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Assembly and operating instructions Metering pump Hydro/ 4, HA4a in compliance with API 675 Target group: trained, qualified personnel, unless otherwise required. Please carefully read these operating instructions before use. · Do not discard. The operator shall be liable for any damage caused by installation or operating errors.
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Supplemental directives Supplementary information Read the following supplementary information in its entirety! Should you already know this information, you will benefit more from referring to the operating instructions. The following are highlighted separately in the document: Enumerated lists Fig. 1: Please read! Operating guidelines ð...
Functional description Functional description Power end The Hydro HA4a product range represents motor-driven metering pumps with hydraulically operated multi-layer diaphragm (6). The motor moves the hydraulic piston (4) to the front by means of a worm gear and cam (1). The hydraulic piston is connected positively to the cam by a bracket (7) so that the discharge stroke as well as the suction stroke are performed by the force of the motor (so-called “Full Motion Drive”).
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Functional description Liquid end P_HY_0008_SW Fig. 3: Cross-section through the liquid end The heart of the liquid end is a PTFE multi-layer diaphragm (1). The PTFE multi-layer diaphragm hermetically seals the delivery chamber of the dosing head and causes displacement in the dosing head at each pump stroke.
Functional description Diaphragm monitor P_HY_0009_SW Fig. 4: View of the dismantled dosing head with cross-section The diaphragm monitor monitors the multi-layer diaphragm for leaks and faults. The middle diaphragm layer of the multi-layer diaphragm has slots. The slots are connected by a channel in the dosing head (1) to the dia‐ phragm monitoring sensor (2).
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Functional description P_HY_0083_SW 40481023 Fig. 6: Hydro HA, Duplex; a) View from left, b) View from right, c) Overall view...
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Functional description P_HY_0084_SW 40481076 Fig. 7: Hydro HA, Triplex; a) View from left, b) View from right, c) Overall view Power end Oil inspection window Hydraulic end Gearbox vent stopper Liquid end Oil drain stopper Stroke adjustment dial Oil drainage plug Safety relief valve + bleed valve Diaphragm monitor Every power end includes all these components –...
008 bar Fluid T. 40 °C Stroke rate 012 bar 136 rpm ProMinent GmbH, Im Schuhmachergewann 5 - 11 69123 Heidelberg, Germany P_HY_0089_SW Fig. 9: Nameplate data (example), explanation Type Identity code - see above p rtd Maximum pressure, as ordered...
Functional description 1.2.3 HA4a identity code HA4a Hydro/ 4, version a, in compliance with API 675 Drive type Simplex (vertical) S U Duplex Simplex double head D T Triplex M modified Piston Piston Ø 40 mm 063 piston Ø 63 mm Piston Ø...
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Functional description HA4a Hydro/ 4, version a, in compliance with API 675 3-phase 230 V/400 V 50/60 Hz, 3-phase, 230 V/400 V 50/60 Hz, with PTC 3-phase, 230 V/400 V, 50 Hz, (Exe) T3 3-phase, 230 V/400 V, 50 Hz, (Exde) T4...
Functional description 1.2.4 Explanation of the ATEX label Explanation of the pump’s ATEX labelling in accordance with Directive 2014/34/EU and standards EN ISO 80079-36, Unit group No mines or associated underground systems, which can be endangered by firedamp - Unit for use in other areas at risk from explosion Other parameters 3G Ex h...
Safety chapter Safety chapter 2.1 Labelling of Warning Information Introduction These operating instructions provide information on the technical data and functions of the product. These operating instructions provide detailed warning information and are provided as clear step-by-step instructions. The warning information and notes are categorised according to the fol‐ lowing scheme.
Safety chapter 2.2 User qualification WARNING! Danger of injury with inadequately qualified personnel The operator of the system / equipment is responsible for ensuring that the qualifications are fulfilled. If inadequately qualified personnel work on the unit or loiter in the hazard zone of the unit, this could result in dangers that could cause serious injuries and material damage.
Observe the general limitations with regard to viscosity limits, chem‐ ical resistance and density - see also the ProMinent Resistance List (in the Product Catalogue or at www.prominent.com)! Only suitable pumps can be used in areas at risk of explosion.
An unsuitable feed chemical can damage the parts of the pump that come into contact with the chemical. – Take into account the resistance of the wetted mate‐ rials and the ProMinent Resistance List when selecting the feed chemical - see the ProMinent Product Catalogue or visit ProMinent.
Safety chapter WARNING! Adjusted pressure switches fail – The switching point of the 42 V pressure switch must not be changed. – The ATEX pressure switch must not be reprog‐ rammed. It could result in overheating of the pump. WARNING! The inside of the dosing head needs to be constantly filled with medium in normal mode, and the start-up and run-down processes have to be designed in such a way...
The "Decontamination Declaration Form" can be found at www.prominent.com. CAUTION! Use lifting points with suitable lifting means. Secure the pump to prevent it from falling.
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Storage, transport and unpacking Specification Value Maximum air humidity*: 95 % relative humidity *non-condensing (according to DIN IEC 60068-2-30)
Assembly Assembly User qualification: trained qualified personnel Ä Chapter 2.2 ‘User qualification’ on page 15 Compare the dimensions on the dimensional drawing with those of the pump. Assembly of the motor - with designs without motor WARNING! The following instructions relevant in areas at risk from explosion apply in areas at risk from explosion.
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Assembly Motor number: "1"; "3"; "4"; "6" The motor number designates the motor, see B1272 Fig. 12: Situation in the flange with claw coupling (arrow) without motor P_HY_0060_SW Fig. 13: Approximate height (Q) of the coupling claw on the motor shaft Tab.
Assembly 4.2 Space requirement Motor may overheat If the necessary cooling air supply is not guaranteed, the motor may overheat. Maintain sufficient clearance between the air intake – opening and the walls. The distance should be greater than 1/4 the diameter of the air intake opening.
Assembly 4.4 Fastening Capacity too low Vibrations can disturb the liquid end valves. – Secure the metering pump so that no vibrations can occur. Take the dimensions (m) of the fastening holes from the appropriate dimensional drawings or data sheets. Secure the pump foot to the floor using four suitable screws.
Installation Installation 5.1 Installation, hydraulic User qualification: trained qualified personnel Ä Chapter 2.2 ‘User qualification’ on page 15 WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries. Please ensure when handling hazardous substances that you have read the latest safety data sheets provided by the manufacture of the hazardous substance.
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Installation Precise metering is only possible when the back – pressure is maintained above 1 bar at all times. Use appropriate measures to ensure a back pres‐ – sure of approx. 2 bar if you are metering with a free outlet.
Installation 5.1.1 Basic installation notes Examples P_MOZ_0043_SW Fig. 19: (A) standard installation, (B) with pulsation damper Main line Storage tank Tab. 4: Legend for hydraulic diagram Symbol Explanation Symbol Explanation Metering pump Foot valve with filter mesh Injection valve Level switch Back pressure valve or safety valve Manometer...
Installation 5.2 Installation, electrical User qualification: Electrical technician Ä Chapter 2.2 ‘User qualification’ on page 15 What requires electrical installation?: Motor External fan (identity code option) Frequency converter (identity code option) Stroke control drive (identity code option) Stroke actuator (identity code option) Diaphragm monitoring sensor (standard) Earthing wires (to be provided on site) Potential equalisation line (to be provided on site, prescribed in the...
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Installation CAUTION! The motor can be damaged Provide appropriate motor protection devices to protect the motor against overloading (e.g. motor protection switch with thermal overcurrent trip). Fuses do not pro‐ vide motor protection. CAUTION! Only motors with a frequency converter: The motor can be damaged The input current limiter could be damaged if a motor with integrated frequency converter is restarted within 3...
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Installation CAUTION! Only operate stroke length actuators / control drives when the pump is running. Otherwise the power ends will be damaged. Diaphragm monitoring sensor (optional) a) Diaphragm monitoring sensor with switch contact The cable can be connected as required. –...
Start up and operation Start up and operation User qualification: trained qualified personnel Ä Chapter 2.2 ‘User qualification’ on page 15 WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries. Please ensure when handling hazardous substances that you have read the latest safety data sheets provided by the manufacture of the hazardous substance.
Dismantle the section of hose. Fit the discharge line. 6.2 Calibrate the stroke control drive (optional) The stroke control drive is calibrated to the capacity ordered ex-factory. Please contact ProMinent if you wish the stroke control drive to be cali‐ brated to another capacity.
Maintenance Maintenance User qualification: trained and qualified personnel, unless otherwise stated Ä Chapter 2.2 ‘User qualification’ on page 15 WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries. Please ensure when handling hazardous substances that you have read the latest safety data sheets provided by the manufacture of the hazardous substance.
When changing the hydraulic oil, pay attention to wear on the worm Instructed person ating hours gear. Have the power end repaired by ProMinent in the event of increased wear. Change hydraulic oil - refer to "Changing hydraulic oil" in this Instructed person chapter.
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Maintenance WARNING! If the pump must be operated using hydraulic oil compat‐ ible with foodstuffs, then only foodsafe hydraulic oil must be used. Draining the hydraulic oil Perform the following work simultaneously on both dosing heads with double head versions. Set the stroke adjustment dial (1) to “0”.
Maintenance Screw the vent valve (2) back in. Replace the vent screw (4). Check whether all openings are tightly sealed again – especially in areas at risk from explosion! WARNING! Only in areas at risk from explosion: Check after 1 day whether the oil drainage stopper (5) and the oil drainage plug (6) are still tight.
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Maintenance P_HY_0033_SW Fig. 21 WARNING! Warning of injury to eyes The very strong spring (3) and the spring collar (5) on the diaphragm anchor (6) may spring away when loosening the safety collar (4). – Use the mounting aid (8) to dismantle! –...
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- Test the diaphragm rupture sensor - see Screw the suction and pressure line onto the liquid end. P_HY_0009_SW Fig. 22: Areas wetted by Hydro/ 4 (shaded grey) Tab. 5: Tightening torque for screws: Material version Tightening torque SST, HCT 40.0 Nm...
Maintenance 7.5 Using shaped composite seals Leaks are possible Leaks can occur on the pump connection depending on the insert used. The pump is supplied with PTFE moulded compo‐ – site seals with a flare, which are used for the pump connectors, and which seal the connectors between the grooved pump valves and the grooved inserts - P_SI_0021...
Maintenance 7.7 Repairing the diaphragm monitoring sensor 30 V-version Checking the diaphragm monitoring When changing the diaphragm, unscrew the diaphragm monitoring sensor sensor from the dosing head. Check for electrical continuity: Using a blunt insulating probe (Ø 2 ... 3 mm, no sharp edges), press into the channel of the diaphragm monitoring sensor.
Maintenance ATEX version Checking the diaphragm rupture sensor When changing the diaphragm, unscrew the diaphragm rupture sensor from the dosing head. Check that the monitor does not indicate a diaphragm rupture: Using a blunt insulating probe (Ø 2 ... 3 mm, no sharp edges), press into the channel of the diaphragm rupture sensor.
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Maintenance The dosing rate of the hydraulic diaphragm metering pump is only dependent on back pressure to a minimal extent. And the pumps are fac‐ tory-calibrated to the maximum operating pressure. (Value of the max‐ imum operating pressure - see the pressure stage on the indicating dial or the safety relief valve.) The subsidiary or factory can calibrate each pump to a back pressure lower than the nominal pressure ordered.
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Maintenance Fill the measuring vessel with feed chemical. Start the pump. As soon as the back pressure of the system has been reached, determine the fill level Q and start the stopwatch. Allow the pump to run for a short time. At the same time, determine the fill level Q and stop the stopwatch.
Troubleshooting Troubleshooting User qualification: trained and qualified personnel / elec‐ trical technician Ä Chapter 2.2 ‘User qualification’ on page 15 Fault Cause Solution Pump does not reach high pressures The valves are dirty or worn. Repair the valves - see “Repair” or does not prime despite full stroke chapter.
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Troubleshooting Fault Cause Solution The power end motor is very hot. The pressure line is seriously con‐ Remove any constriction of the stricted. pressure line. Have the safety relief valve checked. All other faults. Other causes. Call ProMinent Service.
Decommissioning and disposal Decommissioning and disposal User qualification: trained qualified personnel / electrical technician Ä Chapter 2.2 ‘User qualification’ on page 15 WARNING! Danger from hazardous substances! Possible consequence: Fatal or very serious injuries. Please ensure when handling hazardous substances that you have read the latest safety data sheets provided by the manufacture of the hazardous substance.
Decommissioning and disposal 9.2 Disposal CAUTION! Environmental hazard due to hydraulic oil The pump contains hydraulic oil, which can cause damage to the environment. – Drain the hydraulic oil out of the pump. – Note the local regulations applicable in your country. CAUTION! Danger from compression springs –...
Technical data Technical data Always note the technical data on the nameplate and on the pump data sheet as a priority. Their information has priority over the information given in this chapter. Only with "M - modified" design: Please observe the ”Supplementary information for modified version“...
Technical data thus a control range of 1:10 is fulfilled for a customer-specific “Rated Flow” “Q rtd” (API 675) in the range of 180 ... 207 l/h. HA4a at 60 Hz operation Piston Ø Pressure Pump capacity in l/h at strokes / min (60 Hz) Qrtd min. - Q Stroke Suction Suction /...
Technical data Tab. 7: HA4a Design Weight approx. Simplex 96 kg Duplex 160 kg Duplex - double head 220 kg Triplex 220 kg Triplex 260 kg + Exde motor with frequency converter 10.6 Wetted materials Material ver‐ Dosing head Connector Seals DN15/25 ball DN32/40 plate...
Technical data 10.7.2 Air humidity Specification Value Maximum air humidity*: 95 % relative humidity *non-condensing (according to DIN IEC 60068-2-30) 10.7.3 Installation height Specification Value Maximum installation height*: 1000 m.a.s.l. * Higher installation heights are possible on request. 10.8 Housing degree of protection Specification Value Protection against contact and moisture according to EN IEC 60529...
Technical data 10.9 Motor data Electrical data Tab. 10: HA4 / HP4 Identity code specification HA Machine type standard motor 3- standard motor 3- standard motor 3- standard motor 3- standard motor 3- phase, AC phase, AC + PTC phase, AC + PTC phase, AC + PTC phase, AC + PTC Explosion protec‐...
Technical data Tab. 11: HA4 / HP4 Identity code specifi‐ cation HA Identity code specifi‐ R; Z cation HP Machine type standard motor 3- standard motor 3- standard motor 3- standard motor 3- phase, AC + PTC phase, AC + PTC + phase, AC + FC phase, AC + PTC + external fan...
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Technical data Contact Seal Top part Separating diaphragm Plate Body The contact is an N/C. The contact is an potential-free. For safety reasons, we recommend connecting to a – protective low voltage, e.g. in accordance with EN 60335-1 (SELV ). The cable can be connected as required.
Technical data NAMUR sensor (Specified for EX zones) Seal Top part Separating diaphragm 3a Spring seat Plate Body Spring 5 ... 25 V DC, in accordance with NAMUR and/or DIN 60947-5-6, poten‐ tial-free design. Install the sensor in accordance with the chapter "Instal‐ lation, electrical".
Technical data Required oil volume, approx. Duplex: 2x 5.8 l Triplex: 3x 5.8 l Manufacturer Name Viscosity class Order no. for 1 litre Standard Mobil Mobilube 1 SHC 75 W - 90 1005823 or similar hydraulic oil Food Mobil SHC Cibus 1007610 or similar hydraulic oil Oil between the diaphragm layers: OKS370 (food-safe)
Compare the dimensions on the dimensional drawing with those of the pump. All dimensions are in mm. Further dimensional drawings - see www.prominent.com. P_HY_0091_SW_DE 40468732 Fig. 31: The presentation / dimensions are not strictly binding. Hydro HA4 (HA4a V) Simplex, vertical outer diameter 1: leave a minimum of 200 mm for dismantling.
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Dimensional drawing, example Size Drive type Piston Ø Motor Stroke length Value adjustment V / D / U S/T/R/V/1-3 V / D / U S/T/R/V/1-3 V / D / U S/T/R/V/1-3 V / D / U S/T/R/V/1-3 V / D / U S/T/R/V/1-3 V / D / U K/P/L/Q/W/4-6...
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Dimensional drawing, example Size Drive type Piston Ø Motor Stroke length Value adjustment V / D / U V / D / U V / D / U V / D / U V / D / U V / D / U V / D / U A/B/C/D V / D / U...
Earthing drawing Earthing drawing Simplex single head Hydro HA4 with actuator P_HY_0092_SW Power end, potential equalisation Motor, potential equalisation and functional earthing Actuator (optional), potential equalisation and functional earthing Diaphragm rupture sensor (only with plastic dosing head material), potential equalisation...
Ordering information Ordering information 13.1 Exploded view P_HY_0017_SW Fig. 32: Hydro liquid end. Numbered positions = scope of delivery of spare parts kit S1 (SST). Technical changes reserved. Seals (Set) Valve balls Pressure connector assembly Suction connector assembly Diaphragm 13.2 General Hydraulic oil The pump uses a hydraulic oil that lubricates the gear at the same time.
Manufacturer: Pep‐ Click on “NJ1,5-8GM-N” beside the photo. perl&Fuchs Click on the button for the document you require. Type: NJ1,5-8GM-N Search for and download the document. ProMinent part no.: 710251 The URLs listed provide the most up-to-date versions of the documents.
Machinery Directive 2006/42/EC. RoHS Directive (2011/65/EU) Harmonised standards applied, in EN ISO 12100:2010, particular: EN 809:1998 + A1:2009 + AC:2010, EN 61000-6-2:2005, EN 61000-6-4:2007 + A1:2011, EN 60204-1:2018, EN IEC 63000:2018 Date: 26.10.2020 Download the Declaration of Conformity at www.prominent.com.
EN IEC 63000:2018 Only start up the metering pump when it has been established that the combination of metering pump without motor and motor complies with the provisions of the Machine Directive. Date: 26.10.2020 Download the Declaration of Incorporation at www.prominent.com.
Appendix I, No. 1.5.1 of the Machinery Directive 2006/42/EC. RoHS Directive (2011/65/EU) Harmonised standards applied, in EN ISO 12100:2010 particular: EN 809:1998 + A1:2009 + AC:2010 EN IEC 63000:2018 Date: 26.10.2020 Download the Declaration of Conformity at www.prominent.com.
II 2G Ex h IIC T4 Gb X for § = “L”, “Q”, “W”, % = “0” or “K” II 2G Ex h IIB T4 Gb X for § = “L”, “Q”, “W”, % = “A”, “B”, “C”, “D” X: maximum medium temperature 90 °C Date: 26.10.2020 Download the Declaration of Conformity at www.prominent.com.
II 2G Ex h IIC T4 Gb X for % = "0" or "K" II 2G Ex h IIB T4 Gb X for % = “A” or “B” or “C” or “D” X: maximum medium temperature 90 °C Assess the ignition risk when assembling. Date: 26.10.2020 Download the Declaration of Incorporation at www.prominent.com.
II 2G Ex h IIB T4 Gb X for % = “A” or “B” or “C” or “D” X: maximum medium temperature 90 °C Assess the ignition risk when assembling the pump and motor. Date: 26.10.2020 Download the Declaration of Conformity at www.prominent.com.
UK Declarations of Conformity or Incorporation for HA2 16.1 UK Declaration of Conformity for HA4 For pumps without explosion protection: ProMinent GmbH Im Schuhmachergewann 5 - 11 D - 69123 Heidelberg Germany hereby declare that the product identified below conforms to the basic health and safety requirements of the Regulations, by virtue of its design and construction, and in the configuration placed on the market by us.
UK Declarations of Conformity or Incorporation for HA2 16.2 UK Declaration of Incorporation for HA4 For pumps without explosion protection: ProMinent GmbH Im Schuhmachergewann 5 - 11 D - 69123 Heidelberg Germany hereby declare that the product identified below conforms to the basic health and safety requirements of the Regulations, by virtue of its design and construction, and in the configuration placed on the market by us.
UK Declarations of Conformity or Incorporation for HA2 16.3 UK Declaration of Conformity for machines without motor HA4 For pumps without explosion protection: ProMinent GmbH Im Schuhmachergewann 5 - 11 D - 69123 Heidelberg Germany hereby declare that the product identified below conforms to the basic health and safety requirements of the Regulations, by virtue of its design and construction, and in the configuration placed on the market by us.
UK Declarations of Conformity or Incorporation for HA2 16.4 UK Declaration of Conformity for ATEX HA4 For pumps with explosion protection: ProMinent GmbH Im Schuhmachergewann 5 - 11 69123 Heidelberg Germany hereby declare that the product identified below conforms to the basic health and safety requirements of the Regulations, by virtue of its design and construction, and in the configuration placed on the market by us.
UK Declarations of Conformity or Incorporation for HA2 16.5 UK Declaration of Incorporation ATEX HA4a For pumps with explosion protection: ProMinent GmbH Im Schuhmachergewann 5 - 11 D - 69123 Heidelberg, Germany, hereby declare that the product identified below conforms to the basic health and safety requirements of the Regulations, by virtue of its design and construction, and in the configuration placed on the market by us.
UK Declarations of Conformity or Incorporation for HA2 16.6 UK Declaration of Conformity for ATEX machines without motor HA4 For pumps with explosion protection: ProMinent GmbH Im Schuhmachergewann 5 - 11 69123 Heidelberg Germany hereby declare that the product identified below conforms to the basic health and safety requirements of the Regulations, by virtue of its design and construction, and in the configuration placed on the market by us.
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