Blue-White FLEX-PRO A2 User Manual

Exclusive:

TFD system

TubeFailureDetection

Patented

ProSeries

2

TWO-YEAR WARRANTY

CERTIFIED FINAL DOCUMENT

FLEX-PROR

Peristaltic Metering Pump

SERIES A2V

Operating Manual

ProSeriesR Protected by Patents: 8,418,364; 8,215,931;

by Blue-White Ind. 7,001,153; 7,284,964; 4,496,295 and other patents pending

5300 Business Drive, Huntington Beach, CA 92649 USA Phone: [phone] FAX: [phone]

E mail: [e-mail] | [e-mail] URL: www.Blue-White.com

Page 2			Flex-Pro
		TABLE OF CONTENTS
Section	Heading		Page
1.0	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 3
1.1		Available Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 3
2.0	Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 4
2.1		Materials of Construction . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 4
3.0	Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 5
3.1		Agency Listings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 5
4.0	Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 6
4.1		Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 6
4.2		Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 6
4.3		Installing Injection Fitting and Strainer. . . . . . . . . . . . . . . . .	. . . 7
5.0	Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 8
5.1		Wiring Terminal and I/O Schematics . . . . . . . . . . . . . . . . . .	. . . 9
6.0	How to Operate Flex-Pro - Control Pad. . . . . . . . . . . . . . . . . . .		. . . 10
6.1		Mode Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 11
7.0	Mode0 - Set Remote Start/Stop . . . . . . . . . . . . . . . . . . . . . . . .		. . . 12
7.1		Mode 0 - Set TFD Sensitivity. . . . . . . . . . . . . . . . . . . . . . . .	. . . 13
7.2		Mode 0 - Set FVS (flow verification system). . . . . . . . . . . . .	. . . 14, 15
7.3		Mode 0 - Set 4-20mA Output. . . . . . . . . . . . . . . . . . . . . . . .	. . . 16, 17
8.0	Mode 1 - Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 18, 19
8.1		Mode 1 - Manual Operation Screen Shots . . . . . . . . . . . . . .	. . . 19
9.0	Mode 2 - 4-20mA Input Operation . . . . . . . . . . . . . . . . . . . . . . .		. . . 20, 21
9.1		Mode 2 - 4-20mA Input Screen Shots . . . . . . . . . . . . . . . . .	. . . 21
10.0	Mode 3 - Frequency Input (Hz) Operation . . . . . . . . . . . . . . . . .		. . . 22, 23
11.0	Mode 4 - Pulse Batch (low speed pulse) Operation . . . . . . . . . .		. . . 24, 25
11.1 Mode 4 - Pulse Batch Operation Screen Shots . . . . . . . . . .			. . . 25
12.0	Pump Tube Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 26
13.0	TFD (Tube Failure Detection) . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 26
14.0	Alarm Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 27
15.0	Reverse Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 27
16.0	Tube Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 28
16.1		Tube Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 28
16.2		Tube Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 29
17.0	Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 30
18.0	Pump Head Replacement Parts List . . . . . . . . . . . . . . . . . . . . .		. . . 31
19.0	Output Versus Fluid Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 32
	Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 34

PLEASE READ ENTIRE INSTRUCTION MANUAL PRIOR TO INSTALLATION AND USE.

Flex-Pro

Page 3

1.0Introduction

Congratulations on purchasing Flex-Pro variable speed Peristaltic Metering Pump. A peristaltic pump is a type of positive displacement pump used for pumping a variety of fluids.

Your Flex-Pro pump is pre-configured for tubing that shipped with your metering pump. Tubing assembly has an Identification number printed on tube for easy re-order; such as ND, NH, etc.

Please Note: Your new pump has been pressure tested at factory with clean water before shipping. You may notice trace amounts of clean water in pre-installed tube assembly. This is part of our stringent quality assurance program at Blue-White Industries.

1.1Available Models

	Feed Rate	Max	Max	Max	A2 Model Numbers
		Speed	Pressure	Temperature

Tygothane® A2 Tube Pumps

Meets FDA criteria for food |			Resistant to oils, greases and fuels
	GPH	LPH	ML/Min	RPM	PSI (bar)	F (C)	115V AC	230V AC	220V AC
.04 - 4.0		.15 - 15.2	3 - 253	130	65 (4.5)	130 (54)	A2V24-*GE A2V25-*GE A2V26-*GE
.09 - 9.3		.35 - 35.2	6 - 587	130	65 (4.5)	130 (54)	A2V24-*GG	A2V25-*GG	A2V26-*GG

* Inlet/outlet connection type

S = 3/8” OD x 1/4” ID tubing compressions type connections M = ½” male NPT

C-= 3/4” tri-clamp connections

!Flex-Pro Pumps motor speed is linear over entire 1% to 100% adjustment range.

!Output versus pressure is nearly linear in all models. Larger tubes exhibit greater losses.

!For optimum tube life, specify pump to operate at lowest possible RPM and pressure.

!Feed rates taken in laboratory environment with clean water after 20 minute tube break-in period with a 3 foot (1 meter) suction lift.

Page 4

Flex-Pro

2.0Specifications

2.1Materials of construction

Flex-Pro

Page 5

3.0Features

Peristaltic pump design does not have valves that can clog requiring maintenance.

Self priming - even against maximum line pressure. By-pass valves are not required. Cannot vapor lock or lose prime. Variable speed DC motor.

Rated for continuous duty (24X7).

Specially engineered tubing for long life at high pressures. Meets FDA 21 CFR requirements for food contact applications.

Patented Tube Failure Detection (TFD) system. Senses tube failure by detecting chemical in pump head. Backlit LCD displays motor speed, input signal values, service and alarm status.

CNC precision machined squeeze rollers and CNC machined alignment rollers for optimum squeeze, unparalleled accuracy, and tube life.

Heavy duty rotor - single piece plastic rotor means no flexing and increased accuracy with no metal springs or hinges to corrode.

Inject at maximum pressure in either direction (clockwise and counter clockwise).

Compatible with Blue-White’s output Flow Verification Sensor (FVS) system.

3.1Agency Listings

This pump is ETL listed to conforms to the following:

UL Standard 778 as a motor operated water pump

CSA Standard C22.2 as process control equipment

This pump complies to the Machinery Directive 98/37/EC, BS EN 60204-1, Low Voltage Directive 73/23/EC BS EN 61010-1, EMC Directive 89/336/EC, BS EN 50081-1/BS EN 50082-1.

Enclosure Rating:

NEMA 4X: Constructed for either indoor or outdoor use to provide a degree of protection to personnel against incidental contact with enclosed equipment; to provide a degree of protection against falling dirt, rain, sleet, snow, windblown dust, splashing water, and hose-directed water; and that will be undamaged by external formation of ice on enclosure.

IP66: No ingress of dust; complete protection against contact. Water projected in powerful jets against enclosure from any direction shall have no harmful effects.

Page 6

Flex-Pro

4.0Installation

CAUTION

Risk of chemical overdose. Be certain pump does not overdose chemical during backwash

!and periods of no flow in circulation system.

	CAUTION	Always wear protective clothing, face shield, safety glasses and gloves when working on or
	!	near your metering pump. Additional precautions should be taken depending on solution
		being pumped. Refer to MSDS precautions from your solution supplier.

CAUTION All diagrams are strictly for guideline purposes only. Always consult an expert before

!installing metering pump on specialized systems. Metering pump should be serviced by qualified persons only.

4.1Mounting Location

Choose an area located near chemical supply tank, chemical injection point, and electrical supply. Install pump where it can be easily serviced.

316SS Mounting brackets are included. Mount pump to a secure surface using enclosed mounting hardware.

Mount pump close to injection point. Keep inlet (suction) and outlet (discharge) tubing as short as possible. Longer discharge tubing increases back pressure at pump head.

Important! Install a back flow prevention check valve at discharge side of pump to prevent system fluid from flowing back through pump during tube replacement or if tube should rupture. Important!

A pressure relief valve is recommended at discharge of pump to prevent premature wear and damage to pump tube in event discharge line becomes blocked.

Flex-Pro does not require back pressure. Keep discharge pressure as low as possible to maximize tube life.

4.2Dimensions

Dim

Note: Optional Extended Bracket add 4.5” (11.43cm) to overall height (dimension A). See page 3 for details

Flex-Pro

Page 7

4.3Installing Injection Fitting and Strainer

!	CAUTION		Proper eye and skin protection must be worn when installing and servicing pump.
!	CAUTION		This Pump Has Been Evaluated for Use with Water Only.

Injection Fitting and Strainer for 1/4” (.64cm) I.D. Connection End Models

Install upward for best results

Injection Nose may be trimmed (removed) when injecting into small pipe.

Important!

Page 8

Flex-Pro

5.0Power Connections

WARNING Risk of electric shock – cord connected models are supplied with a grounding

	conductor and grounding-type attachment plug. To reduce risk of electric shock, be
	certain that it is connected only to a properly grounded, grounding-type receptacle.
WARNING	Electrical connections and grounding (earthing) must conform to local wiring codes. Be
	certain that a grounding conductor is connected to terminal T11-1 located in wiring
	compartment.
WARNING	Risk of electric shock - Disconnect electricity before removing wiring compartment
	cover.

Be certain to connect pump to proper supply voltage. Using incorrect voltage will damage pump and may result in injury. Voltage requirement is printed on pump serial label.

Input power: 115VAC 50/60 Hz 1.5 amp or 230/240VAC 50/60 Hz 0.7 amp.

Power switch located in Junction Box.

Use voltage your power cord is rated for.

Cord connected models are supplied with a ground wire conductor and a grounding type attachment plug (power cord). To reduce risk of electric shock, be certain that power cord is connected only to a properly grounded, grounding type receptacle.

Permanently connected models must be properly grounded. Be certain that a grounding conductor is connected to terminal T11-1 located in wiring compartment.

Never strap control (input / output) cables and power cables together.

Power Interruption: This pump has an auto-restart feature which will restore pump to operating state it was in when power was lost.

Note: When in doubt regarding your electrical installation, contact a licensed electrician.

WIRING COMPARTMENT COVER

POWER CORD OPTIONS

6 in.

Three power cord plug types available.

Power cord length is 6 feet (3.83 meters)

(152 mm) Ø .50

Ø .84 in.

(12.7 mm)

(21.3 mm)

2-PLCS.

3-PLCS.

115V 60Hz	230V 60Hz	240V 50Hz
NEMA 5/15 (USA)	NEMA 6/15 (USA)	CEE 7/VII (EU)
max: 125V AC	max: 250V AC	max: 250V AC

Included cable and conduit connectors:

QTY. DESCRIPTION

Flex-Pro

Page 9

5.1Wiring Terminals and I/O Schematics

OUTPUT

P1

N.C. COM

N.O.

T6

4-20mA

T3

REMOTE

INPUT

LINE

NEUTRAL

POWER

OUT

2

3

(-) 1 2(+)

2

(HOT)

(COMMON)

GROUND

1

IN

T7

1 DRY

RELAY

RMT

T11

3 COM

3

2

T2 DIR

1

1

4-20(+)

F1 FUSE 5A SLOW

1

(+)

2

2MotorActive

BLOW (20 X 5MM)

TO COM

(-)

3

3

POWER

BOARD

PLS (-)

232-RS

T12

FVS

4

4

SIG(+)

5

(-)

5

T4

T1

WARNING Risk of electric shock - All wiring must be insulated and rated 300V minimum.

Terminals T1 Thru T8	Power Input Terminal T11
Plug type	Plug type
16 - 24 AWG	14 - 30 AWG

	FUNCTION	TERM	PIN #	RATING	ELECTRICAL SP.
	INPUT:	T1	1	(+) POSITIVE	120 OHM
	4-20 mA				IMPEDANCE, NON
					POWERED LOOP
		T1	3	(-) NEGATIVE
	INPUT:	T1	3	(-) NEGATIVE	0-1000 HZ MAX.
	FREQUENCY, AC
	SINE WAVE, TTL,
	CMOS	T1	4	(+) POSITIVE
	INPUT:	T4	3	(+) POSITIVE
	FVS SYSTEM
	(FLOW VERIFICATION	T4	4	SIGNAL
	SENSOR)
	FV SENSOR ONLY	T4	5	(-) NEGATIVE
	INPUT:
	FVS SYSTEM
	(FLOW VERIFICATION	T4	4	SIGNAL
	SENSOR)
	FS or FP MICRO-FLO	T4	5	(-) NEGATIVE
	FLOW METER ONLY

BLOCK DIAGRAM

Single or dual pump (series) input.		ACTIVE 4-20mA			+
Loop voltage must not exceed 24 Volts.		TRANSMITTER			-
		14-20(+)		SOURCE
	-
FREQUENCY		2Motor	Active
TRANSMITTER		3(-)	GND (-)
SOURCE	+	4PLS	PULSE
		5
	T1
	BLUE-WHITE			RED (+)
	FVS SENSOR			BARE
				BLACK (-)
	BLUE-WHITE			SIGNAL
	MICRO-FLO
	FLOWMETER
	PULSE OUTPUT			NEGATIVE (-)

1	4-20(+)
2MotorActive
3	(-)
4	PLS
5
T1
3	(+)
4	SIG
5	(-)
T4 FVS
3	(+)
4	SIG
5	(-)
T4 FVS

4-20(+)

GND (-)

PWR (+) SIGNAL GND (-)

PWR (+) SIGNAL GND (-)

INPUT:	T3	1	(+) POSITIVE	(-)
REMOTE
START / STOP
(DRY CONTACT C.)	T3	2	(-) NEGATIVE
				(+)

INPUT:	T3	2	(+) POSITIVE					T3		REMOTE
REMOTE										IN
										1 DRY
START / STOP										2 RMT
(WET CONTACT C.)	T3	3	(-) NEGATIVE
										3 COM
OUTPUT:	T6	2	(+) POSITIVE				T6	4-20	(-)1 2(+)
4-20 mA
	T6	1	(-) NEGATIVE
OUTPUT:	T7	1	NORM. CLOSED Form C						1	2	3
									N.C. COM		N.O.
RELAY, 3 AMP				3 AMP MAX AT	SWITCH LOAD	NC	T7
	T7	2	COMMON	250 VAC,	3 AMP MAX @ 250V AC	C	RELAY
				3 AMP MAX AT	3 AMP MAX @ 30V DC			OUT
	T7	3	NORM. OPEN	30 VOLT DC		NO

OUTPUT:	T1	2	SIGNAL	5 TO 24 VDC	CLOSED WHILE MOTOR	4.7K OHM	1	4-20(+)
OPEN COLLECTOR									Active	MOTOR
					IS ENERGIZED		2Motor
										ACTIVE
MOTOR ACTIVE	T1	3	COMMON			NEGATIVE (-)	3	(-)		GND (-)
							4	PLS

50 / 60 HZ

LINE

NEUTRAL

POWER

5

POWER

INPUT:

T11

1

GROUND

AC

T1

115V OR 230VAC

(HOT) (COMMON) GROUND

POWER

T11

3

LINE (HOT)

MANUAL SWITCH

115V TO 230V

POWER

VOLTAGE

T11

2

NEUTRAL

100W

T11

SWITCH

S1

VOLTAGE

FROM

SWITCH

FUSE

F1

N/A

5 AMP

5ASLOW BLOW

(20 X 5MM)

Page 10

Flex-Pro

6.0How to Operate Flex-Pro - Control Pad

Tube Life Timer

To view amount of run time hours on currently installed tube. START + DOWN arrow displays current pump tube timer.

Hold down START button, then press and release DOWN arrow.

START

Flex-Pro

Page 11

6.1Mode Descriptions

Mode 0 - Setup	Mode 0
Press and Hold to configure:		0	SEt
ŸRemote Start / Stop
ŸTFD (Tube Failure Detection) sensitivity
ŸFVS (Flow Verification Sensor) time delay - requires sensor
Ÿ4-20 mA output, available on certain models
Mode 1 - Manual	Mode 1
Run pump locally by selecting pump speed (1 - 100%).	1		SPEED
ŸControl speed by using up or down arrows after start button is			OFF
pressed.
ŸControl speed by entering Mode 1 setup and selecting desired

pump speed (1 - 100%)

Mode 2 - 4-20 mA Input Signal

Mode 2

Run pump remotely via external 4-20 mA signal.

ŸPress and Hold “Select Run Mode” button with Mode 2 selected to configure settings.

ŸSelect Mode 2 and press START button to allow pump to be controlled by external 4-20mA signal.

2 mA

OFF

Hz

Hz

ON