DOSING UNIT WITH TIME CONTROL INSTRUCTIONS MANUAL WARNING!

Transcription

1 DOSING UNIT WITH TIME CONTROL DOSING PUMP WITH TIME CONTROL SERIE DCK STORAGE TANKS SERIE SL INSTRUCTIONS MANUAL WARNING! The equipment must be used only for the utilization for which they have been designed, as shown in the technical documentation. Read carefully this leaflet until the end before starting any operation. Proceed strictly according to all directions included in this manual. Nobel batching units are suitable for the dosing of chemicals supplied by Nobel and, besides, caustic soda, hydrochloric acid and sodium hypochlorite. ANY OTHER APPLICATIONS OF THE EQUIPMENT DIFFERENT THAN THE MENTIONED ONES IS MADE UNDER THE ONLY RESPONSIBILITY OF THE USER. For any assistance concerning the installations, maintenance or utilization of the equipment apply the NOBEL Service Center closest to you or directly: NOBEL S.r.l. via Monfalcone 8 I Milano tel fax REV.1 p2.04-v4.f dos_dck-mi-r1.doc

2 INDEX 1. Safety General Hydraulics Electrical Directions for storage, delivery, installation Technical characteristics Characteristics of the pumps Characteristics of storage tanks Installation How to remove packaging and to move the unit Placing and hydraulic connections Electrical connections Starting-up and priming of the pumps DCK Description of the pumps serie DCK Factory-set How to program the pump CLO = how to adjust current time and day Ad = how to adjust the weekly programs rel = how to set the starting up of an external device tc = how to set the working mode Sd = how to set the special program for each day CAL = calibration of the flow rate Trouble-shooting guide Maintenance Disposal Spare parts...14 s.r.l.milano - ITALY Page 2 of 14 p2.04-v4.f dos_dck-mi-r1.doc

3 1. Safety 1.1. General The equipment has been designed and constructed according to D.P.R. n 459 of 24th July 1996 (regulation for accomplishment of Norms 89/392/CEE, 91/368/CEE, 93/44/CEE and 93/68/CEE regarding the unification of States members laws in so far as machines are concerned). It has been designed and constructed according to European Norms EN 50011, EN , EN , EN 50014, EN , EN , EN , EN , EN Only authorized and skilled personnel will be allowed to carry out installation, start up as well as routine and planned maintenance Hydraulics All operations must be performed by and/or under direct supervision of skilled and authorized operators, using proper tools and personal protection devices if required (CE marked), according to safety regulations for working areas. The operators must be aware of the hazards and danger of the chemicals used in the process. In case of leakage of chemicals and/or in case of accident (contact with skin, eyes, etc.) follow strictly the directions mentioned on the safety bulletins of the chemicals themselves. Before any operation of taking out pipes or part of hydraulic system, it is required to release the pressure inside and empty the part of the system. WARNING: always use proper pipes and tubes. Pressure, working temperature and materials of the used tubing must be always suitable for the operating conditions of the pump as well as for the liquid to be dosed Electrical Before starting any operation on electrical devices, be sure that main power supply is OFF. All operations must be performed by skilled and authorized operators, using proper tools and personal protection devices if required (CE marked), according to safety regulations for working areas. In case of liquid leakage, switch off the main power supply before operate. Before the switching ON, be sure all the parts of the system are perfectly dry. Check that the available electrical power is correct, as shown on technical data, before connection (see Technical Characteristics). Do not make preliminary wiring connections Directions for storage, delivery, installation temperature humidity rel. notes closed rooms 5 40ºC ( F) 5 90% without condensate open space 5 40ºC ( F) 5 90% without condensate protect from sun-light and rain. trasport 5 40ºC ( F) 5 90% without condensate protect from sun-light and rain. installation 5 40ºC ( F) 5 90% without condensate protect from sun-light and rain. s.r.l.milano - ITALY Page 3 of 14 p2.04-v4.f dos_dck-mi-r1.doc

4 2. Technical characteristics temperature min max ºC (ºF) 5 40 (41 104) max viscosity of the liquid to be injected cps 40 power supply V ph/hz 230 1/50 60 max frequency pulses/min 400 protection IP65 material of the pump: body and fitting : PP (PVC-PVDF) membranes and valve seats : PTFE; balls : PYREX (ceramic) materials bottom strainer and injection fitting: PP (PVC-PVDF), FPM (EPDM) chemical compatibility gaskets made in FPM : all chemicals except alkaline ones chemical compatibility gaskets made in EPDM : all chemicals except sodium hypochlorite with sodium hypochlorite suggested FPM, PVC, PVDF and ceramic 2.1. Characteristics of the pumps The model and the main characteristcs of each pump appear on the identification label placed on the left side of the pump itself. The flow of a pump depends on many factors such as the pressure inside the system in which the liquid is injected (back-pressure) and the viscosity of the liquid (linked to its temperature), The pump works correctly when the viscosity is lower than 40 cps. MODEL DCK 601 DCK 602 DCK 901 DCK 902 DCK 903 Backpressure bar/kpa 12/ /1000 6/600 8/800 5/500 1/100 16/ / / /1000 6/600 2/200 5/500 3/300 1/100 flow rate l/h volume of single injection cm MAX height suction m peak absorption power average absorption power Ø tubing mm VA 55 VA 4x VA 55 VA 4x VA 80 VA 4x VA 80 VA 4x6 Ø injection fitting 3 / 8 " ½" 3 / 8 " ½" 3 / 8 " ½" 3 / 8 " ½" weight kg VA 80 VA 8x12 ½ " 3.2 MODELS MODELS s.r.l.milano - ITALY Page 4 of 14 p2.04-v4.f dos_dck-mi-r1.doc

5 2.2. Characteristics of storage tanks The storage tanks are made in shock-resistant plastic (PE) material. They are graduated and suitable to hold the dosing pumps; they are complete with holes and covers for liquid filling. The tanks are suitable to hold the dosing pump using the special bracket supplied with pump. The bracket has to be fixed to tank by 4 self-thread screws. A special seat in the bottom part of the pump body allows to fix the pump itself to the bracket by 2 supplied screws (M4x20). MODEL Capacity dimensions weight liters Ø mm h mm kg SL SL SL SL SL SL SL s.r.l.milano - ITALY Page 5 of 14 p2.04-v4.f dos_dck-mi-r1.doc

6 3. Installation 3.1. How to remove packaging and to move the unit The tank is wrapped in a colourless plastic foils. The pump, if already assembled on the storage tank, is protected with shock-resistant protection. Whether not assembled on storage tank, the pump is packed in a separated carton box. Open the packages and keep the cards and everything contained inside the packaging. Move carefully all components in order to avoid bumps or shock that could seriously damage it. The accessories included in standard supplying are : injection fitting bottom strainer colorless tubing for suction and the vent of the priming manual valve opaque, semirigid tubing for the forcing line screw anchor to fix the pump on the wall bracket and screws to fix the pump on the tank COMPONENTS s.r.l.milano - ITALY Page 6 of 14 p2.04-v4.f dos_dck-mi-r1.doc

7 3.2. Placing and hydraulic connections Place the tank on a perfectly flat surface Assembly the pump on the tank as explained above ( 2.2). The pump can also be fixed to the wall, using the screw anchors included in the supplying. Put in the injection fitting of the pump, included in the supplying, along the same pipe of water. Connect the suction fitting, placed on the bottom side at the center of the body pump, to the bottom strainer, using the supplied smooth colorless PVC tubing; adjust the length of the tubing in order that the bottom strainer will be at 50 mm approx from the bottom of the tank. Connect the vent fitting, placed on right side of the body-pump, to the tank, using the same tubing of the suction line. Connect the forcing fitting, placed on the top side at the center of the body-pump, to the injection fitting, using the semirigid opaque PE tubing (suitable for pressure up to 20 bars, 2000 kpa). WARNING : the forcing tubing vibrates according to the pulses of the pump. Take care that the tubing does not bump against wall or other; the continuous bumping could cause abrasion on the contact-point and, then the breaking of the tubing itself. s.r.l.milano - ITALY Page 7 of 14 p2.04-v4.f dos_dck-mi-r1.doc

8 3.3. Electrical connections The pumps do not require any ground connection, since they are made with components and technologies assuring a double insulation of all electronic components. The pumps are designed to accept small over-voltage; however, in order to avoid damage, it is prefereable that the pump has a power supply separated from the ones of other equipments that can cause over-voltage. The electrical connections are made inside the terminal box, placed in the lower part of the pump. The connections clamps can be taken out. pumps serie DCK connect the power supply (230 V, 50/60 Hz) to the clamps 1 and 2 (the power wire is supplied already connected) connect the level switch (whether provided), to the clamps 5 and 6. TENSION output available on clamps 3 and 4 for time control of external utility (230V/50/60 Hz, max 3A) WARNING : the pump is NOT equipped with ON/OFF main switch : hence it starts immediately to work when power supply is on. 4. Starting-up and priming of the pumps DCK When the installation, the electrical and hydraulic connections have been completed, proceed as follows : turn power supply ON. open the vent fitting by turning counter-clockwise the knob. keep pushed both buttons: the pumps starts to work at the max frequency of 400 pulses/minute. wait until some liquid comes out from the tubing, in order that the pump be full of liquid. release both the buttons and close the vent fitting by turning clockwise the knob. s.r.l.milano - ITALY Page 8 of 14 p2.04-v4.f dos_dck-mi-r1.doc

9 5. Description of the pumps serie DCK FRONTAL PANEL R P1 P2 P3 P5 P6 P7 P4 P8 REL LEV TIME CC CAL Enter enlighted icon REL LEV TIME CC CAL P1 P8 P xx Flow Stop button Enter DISPLAY AREA Description Auxiliary time control output is activated The liquid inside the tank is below the minimum level The hour of the day is shown The volume to be injected is shown flow rate calibration running Remaining programs to be performed during the current day The pump is on constant working mode, xx is the adjusted frequency Minimum level alarn The pump is stopped KEY-BOARD functions Button to select the working mode and confirm It allow to modify the visualization of the display The dosing pumps serie DCK are electronically controlled membrane type, with automatic time controlled dosing of the quantity of desired liquid, adjustable via software by the frontal panel. The pump works by a membrane, the movement of which is driven by a magnet. As the dimension of the injection chamber is the same, the flow of the pumps depends on the frequency (how often the magnet drives the membrane) of the pulses of the magnet. A special level switch (LEV4), can be connected to the pump in order to stop the working of the same when the tank is empty. s.r.l.milano - ITALY Page 9 of 14 p2.04-v4.f dos_dck-mi-r1.doc

10 The following functions are available : dosing of the desired quantity of chemical ( ml), at pre-set time; 8 different programs (combination of time/quantity) for each of 7 days are available (total available independent programs : 56) it is also allowed the continuous working with a fixed set up of the percentage of the frequency of the pulses (equal to the one set up for the time controlled dosing) starting up of an external device (for example a solenoid valve or another pump) according to the following mode (the set-up is only one, available for all pre-set programs) : the starting-up runs for the whole period of the dosing the starting-up has its own timing over than the duration of dosing (0 10 minutes) the additional timing of the starting-up can run before or after the dosing the starting-up can be completely turned off. whether the starting-up of external device is required, but without any dosage, it can be just programmed the time of dosing as desired, but with a correspondent volume of 0 ml set up of the percentage of the frequency of the pulses with which the dosing is made; this set up does not have any influence on the dosed quantity but only on the duration of the dosing itself. the software of the pump calculate automatically the time required to dose the pre-set volume according to the volume really injected in 30 at the max flow rate during calibration; whether the calibration is NOT made on site at the starting-up of the pump, the factory set of flow rate is used for calculation Factory-set The factory set of the pumps DCK at the shipment are the following : Dosing according to time controlled program, frequency pulses 100 % (function TC=tl, P=100). Starting-up of external device excluded (function rel= ) The following table shows the basic settings and correspondent dosages : PUMP calibration value Dosing volume setting Staring of dosing MOD. ml/30s ml time days The settings which must be modified, according to the characteristics of each application are : volume to be dosed according to the chemical used and contents of water of the system in whcih the chmical is injected (required) calibration of the flow rate (recommended) time and frequency of the dosing (optional) s.r.l.milano - ITALY Page 10 of 14 p2.04-v4.f dos_dck-mi-r1.doc

11 6. How to program the pump In order to have access to program menu, push and keep pushed the button ENTER until the display will show the notice PrG blinking (the intermediate notice HOLd has not any meanings). Release the button. The display shows the notice CLO and the icon TIME blinking. Use the arrowsorto highlight the several programming menu : 1. CLO = setting of the current time and day 2. Ad = setting of the weekly program (the same for all days) 3. rel = setting concerning the starting up of external device 4. tc = setting of working mode 5. Sd = setting of the special programs for each day 6. CAL = calibration of the flow rate The button ENTER allows to access to the programming of the visualized menu. In order to exit from programming menu push and keep pushed ENTER until the display shows current time. The exit from the menu happens automatically whether not any button is pushed for a period of 3 minutes CLO = how to adjust current time and day push ENTER, display shows the current time; modify the time using the arrowsor push ENTER to confirm, the display now shows the current day (d1 d7); modify the day using the arrowsor push ENTER to confirm. Note : the current time is kept and saved in memory, even in the case of no power supply for a period of approx 3 years Ad = how to adjust the weekly programs push ENTER, the display shows CHG push ENTER, the display shows dall, the icons TIME and P1 blink. use the arrwsorto move to another program (P2 P8 blink) push ENTER to set or modify the program, the icon of which blinks, the display shows the time of starting of dosing; modify the time of starting of dosing by using the arrowsor push ENTER to confirm, the icon CC blinks, the display shows the number of ml to be dosed; use the arrowsorto adjust the number of ml to be dosed (0 9999) push ENTER to confirm, the display shows again dall, use the arrowsorper to move to another program or to conclude the programming. in order to conclude the programming, push and keep pushed the button ENTER until the display shows the notice busy. From this moment, the pump will work according to new program, the same way all the days of the week, deleting any previous setting. NOTE : during the visualization dall, the entered programs are highlighted with the icon P1 P8 ON, the programs not entered are NOT visualized, the one currently highlighted with the icon P1 P8 blinking; in order NOT to set a program, enter the simbol , which is before the time 00.00, instead of the real time. s.r.l.milano - ITALY Page 11 of 14 p2.04-v4.f dos_dck-mi-r1.doc

12 6.3. rel = how to set the starting up of an external device push ENTER, the icon TIME blinks, use the arrowsorto select the mode : : the external device does NOT start AFt : the external device starts and is ON for the pre-set time after the end of the dosing bef : the external device starts and is ON, for the pre-set time before that the dosing starts (and it remains ON for the whole period of the dosage) push ENTER to confirm, on the display tr 1 appears, use the arrowsorto set the numbers of minutes that the external device must be ON. (0 10) push ENTER to confirm tc = how to set the working mode push ENTER, the icon TIME blinks, use the arrowsor to select the mode : CO : the pump works on constant mode regardless of any program. ti : the pump works according to the pre-set programs. push ENTER to confirm, on the display P100 appears; it is the percentage of the frequency, according to which the pump will work, constant mode as well as programmed dosages); use arrowsor to modify the frequency. push ENTER to confirm Sd = how to set the special program for each day This mode allows to set a different program for each day of the week. The program previously entered with the function Ad are already set inside the program of each day; they are highlighted with correspondent icon (P1 P8) ON. push ENTER, the icon TIME blinks, on the display d 1 appears, with the letter d blinking. push ENTER, on the display the letter d is on, the icons TIME and P1 blink. use the arrowsorto select, in case, another program (P2 P8 blink) push ENTER to set/modify the program the icon of which blinks, the time of the starting of dosing appears; use arrowsorto modify the time of starting of dosing. push ENTER to confirm, the icon CC blinks, the display shows the number of ml to be dosed; use the arrowsorto set the number of ml to be dosed (0 9999) push ENTER to confirm, the display will show again d 1, use the arrowsorto select another program (P2 P8 blink) or conclude the programming of the day by keeping pushed ENTER until the notice d 1 with letter d blinking appears again. use the arrowsorto move to another day of the week (d 1 d 7) push ENTER to set/modify the program of the other days, repeating the same operations above mentioned for the first day, or conclude the programming by keeping pushed ENTER until the notice CAL appears. NOTE : during the visualization of the days d 1 d 7 entered programs are highlighted with the icon P1 P8 ON, the programs not entered are NOT, the one currently highlighted with the icon P1 P8 blinking; in order NOT to set a program, enter the simbol , which is before the time 00.00, instead of the real time. s.r.l.milano - ITALY Page 12 of 14 p2.04-v4.f dos_dck-mi-r1.doc

13 6.6. CAL = calibration of the flow rate The calibration of the flow rate consist in making a dosage at the real conditions of working, measuring the quantity really dosed and entering the found value inside the software of the pump. Proceed as follows : prepare a graduated container with the chemical to be dosed; the capacity of the container should be approx two times the quantity of the standard calibration (see factory set table). put temporarily the suction tubing inside this container check that the pump is correctly primed; otherwise exit by the program mode, and follow the directions for priming as explained at chapter STARTING-UP AND PRIMING OF THE PUMPS. enter into calibration menu CAL. push ENTER, icon CC turns ON and the one CAL blinks, the display shows the number of ml of the calibration previously entered. push ENTER, icon CAL blinks, the display shows AdJ push ENTER, a dosing starts, for a period of 30" (visualized decreasing on display) when the dosing is completed, the icons CC and CAL blink and the display shows again the pre-set ml of calibration; now, they can be modified using the arrowsor( ml) enter as new value the number of ml really sucked from the container during the calibration dosing ; then push ENTER to confirm the entered value. put again the suction tubing at correct position inside the tank. exit from the programming by keeping pushed ENTER until the display shows current time. 7. Trouble-shooting guide In the case of disfunction, the following conditions can happen : VISUALIZATION CAUSE HOW TO SOLVE No signal on the display Power supply off Check correct power supply and the protection fuse placed on the electronic card inside the body pump. The pump does not feed the liquid, although electrically everything is OK. Icon LEV ON There is not any liquid in the tank The pump is not primed The liquid in the tank has reached the minimum level. Refill the liquid inside the tank. Clean and/or replace the hydraulic system Refill the liquid inside the tank; the icon LEV will be switched off. 8. Maintenance Common maintenance of the dosing pump consist of the cleaning of the bottom strainer. If there are deposits of the injected chemical, it can be required the cleaning or replacing of the injection system (tubing, complete body-pump, injection fitting). 9. Disposal The disposal of the unit or parts of it, must be made according to local laws concerning the waste of the materials of which they are made. s.r.l.milano - ITALY Page 13 of 14 p2.04-v4.f dos_dck-mi-r1.doc

14 10. Spare parts 1. kit body-pump complete of O-ring membrane 5. extractable connection 9. O-ring membrane 2. suction/forcing kit 6. horyzontal bracket 10. tubing fixing kit 3. membrane 7. complete magnet 11. injection fitting kit 4. cover of frontal panel 8. complete electronic card 12. bottom strainer kit In the order of spare parts It is strictly required to specify type of pump, material of body and gaskets. s.r.l.milano - ITALY Page 14 of 14 p2.04-v4.f dos_dck-mi-r1.doc