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500 GAL BATCH NEUTRALIZATION SYSTEM

UNI-SOLAR

Project: 81-227

21201 Itasca Street Chatsworth, CA 91311 Phone: (818) 998-3500 office Fax: (818) 998-4939 Web: www.wastechengineering.com

TABLE OF CONTENTS

1. 2. 3. 4. 5.

Operations and Maintenance Manual Drawings Recommended Spare Parts Bill of Material OEM Manuals

Operations and Maintenance Manual

1. 2. 3. 4. 5. 6. 7.

General Terms and Conditions - Warranty Installation Maintenance Equipment and Process Description HMI Screens and Description Troubleshooting Guide

1.

General

1.1 SYMBOLS The following symbols are used in these operating instructions: ATTENTION

Indicates items that may endanger your health or can cause equipment damage if instructions are not adhered to.

NOTE

Marks important additional information.

1.2 SAFETY NOTES Please observe the notes in these operating instructions in conjunction with the data provided are supplied in order to maximize the efficiency and operation of the system: Installation and maintenance work is to be performed only by qualified personnel whom are certified for the actions to be completed and understand fully the scope of work. Tools used for installation and/or maintenance are to be appropriate for the application. Switch off the supply voltage to the tool prior to any work performed in all cases. Safety precautions must be taken when dealing with any part of the system that is under pressure prior to commencement. Take suitable precautions to prevent inadvertent operation or damage by unauthorized action.

1.3 DELIVERY Immediately after receipt of the system, verify all components are undamaged and match the packing slip accompanying the shipment. If there are any discrepancies, please contact Customer Service: Wastech Controls & Engineering, Inc. 21201 Itasca Street Chatsworth, CA 91311 818-998-3500 Main, 818-998-4939 Fax
Section 1 General

2.

Terms and Conditions WARRANTY


Revision 6.00 WASTECH CONTROLS & ENGINEERING INC. IS THE SELLER. WARRANTY: a. Seller warrants the products sold, so far as the same are of Seller's own manufacture, against defects of material and workmanship under normal use and service for a period of 12 months from the shipping date, or as modified by the terms and conditions of the mutually agreed and accepted purchase order. This warranty does not cover ordinary wear and tear, normal component replacement, corrosion, abuse, misuse, overloading, altered products or materials not of Seller's manufacture. Component manufacturers individual warranties will apply but will always cover Sellers warranty period. Software products will be licensed to the customer and are supplied with a limited 60 day warranty from the date of the on-site performance test conducted during startup. Seller warrants the software to substantially perform in accordance with the specification if properly installed and operated on the hardware provided. During the warranty period, Seller agrees to repair or replace at its sole option and in no event shall Seller be liable for consequential damages of any kind. Continuing support beyond the warranty period will be billed on a labor and material basis pH Electrodes are consumable items that have a limited warranty period of thirty (30) days from the startup date or three (3) months from the shipping date whichever occurs first. All other consumables are excluded from the warranty. Seller warrants that the system supplied will meet the wastewater requirements specified in the proposal. This warranty applies only if the influent to the system does not differ from the original specification and the operator follows the Seller provided system instructions. Seller shall have complied with this performance warranty following the satisfactory completion of either (depending upon the language of the proposal or contract) the FAT (Factory Acceptance Test) or on-site performance test conducted during startup. The obligation of Seller under this warranty shall be limited to repairing or replacing, FOB Seller's facility, or allowing credit at Seller's option, any part or parts which may prove to be thus defective, provided that Buyer provides Seller prompt notice of the defect and, if required by Seller, confirms the defect(s) with documentation. It is expressly agreed that this remedy of repair, replacement or credit, at Seller's option, is the exclusive remedy under this contract. If an engineer is needed at the installation and the installation is located further than 400 miles from the Sellers place of business, the Buyer will pay travel expenses to the site. In no event shall Seller be liable for consequential damages resulting from the alleged defect. Seller will comply with all laws applicable to Seller. Buyer will inspect the product at delivery and determine appropriateness for his application. Compliance with basic safety issues, OSHA or similar federal, state and local laws during startup, operation or use of the product(s) is the sole responsibility of the Buyer. This warranty applies only if the influent to the system does not differ from the original specification and the operator follows the Seller provided system instructions. Seller shall have complied with any performance warranty following satisfactory completion of the on-site performance test conducted during startup.
Section 2 Warranty

b.

c.

d.

e.

f.

Wastech Controls & Engineering

g.

Under no circumstances should the equipment be used by untrained or unqualified individuals. Nor should the equipment be used until product instructions and industry standards for safety including warning and cautions provided or generally accepted have been thoroughly reviewed, read and understood. Although uses and performance capabilities are described in Sellers literature, the installer and operator are the ultimate responsible parties for the safe operation of the equipment and chemical compatibility between piping, tank, valve and other component materials of construction and the process liquids. Recommendations found in Sellers literature should be physically checked in the field and equipment should be carefully monitored during startup by factory personnel. This sale is made on the express understanding that there are no express warranties other than those contained in this agreement, and that there are no implied warranties as to fitness (process wise, mechanically or otherwise) or merchant-ability nor are there any warranties which extend beyond this description. GOVERNING LAW: The laws of the State of California shall govern the validity, interpretation and enforcement of any contract of which these provisions are a part.

h.

i.

WARRANTY START DATE:

11/17/08

Section 2 Warranty

3.

Installation
3.1 General Only properly trained and qualified individuals should perform installation procedures. Failure to follow the instructions held within or use of improper tools and procedures during the installation will invalidate the system warranty. In order for the system to operate properly, wastewater to be treated must be free of debris prior to filling the System.

Refer to the mechanical drawings for the system for installation location and arrangement details. The required reagent chemical(s) for the system are: o o 50% Sulfuric Acid (H2SO4) or Citric Acid

3.2 Electrical Power Requirements All electrical connections should be sealed properly to prevent water from entering the conduit. Failure to do so will invalidate the warranty.

Follow local, State, and federal regulations in addition to all company policies in regards to wiring. It is up to the installation team to determine and follow relevant guidelines. The power supply to the panel should be conditioned in order to protect the system, as well as ensure proper operation. Voltage sags and spikes can be damaging over time.

At the time of commissioning, it is suggested that the incoming power source (i.e. voltage, phase and frequency) is verified before applying power to the system.

Refer to the electrical drawings for the system power supply and wiring interconnection requirements.

A visual inspection is necessary to verify that no damage occurred during shipment and that there are no loose wire terminations. The required power supply for the system is 120 VAC, 1-phase, 60 Hz, 30 Amps.
Section 3 Installation

Wastech Controls & Engineering

3.3 Equipment Installation and Commissioning Procedure Installation (By Others) 1. Unpack the unit and remove all shipping packaging. 2. Inspect the unit for damage due to shipment. 3. Carefully move the unit into place. 4. Anchor the unit as shown on the mechanical drawings and as required by the owner and local building authorities. 5. Connect the process piping as indicated on the drawings. 6. Connect any field installed wiring as indicated on the drawings. 7. Connect the electrical incoming power supply to the main disconnect. Physical Inspection (Power OFF) 8. Verify all mechanical connection points are tight and have not become loose during shipment or installation. 9. Verify that all electrical terminations have been completed properly. 10. Verify all installation work by others has been completed and the system is ready to be powered. 11. Remove the pH electrode from the neutralization tank (AE-2) then remove the cap from the tip of the pH electrode. Then re-install back into the corresponding Tank. 12. Verify that the Process Switch is in the OFF position. 13. Fill the system with tap water or wastewater to prevent the pH electrodes from drying out. Testing and Commissioning (Power ON) 14. Turn the main power supply disconnect switch to the ON position. 15. Verify each component on the panel is powered. 16. Verify pH electrode readings. Recalibrate the pH electrodes if necessary. Follow the procedure described in the OEM Manual (+GF+ Signet pH Transmitter) for these steps. 17. Set the Process Switch to the ON position. 18. Verify that the mixer is ON and providing good mixing in the tank (Only when level switch LSH-T2 is wet). 19. Prime the metering pumps by following the procedure in the OEM Manual. 20. Verify proper metering pump actuation in manual mode. 21. Verify proper metering pump actuation in external mode. 22. Verify that all pumps operate correctly according to the Process Description. 23. Verify all alarm actuation and system responses are operating correctly. 24. Complete a batch treatment sequence and evaluate the results. Modify the setpoints as needed to adjust the process to operate as designed. Repeat this until the results are satisfactory. 25. Demonstrate system operation to the Owners technicians and complete the system orientation.

Section 3 Installation

Wastech Controls & Engineering

26.

Complete the Site Acceptance Test form and obtain the signature of the Owners representative.

3.4 pH Electrode Verification and Calibration Whenever calibrating components that require use of hazardous chemicals, power, or procedures it is imperative that proper safety measures are employed in order to protect all parties involved. The pH electrodes included with this system were factory calibrated prior to shipment, but may need to be recalibrated prior to commissioning. Please see the component OEM manuals, in addition to this document, for the procedures involved in calibration of the electrodes. It is recommended that the pH electrode(s) be verified at least once each month, or as required by local authorities, and that a verification log be maintained. pH electrodes should be recalibrated as often as necessary, based on the results of the verification check, or as required by local authorities. pH electrodes will wear out over time; they should be replaced and calibrated when they fail the verification check and calibration procedures. To perform the pH electrode calibration procedure, it is recommended that you have buffer solutions available with pH of 4, 7 and 10. Calibration should be performed using fresh, clean buffer solutions. A minimum of 50 ml of solution should be used. The solution should be discarded after use (never returned to original bottle). The proper calibration procedure must be performed whenever the pH electrode is replaced. pH Electrode Verification Procedure 1. 2. 3. 4. 5. 6. Pour buffer solution(s) into suitable container(s). Turn the Process Switch to the OFF position. Carefully remove the pH electrode from the tank and wipe off excess fluid. Rinse the pH electrode with fresh or deionized (DI) water. Place the electrode in the 7 pH solution (swirl around for a few seconds). Check the pH Transmitter display and verify that the measured reading is within + 0.1 pH of the buffer solution pH value. If not, then recalibrate the electrode. 7. Replace the pH electrode to its original location. 8. If calibration is necessary, follow the calibration procedure per the manufacturer manual. 9. Turn the process switch to the ON position. 10. Update the verification log with the results 11. Procedure is now complete.

Section 3 Installation

Wastech Controls & Engineering

pH Electrode Calibration Procedure (Easy-Cal) 1. 2. 3. 4. Pour buffer solution(s) into suitable container(s). Turn the Process Switch to the OFF position. Carefully remove the pH electrode from the tank and wipe off excess fluid. Rinse the pH electrode with fresh or deionized water.

5. Go to the calibration menu on the pH Transmitter display, by pressing the ENTER buttons for 2 seconds, CALIBRATE ---- Enter Key Code will be displayed. 6. Press three up and one down button to continue. 7. Set: Temperature > will be displayed. a. Press button, temperature +xxx.x C will be displayed, the first segment will blink. b. Use buttons to enter the correct temperature value of the buffer solution where the pH electrode is located. c. Press the Enter button, Saving will be displayed. 8. Press the down button. Set: Standard > will be displayed a. With the pH electrode in 7.0 pH Buffer press button, a pH and mV value will be displayed. b. Use buttons to enter buffer value 07.00 pH . c. Press the Enter button, saving will be displayed. 9. Thoroughly rinse pH electrode in fresh water. 10. Place pH electrode into the 4.0 pH Buffer, gently swishing for ~10 seconds, allowing electrode assembly to stabilize. 11. From pH display, go to the Easy Cal mode, by pressing the button one time. The display will show EasyCal>. 12. Press button, EASY---- will be displayed. 13. Enter three up and one down buttons to continue. 14. BUFFER 1 will be displayed, then it will show a pH to mV value. With the pH electrode still in 7.0 pH Buffer press the Enter button. 15. Buffer 2 will be displayed, then it will show a pH to mV value. 16. Rinse pH electrode in fresh water to remove buffer residue. 17. Place pH electrode in 4.0 pH Buffer, gently swishing for ~10 seconds, allowing measurement to stabilize. 18. Press Enter button, saving will be displayed. Unit will automatically return to main pH display. 19. Replace the pH electrode to its original location. 20. Turn the process switch to the ON position and update the verification log with the results.

Section 3 Installation

Wastech Controls & Engineering

Section 3 Installation

4.

Maintenance
4.1 Preventative Maintenance Only properly trained and qualified individuals should perform maintenance procedures. Failure to follow the instructions held within or use of improper tools and procedures during the installation will invalidate the system warranty. All personnel that may be exposed to hazardous chemicals or electricity should don appropriate personal protection equipment (PPE) for the task being performed.

Please observe the procedures listed in the included OEM manuals when servicing any components. General System Cleaning and Maintenance: o The pumps, tanks, mixer and valves do not require periodic maintenance. o Keeping a maintenance log is recommended for trend analysis. o Operating variables can lengthen or shorten the operating life of pH electrodes. o The glass surface of the pH Electrode must be kept wet at all times. If it is allowed to dry out, it may fail prematurely. If the system is to be idled for more than 24 hours (for maintenance or other operational reasons) the pH Electrode must be kept hydrated by removing the electrode from the tank and soaking the tip in pH 4.0 buffer solution. o If the pH Electrode is allowed to dry out for more than 4 hours, try soaking the electrode in pH 4 buffer solution for 24 to 48 hours, then visually inspect the electrode for surface cracks, swelling, or discoloration. Severely dehydrated electrodes cannot be restored to normal operation, and must be replaced. o When storing boxed, spare pH electrodes, lay the electrode flat to maximize hydration of the glass surface. pH Electrode Verification: o Perform this procedure monthly, or as required by Owner and/or Local Authorities

pH Electrode Recalibration: o Perform this procedure as required from results of pH Electrode Verification procedure

pH Electrode Replacement and Calibration: o Replace the pH Electrode as frequently as required from results of pH Electrode Calibration procedure

Section 4 Maintenance

Wastech Controls & Engineering

pH Electrode Cleaning: o o Cleaning techniques vary depending on the type of coating present on the glass electrode surface or reference junction. Soft coatings can be removed by vigorous stirring, or with directed spray of an applicable detergent or solvent onto the glass electrode surface. Chlorine bleach or mild detergent may be used to remove soft coatings. Always rinse electrode tip in clean water after cleaning. Hard coatings can be chemically removed. Use the least harsh chemical which will remove the contaminant within two (2) minutes without attacking the materials of construction. e.g. calcium carbonate may be removed with a 5% HCL (muriatic acid) solution. Oily or organic coatings can be removed with detergents or an appropriate solvent that does not attack the materials of construction e.g. isopropyl alcohol may be used but acetone must be avoided to prevent damage to the CPVC electrode body

Section 4 Maintenance

UNI-SOLAR

Process and Equipment Description 500 Gal Batch pH Neutralization System

Project No.: 81-227

21201 Itasca Street Chatsworth, CA 91311 Phone: (818) 998-3500 office Fax: (818) 998-4939 Web: www.wastechengineering.com

Wastech Control & Engineering Project No.81-227

500 Gal Batch pH Neutralization System Uni-Solar

Process and Equipment Description


1. Process Description The 500 Gal Batch pH Neutralization System consists of the following major components: One (1) 500 Gal Reaction Tank (T-2) with One (1) Mixer (M-2) One (1) PP Horizontal Centrifugal Pump (P-2) One (1) Acid Metering Pump (P-1) Five (5) Level Switches (LSL T-1, LSL T-2, LSH T-2, LSHH T-2, LD T-2) One (1) Flow Meter Sensor (FE 2) One (1) pH Probes (AE 2) One (1) PLC-based Control System The Control System controls pH adjustment within Reaction Tank T-2 and monitors and records the effluents flow to verify that the waste discharged has a pH between 6 and 9. 2. Equipment Description 2.1 Reaction Tank (T-2) The Reaction Tank (T-2) is where the waste water is neutralized. Waste water influent is transferred from an existing sump into the Reaction Tank using an existing pump. During the neutralization process a metering pump adds acid to the reaction tank. The Mixer (M-2) provides mixing inside the Reaction Tank to assist in the complete and efficient neutralization of the waste water. As the water is pumped using a transfer pump (P-2) to the sewer the flow is recorded and logged in the PLC. The Reaction Tank consists of the following equipment:

a)

Reaction Tank (T-2) Reaction Tank (T-2) is a 500 gallon molded PP tank equipped with three Level Switches, mixer and pH probe.

b)

Centrifugal Pumps (P-2) The Centrifugal Pumps (P-2) is a horizontal centrifuge pump made out of PP and has an operating capacity of 30 gpm at 33 TDH.

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500 Gal Batch pH Neutralization System Uni-Solar

c)

Level Switch (LS T-2) The three level switches control the operation based on the liquid level within the Reaction Tank (T-2). The Low Level Switch (LSL T-2) stops Pump (P-2) to prevent it from running dry and activates the existing transfer pump to re-fill the Reaction Tank. The High Level Switch (LSH T-2) de-activates the existing transfer pump stopping the filling and starts the neutralization process. High High Level Switch (LSHH T-2) triggers an audio/visual alarm when made to alert the operator that the tank is about to overflow.

d)

pH Probe (AE T-2) The pH Probe (AE T-2) measures the pH in the Reaction Tank when the waste water is being neutralized and is logged by a digital data recorder.

e)

Leak Detector (LD T-2) Leak Detector Switch (LD T-2) triggers an audio/visual alarm when made to alert the operator that the tank is leaking or overflowing.

2.2 Monitoring Pipe Spool a) Flow Meter (FE 2) The flow meter sensor measures the effluent flow rate and is logged by a digital data recorder.

2.3 Chemical Delivery System The Chemical Delivery System transfers acid to the Reaction Tank when directed by the Control System. The Chemical Delivery System includes the following equipment: a) Acid Metering Pump (P-1) Acid Metering Pump (P-1) pumps acid into the Reaction Tank when the pH of the waste water is above the set point. b) Level Switch (LSL T-1) Level Switch (LSL T-1) activates an alarm when the level gets low indicating that the acid tank needs to be refilled. END OF PROCESS DESCRIPTION

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UNI-SOLAR

HMI Screens and Description 500 Gal Batch pH Neutralization System

Project: 81-227

21201 Itasca Street Chatsworth, CA 91311 Phone: (818) 998-3500 office Fax: (818) 998-4939 Web: www.wastechengineering.com

Wastech Controls & Engineering Project No. 81-227

Batch Neutralization System Uni-Solar

1.0

MAIN MENU The HMI consists of several screens that are accessible by an operator. The main menu screen acts as a portal to all sub-screens and sub-systems.

Each screen can be accessed by selecting the appropriate screen push-button located along the right side of the screen.

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2.0

STATUS OVERVIEW (Screen 1) The status overview display provides visual feedback to the operator.

Status Screen 1 shows the current operating status of the batch neutralization system. Reaction Tank T-2 displays include: 1. 2. 3. 4. 5. 6. 7. 8. Current level sensor status (dry/wet) for low, high, and high high level sensors Current pH reading. Current acid pump (P-1) speed (in percent) Current discharge pump (P-2) status (run, idle) Current mixer (M-2) status (run, idle) Current inlet permissive status (open, close) Current discharge valve (ABV-2) status (open, close) Current T-2 sequence status, multi-state indicator located in the upper right corner of the screen. (T-2 filling, T-2 treat, T-2 drain)
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Wastech Controls & Engineering Project No. 81-227

Batch Neutralization System Uni-Solar

9. Current acid set-point, and high and low pH limits (HMI adjustable) 10. Active batch timers for monitoring time for pH adjustment, T-2 drain, and pH OK timer.

Acid tank T-1 displays include: 1. Current level sensor status (dry/wet) for low level sensor The return RET push-button will return the operator to the main menu. The HELP push-button displays:

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3.0

Settings menu The Settings Menu is a portal to all selectable system parameters. Select the desired category by selecting the appropriate parameter push-button. The return RET pushbutton will return the operator to the main menu, the status STAT push-button will return the operator to the system status screen.

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3.1.1 Reaction Tank T-2 pH Metering Pump Tuning

All of these fields are numeric inputs used to dial-in the chemical addition based on the sensitivity of the systems chemistry. 1. Set-point: is the target value for each respective pump. Low pH is adjusted by the caustic set-point and High pH is adjusted by the acid set-point. 2. Gain: is defined as percent controller output per percent transmitter output (%CO/%TO). It defines the rate in which the controller ramps up or down the pump speed based on the difference of the monitored variable from set-point. 3. pH Dead-band: prevents on/off chatter of the chemical pump around the target setpoint. If the Acid set-point is 5.7, then the chemical pump will continue to add chemical until the pH reading is 5.67 (If the dead-band is set to .03) and the acid pump will not start until the pH rises to 5.73. 4. Bias: is the percent speed in which the pump runs while crossing the set-point. To speed up the titration process it is beneficial to have a value in bias so the system
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Wastech Controls & Engineering Project No. 81-227

Batch Neutralization System Uni-Solar

does not take to long creeping to the set-point. For example if the acid pump has a bias value of 10% then as the pH reading matches the set-point, the chemical pump is running at 10% speed. If dead-band is enabled then the pump will remain running at 10% speed until the Set-point + Dead-band value is reached. Following item 3 when the pH matches 5.7 the pump is running 10 % until the pH lowers to 5.67 at which point the pump is turned off. 5. Start Damp: is a preset timer that delays chemical addition when the pH drifts from set-point. For example if acid start damp is 5, when the pH drifts below the acid setpoint, after 5 seconds then the acid delivery will begin. Useful for fast oscillating reactions. 6. On-Time: used in conjunction with the OFF-Time, these two timers cycle the pump on and off during neutralization. Particularly useful in buffered solutions. 7. Off-Time: See point 2. If no off-time is desired, set the off-time value to zero.

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Batch Neutralization System Uni-Solar

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3.1.2 Reaction Tank T-2 pH Limits

This screen is used to input the upper and lower pH limits for reaction tank 2 discharge tolerances. These settings are not used for control of the chemical metering pumps, but are used for pH alarms. The pH IN RANGE DAMP TIMER (pH OK) keeps track of the duration of time the pH remains within acceptable discharge limits while the reaction tank is in the pH treat mode. When this timer expires during the RT-2 treatment step, the batch is permitted move to the next appropriate step. The WARNING OFFSET is used as a pre-emptive alarm. Alarm is triggered if the pH > high setpoint offset during discharge, or pH < low setpoint + offset during discharge. The DRAIN INTERLOCK is used to halt any draining of the reaction tank into the sewer. This interlock will cause the batch to re-evaluate its current status and either return to the pH treatment mode or if necessary refill to the high level.

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3.1.3 Batch Settings

This screen is used to input tank RT-2 batch alarms. The EXCESS TREAT TIME is used to monitor the time required for the reaction tank to neutralize a full batch to current limits. The EXCESS DRAIN TIME is used to monitor the time required for the reaction tank to empty its contents to the low level.

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4.0

Maintenance Menu The maintenance menu is a portal to two screens. Select the desired category by selecting the appropriate parameter push-button.

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4.1.1 Tank T-2 HOA

The maintenance screens provide the user with the ability to bump (jog) equipment based on location. Pressing the SET button will energize or de-energize the respective device output. Analog devices also include a numeric input which allows the operator to input a required run speed.

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4.1.2 Sequence Reset

To reset the current batching sequence: 1. Place the process switch (located on the front of the main control panel) to off. 2. Press the reset PB (pushbutton).

This will default the sequence back to step one (T-2 fill).

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5.0.1 Active Alarms

The active alarm screen displays all currently active alarms in the system. If blank then there are no active alarms. Press the Alarm History PB to view the alarm history screen.

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5.0.2 Alarm History

The alarm history records information on triggered alarms in the terminal. Each alarm is time/date stamped, with a maximum queue of 50 alarms. All alarms whether active or inactive will be displayed.

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6.0

Alarm Banner The alarm banner is a display that pops up over the current screen when an alarm is triggered. All screen objects (or covered objects) are temporarily disabled. The banner contains a message describing the alarm condition. It also contains alarm buttons that allow the operator to act on the alarm. When alarms are triggered, they are added to the Alarm List. When the alarm in the banner is acknowledged or cleared, the next alarm is displayed. The banner displays messages in chronological order (most recent triggered alarm first).

The ACKNOWLEGE button acknowledges receipt of the alarm currently displayed in the alarm banner. Pressing the close display (located in the upper right corner) button removes the banner from the terminal display but does not clear the alarm condition. The alarm is marked as acknowledged in the alarm list.

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7.0

Alarms 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. ACID TANK T-1 LOW LEVEL ALARM T-2 LOW LEVEL SENSOR FAILURE T-2 HIGH LEVEL SENSOR FAILURE pH TRANSMITTER CURRENT (mA) FAULT LEAK ALARM T-2 HIGH HIGH LEVEL ALARM E-STOP ACTIVATED T-2 EXCESS TREATMENT TIME T-2 EXCESS DRAIN TIME T-2 DRAIN pH OUT OF RANGE T-2 DRAIN pH WARNING LIMIT

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UNI-SOLAR

Trouble Shooting Guide 500 Gal Batch pH Neutralization System

Project: 81-227

21201 Itasca Street Chatsworth, CA 91311 Phone: (818) 998-3500 office Fax: (818) 998-4939 Web: www.wastechengineering.com

Wastech Controls & Engineering Project No. 81-227

500 Gal Batch Neutralization System UNI-SOLAR

Alarm Banner pH Transmitter Current (mA) Fault

Possible Cause(s) 1-pH probe is disconnected from preamplifier. 2-Process Pro has lost power.

Corrective Action(s) 1-Inspect pH probe to ensure that probe is properly connected to preamplifier. 2- Inspect Process Pro, if the screen is blank the Process Pro has lost power. 3-Verify pH display on Process Pro. If the Process Pro has power and the pH probe is connected properly then the pH probe has failed. Replace the pH probe. 1-Inspect wiring between the panel and the level switch. 2-Replace level switch.

3-pH probe has failed.

T-2 Low Level Sensor Failure

1-The wiring to the level switch is disconnected 2-A level switch has failed.

T-2 High Level Sensor Failure T-2 High High Level Alarm T-2 Excess Treatment Time

See T-4 Low Level Sensor Failure 1-Pump P-1 malfunction 1-pH probe fouled. 2-pH probe malfunction 1-Refer to T-2 Low Level Sensor Failure. 1-Clean pH probe. 2- Inspect/calibrate pH probe and replace if necessary. 3-Adjust the neutralization set points to make the adjustment more aggressive. And/or increase the Excess Time Out of Range timer. 4- Replace broken valve and or piping. 5-Replace/repair
Page 2 of 4 Section 7

3-Delay in or slow neutralization reaction.

4- Chemical injection failed due to broken valve or leak in piping. 5-Agitator failed,
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Wastech Controls & Engineering Project No. 81-227

500 Gal Batch Neutralization System UNI-SOLAR

Alarm Banner

Possible Cause(s) causing incomplete mixing. 6-Wastewater contains chemicals that are buffering the pH.

Corrective Action(s) agitator. 6-Remove buffering chemicals from waste water or increase timer for Excess Time Out of Range alarm. (Increasing the timer may not solve the problem).

T-2 Excess Drain Time

1-ABV-2 Ball Valve Not opening 2-Pump P-2 failed causing no transfer out of Reaction Tank T-2.

1-Check CDA Supply to valve 2-Inspect wiring between control panel and pump

T-2 Drain pH Out of Range

1- pH probe fouled. 2- pH probe malfunction.

1- Clean pH probe. 2- Inspect/calibrate pH probe and replace if necessary. 3- Refer to T-2 Excess Treatment time troubleshooting. 4- Remove buffering chemicals from waste water or increase timer for excess time out of range alarm. (Increasing the timer may not solve the problem). 1- Refill Acid Tank (T-1) with acid. 2-Inspect wiring, replace level switch if necessary. 1-Verify pH reading of waste water with pH paper, if the pH probe indicates a different
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3- Tank 2 pH adjustment malfunction. 4- Wastewater contains chemicals that are buffering the pH.

Acid Tank T-1 Low Level Alarm

1- Acid level low in Acid Tank (T-1). 2-Level switch LSL T-1 failed.

T-2 Drain pH Warning Limit

1-pH probe AE T-2 needs calibrating

Nov 20, 2008 Rev. 0

Wastech Controls & Engineering Project No. 81-227

500 Gal Batch Neutralization System UNI-SOLAR

Alarm Banner

Possible Cause(s)

Corrective Action(s) value calibrate pH probe. 2-Extend Treatment Time 1-Check tank/fittings for leaks 2-Replace leak switch Pull out button

2-Neutralization Reaction not complete prior to discharge Leak Alarm 1-Waste water leaked into containment 2-Leak switch failed E-Stop Activated E-Stop button pushed

Nov 20, 2008 Rev. 0

Page 4 of 4 Section 7

Drawings

1. 2. 3. 4. 5. 6. 7.

81227-PI-101 - Process and Instrument Diagram 81227-MG-101 - Mechanical General Arrangement 81227-EE-101 - Electrical Wiring Diagram 81227-EE-102 - Electrical Wiring Diagram 81227-EE-103 - Electrical Wiring Diagram 81227-EE-104 - Electrical Wiring Diagram 81227-EP-101 - Panel Layout

88 in NOZZLE

NOZZLE SCHEDULE DESCRIPTION 2" FNPT 1-1/2" FLG. 2" FNPT 3/4" HOSE ADAPTER QTY 1 1 1 1 SERVICE INLET FROM EXISTING SUMP DISCHARGE TO THE SEWER VENT PORT W/ SCREEN DRAIN TO THE SUMP

P-1

N3

N1

M-2 N4

N1 N2 N3

LSL T-1

N4

NOTES:
CONTROL PANEL 1. SKID SHALL BE CUSTOM FABRICATED FROM 3/4" THK WHITE POLYPROPYLENE. 2. REACTION TANK SHALL BE MOLDED FROM POLYPROPYLENE. 3. ALL FITTINGS AND PIPING SHALL BE CPVC SCH.80, UNLESS OTHERWISE SPECIFIED. 4. ALL INSTALLATION, INTERCONNECTING PIPING AND WIRING PROVIDED BY OTHERS.

65 in

LD T-2

LSHH T-2 LSH T-2 LSL T-2

AT T-2 AE T-2

A B
N2

FE-2

ABV-2
12" X 12" VIEWPORT W/ 1/4" CLEAR PVC COVER

P-2

PLAN VIEW
59 in

SV-2

N2

FE-2

ISOMETRIC VIEW
14 in 19 in

ER: 11893-C1 Date: 8-7-08 BY: D.B.


REV. DATE: BY: DESCRIPTION

LSL T-1

LSHH LSH
87 in 5 30 in 62 3/8 in 53 in 56 in

2 1 0

11/18/2008 09/22/2008 09/12/2007

JM JM JM

AS-BUILT ISSUED FOR FABRICATION SUBMITTED FOR APPROVAL DATE 09/12/2008 09/12/2008 09/12/2008

APPROVALS DRAWN BY: PROJECT ENG.: 30 in ENGINEERING MANAGER: JM KS KPH

PROPRIETARY INFORMATION
7 in 39 in 3 24 5/8 in 4 1/2 in 7 in 6.5 in TITLE:
21201 Itasca Street, Chatsworth, California 91311-4922
Tel: (818) 998-3500 Fax: (818) 998-4939 www.wastechengineering.com
C

2008 WASTECH CONTROLS & ENGINEERING, INC.

2" FNPT W/ PLUG FOR DRAIN

LSLL

THIS DRAWING AND ALL INFORMATION HEREON IS THE PROPERTY OF WASTECH CONTROLS & ENGINEERING INC. ANY COPYING, REPRODUCTION OR UNAUTHORIZED USE WITHOUT WRITTEN CONSENT IS PROHIBITED.

88 in

65 in

GV2CD-WW-306-201 500 Gal. Batch pH Neutralization System Mechanical General Arrangement DWG. NO. 81227-MG-101

REVISION 2

SECTION A-A

SECTION B-B

SIZE
B

SCALE: NTS

SHEET: 1 OF 1

BILL OF MATERIAL RECOMMEND SPARE PARTS LIST


Project No.: 81-227 Description: 500 Gal. Batch pH Neutralization System Customer: United Solar Ovonic Date: 11/03/08 Revision: 0 Item Rev Tag UOM Qty Description Mfr P/N

P-2

EA

Horizontal Centrifugal Pump, 30 GPM @ 33 Feet TDH, 1/2 HP, 115 VAC, 1-PH, 60 HZ, PP, 1.5" MNPT Suction/Discharge, Completed Assembly (Motor and Pump Head) Reaction Tank Mixer/ Lightnin, 115 VAC, 1-PH, 1/4" HP Actuator for 2" Ball Valve, Air to Open, Spring to Closed. Reaction Tank Level Switches, Normally Open, 25 Ft Cable Reaction Tank Level Switches, Normally Closed, 25 Ft Cable Reaction Tank pH probe pH Preamplifier Discharge Line Flow Meter Level Switch, PP, 3/4" MNPT Acid Metering Pump, 3.2 GPH, 115 VAC, PP W/ FKM FUSE, CLASS CC, 5 AMP FUSE, CLASS CC, 10 AMP FUSE, CLASS CC, 15 AMP Power supply, 24vdc, 2.5 AMP, 60W,120vac in FUSE, CLASS CC, 30 AMP SLIM PLC, CPU MODULE, 24 VDC POWER 8 IN / 8 OUT Power supply, 12vdc, 0.6 AMP, 7.5W,120vac in Calibration Chemicals Buffer Solution pH 4 Buffer Solution pH 7 Buffer Solution pH 10

Iwaki

MX-400CV6, VL3503

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

M-2 ABV-2 LSL T-2 LSH T-2 LSHH T-2 AE T-2 AT T-2 FE-2 LSL T-1 P-1 FU4 FU3 FU2 PS2 FU1 PLC PS1 BUFFER BUFFER BUFFER

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

2 2 4 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1

Lightnin Asahi Conery Conery Signet GF Signet Signet Flowline Grundfos Bussman Bussman Bussman Idec LITTELFUS E IDEC Idec Wastech Wastech Wastech

EV5P25 2302020 2900-B3-S125 2901-B3-S125 3-2714. 3-2720. 3-2536-P0 LV10-1201 DME126ARPP/V/CF2-1RRB FNQ-R-5 FNQ-R-10 FNQ-R-15 PS5R-SD24 CCMR30 FC5AD16RS1 PS5R-A12 612-404 612-407 612-410

Page 1 of 1 Printed on 11/3/2008 @ 4:13 PM

BILL OF MATERIAL MECHANICAL & INSTRUMENTATION EQUIPMENT


Project No.: 81-227 Description: 500 Gal. Batch pH Neutralization System Customer: United Solar Ovonic Date: 10/30/08 Revision: 0 Item Rev Tag UOM Qty Description Mfr

ER: 11893-C1 Date: 8-7-08 BY: D.B.

P/N

P-2

EA

Horizontal Centrifugal Pump, 30 GPM @ 33 Feet TDH, 1/2 HP, 115 VAC, 1-PH, 60 HZ, PP, 1.5" MNPT Suction/Discharge, Completed Assembly (Motor and Pump Head) Cylindrical Molded Tank, 500 gallon (52"Dia. X 60"H) PP Reaction Tank Mixer/ Lightnin, 115 VAC, 1-PH, 1/4" HP Ball Valve for ABV, Sch 80 CPVC, 2" Actuator for 2" Ball Valve, Air to Open, Spring to Closed. StandAlone Solenoid Valve, 110 VAC Lock Out Valve, 1/4" Tee Bracket Filter Regulator Gauge For Regulator Reaction Tank Level Switches, Normally Open, 25 Ft Cable Reaction Tank Level Switches, Normally Closed, 25 Ft Cable Reaction Tank pH probe pH Preamplifier Discharge Line Flow Meter Signet CPVC Tee Fitting, 1.5" Signet Sensor End Cap. Level Switch, PP, 3/4" MNPT Acid Metering Pump, 3.2 GPH, 115 VAC, PP W/ FKM Installation Kit for Metering Pump 16 Feet Cable and Plug Kit for Metering Pump Switch-Tek Optic Leak Detection Switch, PP, 3/4" MNPT HP motor, 1800 TEFC, 115/230 V single phase, without cord assembly.

Iwaki

MX-400CV6, VL3503

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0

T-2 M-2 ABV-2 ABV-2 SV-2 SV-2 SV-2 SV-2 SV-2 LSL T-2 LSH T-2 LSHH T-2 AE T-2 AT T-2 FE-2 FE-2 FE-2 LSL T-1 P-1 P-1 P-1 LD T-2

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1

Chem-Tainer Lightnin Asahi Asahi SMC SMC SMC SMC SMC Conery Conery Signet GF Signet Signet GF+Signet GF+Signet Flowline Grundfos Grundfos Grundfos Flowline BALDOR

TC5260AB EV5P25 16013020 2302020 VQZ3153YZ 03T VHS30-N02Z Y300T AW30-N02HZ K-10 2900-B3-S125 2901-B3-S125 3-2714. 3-2720. 3-2536-P0 CPV8T015F P31542 LV10-1201 DME126ARPP/V/CF2-1RRB 96479881 96440448 LO10-1305 271791PSP

Page 1 of 4 Printed on 11/21/2008 @ 9:59 AM

BILL OF MATERIAL MECHANICAL PIPE, FITTINGS, VALVES & MISC. HARDWARE


Project No.: 81-227 Description: 500 Gal. Batch pH Neutralization System Customer: United Solar Ovonic Date: 10/23/08 Revision: 0 Item Rev Tag UOM Qty Description Mfr

ER: 11893-C1 Date: 8-7-08 BY: D.B.

P/N

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 2 0 0 0

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA FT FT FT SHT EA EA EA EA EA EA EA

3 1 1 2 2 1 1 1 1 1 1 2 1 1 1 1 5 20 20 20 6 1 1 1 1 40 1 3

Coupling, PP-Blk, TxT, 2" Male Adapter, CPVC, MNPTx Soc, 3/4" Flange, Van Stone, CPVC, Soc, 11/2" Ball Valve, CPVC w/ FKM O-Ring, Soc x Fnpt, 1-1/2" Elbow, CPVC, Soc, 1-1/2" Reducer Bushing, CPVC, Spig x Soc, 1-1/2" x 3/4" Ball Valve, CPVC w/ FKM O-Ring, Soc x Fnpt, 3/4" Nipple, CPVC, TxT, 2" x 3" Long Elbow, CPVC, Soc, 2 Tee, CPVC, Soc, 2" Reducer Bushing, CPVC, Spig x Soc, 2" x 1-1/2" Female Adapter, CPVC, Soc x Fnpt, 1-1/2" Tee, CPVC, Soc, 1-1/2" Reducer Bushing, CPVC, Spig x Soc, 2" x 3/4" Check Valve, CPVC w/ FKM Oring, 1-1/2" Tee, CPVC, Soc, 3/4" Elbow, CPVC, Soc, 3/4" CPVC Sch 80 pipe, 3/4" OD CPVC Sch 80 pipe, 1-1/2" OD CPVC Sch 80 pipe, 2" OD PP Sheet, 3/4" Thick, 4' x 8' Female Adapter, CPVC, Soc x Fnpt, 3/4" Nipple, CPVC, TxT, 2" x 6" Long Ball Valve, CPVC w/ FKM O-Ring, Soc x Fnpt, 3/4" Male Adapter, CPVC, MNPTx Soc, 3/4" PIPE, 3/4" SCH.80 PVC MALE ADAPTER, CPVC SCH.80, 3/4" MNPTXSOC 3/4" FNPT X SLIP CPVC SCH80, ADAPTER

Nibco Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Spears Simona Spears Spears Spears Spears Spears Spears Spears

2830-020 836C-007 854C-015 1839C-015 806C-015 837C-210 1839C-007 887C-030 806C-020 801C-020 837C-251 835C-015 801C-015 837C-248 4539C-015 801C-007 806C-007 800C-007 800C-015 800C-020 835C-007 887C-060 1839C-007 836C-007 800-007 836C-007 835C-007

Page 2 of 4 Printed on 11/21/2008 @ 9:59 AM

BILL OF MATERIAL ELECTRICAL EQUIPMENT & MATERIALS


Project No.: 81-227 Description: 500 Gal. Batch pH Neutralization System Customer: United Solar Ovonic Date: Enter Rev Date Revision: 0 Item Rev Tag UOM Qty Description Mfr

ER: 11893-C1 Date: 8-7-08 BY: D.B.

P/N

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

DISC DISC DISC FU4 FU3 FU2 CB1 CB2 CB3 PS2 FU1 SSW2 PLC PLC PLC PLC DISPLAY DISPLAY BUZZER ALARM LIGHT AT-4,5 FT-5 DATA LOGGER DATA LOGGER PS1 SSW1

EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1

NON-FUSIBLE DISCONNECT SWITCH, 30 AMP NON-FUSIBLE DISCONNECT SWITCH, 60 AMP PISTOL HANDLE, NEMA 4X FUSE, CLASS CC, 5 AMP FUSE, CLASS CC, 10 AMP FUSE, CLASS CC, 15 AMP CIRCUIT BREAKER, 1 POLE, 0.5AMP CIRCUIT BREAKER, 1 POLE, 1 AMP CIRCUIT BREAKER, 1 POLE, 2AMP Power supply, 24vdc, 2.5 AMP, 60W,120vac in FUSE, CLASS CC, 30 AMP 3-POSITION SELECTOR SWITCH, 2NO SLIM PLC, CPU MODULE, 24 VDC POWER 8 IN / 8 OUT ANALOG OUTPUT MODULE ANANOG INPUT MODULE DC INPUT MODULE 6" MONOCHROME TOUCHSCREEN COMMUNICATION CABLE PIEZO WARBLER -24VDC Pilot light, LED, 24VDC, RED PROCESS-PRO PH TRANSMITTER, PANEL MOUNT PROCESS-PRO FLOW TRANSMITTER, PANEL MOUNT DATACHART 1250, CHANNEL 1: PH 4-20mA/ 0-14 PH, CHANNEL 2: FLOW 4-20mA / 0-50 GPM, 12VDC POWER NEMA 4 COVER FOR DATACHART 1250 Power supply, 12vdc, 0.6 AMP, 7.5W,120vac in Selector switch, 2-position maint., non-illuminated, 1 NO

ABB ABB ABB Bussman Bussman Bussman MOELLER MOELLER MOELLER Idec LITTELFUS E IDEC IDEC Idec Idec Idec Idec Idec INGRAM Idec GF SIGNET GF SIGNET

OT32E3 OT63E3 OHB65L5 FNQ-R-5 FNQ-R-10 FNQ-R-15 FAZ-C0.5 FAZ-C1 FAZ-C2 PS5R-SD24 CCMR30 ASW320N FC5AD16RS1 FC4A-K2C1 FC4A-J8C1 FC4AN16B1 HG2FSB22VCF FC4AKC2CA PW24D HW1P-5Q4R 3-8750-3P 3-8550-3P

23

EA

MONARCH

DC1250-D00

24 25 26

0 0 0

EA EA EA

1 1 1

MONARCH Idec Idec

SPC-1250 PS5R-A12 ASW210N

Page 3 of 4 Printed on 11/21/2008 @ 9:59 AM

BILL OF MATERIAL ELECTRICAL EQUIPMENT & MATERIALS


Project No.: 81-227 Description: 500 Gal. Batch pH Neutralization System Customer: United Solar Ovonic Date: Enter Rev Date Revision: 0 Item Rev Tag UOM Qty Description Mfr

ER: 11893-C1 Date: 8-7-08 BY: D.B.

P/N

27 28 29 30 31 32 33 34 35

0 0 0 0 0 0 0 0 0

PB2 PB1 PB1 CR1-5 CR1-5 ENLOSURE PANEL MCR,MC1 PLC

EA EA EA EA EA EA EA EA EA

1 1 1 1 1 1 1 2 1

Pushbutton, momentary, nonilluminated, flush head, black, (1) N.O. Push-Pull NON illuminated pushbutton, red, 2 NC E.STOP LEGEND PLATE RU RELAY, 4PDT, 24VDC COIL RU4S RELAY SOCKET Enclosure, NEMA 4,36x30x12 Panel MINI CONTACTOR, 24 VDC COIL DC OUTPUT MODULE

Idec Idec Idec IDEC IDEC Hoffman Hoffman ABB Idec

ABW110NBGR AYW402N-R NWAR-27 RU4S-D24 SY4S-05 C-SD363012 C-P3630 BC7C-Y FC4A-T08S1

Page 4 of 4 Printed on 11/21/2008 @ 9:59 AM

O & M Manuals

1. 2. 3. 4. 5. 6. 7. 8. 9.

Iwaki Horizontal Centrifugal Pump # MX 400 Series Lightnin Mixer # EV5P25 Asahi Air to Spring Pneumatic Valve # Type21 Series 79P. Conery Level Switch. +GF+ Signet pH Electrode # 2714 +GF+ Signet pH Pre Amplifier # 2720 +GF+ Signet pH Transmitter # 8750-3 +GF+ Signet Flow Meter # 2536 +GF+ Signet Flow Transmitter # 8550-3

10. Grundfos Metering Pump # DME Series 11. Flowline Leak Detection Switch # LO10 12. Monarch Instrument Digital Data Recorder # 1250

IWAKI AMERICA MAGNETIC DRIVE PUMP MX-(F)250 to 403 SERIES INSTRUCTION MANUAL

Thank you for selecting an Iwaki America MX Series magnetic drive pump. This instruction manual explains the correct handling, maintenance, inspection and troubleshooting procedures for your pump. Please read through it carefully to ensure the optimum performance, safety and long service of your pump.

TABLE OF CONTENTS
1 2 3 4 5 6 7 8 9 Unpacking and Inspection ..................................................................................................... 1 Model Identification Guide ................................................................................................... 2 Specifications......................................................................................................................... 2 Handling ................................................................................................................................ 7 Installation, Piping, and Wiring............................................................................................. 9 Operation ............................................................................................................................. 14 Maintenance and Inspection ................................................................................................ 17 Troubleshooting................................................................................................................... 20 Parts Description and Exploded View................................................................................. 22

10 Disassembly and Assembly of Pump................................................................................... 24 11 Spare Parts ........................................................................................................................... 29 12 Weights and Dimensions ..................................................................................................... 29

This product is patent pending.


180242 Rev. D Sep 2008

Unpacking and Inspection


Iwaki America Mag-Drive Pump
MXMODEL HEAD (FT.) CAPACITY (GPM)

HP SERIAL NO.

Hz.

RPM

IMPELLER DIAMETER DIRECTION OF ROTATION DO NOT RUN PUMP DRY


HOLLISTON, MASSACHUSETTS www.iwakiamerica.com

Open the package and check that the product conforms to your order. Also, check each of the following points. For any problem or inconsistency, contact your distributor at once. 1. Check that the model number and the HP indicated on the nameplate conform to the specifications of your order. 2. Check that all the accessories you ordered are included. 3. Check that the pump body and parts have not been accidentally damaged or that any bolts or nuts have not been loosened in transit.

Model Identification Guide

MX(F)250-403(H)

MX
1

250
2

CFV
3

6
4

1 Series Symbol
MX MX-F 2 Pump Size 250 251 400 401 402H 403H GFRPP casing CFRETFE casing

1 x 1 1 x 1 1.5 x 1.5 1.5 x 1.5 2 x 1.5 2 x 1.5

0.5HP 1.0HP 0.75HP 1.5HP 2.0HP 3.0HP

3 Materials of Bearing/Spindle/O-ring MX CV, CE Carbon/Alumina ceramic/FKM (EPDM) RV, RE PTFE/Alumina ceramic/FKM (EPDM) AV,AE Alumina ceramic/Alumina ceramic/FKM (EPDM) models MX-250 to MX-401 MX-F CFV RFV KKV AFV

High density carbon/High purity alumina ceramic/FKM PTFE/High purity alumina ceramic/FKM SiC/SiC/FKM High Purity Alumina Ceramic/High Purity Alumina Ceramic/FKM

4 Impeller Mark MX 5 50Hz only 6 60 Hz only 7 larger impeller MX-F T,V,W X,Y,Z

50 Hz only 60 Hz only

Specifications
Model Suct x Disch Max. Discharge Pressure (ft) 53 1 x 1 75 6 7 1.5 x 1.5 39 43 59 68 73 99 2 x 1.5 101 126 1 x 1 48 69 V X 1.5 x 1.5 43 34 68 50 70 2 x 1.5 88 107 45 130 70 43 40 65 0.75 HP 65 86 1.2 X 75 120 130 2 HP 3 HP 29.8 32.0 1.5 HP 22.5 13.7 1.2 2 HP 1.0 1.2 3 HP 1.0 1.2 1.0 0.5 HP 1 HP 29.8 29.8 32.0 32.0 17.0 22.5 80 1.2 1.5 HP 22.5 Max Flow (GPM) 40 40 70 1.2 Specific Gravity 1.0 1.0 Motor output @ 50/60Hz 0.5 HP 1 HP 0.75 HP Weight (less motor) lbs. 17.0 22.5 13.7

MX-250 MX-251 MX-400

MX-401

6 7

MX-402 MX-402H MX-403 MX-403H MX-F250 MX-F251 MX-F400

MX-F401

MX-F402 MX-F403

Note 1: The specific gravity limit values shown above are with maximum impellers. The specific gravity limit varies with the diameter. For details, contact your local distributor.

MX-(F)250, MX-251, MX-(F)401


11 12 14 21 13 10 8 5 7 6 4 9 1 2

16 15

19 3

No. 1 2 3 4

Name Front casing Mouth ring Impeller O-ring* Bearing AF CV, CF RV, RF AV, KK Magnet capsule Spindle Rear thrust Rear casing Drive magnet unit Motor Base Motor adapter Hex head bolt Hex head bolt Hex head bolt Flange kit Liner ring Hex head screw

Qty 1 1 1 1

MX-250

MX-251 GFRPP

MX-401

MX-F250

MX-F251 CFRETFE PTFE or SiC CFRETFE

MX-F401

Filler charged fluororesin GFRPP FKM/EPDM JIS B 2401 G165 Carbon

1 Filler charged fluororesin Alumina ceramic Ferrite mag. + polypropylene Alumina Ceramic 99.5% CFRPPS GFRPP

6 7 8 9 10 11 12 13 14 15 16 18 19 21

1 1 1 1 1 1 1 1 4 6 2 2 1 2

Alumina Ceramic HD Carbon PTFE SiC CFRETFE + Ferrite Alumina ceramic or SiC CFRETFE CFRETFE Ferrite mag. + aluminum alloy

0.5 HP

1 HP GFRPP

1.5 HP

0.5 HP

1 HP GFRPP

1.5 HP

FC200 Steel M8 x 20 w/PW, SW SS M8 x 35 w/PW, SW SS M8 x 50 w/PW, SW GFRPP Alumina ceramic 99.5% Steel M8 x 10 CFRETFE Alumina Ceramic 99.5% or SiC Steel M8 x 10

* Additional o-ring materials available upon request.

MX-(F)400
11 12 14 21 13 10 8 5 7 6 4 9 1 2

16 15 19 3

No. 1 2 3 4

Name Front casing Mouth ring Impeller O-ring* Bearing CV, CF RV, RF KK Magnet capsule Spindle Rear thrust Rear casing Drive magnet unit Motor Base Motor adapter Hex bolt Hex head bolt Hex head bolt Flange kit Liner ring Hex head screw

Qty 1 1 1 1

MX400 GFRPP Filler charged fluororesin GFRPP FKM / EPDM JIS B 2401 G135 HD Carbon

MX-F400 CFRETFE PTFE/SiC CFRETFE

5 6 7 8 9 10 11 12 13 14 15 16 18 19 21

1 1 1 1 1 1 1 1 1 4 4 2 2 1 2

Filler charged fluororesin ---Ferrite + polypropylene Alumina ceramic 99.5% CFRPPS GFRPP Ferrite + FCD450 1 or 1.5 HP GFRPP

PTFE SiC Ferrite + CFRETFE Alumina ceramic or SiC CFRETFE CFRETFE

GFRPP FC200 Steel M8 x20 w/PW, SW SS M8 x 30 w/SW SS M8 x 40 w/PW, SW

GFRPP Alumina ceramic 99.5% Steel

CFRETFE Alumina ceramic or SiC M8 x 10

* Additional o-rings materials available upon request.

MX-(F)402(H), MX-(F)403(H)

11

12

14

21

13

10

1 3 2

17

16 15

19 4

No. 1 2 3 4

Name Front casing Mouth ring Impeller O-ring* Bearing CV, CF RV, RF AV, KK Magnet capsule Spindle Rear thrust Rear casing Drive magnet unit Motor Base Motor adapter Hex head bolt Hex head bolt Hex head bolt Lock pin Flange kit, discharge Liner ring Motor bolt Hex head screw Flange kit, suction

Qty 1 1 1 1

MX-402(H), 403(H) GFRPP Filler charge fluororesin GFRPP FKM / EPDM JIS B 2401 G195 Carbon

MX-F402, F403 CFRETFE PTFE or SiC CFRETFE

HD Carbon PTFE SiC Ferrite mag. + CFRETFE Alumina ceramic or SiC CFRPFA CFRETFE

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

1 1 1 1 1 1 1 1 1 4 6 2 2 2 1 4 2 1

Filler charge fluororesin Alumina ceramic Ferrite mag. + polypropylene Alumina ceramic 99.5% CFRPEEK GFRPP Ferrite mag. + aluminum alloy 2 + 3 HP GFRPP FC200 Steel M8 x 20 w/PW, SW SS M10 x 30 w/ SW SS M10 x 60 w/PW, SW CFRPPS GFRPP Alumina ceramic 99.5% SS 3/8 x 3/4 Steel M8 x 10 GFRPP

CFRETFE CFRETFE Alumina ceramic or SiC

CFRETFE

* Additional o-ring materials available upon request.

Handling

CAUTION

Do not run pump dry When the pump is operated for the first time after it was installed or after it was disassembled and repaired, fill the pump chamber with the liquid to be pumped. If the pump runs dry without any liquid, rubbing parts of pump will seize. The moving or rotating parts of MX pumps are lubricated and cooled by the pumped liquid. The pump will be damaged if run dry or with the suction side valve fully closed. If the pump runs dry by mistake, switch off the power and leave it for more than one hour to cool it down slowly. Keep pump away from fire To prevent fire and explosions, do not place dangerous or inflammable substances near to pump. No remodeling Remodeling the pump can cause risk of injury or electrical shock.

Precautions on handling 1. Precautions when pump is started or stopped When discharge line is long and to avoid water hammer, pay attention to the following: . a. When pump is started After priming, close the discharge valve before power is switched on. After the pump is started, gradually open the discharge valve to get the desired duty point. b. When pump is stopped Gradually close the discharge valve and switch off the power. Never close the discharge line suddenly with a solenoid valve. Sudden close of discharge line causes water hammer resulting in pump damage. Do not install or store pump in the following places. Where the temperature falls below 0 deg. C. Where there is corrosive or explosive gas. Where water is splashed (except the pump equipped with weather-proof motor) Where ambient temperature exceeds 40 deg. C. Where humidity exceeds 85% (Allowable humidity : 35 to 85%RH) Prime pump The pump is not self-priming. Before the pump is started, prime the pump with pumped liquid. Dry running causes seizure and quick wear of parts.

2.

3.

4.

Pump allowable pressure Pump allowable pressure is shown below. Do not allow discharge pressure to exceed the allowable pressure.
Model MXMax. allowable pressure PSI (MPa) (F)250 36.3 (0.25) (F)251 47.9 (0.33) (F)400 31.9 (0.22) (F)401 40.6 (0.28) (F)402, 403 62.4 (0.43) 402H .403H 72.5 (0.5)

5.

Liquids to be transferred a. Liquid containing slurry Slurry can not be handled except for type A or KK (with alumina ceramic bearing) which can handle slurry liquid up to 5% concentration, slurry size of 50 micron m or below and hardness up to 80Hs. Contact Iwaki America if you wish to handle slurry liquid. b. Performance influenced by specific gravity and viscosity of liquid Liquid which is heavier or more viscous than water influences the shaft power, discharge capacity and head. The pump you purchased is made according to the specifications you gave us when ordered. If you wish to change the conditions, please contact us. c. Alumina ceramic bearing (types AV, AE) may be worn in a short time depending on the characteristics of liquid (low viscosity etc.). Please contact Iwaki America if you have any questions. d. Influence by temperature Pump performance is not influenced by the change of liquid temperature; however, the temperature will affect the viscosity, vapor pressure and chemical corrosivity. Refer to the chemical resistance table for the permissible temperature for specific chemical liquids. Temperature of liquid to be handled : 0 80 deg. C ( for water) Permissible ambient temperature : 0 40 deg. C Permissible humidity : 35 85% RH

6.

Intermittent operation Frequent stopping and starting may cause pump damage. Keep the start/stop frequency to within six times an hour. Disconnection of magnet coupling If the magnet coupling is disconnected, stop the pump within a minute. If the pump runs with the magnet coupling disconnected, the power of coupling will be decreased.

7.

8.

Use of pump in the range of bell-shaped pump performance curve For the pump which shows bell-shaped performance curve in a small capacity range (Refer to standard performance curve of the pump), if this pump is used at the section of the curve that ascends, the pump may operate unstable and make vibration or noise. To avoid such a surging operation, pay attention to the following: Arrange the discharge piping so that air pockets are prevented. Install the valve near the pump discharge port to adjust discharge capacity.

Installation, Piping, and Wiring

WARNING

Switch off power Be sure someone does not switch power on when the pump is being maintained. Display a sign near the power supply switch to notify others that the pump is being maintained. Do not hold plastic parts when transferring pump When transferring the pump, do not hold plastic parts such as casing, flange or base. Plastic parts may break and the pump may fall resulting in personal injury. The weight of pump is approx. 20 kg max. Put the pump and motor horizontally with the base downward. Electrical work Electrical work should be done by qualified personnel.

Installation Position
1. Install the pump as close to the suction tank as possible (flooded suction). If the suction port of the pump is positioned higher than the suction tank (suction lift), be sure to arrange a foot valve in the priming pipe and the suction pipe. The lifting capability depends upon the liquid properties, temperature, and length of suction piping. For details, consult Iwaki America or your distributor. 2. The pump can be installed indoors or outdoors. However, there should be sufficient space around the pump to enable efficient and easy maintenance.

Installation
1. The pump anchoring area must be greater than the area of the pump baseplate. If the anchoring area is not large enough, the baseplate may be damaged due to the concentration of loads placed on it. 2. Set the pump baseplate on a concrete foundation and fasten the anchor bolts tightly to prevent the pump from vibrating during operation. A sturdy metal (or reinforced) skid or platform is also an acceptable mounting surface. 3. In case there is influence of motor vibration during operation (e.g., sympathetic vibration with piping), an expansion joint should be provided between the pump and the piping before the installation. Otherwise, pipes and gauges may be damaged. 4. MX series pumps should always be mounted horizontally.

Anchor bolt Base Spacer

Fig. 3

10

1.
1 16 2 7 2 12 2 3 4

12 14 2 13 11 12 10 15 6 5

2. 3. 4. 5. 6. 7. 9. 10. 11.

15 17 2 9

12. 13. 14. 15. 16. 17.

Discharge pipe (Use a support to keep the pump free from the load of the pipe.) Valve Check valve Pressure gauge Motor Pump Air vent pipe Drain ditch Vacuum gauge Suction pipe (D=diameter of pipe) (shortest horizontal section with an ascending gradient toward the pump) Pipe support Suction pipe (D=diameter of pipe) 2D, 500mm or above Expansion joint Piping for flushing (discharge side) Piping for flushing (suction side)

Fig. 4

Suction Piping
1. The suction pipe should employ the flooded suction method if possible. The shortest pipe possible, with the minimum number of bends, should be designed. Arrange a proper support on the suction pipe so that the load and the thermal stress of the pipe itself are not applied to the pump. 2. Attach the coupling on the suction pipe carefully, so that no air enters the line. The presence of air in the suction pipe may prevent priming of the pump. 3. Avoid installations with poor suction conditions (e.g. vacuum in suction tank, large suction head or long suction piping). NPSHa should always be at least 2 feet greater than NPSHr. For NPSHr values, refer to the standard performance curve for your pump model or contact Iwaki America or your distributor. 4. When using a bend on the suction side, install a straight pipe which is more than 20 inches long or 10 times as long as the suction port diameter before the suction port of the pump. Use the largest possible radius of curvature for the bend. 5. Do not allow any projection where air may be trapped along the suction pipe. The suction pipe should have an ascending gradient toward the pump. 6. If the diameters of the pump suction port and the suction pipe are different, use an eccentric reducer pipe. Connect the eccentric reducer pipe such that the upper part of it is level. Never use a suction pipe with a diameter smaller than that of the suction port.
11

7.

When using the flooded suction method, the suction pipe should be given a slight ascending gradient toward the pump so that no air pocket is created on the suction side. The end of the suction pipe should be located 18 inches or more below the surface of the liquid. A screen should be provided at the inlet of the suction tank to prevent the entrance of foreign matter into the suction pipe. Foreign matter may cause malfunctioning of the pump. The end of the suction pipe should be a least 1- 1.5D from the bottom of the suction tank. (D=Diameter of suction pipe).

8. 9.

10. When employing the suction lift method, install a foot valve on the suction pipe. 11. When using the flooded suction method, it is recommended that a gate valve be installed on the suction pipe for easier overhaul inspection of the pump. Since this valve is used only in the overhaul inspection of the pump, keep it fully opened during normal pump operation.

GOOD CONDITIONS

UNACCEPTABLE CONDITIONS
AIR TRAP

AIR TRAP

AIR TRAP

AIR TRAP

Fig. 5

12

12. Pay close attention to the lowest level of the liquid in the suction tank so that air entrainment to the suction piping will not occur. The inflow pipe into the suction tank should be distanced from the suction pipe and positioned below the liquid surface as a means of preventing air entrainment to the suction pipe. If air bubbles are generated in the suction tank, install a baffle. 13. It is recommended that a vacuum/pressure gauge be installed on the suction piping approximately 6 pipe diameters from the pump suction port.

Discharge Piping
1. Use proper pipe supports so that the weight of the piping does not load the pump nozzle. 2. If a method other than flooded suction is used, install a special pipe for priming. 3. If the piping is very long, its diameter should be determined by calculating the piping resistance. Otherwise, the specified performance may not be obtained due to increased piping resistance. 4. A check valve should be installed if any of the following conditions exists in the piping: The discharge piping is very long. The discharge head is 50 feet or more. The end of the discharge pipe is located 30 feet higher than the surface of the suction tank. Several pumps are connected in parallel with the same piping. 5. The installation of a gate valve on the discharge pipe is recommended for the adjustment of discharge quantity and for the prevention of motor overload. When installing both a check valve and a gate valve, the check valve should be positioned between the pump and the gate valve. 6. A pressure gauge must be installed on the discharge piping. 7. An air bleeding valve should be installed if the discharge pipe is very long in the horizontal direction. 8. A drain valve should be installed for the drainage of liquid if there is a chance that the liquid in the discharge pipe will freeze.

13

Wiring
Use appropriate wiring materials, follow the instruction manual for the motor and abide by the local and national electrical codes. In addition, follow the instructions given below: 1. Use a motor contactor that conforms to the specifications (voltage, current, etc.) of the pump motor. 2. If the pump is installed outdoors, use waterproof wiring to protect the switches from rainwater and moisture. M MC ON OFF CLR Fig. 6 Motor Motor contactor Push Button Overload relay 3. The motor contactor and push button should be installed a reasonable distance from the pump. 4. Refer to the wiring example shown on the left. (This example does not include the installation of a dryoperation prevention device. Follow the instruction manual of the dry-operation prevention device when installing it.)

Operation
Notes on Operation

1. Never operate the pump with the suction-side valve (gate valve) closed. Otherwise, the internal bushings of the pump will be damaged. 2. In the event of cavitation, stop the pump immediately. 3. If the magnet coupling disconnects, stop the pump immediately. The torque rating of the magnet coupling will be reduced if operation is continued with the coupling disconnected. 4. Liquid temperature fluctuation should not exceed 176o F when starting, stopping, and operating the pump. 5. Be sure to close the discharge valve completely before starting operation in order to prevent water hammer upon start-up. 6. The pump should never be operated for a lengthy period with the discharge valve closed. A resulting rise in temperature of liquid in the pump may cause damage to the pump. 7. In the event of a service power failure, turn off the power switch immediately and close the discharge valve.
14

Start-Up Preparation
When operating the pump for the first time after installation, and when restarting operation after a long interval, prepare for operation as described below. 1. Thoroughly clean the inside of the piping and pump. 2. Tighten the union fittings or flange connecting bolts and baseplate installation bolts. Check that bolts which couple the front casing and the bracket together are securely fastened. 3. Close the cocks of any pressure or vacuum gauges to prevent damage from sudden pressure changes. Open only when taking measurements. 4. Fully open the suction gate valve and partly open the discharge valve. Discharge valve may be adjusted after completion of priming and start-up process. 5. Use a screwdriver to rotate the motor fan and check that the fan rotates smoothly. This also purges any residual air from in and around the impeller. 6. If using flooded suction, measure the pressure in the suction pipe to check that the pump is filled with liquid. 7. Run the motor momentarily to check the direction of motor rotation. The motor should run in the direction indicated by the arrow sealed on the pump. If the direction is reversed, exchange two wires of the three-phase power wires. Note: All Iwaki America MX-(F) series pumps spin counter-clockwise when looking at the suction port of the pump. Naturally, from the motor fan side, this would be viewed as clockwise.

Starting Operation
Pump operation is detailed below. Check/Operation Step
1. Verify valve position. 2. Check that the pump is filled with liquid. 3. Turn ON motor switch momentarily and check for correct direction of pump operation. Suction valve fully open. Discharge valve fully closed. If pump is not filled with liquid, fill it in accordance with steps 5-6 of 'Start-up Preparation'. See the arrow on the casing to confirm the direction of rotation (clockwise when viewed from the motor fan side).

Remarks

15

Check/Operation Step
4. Flow rate adjustment. Once total discharge pressure is increased to shut off pressure. Open discharge valve gradually to set discharge pressure to desired specification. Pump should be operated at a minimum flowrate: 250,251,400,401: 2.5 Gal/min (10 L/min) or more 402H, 403H: 5 Gal/min (20 L/min) or more 402, 403: 10 Gal/min (40 L/min) or more

Remarks
Open valve slowly, paying attention to the motor amp meter to prevent it from being overloaded through excessive opening of the valve.

In case of automatic control, close discharge valve when starting pump and gradually open the discharge valve thereafter. Dont operate the pump with the discharge valve closed for more than one minute. 5. Points to be observed during operation. If pump enters continuous operation check flow meter and confirm that pump operation meets specifications. If flowmeter is unavailable, check values of discharge pressure, suction pressure and current in relation to piping resistance.

Stopping Operation
Check/Operation Step
1. Close discharge valve gradually.

Remarks

Caution Do not cause sudden closure by using solenoid valve, etc. Otherwise, pump may be damaged by water hammer.

2. Stop motor. 3. Points to be observed when stopping pump.

Observe that the motor stops rotating slowly and smoothly. If not, check inside of pump.

If pump operation is stopped in cold weather, liquid inside the pump cavity may freeze and damage the pump. Be sure to drain liquid completely. In case of short-term shut down, which does not allow removal of liquid, use band heater, etc., to prevent liquid from freezing. In case of service power failure turn OFF power switch and close discharge valve.

16

Maintenance and Inspection


Daily Inspection

1. Check that the pump operates smoothly, without generating abnormal sounds or vibration. 2. Check the level of the liquid in the suction tank, and the suction pressure. 3. Compare the discharge pressure and current measured during operation with the specifications indicated on the motor and pump nameplates to verify normal pump load. * Note that the indicated value of the pressure gauge varies in proportion to the specific gravity of the liquid.

Caution The valve of the pressure gauge or vacuum gauge should be opened only when measurements are recorded. It must be closed after completion of each measurement. If the valve remains open during operation, the gauge mechanism may be affected by abnormal pressure caused by water hammer.

4. If a spare pump is included in the installation, keep it ready for use by operating it from time to time.

Periodic Inspection
To ensure efficient, smooth operation of the pump, carry out periodic inspection by following the procedure described below. When carrying out an overhaul inspection, handle the internal bushings and plastic components most carefully. Since the outer drive magnet and inner magnet capsule are very powerful, handle these components with caution. Take care not to trap hands and fingers between the magnets and metal objects. Also avoid positioning the magnets near any electronic device (or ATM cards with magnetic strips) that could be affected by a strong magnetic field.

17

Inspection Interval

Part Drive magnet Rear casing Magnet capsule Impeller

Inspection Points Is there scoring? Is magnet mounted normally? Are hexagonal socket setscrews loose? Are inner perimeters of magnet and motor shaft concentric? Scoring on inner diameter? Cracks in section containing liquid? Stain in rear casing? Scoring in rear face or cylindrical body? Cracks in the plastic of the rear section or cylindrical body? Bearing wear? Any cracks? Cavitation marks? Stain or clogging inside impeller? Dimensional change of impeller? Conical thrust wear? Stain in section containing liquid? Cracks? Wear or crack of thrust ring? Expansion or wear of o-ring? Scoring on inner surface? Cracks? Wear on surface? Clean

Operator Action Contact distributor if any abnormality is observed. Re-install magnet on motor shaft & fasten setscrews. Re-tighten or replace setscrews. Contact distributor if any abnormality is observed. Replace if abnormality is observed.

Every 6 months *Inspection record should be maintained

assembly

Contact your distributor if any abnormality is observed. Contact your distributor if any abnormality is observed. Replace if abnormality is observed (see Tolerance Chart). Replace if abnormality is observed. Eliminate cause. Clean. Replace if abnormality is observed. Replace if abnormality is observed (see Tolerance Chart). Clean. Replace if abnormality is observed. Contact distributor if abnormality is observed. Replace if part is damaged. Contact distributor if abnormality is observed. Replace if abnormality is observed. Replace if wear limit is exceeded.

Every 3 months *Inspection record should be maintained

Every 3 months *Inspection record should be maintained

Front casing

Spindle

18

Wear Limits of Spindle, Bearing, Mouth Ring & Impeller Thrust


Model MX-(F) Bearing I.D. inches (mm) Spindle O.D inches (mm) 250, 251, 400, 401 New Replace 0.709 (18) 0.748 (19) 0.709 (18) 0.669 (17) 402, 402(H), 403, 403(H) New Replace .945 (24) .984 (25) .945 (24) .906 (23)

If the difference between Bearing I.D. and Spindle O.D. exceeds 0.039 in. (1mm), either the bearing or the spindle, whichever has the greater wear, should be replaced regardless of the values in the above table. In case of a ceramic bearing type pump (MX-250-401), the spindle and the bearing should be replaced simultaneously. Initial wear may appear on the sliding parts during the first stages of operation. This should not be mistaken for an abnormal condition.

UPON SHIPMENT STEP 0.078 in (2 mm)

IMPELLER

MOUTH RING

MX-(F) Thickness of mouth ring inches (mm)

250, 251, 400, 401, 402(H), 403(H) New Replace 0.315 (8) 0.236 (6)

The step between the surfaces of the mouth ring and the impeller upon shipment is 0.078 in. (2mm) (0.118 in. (3mm) for MX-250). Replace the mouth ring when this step is reduced to 0 in.

19

Troubleshooting
Symptom on Pump Trouble With discharge valve closed With discharge valve open Pressure gauge and vacuum gauge indicate zero Cause Insufficient priming Dry operation Inspection & Countermeasures Stop pump, feed priming liquid & restart pump.

Liquid is not pumped

Liquid level drops immediately when pump is primed Liquid level drops if discharge valve is opened after starting pump

Foot valve is clogged with foreign matter

Replace strainer. Check if set is clogged with foreign matter.

Pressure & vacuum gauge needles move but return immediately to zero

Air enters through suction pipe or gasket section

Magnet coupling is disconnected

Discharge quantity is small Pressure & Vacuum gauges indicate normal values Vacuum gauge indicates high value Vacuum gauge indicates abnormally high value

RPM of pump is insufficient Pump rotation is reversed, Strainer is clogged with foreign matter, blocking liquid flow Air is trapped in suction pipe Inlet section of impeller unit is clogged with foreign matter Air entering via suction pipe or gasket section Discharge side of pump is clogged with foreign matter Air pocket or resistance in suction pipe

Make sure connection flange in suction piping is sealed airtight. Is suction liquid level abnormally low? Stop pump, use screwdriver to check for easy & smooth rotation of motor fan. Measure current level for low reading Check inside pump cavity for foreign matter. Check if voltage level is normal. Replace drive magnet and/or magnet capsule. Check wiring & motor and fix as necessary. Correct motor wiring. Remove foreign matter in strainer. Inspect suction pipe and modify installation as necessary. Partially disassemble unit and remove foreign matter.

Pressure & Vacuum gauges fluctuate

Check flange gaskets of suction pipe & tighten Remove foreign matter in pump or scale inside of piping. Inspect suction piping installation and make corrective adjustments

Vacuum gauge indicates high value while pressure gauge is normal Pressure gauge indicates high value while vacuum gauge is normal

Discharge pipe section causing high resistance or actual head and loss of head is too high

Check actual head & loss of discharge in pipe.

20

Symptom on Pump Trouble Discharge quantity is too low. With discharge valve closed Pressure gauge indicates low value while vacuum gauge is extremely low. With discharge valve open Pressure gauge and vacuum gauge indicate low values Cause Rotating direction of pump/motor is reversed. Inspection & Countermeasures Correct motor wiring to reverse rotation. (clockwise when viewed from motor side) Make sure voltage & frequency levels are adequate. Check specific gravity & viscosity of liquid. Stop pump, use screwdriver to make sure motor fan rotates easily & smoothly. Improve air ventilation.

Motor overheats.

Insufficient voltage

Overload

Ambient temperature is high. Strainer is clogged with foreign matter, blocking liquid flow. Foundation is inadequate. Anchor bolt is loose. Cavitation from closed or restricted suction pipe. Wear or melting of pump bushing. Damaged inner magnet assembly or pump spindle. Fluctuating dynamic balance of outer drive magnet assembly. Wear of motor bearing.

Discharge quantity is suddenly lowered

Vacuum gauge indicates high value

Remove foreign matter in strainer.

Pump vibrates

Check installation process again. Re-tighten bolt. Clean, eliminate cause of cavitation. Replace. Replace.

Remove or replace.

Replace bearing or motor.

21

Parts Description and Exploded View


11 10

MX-250 - 401

13 9 8 7 6 18 3 12 15 14 4 5

1 16 18

Fig. 9

No. 1 2 3 4 5* 6 7 8 9

Description Front casing Mouth ring Impeller O-ring Bearing Magnet capsule Shaft Thrust collar Rear casing

Qty 1 1 1 1 1 1 1 1 1

No. 10 11 12 13 14 15 16 18 Motor Baseplate

Description Drive magnet

Qty 1 1 1 1 4 6 2 1

Motor adapter Bolt, baseplate w/PW & SW Bolt, front casing w/PW & SW Bolt, front casing w/PW & SW Flange kit

*Item 5 is an integral part of the magnet capsule and not available as an individual item.

22

MX-402 403(H)
10

11

13 9 8 7 6 18 3 17 12
15

14

17 2

1 16 22

Figure 10 No. 1 2 3 4 5* 6 7 8 9 10 Description Front casing Mouth ring Impeller O-ring Bearing Magnet capsule Shaft Thrust collar Rear casing Drive magnet Qty 1 1 1 1 1 1 1 1 1 1 No. 11 12 13 14 15 16 17 18 22 Motor Baseplate Motor adapter Bolt, baseplate w/PW & SW Bolt, front casing w/PW & SW Bolt, front casing w/PW & SW Impeller lock pin Flange kit, discharge Flange kit, suction Description Qty 1 1 1 4 6 2 2 1 1

*Item 5 is an integral part of the magnet capsule and not available as an individual item.

23

10

Disassembly and Assembly of Pump


Caution!

Since the magnets used in the pump are powerful, be careful not to catch your fingers or hand between them during disassembly or assembly. Also, keep the magnet unit away from any electronic device (or ATM card with a magnetic strip) that could be affected by a strong magnetic field. Prior to servicing, the suction and discharge valves must be closed. The piping and the pump often retain some liquid. It is recommended the piping and pump cavity be drained prior to servicing. If dangerous liquid is used, wear protection and flush pump with clean water or decontaminant prior to service. Make sure power to the motor is off.

Disassembly
1. Loosen hex socket head bolts to remove front casing from motor bracket. Drain residual liquid from the casing and clean. 2. Pull out impeller and magnet capsule. (Be careful not to pinch fingers). 3. When removing the impeller from the magnet capsule: For MX-(F)250 to (F)401 Hold the magnet capsule and slightly tap the back side of the impeller with a plastic hammer. If the impeller doesnt slide out easily, place them in hot water (approx. 90C) for 5 minutes.

24

For MX-(F)402(H) and (F)403(H) Turn the lock pin counter clockwise direction by 90 degrees using a slotted screw driver and then push it towards the inside of the impeller. If it is hard to push it out, slightly tap the end of driver handle. If the screw driver can not be used because the groove of pin was crushed, turn the pin from inside of magnet capsule using hex. wrench. In this case pay attention to turn the wrench clockwise. The lock pin will be damaged if it is turned in reverse direction. After the pin is turned, push it in from the outside using a screwdriver or drive pin.

After the two lock pins are removed, remove the impeller from the magnet capsule by slightly tapping the periphery of impeller with plastic hammer. If it is hard to remove, warm it with hot water (approx. 90deg. C) for five minutes and remove it by slightly tapping it as above. Pay attention not to burn yourself. Impeller cannot be separated from magnet capsule unless lock pin is removed. These parts will break if the impeller is removed by force.

4. To remove a rear casing, insert a slotted screwdriver to the periphery of rear casing and slightly twist the screwdriver. Pay attention not to damage the o-ring.

25

Reassembly
Reassemble the pump by reversing the order of disassembly. Take care not to contaminate or damage the seal faces or o-rings. Tighten the bolts uniformly to prevent uneven tightening. 1. Mount the motor adapter to the motor. Depending on the pump model, the base may need to be removed for proper installation. Secure the motor adapter to the motor with the proper hardware. Note: A lock washer may not fit on all models. 2. Place the drive magnet onto the motor shaft with two set screws. For MX-(F) 250 to (F)401 models Adjust the position of the drive magnet on the motor shaft so it measures 0.157 below the face of the motor adapter (see figure). After the magnet height is set correctly, tighten the two set screws to secure the magnet on to the motor shaft. For MX-(F) 402 and (F)403(H) models Adjust the position of the drive magnet on the motor shaft so it measures 0.354 below the face of the motor adapter (see figure). After the magnet height is set correctly, tighten the two set screws to secure the magnet on to the motor shaft.
Motor shaft

H Motor adapter

Drive magnet

3. Mount the impeller to the magnet capsule. For MX-(F)250 to (F)401 models Fit the projected and recessed parts of magnet capsule and impeller together and push the impeller to the bottom. Put the thru hole on the magnet capsule and U shaped hole of impeller together. If there is no gap between the end surface of the impeller and bearing end surface, this means the impeller was installed correctly. If it is hard to press fit them, warm the magnet capsule only by putting it in hot water (approx. 90 deg. C) for five minutes. For MX-(F)402(H) and (F)403(H) models The mating part of the magnet capsule has two holes. The larger hole is for the lock pin (stepped hole on the outside is 6 mm dia and the inside is 12mm dia) and a smaller hole (3mm dia.) is for cooling purposes. The U-shaped hole of the impeller and smaller hole (3 mm dia) of magnet capsule are also for cooling purposes. Insert the impeller into the magnet capsule slowly by positioning the two holes together. If it is hard to insert them, warm the magnet capsule only with hot water (approx. 90 deg. C) for five minutes.

26

After the impeller is inserted (press-fit), insert the lock pins from the inside and then tighten the pin by turning it clockwise 90 degrees from outside with a slotted screwdriver. You will feel a snap when it is fixed securely.

If the groove for a slotted screwdriver is deformed and cannot be used, the pin can be locked from the inside with a 4mm hex. wrench. In this case, turn the wrench counter clockwise. The lock pin may be broken if it is turned in reverse.

4. Make sure no iron pieces or other foreign matters do not adhere to the magnet capsule. Put the magnet capsule with impeller into the rear casing slowly.

5. Mount the rear casing with magnet capsule to the motor adapter.

Caution

Magnet force is very strong. Apply plastic or wooden spacers between the rear casing and bracket to absorb any slack. Be careful not to pinch your fingers.

27

6. Put the o-ring inside the front casing. Make sure there is no dust or cuts on it. For MX-250, 251 and 401 models the recessed and projected portions of rear casing and front casing fit together. Note that there are two recesses on the rear casing and two projections on front casing on the MX-(F)402(H) and (F)403(H) models.

7. Mount the front casing to the motor adapter. Tighten the mounting bolts diagonally and evenly. Tightening torque is shown below. Model MX-(F)250, (F)251, (F)400, (F)401 MX-(F)402, 402(H), (F)403, 403(H) Bolt tightening torque 8.7 ft. lbs. (11.8 N-m) 10.8 ft. lbs (14.7 N-m)

28

11

Spare Parts

Original factory spare parts are necessary to ensure continuous pump operation. Expendable parts, such as bearings, spindles and mouth (thrust) rings should always be kept on hand. Consult your distributor or Iwaki America for the correct part numbers and pricing. When placing orders, supply the following information. 1. Description and item number (according to this instruction manual). 2. Pump model number and serial number (as shown on the nameplate of the pump). 3. Drawing number if you have received a certified drawing.

12 Weights and Dimensions

Note 1: Overall length varies with motor type and manufacturer. Dimensions in inches (mm)
MODEL SERIES W H L a b c d e f g k m

MX-(F)250 MX-(F)251 MX-(F)400 MX-(F)401 MX-(F)402(H) MX-(F)403(H)

6.30 (160) 5.51 (140) 6.30 (160) 10.24 (260)

9.75 (248) 8.62 (219) 9.81 (249) 10.78 (274)

9.39 (239) 9.37 (238) 9.96 (253) 9.53 (242)

5.12 (130) 4.33 (110) 5.12 (130) 8.19 (208)

2.56 (65) 2.13 (54) 2.83 (72) 3.15 (80)

5.12 (130) 3.86 (98) 5.12 (130) 7.87 (200)

4.53 (115) 3.74 (95) 4.53 (115) 4.72 (120)

5.22 (133) 4.88 (124) 5.28 (134) 6.06 (154)

3.25 (83) 3.19 (81) 3.82 (97) 3.27 (83)

6.12 (155) 5.67 (144) 7.01 (178) 5.94 (151) .55 (14) .47 (12)

----

------1.42 (36)

29

Iwaki America Incorporated 5 Boynton Road Hopping Brook Park Holliston, MA 01746 USA TEL: 508-429-1440 FAX: 508-429-1386 www.iwakiamerica.com

LIGHTNIN
STANDARDS ENGINEERING DISTRIBUTION

DIST. SECTION PAGE

55 2.10 0.50

DATE: 21502

EV & W INSTRUCTION

DESCRIPTION P: EV1P2575 EV5, EV6P25 75 Q: V1Q2575 EV5, EV6Q2575 L: EV1L2575 EV5, EV6L25 75 W: W1P2575 W5, W6P25 75 Direct Gear IT3799 IT3800 Direct Gear IT3816 IT3817 Direct Gear IT3814 IT3815 Direct Gear IT3694 IT3695

GENERAL INSTRUCTIONS EV SERIES MIXERS DIRECT DRIVE


SECTION 1 INITIAL INSPECTION, SHIPPING ARRANGEMENTS
1. 1 Check the shipping crates and your LIGHTNIN equipment for possible shipping damage. Report any damage immediately to the carrier and our factory. 1. 2 The mixer and impellers are packed together. The mixer shaft, if over 48 inches long, is packed in a separate container. 1. 3 Do not remove any protective coatings or wrappings until the mixer is ready to be put into service. If the mixer is to be stored, store only in an indoor, clean, dry location with controlled temperatures of 15 C to 40 C (59 F to 104 F).

SECTION 2 MIXER INSTALLATION


2. 1 Refer to Installation drawing for: a. Proper mixer mounting and location. b. Proper minimum impeller offbottom and relative spacing for dual impeller applications. 2. 2 Lockout power before positioning mixer, and review safety instructions before starting mixer. 2. 3 The clamp and beamplate are cast offset at recommended 20 horizontal plane and adjustable 010 in the vertical plane. Clamp and beamplate are also available with zero degree offset in the horizontal plane and adjustable 010 in the vertical plane. Refer to Table 1 for recommended angular positions.

80

20

Table 1 Mixer positioning

2. 4 BOLT TIGHTENING TORQUE RECOMMENDATIONS a. Inadequately or improperly tightened hardware can loosen due to vibration or the reactions imposed by fluid forces. This can result in reduced equipment service life or damage and failure. REVISION DATE 5/15/95 INST. No. IT3694 1996
A

LIGHTNIN

REVISED 3/18/96

MIXERS AND AERATORS

PAGE 1 OF 7

b. Recommended torques for tightening the bolts and screws on your LIGHTNIN mixer are listed with assembly instructions. Use of a torque wrench is recommended to ensure compliance with torque recommendations. c. The amount of torque required to maintain a tight connection can vary considerable for bolts of the same size under different operating conditions. Variations such as basic joint design, compression factors, type and strength of base and hardware material, surface finish of mating parts and lubrication are only some of the factors that influence the tightness of bolted connections for given torque values. d. All bolts should be coated with oil, grease, or an antiseize compound whenever possible. The threads and bearing face of bolt heads and/or nuts should be lubricated. e. ALL BOLTS SHOULD BE RETIGHTENED AFTER THE UNIT HAS BEEN RUN UNDER LOAD FOR TWO (2) WEEKS, AND AT EACH SCHEDULED SHUTDOWN THEREAFTER. f. Unless otherwise specified, it is recommended that metric commercial standard class 8.8 bolts and screws, and class 8 nuts be used for all bolted connections. For inch hardware use GR5.

SECTION 3 SHAFT AND IMPELLER INSTALLATION


3. 1 Install the impeller(s) on the mixer shaft (231) by tightening the set screws in the impeller hub. Refer to the installation drawing for recommended dual impeller spacing if two impellers are supplied. Refer to Impeller Assembly drawing for general impeller orientation. 3. 2 Clean the mixer shaft (231) end and drive quill (51) thoroughly. 3. 3 Orient the drive quill so that the set screw (58) aligns with the hole in the bearing housing (36). Align quill shaft by inserting lower shaft (231) into quill and rotate quill manually. 3. 4 Grasp mixer shaft approximately 20 inches below the shaft top and insert the mixer shaft completely into the drive quill, until it contacts the top of the quill bore. Align flat on shaft with set screw (58). Tighten set screw (58).
MIXER SHAFT (231) DRIVE QUILL (35)

HOUSING (36)

SET SCREW (58) INSTALLATION POSITION Figure 1 Shaft Installation

HEX KEY (72) REMOVE PRIOR TO RUNNING UNIT

3. 5 DRIVE QUILL ORIENTATION a. NORMAL LIGHT CONDITIONS Rotate the drive quill until the set screw (58) aligns with the access hole in the housing (36). Rotate drive quill by inserting lower shaft into drive quill and rotating by hand. b. LOW LIGHT CONDITIONS If the mixer shaft is being installed in low light conditions, the drive quill can be oriented by feel. Insert lower shaft into drive quill and rotate the drive quill (35) by hand until the set screw (58) can be felt with the hex wrench through the access opening. REVISION DATE 5/15/95 INST. No. IT3694 1996
A

LIGHTNIN

REVISED 3/18/96

MIXERS AND AERATORS

PAGE 2 OF 7

3. 6 With the drive quill oriented, insert the 7/32 hex key (72) provided into the housing opening and tighten the set screw (58) to (1530 ftlbs). DO NOT IMPACT THE WRENCH OR USE AN EXTENSION. 3. 7 Check for free movement of all components by rotating the mixer shaft.

SECTION 4 SHAFT REMOVAL


CAUTION: THE UPPER PORTION OF THE MIXER SHAFT (231) MAY BE HOT TO THE TOUCH. ONCE REMOVED FROM THE DRIVE QUILL (35), DO NOT GRASP THE UPPER 20 OF THE MIXER SHAFT. It is recommended that the mixer be removed from the tank before shaft or shaft and impeller are removed. a. Make sure all electrical power is disconnected. b. Grasp impeller by hand (or shaft with a strap wrench) and rotate mixer shaft (231) until the drive quill set screw (58) aligns with the access hole in the housing (36). See Caution above. c. With hex key (72) loosen set screw (58) and back out two (2) turns. See Figure 2. d. Remove mixer shaft from quill. See Caution above.

MIXER SHAFT (231)

DRIVE QUILL (35)

MIXER SHAFT (231) DRIVE QUILL (35) HOUSING (36) HOUSING (36)

SET SCREW (58)

SET SCREW (58) DISENGAGED

HEX KEY (72) REMOVE PRIOR TO RUNNING UNIT

Operating Position Figure 2 Shaft Removal

Release Position

SECTION 5 MIXER OPERATION


5. 1 This LIGHTNIN mixer is designed for continuous operation and normally needs no additional maintenance. CAUTION: IT IS NOT RECOMMENDED TO OPERATE THE MIXER WITH EXTREME VORTEXING OR SURGING OF THE LIQUID BEING MIXED. 5. 2 At the end of two weeks service, check all hardware for tightness. WARNING: AT THE END OF THE MIXING CYCLE, IT IS GOOD PRACTICE TO TURN OFF THE MIXER BEFORE THE TANK HAS BEEN DRAINED TO A LEVEL WHICH WILL RESULT IN EXCESSIVE SPLASHING. THIS MAY RESULT IN SHAFT DAMAGE. REVISION DATE 5/15/95 INST. No. IT3694 1996
A

LIGHTNIN

REVISED 3/18/96

MIXERS AND AERATORS

PAGE 3 OF 7

SECTION 6 LUBRICATION
All mixer bearings are the sealed type and are prepacked with lubricant. Relubrication of these bearings is not necessary.

SECTION 7 DISASSEMBLY INSTRUCTIONS


WARNING: DISCONNECT MOTOR LEADS OR OTHERWISE LOCKOUT POWER SUPPLY BEFORE SERVICING THE MIXER. EYE PROTECTION MUST BE WORN. 7. 1 This mixer is precision manufactured and assembled to provide long trouble free service when properly maintained. If it becomes necessary to disassemble the unit, careful precise reassembly is necessary. 7. 2 Refer to the assembly drawings for location of parts. 7. 3 Equipment that will be required to service the mixer, in addition to standard mechanics tools is, a rubber mallet, retaining ring pliers, metric and inch allen wrenches, arbor press and torque wrench. 7. 4 When disassembling the mixer, clean external surfaces adjacent to prevent dirt from entering the housings. 7. 5 It is recommended that oil seals and gaskets be replaced when the mixer is disassembled. 7. 6 SEAL REPLACEMENT Inspect oil seals and gaskets for nicks, gouges and deformities. When replacing seals: a. Coat the lips of seals with bearing grease. b. Install oil seal with lip facing up as shown in Figure 3. c. Coat the section of shaft sealing surface with oil. 7. 7 BEARING REPLACEMENT a. Old bearings can be removed with a puller or an arbor press. b. New bearings can be pressed on the shafts. Be careful to apply load only to the inner race. c. Make sure the bearings are tightly seated against the shaft or housing shoulders with no clearance. 7. 8 SHAFT REMOVAL Loosen set screw (58) and remove mixer shaft (231) as outlined in Section 4. 7. 9 MOTOR REMOVAL a. Remove the mixer from the tank and remove the mixer shaft (231) as outlined in Section 4. b. Tip the mixer upside down on a workbench. c. Remove the four socket head cap screws (60) holding the bearing housing (36) to the motor (101). d. Lift the bearing housing off the motor. It may be necessary to tap the bearing housing GENTLY with a rubber mallet to get the bearing housing to separate from the motor. e. Remove motor coupling half (63) and insert (65) from motor shaft. 7. 10 BEARING MODULE DISASSEMBLY a. Remove the oil seal (42) from the drive quill (35). This oil seal will be damaged and a new oil seal must be installed when reassembled. b. Remove retaining ring (44). c. Remove upper retaining ring (59). d. Place the bearing housing upright in a press, and press out the drive quill (35) and lower bearing (41). REVISION DATE 5/15/95 INST. No. IT3694 1996
A

LIGHTNIN

REVISED 3/18/96

MIXERS AND AERATORS

PAGE 4 OF 7

e. Remove lower retaining ring (59) and bearing (41) from the drive quill (35). f. Remove upper bearing (41) from housing (36). g. Inspect bearing (41) for excessive wear. Replace if necessary.

SECTION 8 ASSEMBLY INSTRUCTIONS


8. 1 QUILL ASSEMBLY Insert the set screw (58) into the drive quill (35) until it is flush with the bore of the quill. 8. 2 BEARING MODULE ASSEMBLY a. Press the lower bearing (41) onto the drive quill (35) bearing journal. The bearing must seat against the drive quill shaft shoulder with no visible gap. b. Install the lower external retaining ring (59). c. Press the drive quill assembly into the bearing housing (36) from the bottom until the bearing seats on the housing shoulder. d. Install lower retaining ring (44). e. Press oil seal (42) in place with the seal cavity facing as shown in Figure 3. Make sure the oil seal has the internal spring removed. This is a nonlubricated seal, and will run hot and have a shortened life if the spring is not removed. f. Turn the bearing housing over, support the assembly on the quill shaft (35) and install the upper bearing (45) by pressing it into the bearing housing and onto the quill shaft. g. Install the upper retaining ring (59). h. Support the bearing housing assembly in an upright position and press the drive quill downward until the bearing (41) shoulders on the retaining ring (59). This will relieve any locked in axial load on the bearing created during assembly.
BEARING (41) BEARING HOUSING (36)

RETAINING RING (44) OIL SEAL (42) SHOWN WITH SPRING REMOVED

RETAINING RING (59)

Figure 3 Oil Seal Installation 8. 3 FINAL ASSEMBLY (Refer to assembly drawing L17094). a. Install gasket (22) around the bearing housing (36). b. Assemble mixer coupling hub (64) to the quill shaft (35), until it seats against the upper retaining ring (59). Tighten the mixer hub set screw to 5 ftlbs. Install the insert (65) on the mixer hub. c. With the motor upside down on a workbench, assemble the motor coupling hub (63) to the motor shaft as shown in Figure 4. Align motor coupling hub keyway 180 opposite motor output shaft keyway. Motor coupling hub set screw is tightened against motor output shaft ( key is not used in the assembly). Tighten the motor hub set screw to 5 ftlbs. REVISION DATE 5/15/95 INST. No. IT3694 1996
A

MIXER SHAFT (231)

LIGHTNIN

REVISED 3/18/96

MIXERS AND AERATORS

PAGE 5 OF 7

.94 MOTOR COUPLING HUB (63)

MOTOR (101)

Figure 4 Motor Coupling Hub Installation

d. Align coupling hubs and assemble the bearing housing to the motor, using care so as not to damage the flexible element (65) or the gasket (22). e. Bolt the bearing housing (36) to the motor (101), using socket head cap screws (60) and washers (61). Alternately tighten the hardware to 9 ftlbs to ensure that all components are drawn evenly together. f. Install mixer shaft (231) as outlined in Section 3.

SECTION 9 AIR MOTOR REQUIREMENTS


Be sure your compressor has capacity for both pressure and the proper cubic feet per minute air displacement. Wet air, and low pressure will cause sticking of the motor, requiring hand starting. It is important to use an air filter and moisture trap near the motor for removal of foreign matter. Maximum recommended operating pressure is 100 P.S.I.
AIR PRESSURE / AIR CONSUMPTION GUIDE FOR AIR MOTOR DRIVEN MIXER (AIR MOTOR OPERATING AT 1800 RPM) PRESSURE CONSUMPTION REQUIRED H.P. 1/3 1/3 1 1 GAST MOTOR # #2 #2 #4 #4 SHAFT RPM 1800 360 1800 360 * (PSIG) 60 60 85 85 ** (CFM FREE AIR) 15 15 30 30

* Live pressure should be approximately 11/2 times the operating pressure of the air motor. The full line pressure will then be available for overloads and startup. ** CFM free air refers to air at atmospheric conditions measured at the inlet of the compressor. Table 2

SECTION 10 AIR MOTOR LUBRICATION


10. 1 Use only a high detergent lubricant of the recommended viscosity. Recommended oils are shown in Table 3. 10. 2 For continuous duty or high speed operation, it is recommended that an automatic lubricating device in the air line be provided to feed 1 to 3 drops per minute to the motor. If required request optional airline lubricator (part # 151030psp). REVISION DATE 5/15/95 INST. No. IT3694 1996
A

LIGHTNIN

REVISED 3/18/96

MIXERS AND AERATORS

PAGE 6 OF 7

10. 3 For manual oiling, remove the oil cap at the top of the motor, and add one squirt of oil at the end of each 8 hours of operation.

RECOMMENDED LUBRICANT
GAST AD 220 (SAE #10) OR A HIGH DETERGENT AUTOMOTIVE ENGINE OIL DESIGNED FOR ANY ONE OR MORE OF THE FOLLOWING API SERVICE RATINGS SB, SC, SD, SE, CB, CC, CD. A HIGH DETERGENT AUTOMOTIVE ENGINE OIL DESIGNATED FOR ANY ONE OR MORE OF THE FOLLOWING API SERVICE RATINGS SB, SC, CD, CE, CB, CC, CD.

AMBIENT TEMPERATURE GRADE OF OIL BELOW 32 F


32 F TO 100 F DILUTE SAE #10 OIL WITH 25% KEROSENE SAE #10 OIL

101 F TO 200 F

SAE #20 OIL

Table 3 Motor Lubrication

REVISION A

DATE

5/15/95

LIGHTNIN
MIXERS AND AERATORS

1996

INST. No. IT3694 PAGE 7 OF 7

REVISED 3/18/96

GENERAL INSTRUCTIONS EV SERIES MIXER GEAR DRIVE


SECTION 1 INITIAL INSPECTION, SHIPPING ARRANGEMENTS
1.1 Check the shipping crates and your LIGHTNIN equipment for possible shipping damage. Report any damage immediately to the carrier and our factory. 1.2 The mixer and impellers are packed together. The mixer shaft, if over 48 inches long, is packed in a separate container. 1.3 Do not remove any protective coatings or wrappings until the mixer is ready to be put into service. If the mixer is to be stored, store only in an indoor, clean, dry location with controlled temperatures of 15 C to 40 C (59 F to 104 F). When gear drive models have been stored for more than one year, the gear lubricant should be replaced (see Lubrication instructions).

SECTION 2 MIXER INSTALLATION


2.1 WARNING: EYE PROTECTION MUST BE WORN AT ALL TIMES WHILE SERVICING THIS MIXER. 2.2 Refer to Installation drawing for: a. Proper mixer mounting and location. b. Proper minimum impeller offbottom and relative spacing for dual impeller applications. 2.3 Lockout power before positioning mixer, and review safety instructions before starting mixer. 2.4 The clamp and beamplate are cast offset at recommended 20 horizontal plane and adjustable 010 in the vertical plane. Clamp and beamplate are also available with zero degree offset in the horizontal plane and adjustable 010 in the vertical plane. Refer to Table1 for recommended angular positions.

80

20

TABLE 1 Mixer positioning 2.5 BOLT TIGHTENING TORQUE RECOMMENDATIONS a. Inadequately or improperly tightened hardware can loosen due to vibration or the reactions imposed by fluid forces. This can result in reduced equipment service life or damage and failure. REVISION DATE 5/8/95 INST. No. IT3695 LIGHTNIN

LIGHTNIN

REVISED

MIXERS AND AERATORS

1995

PAGE 1 OF 8

b. Recommended torques for tightening the bolts and screws on your LIGHTNIN mixer are listed with assembly instructions. Use of a torque wrench is recommended to ensure compliance with torque recommendations. c. The amount of torque required to maintain a tight connection can vary considerably for bolts of the same size under different operating conditions. Variations such as basic joint design, compression factors, type and strength of base and hardware material, surface finish of mating parts and lubrication are only some of the factors that influence the tightness of bolted connections for given torque values. d. All bolts should be coated with oil, grease, or an antiseize compound whenever possible. The threads and bearing face of bolt heads and/or nuts should be lubricated. e. ALL BOLTS SHOULD BE RETIGHTENED AFTER THE UNIT HAS BEEN RUN UNDER LOAD FOR TWO (2) WEEKS, AND AT EACH SCHEDULED SHUTDOWN THEREAFTER. f. Unless otherwise specified, it is recommended that metric commercial standard class 8.8 bolts and screws, and class 8 nuts be used for all bolted connections. For inch hardware use GR5.

SECTION 3 SHAFT AND IMPELLER INSTALLATION


3.1 Install the impeller(s) on the mixer shaft (231) by tightening the set screws in the impeller hub. Refer to the installation drawing for recommended dual impeller spacing if two impellers are supplied. Refer to Impeller Assembly drawing for general impeller orientation. 3.2 Clean the mixer shaft (231) end and drive quill (51) thoroughly. 3.3 Orient the drive quill so that the set screw (58) aligns with the hole in the bearing housing (36). Align quill shaft by inserting lower shaft (231) into quill and rotate quill manually. 3.4 Grasp mixer shaft approximately 20 inches below the shaft top and insert the mixer shaft completely into the drive quill, until it contacts the top of the quill bore. Align flat on shaft with set screw (58). Tighten set screw (58).
MIXER SHAFT (231) DRIVE QUILL (35)

HOUSING (36)

SET SCREW (58) INSTALLATION POSITION

HEX KEY (72) REMOVE PRIOR TO RUNNING UNIT

FIGURE 1 Shaft Installation

3.5 DRIVE QUILL ORIENTATION a. NORMAL LIGHT CONDITIONS Rotate the drive quill until the set screw (58) aligns with the access hole in the housing (36). Rotate drive quill by inserting lower shaft into drive quill and rotating by hand. b. LOW LIGHT CONDITIONS If the mixer shaft is being installed in low light conditions, the drive quill can be oriented by feel. Insert lower shaft into drive quill and rotate the drive quill (35) by hand until the set screw (58) can be felt with the hex wrench through the access opening. REVISION DATE 5/8/95 INST. No. IT3695 LIGHTNIN

LIGHTNIN

REVISED

MIXERS AND AERATORS

1995

PAGE 2 OF 8

3.6 With the drive quill oriented, insert the 7/32 hex key (72) provided into the housing opening and tighten the set screw (58) to (1530 ftlbs). DO NOT IMPACT THE WRENCH OR USE AN EXTENSION. 3.7 Check for free movement of all components by rotating the mixer shaft.

SECTION 4 SHAFT REMOVAL


4.1 CAUTION: THE UPPER PORTION OF THE MIXER SHAFT (231) MAY BE HOT TO THE TOUCH. ONCE REMOVED FROM THE DRIVE QUILL (35), DO NOT GRASP THE UPPER 20 OF THE MIXER SHAFT. 4.2 It is recommended that the mixer be removed from the tank before shaft or shaft and impeller are removed. 4.3 Make sure all electrical power is disconnected. 4.4 Grasp impeller by hand (or shaft with a strap wrench) and rotate mixer shaft (231) until the drive quill set screw (58) aligns with the access hole in the housing (36). See Caution above. 4.5 With hex key (72) loosen set screw (58) and back out two (2) turns. See Figure 2. 4.6 Remove mixer shaft from quill. See Caution above.

MIXER SHAFT (231)

DRIVE QUILL (35)

MIXER SHAFT (231) DRIVE QUILL (35) HOUSING (36) HOUSING (36)

SET SCREW (58) ENGAGED

SET SCREW (58) DISENGAGED

HEX KEY (72) REMOVE PRIOR TO RUNNING UNIT

Operating Position FIGURE 2 Shaft Removal

Release Position

SECTION 5 MIXER OPERATION


5.1 This LIGHTNIN mixer is designed for continuous operation and normally needs no additional maintenance. 5.2 Variable speed air drive units should not be operated at the lower shafts natural frequency. At this speed the lower shaft will have excessive runout ( 2 T.I.R.) at the end of the shaft while operating in air. Vary the speed 5% to avoid this speed range. CAUTION: IT IS NOT RECOMMENDED TO OPERATE THE MIXER WITH EXTREME VORTEXING OR SURGING OF THE LIQUID BEING MIXED. 5.3 At the end of two weeks service, check all hardware for tightness. WARNING: AT THE END OF THE MIXING CYCLE, IT IS GOOD PRACTICE TO TURN OFF THE MIXER BEFORE THE TANK HAS BEEN DRAINED TO A LEVEL WHICH WILL RESULT IN EXCESSIVE SPLASHING. THIS MAY RESULT IN SHAFT DAMAGE. REVISION DATE 5/8/95 INST. No. IT3695 LIGHTNIN

LIGHTNIN

REVISED

MIXERS AND AERATORS

1995

PAGE 3 OF 8

SECTION 6 LUBRICATION
6.1 Your LIGHTNIN mixer has been lubricated at the factory with the correct type and amount of high quality lubricants. Lubricant cleanliness is protected by properly designed closures. 6.2 All mixer bearings are the sealed type and are prepacked with lubricant. Relubrication of these bearings is not necessary. 6.3 The gear chamber of this LIGHTNIN mixer has been factory filled with a grease suitable for ambient temperature ranges of 20 C to +50 C (4 F to +122 F). Under normal operating conditions, this lubricant need not be changed until the unit has been dismantled for some reason. Refer to Table 2 for lubricant specifications. 6.4 Under adverse operating conditions, periodic changes of lubricant may be necessary. Adverse conditions are defined as operating in very humid, dust laden, chemical atmospheres, or where wide variations in ambient temperatures occurs. Such adverse conditions can lead to deterioration of lubricant compounds and additives and it is recommended that the condition of the grease be checked within six months of startup. Refer to Section 7 for instructions on disassembling the gear unit. NOTE: THE BEARING HOUSING SHOULD BE FILLED 1/2 INCH FROM THE TOP OF THE BEARING HOUSING. ALL GASKETS SHOULD BE CHECKED FOR INTEGRITY AND REPLACED IF THEY ARE DEFORMED, CUT OR DETERIORATED.

Recommended Grease Manufacturer MOBIL OIL CO.


MOTOR (101)

Gear Housing Capacity Pounds .8

Products MOBILITH SHC 1500


Grease Level

GASKET (43)

SPACER (21) FILL GREASE LEVEL 1/2 FROM TOP OF HOUSING

GASKET (22)

RING GEAR (2) BEARING HOUSING (36)

TABLE 2 Lubricant Recommendations & Capacity 6.5 CHANGING GEAR LUBRICANT a . Remove all old grease from the gear chamber and wipe clean. b . Pack the chamber with fresh grease. See Table 2. Paddle the grease to fill voids and remove air pockets, rotating the shaft and shaking the housing while paddling. c . Check for free movement of all components by rotating the drive shaft. REVISION DATE 5/8/95 LIGHTNIN

LIGHTNIN

INST. No. IT3695 PAGE 4 OF 8

REVISED

MIXERS AND AERATORS

1995

SECTION 7 DISASSEMBLY INSTRUCTIONS


WARNING: DISCONNECT MOTOR LEADS OR OTHERWISE LOCKOUT POWER SUPPLY BEFORE SERVICING THE MIXER. EYE PROTECTION MUST BE WORN. 7.1 This mixer is precision manufactured and assembled to provide long trouble free service when properly maintained. If it becomes necessary to disassemble the unit, careful precise reassemble is necessary. 7.2 Refer to the assembly drawings for location of parts. 7.3 Equipment that will be required to service the mixer, in addition to standard mechanics tools is, a rubber mallet, retaining ring pliers, metric and inch allen wrenches, arbor press and torque wrench. 7.4 When disassembling the mixer, clean external surfaces adjacent to prevent dirt from entering the housings. 7.5 It is recommended that oil seals and gaskets be replaced when the mixer is disassembled. 7.6 SEAL REPLACEMENT Inspect oil seals and gaskets for nicks, gouges and deformities. When replacing seals: a . Coat the lips of seals with bearing grease. b . Install oil seal with lip facing up as shown in Figure 3. c . Coat the section of shaft sealing surface with oil. 7.7 BEARING REPLACEMENT a . Old bearings can be removed with a puller or an arbor press. b . New bearings can be pressed on the shafts. Be careful to apply load only to the inner race. c . Make sure the bearings are tightly seated against the shaft or housing shoulders with no clearance. 7.8 MOTOR REMOVAL a . Remove the mixer from the tank. b . Remove mixer shaft (231) from mixer quill drive as explained in Section 4. c . Set the mixer upright on a clean work surface. d . Remove the (4) socket head cap screws (60) holding the bearing housing (36) and spacer (21) to the motor (101). e . Lift the motor (101), motor coupling assembly (102) and sun gear (9) (Figure 4) off the spacer (21). It may be necessary to tap the bearing housing (36) gently with a rubber mallet to get the bearing housing to separate from the spacer and motor. f . Remove the sun gear (9) from the motor coupling (102) and examine for wear. If reuseable replace sun gear in gear mesh. g . Remove the drive coupling (102) from the motor if necessary. 7.9 BEARING HOUSING DISASSEMBLY a . Remove grease from gear chamber of bearing housing (36). b . Remove sun gear (9) and gear carrier assembly (1) as an assembly. Tape these parts together to prevent the sun gear from accidental removal. Remove any remaining old lubricant. c . Remove hardware (7,8) and remove ring gear (1) from bearing housing (36). d . Remove upper retaining ring (59).
REVISION DATE 5/8/95

LIGHTNIN
MIXERS AND AERATORS

LIGHTNIN
1995

INST. No. IT3695 PAGE 5 OF 8

REVISED

e . Place housing motor end down and remove oil seal (42) from drive quill (35). This seal will be damaged and must be replaced. f . Remove lower retaining ring (44). g . Place the bearing housing upright in a press, and press out drive quill (35) and lower bearing (41). h . Remove lower retaining ring (59) and bearing (41) from the drive quill (35). i . Remove upper bearing (41) and oil seal (38) from bearing housing (36). j . Inspect bearing (41) for excessive wear. Replace if necessary.

SECTION 8 ASSEMBLY INSTRUCTIONS


8.1 QUILL ASSEMBLY Insert the set screw (58) into the drive quill (35) until it is flush with the bore of the quill. 8.2 BEARING MODULE ASSEMBLY a . Press the lower bearing (41) onto the drive quill (35) bearing journal. The bearing must seat against the drive quill shaft shoulder with no visible gap. b . Install the lower external retaining ring (59). c . Press the drive quill assembly into the bearing housing (36) from the bottom until the bearing seats on the housing shoulder. d . Install lower retaining ring (44). e . Press oil seal (42) in place as shown in Figure 3. Make sure the oil seal has the internal spring removed. This is a nonlubricated seal, and will run hot and have a shortened life if the spring is not removed. f . Turn the bearing housing over, support the assembly on the quill shaft (35) and install the upper bearing (41) by pressing it into the bearing housing and onto the quill shaft. g . Install the upper retaining ring (59). h . Support the bearing housing assembly in an upright position and press the drive quill downward until the bearing (41) shoulders on the retaining ring (59). This will relieve any locked in axial load on the bearing created during assembly.
BEARING (41) BEARING HOUSING (36) RETAINING RING (44)

RETAINING RING (59)

OIL SEAL (42) SHOWN WITH SPRING REMOVED QUILL SHAFT (35)

FIGURE 3 Oil Seal Installation i . PACK THE GEAR CARRIER (1) with grease and rotate the gears several times to distribute the grease to the needle bearings. Refer to Section 6 for lubricant recommendations. REVISION DATE 5/8/95 INST. No. IT3695 LIGHTNIN

MIXER SHAFT (231)

LIGHTNIN

REVISED

MIXERS AND AERATORS

1995

PAGE 6 OF 8

j . Align the flats on the inside of the gear carrier (1) with the flats on the drive quill (35). Place the gear carrier and sun gear (9) assembly onto the drive quill. k . Install the ring gear (2), hollow pins (5), and hardware (7,8) in bearing housing (36). l . Install gasket (22) in its groove on the bearing housing, and gasket (43) in its groove in the spacer. m . Remove the sun gear (9) from the gear carrier (1). n . Place the drive coupling (102) on the motor shaft if necessary. o . Install the sun gear (9) into the drive coupling (102) until it shoulders against the drive coupling. Tighten the two set screws to 7 ftlbs. p . Set the elevation of the sun gear to the dimension shown in Figure 4 and tighten the remaining two coupling set screws to 7 ftlbs.

SUN GEAR (9)

4.25 DRIVE COUPLING (102)

MOTOR (101)

FIGURE 4 Sun Gear Placement q . Fill the bearing housing with lubricant to approximately 1/2 from the top. Refer to Section 6 for lubricant recommendations. 8.3 FINAL ASSEMBLY a . Bolt the bearing housing (36) and spacer (21) to the motor (101), using socket head cap screws (60) and washers (61). Alternately tighten the hardware to 9 ftlbs to ensure that all components are drawn evenly together. b . Install mixer shaft (231) as outlined in Section 3.

SECTION 9 AIR MOTOR REQUIREMENTS


Be sure your compressor has capacity for both pressure and the proper cubic feet per minute air displacement. Wet air, and low pressure will cause sticking of the motor, requiring hand starting. It is important to use an air filter and moisture trap near the motor for removal of foreign matter. Maximum recommended operating pressure is 100 P.S.I.

REVISION

DATE

5/8/95

LIGHTNIN
MIXERS AND AERATORS

LIGHTNIN
1995

INST. No. IT3695 PAGE 7 OF 8

REVISED

TABLE 3 AIR PRESSURE / AIR CONSUMPTION GUIDE FOR AIR MOTOR DRIVEN MIXER (AIR MOTOR OPERATING AT 1800 RPM)
PRESSURE CONSUMPTION REQUIRED H.P. 1/3 1/3 1 1 GAST MOTOR # #2 #2 #4 #4 SHAFT RPM 1800 360 1800 360 * (PSIG) 60 60 85 85 ** (CFM FREE AIR) 15 15 30 30

* Live pressure should be approximately 11/2 times the operating pressure of the air motor. The full line pressure will then be available for overloads and startup. ** CFM free air refers to air at atmospheric conditions measured at the inlet of the compressor.

SECTION 10 AIR MOTOR LUBRICATION


10.1 Use only a high detergent lubricant of the recommended viscosity. Recommended oils are shown in Table 4. 10.2 For continuous duty or high speed operation, it is recommended that an automatic lubricating device in the air line be provided to feed 1 to 3 drops per minute to the motor. If required request optional airline lubricator (part # 151030psp). 10.3 For manual oiling, remove the oil cap at the top of the motor, and add one squirt of oil at the end of each 8 hours of operation.
RECOMMENDED LUBRICANT
GAST AD 220 (SAE #10) OR A HIGH DETERGENT AUTOMOTIVE ENGINE OIL DESIGNED FOR ANY ONE OR MORE OF THE FOLLOWING API SERVICE RATINGS SB, SC, SD, SE, CB, CC, CD. A HIGH DETERGENT AUTOMOTIVE ENGINE OIL DESIGNATED FOR ANY ONE OR MORE OF THE FOLLOWING API SERVICE RATINGS SB, SC, CD, CE, CB, CC, CD.

AMBIENT TEMPERATURE GRADE OF OIL BELOW 32 F


32 F TO 100 F DILUTE SAE #10 OIL WITH 25% KEROSENE SAE #10 OIL

101 F TO 200 F

SAE #20 OIL

TABLE 4 Motor Lubrication

REVISION

DATE

5/8/95

LIGHTNIN
MIXERS AND AERATORS

LIGHTNIN
1995

INST. No. IT3695 PAGE 8 OF 8

REVISED

Pneumatic Actuators
Specifications Series 79 P: Type Double Piston, Double Rack and Pinion Bodies Aluminum, Glass-filled Polyamide, and 316 ss Torque 46 to 26,696 in-lbs Models Air-to-Air Spring Return (Fail Open) Spring Return (Fail Closed) Air Supply 60 psi 120 psi Air Connections 1/4" NPT Mounting Dim. ISO and NAMUR

Series 79P (Aluminum)


with solenoid valve

Series 79P (Glass-filled Polyamide)


with solenoid valve

Series 79P (316 Stainless Steel)


Standard Features
Manual override For A-A Insert wrench onto flats of stem and rotate For A-S Declutchable gear-operator is required

Standard Features
Standard actuator bodies glass-filled polyamide (highly corrosion resistant) Double piston, double rack and pinion design (polyamide) ISO mounting pattern with female square outdrive (for ease of valve mounting) NAMUR mounting pattern (for accessory mounting solenoids, limit switches, positioners, etc.) Recommended air supply 80 psi (normal) to 120 psi (maximum) filtered air Concentric spring sets (spring return models only) for consistent output torque Available in air-to-air (double acting) and air-to spring (spring return failsafe) models Position Indication through visible indicator knob and actuator shaft flats Actuator shaft in glass filled polyamide with SS insert (Model AP79P), 303 SS (Models B thru D79P) and steel covered by cataphoresis (Model E thru G79P) 24

Options
316 SS bodies (Models BS79P thru DS79P) Aluminum bodies with Rilsan and cataphoresis coating (Models A79P thru D79P) Flush mount NAMUR style solenoids in various NEMA ratings and voltages with mufflers, speed controls, and push button override standard. NAMUR double limit switches in a variety of NEMA ratings (NEMA IV and VII standard) and sensor options (2-mechanical SPDT switches standard) Positoners in either 3-15 psi or 4-20mA for modulating service requiring no solenoid (optional limit switch packages and 4-20mA output signal available) Bus systems ASAHI/AMERICA
Rev. D 06-06

Pneumatically Actuated Ball Valves


WITH OPTIONS

C1

C2

OPTIONS

Type 79 P on Type 21 Ball Valve

HARDWARE

COUPLING PPG BRACKET

H
HARDWARE

H1

Dimensions (Sizes 1/2" 4")


NOMINAL SIZE
INCHES

A Model No. Model No. Air-Air Air-Spring AP79PN AP79PSN AP79PN AP79PSN AP79PN AP79PSN AP79PN AP79PSN AP79PN BP79PSN AP79PN CP79PSN CP79PN CP79PSN CP79PN DP79PSN H 2.76 3.01 3.29 3.64 3.98 4.43 5.12 5.47 6.97 H1 1.14 1.38 1.54 1.85 2.17 2.60 2.83 3.35 4.33 A-A 3.34 3.34 3.34 3.34 3.34 3.34 5.00 5.00 6.49 A-S 3.34 3.34 3.34 3.34 4.40 5.00 5.00 6.49 6.49 A-A 4.22 4.22 4.22 4.22 4.22 4.22 7.00 7.00 9.21

B A-S 5.55 5.55 5.55 5.55 5.86 7.64 8.74 11.49 11.49 A-A 1.47 1.47 1.47 1.47 1.47 1.47 1.97 1.97 2.56

C A-S 1.47 1.47 1.47 1.47 1.73 1.97 1.97 2.56 2.56 A-A 5.41 5.41 5.41 5.41 5.41 5.41 5.89 5.89 6.48

C1 A-S 5.41 5.41 5.41 5.41 5.41 5.41 5.89 5.89 6.48 A-A 1.21 1.21 1.21 1.21 1.21 1.21 1.85 1.85 2.36

C2 A-S 1.21 1.21 1.21 1.21 1.41 1.85 1.85 2.36 2.36

mm

1/2 3/4

15 20 25

1 1/4 32 1 1/2 40 2 3 4 50 80 2 1/2 65

100 DP79PN DP79PSN

35 Green Street, P.O. Box 653, Malden, MA 02148 Tel: 800-343-3618 781-321-5409 Fax: 800-426-7058 E-mail: asahi@asahi-america.com Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.com

25

Pneumatically Actuated Type 23


WITH OPTIONS

C1

C2

OPTIONS
C

12

11

14

10

13

Series 79P on Multiport Valve


B

HARDWARE COUPLING

PPG BRACKET
H

HARDWARE
H1

Dimensions (Sizes 1/2" 4")


NOMINAL SIZE
INCHES

A Model No. Model No. Air-Air Air-Spring H1 3.08 3.56 4.32 5.71 6.66 9.59 11.58 A-A 3.34 3.34 3.34 3.34 3.34 5.00 6.49 A-S 3.34 3.34 3.34 4.40 5.00 6.49 6.49 A-A 4.22 4.22 4.22 4.22 4.22 7.00 9.21

B A-S 5.55 5.55 5.55 5.86 7.64 11.49 11.49 A- A 1.47 1.47 1.47 1.47 1.47 1.97 2.56

C A-S 1.47 1.47 1.47 1.73 1.97 2.56 2.56 A-A 5.41 5.41 5.41 5.41 5.41 5.89 6.48

C1 A-S 5.41 5.41 5.41 5.66 5.89 6.48 6.48 A- A 1.21 1.21 1.21 1.21 1.21 1.85 2.36

C2 A-S 1.21 1.21 1.21 1.41 1.85 2.36 2.36


Rev. D 06-06

H 1/2 15 AP79PN AP79PSN 2.76


3/4

mm

20 AP79PN AP79PSN 3.01 25 AP79PN AP79PSN 3.29 50 AP79PN CP79PSN 4.43 80 CP79PN DP79PSN 5.47 100 DP79PN DP79PSN 6.97

1 2 3 4

1 1/2 40 AP79PN BP79PSN 3.98

26

ASAHI/AMERICA

Pneumatic Actuator and Options


SWITCH ASSEMBLY
2.3
OPEN

SWITCH ASSEMBLY WITH SOLENOID

2.9
OPEN

BEACON OPEN

5.4

2.6 5.4 3.3 1/2"NPT 1/2"NPT


A A
OPEN

1/4"NPT 2HOLES J 0.94 B

E F: DIA. K: THREAD L: DEPTH 4 HOLES 3D VIEW

H 7.5
VIEW A-A

4.8
INSTRUMENT AIR SUPPLY

CAM STOP
6.03

A 1.28 B

ECKARDT POSITIONER

WESTLOCK K-10 POSITIONER

Dimensions (INCHES) ACTUATOR WITH LIMIT SWITCH


E
ACTUATOR SIZE

Dimensions (INCHES) ACTUATOR WITH POSITIONER


E
ACTUATOR SIZE

Air
CONSUMPTION
MODEL NO.

A Cubic Inches 6.0 9.0 19.5 52.0

B C A-A A-S F H G J K L AP79P 1.75 2.56 4.22 5.55 1.65 1.21 1.48 3.34 6mm .16 BP79P 2.16 3.14 4.92 5.86 1.97 1.41 1.73 4.40 6mm .50 CP79P 2.16 3.81 7.00 8.74 2.76 1.85 1.96 5.00 8mm .62 DP79P 2.16 5.15 9.21 11.49 2.76 2.36 2.55 6.49 8mm .75

3-15 4-20 B C A-A A-S psi mA AP79P 1.75 2.56 4.22 5.55 2.28 4.15

AP79P BP79P CP79P DP79P

BP79P 2.16 3.14 4.92 5.86 2.28 4.15 CP79P 2.16 3.81 7.00 8.74 2.28 4.15 DP79P 2.16 5.15 9.21 11.49 2.28 4.15

35 Green Street, P.O. Box 653, Malden, MA 02148 Tel: 800-343-3618 781-321-5409 Fax: 800-426-7058 E-mail: asahi@asahi-america.com Register at our interactive web site for on line ordering, product availability, order tracking, and many useful features: www.asahi-america.com

27

Control Duty Mechanical Narrow Angle Switch

Designed for accurate liquid level control in many applications including potable water or sewage environments. The float switch can be utilized to signify specific water levels or for direct alarm actuation. NORMALLY OPEN (N/O) As the float rises 1" (5) above horizontal, the contacts become closed and actuate (turn on) the switch. This float is generally used in pump down applications. NORMALLY CLOSED (N/C) As the float rises 1" (5) above horizontal, the contacts become open and actuate (turn off) the switch. This float is generally used in pump up applications. SINGLE POLE, DOUBLE THROW (SPDT) A variation of the N/O & N/C, this float switch can be wired to operate as either (but not both) a normally open or a normally closed switch based on the users need.

The mechanically activated micro switch is designed to operate under a min/max temperature of 32-190 F , and has an electrical rating of 10 AMPS @ 120 VAC or 5 AMPS @ 240 VAC. The power cord is a chlorinated polyethylene type SJOOW-300 Volt on 16/2 for N/O or N/C switch or 16/3 for SPDT switch. The float is constructed of a durable ABS material, and is tested and proven to be leak proof, shock proof, and impact resistant. The cord weight is made of zinc plated cast iron. At 1.22 lbs. the split weight design allows for easy adjustment, and a secure and permanent attachment to the cord.

20

Conery Mfg Inc 1380 Enterprise Pkwy Ashland, Ohio 44805

SIGNET 2714-2717 Twist-Lock pH and ORP Electrodes


3-2714.090-1 G-1/02 English

ENGLISH

SAFETY INSTRUCTIONS 1. Depressurize and vent system prior to installation or removal. 2. Confirm chemical compatibility before use. 3. Do not exceed maximum temperature/pressure specifications. 4. Wear safety goggles or faceshield during installation/service. 5. Do not alter product construction. 6. When using chemicals or solvents care should be taken and appropriate eye, face, hand, body, and/or respiratory protection should be used.

1. Technical Data
1.1 General Compatibility: +GF+ SIGNET 2720 Twist-Lock Preamplifier

BAR PSI 7 100


2714-HF

Pipe Size Range: 1/2 in. and up. Use +GF+ SIGNET installation fittings to 4 in. Use pipe adapter in pipes over 4 in. Submersion with 2720 pre-amplifier requires 3/4 in. NPT or ISO 7-R 3/4 in. male threaded extensions Efficiency: Wetted Materials: >97% @ 25C (77 F) CPVC Body Glass FPM O-rings Porous UHMW Polyethylene reference junctions ORP: Platinum sensing surface 2714, 2715: Flat surface resists fouling 2716, 2717: Bulb surface for general use 2714-HF: Extended use in applications with trace hydrofluoric acid (<2%) 2716-DI: Extended use in pure waters (<100 S) Nylon Filament Ag/AgCl 0.2 kg (0.4 lb)

5 3 2

75 50 25 0 10 32 50 25 77 50 122
2714

75 167

C F

1.4 Temperature and pressure specifications ORP electrode operating Temperature/Pressure 6.89 bar @ 0C to 65C (100 psi @ 32 to 149 F) 4.00 bar @ 66C to 85C (58 psi @150 to 185F) 2716 and 2716-DI pH electrode operating Temperature/Pressure 6.89 bar @ 0C to 65C (100 psi @ 32 to 149 F) 4.00 bar @ 66C to 85C (58 psi @150 to 185F) 2714 pH electrode operating Temperature/Pressure 6.89 bar @ 10C to 65C (100 psi @ 50 to 149 F) 4.00 bar @ 66C to 85C (58 psi @150 to 185F) 2714-HF pH electrode operating Temperature/Pressure 6.89 bar @ 0C to 50C (100 psi @ 32 to 122 F) Storage Temperature: > -12 C (11 F) 1.5 Dimensions
1.0 in. (27 mm) 1.0 in. (27 mm)

Primary Functions:

Secondary Junction: Element: Shipping Weight:

1.2 2714 and 2716 pH Electrodes Operating Range: 0 to 14 pH (2714-HF: 0 to 12 pH) Reference: Electrolyte: Solidified Acrylamide Gel 3.5M KCI (2714, 2714-HF, 2716) 0.1 M KCl (2716-DI) Temperature Sensor: 3K Balco (3000 = 25C) ResponseTime: <5 s for 95% of signal change Response Time, : 140 s (2714), 196 s (2716) 1.3 2715/2717 ORP Electrodes Operating Range: -999 to +999 mV Reference: Electrolyte: Solidified Acrlyamide Gel 3.5M KCL Response Time: Application dependent

1.2 in. (30.5 mm) 3.8 in. (97 mm) 2.6 in. (65 mm)

1.2 in. (30.5 mm) 4.1 in. (104 mm) 2.6 in. (65 mm)

3.4 in. (86 mm)

3.4 in. (86 mm)

0.9 in. (23 mm)

0.9 in. (23 mm)

Flat electrode
SIGNET 2714-2717 Twist-Lock pH and ORP Electrodes

Bulb electrode
page 1 of 4

2. Electrode care and application


pH/ORP electrodes are similar to batteries; they age with time and usage. The following information will help maximize electrode life. 2.1 Conditions to Avoid: High temperatures, strong acids or caustics will elevate electrochemical reactions and speed electrode aging. Coatings on the glass or junction surfaces (i.e. proteins) cause extended response time and inaccurate measurement. Never store the electrode tip in deionized (DI) water. Never expose electrode to temperatures below -12 C (10 F) or allow it to dehydrate. These conditions will damage the electrode. Never scrape or sand the glass electrode surface. Treat glass electrode surfaces with care. The glass is very thin and requires care to prevent accidental breakage. 2.2 Submersible Installation Tips: Mount electrodes in a location with ample clearance for removal for periodic cleaning and recalibration. Choose a location that keeps the electrode glass completely submerged at all times. Place the electrode tip in pH 4 buffer during system maintenance or storage to avoid dehydration. Mount the electrode near tank outlet away from reagent addition areas.
30

YES

YES

30 NO NO

2.3 In-Line Installation Tips: pH and ORP electrodes respond best in moving fluids. The internal measuring electrode chamber contains a wire within a liquid and a slight amount of air. The electrode must be mounted at least 30 from horizontal to ensure proper sensing. Mounting angles less than 30 will impede performance.

NO

3. pH Electrode Calibration
All pH electrodes are designed to ensure linearity during their lifespan. The following sections define proper electrode operation. 3.1 Offset (STD) Electrode offsets occur due to: Clogged reference junction Aged or contaminated reference solution/wire Check offsets in a pH 7 buffer @ 25 C. The theoretical output is 0 mV. Any deviation from 0 mV is the pH electrode offset. pH Electrode Offset pH 7 buffer @ 25C
Theoretical mV Values @ 25C pH mV 2 + 295 mV 3 + 236 mV 4 +177 mV 5 +118 mV 6 + 59 mV 7 0 mV 8 - 59 mV 9 - 118 mV 10 - 177 mV 11 - 236 mV 12 - 295 mV

Theoretical: 7.0 pH (0.0 mV) New: pH 7 0.25 pH (15 mV) Reliable: pH 7 0.85 pH ( 50 mV) Electrode offsets greater than 0.85 pH (50 mV) indicate the electrode requires cleaning or replacement. See section 5: Maintenance and cleaning.
C 2 15 25 35 45 55 0.15 0 0.15 0.3 0.45 3 0.12 0 0.12 0.24 0.36 4 0.09 0 0.09 0.18 0.27 5 0.06 0 0.06 0.12 0.18 6 0.03 0 0.03 0.06 0.09 pH Error 7 0 0 0 0 0 8 0.03 0 0.03 0.06 0.09 9 0.06 0 0.06 0.12 0.18 10 0.09 0 0.09 0.18 0.27 11 0.12 0 0.12 0.24 0.36 12 0.15 0 0.15 0.3 0.45

3.2 Slope (SLP) Electrode slope is the number of mV per pH unit. At 25C the theoretical slope is 59.16 mV per pH. Temperature has an appreciable affect on electrode slope. Reliable instrumentation includes temperature compensation. The graph below illustrates potential pH error when a temperature compensated instrument is not used.

Recommendations: Calibrate temperature before calibrating the standard and slope. The mV offset will track across the entire pH range. The slope is usually not affected by offset changes. (i.e. pH 7= +10 mV, pH 4= +187 mV); slope = 59 mV Coatings on the glass may affect sensor slopes. See section 5 maintenance and cleaning. A constant output near 0 mV in all buffer solutions indicates a shorted electrode that must be replaced. 3.3 Response Time/Stability Response time and stability are affected by the condition of the pH electrode's glass surface (ORP electrode - Platinum surface), reference junction, and reference solution. Restoration to acceptable levels can often be accomplished by cleaning the electrode's glass surface (ORP electrode - Platinum surface) and reference junction. Electrode mV values should remain stable 3 mV. Conditions that may cause fluctuations are: 1. Electrode coating 2. Ground fault: If proper operation is observed in the beaker, but is unstable in the application, a ground fault probably exists. Using instrumentation with isolated inputs and outputs may restore stable operation. Solution grounding may also restore stable operation.
page 2 of 4 SIGNET 2714-2717 Twist Lock pH and ORP Electrodes

4. ORP Electrode Calibration


All ORP electrodes are designed to ensure linearity during their lifespan. The following sections define proper electrode operation. 4.1 Offset (STD) Electrode offsets occur due to: Clogged reference junction Aged or contaminated reference solution/wire Offsets are easily checked in pH 7 buffer saturated with quinhydrone @ 25 C; since the theoretical output is +87 mV. Any deviation from +87 mV is the ORP electrode offset (i.e. +90 mV). Quinhydrone is the oxidizer measured by the ORP electrode and is required for calibration. To guarantee buffer saturation, mix 1/8g quinhydrone per 50 mL of pH buffer. ORP Electrode Offset: Solution: pH 7 or pH 4 buffer saturated with Quinhydrone @ 25 C pH 7 + Quinhydrone + 87 mV 87 15 mV 87 50 mV pH 4 + Quinhydrone + 264 mV +264 15 mV +264 50 mV

Theoretical mV: New: Reliable:

Electrode offsets greater than 50 mV indicate the electrode requires cleaning or replacement, see section 5.2.

4.2 Slope (SLP) ORP slope errors are generally caused by contamination of the platinum electrode surface. Cleaning the electrode surface will usually restore proper values, response time, and stability. Common ORP Values Reaction Cr Cr2+ + 2eFe Fe2+ + 2eCr2+ Cr3+ + e4OH- O2 + 2H2O + 4e 2I- I2 + 2eTi2+ Ti3+ + eNi Ni2+ + 2ePb Pb2+ + 2eFe Fe3+ + 3eH2 2H+ + 2eFe2+ Fe3+ + eAg Ag+ + ePb Pb4+ + 4e3Br- Br3- + e2Br- Br2 + 2eClO2- ClO2 + ePt Pt2+ + 2eAg Ag2+ + 2emV - 913 - 440 - 407 - 401 - 400 - 370 - 250 - 126 - 37 0 + 771 + 799 + 800 + 1060 + 1066 + 1160 + 1188 + 1369

Many systems require both pH and ORP calibration. To conserve calibration reference solutions, use pH 7 and 4 buffers for pH calibration first. ORP calibration can be performed with the same buffers by adding quinhydrone.

5. Maintenance and Cleaning


5.1 Maintenance Variables can affect long term pH or ORP electrode life. For this reason, a maintenance log is recommended for trend analysis. When storing boxed sensors, lay the sensor flat to maximize hydration of the glass surface. Keep the glass surface wet at all times. Soak the sensor tip in pH 4.0 buffer during system maintenance intervals. In-line applications should be plumbed with a depression (trap) so liquid is maintained around the sensor tip. If the sensor dehydrates, soak the sensor tip in pH 4 buffer for 24 to 48 hours, then visually inspect the electrode for surface cracks, swelling, or discoloration. Severely dehydrated electrodes cannot be restored to normal operation.

SIGNET 2714-2717 Twist-Lock pH and ORP Electrodes

page 3 of 4

5.2 Cleaning Cleaning techniques vary depending on the type of coating present on the glass electrode surface or reference junction. Soft coatings can be removed by vigorous stirring, or with directed spray of an applicable detergent or solvent onto the glass electrode surface. Chlorine bleach or mild detergent may be used to remove soft coatings. Always rinse electrode tip in clean water after cleaning. Hard coatings can be chemically removed. Use the least harsh chemical which will remove the contaminant within two (2) minutes without attacking the materials of construction. e.g. calcium carbonate may be removed with a 5% HCL (muriatic acid) solution. Oily or organic coatings can be removed with detergents or an appropriate solvent that does not attack the materials of construction e.g. isopropyl alcohol may be used but acetone must be avoided to prevent damage to the CPVC sensor body. ORP electrode surface (platinum rod) can be gently sanded with 600 grit wet and dry silicone or carbide sandpaper, jewelers rouge, crocus cloth, or very fine steel wool.

WARNING! Wear appropriate eye, face, hand, body, and respiratory protection when using chemicals or solvents.

6. Replacement parts and accessories


Mfr. Part No. 3-2714 3-2714-HF 3-2715 3-2716 3-2716-DI 3-2717 3-2759 3-2759.393 3-2720 3-2720-2 P31515-0P200 P31515-0C200 P31515-0V200 3-0700.390 1220-0021 1224-0021 1228-0021 Code 198 844 300 198 844 305 198 844 301 198 844 302 198 844 306 198 844 303 159 000 762 159 000 765 198 864 602 198 864 603 159 000 630 159 000 631 159 000 459 198 864 403 198 801 186 198 820 006 198 820 007 Description Flat pH Electrode Flat pH Electrode, HF Resistsant Flat ORP Electrode Bulb pH Electrode Bulb pH Electrode, DI Resistant Bulb ORP Electrode pH/ORP Simulator/System Tester Adapter Cable for use with 2720 Preamplifier, 3/4 in. NPT Preamplifier, ISO 7-R 3/4 in. PVC Pipe Adapter CPVC Pipe Adapter PVDF Pipe Adapter pH Buffer Kit O-ring, FPM (standard) O-ring, EPR O-ring, Kalrez

3-2759 pH/ORP Simulator/System Tester

ORP

pH

a o n m

b c d c

CAUTION! Apply O-ring lubricant to sensor O-rings prior to assembly. Unlubricated O-rings may score the sealing surface in the 2720. Technical Features a) Male BNC connector b) Keyed for a simple sure fit c) Viton O-rings d) Silicone-bushing seal e) Double junction f) Ag/AgCl reference element g) Platinum sensing surface (ORP) or flat pH glass h) Porous UHMW polyethylene reference junction

i) j) k) l) m) n) o)

3K Balco thermistor Solidified acrylamide reference electrolyte Ag/AgCl measuring element Large reference volume Epoxy seal Shielding 10K I.D. resistor for ORP sensor

l k j i h e f g

SIGNET
Signet Scientific Company, 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. Tel. (626) 571-2770 Fax (626) 573-2057 For Worldwide Sales and Service, visit our website: www.gfsignet.com Or call (in the U.S.): (800) 854-4090 GEORGE FISCHER Piping Systems
3-2714.090-1/(G-1/02) English Signet Scientific Company 2001 Printed in U.S.A. on recycled paper

page 4 of 4

SIGNET 2714-2717 Twist Lock pH and ORP Electrodes

SIGNET 2720 Twist-Lock pH/ORP Preamplifier


3-2720.090-1
C-7/02 English

ENGLISH

SAFETY INSTRUCTIONS FOR IN-LINE ELECTRODE INSTALLATION 1. Do not remove from pressurized lines. 2. Do not exceed maximum temperature/pressure specifications. 3. Wear safety goggles or face shield during installation/service. 4. Do not alter product construction. Failure to follow safety instructions may result in severe personal injury!

1. Wiring
Preamplifier:
Silver (earth ground)

Preamplifier: (mV Input) (Iso. Gnd) (T+) (T-) (V+) (V-) 5700
ENTER

Silver (earth ground)

Brown Blue Green White Red Black pH Electrodes: 2714 2714-HF 2716 2716-DI Preamplifier: Red Black Green Brown White Blue pH Electrodes: 2714 2714-HF 2716 2716-DI Use X1 gain selection ORP Electrodes: 2715 2717

ALARM 1

4 2

pH

10 12

ALARM 2

Brown Blue Black Red Green White pH Electrodes: 2714 2714-HF 2716 2716-DI Preamplifier: ORP Electrodes: 2715 2717

(mV Input) (Iso. Gnd) (V-) (V+) (T+) (T-) +GF+ SIGNET 8710

14

+GF+ SIGNET

Silver (earth ground)

Silver (earth ground)

(#10) V+ (#11) V(#12) T+ (#13) Ain (#14) ISO (#14) ISO

pH CONTROLLER
RLY 1 RLY 2 RLY 3 RLY 4

Red Black Green


mV

ENTER

MOD

pH

White Brown Blue ORP Electrodes: 2715 2717 Use X1 gain selection

TEMP CAL RELAY OUTPUT

(#10) V+ (#11) VN/C N/C (#13) Ain (#14) ISO

ORP CONTROLLER
RLY 1 RLY 2 RLY 3 RLY 4

ENTER

MOD

ORP

mV

CAL

RELAY

OUTPUT

+GF+ SIGNET 9030

+GF+ SIGNET 9040

Technical Notes: Use 6-conductor shielded cable for cable extensions to 120 m (400 ft) Shield must be maintained through cable splice

2. +GF+ SIGNET Fittings


Type Plastic tees Description 0.5 to 4 in. PVC or CPVC Mounts via glue-on fittings 2 to 4 in., use 1-7/16 in. hole in pipe Align wedge arrows with saddle arrows during assembly. Type Carbon steel weld-on weldolets Carbon steel threaded tees Description 2 to 4 in, use 1-7/16 in. hole in pipe Remove insert before welding Installed by certified welder only 0.5 to 2 in. Mounts on threaded pipe ends

PVC saddles

Iron strap-on saddles

2 to 4 in., use 1-7/16 in. hole in pipe

Universal pipe adapter for large pipes, #P31515-OV200

For existing pipe fittings 2 in. and up External 1-1/4 inch NPT male threads

Consult your local +GF+ SIGNET distributor for additional fitting information.

3. Recommended Position
3/4 in. NPT OR ISO 7/1-Rc 3/4 female threads
Customer supplied: 3/4 in. NPT nipple (male) J-box flex conduit
C. B. D. A.

Customer supplied: 3/4 in. NPT threaded pipe (A) J-box (B) Flex conduit (C) Quick release pipe clamp (D) Tank flange (E)

B. C. A.

0
+60

E.

-60
In-Line

2 in. min.

Process pipe

Open tanks

Closed tanks

Vertical (0) position optimum 4 fps or less for max. performance and sensor life

Caution: If liquid level is not constant, always ensure liquid contact with electrode tip

4. Installation
In-line Applications Submersible Applications

Sealant Preamplifier Preamplifier Customer supplied pipe 3/4 in. NPT or ISO 7/1-Rc 3/4 A. O-ring lubricant recommended (factory applied) C. B. Align marks Hand tighten only! A. O-ring lubricant recommended (factory applied) C. B. Align marks Sealant

#P31542 Sensor Cap (purchased separately)

Fitting inlet

Fill with 3 to 4 in. of sealant

Attach 3/4 in. watertight pipe to the top of the 2720. Secure the threaded connection to prevent any leakage. For additional defense against possible accumulation of condensation at the back seal area of the sensor, fill the lower 3 to 4 inches of conduit or extension pipe with a flexible sealant such as silicone.

5. Accessories

Part no. P31542

Description Sensor cap Sensor O-ring, 2 required

Material PP

Code 198 801 630

1220-0021 1224-0021 1228-0021

Viton EPR Kalrez

198 801 186 198 820 006 198 820 007

CAUTION! When replacing O-rings, apply O-ring lubricant to sensor O-rings prior to preamplifier/electrode assembly. Unlubricated O-rings may score the preamplifier sealing surface.

6. Specifications
+GF+ SIGNET 2720 Twist-Lock pH/ORP Preamplifier Housing material: CPVC Compatible sensors: 2714 Flat Surface pH Electrode 2714-HF Flat Surface pH Electrode 2715 Flat Surface ORP Electrode 2716 Bulb pH Electrode 2716-DI Bulb pH Electrode 2717 Bulb ORP Electrode Input Impedance: >1011 Operating temp.: 0 to 80 C Gain: X1 (unity) Input power: 4.5 to 8 VDC, dual supply Current consumption: <1 mA, dual supply Quality standard: CE +GF+ SIGNET pH/ORP Electrodes General Specifications Wetted parts: Sensor body: CPVC O-rings: Viton Electrode junction: Porous UHMW polyethylene Quality standard: CE Maximum pressure/temperature ratings: 7 bar (100 psi) max. @ 65 C (149 F) 4 bar (58 psi) max. @ 85 C (185 F)
BAR PSI 7 100 5 75 50 25 F C 77 122 167 212 25 50 75 100

Dimensions:

Std.15 ft/ 4.6 m cable

3/4 in. NPT OR ISO 7/1-Rc 3/4 female threads

3.6 in./ 91 mm

1.8 in./ 46 mm

SAFETY INSTRUCTIONS FOR IN-LINE ELECTRODE INSTALLATION 1. Do not remove from pressurized lines. 2. Do not exceed maximum temperature/pressure specifications. 3. Do not install/service without following installation instructions (see sensor manual). 4. Wear safety goggles and faceshield during installation/service. 5. Do not alter product construction. 6. Failure to follow safety instructions could result in severe personal injury!

7. Preamplifier Troubleshooting
Procedure: A. Install sensor adapter into preamplifier B. With preamplifier and instrument connected, simulate pH 4, 7, and 10 and record displayed mV readings (right) and approximate preamplifier response time between simulations. C. Refer to table on next page for preamplifier troubleshooting tips.
Simulator Input 4.00, +177 mV 7.00, 0 mV 10.00, -177 mV Preamplfier response time: Actual displayed mV ________________________ ________________________ ________________________ ________________________

With simulator connected

Error Condition A) mV output stuck at zero B) mV output erratic C) mV output stuck at 1.4 VDC

Possible Cause A) Shorted input signal B) Faulty preamplifier or wiring C) Faulty preamplifier

Possible Remedy A) Check preamplifier cable connections and shielding. B) Verify preamplifier shield connections. Verify cable shield wire has been maintained through each cable splice. C) Replace preamplifier

Okay with simulator connected but fails with electrode

A) mV output stuck near zero B) mV output erratic C) Output stuck at 1.4 VDC

A) Cracked electrode glass B1) Poor contact between electrode and preamplifier connectors B2) Fouled electrode reference or aged electrode B3) Ground loop C) Faulty preamplifier

A) Replace electrode B1) Check contacts between electrode and preamplifier. Contacts must be clean and dry. B2) Clean electrode, see electrode manual B3) Isolate electrode in test beaker. If output is stable, ground loops may exist causing erratic behavior; isolate instrument outputs (i.e. 4 to 20 mA, 0 to 5 VDC). C) Replace preamplifier

8. Electrode Maintenance and Cleaning


8.1 Maintenance Variables can affect long term pH or ORP electrode life. For this reason, a maintenance log is recommended for trend analysis. When storing boxed sensors, lay the sensor flat to maximize hydration of the glass surface. Keep the glass surface wet at all times. Soak the sensor tip in pH 4.0 buffer during system maintenance intervals. In-line applications should be plumbed with a depression (trap) which ensures liquid is maintained around the sensor tip. If sensor dehydration has occurred, soak the sensor tip in pH 4 buffer for 24 to 48 hours, then visually inspect the electrode for surface cracks, swelling, or discoloration. 8.2 Cleaning Cleaning techniques vary depending on the type of coating present on the glass electrode surface or reference junction. Soft coatings: can be removed by vigorous stirring, or with directed spray of an applicable detergent or solvent onto the glass electrode surface. Chlorine bleach or mild detergent may be used to remove soft coatings. Always rinse electrode tip in clean water after cleaning. Hard coatings: can be chemically removed. Always use the least harsh chemical which will remove the contaminant within two (2) minutes without attacking the materials of construction. e.g. calcium carbonate may be removed with a 5% HCL (muriatic acid) solution. Oily or Organic Coatings: can be removed with detergents or an appropriate solvent that does not attack the materials of construction e.g. isopropyl alcohol may be used but acetone must be avoided to prevent damage to the CPVC sensor body. ORP electrode surface (platinum rod): can be gently sanded with 600 grit wet and dry silicone or carbide sandpaper, jewelers rouge, crocus cloth, or very fine steel wool.

WARNING! When using chemicals or solvents care should be taken and appropriate eye, face, hand, body, and/or respiratory protection should be used.

9. Replacement parts and accessories


Mfr. Part No. 3-2720 3-2720-2 3-2714 3-2714-HF 3-2715 3-2716 3-2716-DI 3-2717 3-2759 3-2759.393 3-0700.390 Code 198 864 198 864 198 844 198 844 198 844 198 844 198 844 198 844 159 000 159 000 198 864 602 603 300 305 301 302 306 303 762 765 403 Description Preamplifier, 3/4 in. NPT Preamplifier, ISO 7-R 3/4 in. Flat pH Electrode Flat pH Electrode, HF Resistsant Flat ORP Electrode Bulb pH Electrode Bulb pH Electrode, DI Resistant Bulb ORP Electrode pH/ORP Simulator/System Tester Adapter Cable for use with 2720 pH Buffer Kit

3-2759 pH/ORP Simulator/System Tester

ORP

pH

SIGNET
Signet Scientific Company, 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. Tel. (626) 571-2770 Fax (626) 573-2057 For Worldwide Sales and Service, visit our website: www.gfsignet.com Or call (in the U.S.): (800) 854-4090 GEORGE FISCHER Piping Systems
3-2720.090-1/(C-7/02) English Signet Scientific Company 2002 Printed in U.S.A. on recycled paper

+GF+ SIGNET 8750-3 pH/ORP Transmitter Instructions

ENGLISH

3-8750.090-3

B-10/99 English

CAUTION!
Remove power to unit before wiring input and output connections. Follow instructions carefully to avoid personal injury.

Contents
1. 2. 3. 4. Installation Specifications Electrical Connections Menu Functions
Relay 1

pH/ORP 10.20 pH 25.0C


Relay 2

ENTER

1. Installation
The transmitter is available in two versions: a panel mount version, and an integral version for installation near the sensor (universal assembly) panel gasket

terminals
1.1 Panel Installation The Panel Mounting kits are supplied with the hardware to install instrumentation into panels and maintain a NEMA 4X watertight seal. 1. 2. 3. 4. 5. Punch out panel and de-burr edges. Recommended clearance on all sides between instruments is 1 inch. Place gasket on instrument, and install in panel. Slide mounting bracket over back of instrument until quick-clips snap into latches on side of instrument. Connect wires to terminals. To remove, secure instrument temporarily with tape from front or grip from rear of instrument. DO NOT RELEASE. Press quick-clips outward and remove.

latch

mounting bracket

quick-clip

1.2 Universal Assembly (3-8050) 1. Install transmitter base 2. Connect wires to transmitter. 3. Close unit and secure with push and twist lock. Seal cable entry.

wires

seal

2 . Specifications
General Compatible electrodes: +GF+ SIGNET 3-2720 pH/ORP Preamplifier/Electrode Accuracy: 0.03 pH, 2 mV's ORP Enclosure: Rating: NEMA 4X/IP65 front Case: PBT Window: Polyurethane coated polycarbonate Keypad: Sealed 4-key silicone rubber Weight: Approx. 325g (12 oz.) Display: Alphanumeric 2 x 16 LCD Contrast: User selected, 5 levels Update rate: 1 second Environmental Operating temperature: -10 to 70C (14 to 158F) Storage temperature: -15 to 80C (5 to 176F) Relative humidity: 0 to 95%, non-condensing Standards and Approvals CSA, CE, UL listed Manufactured under ISO 9001
+GF+ SIGNET 8750-3 pH/ORP Transmitter Instructions

Electrical Sensor input range: pH: 0.00 to 14.00 pH temp. 3K Balco, -25 to 120C (-13 to 248F) ORP: -1000 to +2000 mV, isolated (10K I.D. resistance T+, T-) Current output: 4 to 20 mA, isolated, fully adjustable and reversible Power: 12 to 24 VDC 5%, regulated Max loop impedance: 50 max. @ 12 V, 325 max. @ 18 V, 600 max. @ 24 V Update rate: 0.5 seconds Accuracy: 0.03 mA @ 25C, 24 V Open-collector outputs: Hi, Lo, Pulse Programmable Open-collector, isolated, 50 mA sink or source, 30 VDC max. pull-up voltage

Internal open-collector output circuit 15 S

Outputs 1 2 6 _ 8 5 + 7
page 1 of 8

Isolation

,E A IE I
2= A K J
'$ ! & E 

.EA @
'$

K J
! & E 

2= A '$ ! & E  FJE = ' N'   &

+KJ KJ '$ ! & E  & ! ! E 

4A=H + LAH

! $ N ! $ E   !  E

#$ "  $ E  '% ! & E   E 

$ " & E 

3.

Electrical Connections

Caution: Failure to fully open terminal jaws before removing wire may permanently damage instrument. Wiring Procedure 1. Remove 0.5 - 0.625 in. (13-16 mm) of insulation from wire end. 2. Press the orange terminal lever downward with a small screwdriver to open terminal jaws. 3. Insert exposed (non-insulated) wire end in terminal hole until it bottoms out. 4. Release orange terminal lever to secure wire in place. Gently pull on each wire to ensure a good connection. Wiring Removal Procedure 1. Press the orange terminal lever downward with a small screwdriver to open terminal jaws. 2. When fully open, remove wire from terminal. System Power/Loop 1. System Power/Loop 1 + 2. System Power/Loop 13. Loop 2+ 4. Loop 2Open Collector Output 5. Output 1+ 6. Output 1 7. Output 2+ 8. Output 2Preamplifier/Sensor Input 9. Red (V+) 10. Black (V-) 11. Shield (Sensr GND) 12. Earth GND 13. Brown (mV input) 14. Blue (ISO GND) 15. Green (Temp+) 16. White (Temp-) Description 12-24 VDC 5%, system power and current loop connections. Max. loop impedence: 50 max. @ 12 V, 325 max. @ 18 V, 600 max. @ 24 V
16
Temp (WHITE) Temp + (GREEN) Iso. GND (BLUE) mV Input (BROWN)

2 1

Open-collector transistor output programmable as: High/Low alarm with adjustable hysteresis Proportional pulse output Disable (Off) selection
4 3
Loop 2 Loop 2 +

15 14 8 7 6 5
Output 2-

13 12 11 10

Output 2+ Output 1-

Earth GND Sensr Gnd (SHIELD) V(BLACK) V+ (RED)

Preamplifier positive System Pwr 2 Loop 1 Preamplifier negative System Pwr Preamplifier shield 1 Loop 1 + Connect if electrical noise is present Preamplifier mV output Preamplifier ground TC element (3K Balco pH, 10K ORP ID resistance) TC element (3K Balco pH, 10K ORP ID resistance)

Output 1+

Wiring Tips: Do not route sensor cable in conduit containing AC power wiring - electrical noise may interfere with sensor signal. Routing sensor cabling in grounded metal conduit may prevent moisture damage, electrical noise, and mechanical damage. Seal cable entry points to prevent moisture damage. When placing two wire ends into a single terminal, solder or crimp ends together.

page 2 of 8

+GF+ SIGNET 8750-3 pH/ORP Transmitter Instructions

3.1 System Power/Loop Connections


Stand-alone application, no current loop used Transmitter
Terminals
Loop2Loop2+ Sys. Pwr. Loop Sys. Pwr. Loop +

Connection to a PLC with built-in power supply Transmitter


Internal PLC Connection

PLC
Terminals

4 NC 3 NC 2 1

Power Supply DC 12 - 24 V

Terminals
Loop2Loop2+

- +

Power Supply Power Supply

Sys. Pwr. Loop Sys. Pwr. Loop +

4 3 2 1

- + - + - +

Power Supply Ground Power Supply Channel 1 4-20 mA in Channel 1 4-20 mA in Channel 2 4-20 mA in Channel 2 4-20 mA in

Connection to a PLC/Recorder, separate supply Transmitter


Terminals
Loop2Loop2+ Sys. Pwr. Loop Sys. Pwr. Loop +

DC 12 - 24 V

Example: Two transmitters connected to PLC/Recorder with separate power supply Transmitter 1
Loop2Loop2+ Sys. Pwr. Loop Sys. Pwr. Loop +

4 3 2 1

- +
- + - +

Power Supply Power Supply

PLC or Recorder
Channel 1 4-20 mA in Channel 1 4-20 mA in Channel 2 4-20 mA in Channel 2 4-20 mA in

4 3 2 1 4 3 2 1

DC 12 - 24 V

- +
+ + + +

Power Supply Power Supply

PLC or Recorder
Channel 1 Channel 1 Channel 2 Channel 2 Channel 3 Channel 3 Channel 4 Channel 4

Transmitter 2
Loop2Loop2+ Sys. Pwr. Loop Sys. Pwr. Loop +

3.2 Sensor Input Connections Wiring Tip: Do not route sensor cable in any conduit containing AC power wiring - electrical noise may interfere with the signal.

Terminals

16 15 14 13 12 11 10 9

White (Temp) Green (Temp) Blue (ISO GND) Brown (mV input) Silver (Shield) Black (V-) Red (V+)

Preamp: +GF+ SIGNET 2720 pH Electrodes +GF+ SIGNET 2714, 2714-HF +GF+ SIGNET 2716 ORP Electrodes: +GF+ SIGNET 2715 +GF+ SIGNET 2717

* (connection of terminal 14 to Earth GND may reduce electrical interference)

3.3 Output Functions Low: Output triggers when process variable is less than setpoint. High: Output triggers when process variable is higher than setpoint. Example: In Low Alarm Mode Operation, the output becomes active when the process drops below the setpoint, and becomes inactive when the process rises above the setpoint plus hysteresis. The opposite is true for High Alarm Mode.

Disable: Disables output. Proportional Pulse Mode Operation The output emits a 100 mS pulse (simulated contact closure) at rate defined by the Output, Pulse Range, Output Rate, and the process condition (0 to 400 pulses/minute, as programmed) Example: As the process falls below 10 the output will start pulsing in relation to the process value, the max pulse endpoint and the programmed pulses/min. Pulse rate will increase as the process approaches the programmed endpoint.
100 pulses

2H ?AII 0OIJAHAIEI 5AJF E J

KJFKJ )?JELA KJFKJ 1 =?JELA

Pulse rate

10 = 1 pulses/min. 7.5 = 50 pulses/min. 5 = 100 pulses/min.

10 Out 0 pu Pu t1 ls R es at /m e: in >

Relay 1 or Relay 2 5
Relay 1: Pulse 10.00005.0000>

0 pulses

10

Process variable

6E A
+GF+ SIGNET 8750-3 pH/ORP Transmitter Instructions

Startmax. pulse endpoint

page 3 of 8

4. Menu Functions - pH
VIEW Menu: is displayed during standard operation. Press UP or DOWN buttons to view process parameters. Press UP and DOWN buttons at the same time, to exit any other display and return to VIEW menu. Display will return to VIEW menu in 10 minutes unless a key is pressed. CALIBRATE Menu: contains display setup and output parameters. A security code feature prevents unauthorized CALIBRATE: ---tampering. To access CALIBRATE menu: Enter Key Code Press ENTER button for 2 seconds to display: XXXX Press UP, UP, UP, DOWN buttons in sequence CALIBRATE: ---Enter Key Code to display: OPTIONS Menu: contains setup and display features for minor display or output adjustments. To access OPTIONS menu: OPTIONS: --- Press ENTER button for 5 seconds to display: Enter Key Code Press UP, UP, UP, DOWN buttons in sequence to display: ---OPTIONS: XXXX
Enter Key Code

Menu Tips Right button scrolls to right, from top to bottom row, and allows editing when ">" symbol is shown. In CALIBRATE or OPTIONS menus, the transmitter will continue to measure and control outputs. When > is pressed, the input value is held at the last measured process value. When sensor is not connected, unit will display CHECK SENSOR and any output controlled by sensor will be at 3.6 mA or OFF.

Example To change date, first enter CALIBRATE menu (Press ENTER button for 2 seconds; Press UP, UP, UP, DOWN buttons in sequence) Once in CALIBRATE menu, press UP button 1 time.
1. Display shows right arrow 2. Press RIGHT button to display "01" blinking 3. Press buttons to scroll through numbers. 4. Press ENTER button to save 5. Display now reads new date

LAST CAL: 01-01-99 >


+GF+ SIGNET
ENTER

LAST CAL: 01-01-99


+GF+ SIGNET
ENTER

LAST CAL: 08-01-99


+GF+ SIGNET
ENTER

SAVING
+GF+ SIGNET
ENTER

LAST CAL: 08-01-99


+GF+ SIGNET
ENTER

Menu Functions - pH
View Menu pH: Temp: Input: mV Loop1 Output: mA Loop2 Output: mA Last Cal: Date Easy Cal: > Range 0-15 pH 0 - 100C 999 mV 4-20 mA 4-20 mA 00-00-00 to 39-39-99 Buffer solutions 4, 7, 10 Calibrate Menu Set: Temperature > Set: Standard > Set: Slope > Loop1 Range: pH 0.00 -> 14.00 > (4mA) (20 mA) Loop2 Range: C 0.0 -> 100.0 > (4mA) (20 mA) Output1 Source: pH > Output1 Mode: Low > Range 25C 0-14 pH 0-14 pH 0-14 pH Preset N/A N/A N/A 0->14 pH Output1 Active: Low > Output2 Active: Low > Temp Display: C > Loop1 Adjust: 4.00 mA > Loop 1 Adjust: 20.00 mA > Loop2 Adjust: 4.00 mA > Loop 2 Adjust: 20.00 mA > Test Loop1: > Test Loop2: > Test Output1: > Test Output2: > Options Menu Contrast: Level > Averaging: Off > Range 1-5 Off Low (4secs) High (8secs) Low High Low High C F 3.8 to 5.0 mA 19.0 to 21.0 mA 3.8 to 5.0 mA 19.0 to 21.0 mA 4-20 mA 4-20 mA On or Off On or Off Preset 3 Off

Low Low C 4.00 mA 20.00 mA 4.00 mA 20.00 mA N/A N/A N/A N/A

0-100 C (32-212 F)

0-100 C (32-212 F)

pH or Temp. Off Low Hi Pulse 0-14 pH 0-14 pH 0-14 pH

pH (Output1) Temp (Output2) Low (Output1) Hi (Output2)

Settings repeat for Output2

Low or High selected Output1 Setpnt: 4.00 pH > Output1 Hys: 0.50 pH > Pulse selected Output1 Range: pH 4.00 -> 10.00 > (Start>Endpoint) Output1 PlsRate: 120 pulses/min > Last Cal: 01-01-99 >

4.0 pH (Output1) 45C (Output2) 0.5 pH (Outpu1) 1.0 C (Output2) 4 ->10 pH (Output1) 45 ->80C (Output2) 120 pulses/min 01-01-99

0-400 pulses/min 00-00-00 to 39-39-99

page 4 of 8

+GF+ SIGNET 8750-3 pH/ORP Transmitter Instructions

EASY CAL Procedure - pH


This procedure simplifies system calibration using standard pH buffers. Use 4.0, 7.0, 10.0 pH buffers only. If standard pH buffers are not available, the system can be calibrated using the CALIBRATE menu STANDARD and SLOPE settings. Access CALIBRATE menu and set sensor temperature before performing EASY CAL for new electrode installations.
EASY CAL: ---Enter Key Code Press UP, UP, UP, DOWN buttons in sequence to enter menu, ____ XXXX will appear during code entry.

To Calibrate:
Place Sensor in pH Buffer #1
Place electrode tip in first pH buffer pH 7.0 = 0 mV pH 4.0 = 177 pH 10 = -177 Limit 50 mV

Response:
* 6.90 pH -005 mV *

To Accept:
6.90 pH -005 mV
ENTER

* For best results, gently stir the submerged electrode for approximately 5 seconds during the stabilization period. Large temperature differences from process fluids to buffers may require longer stabilization time. Theoretical mV values pH @ 25C mV 2 +296 3 +237 4 +177 5 +118 6 +59 7 +0 8 -59 9 -118 10 -177 11 -237 12 -296

Allow for stabilization


1 *

to accept

7.00 pH -005 mV

30 seconds*

Place Sensor in pH Buffer #2

3.93 pH +179 mV

3.93 pH +179 mV

Place electrode tip in second pH buffer.

Allow for stabilization

Press ENTER to accept second buffer calibration.


* 4.00 pH +179 mV

30 seconds* To exit menus and return to VIEW press UP and DOWN button at the same time Display returns to VIEW Menu in 10 minutes or when ENTER is pressed

Good Easy Cal Press <ENTER>

Technical notes: The difference between the actual mV and value shown is a good indication of the condition of the electrode. Differences in excess of 50 mV may indicate a need to service the electrode.

Troubleshooting - pH
Display + -- -- --- -- -- -Check Sensor ? Problem Over or under range No sensor detected You may enter the CALIBRATION and OPTIONS menu to program setpoint values even though Check Sensor? is displayed. Electrode not installed in preamplifier Solution Verify Connect sensor/preamplifier or proper resistance for unit of measure. 3K for pH.

Out of Range Check Sensor Out of Range Use Manual CAL

1. Install sensor in preamp 2. Verify 3K Balco connection to transmitter (White/Green wires from preamplifier) 1. Use pH 4, 7, 10 buffers 2. Clean probe and retry EASY CAL. Use Manual calibration for Standard and Slope if mV offset exceeds 50 mV. Place probe in alternate buffer solution. 1. Verify preamplifier wiring 2. Check preamplifier with 2719 preamplifier tester. 3. Disconnect preamp. "Out of Range Check Sensor" should appear 1. Use pH values with a greater difference in reading. 4,7,10 2. Maintain probe and retry 1. Use pH values with a greater difference in reading. 4,7,10 2. Clean probe and retry Press any key to reload presets, then reprogram setpoints
page 5 of 8

1. Did not use pH 4, 7, 10 buffers 2. Excessive probe mV offset

! Same Buffer (EasyCal only) 15.00 pH Temperature or 0.00 pH Temperature Standard too close to Slope ! Slope too close to Standard ! SETUP READ ERROR Press Any Key

Same buffer used for Standard and Slope. Excessive positive or negative mV input from preamplifier

1. pH Standard value within 2 pH units (120 mV) of Slope value 2. Probe efficiency is too small 1. pH Slope value within 2 pH units (120 mV) of Standard value 2. Probe efficiency is too small Memory fault occurred

+GF+ SIGNET 8750-3 pH/ORP Transmitter Instructions

4. Menu Functions - ORP


VIEW Menu: is displayed during standard operation. Press UP or DOWN buttons to view process parameters. Press UP and DOWN buttons at the same time, to exit any other display and return to VIEW menu. Display will return to VIEW menu in 10 minutes unless a key is pressed. CALIBRATE Menu: contains display setup and output parameters. A security code feature prevents unauthorized CALIBRATE: ---tampering. To access CALIBRATE menu: Enter Key Code Press ENTER button for 2 seconds to display: ---XXXX Press UP, UP, UP, DOWN buttons in sequence CALIBRATE: Enter Key Code to display: OPTIONS Menu: contains setup and display features for minor display or output adjustments. To access OPTIONS menu: OPTIONS: --- Press ENTER button for 5 seconds to display: Enter Key Code Press UP, UP, UP, DOWN buttons in sequence ---OPTIONS: XXXX to display: Enter Key Code Menu Tips Right button scrolls to right, from top to bottom row, and allows editing when ">" symbol is shown. In CALIBRATE or OPTIONS menus, the transmitter will continue to measure and control outputs. When > is pressed, the input value is held at the last measured process value. When sensor is not connected, unit will display CHECK SENSOR and any output controlled by sensor will be at 3.6 mA or OFF.

Example To change date, first enter CALIBRATE menu (Press ENTER button for 2 seconds; Press UP, UP, UP, DOWN buttons in sequence) Once in CALIBRATE menu, press UP button 1 time.
1. Display shows right arrow 2. Press RIGHT button to display "01" blinking 3. Press buttons to scroll through numbers. 4. Press ENTER button to save 5. Display now reads new date

LAST CAL: 01-01-99 >


+GF+ SIGNET
ENTER

LAST CAL: 01-01-99


+GF+ SIGNET
ENTER

LAST CAL: 08-01-99


+GF+ SIGNET
ENTER

SAVING
+GF+ SIGNET
ENTER

LAST CAL: 08-01-99


+GF+ SIGNET
ENTER

Menu Functions - ORP


View Menu ORP: mV Input: mV Loop1 Output: mA Loop2 Output: mA Last Cal: Date Easy Cal: > Range -1000 to +2000 mV 4-20 mA 4-20 mA 00-00-00 to 39-39-99 87 and 264 mV solutions Calibrate Menu Set: Standard > Set: Slope > Loop1 Range: mV -1000->+1000 (4mA) (20 mA) Loop2 Range: mV -1000 ->+1000 > (4mA) (20 mA) Output1 Mode: Low > Range -1000 to +2000 mV -1000 to +2000 mV -1000 to +2000 mV -1000 to +2000 mV Preset N/A N/A -1000 to +1000 mV -1000 to +1000 mV Options Menu Contrast: Level > Averaging: Off > Output1 Active: Low > Output2 Active: Low > Loop1 Adjust: 4.00 mA > Loop 1 Adjust: 20.00 mA > Loop2 Adjust: 4.00 mA > Loop 2 Adjust: 20.00 mA > Test Loop1: > Test Loop2: > Test Output1: > Test Output2: > Range 1-5 Off Low (4secs) High(8secs) Low High Low High 3.8 to 5.0 mA 19.0 to 21.0 mA 3.8 to 5.0 mA 19.0 to 21.0 mA 4-20 mA 4-20 mA On or Off On or Off Preset 3 Off

Low Low 4.00 mA 20.00 mA 4.00 mA 20.00 mA N/A N/A N/A N/A

Off Low Hi Pulse -1000 to +2000 mV 0 to 2000 mV -1000 to +2000 mV 0-400 pulses/min 00-00-00 to 39-39-99

Low (Output1) Hi (Output2)

Settings repeat for Output2

Low or High selected Output1 Setpnt: -500 mV > Output1 Hys: 10 mV > Pulse selected Output1 Range: mV -500 -> +500 > (Start>Endpoint) Output1 PlsRate: 120 pulses/min > Last Cal: 01-01-99 >

-500 mV 10 mV

-500 to +500 mV 120 pulses/min 01-01-99

page 6 of 8

+GF+ SIGNET 8750-3 pH/ORP Transmitter Instructions

EASY CAL Procedure - ORP


This procedure simplifies system calibration using standard pH buffers. Use 4.0, 7.0 buffers saturated with Quinhydrone (customer supplied). If standard pH buffers are not available, the system can be calibrated using the CALIBRATE menu STANDARD and SLOPE settings. Access CALIBRATE menu and set sensor temperature before performing EASY CAL for new electrode installations.
EASY CAL: ---Enter Key Code Press UP, UP, UP, DOWN buttons in sequence to enter menu, will appear during code entry.

To Calibrate:
Place Sensor in ORP Buffer #1

Response:
* ORP: + 84 mV Input: + 82 mV

To Accept:
* ORP: + 84 mV Input: + 82 mV
ENTER

* For best results, gently stir the submerged electrode for approximately 5 seconds during the stabilization period. Large temperature differences from process fluids to buffers may require longer stabilization time.

Place electrode tip in first pH buffer; pH 7.0 87 mV pH 4.0 246 mV

Allow for stabilization


1

to accept

* ORP: + 87 mV Input: + 82 mV

30 seconds*

Place Sensor in ORP Buffer #2

* ORP: +262 mV Input: +260 mV

* ORP: +262 mV Input: +260 mV

Place electrode tip in second (different) pH buffer. pH 4.0 246 mV pH 7.0 87 mV

Allow for stabilization

Press ENTER to accept second buffer calibration.


* ORP: +264 mV Input: +260 mV

30 seconds*

To exit menus and return to VIEW press UP and DOWN button at the same time

Display returns to VIEW Menu in 10 minutes or when ENTER is pressed

Good Easy Cal Press <ENTER>

Technical notes: The difference between the actual mV and value shown is a good indication of the condition of the electrode. Differences in excess of 50 mV may indicate a need to service the electrode.

Troubleshooting - ORP
Display Check Sensor ? Problem No sensor detected. You may enter the CALIBRATION and OPTIONS menu to program setpoint values even though Check Sensor? is displayed. Electrode not installed in preamplifier Solution Connect sensor/preamplifier or proper resistance for unit of measure. 3K for pH, 10K for ORP.

Out of Range Check Sensor Out of Range Use Manual CAL

1. Install sensor in preamp 2. Verify 3K Balco connection to transmitter (White/Green wires from preamplifier) 1. Use pH 4, 7 buffers saturated with quinhydrone 2. Clean probe and retry EASY CAL. Use Manual calibration for Standard and Slope if mV offset exceeds 50 mV. Place probe in alternate buffer solution. 1. Verify preamplifier wiring 2. Check preamplifier with 2719 preamplifier tester. 3. Disconnect preamp completely out of range. Check Sensor should appear 1. Use ORP values with a difference in reading greater than 120 mV's. 2. Maintain probe and retry 1. Use ORP values with a difference in reading greater than 120 mV's. 2. Maintain probe and retry Press any key to reload presets, then reprogram setpoints
page 7 of 8

1. Did not use pH 4, 7 buffers saturated with quinhydrone 2. Excessive probe mV offset Same buffer used for Standard and Slope. Excessive positive or negative mV input from preamplifier

! Same Buffer EasyCal only) Display stuck at ORP: +2000 mV or ORP: -1000 mV Standard too close to Slope ! Slope too close to Standard ! SETUP READ ERROR Press Any Key

1. ORP Standard value within 120 mV of Slope value 2. Probe efficiency is too small 1. ORP Slope value within 120 mV of Standard value 2. Probe efficiency is too small Memory fault occurred

+GF+ SIGNET 8750-3 pH/ORP Transmitter Instructions

+GF+ SIGNET
Signet Scientific Company, 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. Tel. (626) 571-2770 Fax (626) 573-2057 For Worldwide Sales and Service, visit our website: www.gfsignet.com Or call (in the U.S.): (800) 854-4090 GEORGE FISCHER +GF+ Piping Systems
3-8750.090-3/(B-10/99) English Scientific Company 1999 Printed in U.S.A. on Recycled Paper

page 8 of 8

+GF+ SIGNET 8750-3 pH/ORP Transmitter Instructions

SIGNET 515/2536 Rotor-X Flow Sensors


P51530-XX 3-2536-XX

Features
PVDF or Polypropylene molded sensor body Simple Insertion Design Wide Turndown Ratio of 66:1 For DN15 to DN1000 (0.5 to 36 in.) pipes Self-powered Flow Rate (P51530-XX) Process Ready Signal (3-2536-XX) Extended length for wet-tap installations available

Red

Blue

Application
Pure Water Production Filtration systems Chemical Production Liquid Delivery Systems Pump Protection Scrubbers

Description
Invented over 25 years ago by +GF+ SIGNET, the Rotor-X paddle-wheel insertion-flow sensor is a proven flow sensor. These highly repeatable, rugged sensors offer exceptional value with little or no maintenance required. Installation is simple with +GF+ SIGNETs comprehensive line of fittings for all pipe materials in sizes from DN15 to DN1000 (0.5 to 36 in.). Output signal of the 515 is a sinusoidal frequency capable of driving a self-powered flowmeter (3-5090). The 3-2536 has a process-ready opencollector signal and can operate to flows as low as 0.1 m/s (0.3 ft/s).
Rotor-X Sensors P51530-XX 3-2536-XX

Options
Instrument Options

Technical Features
a) 1/2 in. NPT Conduit Connection b) Large bail simplifies insertion/removal c) High-strength ring nut with provision for lead seal installation d) Dual O-ring seal (Viton standard, EPR optional) e) Molded one-piece black glass-filled Polypropylene or natural PVDF body f) Multiple pin materials g) Open-cell rotor with material options b a

e +GF+ has a comprehensive line of fittings from 15mm to 1 m (0.5 to 36 in.) f g

385 50 -1 385 50 -2 385 50 -3 350 90 350 75 351 00 355 00 356 00 390 10

d +GF+ SIGNETs unique "open-cell" rotor design eliminates cavitation at higher flow rates.

www.gfsignet.com

Dimensions
515/2536 Sensor
Standard 7.6 m/25 ft. cable included

8510 / 8512 Integral Sensor with Transmitter (sold separately)

319 Wet Tap Assembly


1-1/4 X 11-1/2 NPSM thread Valve handle (open position shown) Plugpressure relief

1-1/4" NPSM threaded cap

102 mm/ 4.0 in.

-X0 or -X1

-X (0 thru 5) 26.7 mm/ 1.05 in.


222 mm/ 8.75 in.

Pipe Range: 1/2 to 4 in. -X 0 = 104 mm/4.1 in. 5 to 8 in. -X 1 = 137 mm/5.4 in. 10" and up -X 2 = 213 mm/8.4 in. 1/2 to 4 in. -X 3 = 219 mm/8.6 in. 5 to 8 in. -X 4 = 254 mm/10 in. Wet-tap Lengths 10" and up -X 5 = 331 mm/13 in.

-X0 = 152 mm/6.0 in. -X1 = 185 mm/7.3 in.

74 mm/2.9 in. Adapts to SIGNET flow fittings Extended 515 sensor included (not shown) 7 bar/100 psi max. @ 20C/68F Max. installation/removal pressure: 1.7 bar/25 psi @ 22C/72F

Fitting Types
Refer to Fitting Specification Sheets for detailed part numbers
Type Plastic tees: PV8T CPV8T PV8Txxx F CPV8TxxxF Plastic Saddles:
PV8S (PVC) CPV8S (CPVC)

Description 0.5 to 4 in. versions PVC or CPVC Mounts via glue-on fittings

Type Threaded tees: Iron (IR4T) Carbon Steel (CS4T) 316 SS (CR4T)

Description 0.5 to 2 in. versions Mounts on threaded pipe ends

2 to 4 in., cut 1-7/16 in. hole in pipe 6 to 8 in., cut 2-1/4 in. hole in pipe Pipes over 8 in., use iron or fiberglass saddle 2 to 4 in., cut 1-7/16 in. hole in pipe Over 4 in., cut 2-1/4 in. hole in pipe Special order over 12 in. 2 to 4 in., cut 1-7/16 in. hole in pipe Over 4 in., cut 2-1/4 in. hole in pipe Remove insert before welding Installed by certified welder only Special order over 12 in.

Fiberglass tees & saddles: FPT FPS

1.5 in. to 8 in. PVDF insert > 8 in. PVC insert Special order over 12 in. Metric wafer fitting For pipes DN 65 to 200 mm PP or PVDF

Iron strap-on saddles: IR8S

Polypropylene (PPMT)

Weldolets: Copper/Bronze (BR4B) Carbon Steel (CS4W) 316SS (CR4W)

PVDF (SFMT) Polypropylene (PPMT) PVDF (SFMT) Metric union fitting For pipes from DN 15 to 50 mm PP or PVDF

www.gfsignet.com

Installation
Six common installation configurations are shown here as guidelines to help you select the best location in your piping system for a paddlewheel flow sensor. Always maximize distance between sensors and pump sources.

Inlet Flange

Outlet Reducer 90 Elbow

10x I.D.

5x I.D.

15x I.D. 2 x 90 Elbow 3 dimensions

5x I.D.

20x I.D.

5x I.D.

Valve/Gate

2 x 90 Elbow

50x I.D.

5x I.D.

40x I.D.

5x I.D.

25x I.D.

5x I.D.

Sensor Mounting Position


Horizontal pipe runs: Mount sensor in the upright (0) position for best overall performance. Mount at a maximum of 45 when air bubbles are present. Do not mount on the bottom of the pipe when sediments are present. Vertical pipe runs: Sensor must be mounted in lines with UPWARD flow only.
-45 +45

Process Pipe

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Wiring
515 Sensor Connection to +GF+ SIGNET Instruments
Blk Frequency (-) Red Frequency (+) Shield

2536 Sensor Connection to +GF+ SIGNET Instruments


Black Sensor Power Red Frequency in Shield Ground DC sensor power supplied from +GF+ SIGNET instrument. * 10K Pull-up resistor may be required for non-SIGNET brand instrument

Technical Data
General (for both 515 & 2536) Pipe Size Range: 15 to 1000 mm (0.5 to 36 in.) Linearity: 1% of full range Repeatability: 0.5% of full range Minimum Reynolds Number Required: 4500 Wetted Materials: Sensor Body: Glass-filled Polypropylene (black) or PVDF (natural) O-rings: FPM-Viton (std) or EPDM or FPM-Kalrez Pin: Titanium or Hastelloy-C or PVDF; other materials options available Rotor: Black PVDF or Natural PVDF; optional Tefzel with or w/o Fluoralloy B sleeve Cable Type: 2-conductor twisted pair with shield (22 AWG) Weight: -X0 454 grams -X1 476 grams -X2 680 grams -X3 794 grams -X4 850 grams -X5 1 kg P31940 1 .2 kg Standards and Approvals (for both 515 & 2536): Manufactured under ISO 9001 CE General (515 Only) Flow Rate Range: 0.3 to 6 m/s (1 to 20 ft./s) Pipe Size Range: DN15 to DN1000 (0.5 to 36 in.) Cable Length: 7.6 m (25 ft.)/60 m (200 ft.) maximum Signal: Frequency: 19.7 Hz per m/s nominal (6 Hz per ft/s) Amplitude: 3.3 V p/p per m/s nominal (1 V p/p per ft/s) Source Impedance: 8 K Standards and Approvals (515 only): FM Class I, II, II/Div./groups A-G General (2536 Only) Flow Rate Range: 0.1 to 6 m/s (0.3 to 20 ft./s) Pipe Size Range: DN15 to DN1000 (0.5 to 36 in.) Cable Length: 7.6 m (25 ft.)/300 m (1,000 ft.) maximum Signal: Frequency: 49Hz per m/s nominal (15 Hz per ft/s nominal) Supply voltage: 3.5 to 24 VDC regulated Supply current: <1 .5 mA @ 3.3 to 6 VDC <20 mA @ 6 to 24 VDC Output Type: Open collector transistor, sinking Output Current: 10 mA max.
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Fluid Conditions
Sensor Pressure / Temperature Ratings: Glass-filled Polypropylene Body: 12.5 bar (180 psi) max. @ 20C (68F) 1.7 bar (25 psi) max. @ 90C (194F) PVDF Body: 14 bar (200 psi) max. @ 20C (68F) 1.7 bar (25 psi) max. @ 100C (212F) 319 Wet-Tap Assembly: 7 bar (100psi) max. @ 20C (68F) 1.7 bar (25 psi) max. @ 66C (150F) Note: Wet-tap max. installation/removal pressure: 25 psi @ 22C (72F).

bar 14

psi 200

11 160
Po
PV

8 6 3

120 80 40

lyp ro

DF

9 31

py le ne

et W

ap -T

F C

0 -18

40 4

80 27

120 49

160 71

200 93

240 115

Ordering Information
515/8510-XX (Sinusoidal) Mfr. Part No. Code Pipe Sizes Body P51530-H0 198 801 659 0.5 to 4 in. Polypro P51530-P0 198 801 620 0.5 to 4 in. Polypro P51530-P1 198 801 621 5 to 8 in. Polypro P51530-P2 198 801 622 10 to 36 in. Polypro P51530-P3 198 840 310 0.5 to 4 in. Polypro P51530-P4 198 840 311 5 to 8 in. Polypro P51530-P5 198 840 312 10 to 36 in. Polypro P51530-S0 198 801 661 0.5 to 4 in. Polypro P51530-T0 198 801 663 0.5 to 4 in. Natural PVDF P51530-T1 198 801 664 5 to 8 in. Natural PVDF P51530-V0 198 801 623 0.5 to 4 in. Natural PVDF P51530-V1 198 801 624 5 to 8 in. Natural PVDF P51530-V2 198 801 625 10 to 36 in. Natural PVDF 3-8510-P0 198 864 504 0.5 to 4 in. Polypro 3-8510-P1 198 864 505 5 to 8 in. Polypro 3-8510-T0 159 000 622 0.5 to 4 in. Natural PVDF 3-8510-V0 198 864 506 0.5 to 4 in. Natural PVDF 2536/8512-XX (Open-Collector) 3-2536-P0 198 840 143 0.5 to 4 in. Polypro 3-2536-P1 198 840 144 5 to 8 in. Polypro 3-2536-P2 198 840 145 10 to 36 in. Polypro 3-2536-T0 198 840 149 0.5 to 4 in. Polypro 3-2536-V0 198 840 146 0.5 to 4 in. Natural PVDF 3-2536-V1 198 840 147 5 to 8 in. Natural PVDF 3-8512-P0 198 864 513 0.5 to 4 in. Polypro 3-8512-P1 198 864 514 5 to 8 in. Polypro 3-8512-T0 198 864 518 0.5 to 4 in. Natural PVDF 3-8512-V0 198 864 516 0.5 to 4 in. Natural PVDF Wet-Tap Sensor and Valve Assembly (Fitting Separate) MK319/515-P3 198 840 119 0.5 to 4 in. Polypro MK319/515-P4 198 840 120 5 to 8 in. Polypro MK319/515-P5 198 840 121 10 to 36 in. Polypro Rotor/Pin Blk PVDF/Hastelloy-C Blk PVDF/Titanium Blk PVDF/Titanium Blk PVDF/Titanium Blk PVDF/Titanium Blk PVDF/Titanium Blk PVDF/Titanium Blk PVDF/Natural PVDF Natural PVDF Natural PVDF Nat. PVDF/Hastelloy-C Nat. PVDF/Hastelloy-C Nat. PVDF/Hastelloy-C Blk PVDF/Titanium Blk PVDF/Titanium Natural PVDF Nat. PVDF/Hastelloy-C Blk PVDF/Titanium Blk PVDF/Titanium Blk PVDF/Titanium Natural PVDF Nat. PVDF/Hastelloy-C Nat. PVDF/Hastelloy-C Blk PVDF/Titanium Blk PVDF/Titanium Natural PVDF Nat. PVDF/Hastelloy-C Blk PVDF/Titanium Blk PVDF/Titanium Blk PVDF/Titanium Installation Remote Remote Remote Remote Remote Wet-Tap Remote Wet-Tap Remote Wet-Tap Remote Remote Remote Remote Remote Remote Integral Integral Integral Integral Remote Remote Remote Remote Remote Remote Integral Integral Integral Integral Remote Wet-Tap Remote Wet-Tap Remote Wet-Tap

Accessories
Rotors 515/8510-XX Mfr. Part. No. Code M1538-2 198 801 181 P51547-3 159 000 474 M1538-4 198 820 018 P51550-3 198 820 043 3-0515.322-1 198 820 059 3-0515.322-2 198 820 060 3-0515.322-3 198 820 017 Description Rotor, PVDF Black Rotor, PVDF Natural Rotor, Tefzel Rotor and Pin, PVDF Natural Sleeved Rotor, PVDF Black Sleeved Rotor, PVDF Natural Sleeved Rotor, Tefzel
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Accessories (continued)
Rotors 2536/8512-XX Mfr. Part No. Code 3-2536.320-1 198 820 052 3-2536.320-2 159 000 272 3-2536.320-3 159 000 273 3-2536.321 198 820 054 3-2536.322-1 198 820 056 3-2536.322-2 198 820 057 3-2536.322-3 198 820 058 Rotor Pins M1546-1 198 801 182 M1546-2 198 801 183 M1546-3 198 820 014 M1546-4 198 820 015 P51545 198 820 016 O-Rings 1220-0021 198 801 186 1224-0021 198 820 006 1228-0021 198 820 007 Miscellaneous P31536 198 840 201 P31536-1 198 840 202 P31536-2 159 000 649 P31542 198 801 630 P31542-3 159 000 464 P31934 159 000 466 P51589 159 000 476 5523-0222 159 000 392 3-8051 159 000 187 Description Rotor, PVDF Black Rotor, PVDF Natural Rotor, Tefzel Rotor and Pin, PVDF Natural Sleeved Rotor, PVDF Black Sleeved Rotor, PVDF Natural Sleeved Rotor, Tefzel Pin, Titanium Pin, Hastelloy-C Pin, Tantalum Pin, Stainless Steel Pin, Ceramic O-Ring, FPM-Viton O-Ring, EPDM O-Ring, FPM-Kalrez Sensor Plug, Polypro Sensor Plug, PVDF Metric Sensor Plug, PVDF Sensor Cap, Red (for use w/515) Sensor Cap, Blue (for use w/2536) Conduit Cap Conduit Adapter Kit Cable, (per foot) Transmitter Integral Adapter

Engineering Specifications for both 515 and 2536 Flow Sensors


The flow sensor shall use a four-blade, open-cell rotor design using insertion paddlewheel technology. Linearity of the output signal with respect to flow rate shall be 1 % of full range. Measurement repeatability of the output signal with respect to flow rate shall be 0.5 % of full range. The sensor body shall be made of injection-molded polypropylene (PP) that shall accommodate up to 12.5 bar @ 20C (180 psi @ 68F) and 1.7 bar @ 90C (25 psi @ 194F). As an alternative, the sensor shall be made of injection-molded polyvinylidene fluoride (PVDF) that shall accommodate up to 14 bar @ 20C (200 psi @ 68F) and 1.7 bar @ 100C (25 psi @ 212F). The sensor shall attach to a pipe via a variety of insertion-style installation fittings supplied by the flow sensor manufacturer. Attachment shall use a 1-1/4 X 11-1/2 NPSM threaded cap. Sealing shall be accomplished with a double O-ring seal. O-rings shall be made of FPM-Viton, FPM-Kalrez or EPDM. The sensor shall be equipped with 0.5 in. female conduit connection. The sensor shall require no electrical power. The sensor shall provide an output signal of 3.3 V p-p per m/s nominal (1 V p-p per ft/s) at a frequency of 19.7 Hz per m/s nominal (6 Hz per ft/s) from 0.3 to 6 m/s (1 to 20 ft/s). Output shall be via a twisted pair, foil-shielded cable with drain wire. Supplied cable shall be at least 7.6 m (25 ft) long, with a maximum allowable length of 60 m (200 ft). The operating range of the sensor shall accommodate nominal flow rates from 0.3 to 6 m/s (1 to 20 ft/s). The sensor shall meet appropriate CE standards and FM standards for Classes 1, 11 and 111, Division I/Groups A-G. The sensor shall operate with a power input of 3.3 to 6VDC @ <1.5 mA or from 6 to 24 VDC @ <20 mA. The sensor output shall provide an open-collector pulse at a frequency of 49.2 Hz per m/s nominal (15 Hz per ft/s). Output shall be via a twisted pair, foil-shielded cable with drain wire. Supplied cable shall be at least 7.6 m (25 ft) long, with a maximum allowable length of 300 m (1000 ft). The operating range of the sensor shall accommodate nominal flow rates from 0.1 to 6 m/s (0.3 to 20 ft/s). The sensor shall meet appropriate CE standards.

Engineering Specifications for +GF+ SIGNET 515 Rotor-X Flow Sensor

Engineering Specifications for +GF+ SIGNET 2536 Low Flow Sensor

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SIGNET 8550-3 Flow Transmitter


3-8550.090-3

ENGLISH

C-3/01 English

CAUTION!
Remove power to unit before wiring input and output connections. Follow instructions carefully to avoid personal injury.

Contents
1. 2. 3. 4. Installation Specifications Electrical Connections Menu Functions

Flow Flow1: Flow2: 6.25 GPM 9.75 GPM

ENTER

1. Installation
ProcessPro transmitters are available in two styles: panel mount and field mount. The panel mount is supplied with the necessary hardware to install the transmitter. This manual includes complete panel mounting instructions. Field mounting requires one of two separate mounting kits. The 3-8051 integral kit joins the sensor and instrument together into a single package. The 3-8050 Universal kit enables the transmitter to be installed virtually anywhere. Detailed instructions for integral mounting or other field installation options are included with the 3-8051 Integral kit or the 3-8050 Universal kit. 1.1 Panel Installation 1. The panel mount transmitter is designed for installation using a 1/4 DIN Punch. For manual panel cutout, an adhesive template is provided as an installation guide. Recommended clearance on all sides between instruments is 1 inch. 2. Place gasket on instrument, and install in panel. 3. Slide mounting bracket over back of instrument until quick-clips snap into latches on side of instrument. 4. To remove, secure instrument temporarily with tape from front or grip from rear of instrument. DO NOT RELEASE. Press quick-clips outward and remove.
gasket panel terminals 96 mm (3.8 in.) 96 mm (3.8 in.) Optional Rear Cover 92 mm (3.6 in.) latch
7
Pwr System pLoo Pwr System p+ Loo

mounting bracket

Output

6 5

2 1

sr Gnd SenIELD) (SH sr IN SenD) (RE sr V+ SenACK) (BL

Output

96 mm (3.8 in.) FRONT VIEW Field Mount & Panel Mount

102 mm (4.0 in.)

41 mm (1.6 in.)

56 mm (2.2 in.) 97 mm (3.8 in.)

SIDE VIEW Field Mount

SIDE VIEW Panel Mount

Panel Mount Installation Detail

quick-clips

2. Specifications
General Compatibility: +GF+ SIGNET Flow Sensors (w/freq out) Accuracy: 0.5 Hz Enclosure: Rating: NEMA 4X/IP65 front Case: PBT Panel case gasket: Neoprene Window: Polyurethane coated polycarbonate Keypad: Sealed 4-key silicone rubber Weight: Approx. 325g (12 oz.) Display: Alphanumeric 2 x 16 LCD Update rate: 1 second Contrast: User selected, 5 levels Electrical Power: 12 to 24 VDC 10%, regulated, 122 mA max. Sensor Inputs: Range: 0.5 to 1500 Hz Sensor power: 2-wire: 1.5 mA @ 5 VDC 1% 3 or 4 wire: 20 mA @ 5 VDC 1% Optically isolated from current loop Short circuit protected Current output: 4 to 20 mA, isolated, fully adjustable and reversible
SIGNET 8550-3 Flow Transmitter

Max loop impedance:

50 max. @ 12 V 325 max. @ 18 V 600 max. @ 24 V

Update rate: 100 ms Accuracy: 0.03 mA Open-collector outputs, optically isolated: 50 mA max. sink, 30 VDC maximum pull-up voltage. Programmable for: High or Low setpoint with adjustable hysteresis Pulse proportional to rate or volume (max 300 pulses/min). Environmental Operating temperature: Storage temperature: Relative humidity: Maximum altitude: Insulation category: Pollution degree: -10 to 70C (14 to 158F) -15 to 80C (5 to 176F) 0 to 95%, non-condensing 2000 m (6562 ft) II 2

Standards and Approvals: CSA, CE, UL listed Immunity: EN50082-2 Emissions: EN55011 Safety: EN61010 Manufactured under ISO 9001 and ISO 14001
page 1 of 8

3. Electrical Connections
Caution: Failure to fully open terminal jaws before removing wire may permanently damage instrument.

Wiring Procedure 1. Remove 0.5 - 0.625 in. (13-16 mm) of insulation from wire end. 2. Press the orange terminal lever downward with a small screwdriver to open terminal jaws. 3. Insert exposed (non-insulated) wire end in terminal hole until it bottoms out. 4. Release orange terminal lever to secure wire in place. Gently pull on each wire to ensure a good connection. Wiring Removal Procedure 1. Press the orange terminal lever downward with a small screwdriver to open terminal jaws. 2. When fully open, remove wire from terminal.

2 1

Terminals 3-6: Loop Power 12-24 VDC 10% system power and current loop outputs. Max. loop impedance: 50 max. @ 12 V 325 max. @ 18 V 600 max. @ 24 V

Terminals 11-16: Flow sensor inputs

6 5 4 3 2 1

Loop 2Loop 2+ System Pwr Loop System Pwr Loop + AUX Power AUX Power +

10 9 8 7

Output 2-

16 15 14 13 12 11

Snsr 2 Gnd (SHIELD) Snsr 2 IN (RED) Snsr 2 V+ (BLACK) Snsr 1 Gnd (SHIELD) Snsr 1 IN (RED) Snsr 1 V+ (BLACK)

Output 2+ Output 1-

Output 1+

Terminals 1 and 2: AUXILIARY power Used only if the flow sensor requires more than 1.5 mA current. For Signet sensors this is limited to the following products: 2000 2507 2530 2535 2540 if mfg. prior to Jan. 1999 All dual sensor systems

Internal open-collector output circuit 15 S

Outputs 1 2 _ +

Isolation

Terminals 7-10: Open-collector Outputs Two transistor outputs, programmable (see CALIBRATE menu) as: High or Low setpoint with adjustable hysteresis Pulse based on Volume. Frequency based on flow rate May be disabled (Off) if not used.

page 2 of 8

SIGNET 8550-3 Flow Transmitter

3.1 System Power/Loop Connections Stand-alone application, no current loop used

Connection to a PLC with built-in power supply

Transmitter
Terminals
Loop2Loop2+ Sys. Pwr. Loop Sys. Pwr. Loop + AUX Power AUX Power +

Transmitter Power Supply DC 12 - 24 V


Terminals
Loop2Loop2+

PLC
Terminals

6 NC 5 NC 4 3 2 1

Power Supply Power Supply

Sys. Pwr. Loop Sys. Pwr. Loop + AUX Power AUX Power +

6 5 4 3 2 1

+ + +
Internal PLC Connection

Power Supply Ground Power Supply Channel 2 4-20 mA in Channel 2 4-20 mA in Channel 1 4-20 mA in Channel 1 4-20 mA in

Connection to a PLC/Recorder, separate supply

Transmitter
Terminals
Loop2Loop2+ Sys. Pwr. Loop Sys. Pwr. Loop + AUX Power AUX Power +

Example: Two transmitters connected to PLC/Recorder with separate power supply Loop2Loop2+ Sys. Pwr. Loop Sys. Pwr. Loop + AUX Power AUX Power +

DC 12 - 24 V

Transmitter 1

6 5 4 3 2 1

+ + +

Power Supply Power Supply

PLC or Recorder
Channel 2 4-20 mA in Channel 2 4-20 mA in Channel 1 4-20 mA in Channel 1 4-20 mA in

6 5 4 3 2 1

Transmitter 2

DC 12 - 24 V

+
+ + + +

Power Supply Power Supply

Loop2Loop2+ Sys. Pwr. Loop Sys. Pwr. Loop + AUX Power AUX Power +

Auxiliary Power Note: Auxiliary power is used ONLY if the flow sensors require more than 1.5 mA of current. This is limited to the following Signet flow sensors: 2000, 2507, 2530, 2535 2540 only if manufactured prior to Jan 1999 All dual sensor systems 3.2 Sensor Input Connections

6 5 4 3 2 1

PLC or Recorder
Channel 4 Channel 4 Channel 3 Channel 3 Channel 2 Channel 2 Channel 1 Channel 1

Wiring Tips: Do not route sensor cable in conduit containing AC power wiring. Electrical noise may interfere with sensor signal. Routing sensor cable in grounded metal conduit will help prevent electrical noise and mechanical damage. Seal cable entry points to prevent moisture damage. Only one wire should be inserted into a terminal. Splice double wires outside the terminal.
8550-3

A
A 200 ft. (61 m) B 200 ft. (61 m)

Maximum cable length is 200 ft. for 515/8510-XX, 525, 2517 and any sinusoidal flow signal.

8550-3

Maximum cable length is 1000 ft. for 2536/8512-XX, 2540, vortex, and any square wave flow signal.
Terminals
16 15 14 13 12 11
Snsr 2 Gnd (SHIELD) Snsr 2 IN (RED) Snsr 2 V+ (BLACK) Snsr 1 Gnd (SHIELD) Snsr 1 IN (RED) Snsr 1 V+ (BLACK)

A 1000 ft. (305 m) B 1000 ft. (305 m)

No Aux Power

Aux Power required

515 525 2100 2517 2536 2540 3-8510-XX 3-8512-XX

2000 2507 2530 2535 2540 (mfg prior to Jan 1999) All dual sensor systems

SIGNET 8550-3 Flow Transmitter

page 3 of 8

3.3 Open Collector Output The Open collector output can be used as a switch that responds when the flow rate moves above or below a setpoint, or it can be used to generate a pulse that is relative to the flow volume or to the flow rate. Low Output triggers when the flow rate is less than the setpoint. The output will relax when the flow rate moves above the setpoint plus the hysteresis value. High Output triggers when the flow rate is greater than the setpoint. The output will relax when the flow rate drops below the setpoint plus the hysteresis value.

Process

Hysteresis

Low Setpoint Time

Output active Output inactive Process

Frequency Output is a pulse stream that is based on the input flow sensor signal. Set for 1 (input frequency = output frequency). Set for even numbers (2, 4, 6, 8, . . . . 254 maximum) to scale output frequency. Pulse Output is a pulse based on the volume of fluid that passes the sensor. Set any value from 0.0001 to 99999. The output may be disabled (Off) if not used.

High Setpoint

Hysteresis Time

VIEW menu
During normal operation, ProcessPro displays the VIEW menu. When editing the CALIBRATE or OPTIONS menus, ProcessPro will return to the VIEW menu if no activity occurs for 10 minutes. To select a VIEW display, press the UP or DOWN arrow keys. The selections will scroll in a continuous loop. Changing the VIEW display does not interrupt system operations. No key code is necessary to change display selection. Output settings cannot be edited from the VIEW menu.
Flow Flow1: Flow2: 6.25 GPM 9.75 GPM

ENTER

View Menu
Display Description Monitor the flow rate of Channel 1 and Channel 2 simultaneously. This is the permanent view display. Monitor the delta flow rate (Channel 1 rate - channel 2 rate = Delta Flow) This is a permanent display.

Flow1: 123.4 GPM Flow2: 567.8 GPM Delta Flow: 10.5 GPM

All of the displays below are temporary. After ten minutes the display will return to the permanent display.

Tot1: 1234567.8 Tot2: 123456.78> Perm1: 1234567.8 Gallons Perm2: 123456.78 Gallons Loop 1 Output: 12.00 mA Loop 2 Output: 12.00 mA Last CAL: 06-30-01
page 4 of 8

Monitor channel 1 and channel 2 Resettable Totalizers. Press the RIGHT ARROW key to reset the totalizer. If Reset is locked, you must enter Key Code. Lock or Unlock function is in OPTIONS menu. Monitor channel 1 Permanent Totalizer value. Monitor channel 2 Permanent Totalizer value. Monitor the 4-20 mA Loop 1 output. Monitor the 4-20 mA Loop 2 output. Monitor date for scheduled maintenance or date of last calibration. (See description in Calibrate Menu.)
SIGNET 8550-3 Flow Transmitter

ProcessPro Editing Procedure:


Step 1. Press and hold ENTER key:
2 seconds to select the CALIBRATE menu. 5 seconds to select the OPTIONS menu.

Step 2. The Key Code is UP-UP-UP-DOWN keys in sequence.


After entering the Key Code, the display will show the first item in the selected menu.

Step 3. Scroll menu with UP or DOWN arrow keys. Step 4. Press RIGHT ARROW key to select menu item to be edited.
The first display element will begin flashing.

Step 5. Press UP or DOWN keys to edit the flashing element.


RIGHT ARROW key advances the flashing element.

Step 6. Press ENTER key to save the new setting and return to Step 3.

Notes on Step 1: The View Menu is normally displayed. The CALIBRATE and OPTIONS menus require a KEY CODE.
Press & hold for access:

Notes on Step 2: If no key is pressed for 5 minutes while display is showing "Enter Key Code", the display will return to the VIEW menu.
CALIBRATE: ---Enter Key Code
CALIBRATE: *--Enter Key Code CALIBRATE: **-Enter Key Code

ENTER

VIEW

2s
CALIBRATE OPTIONS

5s

CALIBRATE: ***Enter Key Code

Flow1 Units: GPM >

First item in CALIBRATE menu

Notes on Steps 3 and 4: Refer to pages 6 and 7 for complete listing of menu items and their use. From the Step 3 display, pressing the UP and DOWN keys simultaneously will return the display to the VIEW menu. If no key is pressed for 10 minutes, display will also return to the VIEW menu.

Flow1 Units: GPM >

Step 3

Step 3: Finished Editing?


Press the UP and DOWN keys simultaneously after saving the last setting to return to normal operation.

Output1 Setpnt: 20.0 GPM >

Step 4

Notes on Steps 5 and 6: Output1 Setpnt: All output functions remain active during editing. 20.00 GPM Only the flashing element can be edited. Output1 Setpnt: RIGHT ARROW key advances the flashing element in a continuous loop. Step 10.00 GPM Edited value is effective immediately after pressing ENTER key. If no key is pressed for 10 minutes unit will restore the last saved value and return to step 3. Output1 Setpnt: Step 6 (pressing ENTER key) always returns you to Step 3. 10.00 GPM Repeat steps 3-6 until all editing is completed.

Step 5: Made an Error?


Press the UP and DOWN keys simultaneously while any element is flashing. This will recall the last saved value of the item being edited and return you to Step 3.

Output1 Setpnt: 1 .00 GPM

Step 6

ENTER

Output1 Setpnt:

Saving

Output1 Setpnt: 19.00 GPM >


page 5 of 8

SIGNET 8550-3 Flow Transmitter

Calibrate Menu
Display (Factory settings shown) Description The first three characters set the Flow Rate units of measure. They have no effect on calculations. They may be any alpha or numeric character, upper or lower case. The last character sets the Flow rate Timebase. Select S (seconds, M (minutes, H (hours) or D (days) This setting tells the transmitter how to convert the input frequency from the flow sensor into a flow rate. The K-factor is unique to the sensor model and to the pipe size and schedule. Refer to data in the sensor manual for the correct value. Limits: 0.0001 to 99999. (The K-factor cannot be set to 0.) This setting identifies the Totalizer units. It has no effect on any calculation. It serves as a label only. Each character can be any alpha or numerical selection, upper or lower case. This setting tells the transmitter how to convert the flow sensor signal into a volumetric total. It also is used as the basis for the Open Collector pulse mode. The setting is usually the same as the Flow K-factor, or different by x10 or x100. Limits: 0.0001 to 99999. (The K-factor cannot be set to 0) Select the input source to be associated with Loop output #1: Flow sensor #1, Flow sensor #2, or Delta Flow. Select the minimum and maximum values for the Current loop output #1. The 8550 will allow any values from 0.0000 to 99999.

Flow1 Units: GPM

>

Flow1 K-Factor: 60.000

>

Total1 Units: Gallons

>

Total1 K-Factor: 60.00

>

Loop1 Source: Flow1 Loop1 Range: GPM 000.00 100.00

>

>

Output1 Source: Flow1

>

Select the input source for Open Collector output #1: Flow sensor #1, Flow sensor #2, or Delta Flow.

Output1 Mode: Low

>

Select the mode of operation for Open Collector output #1. Options available are High, Low, Pulse (volumetric), or Frequency (based on rate). The signal may be disabled if not in use. In Low or High Mode, this Open Collector output will be activated when the Flow rate reaches this value. Be sure to modify this setting if you change the Flow Units.

Output1 Setpnt: 1.0 GPM >

Output1 Hys: 5.0 GPM >

The Open Collector output will be deactivated at Setpoint Hysteresis, depending on High or Low Setpoint selection. (See details on page 4.)

Output1 Volume: 100.00 Gallons

>

In Pulse mode, Open collector output #1 will generate one pulse when this volume of flow passes the sensor. (The measurement is based on the Total1 K-factor). The 8550 will allow any value from 0.0001 to 99999. In Pulse mode, this setting defines the duration of Open Collector output pulse #1. The 8550 allows any value from 0.1 seconds to 999.9 seconds.

Output1 PlsWdth: 0.1 Seconds

>

Output1 Freq.: Divide by

1 >

In Frequency mode, Open Collector output #1 will simulate the sensor frequency, divided by this setting. Set for 1 (input frequency = output frequency). Set for even numbers (2, 4, 6, 8 . . . 254 maximum) to scale output fequency. Use this note pad to record important dates, such as annual recertification or scheduled maintenance.

Last CAL: 06-30-01

All functions labeled "1" will repeat for channel 2.

page 6 of 8

SIGNET 8550-3 Flow Transmitter

Options Menu
Display (Factory settings shown) Contrast: 3 Flow1 Decimal *****. Total1 Decimal ******.** Averaging 1: Off Total Reset: Lock Off > > >
.OFF provides the quickest output response to changes in flow. LOW averaging = 4 seconds, HIGH averaging = 8 seconds of input signal. Longer averaging produces more stable display and output response. Lock Off : No key code required to reset the resettable totalizer. Lock On : The Key Code must be entered to reset the resettable totalizer.

Description
Adjust the LCD contrast for best viewing. A setting of 1 is lower contrast, 5 is higher. Select lower contrast if the display is in warmer ambient surroundings. Set the decimal to the best resolution for your application. The display will automatically scale up to this restriction. Select *****., ****.*, ***.**, **.*** or *.**** Set the totalizer decimal to the best resolution for your application. Select ********., *******.*, or ******.**

>

>

Loop1 Adjust: 4.00 Loop1 Adjust: 20.00 Output1 Active: Low Test Loop1: > Test Output 1: > > mA > mA >

Adjust the minimum and maximum current output. The display value represents the precise current output. Adjustment limits: 3.80 mA < 4.00 mA > 5.00 mA 19.00 mA < 20.00 mA > 21.00 mA Use this setting to match the system output to any external device.

Active HIGH: This setting is used to turn a device (pump, valve) ON at the setpoint. Active LOW: This setting is used to turn a device OFF at the setpoint.

Press UP or DOWN keys to manually order any output current value from 3.6 mA to 21.00 mA to test current loop output #1.

Press UP or DOWN keys to manually toggle the state of open collector output #1.

All functions labeled "1" will repeat for channel 2.

SIGNET 8550-3 Flow Transmitter

page 7 of 8

Troubleshooting
Display Condition
- - - - -

Suggested Solutions
Flow rate exceeds display capability

Suggested Solutions
Increase Flow units timebase Move flow decimal one place to the right

Pulse Overrun Output1 Pulse Overrun Output2

Open Collector pulse rate exceeds maximum of 300 pulses per minute. Pulse width set too wide.

Increase Output Volume setting Decrease Output pulse width Reduce system flow rate

Value must be more than 0

K-factors cannot be set to 0.

Enter K-factor between 0.0001 to 99999

Open Collector output is always activated

Hysteresis value too large Defective transmitter

Change the hysteresis value Replace transmitter

SIGNET
Signet Scientific Company, 3401 Aerojet Avenue, El Monte, CA 91731-2882 U.S.A. Tel. (626) 571-2770 Fax (626) 573-2057 For Worldwide Sales and Service, visit our website: gfsignet.com Or call (in the U.S.): (800) 854-4090 GEORGE FISCHER Piping Systems
3-8550.090-3/(C-3/01) English Scientific Company 1999 Printed in U.S.A. on Recycled Paper

page 8 of 8

SIGNET 8550-3 Flow Transmitter

Contents

General data
Performance range, DME Performance range, DMS Digital Dosing Type key Codes 3 3 4 5 5

Pump selection
DME 2 to 12 - standard range DME 19 to 48 - standard range DME 60 to 150 - standard range DME 375 to 940 - standard range DMS 2 to 4 - standard range DMS 8 to 12 - standard range Non-standard options 33 34 35 36 37 38 39

Functions
Overview of functions Capacity range 6 7

Pumped liquids
List of pumped liquids 40

Functions
Capacity control, DME Capacity control, DMS Control panel Menu Operating modes Dosing monitoring Control panel lock Wiring diagram, DME 2 to 48 and DMS-A (AR) Wiring diagram, DME (60 to 940) 8 9 10 12 13 17 18 19 20

Accessories
41

Construction
Sectional drawing, DME (2 to 48) Material specification Sectional drawing, DME (60 to 940) Material specification Sectional drawing, DMS Material specification 22 22 23 23 24 24

Performance curves
DME, DMS, 60 Hz 25

Dimensions
Front-fitted control panel DME 2 to 48, DMS Side-fitted control panel DME 2 to 48, DMS DME (60 to 940) 28 28 29

Technical data
DME (2 to 48) DME (60 to 940) DMS 30 31 32

General data

DME

Performance range, DME


-

Performance range, DMS


-

General data

DMS

Fewer variants to cover all needs The powerful variable speed motor, a turn-down ratio of 1:1000/1:800 and a complete control interface including full pulse control, pulse batch control, internal timer batch control, analog 0/4-20 mA control, level control and fieldbus communication module ensure that nine DME pumps cover the range from 0.00066 to 248.3 gallons per hour, up to 261 psi. The switch mode power supply ensures that the same pump is working precisely, irrespective of the power supply (100-240 V; 50-60 Hz). The DMS version with synchronous motor and a turndown ratio of 1:100 (consisting of four pump sizes and two control versions) cover the range from 0.0066 to 3.17 GPH. The DMS-A pumps have external pulse, analog 4-20 mA and level control interface; the DMS-B version is without external control interface. The DMSD is without control and user interface. The DME and DMS dosing pumps feature diaphragm dosing head with integrated vent valve, suction and discharge ball valves. The pumps are also fitted with a power cable and plug.

Digital Dosing
Digital Dosing represents state-of-the-art technology. This patented Grundfos solution sets new standards, including new principles and methods. Precise and easy setting The operator can easily install and set the pump to discharge exactly the quantity of dosing liquid required in the application. Capacity is read on the digital display in GPH, l/h, or ml/h, while icons are used to identify the operation mode. Unique technology A unique drive and microprocessor control ensure that dosing liquids are discharged precisely and with low pulsation even when the pump is operating with high viscosity or degassing liquids. Instead of the conventional stroke length adjustment, the capacity of the DME is regulated by automatic ajustment of the motor speed during the discharge stroke and by fixed suction stroke speed, ensuring optimal and uniform mixing. The capacity of the DMS is regulated by automatic regulation of the stroke frequency.

General data

DME and DMS

Type key
Example Type range Maximum capacity [l/h] Maximum pressure [bar] Control variant Dosing head material Gasket material Valve ball material Control panel position Supply voltage Valves Connection suction/ discharge Power plug type DME 2 - 18 - A - PP / E / C - F - 2 1 RR B

Codes
Example A - PP / E / C - 2 - 1 Control variant A AG A + Genibus AR A + alarm relay AP A + Profibus B Basic D Only on/off Dosing head material PP Polypropylene PV PVDF SS Stainless steel Gasket material E EPDM V FKM Valve ball material C Ceramic SS 316 SS G Glass Y Hastelloy C Control panel position F Front-fitted S Side-fitted X No control panel Supply voltage 1 1 x 230 V, 50 Hz 2 1 x 120 V, 60 Hz 3 1 x 100-240 V, 50-60 Hz 6 1 x 110 V, 50 Hz 8 1 x 100 V, 50/60 Hz 9 1 x 200 V, 50/60 Hz Valves 1 Standard valve 2 Spring-loaded valve Connection suction/discharge Tubing 6/9 mm 1 Tubing 4/6 mm supplied with the pump Tubing 6/9 mm 2 Tubing 6/12 + 9/12 mm supplied with the pump 3 Tubing 4/6 mm 4 Tubing 6/9 mm 5 Tubing 6/12 mm 6 Tubing 9/12 mm T Tubing 0.17"/0.25" R Tubing 0.25"/0.375" S Tubing 0.375"/0.5" A Threaded Rp 1/4 B Threaded Rp 3/8 V Threaded NPT 1/4" Y Threaded NPT 3/8" E Cementing d.10 mm F Cementing d.12 mm Q Tubing 19/27 + 25/34 W Tubing 32/41 + 38/48 A1 Threaded Rp 3/4" A2 Threaded Rp 1 1/4" A3 Threaded NPT 3/4 A4 Threaded NPT 1 1/4 Power plug F EU (Schuko) B USA, Canada (120 V) G UK I Australia E Switzerland J Japan R R B

Functions

DME and DMS

Overview of functions
DME
2 to 48 60 to 940 AR 60 to 940 B variant A

DMS
variant B variant D

Capacity control, see page 8 Internal stroke frequency control Internal stroke speed control Control panel, see page 10 Capacity setting in liters, milliliters or US gallons Display with background light and soft-touch buttons Easy set-up menu with language options On/off button Maximum capacity button (priming) Green indicator light for operating indication Red indicator light for fault indication Control panel lock Side-fitted as an option Operating modes, see page 13 Manual control Pulse control Analog 0/4-20 mA control Timer-based batch control Pulse-based batch control Functions, see page 17 Dosing monitoring Dual-level control Calibration of pump to actual installation Anti-cavitation (reduced suction speed) Capacity limitation Counters for strokes, operating hours and power on/off Fieldbus communication (variants AP and AG) Overload protection Error message in display Leakage sensor Dosing signal output Power supply, page 16 Switch-mode power supply Inputs/outputs, see page 19 Input for pulse control Input for analog 0/4-20 mA control Input for dual-level control Input for external start/stop Alarm relay output (variant AR) Dosing output Input for external on/off switch

Functions

DME and DMS

Capacity range
-

The maximum capacity is available at any counter pressure within the pump's specified range if it has been calibrated to the actual installation.

Functions

DME

Capacity control, DME


The electronically controlled variable-speed motor of the DME pumps provides optimum control of the stroke speed. As shown in the figure below, the duration of each suction stroke is constant while the duration of each discharge stroke varies according to the capacity set, resulting in optimum discharge flow in any operating situation. The advantages are as follows: The pump is always operating at full stroke length, irrespective of the capacity set, for optimum accuracy, priming and suction. A capacity range of 1:1000 (DME 2 to 48) for each pump size. A capacity range of 1:800 (DME 60 to 940) for each pump size. Even and constant dosing ensuring an optimum mixing ratio at the injection point. Significant reduction of pressure surges, preventing mechanical stress on diaphragm, tubes, connections and other dosing parts exposed to leakage and wear. The installation is less affected by long suction and discharge lines. Easier dosing of highly viscous and gas-containing liquids. The optimum dosing control shown below takes place in any operating mode.

Capacity setting 100%

Discharge duration Suction Discharge

50% Suction Discharge 10% Suction

duration

duration

Functions

DMS

Capacity control, DMS


The electronically controlled synchronous motor of the DMS offers similar advantages of the DME pumps. As shown in the figure below, the suction and discharge stroke speeds are constant while the stroke frequency varies according to the capacity set. The sinusoidal movement of the diaphragm offers the following advantages: The pump is always operating at full stroke length, irrespective of the capacity set, for optimum accuracy, priming and suction. Capacity setting 100% Suction Discharge 50% Suction Discharge 10% Suction duration duration Discharge duration A capacity range of 1:100 for each pump size. Reduction of pressure surges, preventing mechanical stress on diaphragm, tubes, connections and other dosing parts exposed to leakage and wear. The installation is less affected by long suction and discharge lines. Easier dosing of highly viscous and gas-containing liquids.

Functions

DME and DMS

Control panel
LCD Display
ml/h

Indicator lights and alarm output (DME 2 to 48, DMS)


Navigation/ settings

The green and red indicator lights on the pump indicate operation or fault. In control variant AR, the pump can activate an external alarm signal by means of a built-in alarm relay. The alarm signal is activated by means of an internal potential-free contact. The functions of the indicator lights and the built-in alarm relay appear from the table below.
Condition Green LED Red LED Display Alarm output
1

Menu/ accept Navigation/ settings


100%

Green indicator light indicator light On/off button

Priming button Pump running On Off Normal indication

1 2 3 NC NO C

Pump paused

Flashing

Off

Normal indication

1 2 3 NC NO C

Pump fault

Off

On

EEPROM
1 2 3 NC NO C

Supply failure

Off

Off

Off
1 2 3 NC NO C

Control panel fitted to the front.


Pump running, low chemical level 2 On On Normal indication

1 2 3 NC NO C

Empty tank

Off

On

Normal indication

1 2 3 NC NO C

Analog signal < 2 mA The pump is not dosing enough according to the signal from the dosing monitor 3 More pulses than capacity

Off

On

Normal indication

1 2 3 NC NO C

Control panel fitted to the side (not DMS-B).

On

On

Normal indication

Priming button
The pump control panel incorporates a 100% button. Press this button if the maximum capacity is required over a short period, e.g. during start-up. When the button is released, the pump automatically returns to the previous operating mode. When the buttons and are pressed simultaneously, the pump can be set to run for a specific number of seconds at maximum capacity. The remaining numbers of seconds will appear in the display. This feature is useful when flushing the pump. The maximum value is 300 seconds.
100%

1 2 3 NC NO C

On

On

Normal indication

1 2 3 NC NO C

Overheated

Off

On

MAX TEMP

1 2 3 NC NO C

1 2 3

Control variant AR, only. Requires connection to level sensors. Requires dosing monitor function activated and a dosing monitor device connected to the pump.

Press passed.

to stop the pump before the set time has

Functions

DME and DMS

Indicator lights and alarm output (60 to 940)


Condition Green LED Red LED Display Alarm output 1

Condition
1 2

Green LED Red LED

Display

Alarm output 1

Control variant AR, only. Requires connection to level sensors. Requires activation of the dosing monitoring function and connection to a dosing monitor. Please contact a Grundfos service centre. Alarms can be reset after fault conditions are back to normal.

Pump running

On

Off

Normal indication

3
1 2 3 NC NO C

Set to stop

Flashing

Off

Normal indication

5
1 2 3 NC NO C

The pump will make 10 attempts to restart before going into permanent off mode.

Pump fault

Off

On

EEPROM

1 2 3 NC NO C

Supply failure

Off

Off

Off
1 2 3 NC NO C

Pump running, low chemical level 2

On

On

LOW
1 2 3 NC NO C

Empty tank

Off

On

EMPTY
1 2 3 NC NO C

Analog signal < 2 mA

Off

On

NO mA
1 2 3 NC NO C

The dosed quantity is too small according to the signal from the dosing monitor 3

On

On

NO FLOW

1 2 3 NC NO C

Overheating

Off

On

MAX TEMP

1 2 3 NC NO C

Internal communication failure

Off

On

INT COM

1 2 3 NC NO C

Internal Hall Failure

Off

On

HALL
1 2 3 NC NO C

Diaphragm failure (leakage) 5

Off

On

LEAKAGE
1 2 3 NC NO C

Max. pressure exceeded 5

Off

On

OVERLOAD

1 2 3 NC NO C

More pulses than capacity

On

On

MAX FLOW

1 2 3 NC NO C

No detection of motor rotation

On

On

ORIGO
1 2 3 NC NO C

Functions

DME and DMS

Menu
The DME and DMS dosing pumps feature a userfriendly menu which is activated by pressing the button. During start-up, all texts will appear in the English language, but other languages can be selected (see page 16). The example shown below applies only to DME 60 to 940 pumps.

Functions

DME and DMS

Operating modes
Manual control
The pump is dosing constantly according to the quantity set in l/h or ml/h by means of the buttons and . It automatically changes over between the measuring units. Setting range, DME:
DME 2-18 8-10 12-6 19-6 48-3 60-10 150-4 375-10 940-4 Adjustable Flow Range GPH 0.00066 0.002 0.0032 0.0049 0.0127 0.0198 0.0495 0.1238 0.3104 to GPH 0.66 (0.47*) 1.98 (1.47*) 3.17 (2.37*) 4.88 (3.83*) 12.68 (9.77*) 15.85 39.63 99.06 248.32 ml/h 2.5 7.5 12 18.5 48 75 187.5 468.75 1175 to l/h 2.5 (1.8*) 7.5 (5.6*) 12 (9*) 18.5 (14.5*) 48 (37*) 60 150 375 940

Setting range, DME: DME DME DME DME DME DME DME DME DME 2-18: 8-10: 12-6: 19-6: 48-3: 60-10: 150-4: 375-10: 940-4: 0.000023 0.000069 0.000111 0.000204 0.000530 ml/pulse ml/pulse ml/pulse ml/pulse ml/pulse 5.0 ml/pulse 15.0 ml/pulse 24.0 ml/pulse 37.0 ml/pulse 96.0 ml/pulse 120 ml/pulse 300 ml/pulse 750 ml/pulse 1880 ml/pulse.

0.000625 ml/pulse 0.00156 ml/pulse 0.00392 ml/pulse 0.00980 ml/pulse -

Setting range, DMS: DMS DMS DMS DMS 2: 4: 8: 12: 0.00232 0.00370 0.00695 0.01110 ml/pulse ml/pulse ml/pulse ml/pulse 50 ml/pulse 80 ml/pulse 150 ml/pulse 240 ml/pulse

Analog 4-20 mA control


Applies to DME and DMS-A The pump is dosing according to an external analog signal. The dosed capacity is proportional to the input value in mA. 4-20 (default): 20-4: 0-20: 4 mA = 20 mA = 4 mA = 20 mA = 0 mA = 20 mA = 0 mA = 20 mA = 0% 100% 100% 0% 0% 100% 100% 0%.

The figures in brackets indicate the maximum capacity when the anti-cavitation function is activated. See page 15 for adjusted DME 60 to 940 capacities. Setting range, DMS:
DMS 2 4 8 12 Adjustable Flow Range GPH 0.0066 0.0105 0.0198 0.0317 to GPH 0.66 1.05 1.98 3.17 ml/h 2.5 40 75 120 to l/h 2.5 4 7.5 12

20-0:

The maximum capacity limitation, see page 15, will influence the capacity. 100% (20 mA) corresponds to the maximum capacity or the set capacity limitation.

Pulse control
Applies to DME and DMS-A. The pump is dosing according to an external pulse signal, e.g. from a water meter. There is no direct relation between pulses and dosing strokes. The pump automatically calculates its optimal speed to ensure the required quantity is dosed for each pulse. The quantity to be dosed is set in ml/pulse. The pump adjusts its speed and/or stroke frequency according to two factors: frequency of external pulses and the set quantity per pulse.
100 80 60 40 20 0 0 4 8 12 Input signal [mA] 16 20
4-20 mA signal 4-20 mA signal

Functions

DME and DMS

Timer-based batch control


Applies to DME The pump is dosing the set quantity in batches at maximum capacity or the set capacity limitation. The time until the first dosing (NX) and the following sequences (IN) can be set in minutes, hours and days. The maximum time limit is 9 days, 23 hours and 59 minutes (9:23:59). The lowest acceptable value is one minute. IN must be higher than the time required to perform one batch. If IN is lower than the time required, the next batch will be ignored. In case of supply failure, the set dosing quantity, the IN time and the remaining NX time are stored. When the supply is reconnected, the pump will start up with the NX time at the time of the supply failure. This way the timer cycle will continue, but it will be delayed according to the time of the supply failure. This feature is not available on variant "B" pumps. Quantity pr. batch

Setting range (applies to DME only):


Timer-based and pulse-based batch control 0.23 ml/batch to 5 l/batch DME 2: 0.00006 G/batch to 1.32 G/batch 0.69 ml/batch to 15 l/batch DME 8: 0.00018 G/batch to 3.96 G/batch 1.11 ml/batch to 24 l/batch DME 12: 0.00029 G/batch to 6.34 G/batch 2.04 ml/batch to 37 l/batch DME 19: 0.00053 G/batch to 9.77 G/batch 5.3 ml/batch to 96 l/batch DME 48: 0.0014 G/batch to 25.4 G/batch 6.25 ml/batch to 120 l/batch DME 60: 0.0017 G/batch to 31.7 G/batch 15.6 ml/batch to 300 l/batch DME 150: 0.0041 G/batch to 79.3 G/batch 39.1 ml/batch to 750 l/batch DME 375: 0.01 G/batch to 198.1 G/batch 97.9 ml/batch to 1880 l/batch. DME 940: 0.025 G/batch to 496.7 G/batch

Quantity pr. batch

t NX IN Pulse Pulse

Pulse-based batch control


Applies to DME The pump is dosing the set quantity in batches at maximum capacity or the set capacity limitation. The quantity is dosed every time the pump receives an external pulse. If the pump receives new pulses before the batch is completed, these pulses will be ignored. However the manually control DME B cannot be controlled externally.

Anti-cavitation (2 to 48)
Applies to DME When this function is selected, the pump extends and smooths its suction stroke, resulting in softer priming. The anti-cavitation function is used: when pumping liquids of high viscosity when pumping degassing liquids in the case of a long suction tube and in the case of a high suction lift. The maximum capacity is reduced when this function is selected, see table below.
Maximum capacity with anti-cavitation function DME 2 DME 8 DME 12 DME 19 DME 48 0.475 GPH 1.48 GPH 2.38 GPH 14.5 GPH 9.77 GPH 1.8 l/h 5.6 l/h 9 l/h 14.5 l/h 37 l/h

Functions

DME and DMS

Anti-cavitation (60 to 940)


The pump features an anti-cavitation function. When this function is selected, the pump extends and smoothes its suction stroke, resulting in softer priming. The anti-cavitation function is used: when pumping liquids of high viscosity, in the case of a long suction tube and in the case of a high suction lift. Depending on the circumstances, during the suction stroke, the motor speed can be reduced by 75% , 50% or 25% compared to the normal motor speed during the suction stroke. The maximum pump capacity is reduced when the anticavitation function is selected

3. To cover several needs with just one pump size. 4. To adapt the pump to a 4-20 mA signal control with 4 mA corresponding to 0% and 20 mA to the set maximum capacity. In this way it is possible for instance to use a DME 48 for dosing a very small quantity of liquid without changing the input signal. See example below.

Anti-cav max capacity (DME 60 to 150)


DME 60 to 940 DME 60 150 375 940 g/h. (l/h) g/h. (l/h) g/h. (l/h) Max cap. 15.9. (60) 39.6. (150) 99.1. (375) 75% 11.9. (45) 29.6. (112) 74.2. (281) 50% 7.9. (30) 19.8. (75) 49.7. (188) 25% 4.0. (15) 10.0. (38) 24.8. (94)

Example: A DME 48 receives a 12 mA input signal from a control instrument, resulting in a 50% output (according to the analog curve on page 13) and a capacity of 24 l/h. A new situation occurs where it is only necessary to dose 2 l/h. The maximum capacity limitation is set to 4 l/h. The pump is still receiving a 12 mA signal resulting in a 50% output and a capacity of 2 l/h.
12 11 10 9 8 7 6 5 4 3 2 1 0 48 44 40 36 32 28 24 20 16 12 8 4 0 0 4 8 12 16 20 [mA]

g/h. (l/h) 248.3. (940) 186.2. (705) 124.2. (470) 62.1. (235)

Maximum capacity limitation


Applies to DME This function offers the possibility of reducing the maximum capacity (MAX. CAP). It influences the functions in which the pump is normally operating at maximum capacity. Under normal operating conditions, the pump cannot operate at a capacity higher than the one stated in the display. This does not apply to the priming button. By means of this function, a large pump can be set to act as a much smaller pump. Together with the 1:1000/ 1:800 capacity range, the purposes of this function are:

1. To utilize the smooth and even dosing characteristics of the pump at low capacities to achieve improved chemical mixing, improved dosing through long discharge tubes and improved dosing of high-viscous liquids. 2. To improve the dosing of gas-containing liquids: In a large pump, as compared to a small pump, the displaced volume (1) is much larger than the non-displaced volume (2).

The maximum capacity limitation will also reduce the pump speed in timer-based batch control, pulse-based batch control and during calibration where the pump is usually operating at maximum capacity.

Calibration
After start-up, the dosing pumps can be calibrated to the actual installation to ensure that the displayed value (milliliters or liters) is correct. A calibration program in the main menu facilitates this process.

Functions

DME and DMS

Counters
The pump can display "non-resettable" counters for: Accumulated dosed quantity in liters or US gallons. - Accumulated number of dosing strokes. - Accumulated number of operating hours (power on). Accumulated number of times the mains supply has been switched on.
Vent valve

Languages
The display text can be displayed in one of the following languages chosen in the set-up menu: English German French Italian Spanish Portuguese Dutch Swedish Finnish Danish Czech Slovak Polish Russian.
Upper sensor activated

Switch-mode power supply


Applies to DME The DME pump is incorporates a switch-mode power supply. This makes the pump independent of variations in supply voltage and frequency. Operating range: 1 x 100-240 V, 50-60 Hz.

Level control
Applies to DME-A and DMS-A The pump can be connected to a level control unit for monitoring of the chemical level in the tank. The pump can react to two level signals. The following table shows the pump reactions to the sensor signals:
Level sensors Pump reaction Red indicator light is on. Pump . Alarm relay activated. Red indicator light is on. Pump -. Alarm relay activated.

Integrated venting
The DME and DMS dosing pumps are provided with an integrated vent valve. The valve makes it very easy to prime the pump during start-up: The vent valve must be connected to the tank by means of 1/4" tubing.

Lower sensor activated

Applies to control variant AR

Bus communication
Applies to DME The pump is available with an optional built-in module for bus communication with GENIbus (variant AG, DME 2 to 48 only) or PROFIBUS (variant AP) systems. These modules enable remote monitoring and setting via the fieldbus system. All DME features are available via bus communication. The PROFIBUS GDS-file can be downloaded from www.grundfos.com/dosing.

Diaphragm leakage sensor (DME 60 to 940)


For the larger pumps, the vent valve must be connected to the tank by means of 5/8" ID tubing.

The pump can be fitted with a leak sensor that connects to the drain hole of the pump head. In the event of diaphragm leakage, the sensor will activate the pump's alarm relay.

Functions

DME and DMS

Dosing monitoring
Applies to all DME 2 to 48 and DMS AR

Dosing stoke measured Dosing stoke measured

Dosing stoke measured

Monitor mounted on suction side (DME and DMS)

Monitor mounted on discharge side (DMS only)

Monitor mounted in dosing tube. In discharge tube: DMS (in-line) In suction tube: DME and DMS (in-line)

The dosing monitor is designed to monitor the dosing of liquids which may cause gas accumulation in the pump head, thus stopping the dosing process even if the pump is still operating. For every measured dosing stroke, the dosing monitor gives a pulse signal to the level input so that the pump can compare performed pump strokes (from internal stroke sensor) with externally measured physical strokes (from the dosing monitor). If an external dosing stroke is not measured together with the internal dosing stroke, this is considered a fault that may have been provoked by an empty tank or gas in the dosing head. When used together with a , the monitor will only operate if it is mounted on the suction side of the pump. When used together with a , the monitor will also operate if it is mounted on the discharge side of the pump. The dosing monitor should be connected to the level input (pins 2 and 3). This input must be configured to dosing monitoringin the pump's setup menu. Consequently, it cannot be used as level input. Once the input has been set for dosing monitoring and a dosing monitor has been connected and set, the dosing monitoring function will be active.

- - There is no pulse from the dosing monitor corresponding to the internal stroke signal within the acceptable time (the pump is not pumping).

Logic:
If two incorrect dosing strokes are performed, the pump will continue operating, but it will change over to alarm mode, like in case of "low level". The red indicator light will be on and the alarm output, if any, will be activated (variant AR). For each correct stroke the counter is reset and the alarm output, if any, is deactivated.

Operation in connection with vent valve:

Definitions:
- - A pulse from the dosing monitor corresponds to the internal stroke signal within acceptable time.

Functions

DME and DMS

It is possible to add a self-acting solution for liquids that cause gas accumulation by using an automatic vent valve. The solution is the dosing monitor with a pump and an alarm output (control variant AR). The alarm output thus activates the vent valve, which will automatically vent gas accumulated in the dosing head. When the dosing head has been vented, the pump will start pumping again, the alarm output will be deactivated and the vent valve will close.

- , set the quantity to be dosed in ml/ pulse. The actual capacity is indicated in liters per hour (l/h) or milliliters per hour (ml/h). , set the quantity to be dosed in ml per 100 strokes. -, set the quantity to be dosed in liters (l) or milliliters (ml). Under the "QUANTITY" menu item in the "COUNTERS" menu, the dosed quantity is indicated in liters.

Control panel lock


It is possible to lock the buttons on the control panel to prevent maloperation of the pump. The locking function can be set to "ON" or "OFF". The default setting is "OFF". A PIN code must be entered to change from "OFF" to "ON". When "ON" is selected for the first time, "_ _ _ _" will appear in the display. If a code has already been entered, it will appear when an attempt to change to "ON" is made. This code can either be re-entered or changed.

US measuring units:
-, set the quantity to be dosed in gallons per hour (gph). - , set the quantity to be dosed in ml/ pulse. The actual capacity is shown in gallons per hour (gph). , set the quantity to be dosed in ml per 100 strokes. -, set the quantity to be dosed in gallons. Under the "QUANTITY" menu item in the "COUNTERS" menu, the dosed quantity is indicated in gallons (gal). The drawing below shows all possible settings.

It is possible to select metric units (liter/milliter) and US units (gallons).

Metric measuring units:


- , set the quantity to be dosed in liters per hour (l/h) or milliliters per hour (ml/h).

3x

Operating display

Operating display

Functions

DME and DMS

Wiring diagram, DME 2 to 48 and DMS-A (AR)


See pages 30 and 32 for input/output data.
"NO" black

"NC" blue "COM" brown

Control cable Product no.: 2 m cable: 96440447 5 m cable: 96440448

Level cable Product no.: 2 m cable: 96440450 5 m cable: 96440451

Empty tank

Low level The level switch contacts (normally open) must be closed at low level/empty tank.

Control input
Number/color Function 1/brown 2 1 1 2/white Plug 3/blue 2 1 1+2 2 2 1 4/black 5/grey Description

Manual Pulse Pulse + external on/off Analog Analog + external on/off 2 Timer + external on/off 2 Batch 1 1 = Contact for pulse signal / 2 = Contact for external on/off Pumps in analog mode cannot be connected in series.

2 + +

mA signal mA signal

Level input
Number/color Plug 1/brown Low level Low level 2/white Empty tank Empty tank Dosing monitoring 3/blue Low level Empty tank Low level + empty tank Dosing monitoring 4/black

Function

Functions

DME and DMS

Wiring diagram, DME (60 to 940)

2 3 5 1 4 3

2 5 1 4 3

2 1 4

2 3 1

5 2 3 1

4 1 3

2 1 3

2 5

4 3 1

- Product no.: 2 m cable: 96440447 5 m cable: 96440448

Product no.: 2 m cable: 96534214 5 m cable: 96534215

- Product no.: 2 m cable: 96527109 5 m cable: 96527111

Product no.: 2 m cable: 96440450 5 m cable: 96440451

Cable 1: Analog, pulse and leakage input


Number/color Function Analog input 4-20 mA Pulse Pulse Leakage Leakage potential-free 5V potential-free 5V potential-free Gnd potential-free Gnd (-) 4-20 mA input (+) 4-20 mA input 1/brown 2/white 3/blue 4/black 5/grey

Cable 2: Output for alarm relay


Number/color Function Alarm relay output Common Normally open Normally closed 1/brown 2/white 3/blue

Functions

DME and DMS

Cable 3: Stop dosing input and dosing monitor or dosing output


Number/color Function Stop input Stop input Dosing monitor Dosing monitor Dosing output (pump running) Open collector (NPN) can be used for a relay or a lamp. Open collector (NPN) 5V potential-free potential-free potential-free Gnd Gnd potential-free 5V Gnd 1/brown 2/white 3/blue 4/black 5/grey

Useful when the load (e.g. a relay) has one side connected to a power supply which is not the same one as connected to the sensor. When the dosing output is activated, the output provides the Gnd to the load. Recommended supply: max. 24 VDC. Max. current: 100 mA.

Cable 4: Level input


Number/color Function Empty tank input Empty tank input Low level input Low level input potential-free* 5V potential-free* 5V potential-free* Gnd potential-free* Gnd 1/brown 2/white 3/blue 4/black

The function for the potential-free contact sets can be chosen from the display (NO = Normally Open and NC = Normally Closed).

Construction

DME

Sectional drawing, DME (2 to 48)


1 16 15 14 13 2 18 4 5 3 6 7 8 9 25 23 20 19 22 21 10 11 12 24 17 26

-
The DME pump is a motor-driven diaphragm dosing pump consisting of the following main parts: - Designed with a minimum of clearance space to optimise the priming and deaerating capabilities. The dosing head has built-in valve housings. - Double-ball suction valve and single-ball discharge valve. Spring-loaded valves are available as an option. For priming and deaeration complete with connection for a 1/4 tubing. - Sturdy and easy-to-use connections for various sizes of tubing, pipe thread or pipe cementing. PTFE-coated, textile-reinforced EPDM diaphragm designed for long life. With separation chamber, safety diaphragm and drain hole. With diaphragm connecting rod, crank, beltdrive and stepper motor, all mounted on a sturdy frame. Containing drive unit, electronics, control panel and various electrical connections.
The pump can be supplied with spring-loaded valves. Spring material: Hastelloy. The spring is not shown in the sectional drawing.

Material specification
Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Description Backplate Diaphragm Valve assembly O-ring Valve casing Valve ball Valve seat disk Valve seat ring Connection assembly Cone/thread piece Clamping ring Union nut Vent valve screw Vent valve ball Vent valve O-ring Cabinet Power/alarm cable Dosing head Drive belt Connecting rod Origo sensor Crank shaft Power PCB Operation PCB Stepper motor Drive frame Material options 20% glass-filled PP Textile-reinforced EPDM, PTFE-coated Includes items 4 to 8 EPDM/FKM PP/PVDF/316 SS Ceramic/316 SS EPDM/FKM PP/PVDF/316 SS Includes items 10 to12 PP/PVDF/316 SS PP/PVDF PP/PVDF/316 SS PP/PVDF Ceramic/316 SS EPDM/FKM 20% glass filled PP Rubber PP/PVDF/316 SS Rubber, polyamide-reinforced Steel Steel Aluminium

Construction

DME

Sectional drawing, DME (60 to 940)


29 28 27 26 25 24 23 1 2 3 4 38

20

21 5 19 18 17 16 15 14 13 39 6

22

10 12 32

11 9 37 33 8 34 35 7

36

31 30

Material specification
Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Backplate Spring Cabinet Origo sensor Operation PCB (printed circuit board) Power cable Gear BLDC motor Drain hole or leakage sensor Threaded connection Union nut Connection assembly O-ring O-ring Venting valve ball Spring Spring Venting valve house Venting valve tap O-ring End cover Venting valve complete O-ring EPDM/FKM EPDM/FKM EPDM/FKM Ceramic Hastelloy C Hastelloy C PP/PVDF PP/PVDF EPDM/FKM Steel PVC PP/PVDF Rubber Description Material options 20% glass-filled PP DIN 17223 TYPE C 20% glass-filled PP

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Valve seat Valve ball Valve casing Spring O-ring Valve assembly Steel plate Dosing head Safety membrane Power PCB (printed circuit board) Crank shaft I/O PCB (printed circuit board) Connecting rod Steel plate Steel frame Diaphragm

PP/PVDF/SS Ceramic/Glass/SS/ Hastelloy C PP/PVDF/SS Hastelloy C EPDM/FKM Steel PP/PVDF/SS

Steel Steel Steel Steel Textile-reinforced EPDM, PTFE-coated

- - - - - - - -

Construction

DME

Sectional drawing, DMS


1 16 15 14 13 2 18 4 5 3 6 7 8 9 25 20 19 22 23 10 11 12 24 17 26 21

-
The DMS pump is a motor-driven diaphragm dosing pump consisting of the following main parts: - Designed with a minimum of clearance space to optimise the priming and deaerating capability. The dosing head has built-in valve housings. - Double-ball suction valve and single-ball discharge valve. Spring-loaded valves are available as an option. For priming and deaeration complete with connection for a 1/4 tubing. - Sturdy and easy-to-use connections for various sizes of tubing, pipe thread or pipe cementing. PTFE-coated, textile-reinforced EPDM diaphragm designed for long life. With separation chamber, safety diaphragm and drain hole. With diaphragm connecting rod, crank, beltdrive and synchronous motor, all mounted on a sturdy frame. Containing drive unit, electronics, control panel and various electrical connections (DMS-A).
The pump is available with spring-loaded valves. Spring material: Hastelloy. The spring is not shown in the sectional drawing.

Material specification
Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Description Backplate Diaphragm Valve assembly O-ring Valve casing Valve ball Valve seat disk Valve seat O-ring Connection assembly Cone/thread piece Clamping ring Union nut Vent valve screw Vent valve ball Vent valve O-ring Cabinet Power/alarm cable Dosing head Drive belt Connecting rod Dosing stoke auxiliary spring Crank shaft Power PCB Operation PCB Synchronous motor Drive frame Material options 20% glass-filled PP Textile-reinforced EPDM, PTFE-coated Contains items 4 to 8 EPDM/FKM PP/PVDF/Stainless steel Ceramic/316 SS EPDM/FKM PP/PVDF/316 SS Contains items 10 to12 PP/PVDF/316 SS/PVC PP/PVDF PP/PVDF/316 SS PP/PVDF Ceramic/316 SS EPDM/FKM 20% glass-filled PP Rubber PP/PVDF/316 SS Rubber, polyamide-reinforced Steel Steel Aluminium

Performance curves

DME

DME 2-18
-

DME 19-6
-

DME 8-10
-

DME 48-3
-

DME 12-6
-

Performance curves

DME

DME 60-10
-

DME 375-10
-

DME 150-4
-

DME 940-4
-

Performance curves

DMS

DMS 2-11
-

DMS 8-5
-

DMS 4-7
-

DMS 12-3
-

Dimensions

DME and DMS

Front-fitted control panel DME 2 to 48, DMS


4 3/8 B

ml/h

100%

3 7/8

1.97

Side-fitted control panel DME 2 to 48, DMS


5.12 4 3/8 B

ml/h

100%

3 7/8
-- - Pump type A B C D DME 2 DMS 2 DMS 4 5.4 (137) 9.4 (239) 1.4 (36) 6.6 (168)

1.97

DME 8 DMS 8

DME 12 DMS 12

DME 19 7.56 (192) 11.57 (294) 0.59 (15) 7.40 (188)

DME 48

Dimensions

DME and DMS

DME (60 to 940)


A B F

E
-- s DME 60 A B C D E F G H I 6.93 7.8 13.03 11.18 7.09 17.48 1.61 2.91 7.36 (176) (198) (331) (284) (180) (444) (41) (74) (187) 7.8 13.58 11.18 7.09 17.48 1.10 2.91 7.36

DME 150 6.93 (176) (198) (345) (284) (180) (444) (28) (74) (187)

DME 375 9.37 8.58 18.54 14.33 9.06 21.26 1.22 3.74 9.69 (238) (218) (471) (364) (230) (540) (31) (95) (246)

DME 940 9.37 8.58 19.53 14.33 9.06 21.22 0.24 3.74 9.69 (238) (218) (496 (364) (230) (539) (6) (95) (246)

Technical data

DME

DME (2 to 48)
Pump Maximum capacity without anti-cavitation Maximum capacity with anti-cavitation Maximum pressure Maximum stroke frequency Mechanical data
2 1 1

DME 2 [l/h] [GPH] [l/h] [GPH] [bar] [psi] [stroke/min] 2.5 0.66 1.8 0.49 18 261 180 5.9 (1.8) 500 200

DME 8 7.5 1.98 5.6 1.48 10 145 180 9.8 (3) 500 200

DME 12 12 3.17 9 2.78 6 87 180 19.7 (6) 9.8 (3) 500 200 122 (50) 32 (0) 113 (45) 32 (0) 1%

DME 19 18.5 4.88 14.5 3.66 6.2 90 151 9.8 (3) 500 200

DME 48 48 12.68 37 9.51 2.6 38 151 9.8 (3) 100 100

Maximum wet/primed suction lift [ft (m)] Maximum suction lift when priming with wet valves [m] Maximum viscosity with spring-loaded valves
3

[cps]
3

Maximum viscosity without spring-loaded valves Maximum liquid temperature [F (C)] Minimum liquid temperature [F (C)] Maximum ambient temperature[F (C)] Minimum ambient temperature[F (C)] Accuracy of repeatability Weight and size Weight [lb (kg)] Diaphragm diameter [in (mm)] Supply voltage [V] Maximum current consumption [A] Electrical data Maximum power consumption P1 [W] Enclosure class Insulation class Voltage in level sensor input [VDC] Voltage in pulse input [VDC] Signal input Minimum pulse-repetition period [ms] Impedance in analog 0/4-20 mA input [ Maximum loop resistance in pulse signal circuit [ ] Maximum loop resistance in level signal circuit [ ] Signal output Sound pressure Approvals

[cps]

5 (2.3) 1.1 (28) at 100 V at 230 V

5 (2.3)

5 (2.3)

7.5 (3.4) 7.5 (3.4)

1.5 (38) 1.7 (43.5) 2.2 (55) 3.03 (77) 1 x 100-240 V, 50-60 Hz 0.27 0.16 16.2 IP 65 F 5 5 3.3 250 350 350 2 250 CE, VDE, cUL, UL, METI 0.35 0.26 22.1

Maximum load of alarm relay output, at ohmic load [A] Maximum voltage, alarm relay output [V] The sound pressure level of the pump is lower than 70 db(A).

-- - - - - - -

Technical data

DME

DME (60 to 940)


Pump Maximum capacity Minimum capacity Maximum capacity with anti-cavitation 75% [l/h] Maximum capacity with anti-cavitation 50% [l/h] Maximum capacity with anti-cavitation 25% [l/h] Maximum pressure Maximum stroke frequency [stroke/min] Maximum wet/primed suction lift [ft (m)] Maximum suction lift when priming with wet valves [ft (m)] Maximum viscosity with spring-loaded valves Maximum liquid temperature [F, C] Minimum liquid temperature [F, C] Maximum ambient temperature [F, C] Minimum ambient temperature [F, C] Accuracy of repeatability Weight and size Weight [lbs, (kg)] Diaphragm diameter [in, (mm)] Supply voltage [V] Maximum current consumption [A] Electrical data Maximum power consumption P1 [W] Enclosure class Insulation class Cable data Power supply cable [ft, (m)] Voltage in level sensor input [VDC] Voltage in pulse input [VDC] Signal input Minimum pulse-repetition period [ms] Impedance in analog 0/4-20 mA input [ Maximum loop resistance in pulse signal circuit [ ] Maximum loop resistance in level signal circuit [ ] Signal output Approvals Sound pressure The sound pressure level of the pump is lower than 70 dB (A). level
1

DME 60 [GPH (l/h)] [GPH (ml/h)] [GPH (l/h)] [GPH (l/h)] [GPH (l/h)] [psi (bar)] 15.9, (60) 0.0198 (75) 11.9, (45) 7.9, (30) 4.0, (15) 145, (10)

DME 150

DME 375

DME 940

39.6, (150) 99.1, (375) 248.3, (940) 0.0495 (187,5) 0.1238 (468.75) 0.3104 (1175)

29.6, (112) 74.2, (281) 186.2, (705) 19.8, (75) 10.0 (38) 58, (4) 49.7, (188) 124.2, (470) 24.8, (94) 145, (10) 160 19.7 (6) 4.9 (1.5) 3000 cps at 50% capacity 200 122 (50) 32 (0) 113 (45) 14 (-10) 1% 62.1, (235) 58, (4)

[cps]
1

Maximum viscosity without spring-loaded valves

[cps]

25.1, (11.4) 3.1, (79) at 100 V at 230 V

26, (11.8) 4.2, (106)

46.3, (21) 4.9, (124)

49.6, (22.5) 6.8, (173) 2.40 1.0 240

1 x 100-240 V, 50-60 Hz 1.25 0.67 67.1 IP 65 B 4.9, (1.5) 5 5 3.3 250 350 350 2 250 CE, CB, VDE, PSE, CSA

Maximum load of alarm relay output, at ohmic load [A] Maximum voltage, alarm relay output [V]

Technical data

DMS

DMS
Pump DMS-A and AR, B Maximum capacity
1

DMS 2 [l/h] [gph] [l/h] [GPH] [l/h] [GPH] [bar] [psi] DMS-A and AR, B Maximum stroke frequency
2

DMS 4 4 1.05 5.7 18% 1.5 18% 6.9 18% 7 102 180 187.5 225

DMS 8 7.5 1.98 8.7 8% 2.3 8% 10.4 8% 5.4 78

DMS 12 12 3.17 13.7 6% 3.6 6% 16.4 6% 4.33 6% 3.4 49

2.5 0.66 3.3 20% 0.87 20% 3.9 20% 1.03 20% 11 160

DMS-D (50 Hz) DMS-D (60 Hz)

1.82 18% 2.75 8%

Maximum pressure

[stroke/min]

Mechanical data Maximum wet/primed suction lift [ft, (m)]

DMS-D (50 Hz) DMS-D (60 Hz) 5.9 (1.8)

19.7 (6) 6.6 (2) 500 200 122 (50) 32 (0) 113 (45) 32 (0) 1% 5, (2.3) 1.1 (28) 1.3 (32) 1.5 (38) 1.8 (42.5) 1 x 230 V 13%/+10%, 50/60 Hz 9.8 (3) 9.8 (3)
3

Maximum suction lift when priming with wet valves [ft, (m)] Maximum viscosity with spring-loaded valves [mPas] (= cP)
3

Maximum viscosity without spring-loaded valves Maximum liquid temperature [F, C] Minimum liquid temperature [F, C] Maximum ambient temperature [F, C] Minimum ambient temperature [F, C] Accuracy of repeatability Weight and size Weight [lbs, (kg)] Diaphragm diameter [in, (mm)] Supply voltage

[mPas] (= cP)

1 x 120 V 12%/+8%, 60 Hz 1 x 100 V 6%, 50/60 Hz at 100 V 0.2 0.17 0.09 20 IP 65 F 5 5 3.3 250 350 350 2 250 CE, VDE cUL, UL, METI
4

Electrical data

Maximum current consumption [A] Maximum power consumption P1 [W] Enclosure class Insulation class Voltage in level sensor input [VDC] Voltage in pulse input [VDC] Minimum pulse-repetition period [ms] Impedance in 0/4-20 mA analog input [ Maximum loop resistance in pulse signal circuit [ ] Maximum loop resistance in level signal circuit [ ] Maximum load of alarm relay output at ohmic load [A] Maximum voltage, alarm relay output [V] The sound pressure level of the pump is lower than 70 db(A).

at 120 V at 230 V

Signal input

Signal output Sound pressure Approvals


-- - - - - - -

Pump selection

DME and DMS

DME 2 to 12 - standard range



Pump Head Material Control Valve Ball Variant Material Connections,Suction/ Gasket Control Model Discharge [in] Material Position Front Side Front Side Front Side Front Side Front Ceramic AR A SS AR DME 8-10 1.98 GPH (7.5 l/h) up to 145 psi (10 bar) EPDM A FKM PP AR FKM A PVDF AR A SS AR DME 12-6 3.17 GPH (12 l/h) up to 89.9 psi (6.2 bar) EPDM A FKM PP AR FKM A PVDF AR A SS AR WEIGHTS: Shipping weights are approximate. * 1/4" = 0.17 ID x 0.25 OD; 3/8" = 0.25 ID x 0.375 OD; 1/2" = 0.375 ID x 0.5 OD SS 1/4" NPT FKM Ceramic 1/4 or 3/8* FKM Ceramic 1/4 or 3/8* EPDM Front Side Front Side Front Side Front Side Front Side Front Side Front Side Front Side DME12-6 A-PP/E/C-F-21RRB DME12-6 A-PP/E/C-S-21RRB DME12-6 A-PP/V/C-F-21RRB DME12-6 A-PP/V/C-S-21RRB DME12-6 AR-PP/E/C-F-21RRB DME12-6 AR-PP/E/C-S-21RRB DME12-6 AR-PP/V/C-F-21RRB DME12-6 AR-PP/V/C-S-21RRB DME12-6 A-PV/V/C-F-21RRB DME12-6 A-PV/V/C-S-21RRB DME12-6 AR-PV/V/C-F-21RRB DME12-6 AR-PV/V/C-S-21RRB DME12-6 A-SS/V/SS-F-21VVB DME12-6 A-SS/V/SS-S-21VVB DME12-6 AR-SS/V/SS-F-21VVB DME12-6AR-SS/V/SS-S-21VVB 96470274 96470275 96470276 96470279 96470293 96470294 96470296 96470297 96470284 96470288 96470328 96470329 96470331 96470332 96470330 96462476 5.0 SS 1/4" NPT FKM Ceramic 1/4 or 3/8* FKM Ceramic 1/4 or 3/8* EPDM Front Side Front Side Front Side Front Side Front Side Front Side Front Side Front Side DME8-10 A-PP/E/C-F-21RRB DME8-10 A-PP/E/C-S-21RRB DME8-10 A-PP/V/C-F-21RRB DME8-10 A-PP/V/C-S-21RRB DME8-10 AR-PP/E/C-F-21RRB DME8-10 AR-PP/E/C-S-21RRB DME8-10 AR-PP/V/C-F-21RRB DME8-10 AR-PP/V/C-S-21RRB DME8-10 A-PV/V/C-F-21RRB DME8-10 A-PV/V/C-S-21RRB DME8-10 AR-PV/V/C-F-21RRB DME8-10 AR-PV/V/C-S-21RRB DME8-10 A-SS/V/SS-F-21VVB DME8-10 A-SS/V/SS-S-21VVB DME8-10 AR-SS/V/SS-F-21VVB DME8-10 AR-SS/V/SS-S-21VVB 96470158 96470159 96470160 96470161 96470219 96470224 96462441 96470230 96470217 96470218 96470243 96470248 96470268 96470272 96470251 96470255 SS 1/4" NPT FKM 1/4 or 3/8* FKM Side Front Side Front Side Front Side DME2-18 A-PP/E/C-F-21RRB DME2-18 A-PP/E/C-S-21RRB DME2-18 A-PP/V/C-F-21RRB DME2-18 A-PP/V/C-S-21RRB DME2-18 AR-PP/E/C-F-21RRB DME2-18 AR-PP/E/C-S-21RRB DME2-18 AR-PP/V/C-F-21RRB DME2-18 AR-PP/V/C-S-21RRB DME2-18 A-PV/V/C-F-21RRB DME2-18 A-PV/V/C-S-21RRB DME2-18 AR-PV/V/C-F-21RRB DME2-18 AR-PV/V/C-S-21RRB DME2-18 A-SS/V/SS-F-21VVB DME2-18 A-SS/V/SS-S-21VVB DME2-18 AR-SS/V/SS-F-21VVB DME2-18 AR-SS/V/SS-S-21VVB Product Number 96470128 96470129 96470130 96470131 96470135 96470136 96470137 96470138 96470133 96470134 96462440 96470150 96470153 96470154 96470151 96470152 5.0 Ship Weight [lbs]

DME 2-18 0.66 GPH (2.5 l/h) up to 261 psi (18 bar) EPDM A FKM PP AR FKM A PVDF Ceramic 1/4 or 3/8* EPDM

5.0

Pump selection

DME and DMS

DME 19 to 48 - standard range



Pump Head Material Control Variant Valve Ball Material Connections, Suction/ Discharge [in] Gasket Control Model Material Position Product Number Ship Weight [lbs]

DME 19-6 4.88 GPH (18.5 l/h) up to 87 psi (6 bar) EPDM A FKM PP AR FKM A PVDF AR A SS AR DME 48-3 12.68 GPH (48 l/h) up to 37.7 psi (2.6 bar) EPDM A FKM PP AR FKM A PVDF AR A SS AR WEIGHTS: Shipping weights are approximate. * 1/4" = 0.17 ID x 0.25 OD; 3/8" = 0.25 ID x 0.375 OD; 1/2" = 0.375 ID x 0.5 OD SS 3/8" NPT FKM Ceramic 3/8 or 1/2* FKM Ceramic 3/8 or 1/2* EPDM Front Side Front Side Front Side Front Side Front Side Front Side Front Side Front Side DME48-3 A-PP/E/C-F-21SSB DME48-3 A-PP/E/C-S-21SSB DME48-3 A-PP/V/C-F-21SSB DME48-3 A-PP/V/C-S-21SSB DME48-3 AR-PP/E/C-F-21SSB DME48-3 AR-PP/E/C-S-21SSB DME48-3 AR-PP/V/C-F-21SSB DME48-3 AR-PP/V/C-S-21SSB DME48-3 A-PV/V/C-F-21SSB DME48-3 A-PV/V/C-S-21SSB DME48-3 AR-PV/V/C-F-21SSB DME48-3 AR-PV/V/C-S-21SSB DME48-3 A-SS/V/SS-F-21YYB DME48-3 A-SS/V/SS-S-21YYB DME48-3 AR-SS/V/SS-F-21YYB DME48-3 AR-SS/V/SS-S-21YYB 96470363 96470364 96470365 96470366 96470370 96470371 96470372 96470373 96470367 96470369 96470374 96462491 96470377 96470378 96470375 96470376 7.5 SS 3/8" NPT FKM Ceramic 3/8 or 1/2* FKM Ceramic 3/8 or 1/2* EPDM Front Side Front Side Front Side Front Side Front Side Front Side Front Side Front Side DME19-6 A-PP/E/C-F-21SSB DME19-6 A-PP/E/C-S-21SSB DME19-6 A-PP/V/C-F-21SSB DME19-6 A-PP/V/C-S-21SSB DME19-6 AR-PP/E/C-F-21SSB DME19-6 AR-PP/E/C-S-21SSB DME19-6 AR-PP/V/C-F-21SSB DME19-6 AR-PP/V/C-S-21SSB DME19-6 A-PV/V/C-F-21SSB DME19-6 A-PV/V/C-S-21SSB DME19-6 AR-PV/V/C-F-21SSB DME19-6 AR-PV/V/C-S-21SSB DME19-6 A-SS/V/SS-F-21YYB DME19-6 A-SS/V/SS-S-21YYB DME19-6 AR-SS/V/SS-F-21YYB DME19-6 AR-SS/V/SS-S-21YYB 96470333 96470334 96470350 96470351 96462477 96470354 96470355 96470356 96470352 96470353 96470357 96470358 96470361 96470362 96470359 96470360 7.5

Pump selection

DME and DMS

DME 60 to 150 - standard range



Pump Head Material Control Variant Valve Ball Material Connections, Suction/ Discharge Gasket Material Control Position Model Product Number Ship Weight [lbs]

DME 60-10 15.85 GPH (60 l/h) up to 145 psi (10 bar) EPDM AR FKM PP B FKM AR PVDF B AR SS B DME 150-4 39.6 GPH (150 l/h) up to 58 psi (4 bar) EPDM AR FKM PP B FKM AR PVDF B AR SS B WEIGHTS: Shipping weights are approximate. SS 3/4" FNPT FKM Ceramic 3/4" FNPT FKM Ceramic 3/4" FNPT EPDM Front Side Front Side Front Side Front Side Front Side Front Side Front Side Front Side DME150-4 AR-PP/E/C-F-21A3A3B DME150-4 AR-PP/E/C-S-21A3A3B DME150-4 AR-PP/V/C-F-21A3A3B DME150-4 AR-PP/V/C-S-21A3A3B DME150-4 B-PP/E/C-F-21A3A3B DME150-4 B-PP/E/C-S-21A3A3B DME150-4 B-PP/V/C-F-21A3A3B DME150-4 B-PP/V/C-S-21A3A3B DME150-4 AR-PV/V/C-F-21A3A3B DME150-4 AR-PV/V/C-S-21A3A3B DME150-4 B-PV/V/C-F-21A3A3B DME150-4 B-PV/V/C-S-21A3A3B DME150-4 AR-SS/V/SS-F-21A3A3B DME150-4 AR-SS/V/SS-S-21A3A3B DME150-4 B-SS/V/SS-F-21A3A3B DME150-4 B-SS/V/SS-S-21A3A3B 96528982 96528983 96528984 96528985 96528990 96528991 96528994 96528996 96528986 96528987 96528998 96528999 96528988 96528989 96529001 96529003 26 SS 3/4" FNPT FKM Ceramic 3/4" FNPT FKM Ceramic 3/4" FNPT EPDM Front Side Front Side Front Side Front Side Front Side Front Side Front Side Front Side DME60-10 AR-PP/E/C-F-21A3A3B DME60-10 AR-PP/E/C-S-21A3A3B DME60-10 AR-PP/V/C-F-21A3A3B DME60-10 AR-PP/V/C-S-21A3A3B DME60-10 B-PP/E/C-F-21A3A3B DME60-10 B-PP/E/C-S-21A3A3B DME60-10 B-PP/V/C-F-21A3A3B DME60-10 B-PP/V/C-S-21A3A3B DME60-10 AR-PV/V/C-F-21A3A3B DME60-10 AR-PV/V/C-S-21A3A3B DME60-10 B-PV/V/C-F-21A3A3B DME60-10 B-PV/V/C-S-21A3A3B DME60-10 AR-SS/V/SS-F-21A3A3B DME60-10 AR-SS/V/SS-S-21A3A3B DME60-10 B-SS/V/SS-F-21A3A3B DME60-10 B-SS/V/SS-S-21A3A3B 96528925 96528926 96528927 96528928 96528973 96528974 96528975 96528976 96528929 96528970 96528977 96528978 96528971 96528972 96528980 96528981 25

Pump selection

DME and DMS

DME 375 to 940 - standard range



Pump Head Material Control Variant Valve Ball Material Connections, Suction/ Discharge Gasket Material Control Position Model Product Number Ship Weight [lbs]

DME 375-10 99.06 GPH (375 l/h) up to 145 psi (10 bar) EPDM AR FKM PP B FKM AR PVDF B AR SS B DME 940-4 248.3 GPH (940 l/h) up to 58 psi (4 bar) EPDM AR FKM PP B FKM AR PVDF B AR SS B WEIGHTS: Shipping weights are approximate. SS 1 1/4" FNPT FKM Glass 1 1/4" FNPT FKM Glass 1 1/4" FNPT EPDM Front Side Front Side Front Side Front Side Front Side Front Side Front Side Front Side DME940-4 AR-PP/E/G-F-21A4A4B DME940-4 AR-PP/E/G-S-21A4A4B DME940-4 AR-PP/V/G-F-21A4A4B DME940-4 AR-PP/V/G-S-21A4A4B DME940-4 B-PP/E/G-F-21A4A4B DME940-4 B-PP/E/G-S-21A4A4B DME940-4 B-PP/V/G-F-21A4A4B DME940-4 B-PP/V/G-S-21A4A4B DME940-4 AR-PV/V/G-F-21A4A4B DME940-4 AR-PV/V/G-S-21A4A4B DME940-4 B-PV/V/G-F-21A4A4B DME940-4 B-PV/V/G-S-21A4A4B DME940-4 AR-SS/V/SS-F-21A4A4B DME940-4 AR-SS/V/SS-S-21A4A4B DME940-4 B-SS/V/SS-F-21A4A4B DME940-4 B-SS/V/SS-S-21A4A4B 96529137 96529139 96529151 96529155 96529163 96529164 96529165 96529166 96529158 96529160 96529167 96529168 96529161 96529162 96529169 96529170 50 SS 1 1/4" FNPT FKM Glass 1 1/4" FNPT FKM Glass 1 1/4" FNPT EPDM Front Side Front Side Front Side Front Side Front Side Front Side Front Side Front Side DME375-10 AR-PP/E/G-F-21A4A4B DME375-10 AR-PP/E/G-S-21A4A4B DME375-10 AR-PP/V/G-F-21A4A4B DME375-10 AR-PP/V/G-S-21A4A4B DME375-10 B-PP/E/G-F-21A4A4B DME375-10 B-PP/E/G-S-21A4A4B DME375-10 B-PP/V/G-F-21A4A4B DME375-10 B-PP/V/G-S-21A4A4B DME375-10 AR-PV/V/G-F-21A4A4B DME375-10 AR-PV/V/G-S-21A4A4B DME375-10 B-PV/V/G-F-21A4A4B DME375-10 B-PV/V/G-S-21A4A4B DME375-10 AR-SS/V/SS-F-21A4A4B DME375-10 AR-SS/V/SS-S-21A4A4B DME375-10 B-SS/V/SS-F-21A4A4B DME375-10 B-SS/V/SS-S-21A4A4B 96529006 96529114 96529116 96529117 96529123 96529124 96529125 96529126 96529118 96529119 96529128 96529130 96529120 96529121 96529132 96529135 47

Pump selection

DME and DMS

DMS 2 to 4 - standard range



Pump Head Material Control Variant Valve Ball Material Connections, Suction/Discharge [in] Gasket Material Control Position Model Product Number Ship Weight [lbs]

DMS 2-11 0.66 GPH (2.5 l/h) up to 160 psi (11 bar) EPDM A FKM EPDM PP AR Ceramic 1/4 or 3/8** FKM B D* A PVDF AR B D* A SS AR B D* DMS 4-7 1.05 GPH (4 l/h) up to 101.5 psi (7 bar) SS 1/4" NPT Ceramic 1/4 or 3/8** EPDM FKM EPDM FKM FKM FKM FKM FK M FKM FKM FKM FK M Front Side Front Side Front Side Front Side Front Front None None Front Side Front Side Front None Front Side Front Side Front None Front Side Front Side Front Side Front Side Front Front None None Front Side Front Side Front None Front Side Front Side Front None DMS2-11 A-PP/E/C-F-21RRB DMS2-11 A-PP/E/C-S-21RRB DMS2-11 A-PP/V/C-F-21RRB DMS2-11 A-PP/V/C-S-21RRB DMS2-11 AR-PP/E/C-F-21RRB DMS2-11 AR-PP/E/C-S-21RRB DMS2-11 AR-PP/V/C-F-21RRB DMS2-11 AR-PP/V/C-S-21RRB DMS2-11 B-PP/E/C-F-21RRB DMS2-11 B-PP/V/C-F-21RRB DMS2-11 D-PP/E/C-X-21RRB DMS2-11 D-PP/V/C-X-21RRB DMS2-11 A-PV/V/C-F-21RRB DMS2-11 A-PV/V/C-S-21RRB DMS2-11 AR-PV/V/C-F-21RRB DMS2-11 AR-PV/V/C-S-21RRB DMS2-11 B-PV/V/C-F-21RRB DMS2-11 D-PV/V/C-X-21RRB DMS2-11 A-SS/V/SS-F-21VVB DMS2-11 A-SS/V/SS-S-21VVB DMS2-11 AR-SS/V/SS-F-21VVB DMS2-11 AR-SS/V/SS-S-21VVB DMS2-11 B-SS/V/SS-F-21VVB DMS2-11 D-SS/V/SS-X-21VVB DMS4-7 A-PP/E/C-F-21RRB DMS4-7 A-PP/E/C-S-21RRB DMS4-7 A-PP/V/C-F-21RRB DMS4-7 A-PP/V/C-S-21RRB DMS4-7 AR-PP/E/C-F-21RRB DMS4-7 AR-PP/E/C-S-21RRB DMS4-7 AR-PP/V/C-F-21RRB DMS4-7 AR-PP/V/C-S-21RRB DMS4-7 B-PP/E/C-F-21RRB DMS4-7 B-PP/V/C-F-21RRB DMS4-7 D-PP/E/C-X-21RRB DMS4-7 D-PP/V/C-X-21RRB DMS4-7 A-PV/V/C-F-21RRB DMS4-7 A-PV/V/C-S-21RRB DMS4-7 AR-PV/V/C-F-21RRB DMS4-7 AR-PV/V/C-S-21RRB DMS4-7 B-PV/V/C-F-21RRB DMS4-7 D-PV/V/C-X-21RRB DMS4-7 A-SS/V/SS-F-21VVB DMS4-7 A-SS/V/SS-S-21VVB DMS4-7 AR-SS/V/SS-F-21VVB DMS4-7 AR-SS/V/SS-S-21VVB DMS4-7 B-SS/V/SS-F-21VVB DMS4-7 D-SS/V/SS-X-21VVB 96469328 96469358 96469376 96469377 96469391 96469392 96469394 96469399 96469451 96469456 96508016 96508017 96469378 96469390 96469403 96469408 96469467 96508019 96469419 96469424 96469411 96469414 96462492 96508090 96469468 96469469 96469470 96469471 96469474 96469487 96469489 96469490 96469513 96469493 96508091 96508092 96469472 96469473 96469492 96469508 96469514 96508093 96469511 96469512 96469509 96469510 96462515 96508094 5,0

EPDM A FKM EPDM PP AR Ceramic 1/4 or 3/8** FKM B D* A PVDF AR B D* A SS AR B D* WEIGHTS: Shipping weights are approximate. * See pg 32 for DMS D capacity range. ** 1/4" = 0.17 ID x 0.25 OD; 3/8" = 0.25 ID x 0.375 OD; 1/2" = 0.375 ID x 0.5 OD. SS 1/4" NPT Ceramic 1/4 or 3/8** EPDM FKM EPDM FKM FKM FKM FKM FKM FKM FKM FKM FKM

5.0

Pump selection

DME and DMS

DMS 8 to 12 - standard range



Pump Head Material Control Variant Valve Ball Material Connections, Suction/ Discharge [in] Gasket Material Control Position Model Material Number Ship Weight [lbs]

DMS 8-5 1.98 GPH (7.5 l/h) up to 78.3 psi (5.4 bar) EPDM A FKM EPDM PP AR Ceramic 1/4 or 3/8** FKM B D* A PVDF AR B D* A SS AR B D* DMS 12-3 3.17 GPH (12 l/h) up to 49.3 psi (3.4 bar) SS 1/4" NPT Ceramic 1/4 or 3/8** EPDM FKM EPDM FKM FKM FKM FKM FKM FKM FKM FKM FKM Front Side Front Side Front Side Front Side Front Front None None Front Side Front Side Front None Front Side Front Side Front None Front Side Front Side Front Side Front Side Front Front None None Front Side Front Side Front None Front Side Front Side Front None DMS8-5 A-PP/E/C-F-21RRB DMS8-5 A-PP/E/C-S-21RRB DMS8-5 A-PP/V/C-F-21RRB DMS8-5 A-PP/V/C-S-21RRB DMS8-5 AR-PP/E/C-F-21RRB DMS8-5 AR-PP/E/C-S-21RRB DMS8-5 AR-PP/V/C-F-21RRB DMS8-5 AR-PP/V/C-S-21RRB DMS8-5 B-PP/E/C-F-21RRB DMS8-5 B-PP/V/C-F-21RRB DMS8-5 D-PP/E/C-X-21RRB DMS8-5 D-PP/V/C-X-21RRB DMS8-5 A-PV/V/C-F-21RRB DMS8-5 A-PV/V/C-S-21RRB DMS8-5 AR-PV/V/C-F-21RRB DMS8-5 AR-PV/V/C-S-21RRB DMS8-5 B-PV/V/C-F-21RRB DMS8-5 D-PV/V/C-X-21RRB DMS8-5 A-SS/V/SS-F-21VVB DMS8-5 A-SS/V/SS-S-21VVB DMS8-5 AR-SS/V/SS-F-21VVB DMS8-5 AR-SS/V/SS-S-21VVB DMS8-5 B-SS/V/SS-F-21VVB DMS8-5 D-SS/V/SS-X-21VVB DMS12-3 A-PP/E/C-F-21RRB DMS12-3 A-PP/E/C-S-21RRB DMS12-3 A-PP/V/C-F-21RRB DMS12-3 A-PP/V/C-S-21RRB DMS12-3 AR-PP/E/C-F-21RRB DMS12-3 AR-PP/E/C-S-21RRB DMS12-3 AR-PP/V/C-F-21RRB DMS12-3 AR-PP/V/C-S-21RRB DMS12-3 B-PP/E/C-F-21RRB DMS12-3 B-PP/V/C-F-21RRB DMS12-3 D-PP/E/C-X-21RRB DMS12-3 D-PP/V/C-X-21RRB DMS12-3 A-PV/V/C-F-21RRB DMS12-3 A-PV/V/C-S-21RRB DMS12-3 AR-PV/V/C-F-21RRB DMS12-3 AR-PV/V/C-S-21RRB DMS12-3 B-PV/V/C-F-21RRB DMS12-3 D-PV/V/C-X-21RRB DMS12-3 A-SS/V/SS-F-21VVB DMS12-3 A-SS/V/SS-S-21VVB DMS12-3 AR-SS/V/SS-F-21VVB DMS12-3 AR-SS/V/SS-S-21VVB DMS12-3 B-SS/V/SS-F-21VVB DMS12-3 D-SS/V/SS-X-21VVB 96469516 96469523 96469529 96469534 96462494 96469637 96469638 96469651 96469676 96469678 96508095 96508097 96469537 96469636 96469656 96469659 96469682 96508098 96469672 96469675 96469663 96469668 96462686 96508099 96469700 96469703 96469707 96469711 96469722 96469726 96469730 96469734 96469775 96469777 96508100 96508101 96469714 96469718 96469735 96462495 96469786 96508103 96469766 96469771 96469763 96469764 96469791 96508104 5.0

EPDM A FKM EPDM PP AR Ceramic 1/4 or 3/8** FKM B D* A PVDF AR B D* A SS AR B D* WEIGHTS: Shipping weights are approximate. * See pg 32 for DMS D capacity range. ** 1/4" = 0.17 ID x 0.25 OD; 3/8" = 0.25 ID x 0.375 OD; 1/2" = 0.375 ID x 0.5 OD. SS 1/4" NPT Ceramic 1/4 or 3/8** EPDM FKM EPDM FKM FKM FKM FKM FKM FKM FKM FKM FKM

5.0

Pump selection

DME and DMS

Non-standard options
Option Spring-loaded check valves Profibus GENibus PTFE check valves with Ceramic or PTFE balls PTFE balls in PP or PVDF check valves SS balls in PP or PVDF check valves 1/2" NPT connections on PP or PVDF pumps Metric inlet/discharge connection International supply voltages/plug types PTFE gaskets Hastelloy C balls Available with DME, DMS DME DME 2 to 48 DME 2 to 48, DMS DME 2 to 48, DMS DME, DMS DME 2 to 48, DMS DME, DMS DME, DMS DME 60 to 940 DME 60 to 940

Please contact the factory for ordering information.

Pumped liquids

DME and DMS

List of pumped liquids


The resistance table below is intended as a general guide for material resistance (at room temperature), and does not replace testing of the chemicals and pump materials under specific working conditions.

The data shown are based upon information from various sources available, but many factors (purity, temperature, abrasive particles, etc.) may affect the chemical resistance of a given material. Some of the liquids in this table may be toxic, corrosive or hazardous. Please be careful when handling these liquids.
Materials Pump housing Gasket Ball

Pumped liquid 20C

Concentration %

Acetic acid Aluminium chloride Aluminium sulphate Ammonia, aqueous Calcium hydroxide 7 Calcium hypochlorite

CH3COOH AlCl3 Al2(SO 4)3 NH 4OH Ca(OH)2 Ca(OCl) 2 H2CrO 4 CuSO4 FeCl3 Fe 2(SO4)3 FeCl2 FeSO 4 HCl H 2 O2 HNO 3 CH 3COOOH KOH KMnO4 NaClO3 NaCl NaClO2 NaOH NaOCl Na2S Na 2SO3 H2SO3
4 3

25 60 85 40 60 28 20 10 30 40 50 30 100 100 100 50 < 25 25-37 30 10 30 40 70 5 50 10 30 30 20 20 30 50 20 30 20 6 < 80 80-98

Chromic acid

Copper sulphate Ferric chloride


3

Ferric sulphate Ferrous chloride Ferrous sulphate

Hydrochloric acid Hydrogen peroxide

Nitric acid

Peracetic acid Potassium hydroxide Potassium permanganate Sodium chlorate Sodium chloride Sodium chlorite Sodium hydroxide Sodium hypochlorite Sodium sulphide Sodium sulphite Sulphurous acid Sulphuric acid
6

H2SO4

- -- - - - - - - - -- - - -- -

Accessories

Overview

--Grundfos offers a comprehensive range of accessories covering every need when dosing with Grundfos dosing pumps.

Overview

Back-pressure or relief See page 57

Injection valve See page 47

Automatic vent valve See page 60

Pulsation dampener See page 61

Multifunction valve See page 49

Flow indicator See page 51

Priming aid See page 62

Cable and plug See page 43

Tubing See page 45

Wall bracket See page 67 Installation kit See page 42 Dosing monitor See page 50

Rigid suction line See page 53 Foot valve See page 46

Rigid suction line with level sensors See page 53 Level control unit See page 53 Tank See page 63

Hand mixer See page 66

Accessories

Installation kit

Installation kit
The installation kit includes: foot non-return valve with strainer and weight injection non-return valve, spring-loaded 20 ft PE discharge tubing 6 ft m PVC suction tubing 6 ft m PVC vent tubing.

Pump type

Materials Housing Ball EPDM PP Ceramic FKM Gasket

Tubing Connections Suction 1/4" 3/8" 1/2" 1/4" 3/8" 1/2" 1/4" Vent 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4"

Product Number 96480670 96479881 96479947 96480674 96479898 96479948 96480675 96479899 96479949

DME 2 to 48 DMS

PVDF

FKM

Ceramic

3/8" 1/2"

Inner/Outer tubing diameter sizes


Tube size 1/4" 3/8" 1/2" ID 0.17" 1/4" 3/8" OD 1/4" 3/8" 1/2"

Accessories

Cable and plug

Cable and plug


Cable and plug for connection of pump to external control devices, such as process controllers, flow meters, start/stop contacts, and level sensors. Grundfos level control units are factory-fitted with cable and plug connection for Grundfos dosing pumps. The cables and plugs fit all dosing pumps, types DME and DMS-A. Cable material: PUR (0.34 mm 2) Plug type: M12.

Signal

Number of poles 5

Type Control cable with plug Plug terminal without cable Control cable with plug Control cable with plug Plug terminal without cable Extension cable Control cable with plug Control cable with plug Relay cable with plug Relay cable with plug

Cable length [ft] 6.5 16 6.5 16 6.5 6.5 16 6.5 16

Product number 96440447 96440448 96440449 96440450 96449451 96440452 96483235 96527109 96527111 96534214 96534215

Pulse, 0/4-20 mA, start/stop

Dual-level or stop signal

Stop dosing input and output*

5 3

Alarm Relay Cable* *) Only DME 60 to 940

Note - DME 2 to 48 and DMS AR versions have alarm relay cable hard-wired to pump.

Accessories

Diaphragm leakage sensor

Diaphragm leakage sensor (DME 60 to 940)


Optoelectronic leakage sensor to be inserted in the drain hole behind the diaphragm for sensing diaphragm breakage or leakage. The sensor unit consists of: Transmitter receiver Holder for fitting sensor in the backplate M12 plug and wire to transmit signal to pump. When the liquid gets into contact with the sensor, the light refraction changes, causing the sensor to emit a signal. The signal emitted from the sensor triggers the pump to stop dosing and give pump output alarm.

Pump type DME 60-940 (l/h)

Size M12

Type Leakage sensor M12

Cable length [m] 0.5 m

Product number 96534443

Accessories

Tubing

Tubing
Tubing in various materials, sizes and lengths.

Inner/outer diameter (in) 0.17 x 1/4

Material PVC PVC

Maximum pressure (psi) 85 73

Length (ft) 20 100 20

Product Number 91127749 91127750 91127825 91127751 91127753 91127826 91127752

1/4 x 3/8

PE

192 100

ETFE

290

100 20

3/8 x 1/2

PE

123 100

Accessories

Foot valve

Foot valve
Foot valve complete with non-return valve, strainer and tube or pipe connection.

Dimensions
DN 4, DN 8 Tubing/non-return valve DN 6, DN 10, DN 15, DN 20, DN 25 Hose clamp Pipe cementing

Non-return valve

Max flow rate GPH (l/h)

Size

Housing

Materials Gasket EPDM

Ball Ceramic Ceramic Ceramic SS Ceramic Ceramic Ceramic SS SS SS Ceramic SS Glass SS

PP 4 (15) DN 4 PVDF 12.7 (48) DN 6 SS FKM FKM CSM EPDM PP 19 (72) DN 8 PVDF 39.6 (150) 99.1 (375) 248.3 (940) DN 10 DN 15 DN 25 SS SS SS PP 248.3 (940) NPT 3/4" PVDF SS PP PP PVDF SS FKM FKM CSM CSM CSM EPDM FKM FKM FKM EPDM FKM FKM FKM

Connection ID/OD or NPT 0.17" x 1/4" Tubing 1/4" x 3/8" 0.17" x 1/4" Tubing 1/4" x 3/8" 0.17" x 1/4" Tubing 1/4" x 3/8" NPT 1/4" 1/4" x 3/8" Tubing 3/8" x 1/2" 1/4" x 3/8" Tubing 3/8" x 1/2" 1/4" x 3/8" Tubing 1/4" x 3/8" NPT 1/2" NPT 1/2" NPT 1" Type

Dimensions (in) L (in)

Product Number 96480503 96479782 96480589 96479784 96480589 96479784 96479794 96480621 96479798 96480622 96480623 96480624 96479801 96480625 96480627 96480628 96566136 96566138 96566139 96537921 96566145 96566146 96566147 96537970

1.4

2.8

1.3

1.5

1.4

2.8

2 2.5 3.5

2.2 3.7 4.7

NPT

3/4"

3/4"

248.3 (940)

NPT 1 1/4"

NPT

1 1/4"

1 1/4"

Accessories

Injection valve

Injection valve
Injection valve complete with spring-loaded non-return valve, injection pipe and tube or pipe connection. Spring material: Hastelloy Opening pressure: DN 4, DN 8: 10 psi (0.7 bar) DN 6, DN 10, DN 15, DN 25: 16 psi (1.1 bar). Maximum temperature: PP, PVDF: 122 F (50 C) PVC: 104 F (40 C) Stainless steel: 176 F (80 C).

-DN 4, DN 8 DN 6, DN 10, DN 15, DN 20, DN 25

Non-return valve

Max flow rate GPH. (l/h)

Size

Housing

Materials Gasket EPDM

Ball Ceramic Ceramic Ceramic SS Ceramic Ceramic Ceramic Glass SS Ceramic SS Glass SS

PP 3.2 (12) DN 4 PVDF 19 (72) DN 6 DN 6 SS FKM FKM AF EPDM FKM PVDF PVC SS PP 248.3 (940) NPT 3/4" PVDF SS PP PP PVDF SS FKM FKM CSM EPDM FKM FKM FKM EPDM FKM FKM FKM

PP 19 (72) DN 8

39.6 (150)

DN 10

Connection ID/OD or NPT 0.17" x 1/4" Tubing 1/4" x 3/8" 0.17" x 1/4" Tubing 1/4" x 3/8" 0.17" x 1/4" Tubing 1/4" x 3/8" 1/4" NPT 1/2" 1/4" x 3/8" Tubing 3/8" x 1/2" Tubing 1/4" x 3/8" 3/8" x 1/2" Tubing 1/4" x 3/8" 3/8"x1/2" Tubing 1/4" x 3/8" NPT 3/8" Type

Dimensions d (in) L (in)

Product Number 96480641 96479805 96480642 96479806 96480643 96479807 96479804 96480629 96480644 96480645 96480646 96479808 96480647 96479809 91129485 96480640 96566142 96566143 96566144 96537923 96566148 96566149 96566152 96537971

1/2" NPT

1.3

1/2" NPT

3.9

1/2" NPT

1.3

1/2" NPT 1" NPT

3.9 3.9

NPT

3/4"

3/4" NPT

248.3 (940)

NPT 1 1/4"

NPT

1 1/4"

1 1/4" NPT

Accessories

Hot injection valve

Hot injection valve


The hot injection valve kit is a complete assembly with shut-off valve, pipe, and tubing connection fitting for chemical injection into steam and hot water applications. It allows for direct dosing into systems with a maximum liquid temperature of 302 F (150 C) at the point of injection. The hot injection valve kit is delivered non-assembled to facilitate adaptation to the actual application.

-
Shut-off ball valve Pipe Pipe connection Tubing connection Max. injection point temperature 316 SS 316 SS 316 SS PVDF 302 F (150 C)

--
Shut-off ball valve Pipe Pipe connection Tubing connection 1/2" 8/10 mm 1/2"

3/8" ID 1/2" OD.

Material Max. flow rate GPH [l/h] 5.3 (20) Size Connection DN 4 PVDF Gasket FKM Ball Ceramic Type Tubing

Connection Product number Tubing diameter 3/8" / 1/2" 96567703

Accessories

Multifunction valve

Multifunction valve
Compact valve unit for direct mounting on the pump discharge connection. The valve has four functions: - -- - -- Relief pressure: Constant counter pressure: Maximum volume: 160 psi (11 bar) 22 psi (1.5 bar) 13 GPH (50 l/h).

--

Pump type SS DME, DMS*

Materials Housing PVDF PP Gasket FKM EPDM FKM FKM EPDM FKM Diaphragm PTFE PTFE PTFE PTFE PTFE PTFE A

Dimensions E M28 x 2 M30 x 3.5 M30 x 3.5 M30 x 3.5 M30 x 3.5 M30 x 3.5 M28 x 2 M30 x 3.5 M30 x 3.5 M30 x 3.5 M30 x 3.5 M30 x 3.5

Product Number 96497411 96440584 96440585 96440586 96496470 96446752

DME 2 to 48

DMS

PVDF PVC PVC

* M28 x 2 fits stainless steel pump heads

Accessories

Dosing monitor

Dosing monitor
The dosing monitor is used in connection with the dosing monitoring function of DME 2 to 48, and DMS-A, AR pumps. The monitor sends a pulse signal (closed contact) for every measured dosing stroke. As the DME pump will often operate without pulsation on the discharge side, the monitor must always be installed on the suction side. The monitor for a DMS pump can be installed on both suction and discharge side. Maximum pressure: Maximum volume: Maximum liquid temperature: Maximum liquid viscosity: Maximum load of pulse transmitter (reed contact): Materials in contact with liquid: 145 psi (10 bar) 13 GPH (50 l/h) 95 F (35 C) 20 cps 48 VAC/VDC, 0.5 A PMMA/PVC/FKM.

Dosing stroke measured Dosing stroke measured

Dosing stroke measured

Monitor mounted on suction side (DME and DMS)

Monitor mounted on discharge side (DMS only)

Monitor mounted in dosing tube. In discharge tube: DMS In suction tube: DME and DMS

Selection table
Mounting Pump head Gasket FKM Inline PP, PVDF FKM EPDM Pump discharge* PP, PVDF FKM EPDM FKM EPDM Material PVDF PP PVDF Not needed Pump connection is used on inlet of monitor Not needed Pump connection is used on inlet of monitor Includes 1/4", 3/8" and 1/2" tubing connections Connection kit Product number 96470726 96470725 96493010 96470723 96492899 96470724 96493011

Pump inlet *Not suitable for DME pumps

PP, PVDF

Not stuitable for SS pump heads

Accessories

Flow indicator

Flow indicator
The flow indicator is used for discharge monitoring. When the dosing pump is discharging liquid, the white ball will jump in the transparent pipe. Each dosing stroke causes a ball jump. The design of the flow indicator allows ball movements to be seen at flow rates from 0.026 to 11.9 GPH. At a steady flow, the ball will always be in the top position. The flow indicator installs and retrofits easily. Material : Maximum pressure: Maximum pulsed flow: PVC grey, PVC transparent, PVDF, FKM, ceramic AI2O3. 145 psi (10 bar) 11.9 GPH (45 l/h).

--

Pump type DME 2 to 48 DMS

Dimensions A M30 x 3.5 B M30 x 3.5 C [mm] 44 D [mm] 55

Product number 96446763

Accessories

Adaptor

Adaptor
The adaptors are used for the connection of DME and DMS pumps to suction and discharge tubing sizes other than Grundfos standard sizes. The product number comprises two sets.

Tubing connections (without union nut)


Pump type Size ID 0.17" DME 2 to 48 DMS 1/4" 3/8" OD 1/4" 3/8" 1/2" Material PP PVDF PP PVDF PP PVDF Product Number 91128441 91128442 91128437 91128438 91128439 91128440

Male threaded connection (with union nut)


Pump type PPorPVDF DME 2 to 48, DMS Connection Union nut M30 x 3.5 Male NPT 1/2" Material PP PVDF Product Number 96560564 96560570

Female threaded connection (with union nut)


Pump type DME 60, DME 150 DME 375, DME 940 Size ID 3/4" NPT 1 1/4" NPT Material PVC SS PVC SS Product Number 96537892 96537894 96537893 96537895

Accessories

Level control unit

Level control unit


For dosing pumps with level control input (variant A), complete with level sensors (NO-contacts), ceramic weight, cable and plug for pump connection. Material: Level cable length: Level plug type: Maximum load of level contacts: PVC 8.2 ft M12, 4-pole 50 V, 0.5 A

--

Function of level contacts: Low level/empty tank = closed contact Product number: 96440539.

Accessories

Rigid suction line

Rigid suction line


The pre-assembled rigid suction line features an adjustable length for use with a tank. It consists of foot valve with strainer, rigid suction pipe, tank connection thread, and suction tube. For control variant A pumps, the suction line is available with level sensors (NO-contacts) for warning and empty-tank signals, supplied complete with cable and plug for pump connection. Material: Material, wetted parts: Suction tubing length: Level cable length: Level plug type: Maximum flow: Maximum load of level contacts: PVC PVC, glass 4.9 ft, PVC-tube 4.9 ft M12, 4-pole 13 GPH (50 l/h) 50 V, 0.5 A

Function of level contacts: Low level/empty tank = closed contact PE screw cap: Product Number: 15/16 in (33.5 mm) 96483418.

Accessories

Rigid suction line

Dimensions [mm]
With level sensors Without level sensors

Maximum Length (in)

Grundfos tank size (l, US Gal)

Suction Tubing (in) ID 0.17 1/4 3/8 0.17 OD 1/4 3/8 1/2 1/4 3/8 1/2 1/4 3/8 1/2 1/4 3/8 1/2 1/4 3/8 1/2 1/4 3/8 1/2 96480729 96479974 96480737 96480730 96480734 96480738 96480731 96479975 96480739 96480732 96480735 96480000 96480727 96479973 96479999 96480728 96480733 96480736

Product Number with level sensors without level sensors 96480710 96480716 96480723 96480711 96480717 96480724 96480712 96480718 96480725 96480713 96480719 96480726 96480707 96480714 96480720 96480709 96480715 96480721

21

60 (16)

29

100 (26)

1/4 3/8 0.17

31

200 (53)

1/4 3/8 0.17

35

300 (79)

1/4 3/8 0.17

44

500 (132)

1/4 3/8 0.17

49

1000 (264)

1/4 3/8

Accessories

Back-pressure or relief valve

-- Adjustable valve for installation in the discharge tube. Installed in-line, the valve functions as a counterpressure valve optimising dosing accuracy into systems with fluctuating pressure or as anti-siphoning valve when dosing into pressureless systems. Installed in a T-connection with the valve outlet connected to the tank, the valve functions as a pressure relief valve or a safety valve, protecting the pump and the discharge tube against excessive pressures. Pressure range: 0-145 psi (0-10 bar)

Diaphragm material: PTFE.

Accessories

Back-pressure or relief valve

Back-pressure or relief valve


DN 6, DN 10, DN 15 DN 25, DN 32, DN 40

Size

Maximum Flow GPH (l/h) A

Dimensions C (mm) H (mm)

Housing material

Connections Type Tubing NPT Size (ID/OD) 0.17"/ 1/4" 1/4" / 3/8" 3/8" / 1/2" 1/4" 0.17"/ 1/4" 1/4" / 3/8" 3/8" / 1/2" NPT 1/4" 1/4" 1/4" / 3/8" 3/8" 1/4" / 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" 1/2" 1" 1" 1 1/4" 1 1/2" NPT Tubing NPT Tubing NPT NPT NPT NPT NPT NPT NPT NPT NPT

Product Number 96487951 96487906 96487905 96487950 96487908 96487972 96487970 96487907 96487973 96487899 96487898 96487941 96487940 96487942 96487943 96487944 96487945 96487897 96487946 96487947 96487948 96487949

PVC

DN 6

6.6 (25)

1/4"

40

42 PVDF Tubing

316 SS PVC DN 10 19.8 (75) 3/8" 55 147 PVDF 316 SS PVC DN 15 55.5 (210) 1/2" 75 152 PVDF 316 SS DN 25 DN 32 DN 40 103 (390) 169 (640) 260 (940) 1" 1 1/4" 1 1/2" 140 140 152 240 242 252 PP 316 SS PP PP

Accessories

Valve assembly

Valve assembly
Complete assembly of: counter-pressure and relief valve Valve diaphragm material: PTFE Pressure range of counter-pressure and relief valve: 0 to 145 psi (0 to 10 bar).

Back-pressure and relief valve

Valve functions Back-pressure and relief valve

Size

Maximum Flow GPH (l/h)

Dimensions A H (mm)

Housing material

DN 6

6.6 (25)

1/4"

155

PVC

316 SS DN 10 19.8 (75) 3/8" 174 PVC 316 SS PVC 316 SS

DN 15

55.5 (210)

1/2"

180

Connections Type Size (ID/OD) 0.17"/ 1/4" Tubing 1/4" / 3/8" 3/8" / 1/2" NPT 1/4" NPT 1/4" Tubing 1/4" / 3/8" NPT 3/8" NPT 3/8" NPT 1/2" NPT 1/2"

Product Number 96524665 96524666 96524667 96524668 96524669 96524670 96524671 96524672 96524673 96524674

Accessories

Vent valve

Vent valve
Manual vent valve for direct fiting into the DME 2 to 48 and DMS pumps.

Pump type

Valve materials Housing PP PP PV Gasket EPDM FKM FKM Ceramic Ball

Vent connection

Product number 96534792

DME 2 to 48 DMS

1/4

96534794 96534796

Accessories

Automatic vent valve

Automatic vent valve


Automatic vent valve for direct fitting on the pump discharge connection. Valve housing material: O-ring material: Valve ball material: Valve seat material: Pump head material: Power cable length: Opening pressure: Maximum flow: Supply voltage: Plug type: PMMA/PVC FKM Glass PVDF PP/PVDF 5 ft 145 psi (10 bar) 11.9 GPH (45 l/h) 1 x 120V, 50-60 Hz US.

The valve is available with and without timer.


The valve is continuously connected to the power supply. The opening time and opening intervals are set on the timer.


The valve will open when power is supplied to the valve. This version is ideal for operation in connection with a dosing monitor.

Automatic vent valve with timer (mm)

Pump type DME 2 to 48 DMS

Dimensions A+B M30 x 3.5

Voltage 1 x 120 V, 50-60 Hz

Plug US

Product number With timer 96441084 Without timer 96471086

Accessories

Pulsation dampener

Pulsation dampener
The pulsation dampener can be installed both in the suction or discharge line for reducing pressure surges, thereby ensuring a steady flow. The dampener is particularly suitable for long discharge lines and/or lines with a small diameter. Installed in the discharge line, the dampener can be used to optimize dosing accuracy and to protect the pump and discharge line against pressure surges. Depending on the system pressure, it may be necessary to install a back-pressure valve after the dampener to optimize its function. Maximum pressure: 145 psi (10 bar).

Pulsation dampener
Size 80 Size 250 Sizes 750

Size

Maximum flow rate [l/h]

Materials Housing PP Diaphragm CSM CSM FKM CSM FKM CSM FKM CSM FKM CSM FKM NPT NPT Tubing Type

Connections Inner/outer tubing or pipe diameters/ thread 1/4" / 3/8" A

Dimensions [mm] B C D E Product number 96479971 172 G 3/4" M6 50 96480706 96479972 96480694 1/2" 314 140 G 1 1/4" M8 58 96480693 96480696 96480695 96480700 1/2" 363 347 G 1 1/4" 9 72 96480698 96480704 96480703

80

15.9 (60)

PVC PVC PP

250

39.6 (150) PVC PP

750

99 (375) PVC

Accessories

Priming aid

Priming aid
The priming aid is a transparent, air-tight collector with a screw cap on top. It is mounted between the tank and the pump. The inlet from the tank and the outlet to the pump are both at the bottom of the collector. The priming aid is supplied with a bracket for wall mounting and a rod for mounting on top of the tank. The priming aid has the following functions: . The priming aid facilitates priming in case of frequent stops and/or high suction lifts by eliminating or reducing the dry-suction phase. - . Gas occurring in the suction tube is trapped in the top of the priming aid to prevent it from entering the dosing head. - . The dampening gas cushion in the top of the priming aid reduces pressure surges, resulting in optimum dosing accuracy and reduced risk of cavitation. Material: PVC.

Size 95

Size 250

Priming capacity size [ml] 95

Connection Product Number Type ID 0.17" Tubing 1/4" 1/4" OD 1/4" 3/8" 3/8" 96480692 96479970 96480690

250

Accessories

Tank

Tank
Closed cylindrical tank with screw cap and threaded connection for rigid suction line. Material: Liquid temperature: PE Minimum: -4 F (-20 C) Maximum: 113 F (45 C).

Pump mounting plate: The DME 2 to 48 and DMS pumps can be mounted direct on the tank top by means of adapter plates. Material: PP. DME 2 to DME 12 and DMS: 96446765 DME 19 and DME 48: 96446766. Floor mounting bracket: Material: Set of four: PE 96446767.

Accessories

Tank

Dimensions

Tank size Litres 60 100 200 300 500 1000 Gallons 16 26 53 79 132 264 D

Dimensions [mm] H 575 790 845 950 1080 1358 kg 4.5 7.0

Weight lbs 10 16 29 34 60 86

Product number 96417362 96417363 96417364 96441296 96417365 96417366

415 470 600 675 815 1080

13.0 15.0 17.0 39.0

Without pump mounting holes.

Accessories

100-liter tank

100-liter tank
Closed square tank with screw cap and mounting platform for single or parallel pump mounting. The pump mounting platform is raised above the screw cap to protect pumps and connections when filling chemical into the tank. The height difference also allows for direct mounting of the dosing monitor on the suction side. Material: Weight: MDPE 15 kg


DME and DMS pumps can be fitted direct on the platform by means of brass inserts moulded into the platform.


Single or parallel mounting of DME 2 to 48 and DMS. The tank includes a raised 3/4" RG boss for a drain. Material thickness: 4 mm.
Tank size 26 g (100 l) Product number 96489271

Max. material temperature: 122 F (50 C) Liquid temperature: Minimum -4 F (-20 C) Maximum 113 F (45 C).

Dimensions [mm]

152

M5

137 192 500

Accessories

Hand mixer

Hand mixer
Hand mixer with adjustable length for mixing of chemicals in a tank. The mixer is designed for Grundfos chemical tanks. Material: PVC.
Tank size [l] 60 100 200 300 500 1000 Maximum length, L [mm] 450 600 750 850 950 1200 Product number 96417377 96417378 96417379 96446784 96417380 96417381

--

Accessories

Wall bracket

Wall bracket
Wall bracket for easy installation of the dosing pump on a wall.

-221 133 123.5

A-A 5

Pump type DME 2 to 48 DMS

Material PP

Product number 96441202

-- - - -- - --

- - --

- -

Warranty, Service & Repair


To register your product with the manufacturer, fill out the enclosed warranty card and return it immediately to: Flowline Inc. 10500 Humbolt Street Los Alamitos, CA 90720. If for some reason your product must be returned for factory service, contact Flowline Inc. to receive a Material Return Authorization number (MRA) first, providing the following information: 1. Part Number, Serial Number 2. Name and telephone number of someone who can answer technical questions related to the product and its application. 3. Return Shipping Address 4. Brief Description of the Symptom 5. Brief Description of the Application Once you have received a Material Return Authorization number, ship the product prepaid in its original packing to: Flowline Factory Service MRA _____ 10500 Humbolt Street Los Alamitos, CA 90720 To avoid delays in processing your repair, write the MRA on the shipping label. Please include the information about the malfunction with your product. This information enables our service technicians to process your repair order as quickly as possible.

Optic Level Switch LO10 Series Owners Manual

NRTL/C
Version 3.2A 2001 FLOWLINE Inc. All rights reserved. Manual # LO900001 10/01

WARRANTY
Flowline warrants to the original purchaser of its products that such products will be free from defects in material and workmanship under normal use and service for a period which is equal to the shorter of one year from the date of purchase of such products or two years from the date of manufacture of such products. This warranty covers only those components of the products which are non-moving and not subject to normal wear. Moreover, products which are modified or altered, and electrical cables which are cut to length during installation are not covered by this warranty. FLOWLINE's obligation under this warranty is solely and exclusively limited to the repair or replacement, at FLOWLINE's option, of the products (or components thereof) which FLOWLINE's examination proves to its satisfaction to be defective. FLOWLINE SHALL HAVE NO OBLIGATION FOR CONSEQUENTIAL DAMAGES TO PERSONAL OR REAL PROPERTY, OR FOR INJURY TO ANY PERSON. This warranty does not apply to products which have been subject to electrical or chemical damage due to improper use, accident, negligence, abuse or misuse. Abuse shall be assumed when indicated by electrical damage to relays, reed switches or other components. The warranty does not apply to products which are damaged during shipment back to FLOWLINE's factory or designated service center or are returned without the original casing on the products. Moreover, this warranty becomes immediately null and void if anyone other than service personnel authorized by Flowline attempts to repair the defective products. Products which are thought to be defective must be shipped prepaid and insured to FLOWLINE's factory or a designated service center (the identity and address of which will be provided upon request) within 30 days of the discovery of the defect. Such defective products must be accompanied by proof of the date of purchase. Flowline further reserves the right to unilaterally wave this warranty and to dispose of any product returned to Flowline where: a. There is evidence of a potentially hazardous material present with product. b. The product has remained unclaimed at Flowline for longer than 30 days after dutifully requesting disposition of the product. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF THIS WARRANTY. This warranty and the obligations and liabilities of Flowline under it are exclusive and instead of, and the original purchaser hereby waives, all other remedies, warranties, guarantees or liabilities, express or implied. EXCLUDED FROM THIS WARRANTY IS THE IMPLIED WARRANTY OF FITNESS OF THE PRODUCTS FOR A PARTICULAR PURPOSE OR USE AND THE IMPLIED WARRANTY OF MERCHANT ABILITY OF THE PRODUCTS. This warranty may not be extended, altered or varied except by a written instrument signed by a duly-authorized officer of Flowline, Inc.

SPECIFICATIONS
Step One Accuracy: Repeatability: Supply voltage: Consumption: 1 mm in water .5 mm in water 12 - 36 VDC Relay: 25 mA FET: 5mA (dry) 19 mA (wet) Relay rating: 60 VDC/VAC @ 1A FET rating: 36 VDC @ 100 mA Switch output: Selectable NO or NC Temperature range: F: -40 to 194 C: -40 to 90 Pressure range: 150 psi (10 bar) @ 25 C., derated @ 1.667 psi (0.113 bar) per C. above 25 C. Sensor material: Polypropylene (PP) or Perfluoroalkoxy (PFA) Sensor rating: NEMA 6 (IP68) Mounting threads: Short: 3/4" NPT (3/4" BSP) Long: 3/4" NPT (3/4" G) Mounting gasket: Viton (3/4"), metric only Cable type: 8 ft. (2.5 m), 4-wire (relay) or 3-wire (FET), 22 gauge with shield & PP or PFA jacket CSA approval: Class I, Groups A, B, C & D; Class II, Groups E, F & F; Class III CSA entity parameters: Vmax = 32 VDC Imax = 0.5 A Ci = 0 F Li = 0 mH Certificate number: LR 79326-4 CE compliance: EN 50082-2 immunity EN 55011 emission
Ambient Sensor Temperature (C)

Intrinsically Safe Control Drawing


NON-HAZARDOUS LOCATION HAZARDOUS LOCATION Class I, Groups A,B, C, and D Class II, Groups E, F, and G Class III, (see note 1) Sensor Models LP10 LP50 LU10 LO10 Entity Parameters Vmax = 32V Imax = 0.5A Ci 0 Li 0

Associated Equipement (see notes 2 and 5)

Red Wire Black Wire Shield

Notes: 1. LP50 series sensor suitable for Class I, Groups A, B, C, and D locations only. 2. CSA certified associated equipment with entity parameters. 3. Vmax Voc, Imax Isc, Ci + Ccable Ca, Li + Lcable La. 4. Installation should be in accordance with CEC Part I, or NFPA 70. 5. Associated equipment must be installed per manufacturers instructions. Sensor Drawing: LSD1
Rev. A 7-21-95

Optic Switch

LO10 - _ _ _ _
Sensor Material
1 - PP 2 - PFA
Max. Series Resistance (Ohms)

Operating Pressure (psi)

175 150 125 100 075 050 025

Temperature/Pressure Derating
Unacceptable Range

Acceptable Range

000 -40 -20

00

20

40

60

80 10

Maximum Temperature/Voltage Derating @ Continuous 20 mA Current 100 Unacceptable 80 Range 60 40 20 Acceptable Range 00 -20 -40 12 18 24 30 36
Operating Voltage (VDC)

Flowline 4 or 20 mA Electrical Loading Limits 1,400 1,200 Unacceptable Range 1,000 800 600 400 200 0 12 18

Sensor Length
3 - Short 4 - Long

Mounting Thread
0 - 3/4" NPT 2 - 3/4" G

Switch Output
Acceptable Range

0 - Intrinsically Safe 2 - FET, N-Channel 3 - FET, P-Channel 5 - Relay


36

24

30

Temperature (C) PP PFA

Supply Volyage (VDC)

Dimensions
FET Red (+) Black (-) White FET Shld

3/4" NPT (3/4" BSP)

3/4" NPT (3/4" G)


(19mm)

8' Cable (2.5m)

2.1" (54mm) 2.8" (71mm) 4.5" (114mm)


3/4" NPT (3/4" BSP) 3/4" NPT (3/4" BSP)
(19mm)

RELAY Red (+) Black (-) White NO/NC Green COM Shld

8' Cable (2.5m)

(19mm)

0.7"

1.3" (32mm) 3.0" (76mm)

0.7"

* all dimensions are Nominal

0.7"

SAFETY PRECAUTIONS
Step Two

INTRODUCTION
Step Three

About this Manual:


PLEASE READ THE ENTIRE MANUAL PRIOR TO INSTALLING OR USING THIS PRODUCT. This manual includes information on all models of Optic level switches from Flowline, LO10 series. Please refer to the part number located on the switch label to verify the exact model which you have purchased.

About Optical Sensing


FLOWLINE's LO10 series powered optic sensors use principles of optical refraction to detect the presence or absence of fluid. A pulsed infrared light beam is internally generated by a light emitting diode and aimed at the slanted optical tip of the sensor. If the tip is dry, the light beam bounces at a 90 degree angle to a receiving photo transistor, and the internal electronics convert this to a two-wire, 5 mA signal output. If the tip is immersed in liquid, the light beam will refract out into the liquid instead of being reflected to the photo transistor, and the sensor will generate a 19 mA signal output. In addition to the 4 or 20 mA output there is also a FET switch output (NPN or PNP) and a 1A Relay output. Both outputs can be configured for either NO or NC operation. Because the reflective properties of the tip do not change until the tip meets a body of fluid, the LO10 series is unaffected by the density, low dielectric, or changes in the acoustic impedance of the application fluid. Because it uses pulsed infrared light (940 nanometers) with synchronous detection, it is resistant to the effects of ambient light. However, an optical sensor may not detect the presence or absence of specular application liquids that reflect light (such as milk), or viscous liquids (such as paint) that form a coating on the sensor tip. Do not confuse the L010 series with the LF series of fiber optic sensors. The LF series sensors, while they use the same optical reflection principles as the LO10 series, are an intrinsically safe design that bring no electrical power to the sensor itself. Light beams are generated externally by a LC65 or LC60 controller.

Users Responsibility for Safety:


Flowline manufactures a wide range of liquid level sensors and technologies. While each of these sensors is designed to operate in a wide variety of applications, it is the users responsibility to select a sensor model that is appropriate for the application, install it properly, perform tests of the installed system, and maintain all components. The failure to do so could result in property damage or serious injury.

Proper Installation and Handling:


Because this is an electrically operated device, only properlytrained staff should install and/or repair this product. Use a proper sealant with all installations. Note: Always install the Viton gasket with all versions of the LO10-__2_. The G threaded version will not seal unless the gasket is properly installed. Never overtighten the sensor within the fitting, beyond a maximum of 80 inch-pounds torque. Always check for leaks prior to system start-up.

Material Compatibility:
The LO10 series sensor is available in two different wetted materials. Models LO10-1___ are made of Polypropylene (PP). Models LO10-2___ are made of Perfluoroalkoxy, also known by the trade name Teflon, (PFA). Make sure that the model you have selected is compatible with the application liquid. To determine the chemical compatibility between the sensor and its application liquids, refer to an industry reference such as the Compass Corrosion Guide (available from Compass Publications, phone 619-589-9636).

Wiring and Electrical:


The supply voltage used to power the LO10 series sensor should never exceed a maximum of 36 volts DC. Electrical wiring of the sensor should be performed in accordance with all applicable national, state, and local codes.

Flammable, Explosive and Hazardous Applications:


Only the LO10-___0 series switch is rated for use in hazardous locations. Refer to the certificate of Compliance for all applicable intrinsically safe ratings and entity parameters for the LO10-___0. Refer to the National Electric Code (NEC) for all applicable installation requirements in hazardous locations. DO NOT USE THE LO10-___2, LO10-___3 or LO10-___5 GENERAL PURPOSE SWITCH IN HAZARDOUS LOCATIONS.

WARNING
The maximum current draw on the FET switch is 100 mA. FLOWLINE's LO10 series sensors are not recommended for use with electrically charged application liquids. For the most reliable operation, the liquid being measured will need to be electrically grounded. Note: Always install the Viton gasket with all versions of the LO10-__2_. The G threaded version will not seal unless the gasket is properly installed.

INSTALLATION
Step Four

ELECTRICAL
Step Five Supply Voltage: The supply voltage to the LO10 series sensor should never exceed a maximum of 36 VDC. Flowline controllers have a built-in 13.5 VDC power supply which provides power to all of FLOWLINE's electrically powered sensors. Alternative controllers and power supplies, with a minimum output of 12 VDC up to a maximum output of 36 VDC, may also be used with the LO10 series sensor. Required Cable Length: Determine the length of cable required between the LO10 series sensor and its point of termination. Allow enough slack to ensure the easy installation, removal and/or maintenance of the sensor. The cable length may be extended up to a maximum of 1000 feet, using a well-insulated, 20 gauge shielded wire. Wire Stripping: Using a 10 gauge wire stripper, carefully remove the outer layer of insulation from the last 1-1/4" of the sensor's cable. Unwrap and discard the exposed foil shield from around the signal wires, leaving the drain wire attached if desired. With a 20 gauge wire stripper, remove the last 1/4" of the colored insulation from the signal wires.

Through Wall Installation:


FLOWLINE's LO10 series sensors may be installed through the top, side or bottom of a tank wall. The sensor has male 3/4" NPT threads on either side of a 15/16" wrench flat. This enables the user to select the sensors mounting orientation, installed outside of the tank in, or inside of the tank out.

Smart Trak Installation:


FLOWLINE's Smart Trak LM10 series mounting system is an in-tank fitting which enables users to install up to four FLOWLINE sensors of any technology, to any depth, along the entire length of track. Smart Trak may be installed through the top wall of any tank using a standard 2" NPT tank adapter. If no tank top installation is available, Flowline's side mount bracket, LM50-1001, enables Smart Trak to be installed directly to the side wall of a tank.

Signal Outputs (Current sensing): The standard method used by Flowline controllers; this technology uses only two wires (Red and Black). The sensor draws 5 mA when it is dry, and 19 mA when wet. NC/NO status must be set by the controller. The White wire is not used. Red + Black + 24 VDC Power Supply

Switch Pak Installation:


FLOWLINE's Switch Pak LM45 series mounting system is an in-tank fitting which enables users to install one FLOWLINE sensor, of any technology, to a specific depth. The Flowline sensor may be installed onto the 3/4" NPT adapter at the end of the Switch Pak. Switch Pak may be installed through the top wall of any tank using a standard 2" NPT tank adapter. Flowline's side mount bracket, model LM50-1001, may also be used if top wall installation is not available.
LC06 Junction Box 1/2 Coupling

Shield Ground

Multimeter (mA)

Signal Outputs (FET switching): Allows the sensor to switch a small load on or off directly, using all three wires. Model LO10-___2 is a NPN type switch, which toggle the negative side of the load; model LO10-___3 is a PNP type switch for applications where the switch must be on the positive side of the load. In both FET models, the NO/NC status is set by the polarity of the voltage feeding the Red and Black wires, and the White wire connects to the load. Red Black Shield Ground + White + 24 VDC Power Supply

Switch Pak High Le vel Sensor Model LO10

Multimeter (Volts)

Smart Trak

Signal Output (Relay switching): Allows the sensor to switch a small load on or off directly, using an internal 1A relay (60 VAC/60 VDC). Only model LO10-___5 uses the relay and features 4 wires (red, black, white and green) and a shield wire. The NO/NC status is set by the polarity of the voltage feeding the red and black wires. The green wire is the common for the relay and the white wire is the NO or NC, depending on the polarity of red and black. Red Black Shield Ground White Green + + 24 VDC Power Supply Multimeter (Continuity)

Low Level Sensor Model LO10

Always install the 3/4 Viton gasket with all versions of the LO10-__2_. The G threaded version of the optic level switch will not seal unless the gasket is installed properly.

WIRING
Step Six

WIRING
Step Seven

Models LO10-___2, LO10-___3 & LO10-___5 Only Wiring to a Flowline Controller


LC10 Series Controller (4 or 20 mA signal output)
PU IN T 1

Models LO10-___2 & LO10-___3 Only


Wiring direct to a load, NC operation (FET signal output) Red* Black* + 12 - 36 VDC Power Supply (Sensor) *Reverse Red & Black wires for NO (NC shown)

INVE RT +/-

AC P AC GND NC R C NO DELAY

Shield Ground
(+)

Black Red Shld - Not Used White - Not Used Green* - Not Used

N-Channel

(-)

Load Controller Device (relay, lamp, valve, etc. ) 100 mA Maximum Red* Black*

White

1 5 VAC 220 VAC

+ 12 - 36 VDC Power Supply (Sensor) *Reverse Red &

* Green wire only on LO10-___5

LC40 Series Controller (4 or 20 mA signal output)

P OW E R

I N V E R T D E L A Y I N V E R T D E L AY

--+
R E L AY 1

--+
R E L AY 2

LATCH

INPUT1

INPUT2A

ON OFF

INPUT2B

Load Black wires for NO (NC shown) Controller Device (relay , lamp, valve, etc.) 100 mA Maximum P-Channel Wiring direct to load, Normally Open operation: LO10-___2 and LO10-___3 (FET outputs only): This is the same as the wiring for Normally Closed operation, except the polarity of the Red and Black connections to the sensor is reversed. The other connections remain the same; the sensor and device power supplies remain tied in the same polarity as before. This method will turn the load on when the sensor is wet.

Shield Ground

White

Red Black Shld Not Used - White Not Used - Green* * Green wire only on LO10-___5

Models LO10-___5 Only


Wiring direct to a load, NO operation (Relay signal outRelay Output *Reverse Red & Black wires for NC (NO shown) Red* + 12 - 36 VDC Power Supply Black* - (Sensor) Green White LOAD Shield Controller Device Ground (relay, lamp, valve, etc.) 1A Maximum + 60 VAC/VDC Maximum - Power Supply

put) Wiring direct to load, Normally Closed operation: LO10-___5 (Relay outputs only): This is the same as the wiring for Normally Open operation, except the polarity of the Red and Black connections to the sensor is reversed. The other connections remain the same; the sensor and device power supplies remain tied in the same polarity as before. This method will turn the load on when the sensor is dry.

WIRING
Step Eight

MAINTENANCE
Step Nine

Models LO10-___0 Only:


The LO10-___0 level switch has been approved for use in Class I, Groups A, B, C & D; Class I, Groups E, F & G; Class III; UNDER CERTIFICATE NUMBER LR 79326-4. DO NOT USE THE LO10___2, LO10-___3 OR LO10-___5 IN INTRINSICALLY SAFE APPLICATIONS. The Entity parameter for the LO10-___0 are: Vmax = 32 VDC Imax = 0.5 A Ci = 0 F Li = 0 mH
NON-HAZARDOUS LOCATION HAZARDOUS LOCATION Class I, Groups A,B, C, and D Class II, Groups E, F, and G Class III, (see note 1) Sensor Models LP10 LP50 LU10 LO10 Entity Parameters Vmax = 32V Imax = 0.5A Ci 0 Li 0

General:
The LO10 series sensor itself requires no periodic maintenance except cleaning as required. It is the responsibility of the user to determine the appropriate maintenance schedule, based on the specific characteristics of the application liquids.

Cleaning Procedure:
1. Power: Make Sure that all power to the sensor, controller and/or power supply is completely disconnected 2. Sensor Removal: In all through-wall installations, make sure that the tank is drained well below the sensor prior to removal. Carefully, remove the sensor from the installation. 3. Cleaning the Sensor: Use a soft bristle brush and mild detergent, carefully wash the LO10 series sensor. Do not use a harsh abrasive such as steel wool or sandpaper, which might damage the surface sensor. Do not use incompatible solvents which may damage the sensor's Polypropylene or PFA plastic body. 4. Sensor Installation: Follow the appropriate steps of installation as outlined in the installation section of this manual.

Associated Equipement (see notes 2 and 5)

Red Wire Black Wire Shield

Notes: 1. LP50 series sensor suitable for Class I, Groups A, B, C, and D locations only. 2. CSA certified associated equipment with entity parameters. 3. Vmax Voc, Imax Isc, Ci + Ccable Ca, Li + Lcable La. 4. Installation should be in accordance with CEC Part I, or NFPA 70. 5. Associated equipment must be installed per manufacturers instructions. Sensor Drawing: LSD1
Rev. A 7-21-95

Wiring to a Flowline Controller:


LC90 Series Controller 4 or 20 mA Signal Output Non-Hazardous Area Hazardous Area

P OWER

I N V E R T D E L AY

I N V E RT D E L AY

--+
R E L A Y1

--+
R E L A Y2

L AT C H

INPUT1

INPUT2A

ONOFF

INPUT2B

Red Black Voc Isc Ca La = = = = 17.47 VDC 0.4597 A 0.494 F 0.119 H Vmax Imax Ci Li = = = = 32 VDC 0.5 A 0 F 0 H

Da ta Char t Data Chart 1250 P aper less R ecor der Pa perless Recor ecorder Instr uction Man ual Instruction Manual

15 Columbia Drive, Amherst, NH 03031 Phone: 603-883-3390 Fax: 603-886-3300 Support email: support@monarchinstrument.com

TABLE OF CONTENTS
1.0 INTRODUCTION 1.1 1.2 1.3 1.4 1.5 1.6 1.7 CHART SPEED TO SAMPLE SPEED REVIEWING DATA ZOOMING AND CONDITIONING DATA CUSTOMIZING TRIGGERING THE GRAPHICS LCD DISPLAY OTHER GRAPHIC MODES

2.0 INSTALLATION AND SETUP 2.1 UNPACKING 2.1.1 Initial Inspection 2.1.2 Unpacking Procedure 2.1.3 Detected Damage 2.1.4 Equipment Return 2.1.5 Storage INSTALLATION 2.2.1 Panel Mounting CONNECTION 2.3.1 Power Connections 2.3.2 Input Signal Connections 2.3.3 Relay Output Connections 2.3.4 Digital Input 2.3.5 USB Port (Option) 2.3.6 Ethernet Port (Option) 2.3.7 Isolated DC input (Option) 2.3.8 Cleaning INPUT SCALING ALARMS 2.5.1 Alarm Types 2.5.2 Setting Alarms 2.5.3 Alarm Indication MEMORY CARDS 2.6.1 Care of the Data Cards 2.6.2 Card Storage Capacity and Data Type

2.2 2.3

2.4 2.5

2.6

3.0 BASIC OPERATING INSTRUCTIONS 3.1 3.2 3.3 3.4 3.5 BASIC MODE OF OPERATION VIEWING HISTORIC DATA COMPRESSING AND EXPANDING DATA (TREND VIEWING) ZOOMING DATA (AMPLIFICATION) MENU MODE 3.5.1 EXIT! 3.5.2 ALARM RESET! 3.5.3 RECORD MODE 3.5.4 CURSOR ID! 3.5.5 VIEW FILE 3.5.6 CARD STATUS! 3.5.7 SAMPLE RATE 3.5.8 PASSWORD (PROTECTION) 3.5.9 ADV. SETUP (ADVANCED SETUP - See below) 3.5.10 DISPLAY ADJ (ADJUST) EVENT TRIGGERING 1

3.6

3.7 3.8 3.9

STATUS LINE INDICATORS ENTERING VALUES TOP LEVEL MENU

4.0 ADVANCED SETUP 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 CHANNEL SETUP ALARMS RELAYS DISPLAY DATA CARD CLOCK BEEPER SAMPLE TRIGGER RECORD TRIGGER EXTERNAL INPUT UNIT TAG COMMS

5.0 MISCELLANEOUS 5.1 5.2 5.3 BATTERY BACKUP OPTION ETHERNET OPTION CALIBRATION 5.3.1 Basic Calibration 5.3.2 Examples SPECIFICATIONS

5.4

APPENDICES
APPENDIX A APPENDIX B APPENDIX C APPENDIX D UNITS LABEL CHARACTERS ERROR AND INFORMATION MESSAGES MASTER RESET RE-PROGRAMMING FIRMWARE

SAFEGUARDS AND PRECAUTIONS


Read and follow all instructions in this manual carefully, and retain this manual for future reference. Do not use this instrument in any manner inconsistent with these operating instructions or under any conditions that exceed the environmental specifications stated. This instrument is not user serviceable. For technical assistance, contact the sales organization from which you purchased the product.

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WEEE NOTICE
In order to comply with EU Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE):
This product may contain material which could be hazardous to human health and the environment. DO NOT DISPOSE of this product as unsorted municipal waste. This product needs to be RECYCLED in accordance with local regulations, contact your local authorities for more information. This product may be returnable to your distributor for recycling - contact the distributor for details.

Para obedecer con EU Directiva 2002/96/EC en el Desecho el Equipo Elctrico y Electrnico :


Este producto puede contener la materia que podra ser la salud humana perjudicial para y el ambiente. NO se DESHAGA de este producto el desecho municipal como no clasificado. Estas necesidades del producto para SER RECICLADAS de acuerdo con las regulaciones locales, contactan su administracin local para ms informacin. Este producto puede ser retornable a su distribuidor para reciclar - contacta el distribuidor para detalles.

Afin de respecter la directive europenne 2002/96/EC sur lEquipement Electronique et les Dchets Electriques :
Ce produit pourrait contenir des matires qui peuvent tre dangereuses pour la sant de lhomme et de lenvironnement. Ne pas jetter ce produit dans un container municipal inappropri. Ce produit doit tre recycl en accord avec les arrts locaux; contacter les autorits locales pour plus de renseignements. Ce produit peut tre renvoy au distributeur pour recyclage - Contacter votre distributeur pour plus de details.

Um den Vorschriften der EU-Direktive 2002/96/EC bezueglich elektrischer und elektronischer Abfallstoffe nachzukommen:
Dieses Produkt kann Materialien enthalten, welche gesundheitsgefaehrdend und umweltschdlich sind. Dieses Produkt DARF NICHT wie unsortierter Hausmuell entsorgt werden. Dieses Produkt muss gemaess den oertlichen Bestimmungen recycled werden, bitte kontaktieren Sie die lokalen Behoerden fuer weitere Informationen. Sie koennen dieses Produkt zum Recycling an Ihren Haendler zurueckgeben, bitte kontaktieren Sie den Haendler fuer weitere Details.

MLK 052907 REV1.3

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1.0 INTRODUCTION
This instrument is a versatile Solid State Data Recorder / Panel Indicator. It has all the capability of a traditional paper recorder - variable chart speeds, the ability to review historic data, see trends and more, with a number of specific exceptions - NO PAPER to jam, no ink to smudge and no pens to clog or break. The data is stored in a Compact Flash memory card, which can be easily transported. Of course it does all the regular functions a lot better, and the data can be transferred directly into reports, spreadsheets or analysis programs. Data can be examined and archived on any Windows XPTM compatible machine and can be printed out in various formats as required. This instrument has two universal inputs so it can measure voltage, current, thermocouples and RTDs by simply selecting them from the menu. It also has two potential free alarm output contacts and an isolated digital input. The display can be user configured to graphics, digital or a combination. Maximum data storage is 2 Gigabytes. Communication options include USB and Ethernet ports. Things are done a little differently in a paperless recorder and there are a few new concepts that you may need to become familiar with. There are more features and functions in this unit than you will probably use. It is recommended that you read this manual in its entirety before attempting to use the instrument. The balance of this introduction will attempt to introduce some of the more unique features of this paperless recorder.

1.1

CHART SPEED TO SAMPLE SPEED

A major difference between paper and paperless is SAMPLE SPEED, which is analogous to CHART SPEED in the paper recorder. There is an apparent chart speed, the rate at which the samples appear to move across the Graphics Display, but unlike paper recorders the display is made up of discrete data points, each of which is a distinct sample of the data being measured. The rate of movement across the screen is thus a direct function of the sample rate. The major factor in deciding what sample rate to select is knowing how much data is enough. In a paper recorder a chart speed of 1 inch per hour is fine for a process that does not vary very quickly but would result in a thick blur if trying to record a 1Hz sine wave. Unlike a paper recorder, every point recorded by the paperless recorder is uniquely identifiable, no matter how dense it appears on the screen. It is always better to have too much data than to have too little. The only consideration is the amount of space used in the memory card. To relate chart speed to sample rate we need to consider how we plan to reproduce the data. The graphic LCD display has a density of 70 pixels (data points) per inch; a typical dot matrix printer has 180 pixels per inch and a laser printer 300 pixels per inch. Thus to fill one inch of the display in one hour we need to sample at a rate of 70 samples per hour, a little over once per minute, however if this is now printed on a laser printer it will fill less than 1/3 of an inch. It is the amount and quality of the data that counts. Another advantage of the paperless recorder is that it can sample internally at 100 samples per second (one every 0.01 seconds). These samples can be averaged or peaks or valleys can be detected and then this data can be stored at the chosen sample rate. Trial and experience will yield the best sample speeds for the application. Start with a faster sampling rate than you think you will need; you can always slow it down in the future. As a rule of thumb, one sample every 10 seconds should give the equivalent information that 1 inch per hour of chart paper would.

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1.2

REVIEWING DATA

One of the biggest features of this recorder is its ability to show historic data and trends. The data on the graphics screen can be rewound like a tape recorder, scrolling back in time, displaying past data on the screen while still recording data in real time. The data can also be compressed on screen, showing a whole day or week's worth of recording on one screen, enabling trends or irregularities to be spotted easily. A data cursor can be moved around the screen to uniquely identify samples in both time and amplitude. Refer to Section 3 for the specifics on reviewing data. 1.3 ZOOMING AND CONDITIONING DATA

The recorder acquires data with greater resolution than can be displayed on the screen. The user has the ability to ZOOM in to amplify the data either 2 or 4 times, equivalent to using a magnifying glass on the display. These ZOOM windows can be scrolled up or down to cover the entire data spectrum. The vertical scale automatically adjusts to the zoom level and position to enable resolution of minor changes in input signal. More information. The recorder also acquires data at a rate faster than what may be displayed on the screen. The user can set the sampling rate from 100 samples per second down to 1 sample every 10 minutes. When sampling slower than 100 samples per second, the recorder can be programmed to record the average, maximum or minimum values. Thus if a sample rate of 1 sample per minute is chosen, the recorder will still sample internally at 100 samples per second while computing the average or detect and store either the maximum (peak) value or minimum (valley) value, depending on the mode programmed. It will then store this value when the minute is up. Unless required otherwise, it is recommended that the average value be used for recording since this will tend to filter or smooth the data. See Advanced Setup Menu for details. 1.4 CUSTOMIZING

There are many operating features and parameters that the user can program. All settings are stored in nonvolatile memory and are recalled each time the unit is powered on. The display can be scaled to read in engineering units, and the trace can be labeled accordingly with up to three alphanumeric characters. Four alarms are fully user programmable and can be associated with either channel or the external input. The Alarm levels can be set in the engineering units of the display, the sense of the alarm, the type and the deadband or hysteresis can be individually set for each alarm. Optional relay outputs can be assigned independently to each alarm. A reset delay feature is also available. There are other features which may be programmed by the user including the time stamping mode, either real time or elapsed time, clock update rates, file names, beeper operation etc. (Refer to Advanced Setup)

1.5

TRIGGERING

The recorder has the ability to change sampling speeds and stop or start recording as a result of a triggered event. This event may be tied to any of the four internal alarms or optionally to an external signal. This enables the unit to monitor a process without recording or to record at a slow speed to conserve card space. When an external event or internal alarm condition occurs, the unit will begin recording or change to a higher sample rate for the data of interest. More Information.

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1.6

THE GRAPHICS LCD DISPLAY

J M N
X2

I H G F

D C

Recorder Front View showing TREND Display The above diagram is a representation of the recorder in the TREND mode. The alpha characters around the border point to various features of the unit and are described below. Not shown are the MENUS which pop up over the display. The menus are in the form of those shown in Sections 4 and 5. The numbers in parenthesis below refer to the section that covers the topic in detail. A CompactFlash card slot manually insert a card into the unit to store data and configuration information. Can also be used as a means of updating the firmware in the unit. Cards up to 2 Gigabytes in size can be used. Busy LED (Red) on when the un it is recording and blinks rapidly whenever the unit is accessing the CompactFlash card. Blinks at 1 second rate if unit is triggered but not recording. Do not attempt to remove the card when this light is on . Power LED (Green) on during normal operation. If the optional internal battery pack is present, this LED will blink during power failure to indicate the unit is running off internal batteries. Optional USB interface enables connection to a Windows XP compatible PC. Navigation buttons used to set up and navigate around the display. The buttons are all dual function; the second function is initiated by holding down the MENU button while pressing one of the other buttons. The second function is printed on each button. 6
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D E

Date and Time shows the actual time of day (real time). The time is displayed user selectable in 12 or 24 hour format. The user can also select European or American formats and auto daylight savings adjustment. See Clock setup. Zoom Scale Indicator shows the zoom scale for the channel indicated if > x1. Separate scale for each channel. See zooming. Right hand edge of the graphics area in which the traces are displayed. This is the vertical scale area designated by the scale values at the top, center and bottom of the scale. The most recent data that is displayed in digital form at the top of the display (J) is against the right edge of this scale and moves left with time - the most recent data is to the right and the oldest data is to the extreme left. New data appears against this margin and the oldest data disappears off the screen at the extreme left. The graphic cursor (K) will start against this right edge. Vertical Scale Identifier this display alternates between Channel A and Channel B. It displays the Channel Tag and the Engineering units. See Channel setup. Digital Window the top of the screen displays the values for each Channel including the Channel identifier, the current value and the engineering units. Channel A is displayed on the left and Channel B on the right. This window displays the absolute digital value of the instantaneous (last) reading for the channel, and is the right most sample value on the trend display (G), unless the cursor is active. In that case it shows the value at the point the cursor intersects the trend line. Cursor is displayed when activated in the cursor ID mode. This cursor can be moved using the left and right arr ow buttons. The values in the digital window (J) are the values at the point the cursor intersect the trend line. Date/Time Axis Delimiter the dotted vertical lines placed at equal increments along the Horizontal axes (Time). The Date/Time stamp beside the line indicates the exact position of the line. Both date and time may be shut off or relocated vertically. These lines move with the trace at a speed dependent on the sampling speed. This is configurable in Display Setup. Channel B Trace the trend line is the graphic representation of Time (horizontal) versus Amplitude (vertical) and is shown solid to distinguish it from the Channel A trace, which is shown as a dotted trend line. This is configurable in Display Setup. Graphic TREND Window shows the channel traces, which may be compressed, expanded, zoomed, scrolled and halted. Status Icons these icons appear at various times to indicate the status of the unit and the display. From left to right they are: The numbers 1,2,3 and 4 are the ALARM indicators - one for each alarm. The numbers are present when the alarm is enabled and will blink if the alarm is in an alarm condition. The X indicates the status of the EXTERNAL INPUT and is present when the external input is present. The icon indicates the display is compressed. The horizontal time stamps indicate the current compressed values. The display can function normally in compressed mode, may be paused or the user can scroll back and forth using the left and right arrow buttons. The H indicates the display is in the HOLD condition. While in HOLD, the trends do not update. The display enters the HOLD condition when the ID Cursor (K) is present or the user scrolls in the horizontal direction using the left and right arrow buttons. Exit the HOLD mode by pressing the MENU button. 7

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DO NOT INSERT OR REMOVE THE COMPACT FLASH CARD


WHILE THE BUSY LED IS ON!
1.7 OTHER GRAPHIC MODES In addition to the full screen trend mode shown section 1.6, there are two additional graphic display modes. The Dual Digital mode, as shown below, enables both channels to be shown as Digital values similar to a digital panel meter. The user has the option of showing the displays in normal or reverse video (shown) modes, and the display can be set to blink on Alarm Condition.

The other Graphic mode is a split screen with the trend in the top half and the digital display in the lower half as shown below. When selecting this mode, Channel B is the default digital value, but can be switched in the Advanced Setup menu.

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2.0 INSTALLATION AND SETUP


2.1 UNPACKING 2.1.1 Initial Inspection Exercise care when unpacking the instrument from the shipping carton. The instrument is packed in a custom cardboard box to prevent damage during normal transit. If damage to the shipping carton is evident, ask the carriers representative to be present when the instrument is unpacked. 2.1.2 Unpacking Procedure To unpack your Recorder, first remove the cardboard retainer and instrument from the shipping carton. Check the box for the following contents - The Recorder, two locking bars, two 6-32 x " screws, AC power supply wall unit (unless the unit is the isolated DC model) and this manual. 2.1.3 Detected Damage Remove the instrument from the plastic bag and check for damage if any. Also check that the unit is as ordered. If damage is detected after unpacking the instrument, immediately report any damage to the shipping agent and re-pack the instrument for return it to the factory as described in the following section. 2.1.4 Equipment Return Before returning a damaged or malfunctioning instrument to the factory for repair, contact the sales organization from which you purchased the instrument. A Return Merchandise Authorization (RMA) number must be obtained from the factory before returning an instrument for any reason. 2.1.5 Storage For prolonged storage before installation, re-pack the Recorder in the shipping container and store in a cool, dry area. We do not recommend storage of the Recorder for more than one year. If longer storage time is required, contact the factory for additional storage information. 2.2 INSTALLATION

The instrument is intended to operate in the following environment: Indoor Use Only Installation Category II per IEC 664 Pollution Degree Level II per IEC61010-1 Temperature -10 C to 50 C operating per IEC61010-1 Humidity Maximum relative humidity 80% for temperatures up to 31 C decreasing linearly to 50% relative humidity at 40 C Recorder Power 9.0 +0.5V dc @ 5VA (unless indicated otherwise on the unit) AC Power Requirement (External adapter) 100 - 240 Vac ~ 50/60 Hz NOTE: The recorder is designed to be panel mounted and as such should be considered as permanently connected. Disconnection from the supply must be possible via a customer supplied switch or circuit breaker. This disconnection device must be included in the panel installation and should be clearly marked, it must be in close proximity to the Recorder and easily accessible to the operator. 9
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NOTE: In order to fully comply with the CE EMC Directive 89/336/EEC, connections to the recorder should not exceed 3m (9.8ft) without adding additional filtering. The Recorder fits in a standard DIN panel cutout of 92 x 92 mm (3.62 x 3.62 in.) and requires 140mm (7.5 inches) panel depth not including space for power and input source cable. The thickness of the panel is immaterial, but panels thicker than .125 inch will require that the locking bars be cut down. Actual dimensions are shown below in Figure 2.1:

0.30 [7.62]

5.22 [132.46]

0.41 [10.41]

3.78 [96.00]

3.60 [91.44]

3.78 [96.00] 4.07 [103.38]

0.15 [3.81]

Figure 2.1 Recorder Dimensions WARNING: Do not use this instrument in any manner inconsistent with these operating instructions or under any conditions that exceed the environmental specifications stated. 2.2.1 Panel Mounting The Recorder should be mounted in a vertical panel to ensure proper operation. Ensure you have the proper clearances and proceed as follows: 2.2.1.1 Cut a panel opening 96 mm x 96 mm (3.62 x 3.62 in.). 2.2.1.2 Remove any packaging material from the Recorder. Always handle the unit carefully to avoid damaging the LCD display or scratching the display surface. 2.2.1.3 Remove the locking bars from the Recorder enclosure by removing the captivating screws 2.2.1.4 Insert the Recorder, rear end first, through to front of the panel opening. 2.2.1.5 With the Recorder held firmly in place against the panel, install one of the locking bar assemblies from the rear, by sliding the locking bar tongue into the groove on the side of the Recorder enclosure as shown in Figure 2.2. 2.2.1.6 Insert the retaining screw into the rear of the groove. Using a Phillips screwdriver, tighten the screw until the locking bar is just pressing against the panel. 2.2.1.7 Install the other locking bar assembly into the groove on the opposite side of the Recorder enclosure and tighten as before.

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2.2.1.8 Using the screwdriver, tighten both screws so that the Recorder is held firmly in place. Do not over tighten, to avoid stripping the threads.

DC Power Connector

Relay Outputs Digital Input Retaining Screw (2)

Locking Bar (2)

Analog Inputs

Temperature Compensator

Figure 2.2 Rear View - Installation 2.3 CONNECTION 2.3.1 Power Connections NOTE: The Recorder is designed to be panel mounted and power should be considered to be permanently connected. Disconnection from the supply must be possible via a customer supplied switch or circuit breaker. This disconnection device must be included in the panel installation and should be clearly marked, in close proximity to the Recorder and easily accessible to the operator. THE RECORDER IS DESIGNED TO OPERATE ON 9 Vdc. DO NOT CONNECT AC POWER DIRECTLY TO THE UNIT AT ANY TIME. The power connector is located on the rear panel in the top left corner. There are two voltage options available for the recorder the standard is 9Vdc, which is used with an external universal AC Mains power supply. The external wall power supply is a high efficiency switcher that will work from 100 to 240 Volts AC 50/60 Hz. The other power option is an isolated 12 to 24Vdc input for use with an external DC power supply. The power supply option is marked with a dot in a square on a label above the power connector as shown in Figure 2.3. Check the unit to ensure that the power and inputs are as expected.

WARNING

Figure 2.3
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11

Before connecting any power or inputs to the unit, ensure that all signal wires and power cables are at zero voltage. The DC power is applied to the unit via a three-way screw terminal connector. The power supply is supplied with two tinned leads, the positive lead is identified by the RED shroud over the wire. The third connection is for system GROUND. You will require a small flat-head screwdriver. Connect the power and signal wires accordingly, noting carefully all polarities. Ensure that the unit is properly grounded to a suitable ground within the cabinet. Loosen the screws on the terminal block and insert the exposed conductor cable from the power supply below the screws, under the metal plate. Ensure that the insulation is flush with the terminal block. If it is too long, remove the cable, trim and reinsert. Tighten the screw to firmly hold the cable. Ensure the ground wire is connected and properly grounded at the other end. If you are not using the supplied wall power supply, follow the same procedure carefully identifying the positive supply line. The unit is protected against reverse polarity but not against substantial over voltage. 2.3.2 Input Signal Connections The maximum input on any input channel is 25 Volts DC. Voltages higher than this may permanently damage the unit. Ensure the unit is powered down before connecting any inputs. There are two universal analog inputs Channel A and Channel B. Each is programmed independently of the other. Inputs can be voltage or current (50mA max using an external shunt), thermocouples, RTDs or TTL compatible pulse inputs. Isolation is provided between inputs and the rest of the system. The channels are not isolated from each other. Connection detail for the various inputs is shown in Figure 2.4.

Figure 2.4 - Connection Detail

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When connecting the signal wires, keep polarities correct. The screw terminals are marked on the rear panel - there are four connections per channel. The high or positive signal marked IN+ , and a low or common signal marked IN-. The terminal marked Vo is the Auxiliary voltage output used to drive external sensors at +5Vdc and a maximum of 50mA. The terminal marked I+ is the 1mA current required for RTDs or resistors. Any screen or shield (often the braided wire) should connect directly to the system ground and is used to shield the low level input signals from induced noise pick up. Connect the signal wires to the terminal block in the manner described above. Use wire of adequate gauge to carry the signal. The mA input requires the use of an external 250 ohm shunt (Check with supplier). Thermocouples should be connected with thermocouple wire of the same type as the input; the terminal block is the reference junction. Connect any sheath or braid to the GROUND connection. RTDs have an additional wire, the current source, which is connected to the terminal marked I+. See Figure 2.4. WARNING: Unused inputs must have IN+ and IN- commoned together. CAUTION: Never run signal and power or control wiring together in the same conduit. This practice will prevent possible recording error due to induced signals between lines. Route signal wires away from power wires at the rear panel. NOTE: Ground cable shields at one end only to eliminate the possibility of interference due to ground loop currents. When grounded transducers are used, the shield should be grounded at the sensor end only. 2.3.3 Relay Output Connections

WARNING

To prevent the possibility of electrical shock, use extreme caution when wiring contact output connections. Hazardous potentials may exist on contact output terminals that are floating with respect to instrument ground. WIRES FROM REMOTE SOURCES MAY CONTAIN DANGEROUS POTENTIALS. ENSURE ALL POWER SOURCES ARE DISCONNECTED BEFORE WIRING RELAY CONTACTS.

The relay contacts are rated for AC or DC operation (Maximum recommended voltage - 30 Volts.) Each relay has a set of potential free contacts. There is no polarity to the terminals; it is a normally open contact that closes in alarm condition. These contacts are internally suppressed for EMI/RFI and High Voltage transients resulting from inductive loads. The relays may be programmed as fail safe, which means they are energized in the off condition. This way if the power should fail the relays will open into the alarm condition. See note below. 2.3.4 Digital Input The digital input is optically isolated and is activated by an external dc supply of 5 to 12Vdc at 20mA. The input is via the DIGITAL INPUT + and terminals. The connection is the COMMON for the external input, while the + is the input for the positive voltage. The digital input may be used as an External Trigger to stop or start recording, or may be used to change the sampling speed. Thus the unit can be set to record only when a conveyor is running for example. The External Trigger may also be linked internally to the optional Relay Output. This could be used as a remote "record active" indicator. Refer to Sections on Relay setup and External Input setup. Note: In order to fully comply with the CE EMC Directive 89/336/EEC cables to the

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relay output and digital input should be looped through a ferrite (Type Steward 28R2025-0R0 or similar) close to the terminals. 2.3.5 USB Port (Option) The USB Port is an option and will be installed only if specifically ordered. It is a serial connection to a PC that allows the user to program the recorder remotely, start or stop recording and download real time data. Refer to the separate manual that is supplied with the USB interface option. 2.3.6 ETHERNET Port (Option) The Ethernet Port is an option and will be installed only if specifically ordered. It allows the user to program the recorder remotely, start or stop recording and download real time data. The IP address is set in the Advanced SETUP Menu. Refer to Section 5.2 for detailed instructions on the Ethernet interface option. 2.3.7 Isolated DC input (Option) The unit may be powered by an external DC source with the isolated DC to DC option. Connect the unit to the external DC source and observe the voltage and polarity of the inputs. In order to fully comply with the CE EMC Directive 89/336/EEC the power cable should be looped through the ferrite bead provided, close to the terminals. 2.3.8 Cleaning The unit may be cleaned by wiping with a soft cloth. The front panel and display / keypad may be wiped with a slightly damp soft cloth containing soapy solution or a mild detergent. Do not use any lemon based (citric acid) product to clean the display / keypad. NOTE: THE UNIT IS NOT WATERTIGHT. 2.4 INPUT SCALING

The input to the recorder is often a standard process variable (e.g. voltage) rather than the actual units being measured (e.g. pressure). There are a number of custom conversions available in the unit to take care of special inputs such as thermocouples and RTDs, which need special scaling and linearization. These are preset in the unit and require no modification. There is also the capability to customize any input variable that has a linear relationship to the measured variable. The relationship between the required variable and the input variable must satisfy the equation for a straight line: y = mx + b where y is the output value to be displayed and recorded, x is the input variable (typically volts or milliamps DC), m is the scale factor (slope of the line) which defines the relationship between the input and the displayed variable and is a constant (linear relationship), and the factor b (known as the y intercept) is a constant offset variable that may be positive or negative. This facility to scale the input is found in the ADVANCED SETUP menu and is available to each channel independently. Here the user can easily scale the input and set the displayed units using three alphanumeric characters. The scaling is achieved in the unit in the CHANnel X SETUP option (X = A or B) in the ADVanced SETUP menu. First set the displayed LO SCALE, which may be positive, negative or zero. Then set the displayed HI SCALE for the full-scale input. The unit will then

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automatically compute the scale factor and offset. Setting the engineering units is done in the same menu location using the CHAN UNITS option to set the three alphanumeric characters. Let us assume we have an input from a pressure transducer of 1 to 5 volts DC, corresponding to real world units of zero to 250 PSI (Pounds per Square Inch of pressure). Assume we choose the 0 to 5 volt input. The actual output span of the transducer is 4 volts, with 1 volt = 0 PSI and 5 volts = 250 PSI. This is equivalent to 62.5 PSI per volt. The LO SCALE which is the "0" volt value is equivalent to -62.5 PSI and should be set to this value, and the HI SCALE is set to "250". The engineering units are set to "PSI". The display will now show zero to 250 PSI for 1 to 5 Volts input. The linear scaling is shown in Figure 2.5. 2.5 ALARMS
5 4 INPUT VOLTS 3 2 1 0 -62.5 (OFFSET) 0 125 PSI 250

Figure 2.5

The Recorder has four programmable internal alarms with dual relay output. The alarms can be associated with either analog input channel, can be set as high or low, latching or non-latching with or without lockout capability. Each relay has a set of potential free normally open contacts (Form A - SPNO) that are accessible from the rear panel via screw terminal connections. Alternatively the relays can be set to the failsafe mode, normally closed (Form B SPNC). The relays can be assigned to any, all or none of the alarms. Refer to section on Alarms and Relays in Advanced Setup Menu. 2.5.1 Alarm Types A high alarm is active when the input is greater than the setpoint. A low alarm is active when the input is less than the setpoint. A latching alarm will remain set once activated and must be reset by the operator. Note that the alarm condition should be removed before resetting the alarm or the alarm will activate and latch again. A non-latching alarm will set on alarm condition and automatically reset once the alarm condition is removed. A differential, known as hysteresis or deadband can be introduced so that once an alarm is set (at the setpoint), the input must go beyond the deadband before the alarm resets. This prevents the output relays from chattering in borderline conditions. The deadband is set in absolute units and adds to the setpoint in a low alarm, or subtracts from the setpoint in a high alarm. By way of example, if the setpoint is 100, the hysteresis (deadband) is set to 5, and the alarm is a high type and non latching, then the alarm will activate when the input exceeds 100 and will remain active until the input drops below 95 (100 minus 5). Alternatively the user can set a reset delay from 1 to 255 seconds. This delay must time out once an alarm condition has been removed before the alarm will reset to normal. Lockout prevents an alarm from activating until the setpoint has been traversed in the opposite sense by the input. For example, if we were measuring pressure and had a low alarm set at 100, we may not wish the alarm to be active on start up when the pressure may be low or zero. We really wish to monitor a low-pressure situation once our target pressure has been reached, say 150. The lockout prevents the alarm activating at startup. The alarm remains deactivated until the input exceeds the setpoint. Now the alarm arms and any future time that the input drops below the setpoint, the alarm will activate.

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2.5.2 Setting Alarms Setting and configuration is done in the Advanced Setup Menu. The alarm setpoints are set in the same units as the input type and may be different for each channel. When setting the actual setpoint value, the value may be incremented in steps other than what is expected (unit steps). This is due to the fact that the input is converted into a digital value with a finite resolution. It is not possible to set a setpoint value that cannot be resolved by the internal microprocessor. Select the closest value to the exact value you require; it will always be with 0.5%. The same applies when setting the deadband. Note that when configuring the alarms, there is no correlation between inputs, alarms and relay outputs. These are user defined. Each alarm can be assigned to only one input channel. When setting up each alarm channel, the user should DISABLE the alarm so that parameters may be changed WITHOUT AFFECTING THE RELAYS. This is done in the ALARMS menu by selecting the ENABLE option so that no appears to the left of this option. Once everything is set, select ENABLE once more to activate the alarm, indicated by the presence of the . (Refer to Section on Setting Alarms)

When setting up alarms, you may get unexpected results from the relays if they are
enabled. Ensure there is nothing connected to the relays that could result in an accident due to random closing of the relays during setup and always DISABLE the alarm as described above. Make the changes and then re-enable the alarm. There are many different ways the alarms can be set up. All the alarms can be assigned to a single channel and may be of the same type giving for example a various degrees of high warning and ultimately a high shutdown indication. Als o, the relays may be assigned to any combination of alarms. This would allow a single relay output to indicate any alarm active. The combinations are endless. 2.5.3 Alarm Indication There are three indications of alarm condition: the relay outputs, visual icons on the display and audible alarm. When an alarm is armed and functioning, it is indicated by a small "1", "2", "3" or "4" in reverse video on the bottom left hand side of the graphic display. These status indicators remain on as long as the alarm is enabled. If an alarm is triggered (in alarm condition), the status indicator will blink and the internal beeper will sound. The beeper can be permanently disabled from the Advanced Setup Menu - BEEPER - ALARMS - OFF. The relays close on an alarm condition, assuming they have been set up correctly. The relays can be set as fail-safe by reversing the logic of the alarms (Advanced Setup Menu - RELAYS - FAILSAFE). 2.6 MEMORY CARDS

The memory cards used are standard CompactFlash cards. We recommend the use of Sandisk CompactFlash cards. The cards are keyed and can only go into the recorder right side up. The largest capacity card that can be accommodated is 2 Gigabytes. 2.6.1 Care of the Data Cards Do not expose the cards to direct sunlight or extremes of temperature for any length of time. Do not expose to moisture. Do not bend or twist. Avoid high static discharge. Mail 16

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in suitable packaging to avoid postal damage. When transporting, use an anti -static bag or the plastic enclosure in which the card is supplied. 2.6.2 Card Storage Capacity and Data Type Depending on what else is stored on the card (e.g. configurations files, other data files), data storage capacity can be roughly calculated by the following formulas: Number of samples is card size divided by 4.4. The time that it will take to fill a card is roughly the number of samples divided by the sample rate. For example, a 32MB card will hold roughly 32,000,000 divided by 4.4 = 7,272,727 samples. At 5 samples per second this is 1,454,545 seconds or 404 hours or approximately 16.8 days. If you show the Card Status window (MENU - CARD STATUS), it will indicate how much time is left on the card. It also displays the current Filename that is being used for recording. The files on the card are in DOS standard format and can be managed on any Windows based machine with a CompactFlash reader - internal or external. The content of the files is in proprietary binary format and requires special software to read the data. All units are supplied with the Navigator Lite Software, which allows the data to be exported to Excel.

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3.0 BASIC OPERATING INSTRUCTIONS


The Basic mode of operation encompasses those functions that would be done on a routine basis and relate primarily to viewing and reviewing data with some use of the menu system. The advanced mode, while technically still simple to operate, involves setting up the unit and would typically need to be done only once. 3.1 BASIC MODE OF OPERATION Basic operations are all done using the five buttons on the front panel (shown below) and the first level menu.

Each arrow button has dual functions. The second function is activated by pressing and holding the MENU (2nd Function) button and then pressing any of the other buttons. The 2nd function of each button is denoted by the text under the arrow symbol. (EXPAND, COMPRESS, ZOOM + and ZOOM -). The unit need not be recording to the memory card in order to manipulate data. The data available however is dependent on how long the unit has been operating, the sample rate and the buffer or memory card size. 3.2 VIEWING HISTORIC DATA Any data that is not currently visible on the screen is historic data. To view past data, the left () and right () a rrow buttons are used to rewind () or fas t forward () the data (scrolling). When rewinding, data will be retrieved from the memory card or from the internal buffer and is available as far back as the start of recording. When fast-forwarding, data is available up to real time. The time and date stamp on the screen indicates the relative time of the samples being viewed. Depending on the amount of data to process there may be delays before the screen reacts. Historic viewing by scrolling is limited to the file (or files) created since recording was manually started via the RECORD MODE Menu - ON. If NOT recording, scrolling back in time is limited to the content of the internal buffer. The history buffered is dependent upon the sampling speed. Data is presented as latest data first. It is possible to view data from other files of previously recorded data (or even data recorded on another machine) using the View File menu.

At any stage during the rewind or fast forward process, the screen can be restored to current or real time display by pressing the MENU button. When the data on screen is not current, an .H. appears on the status line to indicate that the rewind or compress mode is active and the data is on Hold.

3.3 COMPRESSING AND EXPANDING DATA (TREND VIEWING) In order to view data trends, it is often necessary to pack more data onto the screen than is normally visible in real time. To compress the data, press and hold the MENU (2nd Function) key and then press the COMPRESS ( ) key. Each time this key is pressed the 18
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amount of data on the screen will double up to a maximum of 32 times (equivalent to 5 sequential key presses). Once compressed, data can be rewound and fast-forwarded as described in the previous section. The data can be expanded back after being compressed by pressing and holding the MENU key and then pressing the EXPAND () button. Note that compression displays peak values (both high and low). Thus even though data is compressed, all amplitude information is present on the display. At compressions of 16 times or greater, the redraw time of data on the screen slows down due to the large amounts of data that must be manipulated.

At any stage during the compression or expansion process, the screen can be restored to current or real time display by pressing the MENU button. When the data on screen is compressed, a appears on the status line to indicate that the compress mode is active.

3.4 ZOOMING DATA (AMPLIFICATION) As a result of the small display area available, it is not always possible to see small changes in amplitude of the recorded signals even though the resolution of the internal converters can measure it. To overcome this problem you can ZOOM in on a portion of the graph and get increased resolution. ZOOM applies to each channel independently. The trace that will zoom is the one whose scale is shown to the right. To adjust the other trace simply wait for its scale to appear. To ZOOM in and amplify the graph, press and hold the MENU key, press the ZOOM+ () button and then release both buttons. The display will zoom in by 2. Note that the scale units change to reflect the increased zoom level. There are three zoom levels available: x1, x2 and x4. To decrease the zoom level (or zoom out), press and hold the MENU key, press the ZOOM- ( ) button and then release both buttons. While adjusting the zoom, scale flipping is suspended. Turning the other trace off will also suspend flipping. Note that when zoomed in at any zoom level, the () and () buttons will move the graph relative to the window enabling viewing of any part of the graph within the zoom window. When zooming, the trace expands or contracts about the centerline. If zooming drives the trace off the screen, it will automatically reposition itself at the top or bottom vertical edge of the chart. Once in a zoom level, all functions are operational on the zoomed display.

When in a zoom mode, the zoom level is indicated in the lower half of the scale for the associated channel (X2, X4 etc.). No indication indicates normal scale (X1). To exit the zoom mode, zoom out (MENU + ) as far as possible until the scale value disappears x1 mode.

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3.5 MENU MODE At any time when in normal view mode, pressing the MENU button will bring up the user menu as shown to the right. Note that the menu "pops up" over the graphics display. The unit continues to record and will not lose data. There is also a time out option that will return a menu display back to a graphic display after a period of inactivity. (Refer to Advanced Setup DISPLAY - MENU TIMEOUT). UNIT TAG EXIT! .. . ALARM RESET! RECORD MODE.. CURSOR ID! VIEW FILE.. CARD STATUS! SAMPLE RATE.. PASSWORD.. ADV.SETUP.. DISPLAY ADJ..

When the menu is active, the Left Arrow () and Right Arrow
() buttons act as ESCAPE keys to return to a previous level without activating any function.

The user moves about the menu using the Up Arrow () and Down Arrow () buttons. The current selection is always highlighted in reverse. To select a function, simply move to it with the () and () buttons and then press the MENU button once. To go back a level without activating any function, simply press the () or () buttons. Note that the menu has more options than can be displayed at once on the screen. When a selection gets to the top or bottom of the menu list, the list will scroll until the last entry is reached then wrap around. Pressing and holding the () and () buttons will activate an Auto Repeat function and cause the highlight bar to scroll automatically. The menu has multiple levels. An option with a secondary level is indicated by .. after the name. Access to the various levels can be controlled by a password (Refer below). 3.5.1 EXIT! When the menu is displayed, it defaults to the EXIT selection. At this point, pressing the MENU button will return to the graphic display. 3.5.2 ALARM RESET! Pressing the MENU button after selecting ALARM RESET! will reset any alarm that is active and latched and then exit the Menu Mode. If the alarm is not latched but is still in alarm, selecting this option will briefly reset the alarm, which will then activate again. 3.5.3 RECORD MODE.. To begin or end recording in the data card, press the MENU button, use the Up Arrow ( ) or Down Arrow () button to highlight RECORD MODE and then press the MENU button again. Several options appear in a sub window: OFF , ON and TRIGGERED. To exit at this stage without changing the current setting, press either the Left ( ) or Right ( ) Arrow button. Otherwise, use the Up Arrow () or Down Arrow () button to make a selection and then press the MENU button. The active selection is indicated by a to the left of the option. If you are using the alarms or external input to control the recording, select TRIGGERED for triggered operation. OFF and ON will always stop or start a recording irrespective of the state of any of the record triggers. (Refer to Event Triggering.)

The RECORD MODE menu option may be password protected. Before selecting ON or TRIGGERED to begin a recording, ensure that a Memory Card is in place and that there is sufficient space available to contain your new data. (Refer to CARD STATUS below.)

To return to the graphic screen, press either the Left ( ) or Right () Arrow button. For further details on other options under RECORD MODE, refer to ADV. SETUP DATA CARD. 20
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Note: While recording, the recorder automatically switches to OFF when a card is removed, or if it is not present when power is applied. This will require a manual restart of the recording when a new card is inserted. If the card remains in the slot while power is removed the recorder restores the recording state it was in when the power was interrupted. 3.5.4 CURSOR ID! The Cursor ID mode enables the user to accurately pinpoint the time and amplitude of any sample in the graphics window. The unit has to be in the full graphic mode for this option to work. To enable this function, press the MENU button, use the Up Arrow () or Down Arrow ( ) button to highlight CURSOR ID! and then press the MENU button again. The Menu will vanish revealing the Graphics screen and a single data cursor against the right edge of the display area. Note: The Cursor ID mode will not activate if the Trend is compressed. The screen will be in the HOLD mode and the data window at the top of the screen and time/date stamp at the lower right will show the values of the samples under the data cursor. The status line will show the highlighted .H. to indicate that the data and timestamp is that of the data under the cursor and not real time data. Using the Left ( ) or Right () buttons the user can move the data cursor to the point of interest. The data window at the bottom of the screen will show the time and date of the sample and the digital readings at the top of the screen - A (and B in dual c hannel units) show the absolute value. Note that at the extremities of the data, the cursor hits an end point and then the data scrolls beneath it. This method can be used to accurately identify unique points on the graphics display no matter how busy the traces appear. To return to normal (real time) mode, press the MENU button. Note that entering the Cursor ID mode does not affect the real time acquisition of data. 3.5.5 VIEW FILE The user can view data from files other than the one currently being recorde d. The View File option allows the user to view previously recorded data on the data card from the very first file through to the current data. The display HAS TO BE IN THE FULL GRAPHIC MODE for this to work. To view a file on the memory card, press the MENU button, use the Up Arrow ( ) or Down Arrow () button to highlight VIEW FILE and then press the MENU button again. The current filename will be displayed. To view historic data from this file, simply press the MENU button. To choose a different file on the memory card, press the Left Arrow ( ) button twice to display a directory listing of all files on the card. Then use the Up Arrow () or Down Arrow () button to highlight the desired file and press the MENU button twice to select it. When viewing from a file, the status line will show a highlighted .F. to indicate that the data being viewed is from a File on the memory card. All View, Compress and Zoom functions work on the prerecorded file. Use the Left ( ) or Right () buttons to move through the file. Data will be presented as oldest samples first. To return to the current real time trend, press the MENU button. View File will automatically abort if the data card is removed. 3.5.6 CARD STATUS! To display the status of the memory card, press the MENU button, use the Up Arrow ( ) or Down Arrow () button to highlight CARD STATUS! and then press the MENU 21

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button again. A pop-up window will be displayed showing information about the memory card including the size of the card, the amount of space left as a percentage and the equivalent record time at the current settings. To remove the Card Status pop-up window, select CARD STATUS! again. 3.5.7 SAMPLE RATE To adjust the sample rate (the rate at which data is recorded and displayed), press the MENU button, use the Up Arrow () or Down Arrow () button to highlight SAMPLE RATE and then press the MENU button again.

The SAMPLE RATE menu option may be password protected.

When entering the SAMPLE RATE menu, the rate highlighted is the current sampling rate . To exit at this stage without changing the current setting, press either the Left ( ) or Right () button. In this manner the user can check the current sampling rate at any time without affecting the recording. To change the sampling rate, use the Up Arrow () or Down Arrow () button to highlight the desired sample rate and then press the MENU button. The sample rates vary from a high of 100 S/sec (Samples per second) to the slowest 10 min/S (minutes per sample, sec/S is seconds per sample). To return to the graphic screen, press either the Left ( ) or Right () button. 3.5.8 PASSWORD (PROTECTION)

To set, reset or change a password, press the MENU button, use the Up Arrow () or Down Arrow () button to highlight PASSWORD and then press the MENU button.

This menu option may be password protected.

Follow the prompts. Enter a 4-digit password using a combination of buttons. The key presses are echoed in a pop-up window and roll around, first in first out. Once you have entered your password, press the MENU button. If you are entering a new password, you will be asked to repeat your password and then press the MENU button. At this point the password is entered and the unit is protected. To clear the password, enter the current password and then simply press the MENU button when prompted to enter the new password. A null password is no password at all. 3.5.9 ADV. SETUP (ADVANCED SETUP) See Section 4. 3.5.10 DISPLAY ADJ (ADJUST) To adjust the backlight brightness and viewing angle, press the MENU button, use the Up Arrow ( ) or Down Arrow () button to highlight DISPLAY ADJ and then press the MENU button again. Adjust the Viewing Angle using the and keys and the Back light Intens ity using the and keys. Press the MENU button to accept the changes and exit.

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3.6 EVENT TRIGGERING The recorder has the ability to be triggered by certain events that are generated internally or, optionally, externally, which will enable it to automatically change sampling speed or begin or end a recording session. The trigger can be any alarm or the external input. The user can thus set the unit to record at a slow sample speed until some alarm condition is triggered and then change to a higher sample rate to record the transient. Another example is the use of the external event trigger to start and stop recording allowing the selective recording of specific events. The event triggering is setup in the Advanced Setup Menu option. The control of recording, stopping and starting is set in the REC. TRIG. (Record Trigger) menu option (Section 4.9), while the changing of sample speed is controlled via the SAMPLE TRIGger menu option where a second set of sample speeds will be presented for the triggered speed change (Section 4.8). This rate may be slower or faster than the regular rate depending on application. The external event may be used in the same manner as the internal alarms for triggering a change of speed or record status. The external event trigger characteristics are set in the ADV. SETUP - EXT. INPUT menu option. If the recorder is triggered but not recording, the red LED will blink at a 1 second interval. 3.7 STATUS LINE INDICATORS The bottom line of the graphics LCD display is used to indicate the status of the display and of the recorder itself. These status icons consist of reverse video characters or letters that appear according to operations performed and are intended to prevent data on the display from being misinterpreted and to indicate the status of the alarms.

1 2 3 4 X H F
From left to right these icons are as follows: 1 2 3 4 - These icon symbols indicate that the alarms are enabled (1 is Alarm 1 etc.). Any number of them may be present depending on how the alarms have been set up. If an alarm is enabled a solid block will be present. If the alarm has exceeded the setpoint (i.e. is in an alarm condition) its symbol will be blinking. X - This symbol indicates that the external input is enabled. If the external input is triggered this symbol will blink.

- This symbol indicates the display is in the COMPRESSED mode. The amount of compression can be determined from the time date stamps on the display. To exit from the Compressed Mode simply press the MENU button. .H.. - This symbol indicates the display is in the HOLD mode. The displayed data is no
longer real time and will not be updated. The Hold mode is entered by pressing either the LEFT or RIGHT arrow button, entering the compressed mode, or viewing any internally buffered data.

.F. - This symbol indicates the data on the display is from a FILE on the MEMORY CARD
and not current data. To view data from a file, use the MENU selection option "VIEW FILE". Note that if currently recording, viewing a file does not disrupt the recording procedure provided that the file you are viewing is on the same memory card as the one you are recording on OR you do not exceed the buffer storage time on the recorder if you are using another memory card.

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3.8 ENTERING DATA When adjusting or entering values you have to use the button keys. Alphanumeric Values The key moves the cursor to the right to s elect the character to be edited. It will wrap around from right to left. The change the character as shown in Appendix A. The ME NU button accepts the data and exits and the key escapes. Numeric Values work a little differently, the value increments and decrements according to the up or down keys. Single presses increment or decrement the value by 1. If the button is pressed and held down the value will increment or decrement in steps of 10. If the MENU button is held down and the or button is pressed and held down, the value increments or decrements by 100. The MENU button accepts the data and exits and the key escapes.

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3.9 TOP LEVEL MENU OVERVIEW

Top Level EXIT ALARM RESET

Level 1

Function Exits from Menu Resets any Alarms. Note if Alarm is still active it will set again. Auto exits menu Enter Password (if set) then press MENU.

RECORD MODE OFF ON TRIGGERED

Stop Recording Start Recording Arm Triggered Recording. An External Event will start and stop recording as programmed. Enter the name for recorded files up to 8 Characters. Use keys. key to escape, clear or list directory Use MENU key to Save and Exit Save Configuration Enter Config File Name - up to 8 Characters. Use keys. key to escape, clear or list directory. Press MENU to save and exit Load Configuration. Enter Config File Name - up to 8 Characters. Use keys. key to escape, clear or list directory. Press MENU to save and exit Unit will restart on successful load Puts chart in HOLD mode and places cursor on screen. Use keys to move cursor and read trend values at top. Press MENU key to exit this mode. Select an existing file on the CARD to browse. Enter File Name - up to 8 Characters. Use keys. key to escape, clear or list directory. Press MENU to browse. Pops up window show memory card status. Includes capacity, % full, time remaining. Select again to remove window. Enter Password (if set) then press MENU.

NAME FILE

SAVE CONFIG

LOAD CONFIG

CURSOR ID

VIEW FILE

CARD STATUS SAMPLE RATE 100 S/sec to 10 sec/S

Select sample rate from 100 Samples/sec to 10 min/Sample. Use keys to navigate key to escape without change. Use MENU key to select and exit Enter Password using then press MENU Repeat at prompt, press MENU to select and exit Enter Password (if set) then press MENU. See Section 4 Adjust Viewing angle (VIEW) and Back Light (BKLT) . Press MENU to exit.

PASSWORD

ADV. SETUP

DISPLAY ADJ.

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4.0 ADVANCED SETUP


The ADVANCED SETUP menu may be password protected. This menu is used to program the various operating parameters of the recorder. This includes analog inputs, alarms, display settings, the clock and various trigger modes. All items on this menu have one or more sub-menus. To locate the Advanced Setup menu, press the MENU button from any normal view mode. The Advanced Setup menu will not be visible when the menu first appears. Use the Up Arrow () and Down Arrow () buttons to scroll and highlight ADV. SETUP and press the MENU button. This will bring up the Advanced Setup menu shown on the left. Current settings in sub menus are indicated by a (check mark) along side the item or by the item being highlighted. See above for details on entering data. 4.1 CHANNEL SETUP This menu option enables the user to program the inputs of the recorder. Each channel can be set up as an analog input volts, currents, thermocouple or RTDs, or as digital inputs from RPM or frequency measurements. There is no need to swap out modules since the inputs are universal. Filtering may be applied to each channel for stability of readings or to catch peak values if the display rate is slower than the sample rate. (The unit always samples at 100 samples per second per channel. For increased accuracy each range may be calibrated independently. Use the Up Arrow () and Down Arrow () buttons to scroll and highlight CHAN n SETUP (n = A or B) and press the MENU button. The menu options are shown expanded below.
INPUT TYPE VOLTS 250mV to 25.0Vdc mA 4-20 mA to 0 - 50mAdc THERMOCOUPLE J, K, K(hi)T, E RTDs Pt385 or 392 FREQUENCY 100 Hz to 10kHz SPEED 100 RPM to 600,000 RPM OFF Select Speed for Full Scale Range Turns Channel OFF (toggles) =OFF Default value is low end of range. For Offset. Use keys to adjust key escapes, MENU key to Save and Exit Default Value is top end of range. For Full Scale. Use keys to adjust. key escapes, MENU key to Save and Exit Select Frequency for Full Scale Range Select required RTD Type Select required Thermocouple (T/C) type Select full scale input Current. Input is for DC milliAmps. External Shunt of 250 Ohms is required. Select full scale input Voltage Input is for DC Volts Note: Menu will differ depending on Input Type selection

CHAN A SETUP.. CHAN B SETUP.. ALARMS.. RELAYS.. DISPLAY.. DATA CARD.. CLOCK.. BEEPER.. SAMPLE TRIG.. REC. TRIG.. EXT. INPUT.. UNIT TAG.. COMMS..

LO SCALE

HI SCALE

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CHAN TAG

Enter a Channel Tag Identifier up to 5 Characters. Use keys. to clear or escape. Use MENU key to Save and Exit Default value is Range value Enter a Channel Units. Some Ranges have defaults. Enter up to 3 Characters. Use keys. to clear or escape. Use MENU key to Save and Exit Note: Unit always samples at 100 samples/sec internally No filtering Display shows AVERAGE over last sample interval Display shows HI PEAK (max) values over last sample interval Display shows LO PEAK (min) values over last sample interval Averages last 10 samples continuously Choice is: NEITHER CHAN A CHAN B BOTH (If applicable) - Input zero and adjust for zero. MENU to accept. Input Max Span value and adjust for correct value. MENU to accept. Copies default calibration value to this range Copies default value to all ranges

CHAN UNITS

FILTER NORMAL AVERAGE HI PEAK LO PEAK FAST FILT

CALIBRATION CAL ZERO

CAL SPAN CAL NOMIN. CAL NOMIN. ALL

4.2 ALARMS This option is used to program the alarms. There are four alarms and each is programmed independently. Each alarm may be turned on or off and may be assigned to either channel. Use the Up Arrow () or Down Arrow () buttons to scroll and highlight ALARMS.. and press the MENU button. The menu options are shown expanded below.
ALARM n (n = 1,2,3,4) Turn Alarm n on or off - ENABLED is on Select if ALARM is HIGH SETPOINT Set ALARM Trip point. Use keys to adjust to escape, MENU key to Save and Exit Set ALARM DeadBand point. Use keys to adjust to escape, MENU key to Save and Exit Select CHAN A as Source for Alarm Select CHAN B as Source for Alarm Select if ALARM is LOW

ENABLE HIGH

DEADBAND CHAN A CHAN B Same as HIGH

LOW

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HOLD OFF RESET DELAY LATCHING LOCK OUT DEFAULT

Use keys to enter time in seconds from Alarm till relays pull in. Use keys to enter time in seconds from RESET till relays drop out. Toggle using MENU - make alarm latching Prevents a low alarm activating until the setpoint has been exceeded once

4.3 RELAYS This option is used to program the physical relay outputs. There are two relays and each is programmed independently. The relays can be assigned to one or more ALARM events or the EXTernal INPUT. Use the Up Arrow () or Down Arrow () buttons to scroll and highlight RELAYS.. and press the MENU button. The menu options are shown below.
RELAY 1 OFF ALARM 1 ALARM 2 ALARM 3 ALARM 4 EXT INPUT RELAY 2 FAILSAFE NEITHER RELAY1 RELAY2 BOTH RELAY is OFF RELAY is tied to ALARM 1 RELAY is tied to ALARM 2 RELAY is tied to ALARM 3 RELAY is tied to ALARM 4 Relay is tied to EXTernal INPUT same as RELAY 1 Relays are energized in the non alarm condition Select Neither relay as failsafe Select RELAY 1 as failsafe Select RELAY 2 as failsafe Select both relays as fail safe

4.4 DISPLAY This option is used to set up the display. The Window Configuration allows the user to choose how to display data - either as a trend or as digital values or as a combination of both. The time stamp that appears on the trend can be customized, the menu can be set to disappear and have the display revert back to normal, and the backlight can be set to go off after a period of inactivity. (The backlight will restore on any event.) Use the Up Arrow () or Down Arrow () buttons to scroll and highlight DISPLAY.. and press the MENU button. The menu options are shown below.
WINDOW CONFIG TREND DUAL DIGITAL BOTTOM DIGITAL INV DIGITAL ALARM BLINK DIGITAL <--> Set display to full screen TREND (both Channels) Set display to DUAL DIGITAL readouts Set display to TREND in top half, DIGITAL in lower half (CH B) Set DIGITAL display to WHITE characters on DARK background. DIGITAL value will blink when in alarm SWAP the position of dual digital windows.

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TIME STAMP NONE TIME ONLY TIME & DATE TOP MIDDLE BOTTOM MENU TIMEOUT NEVER 30 SEC to 30 MINUTES BACKLIGHT LIGHT TIMEOUT NEVER 30 SEC to 30 MINUTES BATTERY OFF PEN TYPE CHAN A - - SOLID DOT DASH DOT-DASH CHAN B -DISPLAY ADJ. Set CHAN A TREND line to SOLID ______ Set TREND line to a series of DOTS . Set TREND line to a series of DASHES - - - Set TREND line to a series of DOTS and DASHES Set CHAN B TREND lines as above Same as Top Level Menu option (see page 23) BackLight will never shut off Choose time to backlight shut off from 30 seconds to 30 Minutes after inactivity. Select to turn back light off in battery mode to save power. (battery is optional) MENU will never Collape (and revert to display mode) Choose MENU TIMEOUT from 30 seconds to 30 Minutes. Menu will revert back to normal display. No imprint of TIME or DATE on TREND display TIME imprints on TREND display TIME and DATE imprint on TREND display Set location of Time (& Date) imprint to TOP of TREND Set location of Time (& Date) imprint to MIDDLE of TREND Set location of Time (& Date) imprint to BOTTOM of TREND

4.5 DATA CARD This option contains duplicate menu items to those found in the RECORD MODE menu. In addition it enables the user to test the card and format it for use (recommended). Use the Up Arrow () or Down Arrow () buttons to scroll and highlight DATA CARD.. and press the MENU button. The menu options are shown below.
NAME FILE Enter the name for recorded files up to 8 Characters. Use keys. key to escape Use MENU key to Save and Exit Save Configuration Enter Config File Name - up to 8 Characters. Use keys. key to escape. Press MENU to save and exit Load Configuration. Unit will show list of files. Use to select, key to escape. MENU to select and load. Unit will restart on successful load This is a non-destructive test to check the card.

SAVE CONFIG

LOAD CONFIG

TEST CARD

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ERASE CARD FORMAT CARD

Erase File. Unit will show list of files on card Use to select, key to escape. MENU to select and erase. This will FORMAT the card for use in the recorder. ALL DATA WILL BE DESTROYED

4.6 CLOCK This option allows the user to set the time and date and determine what is displayed for time on the bottom right of the display. Use the Up Arrow () or Down Arrow () buttons to scroll and highlight CLOCK.. and press the MENU button. The menu options are shown below.
MODES TIME OF DAY 24 HR AUTO DST TIME ZONE MM/DD/YY DD/MM/YY SAMPLE TIME DEFAULT SET TIME SET DATE Select Time Display as Real Time Clock Select Time Display as 24 hour or 12 hour AM/PM Select to enable Daylight Saving Time adjust Allow for international time correction. Actual time recorded is GMT. This corrects for current local time so data is global. Select date format as Month/Day/Year Select Date format as Day/Month/Year Show time of actual last sample Select default setup: Time of Day, 12 hour format , DST on, Date format is MM/DD/YY Set Time Adjusts hours. adjusts minutes, MENU accepts Set Date Adjust month/year. adjusts days. MENU accepts

4.7 BEEPER This option allows the user to have various events sound the beeper, Alarms, message boxes and key presses. The tone of the beeper may also be programmed. Use the Up Arrow () or Down Arrow () buttons to scroll and highlight BEEPER.. and press the MENU button. The menu options are shown below.
ALARMS OFF ALARM 1 ALARM 2 ALARM 3 ALARM 4 EXT INPUT ALARM TONE TONE A TONE B TONE C TONE D MSG BOXES BUTTONS BEEP on ALARMS turned off if checked Beep on Alarm 1 Beep on Alarm 2 Beep on Alarm 3 Beep on Alarm 4 Beep on External Input Not selected is a continuous high tone Select Alarm TONE A - add warbling effect Select Alarm TONE B - add short silence between tones Select Alarm TONE C - add longer silence between tones Select Alarm TONE D - add long silence between tones BEEP on POP-UP MESSAGE BOXES active if checked BEEP on BUTTON PRESS active if checked

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4.8 SAMPLE TRIGGER This option allows the user to program what will trigger a change of sample rate in the displayed or recorded data. Use the Up Arrow () or Down Arrow () buttons to scroll and highlight SAMPLE TRIG.. and press the MENU button. The menu options are shown below.

Note that if an event is selected to change the sample rate, when exiting the menu

the sample rate menu will be displayed. Use the Up Arrow () or Down Arrow () buttons to scroll and highlight the new sample speed and press the MENU button to select and the Left Arrow () button to exit.
No Sample Rate change if checked Sample Rate change on Alarm 1 Sample Rate change on Alarm 2 Sample Rate change on Alarm 3 Sample Rate change on Alarm 4 Sample Rate change on External Input

OFF ALARM 1 ALARM 2 ALARM 3 ALARM 4 EXT INPUT

4.9 RECORD TRIGGER This option allows the user to choose an event to start the recording. Use the Up Arrow () or Down Arrow () buttons to s croll and highlight REC. TRIG.. and press the MENU button. Select either OFF, ALARM 1 through 4 or EXTERNAL INPUT as the record trigger.

Note that if an alarm reset delay is set (see Section 4.2), the unit will continue to
record for this time period AFTER the alarm has gone away. 4.10 EXTERNAL INPUT This option allows the user to program the external digital input. This needs to be programmed before it can be used for event triggering if programmed above. Use the Up Arrow () or Down Arrow () buttons to scroll and highlight EXT. INPUT.. and press the MENU button. The menu options are shown below.
ENABLE HIGH LOW HOLD OFF RESET DELAY LATCHING LOCK OUT Enable External Input External Sense is HIGH to register. (> 5V) External Sense is LOW to register (=0V) Time in seconds from EXT input present till recognized Time in seconds from EXT input absent till recognized Once set, will remain set till the RESET option is pressed External Input requires a change of state in order to be recognized. For a High condition on startup or reset, if the input is high at that time it needs to go low first, then high in order to be recognized. Set Defaults - Disabled, High level, all else set to zero

DEFAULT

4.11 UNIT TAG The unit tag is used to identify the recorder. It is saved to the data file when recording and can be read back by the analyzing software. It is also displayed on the top of the main menu when the MENU button is pressed for the first time. It can be a maximum of 15 31
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characters. Select this option then use the keys to adjust and the key to escape or the MENU key to Save and Exit. See Entering Data above for details. 4.12 COMMS This option allows the user to set the IP Address, Subnet Mask and Default Gateway for the Ethernet Option. Use the key to select the digit to change (Indicated by [123]) and to change it. Use the MENU to accept or to escape.

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5.0 MISCELLANEOUS
5.1 BATTERY BACKUP OPTION If the recorder contains the Battery Backup Option, there is a toggle switch on the back panel below the terminal block. The switch is marked ON and OFF. In the OFF position, the battery is disconnected from the load and the recorder is off. The battery charges with the switch OFF when the recorder is plugged into AC power. In the ON position, with external power applied, the unit runs normally and automatically switches to battery backup in the event of a power failure. The recorder continues to run from the battery until power is restored. If the battery voltage reaches a preset low voltage threshold, the battery is automatically disconnected and the recorder shuts off. When external power is restored, the unit starts up normally and the batteries begin to recharge. Likewise, the unit can run off internal battery without external power by simply turning the unit ON. The recorder switch should be turned OFF when not in use. Additionally there is a procedure to turn the backlight off when the unit is running on battery. See Section 4.4. This action extends the battery life and the unit continues to operate normally. The green power LED on the front panel will blink when the recorder is being powered from the battery. Run times vary from 8 to more than 12 hours depending on load conditions. It takes 10 to 14 hours for the battery to fully charge. 5.2 ETHERNET OPTION Setting the IP Address The recorder needs to have the IP address set manually by the user. The address should be set so it is compatible with the environment into which it connects. To set the IP address: Select MENU. Using the buttons select ADV SETUP then COMMS. Select IP ADDRESS then use the keys to set an address. ( selec ts which group of digits to adjust then changes the n umber.) To accept the address, press the MENU button. The IP address you set depends on how you plan to access the device. If you have a local area network connection, the IP address needs to match the subnet setting on your computer. The address will be in the form 192.168.0.210. Check your computers IP Address then set the recorder address so that the first three sets of numbers match that of your computer. The last digit should be different and should be unique check with your IT department if you are unsure. Select SUBNET MASK and set it to 255.255.255.0, which is typical, or to whatever your system requires and then press the MENU key. Use the key to exit the menu. If you plan to access the recorder from outside your local area network, then you need to set the Default Gateway IP address. Again, you can get this information from your own PC settings. The Default Gateway is used by the recorder when an IP packet's destination address belongs to someplace outside the local subnet (thus requiring more than one hop of Ethernet communication). The Default Gateway address is usually an interface belonging to the LAN's border router. Connect the Ethernet cable to the recorder. There are two LEDs on the connector - one indicates connection, the other indicates activity. To connect the recorder directly to your

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computer you need to use a crossover cable. You can connect using a hub or a switch using a patch cable. The connection can be tested by using the DOS Command Box and pinging the units. At the DOS prompt type: Ping 192.168.0.210 (use the IP address you set). If the connection is good you will see a series of replies from the recorder. If you cannot connect, try pinging the address with the recorder disconnected from the Ethernet. If you get a reply, there is another device with that IP address. Change the IP address on the recorder. There are two methods of connecting to the recorder over the Ethernet - Browser connection and Navigator Software. Browser connection Launch your browser (Internet Explorer preferred V6 or later). You need to ENABLE ACTIVE X and JAVASCRIPT. (From the browser toolbar, select TOOLS then INTERNET OPTIONS then SECURITY. Select CUSTOM LEVEL and choose MEDIUM LOW or adjust the settings manually). Enter the Recorder IP address into your browser and click GO. You should see a picture of the Recorder and the data should update at a 3 to 5 second update rate depending on Ethernet traffic and recorder chart speed (slower chart speeds will result in faster updates over the Ethernet.) Note that the browser shows the recorder status in real time. Navigator Software The Navigator software enables the user to fully interact with the recorder over the Ethernet. You can alter settings, stop and start recording, download data in real time for plotting or archiving on the PC, and you can download historic data files. Refer to the Navigator Software manual for additional information. 5.3 CALIBRATION Before leaving the factory, the recorder is calibrated using NIST traceable sources. The calibration values are stored in non-volatile memory. The unit is calibrated to meet specification but the user may wish to re-calibrate the unit, or calibrate specific input ranges for increased accuracy. Calibration is the process of fine tuning each input for various differences that may arise due to manufacturing processes, gain errors, temperature offsets and other physical parameters. Real analog to digital (A/D) converter values are corrected by first adding an offset correction value, nominally zero, to the reading to correct for offsets from zero, and then multiplying it by a span correction value that's nominally 1 to correct for gain errors. Calibration setup can be found in the Channel x Setup Menu (x = A or B) under the ADVANCED SETUP menu options. Each channel needs to be calibrated independently. There are four options on the calibration menu: CAL ZERO SPAN adjusts the offset correction above or below actual 0 (zero), in steps equal to the resolution of the A/D converter itself. adjust a span correction value above or below actual 1, also in small amounts.

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NOMINAL

depending on the input range selected, either resets the correction values to 0 and 1, or copies those values from the range it's a derived from. This usually affects only the input type category selected for the current channel.

NOMINAL ALL will reset all correction values for all input types on both channels when selected from any input type and channel, a sort of master reset. This is the default in the event that calibration data is found to be corrupted in the non-volatile memory. 5.3.1 Basic Calibration All calibration values are derived from a couple of key calibrat ion points. Thereafter, any fine-tuning done to a specific input on a channel is saved for that channel and input range only. The key calibration constants are for: Lo Volts Hi Volts covering the 250mV, 1.25V, 2.50V ranges and should be done on the 250mV range each channel covering the 5.00V, 12.5V, 25.0V ranges and should be done on the 5.00V range each channel which are derived from the Lo Volts calibration value require an additional offset to compensate for the ambient temperature sensor each channel which are derived from Lo Volts calibration value require an additional span calibration to correct for the internal current source each channel which are derived from the Hi Volts calibration value require an additional span calibration to correct for the external resistor (Customer supplied) each channel requires only a time base calibration shared for both channels

THERMOCOUPLES

RTDs

CURRENTS

FREQ and SPEED

In general, to calibrate an analog input, first set the specific channel to an input type in the ADVANCED SETUP MENU - CHANNEL SETUP - INPUT TYPE (see Section 4.1). Once an input type has been chosen, select CALIBRATION (see Section 4.1). Do not change the units from the default values set when that range is selected (i.e. leave volts as volts and current as current). Apply a "zero" value to the input and using the up () and down () arrow buttons adjust the OFFSET until the onscreen indications shows zero. Apply a "high" value to the same input and using the up ( ) and down () arrow buttons adjust the SPAN until the onscreen indication agrees with the input (Note use an input value slightly less than the full scale value to prevent an overrange indication). Repeat for all input types and channels to be used, if not all of them . 5.3.2 Examples Volts: Should be done for the Lo Volts - 250mV, 1.25V, 2.50V ranges, and Hi Volts 5.00V, 12.5V, 25.0V ranges using the 250mV and 5.00 volt ranges respectively. For each channel individually, set the input for 250mV and go to Calibration. Short the input

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and adjust the OFFSET until 0 is indicated. Then apply a near full scale input (so as to not over range the input, say 240 mV on the 250 mV range) and adjust the SPAN. Thermocouples: (preferred method) First calibrate lo VOLTS range (250mV) for the same channel as described above. Then switch to Thermocouple range. Select NOMINAL to copy the volts calibration to thermocouple range. The recorder is now calibrated for ideal sensors. Refine the calibration by either shorting the input (you need to know the ambient temperature) or attaching a thermocouple sensor or calibrator of the correct type for the selected range, and then if necessary, adjust the OFFSET until the correct temperature is displayed this corrects the ambient temperature sensor. If there's a known "high" temperature source handy use that to fine-tune the SPAN value. Currents: (preferred method) First calibrate Hi VOLTS range (5.00V) for the same channel as described above. Then switch to any CURRENT range. Select NOMINAL to copy the volts calibration to the current range. The recorder is now calibrated for ideal resistor (250 ohm). Refine calibration for resistor and sensor current tolerances by attaching a 250 ohm +0.1% resistor and input sensor matching the selected range. Apply low value inputs to adjust the OFFSET value, and high value inputs to adjust the SPAN value. RTDs: (preferred method) First calibrate lo VOLTS range (250mV) for the same channel as described above. Then switch to RTD range. Select NOMINAL to copy the volts calibration to RTD range. The recorder is now calibrated for ideal sensors and internal current source. Refine the calibration by applying an accurately known resistance for a given temperature (you may need resistance to RTD tables). Adjust the SPAN until the correct temperature is displayed this corrects for the internal current source. Frequency (RPM or Hz): Apply a calibrated frequency input near the high end of the selected input range of either channel. Adjust SPAN until the indicated value is correct. There is no applicable OFFSET adjustment to be made. Recommended procedure for full initial calibration, in this order: - Calibrate 250 mV range, both channels using a calibrated source. - Calibrate 5.00 V range, both channels using a calibrated source - Calibrate any T/C range, both channels using the NOMINAL method. - Calibrate any RTD range, both channels using NOMINAL method - Calibrate any current range, both channels using NOMINAL method - Calibrate any Tach range, either channel using a calibrated signal source. NOTES: As with other numeric editing, the rate that a calibration value is adjusted accelerates with the length of time the button is pressed. Calibrating either channel for tachometry calibrates both channels and does not have to be repeated for each channel as they use the same base counter. Additionally there's no OFFSET adjustment for these inputs. Thermocouple and RTD linearization tables are very accurate; usually calibrating the 250mV range for the same channel and then copying the calibration values using NOMINAL should be enough. Remaining sources of error are the ambient sensor (probably small) for the thermocouple and the current source (small) for the RTD, and the actual sensors themselves. The ambient sensor can be calibrated by adjusting the OFFSET with the thermocouple at some known temperature (such as ice water) or a known room temperature with a wire short on the input. The input sensor span adjustment would need a high temperature point to calibrate.

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There can be interaction between the OFFSET and SPAN with the thermocouple input since it can't be easily determined when exactly 0 volts is applied in combination from the ambient and input sensors. This can happen with other input types where the input used for the OFFSET adjustment does not present 0 volts to the input. Calibration values are copied to an EEPROM (non volatile) device when performing the calibration operations. These values are copied from the EEPROM upon every power up of the recorder and tested for corruption. If the values are found in error then nominal values are inserted in all categories. 5.4 SPECIFICATIONS Input Power: Recorder: 9Vdc +0.5V @ 5VA (depends on external loads) External AC Universal adaptor: 100 240Vac 50/60 Hz Optional isolated: 12 24 Vdc input (not compatible with Battery Backup Option) Internal battery pack provides uninterrupted operation during black out. 6Vdc 2400 mAH NiMH Backup Time: Depends on external load Without Ethernet: 6 hours typical With Ethernet: 2.5 hours typical 2 outputs 5Vdc @ 50mA to power external sensors Isolation 300V DC/AC to system ground/chassis. 2 Isolated input: 300V AC/DC to system ground/chassis. Inputs share a common ground connection. Resolution: 0.025% Ranges: 0 to 250mV; 1.25V; 2.5V; 5V; 2.5V; 25V Accuracy 0.1%. Accuracy: 0.1% excluding 250 ohm external shunt (required) Ranges: 0 20mA; 4 20mA; 0 50mA; 10 50mA Accuracy: 0.3%. Ambient temp. sensor accuracy +1.5 J K T E RTD: -100 to 760 C -100 to 1000C -100 to 400 C -80 to 400 C +2C +2C +2C +2C (-148 to 1400 F +3F) (-148 to 1830 F +3F) (-148 to 750 F +3F) (-112 to 750 F +3F)

Battery Option:

Output:

No of Channels: Universal DC Input:

DC Input: Voltage:

Current: Thermocouple:

2 or 3 wire. Resolution 0.1C, Accuracy 0.3% Internal current source: 1mA 100 ohm Pt385 -100 to 750C (-148 to 1380 F) 100 ohm Pt 392 -100 to 750C (-148 to 1380 F) Range: Accuracy: 0 10,000 Hz or 0 600,000 RPM Freq: +1Hz; RPM: +1 RPM to 9,999 RPM then +10RPM Input: low: <1.0Vdc high: >3.0Vdc <12Vdc Pulse width: 10 sec minimum

Frequency Input (Hz)/ Speed Input (RPM):

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Input Impedance: Measurement Rate: Math Function: Media: Display:

>100k up to 100 samples/sec per channel y = mx + b; average, hi peak., lo peak

Compact Flash to 2 GB LCD Graphics 160 x 80 pixels black FSTN with White LED backlight User controlled Backlight level and Contrast adjust (electronic) Display Modes: Trending (Horizontal), Large Dual Digital Readout, Mixed Mode User Interface: 5 buttons keypad with 2nd Function operation Clock: Internal battery backed clock, with auto leap year and daylight savings Relay Output: Two alarm outputs: 30V 0.5A Form A relays Opto-isolated Input: One input 5 to 12Vdc operation @ 10mA typical. Audible: Internal buzzer (tones) Dimensions: Front panel 96mm x 96mm (1/4 DIN) x 152mm (3.78 x 3.78 x 6 inches). Environmental: Indoor Use Only Installation Category II per IEC 664 Pollution Degree Level II per IEC61010-1 Altitude up to 2,000 m Temperature -10 C to 50 C operating per IEC61010-1 Humidity Maximum relative humidity 80% for temperatures up to 31 C decreasing linearly to 50% relative humidity at 40 C. CE EN61326 EMI/EMC EN61010-1 Safety UL and cUL (Power Supply)

Certification:

Optional Communications USB Ethernet Front panel USB 2.0 slave port for data transfer and configuration. 10/100 Ethernet

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APPENDIX A - UNITS LABEL CHARACTERS


The following is a list of the characters are available any place text can be entered. The list will start with the A character (underlined) and the UP and DOWN arrows move through the list in order left to right. The characters in shadow are NOT legal for file names.

(space) .( 0 8 .@ . H P X .`. h p x .

! ) 1 9 A I Q Y a i q y

" * 2 .: B J R Z b j r z

# + 3 ; C K S ..[ c k s .{

$ , 4 < D L T \ d l t |

% 5 = E M U ] e m u }

& . 6 > F N V ^. f n v ~ .

'.. /.. 7 ?. G O W _ g o w #.

APPENDIX B - ERROR AND INFORMATION MESSAGES


The following messages appear on the Graphics screen as a result of the following: (suggested solutions appear in italics ) ACCESS DENIED An incorrect password was entered while attempting to gain access to a password protected function. Find someone who has the right password. BAD FILENAME CARD ABSENT The filename entered does not meet the DOS requirement. Use A to Z and 0 to 9 without spaces, 8 characters max. Re-enter the name. Failed attempt to read from (viewing) or write to (recording) a memory card which is not present. Insert a card.

CARD ACCESS ERROR Failed attempt to read or write a memory card due to file data corruption. Format and erase card - data will be lost. CARD FULL Failed attempt to write to a memory card which is filled to capacity. Exchange card with a new one that has spare capacity.

ENTER CURRENT PASSWORD You have attempted to access a password protected function and must enter the password to continue. Enter current password. ENTRIES MISMATCH This time password did not match last time password when setting up. Try it again, only more slowly.

ENTRY ERROR

An illegal number of keystrokes were entered while entering the password. Try it again, only more slowly.

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FILE NOT FOUND Failed attempt to read a data file or configuration file due to the fact that no such file exists on the memory card. Get the correct card. FORMAT CARD Card is incompatible or unformatted. Requires formatting.

OVERWRITE CONFIG. FILE? A config file already exists on the memory card. Writing to the card will overwrite this existing file. The unit is checking user intent. Press the UP ARROW key to overwrite the existing file, any other key to exit. STOP RECORDING FIRST The function you are trying to perform cannot be done while the unit is in record mode. Stop recording and try again.

TEST FAIL

The card has errors on it and did not pass the card test. Try reformatting the card or swap the card.

APPENDIX C - MASTER RESET


The master reset is used to restore all factory defaults to the unit. It is used in the unlikely event of the unit losing or corrupting the contents of its nonvolatile memory. All user configurations will be lost. To reset the unit to the factory defaults, hold the two outer keypad buttons down simultaneously (The DOWN and LEFT arrows) while powering up the unit. Wait two to three seconds and then release.

APPENDIX D RE-PROGRAMMING FIRMWARE


The operating firmware in the unit is programmed into flash memory and can be updated in the field. It is loaded from the compact flash card. Users can upgrade their firmware by simply downloading the latest firmware from the Company website, saving it onto the CompactFlash card, inserting the CompactFlash card into the unit and following the steps below. The upgrade file is named MRUPG.hex. Once this file is on the CompactFlash card, insert the card into the unit and turn the power off. Press and hold the MENU button and Left Arrow () simultaneously and power the unit back on. The POWER LED will come on fully bright; the other will blink as the card is accessed. If the program is loaded successfully, the two LEDs will alternate. If the load failed, the two LEDs will blink in unison. It takes 10 to 15 seconds to load the program. If the load should fail, try it again. If it still fails, reload the file on the card. Remove the power and re-apply it. The screen will show the latest firmware revision and build date.

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