Supplementary instructions Sigmas with hygienic pump head EN Two sets of operating instructions are required for the safe, correct and proper operation of the metering pumps: this set of supplementary instructions and the corresponding "Operating instructions for the diaphragm motor driven metering pump Sigma". Both sets of operating instructions are only valid when read together. 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. Part no. 986047 BA SI 072 03/17 EN
Table of contents Table of contents 1 Sigma 1... 3 1.1 Sigma 1 Performance Data... 3 1.2 Wetted Materials... 4 1.3 Dimensional Drawings of Sigma 1... 5 1.4 Spare Parts Lists for Sigma 1... 6 2 Sigma 2... 7 2.1 Sigma 2 Performance Data... 7 2.2 Wetted Materials... 8 2.3 Dimensional Drawings of Sigma 2... 8 2.4 Spare Parts Lists for Sigma 2... 9 3 Sigma 3... 10 3.1 Sigma 3 Performance Data... 10 3.2 Wetted Materials... 11 3.3 Dimensional Drawings of Sigma 3... 12 3.4 Spare Parts Lists for Sigma 3... 12 4 Intended use... 14 5 Assembly of the Hygienic Pump Head... 15 6 Notes on Cleaning Metering Pumps with Hygienic Pump Head... 16 7 Inspection / Troubleshooting... 19 8 EHEDG Certificate... 20 2
Sigma 1 1 Sigma 1 1.1 Sigma 1 Performance Data S1Ba with hygienic pump head at 50 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate Priming lift Connector size bar l/h ml/stroke Strokes/min m WS DN 12035 10 31 3.5 143 1.15 10 12017 10 16 3.6 73 0.7 10 10050 10 43 3.5 205 1.15 10 10044 10 39 4.5 143 1.8 10 10022 10 21 4.7 73 1.8 10 07065 7 58 4.7 205 1.8 10 07042 7 38 8.7 73 1.8 15 04120 4 108 8.8 205 1.8 15 04084 4 76 8.8 143 1.8 15 All figures are guideline figures for water at 20 C. The priming lift applies to clean, moist valves, an empty suction line and empty liquid end - with correct installation (valve springs reduce the values). S1Ba with hygienic pump head at 60 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate Priming lift Connector size bar l/h ml/stroke Strokes/min m WS DN 12035 10 37 3.5 172 1.15 10 12017 10 19 3.6 88 0.7 10 10044 10 47 4.5 172 1.8 10 10022 10 25 4.7 88 1.8 10 07042 7 46 8.7 88 1.8 15 04084 4 91 8.8 172 1.8 15 All figures are guideline figures for water at 20 C. The priming lift applies to clean, moist valves, an empty suction line and empty liquid end - with correct installation (valve springs reduce the values). 3
Sigma 1 S1Cb with hygienic pump head Type Minimum pump capacity at maximum back pressure Maximum stroke rate Priming lift bar l/h ml/stroke Strokes/min m WS DN 12035 10 37 3.5 172 1.15 10 12017 10 19 3.6 88 0.7 10 10050 10 42 3.5 200 1.15 10 10044 10 47 4.5 172 1.8 10 10022 10 25 4.7 88 1.8 10 07065 7 56 4.7 200 1.8 10 07042 7 46 8.7 88 1.8 15 04120 4 106 8.8 200 1.8 15 04084 4 91 8.8 172 1.8 15 All figures are guideline figures for water at 20 C. Connector size The priming lift applies to clean, moist valves, an empty suction line and empty liquid end - with correct installation (valve springs reduce the values). 1.2 Wetted Materials Dosing head Valve housing Seals / diaphragms Inner part 1.4404 1.4435 PTFE 1.4404/EPDM 4
Sigma 1 1.3 Dimensional Drawings of Sigma 1 Dimensional drawing of Sigma 1, S1Cb with hygienic pump head P_SI_0157_SW Fig. 1: Dimensional drawing of Sigma 1, S1Cb with hygienic pump head - dimensions in mm 5
Sigma 1 1.4 Spare Parts Lists for Sigma 1 Sigma 1 with hygienic pump head A A 61_05-104_01_45 Pos. Type Quantity Article Order No. 104 A, B 1.000 Hyg. connection set TCVC DN10 1035924 104 C 1.000 Hyg. connection set TCVC DN15 1035945 121 A-C 2.000 Hyg. valve seal TCVC 1035921 122 A-C 2.000 Hyg. valve inner part EPDM with seal 1038124 123 A, B 1.000 Hyg. valve top part TCVC DN10 1035919 123 C 1.000 Hyg. valve top part TCVC DN15 1035933 124 A, B 1.000 Hyg. valve bottom part TCVC DN10 1035920 124 A 1.000 Hyg. valve bottom part TCVC DN15 1035944 125 A- B 2.000 Hyg. clamp connection TRICLAMP TCVC 1035923 200 A 1.000 Diaphragm 70 x 32 -M6 PTFE 1010279 200 B 1.000 Diaphragm 70 x 37 -M6 PTFE 1010282 200 C 1.000 Diaphragm 77.0x 33.5 -M5 PTFE 1000250 202 A, B 4.000 Cyl. screw DIN 912 M 5x 80 468080 202 C 6.000 Cyl. screw DIN 912 M 5x 80 468080 6
Sigma 2 2 Sigma 2 2.1 Sigma 2 Performance Data S2Ba with hygienic pump head at 50 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate bar psi l/h gph ml/stroke Strokes/m in Priming lift m WS Connector size DN 16130 10 145 117 31.0 9.87 198 1.9 15 16090 10 145 81 21.3 10.20 132 1.9 15 16050 10 145 45 11.8 10.19 73 1.9 15 07220 7 100 180 47.6 22.73 132 2.8 20 07120 7 100 115 30.4 26.28 73 2.8 20 All figures are guideline figures for water at 20 C. The priming lift applies to a filled suction line and filled liquid end - with correct installation. S2Ba with hygienic pump head at 60 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate bar psi l/h gph ml/stroke Strokes/m in Priming lift m WS Connector size DN 16090 10 145 97 25.5 10.20 158 1.9 15 16050 10 145 53 14.0 10.19 87 1.9 15 07220 7 100 216 56.9 22.73 158 2.8 20 07120 7 100 137 36.2 26.28 87 2.8 20 All figures are guideline figures for water at 20 C. The priming lift applies to a filled suction line and filled liquid end - with correct installation. S2Cb with hygienic pump head Type Minimum pump capacity at maximum back pressure Maximum stroke rate bar psi l/h gph ml/stroke Strokes/m in Priming lift m WS Connector size DN 16130 10 145 118 31.3 9.87 200 1.9 15 16090 10 145 98 25.9 10.20 160 1.9 15 16050 10 145 55 14.5 10.19 90 1.9 15 07220 7 100 218 57.7 22.73 160 2.8 20 07120 7 100 142 37.5 26.28 90 2.8 20 All figures are guideline figures for water at 20 C. The priming lift applies to a filled suction line and filled liquid end - with correct installation. 7
Sigma 2 2.2 Wetted Materials Dosing head Valve housing Seals / diaphragms Inner part 1.4404 1.4435 PTFE 1.4404/EPDM 2.3 Dimensional Drawings of Sigma 2 Dimensional drawing of Sigma 2, S2Cb with hygienic pump head Fig. 2: Dimensional drawing of Sigma 2, S2Cb with hygienic pump head - dimensions in mm P_SI_0158_SW 8
Sigma 2 2.4 Spare Parts Lists for Sigma 2 A A 61_05-104_01_46 Pos. Type Quantity Article Order No. 104 A 1.000 Hyg. connection set TCVC DN15 1035945 104 B 1.000 Hyg. connection set TCVC DN20 1035948 121 A, B 2.000 Hyg. valve seal TCVC 1035921 122 A,-C 2.000 Hyg. valve inner part EPDM with seal 1038124 123 A 1.000 Hyg. valve top part TCVC DN15 1035933 123 B 1.000 Hyg. valve top part TCVC DN20 1035950 124 A 1.000 Hyg. valve bottom part TCVC DN15 1035944 124 B 1.000 Hyg. valve bottom part TCVC DN20 1035949 125 A, B 2.000 Hyg. clamp connection TRICLAMP TCVC 1035923 200 A 1.000 Diaphragm 86.5x 46.0 P 792495 200 B 1.000 Diaphragm 123.5x 75.0 P 792496 202 A 6.000 Hexagonal screw DIN 931 M 6x 80 468166 202 B 6.000 Hexagonal screw DIN 931 M 6x 90 468167 9
Sigma 3 3 Sigma 3 3.1 Sigma 3 Performance Data S3Ba with hygienic pump head at 50 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate Priming lift Connector size bar l/h ml/stroke Strokes/min m WS DN 120145 10 127 29.3 72 2.8 20 120190 10 178 28.8 103 2.8 20 120270 10 205 23.8 144 2.8 20 120330 10 217 20.0 180 2.8 20 070410 7 335 77.5 72 4.2 25 070580 7 446 72.1 103 4.2 25 040830 4 616 71.3 144 4.2 25 041030 4 761 70.4 180 4.2 25 All figures are guideline figures for water at 20 C. The priming lift applies to a filled suction line and filled liquid end - with correct installation. S3Ba with hygienic pump head at 60 Hz operation Type Minimum pump capacity at maximum back pressure Maximum stroke rate Priming lift Connector size bar l/h gph ml/stroke Strokes/min m WS DN 120145 10 151 39.9 29.3 86 2.8 20 120190 10 215 56.7 28.8 124 2.8 20 120270 10 247 65.2 23.8 173 2.8 20 070410 7 400 105.7 77.5 86 4.2 25 070580 7 537 141.7 72.1 124 4.2 25 040830 4 741 195.6 71.3 173 4.2 25 All figures are guideline figures for water at 20 C. The priming lift applies to a filled suction line and filled liquid end - with correct installation. 10
Sigma 3 S3Cb with hygienic pump head Type Minimum pump capacity at maximum back pressure Maximum stroke rate Priming lift bar l/h gph ml/stroke Strokes/min m WS DN 120145 10 158 41.8 29.3 86 2.8 20 120190 10 208 54.9 28.8 124 2.8 20 120270 10 257 67.8 23.8 173 2.8 20 070410 7 419 110.6 77.5 86 4.2 25 070580 7 519 137.2 72.1 124 4.2 25 040830 4 771 203.6 71.3 173 4.2 25 All figures are guideline figures for water at 20 C. Connector size The priming lift applies to a filled suction line and filled liquid end - with correct installation. 3.2 Wetted Materials Dosing head Valve housing Seals / diaphragms Inner part 1.4404 1.4435 PTFE 1.4404/EPDM 11
Sigma 3 3.3 Dimensional Drawings of Sigma 3 Dimensional drawing of Sigma 3, S3Cb with hygienic pump head P_SI_0159_SW Fig. 3: Dimensional drawing of Sigma 3, S3Ca with hygienic pump head - dimensions in mm 3.4 Spare Parts Lists for Sigma 3 A A 61_05_104_01_47 12
Sigma 3 Pos. Type Quantity Article Order No. 104 A 1.000 Hyg. connection set TCVC DN20 1035948 104 B 1.000 Hyg. connection set TCVC DN25 1035958 121 A, B 2.000 Hyg. valve seal TCVC 1035921 122 A-C 2.000 Hyg. valve inner part EPDM with seal 1038124 123 A 1.000 Hyg. valve top part TCVC DN20 1035950 123 B 1.000 Hyg. valve top part TCVC DN25 1035955 124 A 1.000 Hyg. valve bottom part TCVC DN20 1035949 124 B 1.000 Hyg. valve bottom part TCVC DN25 1035956 125 A, B 2.000 Hyg. clamp connection TRICLAMP TCVC 1035923 200 A 1.000 Diaphragm 123.5x 75 - M10 1004604 200 B 1.000 Diaphragm 178 x 132 - M10 1002835 202 A 6.000 Hexagonal screw DIN 931 M 6x100 468168 202 B 8.000 Hexagonal screw DIN 931 M 8x110 1005296 13
Intended use 4 Intended use Supplementary information to the 'Intended Use' in the "Operating Instructions for Sigma": The pump is only intended for use in sealed systems with CIP (cleaning in place) in the hygienic sector. (EHEDG-certified, type EL Class I) 14
Assembly of the Hygienic Pump Head 5 Assembly of the Hygienic Pump Head Select the hygienic pump head by its identity code under "Dosing head design" - "H hygienic pump head" (only with stainless steel pump heads). The hygienic head is supplied assembled on the pump (welded assembly (item 100)); the valves (item 104) are packed in bags. Assemble the pump so that the EHEDG symbol on the hygienic pump head is legible. Fit the valves (item 104) as shown on the Figure Make sure that the flat inner side of the valves is always facing downwards as well as the O-ring on the fastening body (item 122) - see Figure 61_05-104_01_46-04x01_B2 15
Notes on Cleaning Metering Pumps with Hygienic Pump Head 6 Notes on Cleaning Metering Pumps with Hygienic Pump Head General Metering pumps of the Sigma product range, fitted with hygienic head, are used to pump and meter high-grade, hygienically flawless and microbiologically sensitive liquids. They therefore need to be thoroughly cleaned at the end of a production process and be absolutely clean and free of germs that could be harmful to the product, or even pathogens, at the start of a new production process. ProMinent therefore recommends including the metering pumps in an HACCP and/or in-house hygiene scheme. Certification The cleaning-friendly construction of ProMinent metering pumps with hygienic pump head in compliance with the requirements of the EHEDG (www.ehedg.org) has been confirmed by the TU Munich-Weihenstephan Certification Office and correspondingly certified (EHEDG Type EL class I). Inclusion in CIP (Cleaning In Place) ProMinent recommends including metering pumps with hygienic pump head in the CIP (Cleaning in Place) process. This means that the pump is cleaned in a circular and/or continuous process without having to be dismantled. It involves the following steps, depending on the level of impurities: 1 - Pre-flushing with water 2 - Flushing with alkali 3 - Interim flushing with water 4 - Flushing with acid 5 - Flushing with clear water Flush the liquid end Use a suitable medium to flush the liquid end. 1 Rinsing water 2 Flushing assembly 1 2 P_MAZ_0019_SW Fig. 4: Manual flushing equipment 3 1 2 P_MAZ_0020_SW Fig. 5: Automatic flushing equipment There are two versions of flushing equipment: Manual flushing equipment Automatic flushing equipment There are two flushing principles: Flushing when metering is interrupted (intermittent flushing) Flushing when metering is finished. Problems may arise if flushing cannot be performed properly. Ensure that the metering pump is idle during flushing. Do not exceed the maximum permitted flushing pressure of 2 bar! 16
Notes on Cleaning Metering Pumps with Hygienic Pump Head Flow velocity Fundamental prerequisite for a successful CIP (cleaning in place) is a turbulent flow at a minimum flow velocity of 1.5 m/s based on the pipe diameter of the pump inlet. Should this flow velocity not be reached due to the inherent capacity of the pump type, then a centrifugal pump should be installed upstream as a booster pump. However, never exceed the maximum permitted priming pressure on the suction side - see "Technical Data". Stroke rate and stroke length The metering pump should run at a minimum stroke rate of 72 strokes/min and at 100% stroke length during CIP (Cleaning in Place) to ensure that liquid flows perfectly through the hygienic pump head. Drainage of residual liquid / Self-draining Tightly sealed non-return valves are fitted in ProMinent metering pumps with hygienic pump head. That is why the dosing head needs to be manually drained after the CIP (Cleaning in Place) step by opening the clamps and/or using compressed air to ensure that any residual liquid is drained. In doing so it is imperative that you ensure using fittings and pipework that no cleaning solution can enter parts of the system that carry product. When using compressed air, use appropriate fittings and pipework to ensure that any residual liquid is fully blown out. Make sure that the pump is at a standstill when doing so. Materials of wetted parts The following wetted materials are used in ProMinent metering pumps with hygienic pump head: A A 61_05_104_01_47 Fig. 6 Item. no. Wetted materials 100 Stainless steel 1.4404 104, 122, 123 Stainless steel 1.4435 200 PTFE 125 Gylon BIO PRO (PTFE material) Part of 122 EPDM, if item 122 has a seal Gylon BIO PRO is a registered trademark of Garlock Sealing Technologies 17
Notes on Cleaning Metering Pumps with Hygienic Pump Head Chemical resistance Check the resistance of the wetted parts to the CIP (Cleaning in Place) media used in detail. Temperature resistance ProMinent metering pumps with hygienic pump head can be exposed to temperatures of max. 120 C at 2 bar for a maximum of 15 minutes. Process connections ProMinent metering pumps with hygienic pump head are supplied as standard with welded ends in compliance with DIN 11850 Range 2. The pumps are dismantled by loosening the BIO CONNECT clamp connection by means of which the valves can be separated into a top and bottom half. Note this when designing the connecting pipework. Connection adapters can be customised and fitted at any time. Cleaning without CIP (Cleaning in place) Adapt the cleaning process if no CIP-compatible connections (e.g. milk pipe connectors DIN 11851, hose connectors, Clamp DIN 32676) are used or only used to a limited extent. 18
Inspection / Troubleshooting 7 Inspection / Troubleshooting Regularly check and, if necessary, replace the "Hygienic valve seal TCVC" (121). Replace the "Hygienic valve inner part EPDM with seal" (122) if it is damaged or worn. Replace the "Hygienic valve inner part EPDM with seal" (122) if the pump leaks at the valve. 19
EHEDG Certificate 8 EHEDG Certificate 20
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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 2010