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37

Installation

6 START-UP AND REGULATION

FIXING: Check that the pump is properly secured

HYDRAULIC CIRCUIT CHECK: Check that all valves are open, and that the priming and relief

valve outlets are diverting the liquid to a container

PUMP CHECK: Make a visual/auditory check of the correct operation of the pump.

PRIMING: To facilitate pump priming, open the priming valve.

OVERPRESSURE PROTECTION: Adjust the safety, overpressure or pressure relief valve to the

desired pressure to protect the installation, while never exceeding the nominal pressure of the
pump.

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Summary of Contents for DOSmart AC

Page 1: ...ENGLISH ...

Page 2: ...n examples 12 4 3 2 Installation recommendations 13 4 4 ACCESSORIES 14 4 4 1 Diaphragm leakage detector 14 4 4 2 Pressure sensor 14 4 4 3 Pulse output isolator 14 5 OPERATION 15 5 1 OPERATING MODES 17 5 1 1 Manual mode 17 5 1 2 Proportional mode 17 5 1 3 Analogue mode 19 5 1 4 Batch mode 20 5 1 5 ModBus mode 23 5 2 CONFIGURATION 24 5 2 1 Pump calibration 24 5 2 2 Dosing mode 24 5 2 3 Setup 26 5 2 ...

Page 3: ...bleshooting Possible cause and solution 43 Electrical Wiring 45 CE DECLARATION OF CONFORMITY 47 WARRANTY 47 To avoid personal injury risks and damage to the environment and to ensure proper equipment operation personnel responsible for installing commissioning and maintaining the equipment must follow the instructions in this manual with special attention to the detailed recommendations and warnin...

Page 4: ...re industries Operating modes ed Analogue dosing proportional to a 0 4 20 mA analogue signal te Proportional to pulses dosing by cycles proportional to input pulses Dosing by volume dosing of a given volume Manual remote or timed activation emote or timed activation ModBus Dosing control via ModBus RTU protocol Code formulation MOTOR STA 100 240 Vac STD 24 Vdc DIAMETER D50 ø 50 mm D69 ø 69 mm HEAD...

Page 5: ...is designed to allow the equipment to be transported and stored without damage provided this takes place in dry ventilated spaces away from heat sources The packing contains DOSmart AC dosing pump Instruction manual Connection accessories for 4x6 6x8 6x12 10x12 conduit ...

Page 6: ... 3 3 3 3 Max viscosity std valve and minimum DN pipe mPa s 100 10 200 100 200 200 100 Max viscosity M valve with spring and DN15 pipe mPa s 3000 3000 3000 3000 2100 2000 600 Max viscosity M valve SS1 with spring and DN15 pipe mPa s 3000 3000 3000 3000 3000 3000 1800 Max viscosity M valve SS2 with spring and DN15 pipe mPa s 3000 3000 3000 3000 3000 3000 1800 Valve connections 4x6 4x6 6x8 6x12 6x8 6...

Page 7: ...el sensor input pre warning Level sensor input alarm Leak detector input Flow detector input Pressure sensor input RS 485 ModBus serial port 4 20 mA logging and monitoring output Log output monitoring and control of second pulse pump Alarm output relay Level alarm output relay DIMENSIONS 267 183 83 253 248 296 172 143 ...

Page 8: ... 2 1 0 F31 D69 16 14 12 18 l h Bar 6 4 2 0 F51 D50 l h Bar 39 40 41 42 43 44 3 2 1 0 F41 D69 8 9 7 10 11 12 13 14 l h Bar 6 8 6 4 2 0 F30 D50 10 8 6 4 2 0 12 F50 D50 23 24 25 26 27 28 29 l h Bar 0 F31 D50 2 4 1 5 3 2 3 1 4 5 l h Bar 0 10 8 6 4 2 0 12 14 16 S50 D50 5 6 4 7 8 9 l h Bar 3 0 5 1 5 0 5 1 5 2 5 7 5 3 1 ...

Page 9: ...water away from heat sources and with renovation of air Fix the pump on a rigid horizontal surface Provide enough space to comfortably perform basic maintenance and facilitate installation and removal Fix the pump to the chosen flat surface using 4 screws See drawing 81 234 129 5 8 81 234 129 ...

Page 10: ...I N I N I N 2 4 A B 27 28 29 30 31 32 33 34 35 36 2 4 C NO 5 V H L 37 38 39 40 41 42 43 44 45 46 I N N O NC CN O NC C P 1 2 ENCODER Inputs Outputs External quick connectors Flow Leakage Pressure Red Blue Yellow ENCODER 1 2 3 4 5 6 7 8 10 11 12 FLOW LEAKAGE PRESSURE VENTILATION RS 485 4 20 mA PULSE PULSE ALM LEVEL ALM REMOTE LEVEL 1 LEVEL 2 4 20 mA 4 20 mA ITC controllers Pulse input ITC flowmeter ...

Page 11: ... Remote Voltage free contact 18 Remote Voltage free contact 19 Level sensor 1 Voltage free contact 21 Level sensor 2 Voltage free contact 22 Common level sensor Voltage free contact Outputs 33 RS 485 5 Vdc 34 RS 485 H B 35 RS 485 L A 36 RS 485 37 4 20 mA monitor output Not isolated 38 4 20 mA monitor output Not isolated 39 Monitor pulse output Signal Not isolated 40 Monitor pulse output Not isolat...

Page 12: ...ice in the diaphragm loss collars a hose or pipe made of material compatible with the product to be dosed must be connected to the bottom of the cylinder and the liquid must be collected in a safe place 6 Priming and drain valve built into the pump 7 Pressure relief valve Install a pressure relief valve in a bypass as close as possible to the pump in order to protect the pump and the installation ...

Page 13: ... Long discharge L 5 m 16 ft Long suction L 2 m 6 5 ft Air in suction Siphon DISCHARGE SUCTION L Ø L Ø h p h PIPE SIZE Øint L 2 m L 5 m 4 4 4 6 13 10 60 13 15 40 20 60 Q max l h PIPE SIZE Øint L 2 m L 5 m 4 4 4 6 13 13 10 60 40 15 60 Q max l h Q max l h ...

Page 14: ...aphragm leakage detector kit 50 29 068 P 69 29 063 P 4 4 2 Pressure sensor The pressure sensor protects the pump from working in overpressure conditions when the pressure alarm is activated Connect the 4 20 mA 10 bar pressure sensor Ref 18705 as shown in the drawing 18705 1 24 2 1 24 10 11 12 PRESSURE 2 4 4 3 Pulse output isolator 38 39 40 41 27 28 29 31 32 33 34 The pulse output isolator allows a...

Page 15: ...hich is released during the discharge cycle By varying the speed of the motor and depending on the operating mode selected in the Control Unit the equipment will regulate the flow to the desired value with a maximum variation of 1 3000 SYSTEM DESCRIPTION LCD screen Keyboard Exit without confirming Validate Run Stop Increase decrease value Scroll left Scroll right test ESC ENT Inputs outputs Contro...

Page 16: ...Programming locked Flow rate fault Level 1 Leakage Level 2 Overpressure Loss of pulse Manual Level 1 Pump calibration Proportional Level 2 Dosing Mode Analogue Flow rate Standard ST Batch Leakage Pressure Slow Suction 1 SS1 Slow Suction 2 SS2 Set Up In Out Dosing pump Pressure Input Units Flow detector Inputs Real time Flowmeter Pulse output Counters Lock code Outputs 4 20 mA out Info Unit ModBus ...

Page 17: ...d manually l h 0 0 0 0 0 0 MODE MODE Manual Proportional Analog Batch l h M o 0 0 0 0 0 0 off l l h M 3 1 4 4 ENT ENT ENT Increase decrease flow Start stop the pump The pump will start if the Remote Activation input is activated Proportional to a pulse input from a flowmeter 1 X Y for low frequency pulses 0 005 30 Hz 2 ppm for high frequency flowmeters 1 300 Hz l h 0 0 0 0 0 0 MODE MODE Manual Ana...

Page 18: ...figuration section For flowmeter setup See the Configuration section l h 60 0 l 2 5 3 6 6 25 12150 l h 30 m3 h l 6 2 8 9 15 5 Select the number of pump cycles Change by pressing and validate by pressing ENT Select pump speed in Change by pressing and validate by pressing ENT For Y 1 Q must be set at less than 50 Select the maximum number of pulses in memory Change by pressing and validate by press...

Page 19: ...me set ENT ENT l h 0 0 0 0 0 0 MODE x2 MODE Manual Proportional Batch Analog 1 l h 00mA o 0 0 0 0 0 0 5 1 3 1 Analogue mode settings ANALOG INPUT INPUT 16 0 mA 100 00 0 mA 067 ANALOG INPUT INPUT 16 0 mA 100 00 0 mA 067 25 0 25 0 Select mA input for the first point Change by pressing and validate by pressing ENT Select ON to perform proportional dosing with a volume limit The pump will stop when it...

Page 20: ...y time In any of the operating modes the speed of the pump can be defined in ANALOG INPUT INPUT 16 0 mA 100 067 ANALOG INPUT 4 mA 000 SPAN 20 mA 100 l h 2 8 0mA l 2 5 3 6 Start stop the pump The pump will start if the Remote Activation input is activated ENT 100 41 22 0 mA 100 41 22 0 mA 100 41 22 0 mA 100 41 22 0 mA ENT ENT l h 0 0 0 0 0 0 MODE x2 MODE Manual Proportional Analog ModBus Batch 01 6...

Page 21: ...p Stroke Start Man BATCH MODE Flow 000 Stop Stroke Start Ext BATCH MODE Flow 000 Stop Stroke Start Time BATCH MODE Stop Stroke Start Man Flow 050 BATCH MODE Start Man Flow 050 Stop Stroke ENT ENT 5 1 4 2 Select stroke frequency in flow 5 1 4 3 Select stop mode BATCH MODE Start Man Flow 050 Stop 000050 St Volume 208 15ml Manual start the pump by pressing ENT Change by pressing and validate by press...

Page 22: ...50 Stop Time 01 379 l 00 000 l l 5 0 7 3 00 00 10 00 00 00 l 5 0 7 3 01 379 00 000 l l 00 10 00 l 5 0 7 3 00 00 10 00 00 00 00 10 00 l 5 0 7 3 Volume to be dosed Volume counter Dosing time Time counter Initial frequency Volume to be dosed Volume counter Start time Execution time Time counter BATCH MODE Start Man Flow 050 Stop 00 00 10 Volume 34 722 ml Change by pressing and validate by pressing EN...

Page 23: ...ut 20 ms Time out message end 100 ms Important If an RS232RS485 or similar type converter is required make sure that the signal emitted does not produce an echo signal 1 1 2 2 21304 142 1 2 3 4 5 When the contact is closed RUN the pump may be run manually via the ENT key After stopping the pump manually via the keypad it is necessary to reset the Remote Input open and close to start the pump again...

Page 24: ...flow to be calibrated in real working conditions via a product suction test of a given duration For a correct calibration a test duration of at least 60 seconds must be entered The pump will automatically start during the time of the test Once the test is finished the suction volume must be entered With this result the equipment will recalculate the dosing flow l h 0 0 0 0 0 0 MODE 25 0 PUMP CALIB...

Page 25: ...or Slow Suction 1 and the discharge cycle speed is also reduced to 50 to avoid overpressure in long deliveries In this mode the flow is reduced to 50 5 2 2 1 Low pulsation standard The Standard ST mode is the normal operating mode where the doser has symmetrical behaviour during suction and discharge of the product while working at maximum capacity As the flow rate is reduced the discharge cycle i...

Page 26: ...eed the entered value under any circumstances Maximum pressure Dosing pump maximum working pressure Compensation of working pressure Flow compensation as a function of working pressure l h 0 0 0 0 0 0 MODE 25 0 DOSING PUMP Flow Flow max Limit Pres Alm Pres Comp 12 5 l h l h Bar 25 0 100 05 0 Off DOSING PUMP Flow Flow max Limit Pres Alm Pres Comp 12 5 l h l h Bar 25 0 100 05 0 Off DOSING PUMP Flow ...

Page 27: ... max Limit Pres Alm Pres Comp 12 5 l h l h Bar 25 0 100 05 0 Off 5 2 3 2 Units Select the units for flow pressure and proportionality x2 ENT ENT ENT CONFIGURATION SET UP IN OUT PUMP CALIBRATION DOSING MODE SET UP DOSING PUMP FLOWMETER LOCK CODE UNITS MODBUS UNITS Flow Pressure BAR Proportional LITERS UNITS Flow Pressure Proportional LITERS BAR UNITS Flow GALONS Pressure PSI Proportional ppm l h 0 ...

Page 28: ...ter constant volume pulse or pulses volume must be entered Previously select the type of flowmeter for low or high frequency Low frequency for water meters with low frequency outputs 0 005 Hz to 30 Hz The constant is expressed in volume pulse litres pulse gallons pulse High frequency for flowmeters with high frequency outputs 1 to 300 Hz The K factor constant is expressed in pulses volume pulses l...

Page 29: ...top Bits Baudrate MODBUS ADDRESS Address 001 9600 8 N 1 Data Bits Parity Stop Bits Baudrate MODBUS ADDRESS Address 001 9600 8 N 1 Data Bits Parity Stop Bits Baudrate Pressing ESC for 3 seconds locks the pump Press ESC for 3 seconds to enter the code and unlock the pump Enter the code starting with the units from right to left Change values by pressing and validate by pressing ENT Change by pressin...

Page 30: ... detector is an accessory that allows the pulses of the supplied flow to be monitored x2 x2 ENT ENT ENT ENT CONFIGURATION SET UP IN OUT PUMP CALIBRATION DOSING MODE CONFIGURATION SET UP IN OUT PUMP CALIBRATION DOSING MODE INPUTS PRESSURE FLOW DETECTOR OUTPUTS PULSES 4 20mA PRESSURE INPUT 4 mA 000 0 bar 20 mA 000 0 bar PRESSURE INPUT 4 mA 000 0 bar 20 mA 020 0 bar INPUTS PRESSURE FLOW DETECTOR OUTP...

Page 31: ... INPUTS PRESSURE FLOW DETECTOR OUTPUTS PULSES 4 20mA ENT 4 20mA OUTPUT Out In4 20mA 4 20mA OUTPUT 4mA 004 20mA 096 Out Flow l h 0 0 0 0 0 0 MODE 25 0 Enter the volume of product dispensed for each product Change by pressing and validate by pressing ENT Set whether the pulse output is the same as the pulse input Change by pressing and validate by pressing ENT Enter the flow rate at which the 4 mA w...

Page 32: ...NT ENT ENT LEVEL 1 PRE EMPTY Alarm Relay out OFF Stop pump OFF OFF LEVEL 1 PRE EMPTY Alarm ON Level relay Stop pump OFF OFF LEVEL 1 PRE EMPTY Alarm ON Relay out Stop pump OFF OFF LEVEL 1 PRE EMPTY Alarm ON Level relay Stop pump OFF OFF LEVEL 1 PRE EMPTY Alarm ON Level relay ON Stop pump OFF MENU ALARM LEVEL 2 FLOW LEAKAGE PRESSURE LEVEL 1 MENU ALARM LEVEL 2 FLOW LEAKAGE PRESSURE LEVEL 1 l h 0 0 0 ...

Page 33: ...op pump OFF OFF FLOW FAILURE Alarm ON Relay out ON Stop pump OFF l h 0 0 0 000 MODE 25 0 Activate or deactivate the alarm by pressing and validate by pressing ENT 5 3 3 Flow fault alarm Dosing flow detector alarm See section 4 2 4 2 Setup Inputs Flow Detector Activate or deactivate the Alarm Relay output when the unit is in alarm by pressing and validate by pressing ENT Activate or deactivate stop...

Page 34: ...uctive liquids min 0 05 mS ENT ENT x3 x3 DIAPHRAGM LEAKAGE Alarm Relay out OFF Stop pump OFF OFF MENU ALARM LEVEL 2 FLOW LEAKAGE PRESSURE LEVEL 1 l h 0 0 0 000 MODE 25 0 5 3 5 Overpressure alarm Overpressure detection alarm Automatic reset Activate or deactivate the Alarm Relay output when the unit is in alarm by pressing and validate by pressing ENT Activate or deactivate stop the pump when the a...

Page 35: ...TY Alarm ON Level relay Stop pump OFF OFF OVER PRESSURE Alarm ON Relay out ON Stop pump OFF MONITOR COUNTERS INFO UNIT REAL TIME l h 0 0 0 0 0 0 MODE 25 0 Analogue output value mA External pulse output value pulses hour or minute Level 2 sensor alarm output Alarm output Analogue input value mA Pressure sensor input value bar psi External pulse input value Hz External pulse input value Remote contr...

Page 36: ...reset Volume since last reset Total operating time hours Short circuit alarms Overload alarms High temperature alarms High temperature alarms chip Motor connection fault alarms Input voltage alarms Unit code Serial number Nominal pump flow l h or GPH Maximum pressure bar or psi Cycles min Cycle volume Reducer Calibration factor Hardware version Software version 5 4 3 Info Unit RESET COUNTERS 2 ENT...

Page 37: ... valve outlets are diverting the liquid to a container PUMP CHECK Make a visual auditory check of the correct operation of the pump PRIMING To facilitate pump priming open the priming valve OVERPRESSURE PROTECTION Adjust the safety overpressure or pressure relief valve to the desired pressure to protect the installation while never exceeding the nominal pressure of the pump ...

Page 38: ... 44303 55120 55118 P D50 67104 2 P D69 55303 55116 55105 55119 55103 55 109 55 109 Piñón 55610 60304 62318 55305 Corona 55154 55305 55306 55601 55300 63212 63213 55304 55302 55 100 MODEL CROWN PINION S50 D50 55132 55129 F50 D50 55132 55129 F30 D50 55133 55106 F51 D50 55131 55129 F31 D50 55107 55106 F41 D69 55130 55128 F31 D69 55107 55106 ...

Page 39: ...39 Maintenance 55606 55605 59309 59353 55655 M12 73654 M2 73615 M12 C 55202 55150 29620 55149 55 100 55309 ...

Page 40: ...88 1 55303 D15 DIN471 safety ring 1 55304 Allen screw M4x4 DIN913 1 55305 Bearing 6201 2RSH 12x32x10 2 55306 Bearing 61909 2RS 45x68x12 2 55310 Bolt 4x20 E0210 A2 6 55601 Hall Sensor PCB 1 55605 Dosmart power PCB 1 55606 240 Vac 24 Vac power supply 1 55610 NEMA 23 step motor 1 55655 M12 3 pin male panel connector 1 55 800 1 P Double ball pipe suction valve 3 4 1 55 801 P Pipes delivery valve 3 4 1...

Page 41: ... P 60877 1 P Pins 55825 P 55827 P 55829 P 4x6 6x8 6x12 10x12 60811 1 P 62310 60813 1 P 64348 60308 55822 P 62310 60813 1 P 64348 60308 55822 P 62310 55820 P 62310 Pins Flanges 60811 1 P Flanges Pins 62310 55819 P 62310 62310 60815 1 59306 59303 59810 1 P 59303 59800 1 60813 1 P 64348 60308 60812 1 P 62310 60813 1 P 64348 60308 60812 1 P ...

Page 42: ...ndling the liquid being dosed PERIODIC MAINTENANCE Check the condition of the suction filter once a month Check the condition of the valves every 3 months or 1000 hours We recommend periodically circulating clean water through the dosing pump coinciding for example with the emptying of the tank in order to remove andy precipitated remains from inside the cylinder or in the suction and discharge pi...

Page 43: ...k area to ensure temperature conditions within the tolerated range The pump is working with overpressure Check that the line pressure is lower than the maximum allowable pressure of the unit Incorrectly dimensioned discharge pipe Shorten the discharge pipe or increase its diameter Overload AL 3 The pump is working with overpressure Check that the line pressure is lower than the maximum allowable p...

Page 44: ...d to be injected Dirty or damaged suction or discharge valve Clean or change valves Dirty suction filter Clean filter Air enters the suction pipe Check tightness of connection points Cavitation in suction Increase pipe diameter Reduce the suction pipe length Reduce speed by using a variator Use a less viscous liquid Pump drips liquid from hole in bottom of cylinder Damaged diaphragm Change diaphra...

Page 45: ...C Inputs Outputs External quick connectors ENCODER 1 2 3 4 5 6 7 8 10 11 12 FLOW LEAKAGE PRESSURE VENTILATION RS 485 4 20 mA PULSE PULSE ALM LEVEL ALM REMOTE LEVEL 1 LEVEL 2 4 20 mA 4 20 mA ITC controllers Pulse input ITC flowmeter Remote activation Level sensors Brown Brown Brown Black White White Blue Blue 1 2 3 4 5 Black Grey 1 REMOTE 2 REMOTE 3 LEVEL 1 4 LEVEL 2 5 COMMON 24 Vdc Motor 110 240 V...

Page 46: ......

Page 47: ...uctions in the instruction manual Antón Planas Manager WARRANTY I T C S L guarantees the product specified in this document for a period of 1 year from the date of purchase against all manufacturing or material defects provided that installation use and maintenance of the equipment are correct The equipment must be sent free of charge to our workshop or I T C S L accredited technical service and i...

Page 48: ...Original Manual Ed 17 02 2021 EN C Vallès 26 Pol Ind Can Bernades Subirà P O Box 60 08130 Santa Perpètua de Mogoda BARCELONA Tel 93 544 30 40 Fax 93 544 31 61 e mail itc itc es www itc dosing pumps com ...

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