ProMinent Sigma / 2 Basic Type SBKa Operating Instructions Manual Download Page 1

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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.

Summary of Contents for Sigma / 2 Basic Type SBKa

Page 1: ...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 ...

Page 2: ...g 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 ...

Page 3: ... 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 capacit...

Page 4: ...With ProMinent logo standard 1 Without 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 standar...

Page 5: ... 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 ...

Page 6: ...ies 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 n Only use the pump to meter liquid metering chemicals n In potentially explosive atmospheres in zone 1 device category II 2G explosion group II C only operate ...

Page 7: ...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...

Page 8: ...afe 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 es...

Page 9: ... 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 ...

Page 10: ...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 ...

Page 11: ...Danger of material damage The device can be damaged by 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 when the red gear bleeding plug is pushed in The packaged unit should also only be stored or trans ported in accordance with the stipulated storage condi tions The p...

Page 12: ...ipment and control elements SBKa 1 Liquid end 2 Drive motor 3 Gear bleeding plug 4 Drive unit 5 Stroke length adjustment knob 75 50 Fig 5 Adjusting the stroke length n 100 10 rotations n 10 1 rotation n 0 2 1 scale mark on stroke adjustment dial Overview of equipment and control elements 12 ...

Page 13: ...PG11 PG9 1 2 3 A B P_SI_0036 Fig 6 Front cover for version with pacing relay A Pacing relay cable B Supply voltage cable for pacing relay PCB Overview of equipment and control elements 13 ...

Page 14: ...he feed chemical flows through the discharge valve 3 out of the dosing head As soon as the piston moves in the opposite direction the discharge valve 3 closes due to the negative pressure in the dosing head and fresh feed chemical flows through the suction valve 1 into the dosing head Use the flushing collar 6 to flush the sealing surface of the piston P_SI_0144_SW 3 2 7 4 6 5 1 Fig 7 Cross sectio...

Page 15: ...rate 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 Position the pump so that control elements such as the stroke length adjustment knob or the indicating dial A are easily accessible 1 Discharg...

Page 16: ...ty too low Vibrations can disrupt the liquid end valves Secure the metering pump so that no vibrations can occur Take the dimensions m for the fastening holes from the appropriate dimensional drawings or data sheets Fix the pump base to the base with suitable screws Liquid end alignment Fastening DN m m P_MOZ_0015_SW Fig 11 Assembly 16 ...

Page 17: ...ct it from excess temperature following running dry or a suit able temperature monitor In the event of differing temperature classes amongst the diverse components operation of the complete pumps should be based on the component with the lowest temperature class Ensure that installations in areas at risk from explosion are checked by a recognisably trained skilled opera tive Please note the releva...

Page 18: ...ggressive or toxic feed chemicals Install a relief valve that limits the pressure of the pump to the maximum permissible operating pressure of the system CAUTION Uncontrolled flow of feed chemical Feed chemicals can leak through a stopped metering pump if there is back pressure Use an injection valve or a vacuum breaker CAUTION Uncontrolled flow of feed chemical Feed chemical can leak through the ...

Page 19: ...liquid is drained off via the flushing collar and a hose nozzle without other parts of the liquid end coming into contact with the medium 1 Connect a hose to the lower hose nozzle 2 Route the hose into a collection vessel for the leakage liquid CAUTION A flushing equipment must be connected when using very aggressive or toxic media or when using media with a poor lubricating effect The flushing ag...

Page 20: ...ponents in areas at risk from explosion Note the enclosed documentation for the individual elec trical components WARNING Danger of electric shock Unprofessional installation may lead to electric shocks Cable end sleeves must be crimped onto all cut to length cable conductors Only technically trained personnel are authorised to undertake the electrical installation of the device WARNING Danger of ...

Page 21: ...inst heating from overloading Ensure that motors are only installed and inspected by a recognisably trained skilled operative in areas at risk from explosion Observe the enclosed operating instructions for the Ex motor CAUTION Provide appropriate motor protection devices e g motor pro tection switch with thermal overcurrent trip to protect the motor against overloading Fuses do not provide motor p...

Page 22: ...by frequency converters Connect the motors in accordance with the enclosed 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 be damaged Connect the stroke sensor to a suitable monitoring device according to the technical data provided with the monitoring dev...

Page 23: ...lue Unit Maximum voltage 24 VDC Maximum current 100 mA Closing duration approx 100 ms Service life 50 x 106 10 V 10 mA Play at rated load The contacts are potential free The pacing relay is a N O as standard Supply voltage for pacing relay PCB Available supply vol tages Mains supply fre quency Power consumption 230 V AC 180 254 V 50 60 Hz 10 mA at 230 V 50 Hz 115 V AC 90 134 V 50 60 Hz 15 mA at 11...

Page 24: ...shing pipes or bleed lines have been connected CAUTION Prior to commissioning check that the power end motor and corresponding ancillary equipment is connected in compli ance with the regulations CAUTION When using pumps with speed control observe the instruc tions in the frequency converter operating instructions CAUTION Possible environmental and material damage In event the red gear bleeding pl...

Page 25: ...ctrical Installation Only adjust the stroke length when the pump is running This is easier and also better for the pump Check for the correct leakage at the bottom flushing connector Leakage for run in packing 10 120 drops min Check for the correct function of the auxiliary equipment and for correct interplay Checking the direction of rotation Adjusting the stroke length Checking for correct leaka...

Page 26: ...ments Only perform tests and repairs in compliance with DIN EN IEC 60079 17 and only permit experienced per sonnel who have the requisite knowledge to perform the work These measures constitute the minimum protective measurements stipulated by ProMinent It is the duty of the operator to eliminate any other dangers identified by appropriate measures WARNING It is mandatory that you read the safety ...

Page 27: ...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 Under heavy loading e g continuous operation shorter maintenance intervals are recommended than those given Keep...

Page 28: ...e metering lines at both discharge and suction ends Check the leak tightness of the entire liquid end Check whether the leakage level is OK 10 120 drops min Check the oil level Check that the electrical connections are intact Check whether the pump is transporting media correctly run briefly at high power Observe the max imum permissible operating pressure Interval Maintenance work After approx 5 ...

Page 29: ...w 1 2 Place an oil trough under the oil drain plug 2 3 Unscrew the oil drain plug 2 from the power end housing 4 Allow the gear oil to run out of the power end 5 Screw in the oil drain plug 2 with a new seal Filling with gear oil Prerequisites Gear oil according to the Ordering information chapter is available 1 Start the pump 2 Slowly pour gear oil through the vent screw 1 opening until the oil i...

Page 30: ...ing any work on hydraulic parts WARNING Risk of fingers being crushed Under unfavourable conditions the stroke axle or displace ment body can cause crushing of the fingers Disconnect the pump from the mains power supply and ensure that it cannot be switched on again by unauthor ised persons WARNING Risk of injury from the fan impeller The fan impeller beneath motor s fan cowling can cause severe i...

Page 31: ...e machined side must point in the flow direction with all valve seats When assembling the valves take note of the sequence Teflon Metal Teflon Metal 1 Slide into the valve body 1 one after another n one seal 2 and one valve seat 3 correct n one seal 2 and one valve bushing 4 n If fitted one spring into the spring guide of the valve seat 3 n one ball 5 into the valve body 1 n one seal 2 and the sec...

Page 32: ...gain 4 If the liquid end has not been flushed according to the above pro cesses then protect yourself against the feed chemical protective clothing safety glasses After dismantling immediately place parts that have been wetting with the medium in a trough with a suitable medium for flushing in dangerous media were used flush and rinse thoroughly 5 Unscrew the hydraulic connectors on the discharge ...

Page 33: ...crews 25 of the dosing head flange 3 and remove the dosing head flange 3 Loosen the screws 27 of the guide ring 5 and remove it 4 Remove the flushing collar 4 the V sleeve packing 20 the washer 6 and spring 16 5 Thoroughly clean the sealing area in the dosing head 6 Clean the piston 2 the guide sleeves 6 and the flushing collar 7 7 Dispose of the V sleeve packing 20 the O ring 21 from the flushing...

Page 34: ... tighten the guide ring 5 with a new guide band 24 on the dosing head 8 Tighten the screws 27 Tightening torque 5 Nm 9 Place the dosing head flange 3 on the liquid end and tighten Tightening torque 7 Nm 10 Carefully push the piston 2 into the liquid end P_SI_0147_SW Fig 18 Section through the liquid end 2 Piston 4 Flushing collar 5 Guide ring 21 O ring 23 FOI ring 24 Guide band 1 Place the liquid ...

Page 35: ...4 Attach the upper protective cover to the turret 5 If fitted Connect the flushing tubes to the hose nozzles Repairs 35 ...

Page 36: ...isite knowledge WARNING Hot surface In event the power end motor is loaded excessively its sur face may become very hot Avoid contact If necessary mount a guard plate WARNING Danger of an electric shock Personnel working on electrical parts can be electrocuted if all electrical lines carrying current have not been discon nected Disconnect the supply cable before working on the motor and prevent it...

Page 37: ... unauthor ised persons Depressurise the system before commencing any work on hydraulic parts Fault description Cause Remedy Personnel Pump does not prime in spite of full stroke motion and bleeding The valves are dirty or worn Repair the valves see chapter enti tled Repair Technical per sonnel Pump does not reach high pres sure rates The valves are dirty or worn Repair the valves see chapter enti ...

Page 38: ...ly clean the liquid end and the housing of chemicals and dirt Adhere to the safety data sheet for the feed chemical 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 ...

Page 39: ...serve the safety data sheet Flush the dosing head thoroughly when using haz ardous feed chemicals 5 Possible additional work see chapter Storage Transport and Unpacking Personnel n Technical personnel Also drain the gear oil refer to the chapter entitled Maintenance Personnel n Technical personnel CAUTION Environmental hazard due to incorrect disposal Note the local guidelines currently applicable...

Page 40: ...002 320 1 9 0 46 71 5 160 1 4 23004 230 4 0 0 52 129 5 115 1 4 10006 100 6 4 0 55 195 5 50 1 4 14006 140 6 1 1 42 71 4 70 1 4 10011 100 11 0 1 43 129 4 50 1 4 05016 50 16 7 1 43 195 4 25 1 4 07012 70 12 4 2 90 71 4 35 1 4 04522 45 22 5 2 91 129 4 22 5 1 4 02534 25 34 1 2 92 195 4 12 5 1 4 04022 40 22 4 5 26 71 4 20 3 8 02541 25 41 5 5 37 129 4 12 5 3 8 01264 12 64 0 5 45 195 4 6 3 8 All figures re...

Page 41: ...0 580 26 5 7 0 84 4 20 3 8 02541 25 362 49 2 13 0 154 4 12 5 3 8 01264 12 174 76 0 20 1 233 4 6 3 8 All figures refer to water at 20 C The suction lift applies to filled suction line and filled liquid end when installed correctly Data Value Unit Reproducibility FK 08 1 0 Reproducibility other 0 5 when installed correctly under constant conditions at least 10 FK 08 30 stroke length and water at 20 ...

Page 42: ...4404 Stainless steel ceramic 13 5 Ambient conditions 13 5 1 Ambient temperatures Data Value Unit Storage and transport temperature 10 50 C Ambient temperature in operation drive motor 10 45 C 13 5 2 Media temperatures Data Value Unit Max temperature long term at max oper ating pressure 90 C Max temperature for 5 min at max 2 bar 150 C Minimum temperature 10 C 13 5 3 Air humidity Data Value Unit Ma...

Page 43: ...er Installation elec trical For more information see Pacing relay in the Relay chapter 5 25 V DC in accordance with Namur or DIN 60947 5 6 potential free design Data Value Unit Nominal voltage 8 VDC Power consumption active surface uncovered 3 mA Power consumption active surface cov ered 1 mA Rated switching distance 1 5 mm Ri 1 kΩ Cable colour Polarity blue brown 13 8 Relay The electrical data fo...

Page 44: ...om those of the standard pumps They can be queried by stating the details of the serial number During operation with an automatic stroke length adjustment control together with a variable speed motor the stroke rate must not fall below 30 strokes min Otherwise technical problems occur because the mechanical resistance of the stroke adjustment spindle becomes too high The motor data sheets for the ...

Page 45: ...ity C at minimum back pressure dependent on the stroke length s B Capacity C dependent on the back pressure p p bar S C l h C l h A B p bar S C l h C l h SBKa 60 Hz SBKa 60 Hz A B 80 60 40 20 0 100 120 0 10 20 30 40 50 60 70 80 90 02541 01264 02534 04522 04022 07012 80 60 40 20 0 100 120 05016 10011 10006 14006 23004 32002 0 5 10 15 20 25 0 10 20 30 40 50 60 70 80 90 80 70 60 50 40 30 20 0 10 0126...

Page 46: ...id end A B C 32002 23004 10006 FK 08 252 164 Rp 1 4 DN8 14006 10011 05016 FK 12 5 252 164 Rp 1 4 DN8 07012 04522 02534 FK 25 252 164 Rp 1 4 DN8 04022 02541 01264 FK 50 259 178 Rp 3 8 DN10 Standard motor Motor control lable EExe motor EExde motor Motor with fre quency con verter 1 ph motor L 426 528 472 448 647 427 Dimensional drawing Sigma SBKa Dimensional drawings 46 ...

Page 47: ...g Sigma piston metering pump 4x 4x 2x 2x P_SI_0137_SW Fig 22 The items listed are included in the spare parts kit Optional accessories not in the spare part kits Liquid end Exploded drawing Sigma piston metering pump 47 ...

Page 48: ...nd Exploded drawings ProMinent product catalogue www prominent com en downloads Spare parts kit Types 32002 23004 10006 Types 14006 10011 05016 Types 07012 04522 02534 Types 04022 02541 01264 FK 08 1001572 FK 12 5 910470 FK 25 910471 FK 50 910472 Scope of supply see exploded view drawings Spare parts kits SST liquid ends Sigma 2 piston ordering information 48 ...

Page 49: ...nt of any modification to the product not agreed with us Extract from the EC Declaration of Conformity Designation of the product Metering pump Sigma product range Product type SBKa and SCKa Serial number refer to nameplate on the device Relevant EC directives EC Machinery Directive 2006 42 EC EC EMC Directive 2004 108 EC Compliance with the protection targets of the Low Voltage Directive 2006 95 ...

Page 50: ...ype SBKa XY Characteristic value X P or L and characteristic value Y 1 or 2 or X 1 2 3 4 or 5 and Y A Serial number refer to nameplate on the device Relevant EC directives EC Machinery Directive 2006 42 EC EC EMC Directive 2004 108 EC EC Ex Directive 94 9 EC Harmonised standards applied in particular Pump without motor EN ISO 12100 1 2 EN 809 EN 13463 1 5 Motor Ex e EN 50014 EN 50019 Motor Ex d EN...

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Page 52: ...986266 1 en_GB 2011 ProMinent Dosiertechnik GmbH Im Schuhmachergewann 5 11 69123 Heidelberg Germany Telephone 49 6221 842 0 Fax 49 6221 842 612 email info prominent com Internet www prominent com ...

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