ProMinent EMFa Operating Instructions Manual
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ProMinent EMFa Operating Instructions Manual

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Operating instructions
Metering pump
Evolution mikro, EMFa / EMHa
These operating instructions form part of combined documentation and, as such, are only valid if used in conjunction with
the other documents.
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.
The latest version of the operating instructions are available on our homepage.
981089
Original operating instructions (2006/42/EC)
EN
Version: BA ORL 012 09/21 EN

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  • Page 1 Operating instructions Metering pump Evolution mikro, EMFa / EMHa These operating instructions form part of combined documentation and, as such, are only valid if used in conjunction with the other documents. Target group: trained, qualified personnel, unless otherwise required. Please carefully read these operating instructions before use. · Do not discard.
  • Page 2 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...

  • Page 3: Table Of Contents

    Table of contents Table of contents Functional description..............5 1.1 Overview of equipment / control elements......6 1.2 Scope of delivery..............7 1.2.1 Scope of delivery of the Evolution mikro......7 1.2.2 Scope of delivery of the Evolution mikro ATEX....7 1.3 Identity code................
  • Page 4 10.2 Disposal................57 Technical data................58 11.1 Reproducibility..............58 11.2 Particle size................. 58 11.3 Performance data..............59 11.3.1 Evolution mikro EMFa............59 11.3.2 EMHa (metal diaphragm)..........61 11.4 Viscosity................62 11.5 Weight................. 62 11.6 Wetted materials..............63 11.7 Ambient conditions.............. 63 11.7.1 Temperatures..............

  • Page 5: Functional Description

    Functional description Functional description P_ORL_0070_SW Interface to the linear motor Hydraulic block hydraulic oil Hydraulic block Diaphragm Dosing head Delivery chamber of the liquid end Slide rod Magnet Piston The “Orlita Evolution mikro” micro-metering pump is a hydraulic diaphragm metering pump with an electronically controlled linear motor as a direct drive.

  • Page 6: Overview Of Equipment / Control Elements

    Functional description 1.1 Overview of equipment / control elements P_ORL_0069_SW Transport protection (in parked position) Pressure relief valve Vent screw Diaphragm rupture indicator Motor - controller connecting cable Bleed / post-suction valve Controller C1100 / 1150 10 Suction valve Motor housing 11 Liquid end Oil inspection window 12 Discharge valve...

  • Page 7: Scope Of Delivery

    Functional description 1.2 Scope of delivery 1.2.1 Scope of delivery of the Evolution mikro By the customer Control cabinet Skid Pump Controller Cable A3428 Fig. 2: Scope of delivery of the Evolution mikro 1 Pump 2 Cable 3 Controller Evolution mikro Standard: Standard: 2 m cable...

  • Page 8: Identity Code

    Functional description 1.3 Identity code Tab. 1: Identity code ordering system for the Evolution mikro - EMFa / EMHa EMFa Drive type EMHa V Simplex (vertical) Piston Piston Ø3 Piston Ø6 Stroke rate 30 strokes/min 60 strokes/min 80 strokes/min 100 strokes/min...
  • Page 9 Functional description Standard linear motor without cable, 24 V DC ATEX linear motor with 2-metre cable, 24 V DC ATEX linear motor with 4-metre cable, 24 V DC ATEX linear motor without cable, 24 V DC Standard linear motor with 2-metre cable Standard linear motor with 4-metre cable Standard linear motor without cable ATEX linear motor with 2-metre cable...
  • Page 10 Functional description CE + ATEX CE + EAC CE + EAC + ATEX CE + UKCA CE + UKCA + ATEX Documentation* German English French Spanish Russian Measuring unit bar, l/h psi, gph kPa, l/h * other languages on request.

  • Page 11: Product Identification Of The Evolution Mikro - Project Version

    Functional description 1.4 Product identification of the Evolution mikro - Project version Tab. 2: Product identification of the Evolution mikro - Project version Product Power end Liquid end range EMFa Evolution with Standard PTFE diaphragm PTFE diaphragm EMHa Evolution mikro ATEX with metal dia‐...

  • Page 12: Safety Chapter

    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.

  • Page 13: User Qualification

    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.

  • Page 14: Intended Use

    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)! The pump is not intended for private use.

  • Page 15: Safety Information

    Safety chapter 2.6 Safety information Safety information 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. The actions required are described in the safety data sheet.
  • Page 16 – 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. WARNING! The inside of the dosing head needs to be constantly...
  • Page 17 With regard to the ignition hazard assessment, it is assumed that the Evolution mikro EMFa / EMHa in accord‐ inside of the dosing head is constantly filled with medium in normal mode ance with EN ISO 80079-36...

  • Page 18: Safety Equipment

    Safety chapter 2.7 Safety equipment Labels The labels on the pump housing must be kept legible at all times. Danger of tipping over Magnetic field Hot surface 2.8 Sound pressure level Sound pressure level Sound pressure level LpA < 70 dB according to EN ISO 20361 at maximum stroke length, maximum stroke rate, maximum back pressure (water)

  • Page 19: Storage, Transport And Unpacking

    Storage, transport and unpacking Storage, transport and unpacking User qualification: trained person / qualified personnel Ä Chapter 2.2 ‘User qualification’ on page 13 WARNING! Only return metering pumps for repair in a cleaned state and with a flushed liquid end - refer to "Decommis‐ sioning! Only return metering pumps with a completed Decon‐...

  • Page 20: Ambient Conditions

    Storage, transport and unpacking CAUTION! Danger of environmental and material damage The unit can be damaged or oil may escape due to incorrect or improper storage or transportation. – Therefore only screw the transport protection pin (1) into the thread in the centre of the plate, Figure A. –...
  • Page 21 Storage, transport and unpacking Specification Value Maximum air humidity*: 95 % relative humidity *non-condensing (according to DIN IEC 60068-2-30)

  • Page 22: Assembly

    Assembly Assembly User qualification: trained and qualified personnel / elec‐ trical technician Ä Chapter 2.2 ‘User qualification’ on page 13 WARNING! In areas at risk from explosion: perform all work in the absence of an explosive atmosphere. Select a clean place. Compare the dimensions on the dimensional drawing with those of the pump.

  • Page 23: Fastening

    Assembly 4.3 Fastening Dosing rate too low Vibrations can disturb the valves of the liquid end. – Secure the metering pump so that no vibrations can occur. Take the dimensions of the fastening holes from the appropriate dimensional or data sheets. Use 3 suitable screws to fix the hydraulic block (pump base) to the supporting floor.

  • Page 24: Installation

    Installation Installation User qualification: trained qualified personnel Ä Chapter 2.2 ‘User qualification’ on page 13 5.1 Installation, hydraulic 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.
  • Page 25 Installation Precise metering is only possible when the back pres‐ sure is maintained at ≧ 3 bar at all times. Use appropriate measures to ensure a back pres‐ – sure of approx. 3 bar if you are metering with a free outlet.

  • Page 26: Basic Installation Notes

    Installation 5.1.1 Basic installation notes Examples P_MOZ_0043_SW Fig. 8: (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 5.2 Installation, electrical...

  • Page 27: Controller

    Installation INFORMATION! Use a suitable isolating device in the control cabinet to de-energise the pump independently of the entire installation (e.g. for repairs). INFORMATION! Only install or uninstall the cable to connect the motor and the controller when no more LEDs are lit on the controller. INFORMATION! Do not bend the cable connecting the motor to the con‐...

  • Page 28: Earthing Wires (To Be Provided On Site)

    Installation 5.2.4 Earthing wires (to be provided on site) Earth the pump in accordance with the “Earthing / potential equali‐ sation drawings for the Evolution mikro” and all electrical compo‐ nents in accordance with their documentation. 5.2.5 Potential equalisation lines (to be provided on site, prescribed in the area at risk from explosion) Earth the pump in accordance with the “Earthing / potential equali‐...

  • Page 29: Terminal Diagram

    Installation 5.2.7 Terminal diagram Internal External Power unit 24 V DC, max. 30 W (controller power supply) 24 V DC / 72 V DC, max. 0.4 kW (motor power supply) Power unit Energy supply Controller Linear motor cable Power supply Signal for Motion control Signal for...
  • Page 30 Installation 5.2.7.1 Main connection and power supply / Emergency Stop A3430 Fig. 11: Main connection and power supply / Emergency Stop 5.2.7.2 Connection between controller and motor Motor connector Control drive A3431 Fig. 12: Controller and motor...
  • Page 31 Installation 5.2.7.3 Drive control terminals X4.9 only works with an analogue signal 2 ... 10 V - the built-in resistor converts your analogue 4 ... 20 mA signal into 2 ... 10 V How to connect a converter for analogue signals to, say, a potentiometer 0 ...
  • Page 32 Installation 5.2.7.4 Connection example showing the external temperature relay Safe side (control cabinet) Unsafe side (EX atmosphere) A3433 Fig. 14: Connection example showing the external temperature relay Circuit breaker Signals (motor, temperature etc.) Power supply Linear motor Control Pt1000 temperature sensors Temperature relay Pt1000 temperature signals Current...
  • Page 33 Installation Power supply Temperature relay Thin cable with black sheath for connection to the temperature relay. Thin cable with black sheath for connection to the temperature relay. A3435 Fig. 16: Connection example showing the external temperature relay...

  • Page 34: Commissioning And Operation

    Commissioning and operation Commissioning and operation User qualification: trained qualified personnel Ä Chapter 2.2 ‘User qualification’ on page 13 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.
  • Page 35 Commissioning and operation Non-ATEX version only: remove the motor cable cover (1). Is the motor cable correctly installed between the motor and the controller? Non-ATEX version only: fit the motor cable cover (1). B1287 Fig. 17: 1 Motor cable cover (standard pump) Finish the electrical installation of the con‐...

  • Page 36: Immediately After Commissioning

    Commissioning and operation Pressure relief valve CAUTION! Never adjust the pressure relief valve. Checking the diaphragm rupture indicator Check whether the diaphragm rupture indicator is installed and is triggering the expected reactions. Removing the transport protection – fitting the vent screw Swap the locations of the transport protection pin and the vent screw on the top of the pump housing.

  • Page 37: H After Commissioning

    Commissioning and operation Is the stroke preferably set to 60 mm when priming? Do the pressure surges of the pump adversely affect the installa‐ tion? Install a pulsation damper if you need to. 6.3 0.5 h ... 1 h after commissioning Is oil leaking somewhere? Has the oil level dropped? Does the liquid end become dangerously hot in high ambient tem‐...

  • Page 38: Maintenance

    Maintenance Maintenance User qualification: trained and qualified personnel, unless otherwise stated Ä Chapter 2.2 ‘User qualification’ on page 13 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.

  • Page 39: Inspection

    Maintenance 7.1 Inspection Inspection WARNING! Only remove the housing covers when no more LEDs are lit on the controller. Interval Inspection point weekly: Check whether the diaphragm rupture indicator is displaying a diaphragm rupture - with the pump running. * Check for excessive noise from the valves and the drive - with the pump running.

  • Page 40: Maintenance Work

    Maintenance Interval Inspection point Re-tighten the threaded joint (tightening torque: 5 Nm). Check whether the external bearings are still firmly screwed to the stator without gaps (tight‐ ening torque: 6 Nm). Check that there are no thick layers of dust on the motor housing and external bearings. Heavy layers of dust interfere with heat radiation.

  • Page 41: Changing The Hydraulic Oil

    Maintenance 7.3 Changing the hydraulic oil Changing the hydraulic oil WARNING! Risk of burns due to hot hydraulic oil The hydraulic oil may become very hot when the pump is exposed to extensive loading. – When draining oil, avoid contact with the oil running out.

  • Page 42: Cleaning Valves

    Maintenance 7.4 Cleaning valves Cleaning a discharge valve (double ball) Individual components can fall out and become dam‐ aged when removing the discharge and suction valves. Clean the discharge and suction valves only one after another, as the valves cannot be differentiated using the arrow markings.
  • Page 43 Maintenance Insert disc Seal Spring (optional) Position the insert disc (6) with the flare on the assembly. The distance between the edge of the valve body and the insert disc (6) depends on the design. Place the large seal (7) between the insert disc (6) and the dosing head.

  • Page 44: Replacing The Diaphragm

    Maintenance 7.5 Replacing the diaphragm B1244 Fig. 24: The open liquid end of the Evo mikro Dosing head Diaphragm package Hydraulic block of the liquid end Place a small tray or an oil cloth underneath. Remove the dosing head from the liquid end. If necessary: clean the parts of the liquid end.

  • Page 45: Replacing The Safety Relief Valve

    Maintenance 7.6 Replacing the safety relief valve WARNING! The safety relief valve is a safety-relevant component and should only be fully replaced if necessary. Remove the old safety relief valve. Pay attention to the position of the new O-ring. Fix the O-ring in place with a little grease if necessary.
  • Page 46 Maintenance 2 new motor bearings Tool Remove the front motor cover. B1296 Remove the side plate on the side without any controls; if neces‐ sary, use a rubber mallet to remove the side plate from the dowel pins. B1297 Lift the rotor a little.
  • Page 47 Maintenance Be careful with very thin displacement bodies as the displacement body could become bent: Fully loosen the threaded connector between the rotor and the con‐ nector; each component has a different spanner size (AF24 and AF19). B1299 Remove the 4 screws at the bottom of the remaining side plate and remove the assembly from the motor and attached parts of the hydraulic block;...
  • Page 48 Maintenance Remove the 4 hexagonal head screws and the associated bearing at both ends of the stator; the rotor is still fitted in the illustration. B1300 Clean the openings. Assembling the motor Insert the new bearings (3) with their wipers (2) at both ends of the stator and secure each one with 4 hexagonal head screws (1) - tightening torque: 6 Nm.
  • Page 49 Maintenance Place the remaining side plate on the dowel pins and tighten. Place the motor cover on the pump and tighten.

  • Page 50: Repairing The Diaphragm Monitoring Sensor

    Repairing the diaphragm monitoring sensor Repairing the diaphragm monitoring sensor Visual display B1316 Fig. 26: Visual display Regularly clean the display.
  • Page 51 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.
  • Page 52 Repairing the diaphragm monitoring sensor ATEX version Checking the diaphragm monitoring When changing the diaphragm, unscrew the diaphragm monitoring sensor sensor from the dosing head. Check that the monitor does not indicate Using a blunt insulating probe (Ø 2 ... 3 mm, no sharp edges), press any diaphragm damage: into the channel of the diaphragm monitoring sensor.

  • Page 53: Troubleshooting

    Troubleshooting Troubleshooting User qualification: trained and qualified personnel / elec‐ trical technician Ä Chapter 2.2 ‘User qualification’ on page 13 9.1 Mechanical faults Fault Cause Solution Remark Noise developing from the Too great axial play of the Set the specific axial play. Check after tightening the housing displacement body...
  • Page 54 Troubleshooting Fault Cause Solution Remark Pressure relief valve is Setting pressure is too low Possible damage after open response Pump meters too little The discharge and suction Check the discharge and across the entire range valves are worn or leaking suction valve for wear and dirt, and replace and/or clean as necessary...

  • Page 55: Electrical Faults

    Troubleshooting Fault Cause Solution Remark A diaphragm rupture is dis‐ Diaphragm damage Change the diaphragm played during operation package. Diffusion through the dia‐ Depressurise the dia‐ phragm phragm rupture indicator; replace the diaphragm package if repeatedly dis‐ played and contact Service if necessary.

  • Page 56: Decommissioning And Disposal

    Decommissioning and disposal Decommissioning and disposal User qualification: trained qualified personnel Ä Chapter 2.2 ‘User qualification’ on page 13 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.

  • Page 57: Disposal

    Decommissioning and disposal 10.2 Disposal WARNING! The motor rotor and also the liquid end both contain a very strong magnet. The magnet can interfere with pacemakers and other electrical equipment. – Maintain a minimum distance of 250 mm from the magnet.

  • Page 58: Technical Data

    Technical data Technical data Always note the technical data on the nameplate, the pump data sheet supplied, and the other applicable documents provided. Their information has priority over the information given in this chapter. Only with "M - modified" design: Please observe the ”Supplementary information for modified version“...

  • Page 59: Performance Data

    Technical data 11.3 Performance data 11.3.1 Evolution mikro EMFa Evolution mikro EMFa 72 V DC Piston Max. Max. pump capacity in l/h at strokes/min Stroke Suction pres‐ volume lift sure theoret‐ ical ml/stroke m water column 0.42 0.42 0.42 0.42 0.42...
  • Page 60 Technical data Evolution mikro EMFa 24 V DC Piston Max. Max. pump capacity in l/h at strokes/min Stroke Suc‐ pres‐ volume tion lift sure theoret‐ ical stroke water column 0.42 0.42 0.42 0.42 0.42 0.42 0.42 0.42 on request 0.42 on request 0.42...

  • Page 61: Emha (Metal Diaphragm)

    Technical data 11.3.2 EMHa (metal diaphragm) Evolution mikro EMHa 72 V DC Piston Max. Max. pump capacity in l/h at strokes/min Stroke Suc‐ pres‐ volume tion lift sure theoret‐ ical stroke water column 0.42 0.42 0.42 0.42 0.42 0.42 0.42 0.42 on request 0.42...

  • Page 62: Viscosity

    Technical data Evolution mikro EMHa 24 V DC Piston Max. Max. pump capacity in l/h at strokes/min Stroke Suction pres‐ volume lift sure theoret‐ ical ml/stroke water column 0.42 0.42 0.42 0.42 0.42 0.42 0.42 0.42 on request 0.42 on request 0.42 All performance data applies at an ambient temperature of 40 °C and 24 V DC power supply.

  • Page 63: Wetted Materials

    -20 ... +40 °C See identity code, characteristic: Ambient conditions Tab. 11: Feed chemical / fluid Material Material abbrevia‐ Min. temperature Max. temp. Max. temp. tion EMFa / EMHa EMFa EMHa Stainless steel -20 °C +80 °C +80 °C -20 °C +80 °C +80 °C...

  • Page 64: Installation Height

    Technical data 11.7.3 Installation height Specification Value Maximum installation height*: 1000 m.a.s.l. * Higher installation heights are possible on request. 11.8 Housing degree of protection Specification Value Protection against contact and moisture according to EN IEC 60529 IP 55 11.9 Diaphragm monitoring sensor The necessary back pressure for the reliable triggering of the diaphragm monitoring sensor is ≧...

  • Page 65: Safety Relief Valve (Evolution Mikro)

    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".

  • Page 66: Supplementary Information With Modified Designs

    Technical data 11.12 Supplementary information with modified designs (With various identity code specifications: "M" - "modified") More The relevant data can differ from that of the standard pumps depending on the modified identity code specifications. The relevant information can also be provided or requested by stating the serial number.

  • Page 67: Motor Data

    Technical data 11.14 Motor data...
  • Page 68 Technical data...

  • Page 69: Dimensional Drawing, Example

    Please use the dimensional drawing enclosed with the documentation for the dimensions specific to your particular pump. Compare the dimensions on the dimensional drawing with those of the pump. All dimensions are in mm. P_ORL_0087_SW 40433074 Fig. 31: Dimensional drawing EMFa S240-PD6...

  • Page 70: Earthing / Potential Equalisation Drawings Of The Evolution Mikro

    Earthing / potential equalisation drawings of the Evolution mikro Earthing / potential equalisation drawings of the Evolution mikro Fig. 32: Earthing / potential equalisation drawings of the Evolution mikro EFMa@...
  • Page 71 Earthing / potential equalisation drawings of the Evolution mikro Potential equalisation of pump Potential equalisation of pump - alternative to 1...

  • Page 72: Ordering Information

    14.1 General EMFa Tab. 13: Type Ø 3 Wear part Order no. Sealing set for Evo mikro EMFa Ø 3* 1115335 PTFE multi-layer safety diaphragm Ø 3 4462 / PTFE 1107488 Double ball valve DN3C 1.4404 / Al2O3 1035931 Tab. 14: Type Ø 6 Wear part Order no.

  • Page 73: List Of Other Applicable Documents

    List of other applicable documents List of other applicable documents Tab. 15: Together with these operating instructions and the documents supplied, these operating instructions apply to the following components, depending on your order – and, with ATEX designs, a type examination certificate for each: Components Standard linear motor - type: P01-48x240/90x240 Data sheet:...

  • Page 74: Declaration Of Conformity

    RoHS Directive (2011/65/EU) Harmonised standards applied, in EN ISO 12100:2010, EN 809:1998 + A1:2009 + AC:2010 particular: EN 61000-6-2:2005 + AC:2005, EN 61000-6-4:2007 + AC:2011 EN 60204-1:2018 EN IEC 63000:2018 Date: 15 March 2021 Download the Declaration of Conformity at www.prominent.com.

  • Page 75: Atex Declaration Of Conformity

    Ex specification of the entire II 2G Ex h IIC T4 Gb X system: X: Ambient temperature 0 ... +60 °C / - 25 ... +40 °C EMFa: max. media temperature 80 °C EMHa: max. media temperature 100 °C Date: 15 March 2021...
  • Page 76 ProMinent GmbH Im Schuhmachergewann 5 - 11 69123 Heidelberg Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-419 Email: info@prominent.com Internet: www.prominent.com 981089, 1, en_GB © 2021...

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