Hydrotech MP Series PULSAtron User Manual

Series MP

ELECTRONIC METERING PUMPS

Installation Operation Maintenance Instruction

READ ALL WARNINGS CAREFULLY

BEFORE INSTALLING

SAFETY INSTRUCTIONS

When using chemical feed pumps, basic safety precautions should always be followed to reduce risk of fire, electric shock, and personal injury. Failure to follow these instructions could result in death or serious injury.

READ ALL INSTRUCTIONS

*** : Secure chemicals & metering pumps, making them inaccessible to children & pets. *** DO NOT PUMP FLAMMABLE LIQUIDS.

*** Do not cut the plug or ground lug off the electrical cord. Consult a licensed electrician for proper installation

or replacement.

** : Always wear protective clothing, including gloves and safety glasses, when working on or near

chemical metering pumps.

** Inspect tubing regularly for cracking or deterioration and replace as necessary. (Always wear protective

clothing and safety glasses when inspecting tubing.)

** Use CAUTION to keep fingers away from rotatiing parts. ** If pump is exposed to direct sunlight, use a U.V. resistant tubing. ** Follow directions and warnings provided from the chemical manufacturer. The user is responsible for

determining the chemical compatibility with the chemical feed pump.

** Make sure the voltage on the pump name tag matches the installation voltage. If pump fails to start, check line

voltage. ** Consult with local health officials and/or qualified water conditioning specialists when treating potable water. ** Always depressurize system prior to installation or disconnecting the metering pump tubing. ** If injection point is lower than the chemical tank and pump, install an anti-siphon valve. ** DO NOT MODIFY PUMP. This poses a potentially dangerous situation and will void the warranty. * : All pumps are factory tested with water. Remove tubing and thoroughly dry if the chemical

being pumped will react with water (for example sulfuric acid). * Hand tighten plastic connections (Do not use wrench). * Consult licensed plumber and electrician before installation to conform to local codes. * NOTE: For accurate volume output, pump must be calibrated under all operating conditions.

TABLE OF CONTENTS

Page

SAFETY INSTRUCTIONS................................................................................................................................. 2

INTRODUCTION ............................................................................................................................................... 3

UNPACKING THE PUMP..................................................................................................................................5

PRECAUTIONS FOR OPERATION...................................................................................................................5

INSTALLATION, PIPING AND WIRING............................................................................................................7

DESCRIPTION OF CONTROLS AND OPERATION........................................................................................13

CONTROL OPTIONS ...................................................................................................................................... 14

RELAY SETTINGS ......................................................................................................................................... 15

ALARMS......................................................................................................................................................... 16

CONTROL REFERENCE SUMMARY ............................................................................................................. 17

START-UP AND OPERATION ........................................................................................................................ 20

MAINTENANCE .............................................................................................................................................. 23

TROUBLESHOOTING ..................................................................................................................................... 25

EXPLODED VIEW DRAWINGS .................................................................................................................... 27

PUMP SPECIFICATIONS .............................................................................................................................. 30

REPAIR SERVICE ......................................................................................................................................... 31

INTRODUCTION

These installation, operation and maintenance instructions cover your electronic metering pump. Refer to the pump nameplate to determine the actual model.

MM PRINCIPLE OF OPERATION

Diaphragm metering pumps are used to dispense chemicals or fluids. This is achieved by an electromagnetic drive mechanism (solenoid) which is connected to a diaphragm. When the solenoid is pulsed by the control circuit, it displaces the diaphragm which, through the use of check valves, moves the fluid out the discharge under pressure. When the solenoid is deenergized it returns the diaphragm and pulls more fluid into the pumphead and the cycle repeats.

The stroke rate of the pumps is controlled via the touchpad and present status is indicated by the LCD display. The stroke length is controlled via the stroke length knob.

MM MATERIALS OF CONSTRUCTION

The wetted materials (those parts that contact the solution being pumped) available for construction are Glass filled polypropylene, PVC, SAN, Hypalon, Viton, Teflon, 316 Stainless Steel, PVDF, Ceramic and Alloy C. These materials are very resistant to most chemicals. However, there are some chemicals, such as strong acids or organic solvents, which cause deterioration of some elastomer and plastic parts, such as the diaphragm, valve seats, or head. Consult Chemical Resistance Guide or Supplier for information on chemical compatibility.

Various manufacturers of plastics, elastomers and pumping equipment publish guidelines that aid in the selection of wetted materials for pumping commercially available chemicals and chemical compounds. Two factors must always be considered when using an elastomer or plastic part to pump chemicals. They are:

1. The temperature of service: Higher temperatures increase the effect of chemicals on wetted materials. The increase varies with the material and the chemical being used. A material quite stable at room temperature might be affected at higher temperatures.

2. Material choice: Materials with similar properties may differ greatly from one another in performance when exposed to certain chemicals.

MM MANUFACTURER’S PRODUCT WARRANTY

The manufacturer warrants its equipment of its manufacture to be free of defects in material or workmanship. Liability under this policy extends for eighteen (18) months from the date of purchase or one ( 1 ) year from date of installation or whichever comes first. The electronic components will be covered under this policy for a period which extends for twenty four (24) months from the date of purchase. The manufacturer’s liability is limited to repair or replacement of any device or part which is returned, prepaid, to the factory and which is proven defective upon examination. This warranty does not include installation or repair cost and in no event shall the manufacturer’s liability exceed its selling price of such part.

The manufacturer disclaims all liability for damage to its products through improper installation, maintenance, use or attempts to operate such products beyond their functional capacity, intentionally or otherwise, or any unauthorized repair. Replaceable elastomeric parts are expendable and are not covered by any warranty either expressed or implied. The manufacturer is not responsible for consequential or other damages, injuries or expense incurred through use of its products.

The above warranty is in lieu of any other warranty, either expressed or implied. The manufacturer makes no warranty of fitness or merchantability. No agent of ours is authorized to make any warranty other than the above.

The European Union Warranty address is listed below, however, please note that the seller should be contacted first.

Steigar 24 NL 1351 AB Almere Netherlands

MM EUROPEAN TECHNICAL FILE LOCATION

P.O. Box 91 Washington NE37 1YH United Kingdom

MM UNPACKING THE PUMP

Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damages should be reported immediately to the carrier and to the seller of the equipment.

The carton should contain:

- Metering Pump

- Clear Flexible Suction Tubing*

- Stiff White Discharge Tubing*

- Footvalve/Strainer Assy.*

- Backpressure Injection Valve Assy.

- One Instruction Book that you are now reading

- Bleed Valve Assembly* (most models)

* These items are included with the standard pump. Items may or may not be included depending on model.

Make sure that all items have been removed from the shipping carton before it is discarded.

PRECAUTIONS FOR OPERATION

Each Electronic Metering Pump has been tested to meet prescribed specifications and safety standards. Proper care in handling, installation and operation will help in ensuring a trouble free installation.

Please read all these cautionary notes prior to installation and start-up of your metering pump.

1. Important: Pump must be installed and used with supplied back pressure/injection valve.

Failure to do so could result in excessive pump output flow.

2. Handle the pump with care. Dropping or heavy impact causes not only external damage to the pump,

but also to electrical parts inside.

3. Install the pump in a place where the ambient temperature does not exceed 40°C (104°F). The pump

is water resistant and dust proof by construction and can be used outdoors, however do not operate the pump submerged. To avoid high internal pump temperatures, do not operate in direct sunlight.

4. Install the pump in a place convenient for its future maintenance and inspection, then fix it to prevent

vibration.

5. Protective caps must be removed prior to installing tubing onto valve assemblies. Use tubing of

specified size. Connect the tubing to the suction side securely to prevent the entrance of outside air. Make sure that there is no liquid leakage on the discharge side.

6. Be careful to check that the voltage of the installation matches the voltage indicated on the pump nameplate. Each pump is equipped with a three prong plug. Always be sure the pump is grounded. To disconnect, do not pull wire but grip the plug with fingers and pull out. Do not use the receptacle in common with heavy electrical equipment which generates surge voltage. It can cause the failure of the electronic circuit inside the pump.

7. Tampering with electrical devices can be potentially hazardous. Always place chemicals and pump installation well out of the reach of children.

8. Never repair or move the metering pump while operating. Always disconnect electrical power. For

safety, always wear protective clothing (protective gloves and safety glasses) when working on or near chemical metering pumps.

9. An air bleed valve is available for most models with tubing connections. Air purges should be performed when the pump chamber contains no fluid at the time of start-up. As a safety measure, connect the return tubing to the air bleed valve and bypass fluid back to storage tank or a suitable drain.

10. Chemicals used may be dangerous and should be used carefully and according to warnings on the label. Follow the directions given with each type of chemical. Do not assume chemicals are the same because they look alike. Always store chemicals in a safe location away from children and others. We cannot be responsible for the misuse of chemicals being fed by the pump. Always have the material safety data sheet (MSDS) available for any fluid being pumped.

11. All pumps are pretested with water before shipment. Remove head and dry thoroughly if you are pumping a material that will react with water, (i.e. sulfuric acid, polymers). Valve seats, ball checks, gaskets, and diaphragm should also be dried. Before placing pump into service, extreme care should be taken to follow this procedure.

12. Valve cartridges are stamped to indicate fluid flow direction. Always install so that markings read from top to bottom, with the arrow pointing in the direction of flow.

13. When metering hazardous material DO NOT use plastic tubing, strictly use proper rigid pipe. Consult supplier for special adapters or valve assemblies.

14. Pump is NOT to be used to handle or meter flammable liquids or materials.

15. Standard white discharge tubing is not recommended for installations exposed to direct sunlight. Consult supplier for special black tubing.

16. Factory will not be held responsible for improper installation of pump, or plumbing. All cautions are to be read thoroughly prior to hook-up and plumbing. For all installations a professional plumber should be consulted. Always adhere to local plumbing codes and requirements.

17. When using pump with pressurized systems, make sure the pressure of the system does not exceed the maximum pressure rating on the pump nameplate. Be sure to de-pressurize system prior to hook up or disconnecting the metering pump.

18. Electronic power modules are equipped with automatic reset thermal overload devices and may reset unexpectedly.

19. The pump is designed to operate using a backpressure/injection valve. If the discharge point is below the liquid level of the source or if the discharge pressure is less than the suction pressure, siphoning may occur. To correct this condition, install an anti-siphon valve or other anti-siphon device. Check local regulations which may apply. (Ref. Figure G1).

20. If the power cord is unplugged or in the event of electrical power interruption while the pump is operating, the pump will remember its last operating state for years and will resume operation as before, whenever power is restored.

INSTALLATION, PIPING AND WIRING

The metering pump should be located in an area that allows convenient connections to both the chemical storage tank and the point of injection. The pump is water resistant and dust proof by construction and can be used outdoors, however do not operate submerged. Avoid continuous temperatures in excess of 40°C (104°F). To do otherwise could result in damage to the pump.

MOUNTING

Typical mounting arrangements are shown in Figures B to E.

Important: Injection point must be higher than the top of the solution supply tank to prohibit

gravity feeding, unless a suitable backpressure is always present at the injection point. Installation of an antisiphon valve will prohibit gravity feeding.

1. For wall or shelf mounting, refer to Figure E. Connect suction tubing to suction valve of chemical pump. Suction valve is the lower valve. Tubing should be long enough so that the footvalve/strainer assembly hangs about 1-2 inches (2.5 - 5 cm) above the bottom of chemical tank. To keep chemical from being contaminated, the tank should have a cover.

2. Flooded suction mounting (installing the pump at the base of the chemical storage tank, Figure C) is the most trouble free type of installation and is recommended for very low output requirements. Since the suction tubing is filled with chemical, priming is accomplished quickly and the chance of losing prime is reduced.

To mount pump, drill 4 holes of .25" (6.3 mm) diameter in the shelf as shown in the dimension drawing (Figure F). Attach pump securely using four #10 bolts and nuts.

3. The pump can be mounted to a wall as shown in Figure D. A wall mount bracket kit is available which includes all necessary hardware to mount the pump to the wall. Mounting the pump other than as shown in Figure D defeats the purpose of the housing drain. Mounting dimensions for the pump are provided in Figure F for reference.

4. The pump can be mounted on top of a solution tank as shown in Figure E. Install chemical pump on the cover. Insert suction tubing through the center hole and cut tubing so foot valve/strainer hangs about 1 or 2 inches (2.5 - 5 cm) above the bottom of the tank. Mount the chemical pump rigidly by drilling four .25" (6.3 mm) holes and using four #10 screws and nuts.

5. USE AN ANTI-SIPHON VALVE IN THE DISCHARGE LINE whenever the fluid pressure in the discharge line is below atmospheric pressure. This can occur if the injection point is on the suction side of a water pump or against a "negative" head such as when feeding down into a well, SEE FIGURE G1.

PIPING

1. Use provided tubing of specified size for connection. Connect tubing securely to prevent leakage of chemical and the entrance of air. Since plastic nuts are used for fittings, they should not be tightened excessively i.e. hand tighten only. NPT suction and discharge valves must NOT be overtightened. Hold fittings in place while adding piping and fittings. NPT suction and discharge valves should only be tightened 25 to 35 in. lbs. (4.46 to 6.25 kg/cm).

2. If the air bleed valve assembly is being used, a return line (tubing) should be securely connected and routed back to the storage tank. To avoid possible injury from chemicals do not attempt to prime using a bleed

valve without installing a return line.

3. To maintain metering performance, a backpressure/injection valve is provided. The injection valve must be installed in the discharge line. Best practice is to install the injection valve at the point of chemical injection.

4. If the discharge tubing is going to be exposed to direct sunlight, black tubing should be used instead of the standard white translucent tubing supplied with each pump. To obtain, contact supplier.

5. To prevent clogging or check valve malfunction always install a strainer assembly to the end of the suction tubing (Figure E). This footvalve/strainer assembly should always be installed 1 to 2 inches (2.5 - 5 cm) above the bottom of the chemical tank. This will help prevent clogging the strainer with any solids that may settle on the tank bottom. The chemical tank and footvalve/strainer should be cleaned regularly, to ensure continuous troublefree operation. If the chemical being pumped regularly precipitates out of solution or does not dissolve easily or completely (e.g. calcium hydroxide), a mixer should be used in the chemical tank. These are readily available in many motor configurations and mountings. To obtain, contact supplier.

6. A flooded suction (tank liquid level always at a higher elevation than the pump) is recommended when pumping sodium hypochlorite (NaOCI) and hydrogen peroxide (H2O2) etc. which are liable to produce air bubbles. Maintaining a low liquid temperature will also help eliminate this problem.

7. Pipe corrosion can result if dilution at the injection point does not occur rapidly. This problem is easily prevented by observing this simple rule: install injection fitting so that the end is in the center of the flow stream of the line being treated. Trim injector tip as required. See Figure H. Note: Extended injection assemblies are available for large water lines. Consult your supplier for more information.

WIRING

1. -- Risk of electrical shock. This pump is supplied with a three prong grounding type power plug. To reduce risk of electric shock, connect only to a properly grounded, grounding type receptacle.

2. The metering pump should be wired to an electrical source which conforms to those on the pump nameplate. (Applying higher voltage than the pump is rated for will damage the internal circuit.)

3. In the electronic circuit of the control unit, measures for surge voltage are made by means of surge absorbing elements and high voltage semiconductors. Nevertheless, excessive surge voltage may cause failure in some areas. Therefore, the receptacle should not be used in common with heavy electrical equipment which generates high voltage. If this is unavoidable, however, measures should be taken by (a) the installation of a surge absorbing element (varistor of min. surge resistance 2000A) to the power supply connection of the pump, or (b) the installation of a noise suppression transformer.

4. In the event of electrical power interruption during pump operation, the pump will remember its setting and automatically resume operation as before, whenever power is restored. If a manual reset is required to resume operation, the electrical circuit serving the pump must be suitably wired. Latching power relays which "drop out" upon loss of power, requiring manual reset, are typically used for this purpose.

WELL PUMP SYSTEM INSTALLATION

1. Ensure that the metering pump voltage matches the voltage of the well pump. Typical well pump electrical circuits are shown in Figure J. All electric wiring should be installed in accordance to local electrical codes by a licensed electrician.

2. Install the backpressure/injection (Figure I) on the discharge side of the metering pump into a tee which is installed into the water line going to the pressure tank. Typical installations are found in figures G1, G2 and G3.

Pumps carrying the "ETL Sanitation' approval (tested to NSF standard 50) are listed for swimming pools, spas, and hot tubs, and when proper materials are selected, are capable of handling but not limited to the following chemical solutions:

12% ALUMINUM SULPHATE 5% SODIUM CARBONATE 10% SODIUM HYDROXIDE 2% CALCIUM HYPOCHLORITE

12.5% SODIUM HYPOCHLORITE 10% HYDROCHLORIC ACID

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