Sigma S2Ca Operating instructions

ProMinent
®
Operating Instructions
ProMinent® Sigma/ 2
S2Ba (Basic Type)
S2Ca (Control Type)
STOP
START
S2Ba
S2Ca
S2Ba
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
S2Ca
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
Please enter the identity code of the device here.
Two sets of operating instructions are necessary to ensure the ProMinent® Sigma/ 2 S2Ba or S2Ca metering pumps
are operated safely and reliably for their intended purpose:
This product specific Sigma/ 2 operating instructions manual and the ”General operating instructions
ProMinent® motor-driven metering pumps and hydraulic accessories” are only valid if read together!
Please completely read through these operating instructions first! · Do not discard!
The operator shall be liable for any damage caused by installation or operating errors!
Part No. 986669
BA_SI_036_06_10_EN.p65
ProMinent Dosiertechnik GmbH · 69123 Heidelberg · Germany
1
08.06.2010, 11:38 Uhr
BA SI 036 06/10 EN
Imprint
Imprint
Operating Instructions for ProMinent® Sigma/ 2 S2Ba/S2Ca
Translation of the original operating manual
© ProMinent Dosiertechnik GmbH, 2002
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg · Germany
info@prominent.com
www.prominent.com
Subject to technical modifications.
®
ProMinent
Page 2
BA_SI_036_06_10_EN.p65
2
08.06.2010, 11:38 Uhr
Control elements and key functions
Control elements: overview
4
3
2
1
5
16
6
7
8
9
10
15
14 13 12
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Operating light (green)
Warning light (yellow)
Error warning light (red)
Stroke length adjuster
LCD display
UP key
DOWN key
P key
STOP/START key
i key
Relay output (optional)
Metering monitor socket
Float switch socket
External control socket
Diaphragm rupture indicator socket
Mains switch
Key functions
In continuous display mode
(operating)
In settings mode
(settings)
Stop pump,
start pump
Stop pump,
start pump
Press briefly
Start batch (in “batch” operating mode only),
Cancel error
Confirm entry- jump to next menu
option or continuous display
Press for 2 s
Press for 3 s
Press for 10 s
Press for 15 s
Change to settings mode
--Software version displayed
Load factory settings (calibration)
--Jump to continuous display
Press x1
Toggle between continuous displays
Toggle between “change individual digits”
and change a figure"
Press x2
---
For “change individual digits”:
jumps to first digit
Press separately
(until “Set” appears)
Change directly alterable values
Select other settings,
change individual digit or figure
Press simultaneously
Prime (in “stroke rate” permanent display)
---
STOP/START key
STOP
START
Press briefly
P key
P
---
i key
i
Arrow keys UP and DOWN
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 3
3
08.06.2010, 11:38 Uhr
p. 52
Select the operating mode here first,
then carry out the settings in the SET menu.
Exceptions: Timer and PROFIBUS®.
p. 43
p. 51
p. 44
next page
BA_SI_036_06_10_EN.p65
4
08.06.2010, 11:38 Uhr
previous page
p. 49
p. 48
p. 49
Calib
Set
Set
Set
P
Set
Set
p. 34
Calib
Set
Set
p. 50
p. 50
p. 50
BA_SI_036_06_10_EN.p65
5
08.06.2010, 11:38 Uhr
Set
Page 6
BA_SI_036_06_10_EN.p65
ProMinent
®
6
08.06.2010, 11:38 Uhr
Operating mode ”Contact” with
memory and transfer factor 5
Operating mode ”Batch” with
memory and transfer factor 5
Table of contents
Page
Identcode ordering system
1
9
Notes on safety of ProMinent ® metering pumps
1.1 General notes
12
1.2 Notes on installation, start-up and operation
12
1.3 Notes on maintenance and repair
13
2
14
Product description S2Ba/S2Ca
2.1 Identification of pump type
14
2.2 Design/Functional description
14
3
2.2.1 Functional description, drive
14
2.2.2 Stroke movement
15
2.2.3 Functional description, delivery unit
16
2.2.4 Integrated overflow valve with bleeder function
17
2.2.5 Diaphragm rupture sensor
19
Technical data
22
3.1 Technical data Sigma/ 2
22
3.1.1 Capacity data
22
3.1.2 Dimensions Sigma/ 2 S2Ba
24
3.1.3 Dimensions Sigma/ 2 S2Ca
25
3.1.4 Dimensions Sigma/ 2 S2Ba
26
3.1.5 Motor data
26
3.1.6 Stroke actuator drive mechanism
27
3.1.7 Stroke adjuster drive mechanism
27
3.1.8 Electrical data, stroke sensor “Sigma”
27
3.1.9 Electrical data, pacing relay “Sigma” (for the basic version)
28
3.1.10Sound intensity level
28
Start-up/Maintenance
30
4
4.1 Start-up
30
4.2 Maintenance
30
4.3 Replacement of wearing parts
31
5
32
Features of the S2Ca metering pumps
5.1 Function description, motors
32
5.2 Function description, controller
33
5.3 Sockets, symbols and wiring diagram
35
5.4 Retrofitting relays
40
®
ProMinent
BA_SI_036_06_10_EN.p65
11
Page 7
7
08.06.2010, 11:38 Uhr
Table of contents
6
Control elements
41
7
Settings
42
7.1 Check adjustable values
43
7.2 Change to settings mode
43
7.3 Select operating mode (MODE menu)
43
7.4 Settings for operating mode (SET menu)
44
7.4.1 Settings for “manual” operating mode
44
7.4.2 Settings for “analogue” operating mode (ANALG menu)
44
7.4.3 Settings for “contact” operating mode (CONTCT menu)
46
7.4.4 Settings for “batch” operating mode (BATCH menu)
48
7.5 Settings for programmable functions (SET menu)
7.5.1 Settings for “calibration” function (CALIB menu)
49
7.5.2 Settings for “auxiliary frequency” function (AUX menu)
50
7.5.3 Settings for the “flow” function (Flow menu)
50
7.6 Setting code (CODE menu)
50
7.7 Cancel total stroke number or total litres (CLEAR window)
50
8
51
Operating
8.1 Manual operation
51
8.2 Remote control
52
9
Troubleshooting
52
10
Decommissioning and disposal
54
11
Spare parts and accessories
55
Annex
58
Motor data sheet
58
EC Declaration of Conformity
59
Exploded diagrams of liquid ends
61
Exploded diagrams of liquid ends
63
®
ProMinent
Page 8
BA_SI_036_06_10_EN.p65
49
8
08.06.2010, 11:38 Uhr
Identcode ordering system
Identcode ordering system
Please enter the identcode on the device label into the grey box below.
®
®
ProMinent
ProMinent
BA_SI_036_06_10_EN.p65
Page 9
9
08.06.2010, 11:38 Uhr
Identcode ordering system
Identcode ordering system
Please enter the identcode on the device label into the grey box below.
®
ProMinent
Page 10
BA_SI_036_06_10_EN.p65
10
08.06.2010, 11:38 Uhr
Notes on safety of ProMinent ® metering pumps
1
Notes on safety of ProMinent ® metering pumps
General user instructions
Please read through the following user instructions carefully! They will help you get the best use
out of the operating instruction manual.
The following are highlighted in the text:
• Enumerations
왘 Instructions
Operating guidelines:
NOTE
Notices are intended to make your work easier.
and safety guidelines:
WARNING
Describes a potentially dangerous situation. If not avoided. could cause fatal or serous
injury.
CAUTION
Describes a potentially dangerous situation. If not avoided. could cause slight or minor
injury or damage to property.
Please also note the guidelines in “General Operating Instruction Manual for ProMinent® MotorDriven Metering Pumps and Hydraulic Accessories”!
Please give the order number and the serial number, which you will find on the nameplates of the
pump itself, in the event of any query or spare part order. This facilitates identification of the
pump.
EX-pump only: The nameplates affixed to the title page are identical to those on the pump
supplied to enable clear identification on the correct operating instruction manual for the pump
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 11
11
08.06.2010, 11:38 Uhr
Notes on safety of ProMinent ® metering pumps
1.1
General notes
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
• The equipment/devices may only be used for their intended purpose.
• ProMinent® metering pumps must not be assembled with parts which are not tested and
recommended by ProMinent otherwise this can lead to injury to persons and damage to
property for which no liability will be accepted!
• Pumps must be accessible at all times to facilitate operation and maintenance. Access
points must not be obstructed or blocked!
• Before carrying out any maintenance and repair work always drain off and flush out the
liquid end first if hazardous or unknown metered media are used!
• When metering hazardous or unknown liquids, always wear safety clothing (safety
goggles, gloves, ...) when working on the liquid end!
• You must observe the guidelines in this operating instructions manual and the ”General
operating instructions manual for ProMinent® motor-driven metering pumps and
hydraulic accessoires” on assembly, installation and maintenance!
1.2
Notes on installation, start-up and operation
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
• The metering pump can contain water residue in the liquid end as the result of testing at
the factory!
If handling media which must not come in contact with water, all traces of water must be
removed from the liquid end before start-up! For this purpose, turn the pump through
180˚ and drain off the liquid end then flush with a suitable medium from above via the
intake connection!
• Do not connect mains voltage to the control cable!
• When operating the metering pump against a closed shut-off element on the pressure
side or in the event of pressure peaks during the metering stroke, the system pressure
can reach a multiple of the maximum permissible operating pressure that can consequently cause the pressure line to burst!
To avoid this situation, an overflow is recommended for the purpose of limiting the
maximum permissible operating pressure of the pump or system.
• Do not connect a metal bypass line to the overflow valve on the PVT delivery unit! This
could cause cracks in the delivery unit!
• Leaks can develop in the relief valve can or parts of it can corrode! For this reason, the
bypass line should only be routed falling continuously and, moreover, the tubing nozzle
should only be inserted facing downwards (see fig. 1)!
• No chemical residues must remain in the bypass line on the relief valve of the liquid end!
Fig. 1
®
ProMinent
Page 12
BA_SI_036_06_10_EN.p65
12
08.06.2010, 11:38 Uhr
Notes on safety of ProMinent ® metering pumps
IMPORTANT
• Set stroke length only with pump in operation!
• Pull the red plug for venting the gear unit during initial operation of the Sigma/ 2 metering
pump (refer to Fig. 3, item 10)!
NOTE
• The pump must be secured in such a way that no vibrations can occur! The valves of the
liquid end must always be positioned vertically in order to ensure trouble-free operation!
• Suction, discharge and bypass lines must always be routed in such a way that a
mechanically stress-free connection is ensured to the dosing head!
The lines must be secured such that no vibrations can occur!
• Only use the clamping rings and hose sockets intended for the relevant hose diameter as
well as original hoses with the specified hose dimensions and wall thickness otherwise
the stability and durability of the connection will not be guaranteed!
Avoid reducing hose sizes!
Fig. 2
Observe the permissible pressure of the hoses!
• The pump is supplied with PTFE moulded composite seals with a flare, which are used
for the pump connections that seal the connections between the grooved pump valves
and the grooved ProMinent (fig. 3).
But if such an insert of a connection is not fluted (e.g. third-party part), a flat elastomer
gasket has to be used (fig. 3). Otherwise, leakage may occur at this connection.
• A vent with return to the supply tank is advisable when metering extremely aggressive or
hazardous media!
Fig. 3
In addition, a shut-off valve should be provided on the delivery or intake side!
1.3
Notes on maintenance and repair
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
• Only send the equipment for repair or maintenance in a cleaned condition and with the
liquid end flushed. However, should any safety precautions be necessary even after
careful draining and cleaning of the equipment, the required information must be listed
in the Safety Declaration!
The Safety Declaration forms part of the inspection/repair contract.
Maintenance or repair work will only be carried out if a Safety Declaration - correctly
and fully completed by an authorised and qualified member of the Operator’s staff is available.
A copy of the form is included in the “General operating instructions for ProMinent
motor-driven dosing pumps and hydraulic accessories” or can be downloaded at
www.prominent.com.
• Only specially trained and authorized persons are permitted to carry out maintenance on
metering pumps and their peripherals!
• If hazardous or unknown metering media are used, always flush out the liquid end first
before carrying out any maintenance and repair work!
• When metering hazardous or unknown liquids, always wear safety clothing (safety
goggles, gloves, ...) when working on the liquid end!
• Always depressurize the delivery line first before carrying out any work on the pump!
Always discharge and flush liquid end!
Observe safety data sheets for metered liquid!
• Disconnect power plug or power supply line before opening the plug!
Isolate relay option if applicable!
Check to ensure power is disconnected!
Secure pump while carrying out repairs to ensure it cannot be switched on unintentionally!
• Pumps for metering radioactive media must not be shipped through standard channels!
NOTE
The metering pump must be in a cleaned condition with the liquid end flushed if returned
for repair!
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 13
13
08.06.2010, 11:38 Uhr
Product description S2Ba/S2Ca
2
Product description S2Ba/S2Ca
Use for intended purpose
• The pump is designed as a liquid medium metering pump; it serves the purpose of metering
liquid medium within the specified line system!
• In potentially explosive atmospheres in zone 1, device category II 2G of explosion group II C,
the pump must only be operated according to the relevant type plate (and the respective EC
Declaration of Conformity) for pumps for potentially explosive atmospheres complying with
Directive 94/9/EC in accordance with the European guidelines.
• As of 01.07.2003, only pumps are permitted to be used in potentially explosive atmospheres
that have the respective markings according to EG-Ex-RL 94/9. The explosion group, category
and protection class declared on the marking must correspond with or be better than the given
conditions in the intended field of application.
• Operate the pump only within the conditions described in the technical data!
• General restrictions with regard to viscosity limits, chemical resistance and density must be
observed (refer to ProMinent® chemical resistance list (equipment catalogue or
www.prominent.com))!
• All other applications or conversion are prohibited!
• The pump is not designed to meter gaseous media as well as solids.
• The pump is not suitable for metering combustible liquids!
• Pumps without respective type plate (and the respective EC Declaration of Conformity) for
pumps for potentially explosive atmospheres must never be operated in potentially explosive
atmospheres.
• Only specifically trained and authorized personnel are permitted to operate the pump!
• You are obliged to observe the data in the operating instructions on the various life phases of
the device!
2.1
Identification of pump type
Fig. 4
The identity code and serial number are given in addition to the standard technical specifications.
These two numbers must always be quoted when making any enquiries as they enable distinct
identification of the type of metering pump.
2.2
Design/Functional description
2.2.1
Functional description, drive
The ProMinent® Sigma/ 2 diaphragm-type metering pump is an oscillatory displacement pump
with the stroke length adjustable in steps of 0.5 %. It is driven by electric motor (1). The rotary
drive of the electric motor is stepped down by worm gear and transmitted via the eccentric roller
(3) to the push rod (4) connected to fork (8) and converted into oscillatory movement. Return
spring (5) presses the fork with push rod positively against the eccentric roller thus producing the
return stroke. The stroke is adjusted by means of stroke adjustment knob (6) and spindle (7) by
limiting the return stroke. Stroke movement is transmitted directly to the displacement diaphragm.
Interacting with the valves, this diaphragm produces the overpressure and vacuum in the liquid
end necessary for delivery. Flow is pulsating.
In the basic type, the electric motor is normally a 3-ph extended-range AC motor (refer to Section 3
for other options).
®
ProMinent
Page 14
BA_SI_036_06_10_EN.p65
14
08.06.2010, 11:38 Uhr
Product description S2Ba/S2Ca
Fig. 5
61_01-101_00_25-01
2.2.2
Stroke movement
a) Stroke progression
at max. stroke rate
and stroke length
b) At reduced stroke length
Stroke speed
+ Delivery stroke
– Intake stroke
0
180
360
Angle reduced stroke length
Fig. 6
Set stroke length dependent on the required delivery capacity.
30
%
30%
75 %
75%
0
50
25
75
20
0
0
25
5
0
5
10
Fig. 7
NOTE
• For outgassing media, please select a stroke length as large as possible!
• For a good mixing, please select a stroke length as large as possible!
• For a precise dosing at quantity-proportional dosing, do not adjust the stroke length
below 20 %!
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 15
15
08.06.2010, 11:38 Uhr
Product description S2Ba/S2Ca
2.2.3
Functional description, delivery unit
The heart of the liquid end is the multi-layer safety diaphragm (2) patented by ProMinent. It
hermetically seals the delivery chamber of the liquid end (4) and produces a displacement in the
dosing head. The end disc (5) made of chemically-resistant plastic, together with the safety
diaphragm (13) separates the drive housing from the delivery unit and protects the drive from
dust and corrosion. Delivery is based on the interaction between intake valve (1) and head valve
(3) of the same design together with the diaphragm movement. The valve balls can be supported
with springs for metering viscous media.
The connection dimensions of valves and liquid ends of the same size but with different materials
are identical. These parts can be interchanged as required.
Materials and dimensions are specified in Section 3, Technical data.
5
3
13
4
2
1
Fig. 8
61_05-103_00_73-03
®
ProMinent
Page 16
BA_SI_036_06_10_EN.p65
16
08.06.2010, 11:38 Uhr
Product description S2Ba/S2Ca
2.2.4
Integrated overflow valve with bleeder function
Task:
The task of the overflow valve is to protect the motor and gear unit against impermissible
overpressure caused by the metering pump.
This function is produced by a spring-loaded ball.
A pressure relief mechanism for the bleeder function is provided.
Design and functional description
(refer to Fig. No. 6 and 7)
Initially, the overflow valve illustrated under item 102 operates as a simple directly controlled
relief valve. As soon as the pressure set with spring item 132 is exceeded, the effective pressure
raises ball item 130. The liquid then flows off into the tank via hose connection item 128.
102
132
130
139
133
128
Overflow valve Sigma/ 2 liquid end, 10 bar PVT
Identcode Type: 16050, 16090, 16130
Overflow valve Sigma/ 2 liquid end, 7 bar PVT
Identcode Type: 07120, 07220
Overflow valve Sigma/ 2 liquid end, 4 bar PVT
Identcode Type: 04350
Fig. 9
61_05-103_00_74-03
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 17
17
08.06.2010, 11:38 Uhr
Product description S2Ba/S2Ca
102
132
130
139
133
128
Overflow valve Sigma/ 2 liquid end, 16 bar SST
Identcode Type: 16050, 16090, 16130
Overflow valve Sigma/ 2 liquid end, 7 bar SST
Identcode Type: 07120, 07220
Overflow valve Sigma/ 2 liquid end, 4 bar SST
Identcode Type: 04350
Fig. 10
61_05-103_00_90-03
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
IMPORTANT
• Once the pump has primed, turn knob item 139 in clockwise direction as far as it will go
towards ”close“! The pump is now operational.
• The bypass line must always be closed and must be routed back into the supply tank.
Connection via hose connection item 128.
• Minimal overflow can occur in the bypass line when the valve operates close to the
overpressure function.
The bleeder function is achieved by turning knob item 139 in counterclockwise direction as far as
it will go towards ”open“: Priming aid for starting up pump against pressure. The force of spring
item 132 relieves ball item 130 which is controlled by the lower spring force of bleeder spring
item 133.
®
ProMinent
Page 18
BA_SI_036_06_10_EN.p65
18
08.06.2010, 11:38 Uhr
Product description S2Ba/S2Ca
Technical data
Corresponding to the type of pump, overflow valves are available for pressure stages pnom 4, 7,
10, 12 and 16 bar with (1.05 ... 1.15) xpnom opening pressure.
Material in contact with metered medium
Material
version
Balls
Integrated
overload
valve
PVT
Ceramic / glass*
PDFE/FPM or EPDM
SST
Stainless steel
1.4404
Stainless steel/
FPM or EPDM
*for 07120, 07220, 04350
FPM = Fluorine Rubber
WARNING
• The relief valve protects the metering pumps against non-permissible excess pressure caused
by the metering pump; it does not protect the station.
• Use the overflow value only in connection with liquid with a viscosity of up to max. 200 mPa s.
• When carrying out maintenance work on the overcurrent valve, pay attention to the tensioned
state of the pressure spring item132! Wear safety goggles!
IMPORTANT
• The ceramic ball and ball seat of the overflow valve are wearing parts. Slight leakage can
occur at the safety valve after a prolonged period of operation. The ball and ball seat
should be replaced if leaks occur.
• The bypass line must always be connected and must be routed back into the supply tank.
• The pump must not be operated without the bypass line connected.
• The bypass line must not be connected in the intake line (the bleeder function will no longer be
guaranteed). The bypass line must be routed back into the supply tank.
2.2.5
Diaphragm rupture sensor
Function:
Monitors the seals in the metering diaphragm. The liquid end can continue to function for a short
period in emergency mode, i.e. full operating pressure, no leakage, even after diaphragm rupture.
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 19
19
08.06.2010, 11:38 Uhr
Product description S2Ba/S2Ca
Design and function description
1
7
6
5
Fig. 11: Section through the diaphragm rupture signalling Sigma
(without electrical component parts)
4
2
3
1 Working layer (^
= working diaphragm)
2 Safety layer (^
= safety diaphragm)
3 Lug
4 Plunger
5 Diaphragm rupture sensor
6 Cylinder, red
7 Cover, transparent
The multilayer safety diaphragm has the same function as the conventional double diaphragm
systems with working and safety diaphragm; however, it has the advantage that both
diaphragms are grouped to form a unit.
If the working layer (1) ruptures, the metering medium penetrates between the working layer
and the safety layer (2) and spreads. The safety layer ensures that no metering medium leaks to
the outside.
As soon as the metering medium reaches the lug (3) at the edge of the multilayer safety
diaphragm, the lug expands. The lug presses on a plunger (4) in the diaphragm rupture sensor
(5) and the sensor triggers.
In mechanical diaphragm rupture sensors, the sunk red cylinder (6) under the transparent
cover (7) jumps to the front such that it is clearly visible.
In electrical diaphragm rupture sensors, a switch switches. A connected signalling unit signals
the diaphragm rupture. In the control version, the diaphragm rupture sensor is connected to the
“socket for diaphragm rupture monitor”. In case of a diaphragm rupture, the red LED indicator
“Fault” is illuminated at the pump, the identifier “Error" and DIAPH flash on the LCD screen.
Depending on the selected Identcode version in “Displacement body”, the pump continues to
meter (“Pump emits alarm”) or stops (“Pump stops”).
®
ProMinent
Page 20
BA_SI_036_06_10_EN.p65
20
08.06.2010, 11:38 Uhr
Product description S2Ba/S2Ca
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
IMPORTANT
• With the S3Ba, the customer should install a diaphragm rupture signal monitor with
electrical diaphragm sensors or ensure that the metering pump will stop after a
diaphragm rupture signal.
• In the event of diaphragm failure, a signal is triggered as from 2 bar system
backpressure.
• Exact pump delivery can no longer be guaranteed after failure of the working diaphragm.
Electrical data for the diaphragm breakage sensor
IMPORTANT
• Before commencing operation, install the provided diaphragm breakage sensor together
with the gasket (Item159) and make the electrical connections.
• For safety reasons it is advisable to connect a safe low voltage (e.g. EN 60335-1 (SELV)).
a) Switch contact
30 V DC/1 A
or
125 V AC/0.6 A
or
250 V AC/0.3 A
The diaphragm sensor is a N/C relay.
NOTE
• The cable priority is arbitrary.
b) Namur sensor, intrinsically
Blue
-
Brown
+
5-25 V DC, Namur type and/or DIN 60947-5-6, zero volt design.
Rated voltage: 8 V DC (Ri ~ 1 kΩ)
Power consumption:
Active surface, uncovered > 3 mA
Active surface, covered < 2 mA
Rated switching distance: 1.5 mm
The monitor/feeder must be capable of evaluating current changes in order to indicate
diaphragm rupture!
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 21
21
08.06.2010, 11:38 Uhr
Technical data
3
Technical data
WARNING
Only with modified version: Observe the “Enhancement with modified version” at the end
of the chapter in all cases!
It replaces and supplements the technical data!
3.1
Technical data Sigma/ 2
3.1.1
Capacity data
Technical data S2Ba at 50 Hz operation
Feed rate at
maximum
back pressure
Max.
stroke
rate
Suction
lift
Admissible
priming
pressure
suction side
Connection
suction /
discharge
side
Shipping
weight
Pump type Sigma
bar
l/h
ml/stroke
strokes/min.
m WC
bar
G - DN
kg
16050 PVT
10
50
11.4
73
7
3
1"-15
15
16050 SST
16
48
11.4
73
7
3
1"-15
20
16090 PVT
10
90
11.4
132
7
3
1"-15
15
16090 SST
16
86
11.4
132
7
3
1"-15
20
16130 PVT
10
130
10.9
198
7
3
1"-15
15
16130 SST
16
125
10.9
198
7
3
1"-15
20
07120 PVT
7
120
27.4
73
5
1
20*
16
07120 SST
7
120
27.4
73
5
1
20*
24
07220 PVT
7
220
27.7
132
5
1
20*
16
07220 SST
7
220
27.7
132
5
1
20*
24
04350 PVT
4
350
29.4
198
5
1
20*
16
04350 SST
4
350
29.4
198
5
1
20*
24
All performance data applies to water at 20 °C.
The suction lift applies when the suction line and liquid end are full and correctly installed.
* Sigma types 07120, 07220 and 04350, the valves used in the liquid end are DN 25 (G11/2). Since DN 20 is usually adequate for
this tubing (see Technical Data, connection-suction/discharge side) the connector parts to be ordered by Identcode (e.g.
washers) have already been reduced to DN 20, i.e. tubing and accessories can be DN 20.
Technical data S2Ba at 60 Hz operation
Feed rate at
maximum
back pressure
Max.
stroke
rate
Suction
lift
Admissible
priming
pressure
suction side
Connection
suction /
discharge
side
Shipping
weight
Pump type Sigma
bar
psi
I/h/gph
strokes/min.
m WC
bar
G - DN
kg
16050 PVT
10
145
60/ 15.9
87
7
3
1"-15
15
16050 SST
16
232
57/ 15.2
87
7
3
1"-15
20
16090 PVT
10
145
108/ 28.5
156
7
3
1"-15
15
16090 SST
16
232
103/ 27
156
7
3
1"-15
20
16130 PVT
10
145
156/ 41
232
7
3
1"-15
15
16130 SST
16
232
150/ 39.6
232
7
3
1"-15
20
07120 PVT
7
100
144/ 38
87
5
1
20*
16
07120 SST
7
100
144/ 38
87
5
1
20*
24
07220 PVT
7
100
264/ 69.7
156
5
1
20*
16
07220 SST
7
100
264/ 69.7
156
5
1
20*
24
04350 PVT
4
58
420/ 111
232
5
1
20*
16
04350 SST
4
58
420/ 111
232
5
1
20*
24
All performance data applies to water at 20 °C.
The suction lift applies when the suction line and liquid end are full and correctly installed.
* Sigma types 07120, 07220 and 04350, the valves used in the liquid end are DN 25 (G11/2). Since DN 20 is usually adequate for
this tubing (see Technical Data, connection-suction/discharge side) the connector parts to be ordered by Identcode (e.g.
washers) have already been reduced to DN 20, i.e. tubing and accessories can be DN 20.
®
ProMinent
Page 22
BA_SI_036_06_10_EN.p65
22
08.06.2010, 11:38 Uhr
Technical data
Technical data S2Ca
Feed rate at
maximum
back pressure
Max.
stroke
rate
Suction
lift
Admissible
priming
pressure
suction side
Connection
suction /
discharge
side
Shipping
weight
Pump type Sigma
bar
l/h
ml/stroke
strokes/min.
m WC
bar
R - DN
kg
16050 PVT
10
145
60/ 16
90
7
2
1"-15
17
16050 SST
16
232
60/ 16
90
7
2
1"-15
22
16090 PVT
10
145
95/ 25
160
7
2
1"-15
17
16090 SST
16
232
95/ 25
160
7
2
1"-15
22
16130 PVT
10
145
136/ 36
200
7
2
1"-15
17
16130 SST
16
232
136/ 36
200
7
2
1"-15
22
07120 PVT
7
100
148/ 39
90
5
1
11/2 - 20*
18
1
07120 SST
7
100
148/ 39
90
5
1
1 /2 - 20*
26
07220 PVT
7
100
232/ 61
160
5
1
11/2 - 20*
18
07220 SST
7
100
232/ 61
160
5
1
1
26
1
1 /2 - 20*
04350 PVT
4
58
350/ 93
200
5
1
1 /2 - 20*
18
04350 SST
4
58
350/ 93
200
5
1
11/2 - 20*
26
All performance data applies to water at 20 °C.
The suction lift applies when the suction line and liquid end are full and correctly installed.
* Sigma types 07120, 07220 and 04350, the valves used in the liquid end are DN 25 (G11/2). Since DN 20 is usually adequate for
this tubing (see Technical Data, connection-suction/discharge side) the connector parts to be ordered by Identcode (e.g.
washers) have already been reduced to DN 20, i.e. tubing and accessories can be DN 20.
Materials in contact with chemicals
Material
version
Liquid end
Suction/
discharge
connector
Seals/
Ball seat
Balls
Springs
Integrated
overload valve
PVT
PVDF
PVDF
PTFE/PTFE
Ceramic / glass*
Hastelloy C
PDFE/FPM or EPDM
SST
Stainless steel
1.4571/1.4404
Stainless steel
1.4581
PTFE/PTFE
Stainless steel
1.4404
Hastelloy C
Stainless steel/
FPM od EPDM
* for 07120, 07220 and 04350
FPM = Fluorine Rubber
Temperature specifications
Permissible storage temperature:
Permissible ambient temperature:
–10 to +50 °C
–10 to +40 °C
Temperature compatibility (medium temperature) of materials
Material:
Long-term at max.
backpressure:
Short-term, max. 15 min.
at max. 2 bar
PVT
65 °C
100 °C
SST
90 °C
120 °C
PPT
50 °C
100 °C
PCT
45 °C
60 °C
The specified temperatures (see above) can be exceeded temporarily, e.g. for sterilisation or
flushing with hot water.
Air humidity:
< 92 % relative humidity, non-condensing
Accuracy
Under constant conditions and in minimum stroke length of 30 % corresponding to following
notes, the reproducibility of the metered quantity is better than ±2 %.
All specifications refer to metered quantities with water at 20 °C and correct installation of the
metering pump.
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 23
23
08.06.2010, 11:38 Uhr
Technical data
3.1.2
Dimensions Sigma/ 2 S2Ba
Tube nozzle sv d16 S with
thread DIN ISO 228-G3/4
C
Connection
variations
L
Ø 165
B
A
ØG
PVDF
Ø16
185
PP/PVC/PTFE
max. 40
SS
F
6.5
120
44
K
136
27+7
28
D
120
225
E
Fig. 12
61_01-101_00_27-73
Dimensions Sigma/ 2 (in mm)
Type
Connection
A
B
C
D
E
F
ØG
I
K
Sigma 04350, 07120, 07220 PVT
DN 25
287
234
G1 1/2"A
118
353
75
156
166
71
Sigma 04350, 07120, 07220 SST
DN 25
287
233
G1 1/2"A
118
345
88
159
140
60
Sigma 12050, 12090, 12130,
16050, 16090, 16130 PVT
DN 15
251
162
G1"A
111
341
72
122
148
63
Sigma 12050, 12090, 12130,
16050, 16090, 16130 SST
DN 15
251
162
G1"A
110
330
88
122
122
53
L*
Höhe L der S2Ba in Abhängigkeit von der Motorausführung
(Maße in mm)
Standard
motor
1 phase
motor
EExemotor
EExdemotor
Motor
variable speed
Motor with
frequency inverter
Identcode-Merkmal
S
M, N
L1, P1
L2, P2
R
V0
L (in mm)
426
427
472
448
523
644
Anschlussvarianten
®
ProMinent
Page 24
BA_SI_036_06_10_EN.p65
24
08.06.2010, 11:38 Uhr
Technical data
3.1.3
Dimensions Sigma/ 2 S2Ca
Tube nozzle sv d16 S with
thread DIN ISO 228-G3/4 A
C
B
ØG
441
Ø 165
185
A
Ø16
max. 40
27+7
6.5
120
F
44
28
79.5
120
136
222
D
K
E
Fig. 13
61_01-101_00_32-73
Dimensions Sigma/ 2 (in mm)
Type
Connection
A
B
C
D
E
F
ØG
I
K
Sigma 04350, 07120, 07220 PVT
DN 25
302
234
G1 1/2"A
118
350
75
156
181
71
Sigma 04350, 07120, 07220 SST
DN 25
302
233
G1 1/2"A
118
342
88
159
155
60
Sigma 12050, 12090, 12130,
16050, 16090, 16130 PVT
DN 15
266
162
G1"A
111
338
72
122
163
63
Sigma 12050, 12090, 12130,
16050, 16090, 16130 SST
DN 15
266
162
G1"A
110
327
88
122
137
53
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 25
25
08.06.2010, 11:38 Uhr
Technical data
3.1.4
Dimensions Sigma/ 2 S2Ba
T
ØP
ØN
170
217
V
E
A-A
120
8
225
44
191
ØD
ØS
ØM
120
A
Fig. 14
A
61_01_101_00_27_73
K
Dimensions Sigma/ 2 (in mm)
Motor flange
ØP
ØM
ØN
B 14/105
105
85
70
56 C/138
5.43⬙
5.88⬙
4.5⬙
B 14/160
160
130
110
B 14/200
200
165
130
B 5/140*
140
115
95
ØS
ØD
E
T
K
L
V
19
29
3,5
5
16,3
288
0.62⬙
1.14⬙
0.16⬙
0.2⬙
0.72⬙
12.2⬙
9
14
29
6
5
16,3
290
11
19
52,5
6
6
21,8
323
11
26
3,5
4
12,8
230
7
0.43⬙
9,5
* assembly without adapt flange direct on pump housing
3.1.5
Motor data
Electrical Data
Identcode
characteristic
Rated voltage
System
Rated
frequency power
S
3 ph, IP 55
220-240 V/380-420 V
50 Hz
0.25 kW
250-280 V/440-480 V
60 Hz
0.25 kW
M
1 ph AC, IP 55
230 V ±5 %
50/60 Hz
0.18 kW
N
1 ph AC, IP 55
115 V ±5 %
60 Hz
0.18 kW
L1
3 ph, II2GEEXeIIT3
220-240 V/380-420 V
50 Hz
0.18 kW
L2
3 ph, II2GEEXdIICT4 220-240 V/380-420 V
50 Hz
0.18 kW
with PTC thermistor, speed adjustment range 1:5
P1
3 ph, II2GEEXeIIT3
250-280 V/440-480 V
60 Hz
0.18 kW
P2
3 ph, II2GEEXdIICT4 250-280 V/440-480 V
60 Hz
0.21 kW
with PTC thermistor, speed adjustment range 1:5
R
3 ph, IP 55
230 V/400 V
50/60 Hz
0.37 kW
with PTC thermistor, speed adjustment range 1:20
with external fan 1 ph 230 V; 50/60 Hz
V0
1 ph, IP 55
230 V ±5 %
50/60 Hz
0.37 kW
variable speed motor with integrated
frequency converter
For more details you can request the motor specification sheets. Custom motors and/or custom
motor flanges are available on request.
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
®
ProMinent
Page 26
BA_SI_036_06_10_EN.p65
26
08.06.2010, 11:38 Uhr
Technical data
Fuse data
IMPORTANT
• The motors are not fuse-protected. Fit a motor circuit breaker!
• When connecting the motor, make sure that it rotates in the correct direction (see Fig. 11).
direction of rotation
Protection against accidental contact and moisture (IP)
Motor: IP 55 DIN EN 60034-5 (in accordance with DIN VDE 0470 Part 1, corresponds to
EN 60529 and IEC 529).
Air humidity
Air humidity: maximum 90 % relative humidity, non-condensing.
External fan
Notes on the speed-controlled motor with separate fan and temperature monitoring may be
found in the “General Operating Instructions ProMinent® Motor-Driven Metering Pumps and
Hydraulic Accessories”.
Fig. 15
S2Ba/S2Ca-026-D
3.1.6
Stroke actuator drive mechanism
230 V ± 10 % 50/60 Hz
11.7 W
115 V ± 10 %
11.7 W
3.1.7
60 Hz
Stroke adjuster drive mechanism
230 V ± 10 % 50/60 Hz
6.5 W
115 V ± 10 %
6.5 W
60 Hz
Cf. “Appendix” for terminal connection diagram.
3.1.8
Electrical data, stroke sensor “Sigma”
a) Reed contact (Identcode characteristic “Stroke sensor”: 2)
Pin 1 (white)
=
4.5 V to 24 V, max. 10 mA
Pin 2 (brown)
=
OUT, open collector, 24 V, 20 mA
Pin 3 (green)
=
GND
Pulse width (low) ≥
4 ms (depending on gearbox and power frequency)
Blue
-
Brown
+
b) Namur sensor, intrinsically (Identcode characteristic “Stroke sensor”: 3)
5-25 V DC, Namur type and/or DIN 19234, zero volt design.
Rated voltage: 8 V DC (Ri ~ 1 kΩ)
Power consumption:
Active surface, uncovered > 3 mA
Active surface, covered < 1 mA
Rated switching distance: 1.5 mm
The monitor/feeder must be capable of evaluating current changes in order to indicate
diaphragm rupture!
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
IMPORTANT
• Before commencing operation, install the provided diaphragm breakage sensor together
with the gasket (Item159) and make the electrical connections.
• For safety reasons it is advisable to connect a safe low voltage (e.g. EN 60335-1 (SELV)).
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 27
27
08.06.2010, 11:38 Uhr
Technical data
3.1.9
Electrical data, pacing relay “Sigma” (for the basic version)
Relay input
(power supply for the relay board)
Input voltage
Mains frequency
Power consumption
200/230 V AC (180-254 V)
50/60 Hz
10 mA (230 V/50 Hz)
100/115 V AC (90-134 V)
50/60 Hz
15 mA (115 V/60 Hz)
24 V DC (20-28 V)
-
10 mA at 24 V DC
Relay output
Voltage, max.
24 V DC
Current, max.
100 mA
Hook up duration
Standard
100 ms
adjustable
The contacts are zero volt.
3.1.10 Sound intensity level
The sound intensity level is
< 75 dB (A) for diaphragm liquid ends with ball valves and valve springs
< 70 dB (A) for all other liquid ends
at maximum stroke, maximum stroking rate, maximum back pressure (water) in accordance with
DIN EN 12639 (noise measurement in fluid pumps)
®
ProMinent
Page 28
BA_SI_036_06_10_EN.p65
28
08.06.2010, 11:38 Uhr
Technical data
Supplement for modified version
(For Identcode feature “Type“: “M modified“)
[Affix label with modified data here!]
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 29
29
08.06.2010, 11:38 Uhr
Start-up/Maintenance
4
Start-up/Maintenance
WARNING
• For all metering pumps for metering inflammable media applies: Starting up and
emptying only supervised by a competent person.
IMPORTANT
Observe the safety notes provided in Section 1.
4.1
Start-up
All general guidelines in the accompanying ”General operating instructions ProMinent®
motordriven metering pumps and hydraulic accessories” apply.
WARNING
Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
4.2
Maintenance
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
• Only send the equipment for repair or maintenance in a cleaned condition and with the
liquid end flushed. However, should any safety precautions be necessary even after
careful draining and cleaning of the equipment, the required information must be listed
in the Safety Declaration!
The Safety Declaration forms part of the inspection/repair contract.
Maintenance or repair work will only be carried out if a Safety Declaration - correctly
and fully completed by an authorised and qualified member of the Operator’s staff is available.
A copy of the form is included in the “General operating instructions for ProMinent
motor-driven dosing pumps and hydraulic accessories” or can be downloaded at
www.prominent.com.
IMPORTANT
After loosening the liquid end screws (e.g. to change the valves or diaphragm), the screws
must be retightened clockwise to the specified tightening torque.
What requires maintenance?
• Secure fit of liquid end screws.
• Secure fit of metering lines (intake and delivery sides).
• Secure fit of head valve and intake valve.
• Leakage hole at end disc for moisture (indicates possible diaphragm failure).
• Operate pump continuously for a short period of time in order to check whether it delivers
correctly.
Maintenance intervals
General recommendation for maintenance intervals - every 3 months.
Shorter intervals are recommended if operated under load conditions (e.g. continuous operation).
The gear oil should be changed after approx. 5000 duty hours.
Gear oil ISO viscosity class VG 460, e.g. Mobil Gear 634,
ProMinent Order No. 555325 (Amount of oil approx. 0.5 l).
The metering diaphragm is a wearing part whose service life is dependent on following parameters:
• System backpressure.
• Operating temperature.
• Properties of medium to be metered.
The service life of the diaphragm is restricted in the case of abrasive media. In such cases, it is
recommended to check the diaphragm more frequently and to install a diaphragm failure monitor.
®
ProMinent
Page 30
BA_SI_036_06_10_EN.p65
30
08.06.2010, 11:38 Uhr
Start-up/Maintenance
4.3
Replacement of wearing parts
Replacing diaphragm (see exploded diagrams in appendix!)
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
• Replacement of the diaphragm (see exploded view in the annex).
IMPORTANT
• Flush liquid end first in the case of hazardous media. For this purpose, force water or a
suitable flushing agent through the intake connection of the liquid end with a wash
bottle.
• In case of any replacement, genuine replacement parts are to be used!”
왘 Set the stroke length to zero when the pump is running. Switch the pump off.
왘 Unscrew the diaphragm rupture sensor from the dosing head.
왘 Slacken the six screws from the dosing head and remove the dosing head with screws.
왘 Then release the diaphragm from the driving rod by jerking anti-clockwise and unscrew.
왘 Screw on the new diaphragm onto the driving rod until it has a tight fit.
왘 Install the dosing head with the screws so that the suction connector is pointing downwards
(observe the flow direction / arrow marking on the valves).
왘 Screw the diaphragm rupture sensor into the dosing head.
왘 Switch on the pump.
왘 Adjust th e stroke length to 100 %, screw in the screws and tighten cross-wise with
7.5 ±0,5 Nm.
왘 Check the pump for leaks at max. pressure.
NOTE
The tightening torque of the liquid end screws should be rechecked after 24 hours of
operation.
The tightening torques of the liquid end screws should be checked every 3 months for the
PVT material version.
1
2
3
A
1 Diaphragm
2 Backplate
3 Clip
P_SI_0029
A Tolerance range
Fig. 16
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 31
31
08.06.2010, 11:38 Uhr
Start-up/Maintenance / Features of the S2Ca metering pumps
5
3
13
4
2
Fig. 17
61_05-103_00_73-03
1
GUIDELINE ON VALVE INSTALLATION
In the case of suction problems during installation, place the valves on a firm surface and tap the
PTFE ball seat disk lightly with a brass rod and a hammer weighing about 300 g. Let the valves
operate in the wet state.
approx. 300 g
Brass rod 9 mm diam. x approx. 200 mm
Fig. 15
S2Ba/S2Ca-019-D
NOTE
• If suction problems with the pump or leakage at the overcurrent valve are encountered,
first clean the ball and the ball seat disc.
• For media containing particles larger than 0.3 mm it is absolutely essential to install a
filter in the suction line.
5
Features of the S2Ca metering pumps
5.1
Function description, motors
The pump has an integrated electronic overload cut-out in all versions. This responds as soon as
the maximum admissible power consumption is reached and stops the motor.
왘 If the motor stops due to a system overload the electronic controller detects the fault and
transmits a message which is displayed on the display panel and at the pump.
왘 The fault signal can be cancelled by pressing the ”P“ key, altering the level for a brief period at
the pause input (switch function) or by reconnecting the pump to the mains.
IMPORTANT
If the motor has been switched off via the electronic overload cut-out, check that the pump
is not continuously overloaded.
®
ProMinent
Page 32
BA_SI_036_06_10_EN.p65
32
08.06.2010, 11:38 Uhr
Features of the S2Ca metering pumps
NOTE
• Sigma control pumps are fitted with a 3-phase WBS motor, but thanks to the internal
microprocessor control, are connected directly to a 1-phase line voltage. The connection
data of the pump below is therefore different to that of the motor (see chapters
“Technical Data” - “Motor Data”, “Identcode Feature” “S”).
• The performance data in 3.1.1 are measured with the S2Ba (base model with 3-phase
motor). If the S2Ba has been fitted with a 1-phase motor there may be up to 5 % speed
reduction due to the different motor characteristic curve, i.e. corresponding 5 % reduced
feed rate.
• The controller changes over to digital stroking mode at low stroke frequencies! This takes
place at stroke frequencies below 1/3 of the maximum stroke frequency. This function is
designed to ensure sufficient cooling of the motor and low stroke frequencies.
Type: 100 – 230 V ± 10 %, 50/60 Hz
at 100 V
at 230 V
250 W
250 W
nominal current
3.2 A
2.0 A
peak current (in operation)*
10 A
5.5 A
making peak current
12 A
24 A
fuse, internal**
4.0 AT (1.5kA)
4.0 AT (1.5kA)
nominal output
* internal switching
** Only genuine ProMinent fuses, item no. 732414, may be used!
5.2
Operating modes
Function description, controller
Operating modes are selected using the MODE menu (depending upon identcode, some
operating modes may be absent).
“Analogue” operating mode: (Identcode, control variant: analogue)
The stroke rate is controlled via an analogue electrical signal via the “external control” terminal.
Signal processing is pre-selected at the controller.
“Manual” operating mode:
The stroke rate is controlled manually via the controller.
“Contact” operating mode:
This operating mode offers the opportunity to make fine adjustments with small increase/
decrease factors. Dosing can be activated by a pulse via the “external control” terminal or by a
semiconductor element. With the “pulse control” option it is possible to pre-set a feed quantity
(batch) or number of strokes (factor 0.01 to 99.99) via the control unit.
“Batch” operating function:
This operating mode offers the option of working with larger transfer factors (up to 65535).
Metering can be triggered by pressing the P key or a pulse from the “external control” terminal
via a contact or semiconductor element. A batching quantity or number of strokes can be preselected via the control unit.
“PROFIBUS®” mode: (Identcode, control variant: PROFIBUS®)
This operating mode provides the option of controlling the pump via the PROFIBUS® (see
“Supplementary instructions for ProMinent® gamma/ L and ProMinent® Sigma versions with
“PROFIBUS®”).
Functions
The following functions can be selected using the SET menu:
“Calibrate” function (Identcode, stroke length adjustment: manual + calibration):
The S3Ca can be operated in all operating modes including in calibrating mode. The
corresponding continuous displays can show the actual feed quantity or the feed rate.
Calibration is maintained within the stroke frequency range 0-180 strokes/ min. Calibration is
also maintained when a stroke frequency is altered up to ±10 % scale divisions.
“Auxiliary frequency” function:
It is possible to set a stroke rate in the SET menu, which may be activated via the “external
control” terminal. This auxiliary frequency overrides all other pre-set stroke rate frequencies.
“Flow” function:
Stops the S2Ca when the flow is insufficient. In the SET menu, the number of failed strokes is
entered after which the pump will be turned off.
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 33
33
08.06.2010, 11:38 Uhr
Features of the S2Ca metering pumps
The following functions are available as standard:
“Float switch” function:
Information on the liquid level in the feed chemical container is transmitted to the S2Ca. This
option requires the installation of a 2-stage float switch. This is connected to the “float switch”
terminal.
“Pause” function:
The S2Ca can be stopped by remote control via the “external control” terminal. The “pause”
function operates only via the “external control” terminal.
The following functions are activated by keystrokes:
“Stop” function:
The S2Ca can be stopped by pressing the STOP/START key without disconnecting from the
mains power supply.
“Prime” function:
Priming (short term feed at maximum frequency) is activated by pressing both arrow keys at
the same time (in “Stroke rate” permanent display).
Optional relay
The S2Ca has two connection options (not in PROFIBUS® version).
Optional “fault-indicating relay” or “power relay”:
In the event of fault signals, warning signals or float switch activation signals, connects an
electrical circuit to trigger alarm sirens etc. The relay is retrofitted via an aperture in the power
end.
“Fault indicating and pacing relay” option:
In addition to the fault indicating relay the pacing relay can make a contact with every stroke.
The relay is retrofitted via an aperture in the power end.
Function and error
indicators
The operating and error status is shown via the three LEDs and the “error” indicator on the
LCD (see also section 9):
LCD indicator
If a fault occurs “error” will appear along with an additional fault warning.
LED indicator
Operating indicator (green)
This indicator is lit as long as the S2Ca is operating correctly. It goes out briefly with every
stroke.
Warning indicator (yellow)
This warning light appears if the S2Ca electronics detect a situation that could lead to a fault,
e.g. “liquid levels low 1st stage”.
Error indicator (red)
This warning light appears if a fault occurs, e.g. “liquid levels low 2nd stage”.
Hierarchy of operating modes, functions and fault statuses
The different operating modes, functions and fault statuses each have a differing effect on
whether and how the S2Ca functions. These effects are given below:
1.
Prime
2.
Fault, stop, pause
3.
Auxiliary frequency
4.
Manual, analogue, contact, batch
i.e.
1.
“Prime” can be activated in “Stroke rate” permanent display in any pump status
(as long as it is operable)
2.
“Fault”, “stop” and “pause” stop all system parts up to “prime”.
3.
The stroke rate of the “auxiliary frequency” always overrides the stroke rates of the operating
modes listed in point 4.
®
ProMinent
Page 34
BA_SI_036_06_10_EN.p65
34
08.06.2010, 11:38 Uhr
Features of the S2Ca metering pumps
5.3
Sockets, symbols and wiring diagram
4
2
6
7
1
5
Fig. 16
(1) Socket for two-stage float switch with advance warning and de-activate function (with
function plug*, not illustrated)
(2) External socket for contact or analogue controller with zero volts deactivation via pause
function (with function plug* - not illustrated)
(3) Metering monitor socket for connection of ProMinent® metering monitor
(4) Mains switch (1-pin)
(5) Relay cable (fault indicating or pacing relay)
(6) Socket for diaphragm rupture sensor
(7) Mains lead with plug
*Must be plugged in unless cable attached.
Technical data, relay (control version)
2
Pump type S2Ca
Relay
3
1
4
Fault-indicating relay
Relay type
Fault-indicating relay
pulse generator
Fault-indicating relay
Voltage, max:
250 V 50/60 Hz
24 V DC
24 V 50/60 Hz
Current, max.
2 A (ohmic)
100 mA
100 mA
Hook up duration
1
4
100 ms
Behaviour
see Identcode
see Identcode
see Identcode
Service life
> 200 000 cycles*
> 50 x 106 (10 V 10 mA)
> 200 000 cycles
Relay type
Power relay
Voltage, max.
250 V (50/60 Hz)
Current, max.
16 A (ohmic)
yellow/NO
green/NC
fault indicating relay
white/NO
3
2
Fault-indicating relay + pulse generator
brown/C
pacing relay
Hook up duration
2
1
4
Behaviour
see Identcode
Service life
> 30 000 cycles*
green/NC
* in the case of nominal load
white/NO
brown/C
The contacts are zero volt.
N/C fault indicating relay - the relay closes immediately after the power is switched on and opens
in the event of a fault.
N/O fault indicating relay, the relay closes in the event of a fault.
Use suitable interference suppression (e.g. RC glands) when connecting inductive loads.
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 35
35
08.06.2010, 11:38 Uhr
Features of the S2Ca metering pumps
Wiring diagram
View of cable connectors from front
Universal signal cable (5-core)
5 grey/auxiliary
4 black/ GND
1 brown / pause
Blue and black open
-> alarm signal
Brown and black open
-> alarm signal + pump stops
3 blue / analogue
for
3 brown pause
2 blue/alarm
1 black GND
for
2 white/cod
Float switch cable
Pause function:
brown and black closed
-> pump metering
Metering monitor cable
brown and black open
-> alarm + pump stopped
for
External/contact:
white and black closed
-> start contact for pump
(note pause function:
brown and black closed?)
blue, black
-> analogue output 0/4-20 mA
(note pause function:
brown and black closed?)
4 black/ GND
3 blue
2 white/cod
1 brown / 5 V
Analogue:
Auxiliary frequency:
grey and black closed
-> pump metering at pre-set stroking rate
Circuit examples see p. 38
Diaphragm rupture cable
External/contact cable (2 core)
Contact open -> alarm
-> pump stops with controller type 0
4 white
for
2 brown
1 black/GND
2 blue/alarm
for
Contact closed -> metering stroke
®
ProMinent
Page 36
BA_SI_036_06_10_EN.p65
36
08.06.2010, 11:38 Uhr
Features of the S2Ca metering pumps
Technical data, external contact
Semi-conductor switch elements (e.g. transistors in open-collector circuits) or contactors (relays)
with a residual voltage of -0.7 V can be used as input switch elements.
Controller type 0 (see identity code)
Pin 1 = Pause input (activating function)
Voltage at open contacts: approx. 5 V
Input resistance: 10 kΩ
Controller:
– zero volts contact (approx. 0.5 mA)
– semi-conductor (residual voltage: < 0.7 V)
Pin 2 = Contact input
Voltage at open contacts: approx. 5 V
Input resistance: 10 kΩ
Controller:
– zero volts contact (approx. 0.5 mA)
– semi-conductor (residual voltage: < 0.7 V)
Min. contact duration: 20 ms
Max. pulse frequency: 25 pulses/s
Pin 3 = unused
Pin 4 = GND
Pin 5 = Auxiliary input
Voltage at open contacts: approx. 5 V
Input resistance: 10 kΩ
Controller:
– zero volts contact (approx. 0.5 mA)
– semi-conductor (residual voltage: < 0.7 V)
Controller type 1 (see identity code)
Pin 1 = Pause input (activating function)
Voltage at open contacts: approx. 5 V
Input resistance: 10 kΩ
Controller:
– zero volts contact (approx. 0.5 mA)
– semi-conductor (residual voltage: < 0.7 V)
Pin 2 = Contact input (not active during analogue operation)
Voltage at open contacts: approx. 5 V
Input resistance: 10 kΩ
Controller:
– zero volts contact (approx. 0.5 mA)
– semi-conductor (residual voltage: < 0.7 V)
Min. contact duration: 20 ms
Max. pulse frequency: 25 pulses/s
Pin 3 = Identical to input*
Input load:
approx. 120 Ω
Pin 4 = GND
Pin 5 = Auxiliary input
Voltage at open contacts: approx. 5 V
Input resistance: 10 kΩ
Controller: – zero volts contact (approx. 0.5 mA)
– semi-conductor (residual voltage: < 0.7 V)
* The metering pump makes its first metering stroke at approx. 0.4 mA (4.4 mA) and starts
continuous operation at approx. 19.2 mA.
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 37
37
08.06.2010, 11:38 Uhr
Features of the S2Ca metering pumps
Block circuit diagram S2Ca
Inputs
Empty signal,
Outputs
Pump, Inside
3 brown/pause
warning
2 blue/alarm
Level
monitor
1 black/GND
Fault
indicating
relay
1 brown/5 V
2 white/cod
Metering
monitor
Flow control
3 blue
Metering
monitor
4 black/GND
Diaphragm
rupture
sensor
2 blue/alarm
1 black/GND
VDE cable:
2 green/NC
1 white /NO
4 brown/C
VDE cable:
1 yellow/NO (fault)
Fault
indicating
and
pacing relay
Diaphragm
rupture
sensor
4 green/C (fault)
3 white/NO (pacing)
2 brown/C (pacing)
3 blue/analogue
2 white/contact
Circuit
examples
overleaf
1 brown/pause
4 black/GND
External
activation
5 grey/auxiliary
GND
Mains
®
ProMinent
Page 38
BA_SI_036_06_10_EN.p65
38
08.06.2010, 11:38 Uhr
Features of the S2Ca metering pumps
Circuit examples: universal signal cable
by customer
“External contact“ function
(ProMinent® external/contact cable)
two-core
Cable
Pump, inside
2 white/contact
4 brown/GND
External
activation
Pulse rate,
e.g. contact water meter
“External contact“ function
(ProMinent® universal signal cable)
five-core
3 blue/analogue
2 white/contact
1 brown/pause
4 black/GND
External
activation
5 grey/auxiliary
Pulse rate,
e.g. contact water meter
“Pause“ function
3 blue/analogue
2 white/contact
1 brown/pause
4 black/GND
External
activation
5 grey/auxiliary
Permanent contact,
e.g. from control room
“Auxiliary frequency“ function
3 blue/analogue
2 white/contact
1 brown/pause
4 black/GND
External
activation
5 grey/auxiliary
Permanent contact,
e.g. from control room
“External analogue“ function
3 blue/analogue
2 white/contact
0/4-20 mA
1 brown/pause
4 black/GND
External
activation
5 grey/auxiliary
Analogue signal,
e.g. from magnetic inductive
flow meter
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 39
39
08.06.2010, 11:39 Uhr
Features of the S2Ca metering pumps
IMPORTANT
• The universal signal cable, the external/contact cable and the level monitor cable should
not be less than 1.20 m long, otherwise cable recognition will fail.
5.4
Retrofitting relays
(not in PROFIBUS® version)
Delivery range:
1
1
1
relay circuit set with 2 screw fasteners
relay cable set with socket
seal
Press-out relay opening
WARNING
Disconnect the S3Ca from the mains power supply and rinse liquid end before commencing
work (see section 10)!
IMPORTANT
When preparing the opening, ensure that the punch is not forced through the entire pump
base!
Pump circuits may become damaged.
왘
왘
왘
왘
Inserting the relay component 왘
왘
왘
왘
왘
왘
Place the S2Ca on a firm surface with the relay opening press-out section at the top (see
fig. 21)
Place a punch (dia. 8-15 mm) in the centre of the relay opening press-out section, and
strike briefly and sharply with a hammer (approx. 250 g)
If necessary clean up the edges of the opening
Remove the pressed out section from the S2Ca
Hold the relay component with your right hand gripping the left and right hand edges of
the relay cover, and tilt the front end slightly to the left (see fig. 22)
Push the relay component through the relay opening, holding the upper corner of the lower
edge against the guide rail on the pump base, until the contact of the relay component has
reached the controller contact. (test: can you still move the end of the circuit back and
forth?)
Gently push the relay component right into the opening
Screw the relay cover firmly onto the housing using the screws provided
Insert the relay cable plug seal into the relay cover and screw on the plug (see fig. 24)
The pump is generally programmed ex-factory to ”drop-out action alarm relay“ and – if
fitted – ”pull-up action clock pulse generator relay“. If a switching function is required, the
pump can be reprogrammed at the Heidelberg plant (not necessary in PROFIBUS®-version).
Fig. 21
Fig. 22
®
ProMinent
Page 40
BA_SI_036_06_10_EN.p65
40
08.06.2010, 11:39 Uhr
Features of the S2Ca metering pumps / Control elements
Fig. 21
6
Fig. 24
Control elements
Please acquaint yourself with the S2Ca control elements with the help of the “control elements
and key functions” overview!
Indicators
The LCD display supports the operation and setting of the S2Ca with a range of indicators:
Stop Aux Pause Error
Mem
Calib
Flow
Set
The indicators are interpreted as follows:
Symbol for P key:
The S2Ca is in settings mode.
Close symbol:
In a continuous display: lock (if code has been set).
In settings mode: indicates access to code menu.
Stop:
The S2Ca has been stopped using the STOP/START key.
Aux:
The S2Ca is pumping at the auxiliary frequency. In AUX menu:
the S2Ca is in the AUX menu.
Pause:
The S2Ca has been stopped using the “pause” function
(external).
Error:
A fault has occurred and the pump has been stopped.
Mem:
An additional “memory” function has been set in the “contact”
and “batch” operating modes.
In CNTCT or BATCH menus (“mem” flashes): the memory
function can be set.
Calib:
The S2Ca is in the CALIB menu.
In a continuous display (“calib” flashes”): Deviation from the
stroking rate from the value at the time of the calibration by
more than 10 percent (e.g. in the case of a stroke length of 40%
when it has been set to less than 30% or more than 50%).
Flow:
The S2Ca is in the FLOW menu.
Set:
The S2Ca is in the SET menu.
Exclamation mark:
The number of strokes reached is above the maximum value
(99999) that can be shown in the LCD display.
NOTE
When calibrated, the S2Ca displays the feed rate and the feed capacity in l and/or in l/h or
in gal and/or g/h.
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 41
41
08.06.2010, 11:39 Uhr
Settings
7
Settings
NOTE
• Open out the fold-out page following the title page fully! There you will find the overviews
“control elements and key functions” and “operating settings diagram”.
• If no keys are pressed within a period of 1 minute, the S2Ca will return to a continuous
display.
Basic information for setting up the S2Ca
Confirm entries
Exit menu option
without confirming
Incremental change
of a value
Press the P key briefly;
you will automatically move to the next menu option or to a continuous display.
Press the P key for 3 s:
The entry is cancelled and you will return to a continuous display.
Press the i key 1x;
you can toggle between altering the digits of a value (“change individual digits” = standard) or
incremental alteration of a value (“change a figure”).
Change adjustable values
Press UP or DOWN arrow key;
The flashing digit or figure will start to increase or decrease incrementally.
Confirm adjustable values
For “change individual digits”: confirm each digit using the P key. When the last digit has been
confirmed you will automatically move to the next menu option or to a continuous display.
For “change a figure”; press the P key 1x; you will simultaneously move to the next menu option
or to a continuous display.
Correct wrongly set digits
Press the i key 2x;
you will go back to the first digit.
®
ProMinent
Page 42
BA_SI_036_06_10_EN.p65
42
08.06.2010, 11:39 Uhr
Settings
7.1
Check adjustable values
Before setting up the S2Ca you can check the current settings of adjustable values:
Press the i key (“i” as in “info”) when the S2Ca is in continuous display mode (There is no P key
symbol in the LCD display).
Each time you press the i key you will see a different continuous display. The number of
continuous displays depends upon the identity code, the selected operating mode and the
connected accessories (see overview “continuous displays”).
7.2
Change to settings mode
If you hold down the P key for 2 seconds in any continuous display, the S2Ca will change to the
settings mode.
If CODE 1 is set, the code must be entered after pressing the P key.
The following menu options appear first in the settings mode (see also overview “operating/
settings diagram”):
• MODE menu
• CODE menu (optional)
• SET menu
• CLEAR window
In order to adapt the S2Ca to your process requirements you must:
1. Select the operating mode in the MODE menu.
2. If necessary enter the settings for this operating mode in the SET menu.
Exception: Timer and PROFIBUS®.
IMPORTANT
Note the diagram below!
1.
MODE
menu
CODE
menu
Continuous
display
2s
P
2.
SET
menu
CLEAR
window
7.3
Select operating mode (MODE menu)
The following operating modes are selected via the MODE menu (depending upon identity
code, some operating modes may be absent):
• Manual: for operation by hand
(Identity code, control variant: manual, standard option)
• Analogue: for electronic control
(Identity code, control variant: analogue current)
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 43
43
08.06.2010, 11:39 Uhr
Settings
• Contact: for contact operation
(Identity code, control variant: external 1:1 / external with pulse control)
• Batch: for batch operation
(Identity code, control variant: external with pulse control)
Analog
- ANALOG
Manual
Analog Manual Contact Batch
- MANUAL
P
P
Contact
- CONTACT
Batch
7.4
- BATCH
Settings for operating mode (SET menu)
NOTE
First select the operating mode in the MODE menu!
Exceptions: Timer and PROFIBUS®.
In the SET menu you can adjust various settings depending upon the selected operating mode.
The following programmable function settings menus appear in all operating modes:
• Calibrate (CALIB menu)
• Auxiliary frequency (AUX menu)
• Flow (FLOW menu, available only if flow monitor is connected)
See also section 7.5!
Further settings menus depend upon the selected operating mode.
7.4.1
Settings for “manual” operating mode
There are no other settings menus in the overall SET menu for the “manual” operating mode
apart from those described in 7.5.
7.4.2
Settings for “analogue” operating mode (ANALG menu)
In addition to those settings menus described in 7.5, there is an additional ANALG menu in the
overall SET menu for the “analogue” operating mode.
The stroke rate is controlled by an analogue electrical signal via the “external control” terminal.
You can select three signal-processing methods:
•
0 - 20 mA:
at 0 mA the S2Ca does not operate
at 20 mA the S2Ca operates at 180 max. strokelength
Between these two extremes the stroke rate is proportional to the electrical
signal.
®
ProMinent
Page 44
BA_SI_036_06_10_EN.p65
44
08.06.2010, 11:39 Uhr
Settings
•
4 - 20 mA: at 4 mA the S2Ca does not operate
at 20 mA the S2Ca operates at 180 max. strokelength
Between these two extremes the stroke rate is proportional to the electrical
signal.
For signals of below 3.8 mA a fault will be detected and the S2Ca will stop
(e.g. cable break).
•
Curve:
In the “curve” processing mode you can programme the S2Ca ratios.
There are 3 options available:
•
= straight line
•
= lower band
•
= upper band
Straight line:
.
The following symbol appears in the LCD display:
You can enter any stroke frequency ratio for the S2Ca in proportion to the electrical signal.
You must enter two points P1 (I1, F1) and P2 (I2, F2). F1 is the stroke rate at which the pump
should operate at current I1: the straight line and the ratio are fixed accordingly:
Fmax
P2
F2
P1
F1
0
I1
I2
20
I [mA]
Fig. 25
NOTE
Draw a diagram like the one above - with values for (I1, F1) and (I2, F2) - in order to set
the S2Ca to your required stroke rate!
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 45
45
08.06.2010, 11:39 Uhr
Settings
Lower/upper band:
This processing mode allows you to control a pump via an electrical signal as shown in the
diagrams below.
Lower band
Upper band
e.g. Alkali pump
e.g. acid pump
Fmax
Fmax
P1
F1
P2
F2
P2
F2
P1
F1
0
I1
Fig. 26
I2
20
I [mA]
0
I1
I2
20
I [mA]
Fig. 27
Lower band:
appears in the LCD display. The S2Ca will operate below I1 at F1.
The symbol
Above I2, the S2Ca ceases to operate. Between I1 and I2 the stroke rate is between F1 and F2,
proportional to the signal current.
Upper band:
appears in the LCD display. The S2Ca will cease to operate below I1.
The signal
Above I2, the S2Ca will operate at F2. Between I1 and I2 the stroke rate between is F1 and F2,
proportional to the signal current.
The smallest processable difference between I1 and I2 is 4 mA.
Error processing
In the “ER” (error) menu option you can activate an error processing function for the “curve”
mode. An error message appears for signals below 3.8 mA and the S2Ca stops.
7.4.3
Settings for “contact” operating mode (CONTCT menu)
In addition to those settings menus described in 7.5, there is an additional CONTCT in the
overall SET menu for the “contact” operating mode.
The operating mode “contact” allows you to activate a single stroke or a series of strokes. The
strokes can be activated by a pulse or via the “external control” terminal. This operating mode
is intended to transfer input pulses into a reduction (fraction) or small increase in strokes.
IMPORTANT
The factor resets to “1” if you change to a different operating mode.tity cod
®
ProMinent
Page 46
BA_SI_036_06_10_EN.p65
46
08.06.2010, 11:39 Uhr
Settings
In the “contact - identity code: external with external pulse control” you can enter the number
of pulses after which a stroke should be carried out. “Contact - identity code: external with
external pulse control” is intended for small dosing quantities.
The number of strokes per pulse depends upon the factor, which you can enter. This allows
you to vary to a certain extent the input pulses by a factor of 1.01 to 99.99 and/or reduce by a
factor of 0.01 to 0.99:
“Number of strokes activated = factor x number of input pulses”
Examples
Factor
Increase
Reduction
Pulse (sequential)
1
1
Stroke number (sequential)
2
1
2
25
1
25
99.99
1
99.99
1.50
1
1.5 (1 / 2)
1.25
1
1.25 (1 / 1 / 1 / 2)
1
1
1
0.50
2
1
0.10
10
1
0.01
100
1
0.25
4
1
0.40
2.5 (3 / 2)
(1 / 1)
0.75
1.33 (2 / 1 / 1)
(1 / 1 / 1)
Explanation of increase
At a factor of 1
At a factor of 2
At a factor of 25
For every 1 pulse, 1 stroke is activated
For every 1 pulse, 2 strokes are activated
For every 1 pulse, 25 strokes are activated
Explanation of decrease
At a factor of 1
At a factor of 0.5
At a factor of 0.1
At a factor of 0.75
After 1 pulse, 1 stroke is activated
After 2 pulses, 1 stroke is activated
After 10 pulses, 1 stroke is activated
After 2 pulses, 1 stroke is activated,
then after 1 pulse, 1 stroke is activated,
then after 2 pulses, 1 stroke is activated etc.
®
ProMinent
BA_SI_036_06_10_EN.p65
1
Page 47
47
08.06.2010, 11:39 Uhr
Settings
NOTE
If a remainder occurs when the factor is processed, the S2Ca counts up the remainder
values. When the sum reaches or exceeds “1” the S2Ca will activate a stroke. This ensures
that the stroke number corresponds exactly to the factor throughout the dosing operation.
The number of input pulses which have not been processed are stored by the S2Ca in the
stroke memory. The stroke buffer is limited to the batch size when memory is not activated
(- with “Memory” at 65535 stokes). You can delete it by switching to a different operating
mode.
You can optimally adapt the S2Ca to the respective process, e.g. in connection with contact
water meters.
“Memory” extension function
The “memory” extension function can be optionally activated (“mem” appears in the LCD
display). When “Memory” is activated the S2Ca adds any strokes which could not be carried
out up to the maximum capacity of the stroke buffer – 65535 strokes. If this maximum capacity
is exceeded the pump will register a fault.
7.4.4
Settings for “batch” operating mode (BATCH menu)
In addition to those settings menus described in 7.5, there is an additional BATCH menu in the
overall SET menu for the “batch” operating mode.
The “batch” operating mode is a variant of the “contact” operating mode (see 7.4.3).
You can pre-select a stroke number (no breaks, whole numbers only from 1 to 65535) as well
as a feed quantity (batch). To switch between entries for “stroke number” and “feed quantity”
press the i key 1x in the corresponding menu option (see also overview “operating/settings
diagram”, fold-out page).
The “batch” operating mode is intended for large dosing quantities.
Metering can be actuated by pressing the P-key or via a pulse from the “external control
socket”.
The number of input pulses which have not been processed are stored by the S2Ca in the
stroke memory. The stroke buffer is limited to the batch size when memory is not activated
(- with “Memory” at 65535 stokes). You can delete it by switching to a different operating
mode.
“Memory” extension function
The “memory” extension function can be optionally activated (“mem” appears in the LCD
display). When “Memory” is activated the S2Ca adds any strokes which could not be carried
out up to the maximum capacity of the stroke buffer – 65535 strokes. If this maximum capacity
is exceeded the pump will register a fault.
®
ProMinent
Page 48
BA_SI_036_06_10_EN.p65
48
08.06.2010, 11:39 Uhr
Settings
7.5
Settings for programmable functions (SET menu)
The following programmable function settings menus appear in all operating modes:
•
Calibrate (CALIB menu)
•
Auxiliary frequency (AUX menu)
•
Flow (FLOW menu, available only if flow monitor is connected)
7.5.1
Settings for “calibration” function (CALIB menu)
P
The S2Ca can also run in calibration mode. The corresponding continuous displays show the
current dosing quantities or the feed rate.
The calibration is retained in the event of a change of the set stroke length by up to ±10 scale
rates percent (if the stroke length is set to 40 % the range is 30 % to 50 %). If the stroke length
is changed by more than ±10 scale rates percent the yellow warning light lights up, the permanent display flashes and the flashing “Calib” indicator appears.
NOTE
• Do not go below 30 % stroke length (SEK type: 50 %).
This will significantly affect accuracy of calibration.
• Calibration becomes increasingly accurate the more strokes made by the S2Ca during
calibration (recommended: at least 200 strokes).
WARNING
If using a hazardous feed chemical, the following setting instructions ensure adequate
safety precautions are taken!
Calibration
왘
Insert the suction tube into a measuring cylinder containing the feed chemical - the
discharge tubing must also be correctly installed (operating pressure,…!)
왘
Suck up the feed chemical (press both arrow keys at the same time) when the suction tube
is empty
왘
Note the liquid level in the measuring cylinder and the stroke length
왘
Select the CALIB menu and go the first menu option using the P key
왘
Select “ON” using an arrow key and change to the next menu option using the P key
왘
To commence calibration, press the P key. The S2Ca starts to pump and displays the
number of strokes (“STOP” appears at regular intervals)
왘
After a sufficient number of strokes, stop the S2Ca with the P key
왘
Calculate the dosed quantity (difference between the original quantity and the quantity
remaining)
왘
Enter this quantity in the next menu option and then change to the following menu option
by pressing the P key.
왘
Select the unit (“L” or “gal”) in the “UNIT” menu with an arrow key and push the P-button.
The S2Ca is calibrated.
The corresponding continuous displays show the calibrated values.
The total stroke number and total litres are set during calibration to “0”.
The S2Ca is in the STOP status.
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 49
49
08.06.2010, 11:39 Uhr
Settings
7.5.2
Settings for “auxiliary frequency” function (AUX menu)
The programmable function “auxiliary frequency” allows switching to a different stroke
frequency, which can be set in the AUX menu. It can be activated via the “external control”
terminal. When the auxiliary frequency is activated, “aux” appears in the LCD display.
This auxiliary frequency overrides the current stroke frequency set for the selected operating
mode.
7.5.3
Settings for the “flow” function (FLOW menu)
The flow menu only appears when a dosing monitor is connected to the “dosing monitor”
terminal. This dosing monitor registers each discharge stroke of the S2Ca at the discharge
connector and transmits it back to the S2Ca. If this response transmission is serially omitted
for a period set in the FLOW menu (due to failure or below-minimum dosing) the S2Ca stops.
7.6
Setting code (CODE menu)
The code menu is used to select whether you want to prevent access to parts of the settings
options.
In the first menu option you can choose CODE 1 or CODE 2 (both use the same number).
•
Select CODE 1 to prevent access to the settings mode (¿ in the overview “operating/
settings diagram”, fold-out page). In the next menu option, enter the number you wish to
use as the code.
•
Select CODE 2 to prevent access to the settings options for directly alterable values in the
continuous displays (¡ in the overview “operating/settings diagram”, fold-out page). In the
next menu option, enter the number you wish to use as the code.
•
Select NONE to remove a pre-set security lock.
7.7
Cancel total stroke number or total litres (CLEAR window)
In the CLEAR window you can delete the stored total stroke number and simultaneously the
total litres (= set to “0”). You may then press the P key briefly to exit this window.
The values displayed are counted incrementally from the point of commissioning the pump, or
from the last delete action.
®
ProMinent
Page 50
BA_SI_036_06_10_EN.p65
50
08.06.2010, 11:39 Uhr
Operating
8
Operating
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
This section describes all operating options available to you when the S2Ca is in continuous
display mode (no P key symbol in the LCD display).
NOTE
• Open out the fold-out page following the title page fully! There you will find the overviews
“control elements and key functions” and “operating/settings diagram”.
• Look at the overview “continuous displays”. This page shows you which displays are
available in which operating mode, and which values are directly alterable in the
corresponding continuous displays.
8.1
Set stroke length
Manual operation
Stroke length is continually adjustable within a range of 0-100 %. The recommended stroke
length range, which will practically guarantee technical reproducibility, is 30-100 % (SEK type:
50-100 %).
NOTE
At low stroking rates (less than 1/3 maximum stroking rate) the controller switches to
digital stroking mode. This ensures adequate cooling of the motor at low stroking rates.
The following operating options are available via the different keys (see also figure on the next
page):
Stop/Start S2Ca
Start batch
Load factory settings
Change to settings mode
Check adjustable values
Change directly
alterable values
To stop S2Ca: press STOP/START key.
To start S2Ca: press STOP/START key.
Press the P key briefly in “batch” operating mode.
Press the P key for 15 s to load factory calibration settings!
Current settings will be deleted.
When you press the P key for 2 s in any continuous display the S2Ca will change to settings
mode (see section 7).
If CODE 1 is set, the code must be entered after pressing the P key.
Each time you press the i key you will see a different continuous display. The number of
continuous displays depends upon the identity code, the selected operating mode and the
connected accessories.
To change a value (see below) directly in the corresponding continuous display, press one of
the arrow keys until “set” appears in the LCD display. The delay has been programmed in to
prevent inadvertent changing of values.
If CODE 2 has been set, this code must be entered after pressing the arrow key.
Directly alterable values are as follows:
Stroke rate
Feed rate
Factor
In “manual”, “contact” and “batch” operating modes:
The stroke rate can be altered in the “stroke rate” display.
In “manual” operating mode
The feed rate can be altered in the “feed rate” display.
The factor is the number of strokes activated by an external pulse or a press of the P key (in
“batch” mode only).
In “Batch” operating mode:
You can alter the factor from the “remaining strokes” display.
The S2Ca returns to the original continuous display a few seconds after the factor has been
reset.
Display program version
Press the P key for 10 seconds to display the program version.
Example: “V1052” + “X1010”.
In the case of “LOAD3” release the key immediately!
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 51
51
08.06.2010, 11:39 Uhr
Operating / Troubleshooting
Batch size
Priming
Cancel error
In “batch” operating mode:
The batch size can by changed from the “batch size/remaining litres” display.
The S3Ca returns to the original continuous display a few seconds after the batch size has
been reset.
The “priming” function is activated by pressing both arrow keys at the same time (in “Stroke
rate” permanent display).
Error messages are cancelled by pressing the P key briefly.
Continuous
display
STOP
Stop/start pump
START
2
Change directly alterable values
Prime
P
P
i
P
Start batch (in "batch" operating mode only)
Cancel error
Check adjustable values
2s
1
1 = Security lock (CODE 1)
Settings
mode
8.2
2 = Security lock (CODE 2)
Remote control
Remote control of the S2Ca is possible via a control cable or PROFIBUS® (see Section 5.3 and
Chapter 7, ”Supplementary instructions for ProMinent® gamma/ L and ProMinent® Sigma
versions with PROFIBUS®“ as well as your documentation in the annex).
9
Troubleshooting
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
• Always take suitable precautions when using hazardous chemicals!
• Ensure the equipment is de-pressurised before working on the pump!
Pump primes despite completed stroke action and no venting
Cause
Remedy
Crystalline deposits on the ball seat because valves have dried out.
왘
Remove the suction sleeve from the chemical supply container and rinse out the liquid end
thoroughly.
왘
If still unsuccessful, dismantle valves and clean.
Fluid is seeping from the top plate
Cause
Remedy
The liquid end is not sealed against the pump diaphragm.
왘
Tighten screws in the liquid end.
왘
If unsuccessful, replace the diaphragm (see section 4.3).
®
ProMinent
Page 52
BA_SI_036_06_10_EN.p65
52
08.06.2010, 11:39 Uhr
Troubleshooting
Green LED indicator (operating display) is not lit
Cause
Remedy
Incorrect or no mains voltage.
왘
Use the recommended mains voltage as given in the voltage specification on the
nameplate.
Error Messages
Red LED display is lit, “Error” and “MINIM” flash in the display
Cause
Remedy
Fluid level in the chemical storage tank has reached “liquid level low, stage 2”.
왘
Fill the chemical supply container.
Red LED display is lit, “Error” and “ANALG” flash in the display
Cause
Remedy
S2Ca is in “analogue” operating mode, a fault routine has been programmed in the ANALG
menu and the operating current has fallen below 3.8 mA.
왘
Remedy low operating current.
왘
Switch fault routine “OFF” (see section 7.4.2.).
Red LED display is lit, “Error” and “CNTCT” flash in the display
Cause
Remedy
S2Ca is in “contact” or “batch” operating mode and the extended function “memory” has been
set.
In addition a very large factor has been entered, too many contacts have been input or the Pkey has been pressed too often, resulting in an overflow of the stroke memory.
왘
Press the P-key, saved data will be deleted.
왘
Change S2Ca set up.
Red LED display is lit, “Error” and “FLOW” flash in the display
Cause
Remedy
Cause
Remedy
Dosing monitor not properly connected.
왘
Connect dosing monitor properly.
왘
Press P-key.
Dosing monitor has reported more defective strokes than have been set in the FLOW menu.
왘
Press P-key.
왘
Investigate the cause and remedy.
Red LED is lit. “Error” appears in the display and “MOTOR” is flashing
Cause
Remedy
Cause
Remedy
Cause
Remedy
The motor is not operating accurately because the backpressure is too high.
왘
Reduce backpressure.
왘
Press the P key (reset key).
The motor is overheating.
왘
Check ambient temperature (max. 40 ºC).
왘
Allow motor to cool down.
왘
Press the P key (reset key).
Other motor fault.
왘
Call ProMinent.
왘
Press the P key (reset key).
Red LED is lit. “Error” appears in the display and “TEMPERATURE” is flashing
Cause
Remedy
Cause
Remedy
The temperature in the pump housing is too high because the ambient temperature is too high.
왘
Reduce ambient temperature.
왘
Allow motor to cool down.
왘
Press the P key (reset key).
The temperature in the pump housing is too high because the pump is consuming too much power.
왘
Check installation, rectify if necessary.
왘
Allow motor to cool down.
왘
Press the P key (reset key).
Red LED is illuminated, the display shows “Error” and “DIAPH” flashes.
Cause
Remedy
Metering diaphragm is fractured.
왘
Replace metering diaphragm according to chapter 4.3
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 53
53
08.06.2010, 11:39 Uhr
Troubleshooting / Decommissioning and disposal
Red LED display is lit, “Error” appears in the display and “FAN” is flashing
Cause
Remedy
Fault related to fan in pump housing.
왘
Check fan and replace if necessary.
왘
Press the P key (reset function).
Red LED display is lit, “Error” appears in the display and “SYSTEM” is flashing
Cause
Remedy
Controller fault.
왘
Disconnect the pump from the mains and reconnect.
If the error message continues, send the pump back to ProMinent.
Red LED lights up, “Error” appears in the display and “Menu” flashes.
Cause
Remedy
Stroke buffer full
왘
Rectify fault
왘
Press P key (Make a note of what effect this has on your process).
All other Errors
Please contact your ProMinent branch or representative!
Fault Signals
Yellow LED display is lit
Cause
Remedy
Liquid level in chemical storage tank has reached “liquid level low, stage 1”.
왘
Fill chemical storage tank.
Yellow LED Display is lit and “calib” flashes
Cause
Remedy
The pump is calibrated and the stroke length deviates by more than ±10 % from the value at
the time of calibration.
왘
10
Reset the stroke length or calibrate the pump again to the desired stroke length.
Decommissioning and disposal
Decommissioning
WARNING
• Only EX pump: Please thoroughly read the chapter “Important Additions for Metering
Pumps in the EX Area” of the “General Operating Instructions ProMinent Motor Metering
Pumps and Hydraulic Accessories”!
• When decommissioning the pump, ensure that all dirt and chemicals are cleaned from
the housing and particularly the liquid end.
• Always take suitable precautions when using hazardous chemicals!
• Ensure that the equipment is de-pressurised!
왘
Disconnect the pump from the mains.
왘
Empty the liquid end by placing the pump on its head and allowing the chemical to drain
out.
왘
Rinse the liquid end with a suitable material, thoroughly rinse the liquid end after use with
hazardous materials!
If decommissioning is only temporary, maintain the correct storage conditions:
Storage temperature:
-10 to +50 °C
Air humidity:
< 92 % relative humidity
Disposal
WARNING
Spring under tension!
Take particular care when disassembling the pump as the return spring (Item 5, Chapter 2.2)
is under considerable mechanical tension!
IMPORTANT
Observe your locally applicable regulations (particularly with regard to electronic scrap and
gear oil)!
®
ProMinent
Page 54
BA_SI_036_06_10_EN.p65
54
08.06.2010, 11:39 Uhr
Spare parts and accessories
11
Spare parts and accessories
CAUTION
The assembly and installation of ProMinent® metering pumps with other-make parts that
are not tested and recommended by ProMinent are not permitted and can lead to personal
injury and damage to property for which no liability shall be accepted!
Spare parts
You will find the order numbers for the wearing parts in the exploded view drawings in the
annex. If you require further parts, please order the “Spare parts list ProMinent® Sigma/ 2”.
Actuator for automatic stroke adjustment, setting time approx. 1 sec for 1% stroke length,
feedback potentiometer 1k Ohm enclosure rating IP 54.
Adjuster comprising actuator and incorporating servo controller for stroke length adjustment
via standard signal. Standard signal input 0/4-20 mA, corresponds to stroke length 0 – 100 %.
Manual to automatic mode switch, switch for stroke length adjustment in manual mode,
mechanical position display of 0/4-20 mA actual stroke length value output for remote display.
Variable speed motors with integrated speed changer (Identcode characteristic V)
Power supply 1 ph 230 V, 50/60 Hz, 0.37 kW
Optional external control via 0/4-20 mA
Speed controllers in metal casing (Identcode characteristic Z)
The speed controller kit comprises a speed changer and a 0.37 kW variable speed motor.
Float switches
2-stage, with 2 m connection cable
Alarm relays
For signalling faults
Alarm and pacing relays
For cyclic timing of other devices and for signalling faults.
Control cables
Universal control cable 5-core/2.5 and 10 m
External contact cable 2-core/2.5 and 10 m
Foot valves
With intake filter and non-return ball for connection at end of intake line.
Metering valves
With spring-loaded non-return ball for metering in open or closed systems and for mounting
the metering line.
Backpressure valves
For exact metering at low operating pressure or as overflow safety valve.
Accumulators
For pulsation damping in long metering lines.
Metering monitors
For monitoring metering operations. After an adjustable number of non-acknowledged metering
strokes, a fault is indicated and the metering pump shut down.
Intake assemblies
With foot valve and float switch for expendable packing drums or metering tanks.
Metering tanks
From 35 to 1000 l capacity with lockable screw cover and necessary accessories.
Manual/electric stirrers
For mixing and preparing metering solutions.
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 55
55
08.06.2010, 11:39 Uhr
56
Q (I/h
Q (I/h
BA_SI_036_06_10_EN.p65
Page 56
08.06.2010, 11:39 Uhr
80
4
6
8
10
12
14
S2Ba HM 16050
S2Ba HM 16090
S2Ba HM 16130
S2Ba HM 07120
S2Ba HM 07220
S2Ba HM 04350
100
16
120
100
150
200
250
300
350
400
450
500
0
pressure in (bar)
0
2
Stroke length in (%)
60
Metering capacity diagram S2Ba HM (50 Hz)
40
50
100
150
200
250
300
350
400
0
20
S2Ba HM 16050
S2Ba HM 16090
S2Ba HM 16130
S2Ba HM 07120
450
50
0
0
S2Ba HM 04350
S2Ba HM 07220
500
50
100
150
200
250
300
350
400
450
0
50
100
150
200
250
300
350
400
Metering capacity diagram S2Ba HM (50 Hz)
Q (I/h
Q (I/h
450
0
0
2
20
60
80
Stroke length in (%)
100
4
6
pressure in (bar)
8
10
12
Metering capacity diagram S2Ba HM (60 Hz)
40
Metering capacity diagram S2Ba HM (60 Hz)
S2Ba HM 07220
S2Ba HM 04350
14
S2Ba HM 16050
S2Ba HM 16090
S2Ba HM 16130
S2Ba HM 07120
S2Ba HM 07220
S2Ba HM 04350
120
S2Ba HM 16050
S2Ba HM 16090
S2Ba HM 16130
S2Ba HM 07120
16
Metering capacity diagram
ProMinent
®
BA_SI_036_06_10_EN.p65
57
Q (I/h
Q (I/h
ProMinent
®
08.06.2010, 11:39 Uhr
0
50
100
150
200
250
300
350
400
450
0
50
100
150
200
250
300
350
400
450
0
0
2
20
4
60
Stroke length in (%)
80
6
pressure in (bar)
8
10
12
Metering capacity diagram S2Ca HM
40
S2Ca HM 16050
S2Ca HM 16090
S2Ca HM 16130
S2Ca HM 07120
S2Ca HM 07220
S2Ca HM 04350
Metering capacity diagram S2Ca HM
14
S2Ca HM 16050
S2Ca HM 16090
S2Ca HM 16130
S2Ca HM 07120
S2Ca HM 07220
S2Ca HM 04350
100
16
120
Metering capacity diagram
Page 57
Annex
Motor data sheet
®
ProMinent
Page 58
BA_SI_036_06_10_EN.p65
58
08.06.2010, 11:39 Uhr
EC Declaration of Conformity
For pumps without Ex protection:
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 59
59
08.06.2010, 11:39 Uhr
EC Declaration of Conformity
For pumps with Ex protection:
The EC conformity declarations, the EC series prototype test reports and the operating manuals for the individual components
are also supplied with the pump.
®
ProMinent
Page 60
BA_SI_036_06_10_EN.p65
60
08.06.2010, 11:39 Uhr
Exploded diagrams of liquid ends
Delivery unit Sigma/ 2 350-DN 25 PVT for identity code types: S2Ba/S2Ca 04350, 07120, 07220
Delivery unit Sigma/ 2 130-DN 15 PVT for identity code types: S2Ba/S2Ca 16050, 16090, 16130
Valve spring **
Valve ball
Ball seat
Valve complete DN 25/PVT* Part no. 740615
Valve complete DN 15/PVT* Part no. 792517
Multi-layer diaphragm FM 350* Part no. 1033422
Multi-layer diaphragm FM 130* Part no. 1029771
Valve complete DN 25/PVT* Part no. 740615
Valve complete DN 15/PVT* Part no. 792517
Diaphragm rupture sensor, visual
Part no. 1033323
Spare parts kit FM 350 PVT Part no. 1035953
Spare parts kit FM 130 PVT Part no. 1035951
* The listed items are constituent parts of the spare part kit.
** Special accessories (not included in spare part kit).
Subject to technical modifications.
Fig. 28
61_05-104_01_38-03x01
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 61
61
08.06.2010, 11:39 Uhr
Exploded diagrams of liquid ends
Delivery unit Sigma/ 2 350-DN 25 SST for identity code types: S2Ba/S2Ca 04350, 07120, 07220
Delivery unit Sigma/ 2 130-DN 15 SST for identity code types: S2Ba/S2Ca 16050, 16090, 16130
Valve complete FM 350 SST * Part no. 803708
Valve complete FM 130 SST * Part no. 809404
Valve spring **
Valve ball
Multi-layer diaphragm FM 350 * Part no. 1033422
Multi-layer diaphragm FM 130 * Part no. 1029771
Ball seat
Valve complete FM 350 SST * Part no. 803708
Valve complete FM 130 SST * Part no. 809404
Diaphragm rupture sensor, visual
Part no. 1033323
Spare parts kit FM 350 SST without valve
Spare parts kit FM 350 SST with 2 valves
Spare parts kit FM 130 SST without valve
Spare parts kit FM 130 SST with 2 valves
Part no. 1035960
Part no. 1035959
Part no. 1035957
Part no. 1035954
* The listed items are constituent parts of the spare part kit.
** Special accessories (not included in spare part kit).
Subject to technical modifications.
Fig. 29
61_05-104_01_41-03x01
®
ProMinent
Page 62
BA_SI_036_06_10_EN.p65
62
08.06.2010, 11:39 Uhr
Exploded diagrams of liquid ends
Delivery unit Sigma/ 2 350-DN 25 PVT for identity code types: S2Ba/S2Ca 04350, 07120, 07220
Delivery unit Sigma/ 2 130-DN 15 PVT for identity code types: S2Ba/S2Ca 16050, 16090, 16130
* *
*
*
*
*
Overflow valve assy 10 bar PVA Part no. 1018947
Overflow valve assy 7 bar PVA Part no. 740811
Overflow valve assy 4 bar PVA Part no. 740812
Spare parts kit ÜV 10 bar PVA
Part no. 1031201
Spare parts kit ÜV
7 bar PVA/SSA Part no. 1031200
Spare parts kit ÜV
4 bar PVA/SSA Part no. 1031199
Andere Ersatzteile siehe Fördereinheit ohne Überströmventil (siehe S. 61).
Fig. 30
Subject to technical modifications.
61_05-104_01_39-03x01
Delivery unit Sigma/ 2 350-DN 25 SST for identity code types: S2Ba/S2Ca 04350, 07120, 07220
Delivery unit Sigma/ 2 130-DN 15 SST for identity code types: S2Ba/S2Ca 16050, 16090, 16130
Overflow valve assy 16 bar SSA Part no. 1019246
Overflow valve assy 7 bar SSA Part no. 740815
Overflow valve assy 4 bar SSA Part no. 740814
* *
*
Spare parts kit ÜV 16 bar SSA
Part no. 1031203
Spare parts kit ÜV
7 bar PVA/SSA Part no. 1031200
Spare parts kit ÜV
4 bar PVA/SSA Part no. 1031199
Andere Ersatzteile siehe Fördereinheit ohne Überströmventil
(siehe S. 62).
Fig. 31
Subject to technical modifications.
61_05-104_01_42-03x01
* Die aufgeführte Positionen sind die Bestandteile des Ersatzteilsets.
®
ProMinent
BA_SI_036_06_10_EN.p65
Page 63
63
08.06.2010, 11:39 Uhr
Anschriften- und Liefernachweis durch den Hersteller /
Addresses and delivery through manufacturer /
Adresses et liste des fournisseurs fournies par le constructeur /
Para informarse de las direcciones de los distribuidores, dirigirse al fabricante:
ProMinent Dosiertechnik GmbH
Im Schuhmachergewann 5-11
69123 Heidelberg
Germany
Tel.: +49 6221 842-0
Fax: +49 6221 842-419
info@prominent.com
www.prominent.com
ProMinent
®
Anschr_Lief_Herst_A4_4spr.p65
2
29.07.2009, 10:34 Uhr