INDEX 1.-GENERAL DESCRIPTION 4 2.-CARRIAGE AND MAINTENANCE 4 3.-TECHNICAL FEATURES 5 4.-OPERATION 6

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1 DOSITEC ENGLISH

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3 INDEX 1.-GENERAL DESCRIPTION 4 2.-CARRIAGE AND MAINTENANCE 4 3.-TECHNICAL FEATURES 5 4.-OPERATION INSTALLATION 7 Generalities 7 Hydraulic connection 7 Electric connection START UP 10 DOSITEC - MP 12 DOSITEC - MD 13 DOSITEC - ma 14 DOSITEC - Q 17 DOSITEC - PRC 20 DOSITEC - MF MAINTENANCE List of parts 39 C.E APPROVAL DECLARATION 42 WARRANTY 42 SAFETY RULES To avoid personal or environmental damages and to guarantee a proper operation of the equipment, the staff in charge of the installation, set up and maintenance of the equipment must follow the instructions of this manual, specially recommendations and warnings explicitly detailed. In additon, specific instructions for the chemical products to be dosed should be followed.

4 1.- GENERAL DESCRIPTION The dosing pumps DOSITEC are heavy duty, high precission, electric diaphragm pumps for dosing liquid products. DOSITEC dosing pumps are manufactured with materials that can resist most chemicals products, even acids. They are designed for all sorts of processes where it is necessary to dose a product into a hydraulic network, such as: food, textile, chemical industry, water treatments, etc. (See materials in Technical Features). In case there is any doubt about compatibility of materials with the products to be used please contact ITC S.L. Technical Service. The metering pump has been designed to feed liquids with capacities from 0 to 20 l/h and pressures from 0 to 10 bar. They also include a conexion for a level switch.. DOSITEC models: DOSITEC -MP: Manual Regulation from 0 to100% by potentiometer DOSITEC -MD: Manual Regulation from 0 to100% by keyboard DOSITEC - Q: Proportional regulation DOSITEC - ma: Analogic regulation by a current signal DOSITEC - PRC: Control PH or ORP(Redox) DOSITEC - MF: Multifuntion (Manual flow regulation / proportinonal / Analogical 4-20mA / with timer) 2.- CARRIAGE AND MAINTENANCE The original packing is thought so that the transport and the storage of the team can be made without causing damages to the team, provided they are made inside dry, aired spaces and far from sources of heat, always maintaining the bomb in vertical position. Inside the packing it is included: Dosing pump. 1 semirigid PE hose, white, lenght 2m. 2 Flexible PVC hose transparent crystal type, lenght 2m. Injection valve 3/8 BSP-M Filter manual of instructions 4

5 3.- TECHNICAL FEATURES Flow l/h Pressure Bar C/min Volum ml/cycle Stroke length mm Power supply Volts 230V AC 230V AC 230V AC 230V AC 12V DC 12V DC Power Watts 37 (0.16A) 58 (0.25A) 37 (0.16A) 58 (0.25A) 24 (2 A) 24 (2 A) Weight Kg Maximum suction high: 2 m Mínimum injection pressure: 0,5 bar The products are manufactured according CE regulation. IP 65 protection. Plastic housing: Polypropylene. Working temperature: 5-40 ºC Standard power supply: 230 V (+/-10%) a.c.50 / 60 Hz single phase. Optional power supply:120 V a.c. 50 / 60 Hz single phase. / 12V d.c. FLOW-PRESSURE l/h l/h@10 bar 6 l/h@ 7 bar 2 l/h@ 20 bar 2,5 l/h@ 10 bar bar LIQUID ENDS MATERIALS: DIAPHRAGM: PUMP HEAD: NIPPLES: VÁLVES BODY: VALVES BALL: O-RINGS: SUCTION HOSE: DISCHARGE HOSE : FILTER: PTFE. PVDF PVDF. PVDF Ceramic FPM ( available in EPDM) PVC flexible. Polyethylene. Polypropylene 5

6 5 DIMENSIONES OPERATION The metering pump is activated by a PTFE diaphragm mounted on a piston of an electromagnet. When the piston of the electromagnet is attracted, a pressure is produced in the pump body with an expulsion of liquid from the discharge valve. Once the electric impulse is finished a spring brings the piston back to the initial position, with a recall of liquid through the suction valve. As the operation is simple the pump does not need lubrication, therefore maintenance is reduced almost to zero. The materials used for the construction of the pump make it particularly suitable for aggressive liquids. 6

7 5.- INSTALATIÓN GENERAL Install the pump in a dry place and well away from sources of heat and, in any case, at environmental temperatures not exceeding 40 C. The minimum operating temperature depends on the liquid to be pumped,bearing in mind that it must always remain in a liquid state. Carefully observe the regulations in force in the various countries as regards electrical installations. When the supply cable is devoid of a plug, the equipment should be connected to the supply mains by means of a single-pole circuit breaker having a minimum distance of 3 mm between the contacts. Before accessing any of the electrical parts, make sure that all the supply circuits are open. HYDRAULIC CONNECTION Properly design either in the suction and injection pipe is required, avoiding long lenght and bending pipes as much as possible. t SUCTION FILTER 4 INJECTION PIPE 2 SUCTION PIPE 5 COUNTER-PRESSURE VALVE 3 PRIMING VALVE 6 INJECTION VALVE 7

8 To prime the pump, first connect the priming hose to the priming valve and drive the other side of the hose to a safety place to pour the air mixed with product. PRIMING VALVE Open the priming valve and start the pump at maximum flow until having only liquid in the priming outlet PRIMING HOSE INJECTION HOSE Select the most appropiate injection point in the pipe to inject the product, and place there a 3/8 part to connect the Injection valve 3/8 Install a safety valve in a derivation as near as possible from the pump, in order to protect it and the whole installation from possible over-pressures. This derivation Must derive the liquid to a safe place. 8

9 ELECTRIC CONNECTION The electric protection of the motor must be installed and adjusted following its nominal intensity (overloaded switch disjuntor). A disconnection dispositive must be installed in case of emergency. The equipment must be protected to avoid untimely sudden starts. 230V AC L1 (BLUE) L2 (BROWN) A E B C D YELLOW/GREEN MD Q ma PRC MF A Output RS Transmition 2- Reception 3- Ground 4- Reset B Pulse Input (+) 4- Pulse Input (-) Signal ma (+) 4- Signal ma (-) 1- Pt Pt Common Pt Common Pt Signal Input ma (+) 2- Signal Input ma (-) 3- Pulse Input (+) 4- Pulse Input (-) C Level switch 4- Level switch Level switch 4- Level switch Level switch 4- Level switch 1- Output ma (+) 2- Output ma (-) 3- Level switch 4- Level switch 1- Flow sensor 2- Flow sensor 3- Level switch (remote) 4- Level switch (remote) D Output relay.al3. NO 2-3- Output relay (Com) 4-1- Output relay NO 2- Output relay NC 3- Output relay (Com) 4-1- Output relay NO 2- Output relay NC 3- Output relay (Com) 4- E Connector BNC Electrode ph Electrode ORP (redox) 9

10 6.- START UP AND REGULATION STAND: Check that the pump is properly installed in its stand. CHECKING OF HYDRAULIC CIRCUIT: Check that all valves are opened and that escapes from priming valves derive the liquid to a proper receptacle CHECKING OF PUMP: Check visually/auditorilly the proper working of the pump. OVER-PRESSURE PROTECTION: Adjust the safety valve overpressure or relief to the wished pressure to protect the installation without exceeding the pump nominal pressure. ELECTRIC PROTECTION: Adjust the electric dispositive of electric HOW TO OPERATE WHEN DOSING SULPHURIC ACID In this case it is essential to bear in mind the following: Replace PVC crystal suction hose with polyethilene discharge hose. Empty any residual water from the pump head beforehand. Warning: if the water mixes with sulphuric acid it can produce a large quantity of gas with consequent overheating of the area causing damage to valves and pump head. This operation can also be done with the pump disconnected from the plant by turning the pump upside-down for 15 to 30 seconds and without connecting the hose to the nipples; if impossible, dismount and remount the pump head using the four mounting screws. 10

11 HOW TO OPERATE WHEN DOSING SODIUM HYPOCLORITE Disconnect the pins from the mains or by means of a onnipolar switch with 3 mm minimum distance between the contact. Disconnect discharge hose from process plant. Remove the suction hose (with filter) from the tank and dip it into clean water. Switch on the metering pump and let it operate with water for 5 to 10 minutes. Switch OFF the pump, dip the filter into a hydrochloric acid solution and wait until the acid finishes cleaning. Switch ON the pump again and operate it with hydrochloric acid for 5 minutes in a closed-circuit, with suction and discharge hose dipped into the same tank. Repeat the operation with water. Re-connect the metering pump to the process plant. 11

12 DOSITEC MP MANUAL REGULATION DOSING PUMP Flow can be controlled manually by setting the pump pulse rate by means of a potentiometer. Possibility of a more precise flow rate setting at low frequencies through the two keys 20% and 100% START button 2 STOP button 3 20% flow scale read out button 4 100% flow scale read out button 5 Adjustment knob of injections/min (0-100%) 6 Power LED 7 Pulse LED 8 20% flow scale read out LED 9 100% flow scale read out LED ACCESSORIES - 1 flexible transparent PVC suction hose 2m - 1 semirig white PE injection hose 2m - 1 injection valve 3/8-1 filter - 1 instructions manual - 1 flexible transparent PVC priming hose. 12

13 DOSITEC MD MANUAL REGULATION DOSING PUMP Flow can be controlled manually by setting the pump pulse rate through the keypad from 0 to 100% Increasing value button 2 Decreasing value button 3 START /STOP button 4 Display 5 Power LED 6 Pulse LED ACCESSORIES - 1 flexible transparent PVC suction hose 2m - 1 semirig white PE injection hose 2m - 1 injection valve 3/8-1 filter - 1 instructions manual - 1 flexible transparent PVC priming hose. 13

14 DOSITEC ma ANALOGIC 4-20mA DOSING PUMP Microcontrolled dosing pump with a 4-20mA input for the flow regulation Display selector button (ma / pulse) 2 Increasing values button 3 Decreasing values button 4 Function slection button 5 Enter button 6 Pulse displaying LED 7 Manula function LED 8 LED SET POINT 2 / STOP 9 LED SET POINT 1 / STOP 10 Meter functionled 11 ma displaying LED 12 Display 13 Pulse LED 14 Level alarm LED ACCESSORIES - 1 flexible transparent PVC suction hose 2m - 1 semirig white PE injection hose 2m - 1 injection valve 3/8-1 filter - 1 instructions manual - 1 flexible transparent PVC priming hose. 14

15 LEVEL CONTROL (UPON REQUEST) If the dosing pump is supplied with level control setting and upon request floating level switch. When the level of the additive is lower than the switch, level alarm goes ON, the display will show "FAO", the pump is off giving an optical and sound alarm. The level control alarm goes ON with 5 seconds delay. STARTING THE PUMP Turning on the pump, the instrument switches automatically to the "METER" function. Pressing button ma pulse will show the actual ma input signal. To go back to strokes/min press again. In order to avoid programming and setting errors during the system functioning, the pump is programmed to automatically return to the Meter Mode each time the unit is switched OFF. PRIMING Switch to manual function and select a high frequency to prime the pump. Press the F button to switch to MANUA function. Increase or decrease the injection/min through + /- buttons (recomended about 75% of maximum frequency) PROGRAMMING SET POINT 1Mode Set 1 is used to select the ma input value/min. dosing pump flow and pulse frequency. Press F button and Set 1 LED will switch on. The display will show the pulse frequency previously set. Select the minimum pump output required pressing +/- buttons. If the minimum output is zero set 000. Press ma/pulse button, ma LED will switch on: By pressing +/- buttons, you can select the ma input value corresponding to minimum pump output required. Confirm with Enter. 15

16 To finish the programming procedure and modify the maximum output value, press F button which will automatically change to mode Set 2. SET POINT 2 Mode Set 2 selects the ma input value/max. dosing pump flow and pulse/frequency. Press F button and Set 2 LED wil switch on, the display will show the frequency previously set. Press buttons +/- to set the desired imp/frequency at the maximum pump output required. Press button ma/pulse, the display will show the value previously set. Pressing +/- select the ma input value at the maximum pump output required. Press Enter button. Direct Functioning Mode During production the pumps are programmed for a 4-20 ma direct functioning curve. The pump will start every time the ma signal goes above 4 ma increasing the pulse frequency (and consequently the flow) proportionally to the ma input signal up to maximum imp/min frequency available. E.G. Set 1 minimum signal 4 ma, minimum output. Set 2 maximum signal 20 ma, maximum output. Reverse Functioning Mode Reverse functioning is when the ma signal increases and pump output proportionally decreases. Select the maximum ma signal required with mode Set 1 (in relation to the min. output). E.G. Set 1 maximum signal 20 ma, minimum output. Set 2 minimum signal 4 ma, maximum output. WARNING: Reverse functioning can only be selected when mode Set 1 is always higher than the ma signal. Example n 1: DOSITEC-mA, 10 L/H, 5 BAR, SIGNAL 4-20 ma. Signal 4 ma = 0 l/h (0% pump flow rate) Signal 12 ma = 5 l/h (50% pump flow rate) Signal 20 ma = 10 l/h (100% pump flow rate) Example n 2: SAME MODEL, BUT WITH INVERSE SIGNAL: 20-4 ma Signal 4 ma = 10 l/h (100% pump flow rate) Signal 12 ma = 5 l/h (50% pump flow rate) Signal 20 ma = 0 l/h (0% pump flow rate 16

17 DOSITEC Q PROPORTIONAL DOSING PUMP Microcontrolled dosing pump with a water counter input, for a proportional dosing. Possibility to set a proportion between the pulses from the water counter and the pulses of the dosing pump Decreasing values button 2 Increasing values button 3 Function selection button 4 START / STOP button 5 Display 6 Power LED 7 Pulse LED 8 1xN LED / manual function 9 1XN (M) LED 10 1:N LED ACCESSORIES - 1 flexible transparent PVC suction hose 2m - 1 semirig white PE injection hose 2m - 1 injection valve 3/8-1 filter - 1 instructions manual - 1 flexible transparent PVC priming hose. 17

18 LEVEL CONTROL (UPON REQUEST) If the dosing pump is supplied with level control setting and upon request floating level switch. When the level of the additive is lower than the switch, level alarm goes ON, the display will show "FAO", the pump is off giving an optical and sound alarm. The level control alarm goes ON with 5 seconds delay. PROGRAMMING MANUAL MODE 1XN 100 1XN(M) FC F PROPORTIONAL MODE t MANUAL MODE In manual mode select the desired injection frequency by pressing the arrow buttons, and starting with the START/STOP button )Select the desired injection frequency by pressing START STOP 2)Confirm by START 3)Starting with the STOP button PROPORCIONAL MODE 1XN(M) FC t 1)Select the desired mode F 1XN MODE 1XN 1 F 1XN(M) MODE 1XN(M) 1 F 1:N MODE 1:N 1 2)Select the desired proportion value by pressing 3) Confirm value with START button STOP buttons. 1XN(M) FC t 1XN 4)Starting with the START STOP button. 10 Note: The injection velocity is selected in the manual mode 18

19 1XN Mode The pump is operated by an impulse produced by an external device (e.g. pulse emitting water meter) and it supplies a number of injections equal to the value visualized on the display "N" (set by the operator). In case during the dosing of the "N strokes" other pulses arrive, these are neglected. Example :- Pump set in water meter 1XN mode - Set value on "20" - At the time the water meter gives a pulse to the pump, it starts its 20 dosing injection strokes, if during this phase further shuts of the contact occur, these are neglected. Ended up the 20 injections, the pump is waiting for further pulses from the water meter to restart the dosing cycle. 1XN (M) MODE Like in the 1XN mode but the microprocessor save in its memory all the received pulses. Example The pump receives the first contact and returns a string "N" injections to the maximum frequency (e.g. 120 imps./min). To the arrival of the second contact, the pump computes the time "T" spent by the arrival of the first one and it returns a string of "N" injections not more to the maximum frequency but to that it allows to uniformly distribute them in the time "T". If instead quick contacts goes to the condition N1>4, the pump goes in alarm (AL3), the pump continues working, but will miss the remaining injections. 1:N MODE The pump supplies an injection of chemical only when it has reached a number of pulses (contacts), equal to the value visualized on the display (set by the operator) Example: :- Pump set in water meter 1XN mode - Set value on "20 - At the time the water meter gives 20 pulses, the pump gives one pulse. 19

20 DOSITEC PRC PH, ORP (REDOX) DOSING PUMP Microcontrolled dosing pump for PH or ORP(redox) control Decreasing values button 2 Increasing values button 3 Escape button 4 Cursor movement 5 Enter button 6 LCD display 7 Power LED 8 Pulse LED 9 Alarm LED ACCESSORIES - 1 flexible transparent PVC suction hose 2m - 1 semirig white PE injection hose 2m - 1 injection valve 3/8-1 filter - 1 instructions manual - 1 flexible transparent PVC priming hose. 20

21 DISPLAY DESCRIPTION OVER Overdosing alarm DELAY Delay at powering on SET POINT Set point setting LEVEL Level alarm ALARM Alarms setting MENU Menu selection ON-OFF ON-OFF functioning mode PROP Proportional functioning mode HYST Hysteresis setting 12 Calibration points CALIB Calibration menu SETUP General instrument setting STARTUP Switching on delay setting INPUT MODE Level probe/flow sensor input activation RESET Reset activation DIRECTION Intervention selection MAX Maximum pulses frequency based to maximum measuring value 4 20 ma Output current settings h:m:s Hours:minutes:seconds PH ph measure Rx mv measure % Flow rate percentage Password setting Intervention Alkaline/Oxidant/Directa Intervention Acid/Reductive/Inverse pulses/minute Flow sensor Numeric values visualization 21

22 PARAMETERS AND FUNCTIONS LAYOUT Selection measures to control ph Setpoint setting 7.2 Hysteresis setting 0.1 Choice of the type of intervention Acid ON/OFF or Proportional intervention selection ON-OFF Definition of beginning intervention value PROP Setpoint+1pH First point of calibration procedure --- Second point of calibration procedure --- Minimum alarm point 0.00 Maximum alarm point Over-dosing alarm value 02:00 (h:m) Choise of the type of menu: BASE / FULL BASE Six figures numerical pasword Disable Delay at powering on 00:03 (m:s) Delay exit calibration menu 05:00 (m:s) Calibration check 4 ma 4 ma Calibration check 20 ma 20 ma TYPICAL CHARACTERISTICS Temperature Max. Current relay output Current output PH measure ORP (mv) mesure 0-40ºC 6A (resisitve load) 1A ( inductive load) 4-20mA (dynamic 0-500Ohm) 0-14 (0.01 ph) (+/-1mV) 22

23 LEVEL CONTROL DOSITEC PRC is supplied with level control setting. When the chemical tank is empty, on the display will appear LEVEL and the pump goes in stand by. The level control has 5 seconds of delay. PROGRAMATION The first operation to do is to select the type of parameter (ph or Redox) that is intends to measure and to control. The pump has turned on, on display it appears software revision then the type of controlled parameter that it flashes (default setting ph) Set measure type by means on the +/- and confirm through ENT On display will show the measure's value. SETUP 7.10 ph ph ENT Press to enter in menus, and press you will scroll all 4 menus: MENU SETPOINT MENU SETUP MENU CALIB MENU ALARM MENU SETUP SETUP menu press ENT to reach the desired menu BASE / FULL MENU SETUP base MENU SETUP full Press ENT to change the parameters of setup: On the display will appear the set measure type ph or mv Change by means +/- and confirm through ENT : SETUP ph 23

24 Will appear the protection password. OFF: password dissable To enable the pasword mode press + / - Set a password through +/- to increase or decrease value. Change digit through right arrow. Press ENT to confirm the password MENU SETUP MENU SETUP off oooo After the password has been determined, it is possible to set up the type of sensor that is necessary to install the pump: When a level sensor is needed to be connected, the LEVEL warning will appear, when is necessary to connect a proximity sensor this icon will appear On the display will appear the menu to select the time the pump will use to quite from calibration phase setting to come back to the main measuring display. Press +/- to set the delay time and confirm with ENT On the display will appear to set the delay time from pump switching-on Press +/- for change the time and ENT to confirm. INPUT MODE LEVEL MENU CALIB 10:00 DELAY h:m:s 00:03 DELAY STARTUP h:m:s To solve the problem of inertia of someone electrodes or plant installation, the pump has the possibility to set de delay time from pump switching-on to the measuring and control moment. MENU CALIBRATION menu CALIB press ENT set calibration PH calibration: On the display will appear POINT 1 Put the electrode in buffer solution ph7 Adjust the value on the display up to reach 7.00 with +/- and press ENT to confirm On the display will appear POINT 2 Put the electrode after washing with tap water in the second buffer solution 4.00 or 9.00 ph Adjust the value on the display up to reach 4.00 or 9.00 with +/- and press ENT to confirm POINT 1 CALIB POINT 2 CALIB ph ph 24

25 ORP (redox) calibration: POINT 1: put in short circuit the BNC connector. Using a metal wire, connected the core pin with the external cylinder part. Adjust the value on the display up to reach 0 using +/- and press ENT to confirm. Point 2: put the electrode in buffer solution (250, 475,650 mv) Adjust the value on the display up to reach the buffer solution value using +/- and press ENT to confirm. SETPOINT menu MENU press to change the set point On display will appear the set point value Adjust using +/-, and press ENT to confirm ENT SET ph POINT 7.50 On display will appear the menu to set if the pump has to dose above the set point or bellow this value For dosing an acid chemical select and for dosing alkaline chemical select SET POINT DIRECTION Select with +/- and press ENT to confirm On display will appear the HYSTERESIS menu (only with FULL menu), this is the distance from the set point value, over this value the pump starts or stops it`s dosing Press +/- to set the value and confirm with ENT ph HYST SET POINT0.05 On display will appear to select the regulation mode: ON-OFF- when the pump has to dose it will run at flow rate selected by the user in Flow rate setting, and iit stops at the Setpoint. MODE SET POINT ON-OFF PROP- when the pump will dose proportionality to the set point value. The pump star dosing over setpoint, increasing it s speed up to the max frequency adjustment use will set. Press +/- to select and confirm with ENT MODE SET POINT PROP. 25

26 When select ON-OFF, on the display will appears the maximum frequency adjustment Press +/- to change and ENT to confirm SET POINT 100 % ON-OFF Only in ON-OFF mode it is possible to define the time delay before pump start -up, when going out of the setpoint Press +/- to change and ENT to confirm When select PROP, on the display will appear the maximum measure value to which the pump has to dose at the maximum frequency Press +/- to change and confirm with ENT Only in PROP mode, on the display will appear the maximum frequency adjustment corresponding to the previous value. Press +/- to change and confirm with ENT Only in PROP mode, on the display will appear frequency adjustment corresponding to the Setpoint Press +/- to change and confirm with ENT SET POINT00.03 DELAY ph SET POINT 8.20 PROP. MAX ph SET POINT 100 % PROP. MAX ph SET POINT 0 % PROP. m:s min On the display will appear two measurers values that correspond to the 4-20mA output Press +/- to set the value of the measure to which it has to correspond 4mA output, and confirm with ENT Press +/- to set the value of the measure to which it has to correspond 20mA output, and confirm with ENT SET SET 4 ma ph 0.00 POINT 20mA ph POINT14.00 MENU ALARM menu press ENT to enter in alarm mode ALARM On the display will appear the MAXIMUM value of the measure, where the pump has to go in alarm mode. Press +/- to set the value and confirm with ENT ALARM ph 14.00MAX 26

27 On the display will appear MINIMUM value of the measure, at which the pump has to go in alarm mode. Press +/- to change the value and confirm with ENT ALARM ph 0.00 min On the display will appear OVER DELAY,which is the maximum time allowed to reach the set point value. Over this time, the pump will go in alarm mode Press +/- to change the value and confirm with ENT. Press ESC to return in measure mode ALARM OVER DELAY ph 02:00h:m RESET procedure (partial o total) Turn off and turn on the pump Press ENT MENU SETPOINT press at the same time RESET With this procedure a PARTIAL reset will be actived, the pump return to the default settings but all the calibration will be saved Press twice then press will appear RESET With this procedure a TOTAL reset will be actived, the pump return to the default settings and all the calibration parameters will be lost. Press twice then press will appear RESET With STANBD-BY procedure, the pump is put on stand by Hold down at same time until a appears In order to exit this mode, hold down keys + / - at the same time. 27

28 DOSITEC MF MULTI-FUNCTION DOSING PUMP Dosing pump controlled by a microprocessor that allows a manual flow regulation, which is proportional to an incoming pulse rate, 4-20 ma analogical external signal, or with timer MAN. 120 P/M 15:02 6 MF START STOP Decreasing value button 2 Increasing value button 3 Previous program button 4 Next program button 5 START / STOP button 6 Display 7 Power LED 8 Injection sign LED 9 Alarm sign LED ACCESORIES - 1 flexible transparent PVC suction hose of 2m (6.56 feet) - 1 semi rigid white PE injection hose of 2m (6.56 feet) - 1 injection valve 3/8-1 filter - 1 instructions manual - 1 flexible transparent PVC priming hose 28

29 ALARM LEVEL When the level sensor is connected to the dosing pump (D connector) and detects a lack of additive, stops the injection. This control level have a 5 minutes delay. PROGRAMMING First screens MANUAL 1xN 1xN(M) 1-N ma PPM ALARM REMOTE BUZZER CLOCK TIMER LENGUAGE First step: define the dosing control mode - MANUAL / 1xN / 1xN(M) / 1-N / ma / PPM MANUAL MODE This method allows to operate the pump automatically, running a constant dosing. The pulse rate can be predetermine upon 3 different scales. MANUAL PULSE / MIN. PULSE / MINUTE 120 Select the pulse / minute value through PULSE / HR. PULSE / HOUR 120 Select the pulse / hour value through PULSE / DAY PULSE / DAY 48 Select the pulse / day value through Press START/STOP to confirm the value. It will start running automatically according to the selected frequency. 29 MAN. 120P/M 00:00

30 PROPORTIONAL MODE This operation mode allows running a proportional dosing between the pulses emitted by the water meter, and the pump injections. (Socket B pin 3-4, see page 9) 1XN Function For every pulse received the pump will carry out a series of "N" injections, previously set by the operator, whom can also fix the frequency of the injection. 1xN MENU 1xN 10 Through select the number of injections and press START /STOP to confirm 1x N n= 10 12:00 Example: - Pump set on 1XN function - Value set on: "20" - When the meter or any other element, shut off the contact, the pump starts dosing 20 injections. If there is a new shut off during this process, the pump will not take it in consideration until finishing the 20 injections, then it will restart this process again. 1XN (M) function This function its equivalent to the 1XN function, however in this function all the pulses received are saved at the microprocessor's memory. 1xN(M) MENU1xN(M) 10 Through select the number of injections and press START /STOP to confirm 1xN(M) n=10 12:00 Example: When the pump receives the first pulse or contact returns a series of "N" injections at the maximum frequency, for instance: 120 injections / minute. When the pump receives the second pulse or contact starts computing the time T without exceeding the maximum frequency. When the remaining injections are bigger than 4XN an alarm (AL3) will go on. In that case, the pump will keep running however, the remaining injections will get lost. 30

31 1:N function For each N pulses received the pump does one injection. The value of N can be set for the operator. 1-N MENU 1-N 10 Through select the number of injections and press START /STOP to confirm 1- N n= 10 12:00 Example: - Pump set on 1:N function - Value set on "20 - When the meter shut off the contact 20 times, the pump does one injection. ma (4-20mA) MODE This operation mode allows the flow adjustment through a 4-20 ma analogical external signal. It allows setting the maximum and minimum injection speed, according to the 4-20 ma analogical signal. (Socket B pin 1-2, see page 9) ma SET ma (1) 4.0 SET ma (2) 20.0 PULSE / MIN (1) 0 PULSE / MIN (2) 120 Through select the current value to indicate the minimum flow desired, and then confirm with Through select the current value to indicate the maximum flow desired, and then confirm with Through select the flow (injections/minute) corresponding to the minimum current point. Confirm with Through select the flow (injections/minute) corresponding to the maximum flow desired. Confirm with BELLOW ma (1) STOP BELLOW ma (1) CONTINUE Through select STOP or CONTINUE the injection when the current is bellow the set one (SET ma), then confirm with 31

32 OVER ma (2) STOP OVER ma (2) CONTINUE Through select STOP or CONTINUE the injection when the current is below the set one -SET ma (1). Confirm with When pressing START/STO the pump will start running according to the configuration set. ma : :00 PPM MODE This operation mode allows dosing in Parts Per Million. page 9) (Socket B pin 3-4, see PPM L/P W.METER 0.10 cc/ INJECTION 0,01 SOLUTION % 100 Through select the litter's value per each pulse from the flow meter (select it according to the meter) and confirm with Through select the injection volumen for each cicle of the pump (see page 4) and confirm with Through select the concentration value (%) of the aditive that the pump needs to inject and confirm with SET PPM 1.0 Through select the value in p.p.m (parts per million) that is required, (in a rank from p.p.m) and confirm with When pressing START/STO the pump will start running according to the configuration set. PPM = :00 32

33 ALARMS The pumps provided with flow sensor (which is optional) have a system that in case the pump stops injecting,according to the parameters set, due to any mechanical damage, a alarm goes on and stops the injections. (Socket C pin 1-2, see page 9) ALARM REF. PULSES 0 Through select the pulse rage value of reference and confirm with MAX DIFF. 0 Through select the maximum difference of pulses related to the reference ones, and confirm with TELECONTROL (REMOTE) The pump can be activated and deactivated through an opening and closing contact located a 100 meters (maximum distance). There are two different operation modes: NORMAL or REVERSED REMOTE MENU REMOTE NORMAL MENU REMOTE REVERSED NORMAL mode: Contact opened = pump activated Contact closed = pump in stand-by Through select the function Confirm with REVERSED mode: Contact opened = pump in stand-by Contact closed = pump activated Through select the function Confirm with Note: the wires must be conected at the same connectors of the level probe (Socket C pin 3-4, see page 9) 33

34 BUZZER The pump features an acoustic alarm to warn us of any incidence. BUZZER MENU BUZZER ENABLED The function ENABLED indicates alarm on Through select function Confirm with MENU BUZZER DISABLED The function ENABLED indicates alarm on Through select function Confirm with CLOCK The pump features a clock with time. Some applications may request the activation or deactivation through this clock. CLOCK CLOCK SET 12:00" - MON Through Confirm with select the time CLOCK SET 12:00 - MON Through Confirm with select the day of the week CLOCK SET 2007" JAN 01 Through Confirm with select the year CLOCK SET 2007 JAN 01 Through Confirm with select the month CLOCK SET 2007 JAN 01" Through Confirm with select the day 34

35 TIMER The timer menu carries out up to 8 different cycles of activation and deactivation in one day. TIMER MENU TIMER TIMER OFF Function TIMER OFF deactivates the timer. Through select the function. Confirm with MENU TIMER DAYLY SETS Function DALY SETS set up to 8 different cycles of start and stop Through select the function. Confirm with SET1 ON 1:00 Function SET 1 ON sets the timing to activate the pump Through select the function. Confirm with SET1 OFF 1:20 Function SET 1 OFF sets the timing to deactivate the pump Through select the function. Confirm with Repeat this operation according to the number of cycles (maximum 8) requested in one day. MENU TIMER WEEK SETS SUNDAY SET1 ON 1:00 SUNDAY SET1 OFF 1:20 Function WEEK SETS set up to 8 different cycles of start and stop Through select the function. Confirm with Function SUNDAY SET 1 ON sets the timing to activate the pump on Saturdays. Through select the function. Confirm with Function SUNDAY SET 1 OFF set the timing to deactivate the pump on Saturdays. Through select the function. Confirm with Repeat this operation according to the number of cycles (maximum 8) requested in one day. 35

36 LANGUAGE The language menu allows the selection between two languages. LANGUAGE SET LANGUAGE ENGLISH English menu Through Confirm with select language MENU LINGUA ITALIANO Italian menu Through Confirm with select language 36

37 7.- MAINTENANCE Before any maintenance operation we will check: That the pump is stopped and disconnected from the electric supply. There is no pressure neither inside the head nor in the impulsion pipe. It is advisable to empty the head before opening it. The staff in charge of the maintenance will use the adequate protection means in order to manipulate the dosed liquid. Periodically check the chemical tank level so as to avoid the pump operates without liquid. This would not damage the pump, but may damage the process plant due to lack of chemical. DOSITEC series dosing pumps are all supplied with level control setting. The level switch is not included therefore to be ordered separately. Level control stops pump operation once the level into the chemical is lower then the level switch,activating a L.E.D. on the pump. Check the pump operating condition at least every 6 months, pump head position,screws, bolts and seals; check more frequently where aggressive chemicals are pumped, especially: - pulse and power L.E.D.; - the additive concentration in the process plant; a reduction of this concentration could be caused by the wearing of the valves, in which case they need to be replaced or by the clogging of the filter which then has to be cleaned as in point 3 here below. 37

38 TROUBLE SHOOTING MECHANICAL FAULTS As the system is quite robust there are no apparent mechanical problems. Occasionally there might be a loss of liquid from the nipple because the tube nut has loosened, or more simply the discharge tubing-has broken. Very rarely there may be losses caused by the breakage of the membrane, or by the membrane seals in which case they have to be replaced by disassembling the four screws of the pump head, when re-mounting the pump head ensure that the screws are replaced properly, along with O ring. After repair, the metering pump will need to be cleaned of additive residues which can damage the pump casing. PROBLEM tthe pump gives pulses but doesn t inject CAUSE Valves not clean Damaged valves SOLUTIÓN Remove the suction and injection valves, clean them, and assemble them in the same position. When the parts are swallen, check valve material against a chemical compatibility chart and fit the correct material. Filter not clean Clean the filter The pump doesn t give any pulse and LED are off The pump doesn t give any pulse and green LED is on and red LED is off Power supply failure START failure Chech the power supply. If it still doesn t work contact with the Technical Service Press START/STOP. If it still doesn t work contact with the Technical Service. Pump pulses are not constant The pump gives only one pulse Power supply failure Check the input voltageis within +/- 10% rated voltage Disconnect the pump and contact immediately to the Technical Service 38

39 DOSITEC PARTS F F F F F F F F F F 59849

40 BALL VALVE 4x6 PVDF / FPM Discharge F Suction F CHECK VALVE 4X6 FOOT FILTER 4X P

41 LIST OF PARTS CODE DESCRIPTION UNITS PLATE FOR LEVEL SENSOR STAND ELECTRIC CABLE CONNECTOR G4W1F CONNECTOR G4A5M F CYLINDER DIAPHAGM PVDF CYLINDER CAP DIAPHRAGM FLANGE PTFE DIAPHAGM LOWER LEXAN LOWER LEXAN STROKE REGULATION LEXAN MP LEXAN MD LEXAN Q LEXAN ma LEXAN MF LEXAN PRC CYLINDER COVER HYDRAULIC CASE ELECTRONIC CASE FLOW ADJUSTMENT KNOB CASE O-RING M4X8 INOX SCREW M WASHER O-RING FOR DRAIN VALVE LIP VALVE O'RING M4X35 DIN 912 INOX SCREW O-RING FOR DRAIN VALVE O-RING VITON SCREW 2.9X SCREW 4X16 INOX SCREW 2.9X CABLE CLAMP D ELECTROMAGNET D ELECTROMAGNET MP ELECTRONICA CARD MD ELECTRONICA CARD Q ELECTRONICA CARD ma ELECTRONICA CARD MF ELECTRONICA CARD PRC ELECTRONICA CARD F DRAIN CONNECTER PVDF F SEPARATOR OF INJECTION VALVE PVDF F 3/8" LIP VALVE GUIDE PVDF F DRAIN CONTROL PVDF O-RING F DRAIN SCREW PVDF F DRAIN ROD PVDF CYLINDER FOR INYECTION VALVE BODY OF INYECTION VALVE FOOT FILTER NET FOOT FILTER CONE P 4x6 FOOT FILTER 1 ASSEMBLY F CYLINDER DOSITEC ASSEMBLY PVDF/ FPM /8 CHECK VALVE P FOOT FILTER 4X F SUCTION CHECK VALVE BALL 4x6 PVDF/FPM F DISCHARGE CHECK VALVE BALL4X6 PVDF / FPM 1

42 EC CONFORMITY DECLARATION I.T.C S.L.. Mar Adriàtic, 1 Polígono Torre del Rector Santa Perpètua de Mogoda Declares that all models DOSITEC products, identified by a serial number and year of manufacture, strictly fulfill low voltages directives 73/23/CE and electromagnetic compatibility directives 89/336/CE, as long as installation, use and maintenance are carried out following the prevailing regulation and following the instructions contained in the handbook. Antón Planas Manager WARRANTY I.T.C. S.L. warrants the product specified in this document for a period of 2 years fromt he purchase date except for the wearing parts such as valves, seals, nipples, hoses and filter. This warranty obligation is limited to the free replacement of the damaged parts due to any material or manufacture defect. This warranty does not include periodic maintenance and damage resulting from misuse. The equipment must be sent to I.T.C. S.L. Service Center with prepaid transport charges, and will be sent back with transport charges for customer s account. The warranty document with sales date and shop stamp or an invoice copy must be sent with the equipment. MODEL Date of sale and shop stamp SERIAL # DATE: 42

43

44 Ed: 01/10/2010-AN C/ Del Mar Adriàtic nº 1 Pol. Ind. Torre del Rector P.O. Box STA. PERPETUA DE MOGODA BARCELONA - SPAIN Tel Fax itc@itc.es