ProMinent Hydro HP4 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 015 10/14 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.

www.promhimtech.ru / [email protected]

Summary of Contents for Hydro HP4

Page 1: ...Y 015 10 14 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...

Page 2: ...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...

Page 3: ...ioning 59 12 2 Disposal 60 13 Technical Data 62 13 1 Performance Data 62 13 2 Metering reproducibility 63 13 3 Viscosity 64 13 4 Weight 64 13 5 Wetted Materials 64 13 6 Ambient conditions 64 13 6 1 Te...

Page 4: ...ines ATEX HP4 without heating cartridge 94 19 EC Declaration of Conformity for ATEX HP4 machines with heating cartridge 95 20 EC Declaration of Conformity for ATEX HP4 machines without heating cartrid...

Page 5: ...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 stand...

Page 6: ...EX power end Stroke sensor 0 No stroke sensor standard 1 Stroke sensor compatible with areas at risk from explo sion Stroke length adjustment 0 Manual standard K Manual outdoor SS 1 With servomotor 23...

Page 7: ...e Capacity bar l h bar l h bar l h bar l h 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 with TTT PPT and...

Page 8: ...94 9 EC in accordance with the European guidelines The explosion group category and degree of protection specified on the label should correspond to or be better than the conditions given in the inte...

Page 9: ...d in the operating instructions for the accessory units at the different phases of their respective service lives Task Qualification Storage transport unpacking Instructed person Assembly Technical pe...

Page 10: ...n gers based on their technical training and experience The electrical technician with an additional explosion protection qualifica tion is familiar with all the standards and regulations applicable t...

Page 11: ...fically to intrinsically safe circuits The following information relates essentially to the unique characteristics in areas at risk from explosion but does not replace the standard operating instructi...

Page 12: ...e pump must only be opened at those points required to be opened by these operating instructions It may only be opened in other positions upon receipt of written authorisation from the ProMinent head...

Page 13: ...otective cowling above the motor fan Service Terminal box cover motor Electrical technician ATEX elec trical technician Service Flange cover side Service Only with add on power end motor connection co...

Page 14: ...ons if necessary n Correctly install the motor n With ATEX motors perform an ignition hazard assessment Sound pressure level LpA 75 dB according to EN ISO 20361 at maximum stroke length maximum stroke...

Page 15: ...ape due to 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 with the...

Page 16: ...refer to Technical Data chapter Ambient conditions Storage transport and unpacking 16...

Page 17: ...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 18: ...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 19: ...WARNING EX is relevant to all equipment and methods in areas at risk from explosion With a dog clutch Ensure that the claw on the motor shaft is fixed at the correct height see Fig Motor installation...

Page 20: ...ate 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...

Page 21: ...eed chemicals can heat the liquid ends above the per missible surface temperatures persons can suffer burns from them Avoid contact If necessary mount a guard plate Install the pump so that control el...

Page 22: ...ions can occur 1 Take the dimensions m for the fixing holes from the appropriate dimension or data sheets 2 Use sufficiently strong bolts to fix the pump to the base With externally mounted pumps use...

Page 23: ...ing up in the event of continuous operation by the internal relief valve In the event of differing temperature classes amongst the various components base operation of the complete pumps on the compon...

Page 24: ...urpose use a shut off valve a solenoid valve or a vacuum breaker CAUTION Suction problems possible The valves can no longer close properly when using feed chemicals with a particle size of greater tha...

Page 25: ...kness Only use clamp rings and hose nozzles that correspond to the respective hose diameter Always connect the lines without mechanical tension Only connect steel piping with a flexible piping section...

Page 26: ...used to create a back pressure of approx 1 5 bar CAUTION Warning of unnoticed diaphragm rupture Only above approximately 2 bar system back pressure is a signal generated in the event of a diaphragm r...

Page 27: ...Z_0043_SW 2 1 A B PD 1 2 Fig 14 A standard installation B with pulsation damper 1 Main line 2 Storage tank Symbol Explanation Symbol Explanation Metering pump Foot valve with filter meshes Injection v...

Page 28: ...rthing point e g with an earthing bar in your system Electrically connect units connected to each other with a potential equalisation cable cleanly and permanently to an electrically clean potential e...

Page 29: ...rd n Stroke sensor identity code option n Excess pressure signalling identity code option n Heating cartridge identity code option n Protective temperature limiter identity code option n Earthing wire...

Page 30: ...he mains voltage After switching off allow the unit to stand for at least 3 minutes before restarting If the motor is controlled by a control take this into con sideration at the control CAUTION The p...

Page 31: ...nclosed wiring diagram or according to the wiring diagram affixed to the inside of the housing CAUTION Only operate stroke length actuators control drives when the pump is running Otherwise they will...

Page 32: ...eed supply installed by the customer should be able to eval uate the current variations of the Namur sensor to indicate a diaphragm rupture WARNING In areas at risk from explosion For the Namur sensor...

Page 33: ...rmitted barriers Configuration of rpm and Imax Permitted connector plugs WARNING Never reprogram the pressure switch without the written authorisation of ProMinent GmbH Heidelberg Plug assignment Pin...

Page 34: ...e limiter for ATEX Connect the electrical components in the complete installation supplied cleanly and securely to an electrically clean earthing point for instance using an earthing bar provided on s...

Page 35: ...combined with oxygen During filling and draining of the liquid end an expert must ensure that feed chemical does not come into con tact with oxygen WARNING Hot surface In event the power end motor is...

Page 36: ...k suction and discharge lines liquid end and valves for leak tightness and tighten if necessary Check whether the necessary flushing pipes or bleed lines are connected CAUTION Prior to commissioning c...

Page 37: ...k this against the arrow on the motor housing or the dia gram in the chapter entitled Electrical Installation WARNING Risk of injury from the fan impeller The fan impeller beneath motor s fan cowling...

Page 38: ...ective temperature limiter Do not allow overheating to occur espe cially in areas at risk from explosion 1 Switch on the heating cartridge set the stroke length of the pump to 0 and start the pump 2 A...

Page 39: ...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 se...

Page 40: ...rges are generated by excessive friction Always earth the discharge and suction lines against the pump before working on it to prevent electrostatic charge Have ProMinent Service replace wear parts su...

Page 41: ...he system before commencing any work on hydraulic parts WARNING Warning of dangerous or unknown feed chemical Should a dangerous or unknown feed chemical be used It may escape from the hydraulic compo...

Page 42: ...ews and ordering information in the appendix Check the pump installation for n Leaks n Abnormal noises or squeaking n Abnormal temperatures n Abnormal odours n Abnormal vibrations n Other peculiaritie...

Page 43: ...limitation valve 50 Nm Technical personnel With the pump running check whether bubbles rise in the window of the bleed valve Technical personnel Check that the flow is correct Allow the pump to prime...

Page 44: ...NING Risk of burns due to hot hydraulic oil The hydraulic oil may become very hot when the pump is exposed to extensive loading When draining oil avoid contact with the oil running out WARNING If the...

Page 45: ...vent stopper 3 until the oil inspection window 3 is 1 3 covered 3 Start the pump 4 Allow the pump to run for a further 1 2 minutes 5 Top up with hydraulic oil if necessary 6 Screw the bleed valve 2 b...

Page 46: ...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 the hydraulic components if th...

Page 47: ...nts The hydraulic 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 pump in areas at risk from explosion...

Page 48: ...n 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 Allow t...

Page 49: ...diaphragm diaphragm anchor combination from the diaphragm mounting plate 2 12 Clean the parts completely especially the wetted parts see Fig Fig 19 13 Place the new diaphragm diaphragm anchor combinat...

Page 50: ...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 tighten the knurled screw 2 Slowly fill...

Page 51: ...eat 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 o...

Page 52: ...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 senso...

Page 53: ...ly Take suitable precautions in premises at risk of explosion regarding the feed chemical in the open measuring cylinder see handling instructions below You can only calibrate the capacity when the di...

Page 54: ...oke adjustment dial to reduce the capacity 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 55: ...are only performed by experienced personnel with the requisite knowl edge Only have a recognised competent person check the electrical installation and in particular the intrinsically safe electric c...

Page 56: ...d result in overheating of the pump WARNING Only motors with a frequency converter Danger of electric shock There remains a risk of an electric shock on conducting parts of the motor with an integrate...

Page 57: ...oil inspection window is 1 3 covered see Diaphragm change in the Repair chapter Investigate and remedy the cause of the oil loss Instructed per sonnel An oil inspection window is leaking Replace the...

Page 58: ...system back pres sure was momentarily too high Clear the cause of the back pressure Technical per sonnel The power end motor is very hot The discharge line is seriously constricted n Rectify any cons...

Page 59: ...liquid end and on the housing after operation This chemical residue could be hazardous to people It is mandatory that the safety note relating to the Storage Transport and Unpacking chapter is read be...

Page 60: ...el n Technical personnel 1 Disconnect the pump from the mains power supply 2 Depressurise and bleed the hydraulic system around the pump 3 Flush the liquid end with a suitable medium Observe the safet...

Page 61: ...move the hydraulic cap in line with the Hydro repair and configuration instructions CAUTION Environmental hazard due to hydraulic oil The pump contains hydraulic oil which can cause damage to the envi...

Page 62: ...0400 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 bar G 2...

Page 63: ...24 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 87 560 147 9 86 3 m 1 bar G2 1 4 DN 40 70670 6 87 805 212 7 124 3 m 1 bar G...

Page 64: ...ball valve 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 65: ...pressure 45 C Max temperature for 15 min at max 2 bar 60 C Minimum temperature 10 C Data Value Unit Max temperature long term at max oper ating pressure 65 C Minimum temperature Standard 10 C Minimum...

Page 66: ...inimum temperature Standard 10 C Minimum temperature Low temperature Zone 2 20 C Minimum temperature Low temperature 25 C Data Value Unit Max temperature long term at max oper ating pressure 90 C Mini...

Page 67: ...Data Identity code speci fication Phase protec tion Rated voltage Mains supply frequency Rated output Manufacturer s designation Remarks S 3 phase IP 55 220 240 V 380 420 V 50 Hz 1 1 kW 250 280 V 440...

Page 68: ...with identity code specifi cations S M or N Pay special attention to the oper ating instructions for the motors Special motors or special motor flanges are possible on request 13 9 Diaphragm Rupture S...

Page 69: ...sure stage 7 bar 10 bar 16 bar 25 bar Opening pressure 14 bar 18 bar 25 bar 36 bar 13 11 Pressure Switch For Signalling Overpressure Size Value Unit Maximum voltage 42 V Rated current ohmic load 4 A S...

Page 70: ...pressed in or integrated including accessories ZBE 08S 02 coupling socket M12x1 angled with 2 m wire screened F Sealing material FPM 1 Connecting material Stainless steel 200 Cable length 2 m standard...

Page 71: ...ta see enclosed operating instructions ELMESS protective temperature limiter II 2 G EEx ib IIC IIB II 2 D Ex ib D BVS 06 ATEX F 002 X 13 15 Filling volumes 13 15 1 Hydraulic oil Use Manufacturer Name...

Page 72: ...a of pumps in the modified version can deviate from those of the standard pumps They can be queried by stating the details of the serial number The motor data sheets for the modified version are valid...

Page 73: ...ssure 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...

Page 74: ...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 Part no FMH 1000 DN 32 PVT 1043776 PVT with valve...

Page 75: ...0 101000 1044849 FMH 1400 0704650 070670 070890 071230 071400 1044850 for liquid end Pump type Part no FMH 400 250130 250190 250250 250350 250400 1040874 FMH 625 160210 160300 160400 160550 160625 104...

Page 76: ...lube 1 SHC 75W 90 1005823 Foodsafe Mobil SHC Cibus 220 1007610 or comparative hydraulic oil Seal for Part no Oil drainage stopper copper hydraulic end 1004803 Oil drainage stopper O ring power end 740...

Page 77: ...250350 250400 160210 160300 160400 160550 160625 100330 100480 100635 100880 101000 070465 070670 070890 071230 071400 A SS HC 548 553 583 593 A PV 558 563 596 605 B SS HC PV 287 288 316 322 C SS HC P...

Page 78: ...otor with frequency con verter Motor control lable K 544 505 603 854 636 545 P_HY_0049_SW 61_02 101_00_33 7Ax05_B2 Fig 25 Illustration not strictly binding Liquid end Type 250130 250190 250250 250350...

Page 79: ...HC 90 95 106 116 E PV 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 DN25 G1 1 2 DN25 G1 1 2 DN32 G2 DN40 G2 1 4 L 693 696 752 764 M 120 120 189 189 Stand...

Page 80: ...52 661 B SS HC PV 67 68 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 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...

Page 81: ...7 288 316 322 C SS HC PV 235 235 255 255 D SS HC PV 590 590 630 630 E SS HC 90 95 106 116 E PV 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 G...

Page 82: ...Dimension sheet for Hydro HP4 HP4a tri plex pump Dimensions 82...

Page 83: ...P_HY_0052_SW 61_02 101_00_33 7Ax05_B5 Fig 28 Illustration not strictly binding Dimensions 83...

Page 84: ...7 68 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 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...

Page 85: ...P_HY_0053_SW 61_02 101_00_33 7Ax05_B6a Fig 29 Illustration not strictly binding Dimension sheet for Hydro HP4 HP4a with ATEX FC Dimensions 85...

Page 86: ...otor flange P M N S U Q T R U K 143 145TC 6 575 167 5 875 149 23 4 5 H7 114 3 H7 0 433 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...

Page 87: ...P_HY_0058_SW 61_02 101_00_33 7Ax05_B6c Fig 31 Illustration not strictly binding Dimension sheet for Hydro HP4 HP4a without motor without motor flange Dimensions 87...

Page 88: ...PV 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 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...

Page 89: ...ype 250130 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 780 790 854 873 B SS HC PV...

Page 90: ...HC PV 590 590 630 630 E SS HC 90 95 106 116 E PV 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 69...

Page 91: ...ATEX P_HY_0055_SW 61_02 101_00_33 7Ax05_B9 svg Fig 34 Illustration not strictly binding Dimension sheet for Hydro HP4 HP4a with heating cartridge Dimensions 91...

Page 92: ...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 92...

Page 93: ...approved by us will invalidate this dec laration Extract from the EC Declaration of Conformity Designation of the product Metering pump product range Hydro 2 Hydro 3 and Hydro 4 Product type HP2a HP3a...

Page 94: ...rective 94 9 EC Product type HP4a 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 unit Relevant EC directives EC ATEX D...

Page 95: ...X Directive 94 9 EC Product type HP4a 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 unit Relevant EC directives EC ATEX Dire...

Page 96: ...duct type HP4a A 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 unit Relevant EC directives EC ATEX Directive 94 9 EC EC Machinery D...

Page 97: ...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 unit Relevant EC directives EC ATEX Directive 94 9 EC EC Machinery Dir...

Page 98: ...0 600 700 800 900 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...

Page 99: ...99...

Page 100: ...5 11 69123 Heidelberg Germany Telephone 49 6221 842 0 Fax 49 6221 842 612 email info prominent com Internet www prominent com The latest version of the operating instructions is available on our home...

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