 458 478 478 E SS HC 90 95 106 116 E PV TT 100 105 119 128 F SS HC PV 170 198 226 249 G SS HC PV 6 9 29 58 H SS HC PV 256 284 324 382 J SS HC P...

Page 99: ...0 250190 250250 250350 250400 160210 160300 160400 160550 160625 100330 100480 100635 100880 101000 070465 070670 070890 071230 071400 A SS HC 770 780 841 861 A PV TT 780 790 854 873 B SS HC PV 287 28...

Page 100: ...90 590 630 630 E SS HC 90 95 106 116 E PV TT 100 105 119 128 F SS HC PV 170 198 226 249 G SS HC PV 6 9 29 58 H SS HC PV 256 284 324 382 J Valve DN25 G1 1 2 DN25 G1 1 2 DN32 G2 DN40 G2 1 4 L 693 696 75...

Page 101: ...ATEX P_HY_0055_SW 61_02 101_00_33 7Ax05_B9 svg Fig 34 Diagram is not strictly binding Hydro HP4 dimensions sheet HP4a with heating cartridge Dimensional drawings 101...

Page 102: ...16 Earthing drawing 6 2 3 P_HY_0044_SW 2 Motor 3 Heating cartridge optional 6 Actuator Simplex single head Hydro HP4 with actuator and heating cartridge Earthing drawing 102...

Page 103: ...Declaration of Conformity Designation of the product Metering pump product range Hydro 4 Product type HP4a _ _ _ _ _ _ _ _ _ _ _ _ _ _ 0 _ _ _ with characteristics R or S or T or V or Z Serial number...

Page 104: ...e EU Declaration of Incorporation Designation of the product Metering pump without motor product range Hydro 4 Product type HP4a _ _ _ _ _ _ _ _ _ _ _ _ _ _ 0 _ _ _ with characteristics 0 or 1 or 3 or...

Page 105: ...4a with characteristics L or P and 1 or 2 or V and 2 0 or K or 1 or 2 or A or B or C or D 0 or 1 Serial number see nameplate on the device Relevant directives EU ATEX Directive 2014 34 EU EC Machinery...

Page 106: ...plosion in accordance with the ATEX Direc tive 2014 34 EC Product type HP4a 3 with characteristics L or P and 1 or 2 or V and 2 0 or K or 1 or 2 or A or B or C or D Serial number see nameplate on the...

Page 107: ...with the characteristic 1 or 3 or 4 0 or K or 1 or 2 or A or B or C or D 0 or 1 Serial number see nameplate on the device Relevant directives EU ATEX Directive 2014 34 EU EC Machinery Directive 2006 4...

Page 108: ...Direc tive 2014 34 EC Product type HP4a A 3 with the characteristic 1 or 3 or 4 0 or K or 1 or 2 or A or B or C or D Serial number see nameplate on the device Relevant directives EU ATEX Directive 201...

Page 109: ...600 700 800 900 1000 1100 1200 0 1 2 3 4 5 6 7 8 9 10 11 101000 100880 100635 100480 100330 s 100 80 60 40 20 0 C l h p bar 0 200 400 600 800 1000 1200 1400 1600 1800 0 1 2 3 4 5 6 7 8 C l h 071400 0...

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Page 112: ...984728 3 en_GB 2010 ProMinent GmbH Im Schuhmachergewann 5 11 69123 Heidelberg Germany Telephone 49 6221 842 0 Fax 49 6221 842 419 Email info prominent com Internet www prominent com...

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