Burkert 7800 User Manual

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CONTENTS
Page
1. General description 4
1.1 Applications 4
1.2 Type key 5
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.
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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 [] 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
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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
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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
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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
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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
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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
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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.
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4.7 Menu
The pump features a user-friendly menu which is ac­tivated by pressing the button. During start-up, all texts will appear in English language. To select lan­guage, see section 4.19.
Fig. 5
See section 4.9 See section 4.23
All menu items are described in the following sec­tions. When appears at a menu item, it means that this item is activated. By selecting “RETURN” anywhere in the menu structure, you will return to the operating display without changes.
See section 4.10 See section 4.17
See section 4.11 See section 4.18
See section 4.12 See section 4.19
See section 4.13 See section 4.15
See section 4.14 See section 4.20
See section 6 See section 4.21
See section 4.16
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4.8 Operating modes
Note: The displayed l and ml values are only reliable
if the pump has been calibrated to the actual installa­tion, see section 6.
The pump can run in five different operating modes:
•Manual
•Pulse
•Analog
•Timer (internal batch control)
•Batch (external batch control)
See description in the following sections.
4.9 Manual
The pump is dosing as constantly and evenly as pos­sible, without any external signals.
Set the quantity to be dosed in l/h or ml/h. The pump automatically changes over between the measuring units.
Setting range: DME 2: 2.5 ml/h - 2.5 (1.8*) l/h
DME 8: 7.5 ml/h - 7.5 (5.6*) l/h DME 12: 12 ml/h - 12 (9*) l/h DME 19: 18.5 ml/h - 18.5 (14.5*) l/h DME 48: 48 ml/h - 48 (37*) l/h
* The figures in brackets indicate the maximum ca-
pacity when the anti-cavitation function is acti­vated.
Fig. 6
Set value
4.10 Pulse
The pump is dosing according to an external pulse signal, i.e. a water meter with pulse output or a con­troller.
Set the quantity to be dosed per pulse in ml/pulse. The pump adjusts its capacity according to two fac­tors:
• Frequency of external pulses.
• The set quantity per pulse. Setting range: DME 2: 0.000018 ml/pulse - 5 ml/pulse
DME 8: 0.000069 ml/pulse - 15 ml/pulse DME 12: 0.000111 ml/pulse - 24 ml/pulse DME 19: 0.000204 ml/pulse - 37 ml/pulse DME 48: 0.00530 ml/pulse - 96 ml/pulse
Fig. 7
Set quantity in ml/pulse
Actual capacity in ml/h or l/h
If the set quantity per pulse multiplied by the pulse frequency exceeds the pump capacity, the pump will run at maximum capacity. Excess pulses will be ig­nored and the “actual capacity” display will flash.
4.11 Analog
The pump is dosing according to an external analog signal. The dosed quantity is proportional to the input value in mA.
4-20 (default): 4 mA = 0%. 20-4: 4 mA = 100%. 0-20: 0 mA = 0%. 20-0: 0 mA = 100%.
See fig. 8. The capacity limitation will influence the capacity.
100% corresponds to the maximum capacity of the pump or the set maximum capacity, see section
4.15.
Fig. 8
100
80
60
40
20
20 mA = 100%. 20 mA = 0%. 20 mA = 100%. 20 mA = 0%.
[%]
0-20 mA
4-20 mA
0
0 4 8 12 16 20
[mA]
TM02 4498 1102
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Fig. 9
Value according to analog signal
If 4-20 mA or 20-4 mA is selected and the signal falls below 2 mA, the pump will indicate a fault. This situa­tion occurs if the connection is interrupted, for in­stance if the wire is damaged.
Change the analog mode as illustrated in fig. 10:
Fig. 10
Use the buttons
for navigation
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4.12 Timer
The pump is dosing the set quantity in batches at the maximum capacity or the set maximum capacity, see section 4.15.
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 1 minute. if the pump is stopped by means of the on/off button, empty tank or stop signal, see fig. 11.
During operation, “NX” will always count down from “IN” to zero. In this way, the remaining time until the next batch can always be read.
“IN” must be higher than the time required to perform one batch. If “IN” is lower, the next batch will be ig­nored.
In case of supply failure, the set quantity to be dosed, 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. In this way, the timer cycle will continue, but it has been delayed by the duration of the supply failure.
Fig. 11
NX
Setting range:
7800-2: 0.23 ml/batch - 5 l/batch 7800-8: 0.69 ml/batch - 15 l/batch 7800-12: 1.11 ml/batch - 24 l/batch 7800-19: 2.04 ml/batch - 37 l/batch 7800-48: 5.3 ml/batch - 96 l/batch
Only values corresponding to complete dosing strokes (according to the calibration factor) can be selected.
Example: If the calibration factor is 23.3 (= 0.233 ml/ stroke), the minimum settable value in timer or batch mode will be 0.233 ml -> the next will be 0.466 ml -> the next will be 0.699 ml, etc.
These steps will continue up to a value correspond­ing to 100 dosing strokes. Above this value, the set­ting range has standard steps as in other operating modes.
If the calibration factor is changed after setting of timer or batch mode, the pump will automatically re­calculate a new amount of dosing strokes per batch and change the display value to the nearest possible value compared to the first one set.
The internal timer continues even
Quantity per batch
IN
Fig. 12
TM01 8942 0900
Set quantity per batch
Set IN value in minutes
Set IN value in hours
Set IN value in days
Set NX value in minutes
Set NX value in hours
Set NX value in days
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4.13 Batch
The pump is dosing the set quantity in batches at the maximum capacity or the set maximum capacity, see section 4.15.
The quantity is dosed every time the pump receives an external pulse.
If the pump receives new pulses before the previous batch is performed, these pulses will be ignored.
Fig. 13
Quantity per batch
Pulse Pulse
The setting range is the same as for Timer, see sec­tion 4.12.
Fig. 15
Fig. 14
Set value per batch
4.14 Anti-cavitation
The pump features an anti-cavitation function. 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,
TM01 8947 0900
• in the case of a long suction tube and
• in the case of a high suction lift. The maximum pump capacity is reduced when this
function is selected. See section 2.1 Mechanical data.
Operating display
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4.15 Capacity limitation
This function offers the possibility of reducing the maximum pump 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 which is higher than the one stated in the display. This does not apply to the max­imum capacity button , see section 4.3.
Fig. 16
100%
Fig. 17
Total dosed quantity
Set maximum capacity
Operating display
4.16 Counters
The pump can display “non-resettable” counters for:
•“QUANTITY”
Accumulated value of dosed quantity in litres or US gallons.
•“STROKES”
Accumulated number of dosing strokes.
•“HOURS”
Accumulated number of operating hours.
•“POWER ON”
Accumulated number of times the electricity sup­ply has been switched on.
Total number of strokes
Total number of operating hours
Total number of starts
18
Operating display
Page 17
4.17 Resetting
When “DEFAULT” is activated, the pump will return to the factory settings.
Fig. 18
Note: The calibration is also set back to the default
setting. This means that a new calibration is required when the “DEFAULT” function has been used.
Operating display Operating display
4.18 Return
Fig. 19
The “RETURN” function makes it possible to return from any level in the menu to the operating display without changes after the menu functions have been used.
without changes
4.19 Language
The display text can be displayed in one of the fol­lowing languages:
• English
•German
•French
•Italian
• Spanish
• Portuguese
•Dutch
• Swedish
• Finnish
• Danish
•Czech
•Slovak
•Polish
• Russian
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Fig. 20
Operating display Operating display
4.20 Input setup
Fig. 21 shows all possible settings. The level and stop inputs can be changed from NO
(normally open) to NC (normally closed) function. If changed, the inputs must be short-circuited in nor­mal operation.
Fig. 21
Use the buttons
for navigation
Operating display without changes
For the analog input, one of the following signal types can be selected:
• 4-20 mA (default),
• 20-4 mA,
• 0-20 mA,
• 20-0 mA. See also section 4.11 Analog. Change the level input to an input for dosing monitor-
ing as illustrated in fig. 21.
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4.21 Measuring units
It is possible to select metric units (litre/millilitre) or US units (gallons/millilitre).
Metric measuring units:
In manual and analog modes, set the quantity to be dosed in litres per hour (l/h) or millilitres per hour (ml/h).
In pulse mode, set the quantity to be dosed in ml/pulse. The actual capacity is indicated in litres per hour (l/h) or millilitres per hour (ml/h).
For calibration, set the quantity to be dosed in ml per 100 strokes.
In timer and batch modes, set the quantity to be dosed in litres (l) or millilitres (ml).
• Under the “QUANTITY” menu item in the “COUNTERS” menu, the dosed quantity is indi­cated in litres.
Fig. 22
3 x
US measuring units:
In manual and analog modes, set the quantity to be dosed in gallons per hour (gph).
In pulse mode, set the quantity to be dosed in ml/pulse. The actual capacity is indicated in gallons per hour (gph).
For calibration, set the quantity to be dosed in ml per 100 strokes.
In timer and batch modes, set the quantity to be dosed in gallons (gal).
• Under the “QUANTITY” menu item in the “COUNTERS” menu, the dosed quantity is indi­cated in US gallons (gal).
Operating display Operating display
21
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4.22 Dosing monitoring
A dosing monitor is available as an accessory. Sepa­rate instructions are supplied with the monitor.
Fig. 23
Dosing stroke measured
Monitor mounted on the suction side of the pump
The dosing monitor is designed to monitor the dosing of liquids which may cause gas accumulation in the dosing 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 dosing 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 empty tank or gas in the dosing head.
TM02 2029 3201
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4.23 Control panel lock
It is possible to lock the buttons on the control panel to prevent malfunction 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.
If no code has been entered, a code must be set in the same way as the “NX” and “IN” values described in section 4.12.
If a code has already been entered, active digits are flashing.
If attempts are made to operate the pump in locked condition, “LOCKED” will appear in the display for 2 seconds, followed by “_ _ _ _”. A code must be en­tered. If the entering of a code has not been started within 10 seconds, the operating display without changes will appear.
Fig. 24
If a wrong code is entered, “LOCKED” will appear in the display for 2 seconds, followed by “_ _ _ _”. A new code must be entered. If the entering of a code has not been started within 10 seconds, the operat­ing display without changes will appear. This display will also appear if the entering of the correct code ex­ceeds 2 minutes.
If the locking function has been activated but the control panel is unlocked, the control panel will be locked automatically if it is not operated for 2 min­utes.
The locking function can also be reactivated by se­lecting “ON” in the “LOCK” menu. The previously en­tered code will then appear and must be re-entered by pressing the button four times. The code can also be changed.
The control panel can be unlocked either by means of the selected code or the factory code 2583.
The following buttons and inputs are still active when the panel is locked:
• Priming ( -button).
100%
• On/off button.
• All external inputs.
Operating display
Activating the locking function and locking the control panel:
1. Select “LOCK” in the menu.
2. Select “ON” by means of the buttons and and confirm with .
3. Enter or re-enter a code by means of the buttons
, and .
The locking function has now been activated and the control panel is locked.
Unlocking the control panel (without deactivating the locking function):
1. Press once. “LOCKED” appears in the display for 2 seconds, followed by “_ _ _ _”.
2. Enter the code by means of the buttons , and *.
The control panel has now been unlocked and will automatically be locked again if the control panel is not operated for 2 minutes.
Operating display
Deactivating the locking function:
1. Unlock the control panel as described above.
2. Select “LOCK” in the menu.
3. Select “OFF” by means of the buttons and and confirm with .
The locking function has now been deactivated and the control panel is unlocked.
* The panel can always be unlocked with code 2583.
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5. Start-up
1
2
100%
Step Action
Connect the hoses/pipes:
• Connect the suction and dosing tubes/pipes to the pump.
• Connect a tube to the vent valve, if required, and lead the hose to the tank.
Switch on the electricity supply:
• The display is on.
• The green indicator light is flashing (the pump has stopped).
• Select language, if required, see section 4.19.
3
Select the operating mode (see section 4.8):
• Manual.
•Pulse.
• Analog.
•Timer.
•Batch.
4
Connect the cables:
• Connect the control/level cables, if any, to the pump, see section 3.6.
5
Start the pump:
• Start the pump by pressing the on/off button.
100%
6
100%
• The green indicator light is permanently on.
Priming/venting:
• Press the button on the pump control panel and let the pump run without a counter pressure. Loosen the vent valve by giving it a 1/8 to 1/4 turn, if required. When the buttons and are pressed simultaneously during prim­ing, the pump can be set to run for a specific number of seconds at maximum capacity.
100%
100%
7
Calibration:
• When the pump has been primed and is running at the right counter pressure, calibrate the pump, see section 6.
If the pump is not operating satisfactorily, see section 9. Fault finding chart.
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Page 23
6. Calibration
It is important that the pump is calibrated after instal­lation to ensure that the correct value (ml/h or l/h) appears in the display.
The calibration can be carried out in three different ways:
Direct calibration (recommended). The dosed quantity of 100 strokes is measured di­rectly. See section 6.1.
Indirect calibration. A calibration factor selected from a table is used for the specific installation. This method can be used if it is not possible to carry out a direct cali­bration. Indirect calibration will never be as accu­rate as direct calibration. See section 6.2.
Check calibration. See section 6.3.
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6.1 Direct calibration
Before calibration, make sure:
• that the pump is installed with foot valve, injection
valve, etc. in the existing system.
• that the pump is running at the counter pressure it
is supposed to operate at (adjust the counter pres­sure valve, if required).
• that the pump is operating with the correct suction lift.
To carry out a direct calibration, proceed as follows:
Action Pump display
1. Prime the dosing head and the suction tubing.
2. Stop the pump. The green LED is flashing.
3. Fill a graduated glass with dosing liquid, Q
7800-2: approx. 40 ml 7800-19: approx. 500 ml 7800-8: approx. 150 ml 7800-48: approx. 1000 ml
.
1
7800-12: approx. 250 ml
4. Read and note the quantity Q
.
1
5. Place the suction tubing in the graduated glass.
Q
1
6. Go to the calibration menu, see section 4.7.
7. Press the button twice.
8. The pump is performing 100 dosing strokes.
9. The factory-calibration value appears in the display.
10.Remove the suction tubing from the graduated glass and read Q
11.Set the display value to Q
.
2
Q
d
Q
2
= Q1 – Q2.
d
12.Confirm with the button.
13.The pump is now calibrated and returns to the op­erating display.
26
Set value to Q
d
Operating display
Page 25
6.2 Indirect calibration
7800-8
7800-12
7800-19
7800-48
A value from the following table is to be added to the default factory calibration value in the display. To re­set the pump to the factory calibration value, activate the “DEFAULT” function, see section 4.17.
To use the values, the following must be fulfilled:
• The viscosity and density of the liquid to be dosed must not differ considerably from water at 20°C.
• A Grundfos installation kit or corresponding foot valve, injection valve and hose diameter must be used.
• The length of the dosing hose must not exceed 6 metres.
• The suction lift must lie between 0.1 and 1.5 me­tres.
Pump type
7800-2 1.4 1.1 0.8 0.5 0.2 -0.2 -0.6 -1.2 -1.8 -2.4 -3.0 -3.6
Adding the value:
Fig. 25
Values to be added to the calibration value at various counter pressures [bar]
0-1 1-2 2-3 3-4 4-5 5-6 6-8 8-10 10-12 12-14 14-16 16-18
3.52.72.01.20.4-0.4-1.6-3.1----
2.11.30.4-0.4-1.3-2.1-3.4-----
18.312.26.10-6.1-12.2-21.4-----
24.38.3-8.3---------
Set value to table value + display valu e
Operating display
Operating display without changes
27
Page 26
6.3 Check calibration
In check calibration, the calibration value is calcu­lated by reading the consumption of chemical in a specific period and comparing this with the number of dosing strokes performed in the same period.
This calibration method is very accurate and espe­cially suitable for check calibration after long periods of operation or if direct calibration is impossible. The calibration can for instance be carried out when the chemical tank is replaced or filled.
To carry out a check calibration, proceed as follows:
1. Stop the pump by pressing the button.
2. Read the counter and note the number of dosing
strokes, see section 4.16.
3. Read and note the quantity in the chemical tank.
4. Start the pump by pressing the button and let
it run for at least 1 hour. The longer the pump is operating, the more accurate the calibration will be.
5. Stop the pump by pressing the button.
6. Read the counter and note the number of dosing
strokes, see section 4.16.
7. Read and note the quantity in the chemical tank.
8. Calculate the dosed quantity in ml and the
number of dosing strokes performed during the operating period.
9. Calculate the calibration value as follows:
(dosed quantity in ml/dosing strokes) x 100.
10.Set the calculated value in the calibration menu
like for indirect calibration, see section 6.2.
7. Maintenance
The pump is maintenance-free. However, it is recom­mended to keep the pump clean.
The dosing pump is produced according to the high­est quality standards and has long life. The pump in­corporates wear parts such as diaphragm, valve seat and valve balls.
To ensure long life and to reduce the risk of distur­bance of operation, visual checks should be carried out regularly.
It is possible to order dosing heads, valves and dia­phragms in materials which are suitable for the spe­cific liquid to be pumped. See the product numbers at the end of these instructions.
8. Service
Before returning the pump to Buerkert for service, the safety declaration at the end of these instructions must be filled in by authorized personnel and at­tached to the pump in a visible position.
Note: If a pump has been used for a liquid which is injurious to health or toxic, the pump will be classi­fied as contaminated.
If Buerkert is requested to service the pump, it must be ensured that the pump is free from substances that can be injurious to health or toxic. If the pump has been used for such substances, the pump must be cleaned before it is returned.
If proper cleaning is not possible, all relevant infor­mation about the chemical must be provided.
If the above is not fulfilled, Buerkert can refuse to accept the pump for service. Possible costs of re­turning the pump are paid by the customer.
The safety declaration can be found at the end of these instructions (only in English).
Note: The replacement of the supply cable must be carried out by an authorised Buerkert service work- shop.
28
Page 27
9. Fault finding chart
Fault Cause Remedy
The dosing has stopped or the output is too low.
Pump dosing too little or too much.
Pump dosing irregu­larly.
Leakage from drain hole.
Frequent diaphragm failures.
Valves leaking or blocked. Check and clean valves. Valves incorrectly installed. Remove and fit valves. Check that the arrow
Suction valve or suction pipe/hose leaking or blocked.
Suction lift too high. Install the pump in a lower position.
Viscosity too high. Select the anti-cavitation function, see sec-
Pump out of calibration. Calibrate the pump, see section 6. Pump out of calibration. Calibrate the pump, see section 6.
Valves leaking or blocked. Check and clean the valves.
Diaphragm defective. Install a new diaphragm.
Diaphragm not fastened properly. Install a new diaphragm and ensure that the
Counter-pressure too high (meas­ured at the pump discharge port).
Sediment in dosing head. Clean/flush the dosing head.
on the valve casing is pointing in the liquid flow direction. Check that all O-rings have been fitted correctly.
Clean and seal the suction pipe/hose.
Install a priming tank.
tion 4.14. Install a pipe/hose with larger cross-section. Fit spring-loaded valves.
diaphragm is fastened properly. Check the system. Check the injection valve,
if required. Reduce the dosing stroke by fitting a pulsation dampener.
10. Disposal
Disposal of this product or parts of it must be carried out according to the following guidelines:
1. Use the local public or private waste collection
service.
2. In case such waste collection service does not
exist or cannot handle the materials used in the product, please deliver the product or any haz­ardous materials from it to your nearest Buerkert company or service workshop.
Subject to alterations.
29
Page 28
15
sectional drawing of the dosing head (7800-19 / -48)
14
13
2
18
4
5
3
6
7
8
10
9
11
12
TM01 9976 3500
30
Page 29
assembly / disassembly of dosing head and valves
31
Page 30
dimensions:
130
110
ml/h
D
160
100%
B
C
98
7800-2 7800-8 7800-12 7800-19 7800-48
A = [mm] 137 192 B = [mm] 239 294 C = [mm] 36 15 D = [mm] 168 188
50
A
TM01 9232 0900
32
Page 31
Page 32
Please copy, fill in and sign this sheet and attach it to the pump returned for service
We hereby declare that this product:
Product type:____________________________
Product number:_________________________
is free from hazardous chemicals, biological and radioactive substances
_________________ _________________ Date and signature Company stamp
60
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