Burkert 7800 User Manual
CONTENTS
Page
1. General description 4
1.1 Applications 4
1.2 Type key 5
2. Technical data 6
2.1 Mechanical data 6
2.2 Electrical data 6
2.3 Input/output data 6
2.4 Dimensions 7
3. Installation 7
3.1 Safety instructions 7
3.2 Installation environment 7
3.3 Installation of pump 7
3.4 Installation example 8
3.5 Electrical connection 8
3.6 Connection overview 9
4. Functions 10
4.1 Control panel 10
4.2 Start/stop of pump 11
4.3 Priming/venting of pump 11
4.4 Level control 11
4.5 Indicator lights and alarm output 11
4.6 Fieldbus communication 12
4.7 Menu 13
4.8 Operating modes 14
4.9 Manual 14
4.10 Pulse 14
4.11 Analog 14
4.12 Timer 16
4.13 Batch 17
4.14 Anti-cavitation 17
4.15 Capacity limitation 18
4.16 Counters 18
4.17 Resetting 19
4.18 Return 19
4.19 Language 19
4.20 Input setup 20
4.21 Measuring units 21
4.22 Dosing monitoring 22
4.23 Control panel lock 23
5. Start-up 24
6. Calibration 25
6.1 Direct calibration 26
6.2 Indirect calibration 27
6.3 Check calibration 28
7. Maintenance 28
8. Service 28
9. Fault finding chart 29
10. Disposal 29
1. General description
The Buerkert 7800 dosing pump is a self-priming diaphragm pump.
The pump consists of:
•a cabinet incorporating the drive unit and elec-
tronics,
•a dosing head with back plate, diaphragm,
valves, connections and vent valve,
•a contr ol panel incorporating display and buttons .
The control panel can be fitted either to the end or
to the side of the cabinet.
Being equipped with a stepper motor, this dosing
pump is unique in its field. The stepper motor offers
the possibility of varying the capacity by changing
the duration of the dosing stroke.
Furthermore, the motor is controlled in such a way
that the dosing gets as even and constant as possible, irrespective of the capacity range in which the
pump is operating.
This is carried out as follows:
The speed of the suction stroke is kept constant and
the stroke relatively short, irrespective of the capacity . Contrary to conv entional pumps, which generate
the dosing stroke as a short pulse, the duration of
the dosing stroke will be as long as possible. Thus,
an even dosing without peak values is ensured. As
the pump is always dosing at full stroke length, it ensures the same high accuracy and suction capability,
irrespective of the capacity, which is infinitely variable in the ratio of 1:1000.
The pump features an LCD display and a userfriendly control panel which gives access to the
pump functions.
1.1 Applications
The 7800 dosing pump is designed for handling
chemicals within the following ranges of applications,
among others:
• Drinking water treatment.
• Wastewater treatment.
• Swimming pool water treatment.
• Boiler water treatment.
• Cooling water treatment.
• Process water treatment.
• Washing systems.
Before beginning installation procedures,
these installation and operating instructions should be studied carefully. The installation and operation should also be in
accordance with local regulations and accepted codes of good practice.
4
2. Technical data
2.1 Mechanical data
Maximum capacity without anti-cavitation *
Maximum capacity with anti-cavitation *
1
[l/h] 2.5 7.5 12 18.5 48
1
[l/h] 1.8 5.6 9 14.5 37
Maximum pressure [bar] 18 10 6 6.2 2.6
Maximum stroke rate per minute [stroke/min.] 180 180 180 151 151
Maximum suction lift during operation [m] 6
Maximum suction lift when priming with wet valves [m] 1.8 3 3 3 3
Maximum viscosity with spring-loaded valves *
Maximum viscosity without spring-loaded valves *
[mPas]
2
[mPas] 500 500 500 500 100
Diaphragm diameter [mm] 28 38 42.5 55 77
Liquid temperature [°C] 0 to 50
Ambient temperature [°C] 0 to 45
Accuracy of repeatability ±1%
Sound pressure level [dB(A)] <70
*1 Irrespective of counter pressure
2
Maximum suction lift 1 metre
*
2.2 Electrical data
Supply voltage [VAC] 1 x 100-240
Maximum current consumption [A]
Maximum power consumption P
at 100 V 0.30 0.36
at 230 V 0.16 0.26
[W] 18 22
1
Frequency [Hz] 50-60
Enclosure class IP 65
Insulation class B
Supply cable 1.5 m H05RN-F with plug
2.3 Input/output data
The pump offers various input and output possibilities, depending on control variant.
Signal input
Voltage in level sensor input [VDC] 5
Voltage in pulse input [VDC] 5
Minimum pulse-repetition period [ms] 3.3
Impedance in analog 4-20 mA input [Ω] 250
Maximum loop resistance in pulse signal circuit [Ω] 350
Maximum loop resistance in level signal circuit [Ω] 350
Signal output
Maximum load of alarm relay output, at ohmic load [A] 2
Maximum voltage, alarm relay output [V] 250
7800-2 7800-8 7800-12 7800-19 7800-48
2
200 200 200 200 100
7800- 2, 8, 12 7800-19, 48
6
2.4 Dimensions
See dimensions at the end of these instructions.
All dimensions are in mm.
3. Installation
3.1 Safety instructions
• The liquid is under pressure and may be hazardous.
• When working with chemicals, local safety rules
and regulations must be observed (e.g. wear protective clothes).
• Before starting work on the dosing pump and system, disconnect the electricity supply to the pump,
ensuring that it cannot be accidentally switched
on. Before reconnecting the electricity supply,
make sure that the dosing hose is positioned in
such a way that any chemical left in the dosing
head is not ejected, thereby exposing persons to
danger.
• If the vent valve in the dosing head is used, it must
be connected to a hose which is led back to the
tank.
• When changing a chemical, make sure that the
materials of the dosing pump and system are resistant to the new chemical. If there is any risk of
chemical reaction between the two types of chemicals, clean the pump and system thoroughly before adding the new chemical.
Proceed as follows:
Place the suction tube in water and press the
button until residual chemical has been removed.
Note: 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 number of seconds will appear in
the display. The maximum value is 300 seconds.
100%
3.2 Installation environment
• Exposure to direct sunlight should be avoided.
This applies especially to pumps with plastic dosing heads, as this material can be damaged by
sunlight.
• If the pump is installed outside, an enclosure or
similar protection is required to protect the pump
against rain and similar weathers.
100%
3.3 Installation of pump
• See also the installation example in section 3.4.
• Note: The dosing head may contain water from
the factory test. If a liquid which must not come
into contact with water is to be dosed, it is recommended to let the pump run with another liquid to
remove the water from the dosing head before installation.
• Note: Tighten the bolts in the dosing head after
2 to 5 operating hours (torque 5 Nm).
• Always install the pump on the supporting foot
with vertical suction and discharge ports.
• Always use suitable tools for the mounting of plastic parts. Never apply unnecessary force.
• Make sure that the dosing pump and system are
designed in such a way that neither system equipment nor buildings are damaged in case of leakage from the pump or rupture of hoses/pipes. The
installation of leakage hoses and collecting tanks
is recommended.
• Make sure that the drain hole in the dosing head
points downwards, see fig. 1.
Note: It is important that the drain pipe/hole is not
inserted direct into the tank contents, as gasses
may penetrate into the pump.
Fig. 1
Drain hole
TM01 8420 5099
7
3.4 Installation example
The drawing in fig. 2 shows an installation example.
Fig. 2
The 7800 pump can be installed in many different ways. The sketch below shows a n example with sidefitted control panel. The tank is a Buerkert chemical tank with a Buerkert level control unit.
3.5 Electrical connection
• The electr ical connection of the pump should be
carried out by qual ified perso ns in accordance
with local regulations.
• For electr ical data of the pump, see section 2.2.
• Do not lay signal cables, if any, together with
power cables.
8
TM01 8421 0 204
3.6 Connection overview
Fig. 3
Alarm relay (control variant “AR” only)
“NO” black
“NC” blue
“Com” brown
5
4
4
5
1
3
2
Control cable,
see table below
1
3
2
4
1
3
Level cable,
see table below
2
3
1
4
Empty tank
Low level
Control input:
Number / colour 1 / brown 2 / white 3 / blue 4 / black 5 / grey Description
Function
Manual 2 2
Pulse 1 1
Pulse + external on/off 1 1 + 2 2
Analog – + mA signal
Analog + external on/off 2 2 – + mA signal
Timer + external on/off 2 2
Batch 1 1
1 = Contact for pulse signal
2 = Contact for external on/off
Level input:
Number / colour 1 / brown 2 / white 3 / blue 4 / black
Low level Low level
Function
Low level Empty tank Low level + empty tank
Empty tank Empty tank
Dosing monitoring Dosing monitoring
TM01 8422 0603
9
4. Functions
4.1 Control panel
Fig. 4
Navigation/
settings,
see section 4.7
Maximum capacity
(priming),
see section 4.3
LCD display,
see section 4.7
ml/h
Navigation/
settings,
see section 4.7
Green
indicator light,
see section 4.5
Red
indicator light,
see section 4.5
Connection
alarm relay/bus.
Control variants
“AR”, “AP” and “AG”,
see sections 4.5 and
4.6
100%
M12 connection
pulse/analog input,
see section 4.4
level control,
see section 4.4
Menu,
see section 4.7
On/off button,
see section 4.7
Mains connectionM12 connection
TM01 8423 0100
10
4.2 Start/stop of pump
The pump can be started/stopped in two different
ways:
• Locally on the pump control panel.
• By means of an external on/off switch connected
to the pulse input. See connection overview in
section 3.6.
4.3 Priming/venting of pump
The pump control panel incorporates a button.
Press this button if the maximum pump 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.
During priming/venting, it is recommended to let the
pump run without a counter pressure or to loosen the
vent valve by giving it a 1/8 to 1/4 turn.
Note: When the buttons and are pressed si-
multaneously, the pump can be set to run for a specific number of seconds at maximum capacity. The
remaining number of seconds will appear in the display. The maximum value is 300 seconds.
100%
100%
4.4 Level control
The pump can be fitted with a level control unit for
monitoring of the chemical level in the tank.
The pump can react to two level signals. The pump
will react differently, depending on the influence on
the individual level sensors.
Level sensors Pump reaction
Upper sensor
activated
(closed contact)
Lower sensor
activated
(closed contact)
• Red indicator light is on.
• Pump running.
• Alarm relay activated.*
• Red indicator light is on.
• Pump stopped.
• Alarm relay activated.*
* Control variant “AR” only.
See section 3.6 for connection of the level control
unit and alarm output.
4.5 Indicator lights and alarm output
The green and red indicator lights on the pump are
used for operating and fault indication.
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
Pump
running
Set to stop
Green
LED
On Off
Flash-
ing
Red
LED
Off
Display
Normal
indication
Normal
indication
Alarm
output
132
NC NO C
132
NC NO C
Pump fault Off On EEPROM
23
1
NC NO C
Supply
failure
Off Off Off
132
NC NO C
Pump running, low
chemical
2
level
Empty
2
tank
Analog
signal
On On
Off On
Off On
< 2 mA
The dosed
quantity is
too small
according
to the signal from the
dosing
monitor
Overheating
1
Control variant AR only.
2
Requires connection to level sensors.
3
Requires activation of the dosing monitoring
function and connection to a dosing monitor.
On On
3
Off On
Normal
indication
Normal
indication
Normal
indication
Normal
indication
MAX.
TEMP.
23
1
NC NO C
23
1
NC NO C
23
1
NC NO C
23
1
NC NO C
23
1
NC NO C
1
11
4.6 Fieldbus communication
The pump can be configured for fieldbus applications.
The following bus types are available:
Control variant Bus type
AP Profibus
AG GENIbus
Separate instructions are supplied with each bus
type.
12
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