ProMinent Orlita Evolution Operating Instructions Manual
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ProMinent Orlita Evolution Operating Instructions Manual

Hydraulic diaphragm liquid ends with ptfe diaphragm
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Operating instructions
Hydraulic diaphragm liquid ends with PTFE dia‐
phragm
Orlita
Evolution
®
Serial no. .............................
These operating instructions form part of an operating manual and are only valid if used in conjunction with the documents
in this operating manual.
The operator shall be liable for any damage caused by installation or operating errors.
983747
Please carefully read these operating instructions before use. · Do not discard.
The latest version of the operating instructions are available on our homepage.
EN
BA ORL 007 06/16 EN

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Summary of Contents for ProMinent Orlita Evolution

  • Page 1 Operating instructions Hydraulic diaphragm liquid ends with PTFE dia‐ phragm Orlita Evolution ® Serial no......These operating instructions form part of an operating manual and are only valid if used in conjunction with the documents in this operating manual. Please carefully read these operating instructions before use.

  • Page 2: Table Of Contents

    Table of contents Table of contents Safety..................3 Storage, Transport and Unpacking........10 2.1 Safety information............10 2.2 Transport..............10 2.3 Storage............... 13 2.4 Preservation..............13 Functional Description of Liquid End Components..... 15 Installation, Hydraulic............16 4.1 Basic installation notes..........19 Installation, Electrical............

  • Page 3: Safety

    The hydraulic liquid end is intended for metering flammable media if the relevant information is observed. Observe the general limitations with regard to viscosity limits, chemical resistance and density - see also the ProMinent Resistance List (in the Product Catalogue or at www.promi‐ nent.com)! All other uses or modifications are prohibited.
  • Page 4 Safety Never use the hydraulic liquid end to meter media that reacts exothermically with hydraulic oil. The ATEX design is not intended for the metering of electrically non-conductive media (conductivity less than 50 pS/m). Do not expose the ATEX design to ionising radiation, electro‐ magnetic high frequency radiation within the range of 10 3x10 Hz or ultrasound without putting in place measures in...
  • Page 5 Safety Qualified personnel who open the hydraulic components of the pump have to be able to recognise sealing surfaces so that they do not become scratched. Note: A qualification of equal validity to a technical qualification can also be gained by several years of employment in the relevant field of work.
  • Page 6 Service The Service department refers to service technicians, who have received proven training and have been authorised by ProMinent to work on the system. Safety Information CAUTION! These operating instructions include notes and extracts from German regulations relating to the opera‐...
  • Page 7 The pump must only be opened at those points required to be opened by these operating instructions. It may only be opened in other positions upon receipt of written authorisation from the ProMinent head office, Heidelberg. CAUTION! Danger of personnel injury and material damage The use of untested third party parts can result in per‐...
  • Page 8 Safety CAUTION! Danger from incorrectly operated or inadequately maintained pumps Danger can arise from a poorly accessible pump due to incorrect operation and poor maintenance. – Ensure that the pump is accessible at all times. – Adhere to the maintenance intervals. Information in the event of an emer‐...
  • Page 9 Safety Safety equipment May only be removed by*: "Hot surface" label Only with additional equipment: Their corresponding Technical personnel, Service parts * Only if required by the operating instructions and if the mains cable remains disconnected from the mains voltage. Make sure that all protective equipment is refitted during operation.

  • Page 10: Storage, Transport And Unpacking

    The "Decontamination Declaration Form" can be found at www.prominent.com. CAUTION! Danger of environmental and material damage The unit can be damaged or oil may escape due to incorrect or improper storage or transportation! –...
  • Page 11 Storage, Transport and Unpacking Weight - refer to the "Evolution Data Sheet". P_PZ_0018_SW Fig. 1: Position of slings EF1a and EF2a A. Single pump with motor B. Single pump without motor C. Single pump with motor D. Single pump without motor...
  • Page 12 Storage, Transport and Unpacking P_PZ_0013_SW.svg Fig. 2: Position of slings EF3a and EF4a A. Single pump with motor C. Single pump with motor B. Single pump without motor D. Single pump without motor...

  • Page 13: Storage

    Storage, Transport and Unpacking 2.3 Storage CAUTION! If the pump has been stored for longer than 1 month, then it also has to be preserved - see . Preferably bolt the pump to the pallet supplied and prevent it from toppling over. Ambient conditions Parameter Value...
  • Page 14 Storage, Transport and Unpacking Fig. 3: Preservation oil level in the turrets Stoppage of more than 6 months Dismantle the motor and store in accordance with the manu‐ facturer's instructions. Seal the pump motor flange. After 2 years: Change the oil on the drive unit and hydraulics. Ä...

  • Page 15: Functional Description Of Liquid End Components

    Functional Description of Liquid End Components Functional Description of Liquid End Components Bleed valve (356) At each piston stroke, a bleed valve in the hydraulic end pumps a small amount of hydraulic oil with isolated gas bubbles from the discharge chamber into the hydraulic oil storage chamber, thereby bleeding the discharge chamber.

  • Page 16: Installation, Hydraulic

    Installation, Hydraulic Installation, Hydraulic WARNING! ATEX pumps in areas at risk from explosion – Metering pumps in areas at risk from explosion are provided, as a matter of course, with an appro‐ priate safety relief valve on the outlet side of the metering pump (which is used to protect against excessive heating due to overloading and impact sparks caused by the breakage of power end parts...
  • Page 17 Installation, Hydraulic WARNING! The following measures are an advantage when working with highly aggressive or hazardous feed chemicals: – Install a bleed valve with recirculation in the storage tank. – Install an additional shut-off valve on the discharge or suction ends. CAUTION! Warning of backflow A back pressure valve or a spring-loaded injection...
  • Page 18 Installation, Hydraulic CAUTION! Uncontrolled flow of feed chemical Feed chemical can press through the metering pump in an uncontrolled manner in the event of excessive priming pressure on the suction side of the metering pump. – Do not exceed the maximum permissible priming pressure for the metering pump.

  • Page 19: Basic Installation Notes

    Installation, Hydraulic Recommended maximum mesh width of the filter Nominal width of valve Maximum mesh width of filter [mm] 0.15 0.25 0.25 A discharge-side flow control can help to avoid prob‐ lems. Precise metering is only possible when the back –...
  • Page 20 Installation, Hydraulic P_MOZ_0043_SW Fig. 4: (A) standard installation, (B) with pulsation damper Main line Storage tank Legend for hydraulic diagram Symbol Explanation Symbol Explanation Metering pump Foot valve with filter meshes Injection valve Level switch Multifunctional valve Manometer...

  • Page 21: Installation, Electrical

    Installation, Electrical Installation, Electrical - see "Operating Instructions for the Metering Pump, Drive Unit Orlita ® Evolution"...

  • Page 22: Start Up

    Start Up Start Up - see "Operating Instructions for the Metering Pump, Drive Unit Orlita ® Evolution"...

  • Page 23: Maintenance

    Maintenance Maintenance Safety Information WARNING! ATEX design only: Note the ATEX notes in the operating instructions for the bought-in parts. WARNING! ATEX pumps in areas at risk from explosion Static electricity can cause ignition sparks. – Consider potential equalisation before you approach any pump equipment that could be at a different electrical potential (such as pipes or tools) WARNING!
  • Page 24 Maintenance WARNING! Warning of dangerous or unknown feed chemical Should a dangerous or unknown feed chemical be used: It may escape from the hydraulic components when working on the pump. – Take appropriate protective measures before working on the pump (e.g. safety glasses, safety gloves, ...).

  • Page 25: Inspections And Maintenance Points

    Maintenance 7.1 Inspections and Maintenance Points Maintenance, case-specific Prerequisite: Pump is not in operation and is at room temperature Overpressure has opened the pressure relief valve (358) sev‐ eral times: Immediately check the pressure relief valve and the seals of the liquid end and replace if necessary.
  • Page 26 Maintenance Gear ring of torsionally flexible claw couplings (motor and add- on power end if necessary): Do the gear rings of the torsionally flexible claw coupling show excessive wear? Dismantle motor and add-on power end if necessary. Wear test - see documen‐ tation on torsionally flexible claw couplings Are the fixing bolts tight? Do the discharge valves, suction valves and the pressure relief...
  • Page 27 Maintenance CAUTION! Hydraulic oil can leak out Only open the above screw to check the leakage. The identical other screw is an oil drain. B0820 Fig. 7: Control opening for leakage in the add-on pump flange (multiple pumps only) Maintenance, annual or after 10,000 (Whichever occurs first!) operating hours Prerequisite:...

  • Page 28: Cleaning

    Maintenance 7.2 Cleaning WARNING! Only in areas at risk from explosion: Only clean the pump outside of explosive atmos‐ pheres. CAUTION! Do not allow the cleaning agent to damage the paint on the pump nor penetrate into the inside of the pump. Clean the complete pump housing.

  • Page 29: Changing The Hydraulic Oil

    Maintenance Workplace Preferably use a clean, dry and ventilated space. It should be possible to place the dismantled parts on a clean work surface. Plans Cross-section through the liquid end Parts list for the liquid end Dimensional drawing of metering pump Spare parts Spare parts kits - see Evolution operating manual Always replace: All wear parts on the parts lists marked with a...
  • Page 30 Maintenance B0837 Fig. 8: Oil drainage plug with sealing ring (570) EF1a and EF2a 570 / 580 B0850 Fig. 9: Oil drainage plug with sealing ring EF3a (570) and EF4a (580) Place an oil trough under the turret.
  • Page 31 Maintenance Use the Allen key to unscrew the oil drainage plug with sealing ring from the turret. ð The hydraulic oil runs out of the turret. Place an oil trough under the diaphragm holder (300). B0818 Fig. 10: Pressure relief valve (358) Unscrew the pressure relief valve (358) from the diaphragm holder (300).
  • Page 32 Maintenance Slowly spray a little release agent using a suitable syringe into the injection hole (2) in the dosing head, until release agent emerges from the hole for the diaphragm rupture sensor (1). Screw in the diaphragm rupture sensor (1) and the closing screw for the injection opening (2) until liquid-tight.

  • Page 33: Changing Gear Oil In A Power End/Drive

    Maintenance Check whether all openings are tightly sealed again, espe‐ cially in areas at risk from explosion! Check whether oil is rising under the oil inspection window (336) when the pump is running. Isolated bubbles can rise, but no more. Check the oil level at the vent screws with the dipstick (525) of each turret when the pump is stopped and the stroke length is set to "0".
  • Page 34 Maintenance B0792 Place the oil trough under the oil drainage plug (060). Use a ring spanner to unscrew the oil drainage plug (060). ð Drain the gear oil from the power end/drive. Getriebeöl einfüllen Gear oil required: Types of oil - refer to the "Operating oils and lubricants, hydraulic diaphragm pumps Evolution"...

  • Page 35: Repairs

    Repairs Repairs WARNING! Only allow ProMinent Service to perform work not described here. WARNING! The dosing heads can be relatively heavy. If the dosing heads have lifting lugs, they should be used to move the dosing heads. CAUTION! Check the state of the released O-rings and seals and replace if in doubt.
  • Page 36 Repairs B0818 Fig. 13: Pressure relief valve (358) with protective cap (363) Unscrew the pressure relief valve (358) from the diaphragm holder (300). ð The hydraulic oil runs out of the diaphragm holder (300). B0811 Fig. 14 Loosen the hexagonal nuts (332) and remove the dosing head (100).

  • Page 37: Installing The Diaphragm

    Repairs B0812 Fig. 15 Use an open-ended spanner to remove the holding screw for the diaphragm assembly (101) and remove the diaphragm assembly (101). 8.2 Installing the Diaphragm The lifetime of the diaphragm can be increased by installing the finished diaphragm assembly (101) into the liquid end at the temperature that the feed chem‐...
  • Page 38 Repairs B0813 Fig. 16 Check the seal (109) on the new diaphragm assembly (101) and carefully remove any dirt. CAUTION! The subsequent service life will be longer, the less the diaphragm assembly (101) is now mechanically stressed. Clean all sealing surfaces for the diaphragm assembly (101) on the dosing head (100) and the back plate, the diaphragm holder (300).
  • Page 39 Repairs B0818 Fig. 18: Pressure relief valve (358) with protective cap (363) Screw the pressure relief valve (358) into the diaphragm holder (300). Place the protective cap (363) onto the pressure relief valve (358). Place the dosing head (100) onto the pin screws of the dia‐ phragm holder (300).

  • Page 40: Dismantling The Suction Valve And Discharge Valve

    Repairs B0841 Fig. 20: Tighten the hexagonal nuts (332) in this order Stages for torque Step 1 Step 2 Step 3 Step 4 Step 5 10 % 20 % 50 % 100%* * see parts list for the liquid end CAUTION! Minimum waiting time between levels: 2 min 8.3 Dismantling the suction valve and discharge valve...
  • Page 41 Repairs CAUTION! When dismantling, make sure that the suction valve does not fall out. Materials required: Ring spanner Only depressurise the discharge line when the pump is run‐ ning. Then disconnect the pump from the mains/power supply. The diaphragm holder is thus also depressurised. B0814 Fig.

  • Page 42: Assembling The Suction Valve And Discharge Valve

    Repairs 8.4 Assembling the suction valve and discharge valve CAUTION! Note the fitting position and the direction of flow of the valves. Materials required: Ring spanner Torque wrench Check whether the two holes in the dosing head (100) are absolutely clean. There is no need for a screw connector because of the small dimensions of the liquid end, as the valve housing is hexagonal for ease of...

  • Page 43: Dismantling The Bleed Valve (356)

    Repairs Place the washers on the pin screws and grease the pin screws. Initially tighten the hexagonal nuts manually then tighten with the prescribed tightening torque - see parts list. 8.5 Dismantling the Bleed Valve (356) WARNING! The bleed valve, hydraulic oil and other pump compo‐ nents can become very hot.

  • Page 44: Dismantling The Pressure Relief Valve (358)

    Repairs Materials required: Ratchet with nut Open-end wrench Torque wrench Fit a new bleed valve (356) together with the O-ring. Tighten the bleed valve (356) to the specified tightening torque - see parts list. Screw in the oil inspection window (340) and use an open- end spanner to tighten.

  • Page 45: Rectifying Faults On The Hydraulic Liquid Ends

    Rectifying Faults on the Hydraulic Liquid Ends Rectifying Faults on the Hydraulic Liquid Ends WARNING! ATEX pumps in areas at risk from explosion Immediately stop the pump in the event of leakages, unusual noises, high temperatures, unusual smells, vibrations and rectify the cause. WARNING! ATEX design only: Note the ATEX notes in the operating instructions for...
  • Page 46 Rectifying Faults on the Hydraulic Liquid Ends CAUTION! Warning of feed chemical spraying around Feed chemical can spray out of the hydraulic compo‐ nents if they are manipulated or opened due to pres‐ sure in the liquid end and adjacent parts of the system. –...
  • Page 47 Rectifying Faults on the Hydraulic Liquid Ends Description of fault Cause Remedy Personnel Pump meters too little at Pump valves worn or Clean or replace pump technical personnel all stroke rates leaking valves or replace wear parts soll H, n Pressure relief valve Check the pressure relief Service...
  • Page 48 Rectifying Faults on the Hydraulic Liquid Ends Description of fault Cause Remedy Personnel Delivery flow fluctuates Contaminated feed Install or clean protective technical personnel and remains too low chemical filter Pump valves are dam‐ Clean or replace pump technical personnel aged valves or replace wear parts...

  • Page 49: Decommissioning And Disposal

    Decommissioning and Disposal Decommissioning and Disposal 10.1 Decommissioning WARNING! Danger of an electric shock When working on the motor or electrical auxiliary equipment, there is a danger of an electric shock. – Before working on the motor, take note of the safety instructions in its operating instructions! –...

  • Page 50: Disposal

    Decommissioning and Disposal Temporary decommissioning Personnel: Technical personnel Depressurise and bleed the hydraulic system around the pump. Flush the liquid end with a suitable medium - observe the material safety data sheet! Flush the dosing head thoroughly when using hazardous feed chemicals! Drain the hydraulic oil - see "Maintenance"...
  • Page 51 Decommissioning and Disposal CAUTION! Risk to the environment from oil Oil is to be found in the power end/drive, the liquid ends and hydraulic ends that could cause environ‐ mental damage. – Drain the oil from the pump. – Note the local guidelines currently applicable in your country.

  • Page 52: Index

    Index Index Installation, Hydraulic ..... 16 Installing the bleed valve ....43 Assembling the suction valve and discharge Installing the Diaphragm .
  • Page 56 ProMinent GmbH Im Schuhmachergewann 5-11 69123 Heidelberg, Germany Germany Telephone: +49 6221 842-0 Fax: +49 6221 842-419 Email: info@prominent.com Internet: www.prominent.com Heidelberg, 4, en_GB © 2015...

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