Jesco FEDOS E 5, FEDOS DX 5, FEDOS E 8, FEDOS DX 17, FEDOS E 30 Operating Manual

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FEDOS E/DX

Piston Dosing Pump

Operating Manual

Read this operating manual before using the equipment. To be retained for future reference.

Dosing

Conveying

Control

Liquids Gases Systems

Contents

1. General and Safety Instructions ................................................................................................................................3

2. General .......................................................................................................................................................................7

2.1 Proper intended use .......................................................................................................................................... 7

2.2 Structure of the dosing pump ............................................................................................................................. 7

3. Function .....................................................................................................................................................................8

4. Dimensioned drawings ..............................................................................................................................................9

5. Technical data ..........................................................................................................................................................10

5.1 Electric motor data .......................................................................................................................................... 12

5.2 Technical data, ATE servomotor FEDOS E (optional) ............................................................................................ 13

6. Delivery characteristic curves ................................................................................................................................14

7. Installation ...............................................................................................................................................................15

7.1 General information ......................................................................................................................................... 15

7.2 Installation location .......................................................................................................................................... 16

7.3 Electrical connection of the dosing pump .......................................................................................................... 16

7.4 Wiring diagrams for ATE servomotor for stroke length adjustment ....................................................................... 18

7.5 Level monitoring .............................................................................................................................................. 19

7.6 Pressure control and safety valves .................................................................................................................... 19

7.7 Injection nozzle installation ............................................................................................................................... 20

7.8 Installation example ......................................................................................................................................... 20

8. Operation ..................................................................................................................................................................21

8.1 Stroke length adjustment ................................................................................................................................. 21

8.2 FEDOS DX operating elements.......................................................................................................................... 21

8.3 Switching on/off .............................................................................................................................................. 21

8.4 Operating mode selection ................................................................................................................................ 21

8.5 Alarm .............................................................................................................................................................. 22

8.6 Other settings.................................................................................................................................................. 23

8.7 Factory setting ................................................................................................................................................ 23

8.8 Connections and cable assignments ................................................................................................................. 23

9. Start-up ....................................................................................................................................................................25

9.1 Start up of FEDOS E with ATE servomotor .......................................................................................................... 25

10. Shutdown ...............................................................................................................................................................26

10.1 Disposal of old equipment .............................................................................................................................. 26

Device revision ............................................................................................................................................................26

11. Maintenance ..........................................................................................................................................................27

11.1 Lubrication .................................................................................................................................................... 27

11.2 Maintenance of the bearings .......................................................................................................................... 27

11.3 Maintenance of the ATE servomotor (optional) .................................................................................................27

11.4 Replacing the piston ...................................................................................................................................... 27

11.5 Valves ........................................................................................................................................................... 29

12. Explosion-proof dosing pumps .............................................................................................................................32

12.1 General ......................................................................................................................................................... 32

12.2 Special conditions.......................................................................................................................................... 32

13. Troubleshooting .....................................................................................................................................................33

14. Spare parts .............................................................................................................................................................34

15. External vent (optional) .........................................................................................................................................40

Index.............................................................................................................................................................................41

Declaration of no objection .........................................................................................................................................42

Warranty claim.............................................................................................................................................................43

CE declaration of conformity ......................................................................................................................................44

2 | Operating Manual FEDOS E/DX | Contents

1. General and Safety Instructions

1.1 General

This operating manual contains basic instructions to be followed during installation, operation and maintenance. It is therefore essential for the assembler and the relevant technical personnel/operating company to read this operating manual prior to installation and start-up. It must remain accessible at the place of installation of the system for reference at all times.

Besides the general safety instructions in this "Safety" section, the special safety instructions in the other sections are also to be followed.

1.2 Identiﬁcation of safety instructions in the operating manual

Failure to follow the safety instructions in this operating manual may result in personal injury or damage to the environment and the system. Safety instructions are identiﬁed by the following symbols:

DANGER!

Indicates an immediate danger. Failure to follow this instruction will lead to death or extremely serious injuries.

WARNING!

Indicates a potentially hazardous situation. Failure to follow this instruction may lead to death or severe injury.

CAUTION!

Indicates a potentially hazardous situation. Failure to follow this instruction may lead to minor injury or damage to property.

ATTENTION! or NOTICE!

Failure to follow these safety instructions may endanger the machine and its functions.

IMPORTANT!

This refers to additional information to facilitate operation and ensure the smooth running of the equipment.

Information attached directly to the dosing pump, such as

• cable markings

• markings for ﬂuid connections

must be followed without fail and must remain fully legible at all times.

1.3 Personnel qualiﬁcations and training

The personnel employed for operation, maintenance, inspection, and installation must be suitably qualiﬁed for this work. The responsibilities, areas of competence and personnel supervision must be clearly deﬁned by the operating company. Personnel who do not have the required know-how must be duly trained and instructed. If necessary, this can also be done by the manufacturer/supplier on behalf of the operating company. In addition, the operating company must ensure that the personnel are fully familiar with, and have understood the contents of this operating manual.

1.4 Important safety instructions

When installing and using this electrical device, basic safety precautions should always be followed, including the following:

ATTENTION!

Read and follow all instructions! Keep this operating manual for future reference!

WARNING!

To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times.

General and Safety Instructions | Operating Manual FEDOS E/DX | 3

WARNING!

Risk of electric shock. Connect the device only to a socket outlet with earthing contact protected by a ground fault circuit interrupter (GFCI). Consult a qualiﬁed electrician if you are uncertain whether the socket is protected by a GFCI. Do not bury the cable. Secure cable to avoid damage by lawn mowers, hedge trimmers and other equipment.

WARNING!

To reduce the risk of electric shock, replace the cable immediately if damaged.

WARNING!

To reduce the risk of electric shock, do not use extension lead to connect unit to electric supply; use an appropriately located socket outlet.

1.5 Hazards due to failure to follow safety instructions

Failure to follow the safety instructions may endanger not only persons, but also the environment and the device. Failure to follow the safety instructions may invalidate any damage claims.

The following hazards in particular may result:

• Failure of major equipment functions

• Failure of required maintenance and repair methods.

• Danger to persons due to electrical, mechanical and chemical effects.

• Danger to the environment due to leakage of hazardous substances.

1.6 Safety awareness at work

The safety instructions contained in this operating manual must be observed. The operating company is responsible for ensuring compliance with local safety regulations. Faults that may affect safety must be repaired immediately.

1.7 Safety instructions for the operating company/operator

Leakages of hazardous substances (e.g. aggressive, poisonous) must be disposed of in such a way that they do not pose a risk to persons and the environment. Legal requirements must be observed.

Risks from electric current must be excluded (for further details, refer to the VDE1) regulations and regulations of the local public utilities).

German Association for Electrical, Electronic & Information Technologies

Separate regulations must be observed if the FEDOS E is operated in potentially explosive atmospheres. The operating company must determine the explosion hazard (area classiﬁcation) and select the appropriate equipment. Further information can be found in paragraph 7.1 (Installation), paragraph 7.4 (Electrical connection) and section 12 (Explosion-proof dosing pumps).

1.8 Safety instructions for inspection, maintenance and installation work

The operating company must ensure that all maintenance, inspection and installation work is carried out by authorised and duly qualiﬁed personnel, who have read and understood this operating manual.

Any work on the machine must only be carried out after it has been brought to a complete stop. Always follow the procedure speciﬁed in the operating manual for shutting down the dosing pump/system.

Dosing pumps or systems which convey hazardous media must be decontaminated. All safety and protective equipment must be reattached and activated immediately after the work has been

completed.

CAUTION!

Particular caution is required during repair work with the operation of the FEDOS E in potentially explosive atmospheres. Due to the risk of sparking, care must be taken to prevent metal parts or tools knocking against one another. When repairing, it is better to move the dosing pump out of the area with a potentially explosive atmosphere.

4 | Operating Manual FEDOS E/DX | General and Safety Instructions

Those points speciﬁed in chapter 7.2 "Installation location" and section 9. "Start-up" must be observed before setting into operation.

1.9 Unauthorised modiﬁcation and production of spare parts

The device may only be modiﬁed or converted in consultation with the manufacturer. Use only the manufacturer's spare parts and accessories. Otherwise the warranty is invalidated.

1.10 Inadmissible operating practices

Any methods of operation which contradict chapter 2 "Proper intended use" are inadmissible and will result in the expiry of all liability claims.

1.11 Dosing of chemicals

CAUTION!

When working on dosing systems, the local accident prevention regulations must be observed and the speciﬁed personal protective equipment must be worn. The following standard protective clothing is recommended, depending on the hazardousness of the metered medium:

Protective clothing Protective gloves Protective goggles It is recommended that all persons responsible for the installation and maintenance of piping systems,

hoses and accessories wear this protective clothing. Before working on the dosing pump and system, disconnect it from the mains power supply and prevent it

from being switched on.

CAUTION!

Any chemical still present in the dosing head may spray out when the voltage supply is reconnected. This may lead to chemical or other burns to the face and hands. Dosing lines must always be connected before switching on again.

The chemical resistance of the construction materials in the pump must be veriﬁed before dosing aggressive media!

The pump dosing head and the system connections and lines may be under pressure. Working on the dosing system requires special safety precautions and is allowed only for suitably trained personnel:

CAUTION!

Chemical may spray out. This may lead to chemical or other burns. Always release the pressure before starting work on the dosing pump.

Before working on the dosing head, valves and connections, ﬂush the dosing pump with a harmless medium (water in most cases), to avoid unintentional contact with the metered medium.

The piston area must remain open for control reasons and may be dangerous if accessed directly.

CAUTION!

Stroke movement of the piston! There is a risk of crush injuries to hands. Do not reach into the piston area! Work in the piston area may therefore only be carried out with the dosing pump switched off.

WARNING!

Never look into the open end of a clogged line or valve. Chemicals may emerge unexpectedly and cause chemical or other burns to face and hands.

Before start-up, all screw connections must be inspected for correct tightness and leak-tightness, and must be re-tightened using an appropriate tool if necessary.

General and Safety Instructions | Operating Manual FEDOS E/DX | 5

CAUTION!

If connections at the dosing head are loosened during operation, for venting or other reasons, leaking chemicals must be removed properly. Only in this way is it possible to effectively avoid the risk of injuries caused by chemicals and corrosion at the dosing pump.

ATTENTION!

If changing the chemical, check the materials in the pump and other system parts for chemical resistance. If there is a danger of chemical reaction between the different media, clean thoroughly beforehand.

IMPORTANT!

To operate the pump, mount the fan cowl in order to ensure sufﬁcient cooling of the motor.

The protection class of the control unit is only ensured if the connection ports are protected by caps or the standard connectors are inserted.

DANGER!

Risk of burns. Shock wave: parts may ﬂy off and cause fatal injury. FEDOS DX must not be used in potentially explosive atmospheres under any circumstances.

CAUTION!

Under certain operating conditions, the drive motor of the DX version might heat up considerably. This may cause burns to the hands. To avoid unintentional contact, provide an appropriate safety device.

WARNING!

Lethal voltage!

Proceed with caution when carrying out adjustment work on the inside of the ATE servomotor (optional for FEDOS E). Connections and internal limit switches might be live. Additional limit switches in the ATE drive may be under voltage (live) even when the auxiliary voltage is switched off. After installing the ATE servomotor or before start-up, re-attach the cover.

1.12 Transportation

No special devices are required for transportation of the dosing pumps. However, it is advisable to choose a transport method appropriate for the weight of the dosing pumps (e.g. transport trolley). If transporting with the oil drained, the dosing pump should preferably be placed in the horizontal position. Otherwise, stability must be ensured by screwing it onto the transport frame.

1.13 Scope of delivery

IMPORTANT!

Carefully unpack the dosing pump and any accompanying accessories ordered, so that small parts are not left inside the packaging. Compare the delivery content with the delivery note immediately. If there are any discrepancies, determine the cause.

The following are part of the scope of delivery:

• Dosing pump FEDOS E or DX

• Suction and discharge side connections

• Gear oil

• 2x cables (for FEDOS DX)

• Operating Manual

• ATE servomotor (optional)

• Separate fan (optional)

6 | Operating Manual FEDOS E/DX | General and Safety Instructions

2. General

2.1 Proper intended use

The device is intended for the following purpose only: the conveying and dosing of chemicals. Operating safety is guaranteed only if the device is used for its intended purpose. All other types of use are

prohibited and will invalidate the warranty. The operating conditions described in chapter 5 "Technical Data" must be observed!

2.2 Structure of the dosing pump

n m l

a Dosing head b Suction side valve c Discharge side valve

e Stroke length adjustment f Stroke length adjustment lock g Motor terminal box (FEDOS E voltage supply) h Oil inlet i Oil outlet j Control unit (FEDOS DX) k Operating panel with display l "External switch-off" contact m "Level input" contact n "External control" contact

i o p q

o Voltage supply (FEDOS DX) p Motor connection q Fault signalling relay

General | Operating Manual FEDOS E/DX | 7

3. Function

Piston dosing pumps of the FEDOS series are used in industry, in the process engineering sector, as well as in water conditioning and the treatment of waste water.

FEDOS E

The FEDOS E is used when no control is required for constant dosing. For this the voltage supply is connected directly to the terminal box of the motor. To adapt the dosing capacity the stroke length can be adjusted manually from 0 … 100%, or the motor speed is controlled by means of a separate frequency converter. The FEDOS E is optionally available with remote electrical stroke-length adjustment (ATE servomotor).

The FEDOS E can be operated in Zone 1 potentially explosive atmospheres if the corresponding drive is taken into account. Further information can be found in section 12.

FEDOS DX

The "intelligent" FEDOS DX is used if the dosing pump is to be integrated in controls or automatic control systems. It enables versatile adaptation to a variety of different control signals and system monitoring equipment. The signals required for external activation of the dosing pump can be from simple potentialfree N.O. contacts of water meters or controllers, or analogue 0/4 … 20 mA signals. For contact actuation (pulse control), the stroke frequency can be adapted by division or multiplication. For internal operation (own stroke), the dosing pump can be adjusted continuously between 0 and max. 142 strokes/min, depending on version.

Principle of operation

a b c

max.

a Piston rod b Return spring for suction stroke c Tappet plate d Drive cam e Stroke limiting cam

Like the roller bearings, the worm gear set of the single-speed gear runs in an oil bath. Dosing takes place when the rotation of the drive cam d causes movement of the piston rod a. The suction stroke is produced by the return movement due to spring force. The stroke length is adjusted by limiting the tappet return movement using a manually adjustable cam disk (stroke limiting cam e) as stop. The adjustment range is from 0 to 100%.

min.

max.

8 | Operating Manual FEDOS E/DX | Function

4. Dimensioned drawings

Dimensional drawing FEDOS E/DX

E/DX)A L

1 … 2 125 25

5 … 30 114 25

All dimensions in mm

50 60

Dimensional drawing FEDOS E with ATE servomotor

Motor W

EMG 353

ATB 373

VEM 364

ATEX version 474

184~

Dimensioned drawings | Operating Manual FEDOS E/DX | 9

5. Technical data

FEDOS E/DX 01 03 06 1 21)51)81)171)30

Delivery rate at max.

l/h 0,17 0,31 0,63 1,42 2,13 4,8 8,5 17 31,5

pressure Stroke volume ml/

0,11 0,25 0,25 0,56 1 2 3,7

stroke Max. pressure bar 40 25 max. pressure

bar 100 80 - Stroke frequency rpm 26 48 95 142 Piston-Ø mm 4 6 9 12 17 23 Stroke length mm 9 Suction lift mbar 800 max. supply pressure

∑ static + dynamic

max. ambient tempera-

mbar 500

°C 40 ture2)

Power output E (3~) W 50 250 Power output DX (1~) W 120 Weight kg 11 16

1) E/DX 2…30 not for 60Hz operation, special sizes E/DX 2A … 30A available for 60 Hz operation. The details about delivery rate and stroke frequency are also applicable for 60 Hz operation.

2) Media temperature 60 °C, short time 80 °C.

3) High-pressure version

Dimensioning of the lines

The following approximate values are applicable for the dimensioning (maximum length) of suction and pressure lines:

• 2 m for peak ﬂow velocity of 0.5 … 0.7 m/s

• 10 m for peak ﬂow velocity of 1.0 … 1.5 m/s

(without pulsation damper or suction pressure regulator, and without overdimensioning of the line). This is applicable to chemicals with a maximum viscosity of 20 mPAS (the highest viscosity is at lowest

system temperature, for example in case of delivery in winter) and with a maximum density of 1100 kg/m³. The maximum ﬂow velocity is calculated as follows: Q x π / A (Q = ﬂow rate, A = line diameter).

For all other chemicals and installation situations please refer to the seminar documents of the manufacturer "Kleine Einführung in die Dosiertechnik" (Short introduction into dosing technology) or to other applicable guidelines from specialist literature on ﬂuid dynamics (i.e. Kalide ISBN 3-446-13092-6).

Avoid overloading of the pump, the piping or the instruments.

10 | Operating Manual FEDOS E/DX | Technical data

Control unit (FEDOS DX) Standard version CSA version

Power supply 95 … 264 V AC, 48 … 63 Hz Connection 1.8 m cable,

3-wire, 0.75 mm Shock-proof plug

1.8 m cable, 3-wire, 0.75 mm UL/CSA connector

Power consumption (without motor) 10 W ISO class F Protection class IP 55* Max. admissible ambient temperature 40 °C Digital display 3-digit display for stroke frequency and level status LEDs for functional display in operation (green)

fault (red)

external control (green) Plastic ﬁlm keypad 4 keys for programming and operation Weight 0.8 kg

Inputs

External shut-off External switch off for dosing pump, provided by the

customer, by

potential free contact (normally closed, N.C.),

3.5 mm jack socket (M12x1 plug optional)

Level input Connection of accessories (e.g. suction line with level

switch)

5 V DC voltage, low level alert and main alarm,

Contact: normally closed, N.C.

3.5 mm jack socket (M12x1 plug optional)

External control pulse input or analogue input

RCA socket

3-pin socket

(M12x1 plug optional)

Pulse input potential-free contact (normally closed, N.C.) provided by

operating company

5 V DC voltage

Pulse length min. 30 ms

Multiplication/division of pulses 1 / 2 / 4 / 8 / 16 / 32 / 64 Analogue input 0/4 … 20 mA signal **

Working resistance: 150 Ohm

Outputs

Fault signalling relay voltage-free changeover contact,

max. 250 V AC, 2.5 A or max. 30 V DC, 2.5 A,

Cable connection

* if connection ports are protected by caps, or standard connectors are inserted. **1 If several dosing pumps are connected in series with 4 … 20 mA control, an additional device (splitter) is necessary.

Technical data | Operating Manual FEDOS E/DX | 11

5.1 Electric motor data

FEDOS DX 01…30 E 01…2 E 5…30

Standard motor, type

Speed rpm 1390 1650 1400 Voltage V 1~ 230 120 230/400 Nominal

current Power

output Frequency Hz 50 60 50 Protection class IP 55 IP 55 ISO class F F

Explosion-proof motors for FEDOS E

FEDOS E (ATEX) 01…30 01…30

Type KPER63K4 F63CTV/a4 Explosion protection increased safety

Speed rpm 1370 1410 Voltage V 1~ 230/400 230/400 Nominal

current Power

output Frequency Hz 50 50 Protection class IP 55 IP 55 ISO class F F

AF 63/4B-7R ECS63K4 DAS 63 S4 DAS 63 K4

A 1,15 2,2 0,5 0,95

kW 0,12 0,05 0,25

EExeIIT3

A 0,83/0,48 1,0/0,6

kW 0,12 0,18

EXdellCT4 pressureresistant enclosure

12 | Operating Manual FEDOS E/DX | Technical data

5.2 Technical data, ATE servomotor FEDOS E (optional)

Reversible servomotor with self-locking step-down gear. Connections via cable glands. Angle of rotation limited by two internal limit switches.

Servomotor NK 1510 NK 1510-PMR-NK

Part No. 79466 79468 79467 79469 FEDOS E E4 ... 380 Voltage 230 V AC,

Power consumption 7 VA Regulation

time

Regulation bevel 270° ⇔ 0...100% Protection class IP 65 Ambient temperature -15 ... +60 ℃ Weight 2.5 kg

Inputs

Control 3-point step control 0(4) ... 20 mA Working resistance

at 0/4...20 mA

Outputs

Position feedback signal for remote display

50 Hz 45 s 60 Hz 39 s

50/60 Hz

0...1000 Ohm, max. 2 W 0(4) ... 20 mA

115 V AC, 50/60 Hz

- 250 Ω

230 V AC, 50/60 Hz

0(2) ... 10 V

115 V AC, 50/60 Hz

See the enclosed operating instructions for the ATE servomotor for further technical data.

Technical data | Operating Manual FEDOS E/DX | 13

6. Delivery characteristic curves

0 1 2 3 4 5 6 7 8 9 10

l/h

Hubeinstellung

FEDOS E/DX 01...8

E/DX 01 -1

E/DX 2

E/DX 5

E/DX 8

0 1 2 3 4 5 6 7 8 9 10

l/h

Hubeinstellung

FEDOS E/DX17...30

E/DX 17

E/DX 30

The delivery characteristic curves refer to water at 20 °C (68 °F) and a suction lift of 0.5 m. The medium (density and viscosity) and temperature cause the delivery rate to change. Dosing pumps must therefore be gauged in litres for the application. At 60 Hz operation, values are increased by a factor of 1.2.

14 | Operating Manual FEDOS E/DX | Delivery characteristic curves

7. Installation

7.1 General information

Local rules and regulations must be taken into account when selecting a dosing pump for designing a system, and for installation and operation. This applies to the selection of the appropriate materials for the dosing pump, the handling of chemicals, and electrical installation.

Before installing the pump in areas with a potentially explosive atmosphere, the dosing pump must be checked to ensure that it meets the minimum requirements set by the applicable explosion protection regulations. For this purpose, the data on the dosing pump rating plate must be compared with the local requirements.

The technical speciﬁcations of the dosing pump (section 5) must also be taken into consideration, and the system designed accordingly (e.g. pressure loss for pipe dimensions i.e. nominal diameter and length).

The designer and operating company are responsible for ensuring that the entire system, including the dosing pump, is designed in such a way that no lasting damage occurs to system equipment or buildings in the event of chemical leakage due to the failure of wearing parts (e.g. wear of the packing) or burst hoses. If the chemical system represents a potential source of danger, the installation must be designed in such a way that no unreasonable consequential damage occurs, even if the dosing pump fails. We therefore recommend installing leakage monitors and collecting pans.

CAUTION

The FEDOS E/DX may not be used for dosing combustible and ﬂammable ﬂuids. For constructional reasons piston pumps are not leakage-free. This must be taken into account in the design of the process and the plant.

To increase dosing accuracy and ensure functional reliability, we recommend installing additional valves and accessories. These include pressure control valves, pressure relief valves, leakage monitors and low level indicators, as shown in the installation examples.

Always use appropriate tools for installation work. To avoid damage, never apply excessive force.

IMPORTANT!

To prevent seizing, threaded stainless steel parts (e.g. dosing head and valves) must be lubricated before being assembled (e.g. with PTFE spray).

ATTENTION!

Check the lubricant for compatibility with the chemical.

7.1.1 Installation of FEDOS E with ATE servomotor

The ATE servomotor is connected to the dosing pump and adjusted at the factory. When installing, sufﬁcient installation space of at least 150 mm must be provided in order to allow later maintenance.

The electrical connection of the ATE drive must be made in accordance with locally applicable requirements and may only be carried out by technical personnel. The wiring diagrams (chapter 7.4) show the standard connection variant.

Cable type and cross-section must be chosen according to the motor data. The cable passage through the housing must be made professionally. We recommend using gland con-

nections with strain-relief clamp. The required protection class must be ensured by professional-standard installation of the electrical connections.

ATTENTION!

Note that the ATE servomotor can only be actuated when the main drive motor of the dosing pump is running. This means that the ATE servomotor must be locked electrically. Otherwise, the adjusting eccentric will suffer excessive wear, or be destroyed.

Installation | Operating Manual FEDOS E/DX | 15

7.2 Installation location

The installation location of the dosing pump must be easily accessible by operating and service personnel.

ATTENTION!

Ambient temperatures above 40 °C are not permitted. Radiant heat from apparatus and heat exchangers must be shielded so that heat from the dosing pump can be dissipated sufﬁciently. Avoid exposure to direct sunlight. If the dosing pump is installed outside, provide a roof to protect it from the effects of weather.

Install the pump so that the suction and discharge valves are in vertical position. To ensure stability, the dosing pump must be screwed onto an appropriate surface. The system piping must not exert any force on the connections and valves of the dosing pump. To avoid dosing errors at the end of the process, the dosing pump must be locked electrically and hydraulically.

7.3 Electrical connection of the dosing pump

The electrical connection of the dosing pump must be made according to local rules and regulations and may only be carried out by qualiﬁed technical personnel. Cable type and cross-section of the supply lines must be chosen according to the motor data. The cable passage to the motor terminal box must be made professionally. We recommend using gland connections with strain-relief clamp. The required protection class must be ensured by professional-standard installation of the electrical connections.

For external switch-off of the dosing pump, see paragraph 8.3.

ATTENTION!

Dosing pumps with explosion-proof motors must be installed and commissioned by specialists qualiﬁed to work with equipment intended for use in potentially explosive atmospheres. The user is responsible for ensuring that explosion-proof motors are connected correctly. Both the motor and the dosing pump must be grounded to prevent electrostatic discharges.

DANGER!

Risk of burns. Shock wave: parts may ﬂy off and cause fatal injury. FEDOS DX must not be used in a potentially explosive atmosphere under any circumstances. The electrical connection of the dosing pump must be made according to local rules and regulations and may only be carried out by qualiﬁed technical personnel.

NOTE!

The dosing pump must be plugged into a grounded power outlet. The 230 V AC version of the FEDOS DX is connected by a shockproof earthing-pin plug. The 115 V AC version is equipped with a UL/CSA plug.

NOTE!

Signal cables must not be laid parallel to high-voltage current lines or mains cables. Lay supply and signal lines in separate channels. An angle of 90° is required at line crossings. If signal lines are more than 2 meters long, shielded cables must be used.

ATTENTION!

To avoid premature wear of the gear, always ensure the correct rotation direction of the motor: counterclockwise (to the left), looking toward the fan wheel.

16 | Operating Manual FEDOS E/DX | Installation

7.3.1 Drive motor connection

IMPORTANT!

Note the data on the motor rating plate

Connection FEDOS Phases Motor sup-

Note

plier

U1 V1 W1

L1 L2 L3 PE

U1 V1 W1

L1 L2 L3 PE

FEDOS E three-phase motors

E 3~ All Y-connection (Standard)

3~ All Delta connection

Connection FEDOS Phases Motor supplier Note

U1 Z2

L N PE

T1 L

TB2 TB1

E 1~ ATB

1~ EMG 230 V AC

or 120 V AC (CSA)

U1Z1U2

FEDOS E alternating current motors

Connection FEDOS Motor supplier

Temp.

Run

Stop

DX ATB

PEN

Installation | Operating Manual FEDOS E/DX | 17

Connection FEDOS Motor supplier

T1 L1

Run

U1Z1U2

FEDOS DX alternating curent motors

FEDOS DX Control unit Standard version CSA version

L1 RUN BR (brown) BK (black) L2 STOP BK (black) RD (red) N BU (blue) or GY (grey) WH (white) PE GN/YE (green/yellow) GN/YE (green/yellow)

Connection between FEDOS DX control unit and motor

7.4 Wiring diagrams for ATE servomotor for stroke length adjustment

See the accompanying operating instructions for the ATE servomotor.

L2 N

Stop

DX EMG

18 | Operating Manual FEDOS E/DX | Installation

7.5 Level monitoring

If a level monitor is connected, the jack plug has to be covered by a plastic sleeve in order to maintain the protection class. The required sleeve is part of the level monitor (also in combination with a suction line).

With the level monitor connected, the dosing pump stops if the chemical level in the supply tank is low, in order to prevent air bubbles from entering the suction line and the dosing head. The red LED is lit. As soon as the level contact closes again, the dosing pump restarts.

The level sensor must be designed as a max. N.O. contact. FEDOS is equipped with a 2-stage level monitor. When the ﬁrst contact breaks (low level alert), the red LED

begins to ﬂash. The dosing pump continues to operate. The fault signalling relay is actuated. The dosing pump only stops when the second contact breaks (main alarm). The red LED is lit continuously.

The "low level alert" function is not available when using a 2-pin connector and a simple ﬂoat switch.

NOTE!

A dummy plug (Part No. 29115) must be attached if a ﬂoat switch is not connected. The dosing pump is delivered with a dummy plug already attached. If a ﬂoat switch is to be connected, the dummy plug has to be removed before inserting the jack plug.

7.6 Pressure control and safety valves

Pressure control valves are used to optimise the dosing process. They are used:

• to increase the dosing accuracy in the case of ﬂuctuating backpressure.

• when the dosing lines are long, in order to prevent excess delivery, since the accelerated medium

continues moving due to its own inertia even after the delivery stroke has ended.

• to prevent siphoning, if the supply pressure is higher than system pressure. Pressure relief and safety valves are used for overload protection of the dosing pump and the associated

valves and lines. They prevent inadmissible pressure rises in the delivery side system of the dosing pump; for example, if shutoff valves close while the pump is running, or if the injection nozzle is clogged.

7.7 Injection nozzle installation

Injection nozzles are used to inject the metered medium into the main ﬂow, while at the same time acting as non-return valve. The injection nozzle is usually mounted from the top into the main line. Mounting from below is recommended only for media that have a tendency to crystallise, in order to prevent air bubbles from being trapped in.

For media that tend to contaminate the injection nozzle, we recommend installing an injection nozzle that can be shut off and removed for maintenance purposes.

a Injection nozzle mounted from above, b Injection nozzle mounted from below (for media that tend to crystallise)

Installation | Operating Manual FEDOS E/DX | 19

7.8 Installation example

a Dosing pump b Suction line c Electrical agitator d Tank e Pressure relief valve f Diaphragm shutoff valve g Injection nozzle h Pulsation damper

20 | Operating Manual FEDOS E/DX | Installation

8. Operation

8.1 Stroke length adjustment

ATTENTION!

The stroke length must not be adjusted when the dosing pump is at a standstill!

Proceed as follows to adjust the stroke length:

1. Turn the mounting screw on the adjusting knob counterclockwise (to the left) to loosen it.

2. Set the stroke length to the required value according to the delivery characteristic curves (section 6).

3. Retighten the mounting screw without changing the stroke length setting.

8.2 FEDOS DX operating elements The operating panel has two green LEDs for operation and external control, one red LED for

alarm, one 3-digit multifunctional display and four operator keys.

a "On" LED (Power)

MEMDOS DX

Extern

Alarm

I/O

Mode

b"Extern" LED (ext. control) c "Alarm" LED

i h

d External switch-off connection

e Level input connection f External control connection g "Mode" key (operating mode

selection)

h Selection keys ( ▲ , ▼ ) i "I/O" key (ON/OFF switch) j Display

k Voltage supply l Motor connection m Fault signalling relay connec-

tion

For connection assignments, see 8.8.

8.3 Switching on/off

The dosing pump is switched on/off using the I/O key. When disconnected, the display shows OFF. When the contact is opened for external switch-off, the dosing pump is also switched off. The "Extern" LED is also lit.

ATTENTION!

The dosing pump may be switched on/off remotely only by using the external switch-off - not by using the voltage supply.

8.4 Operating mode selection

The following operating modes can be set by simultaneously pressing the "Mode" and ▲ or ▼ keys:

• Manual control (internal operation)

• Pulse control (external cycle)

• Analogue control (control signal 0/4 … 20 mA)

In the as-delivered state, the dosing pump is set to manual control.

Operation | Operating Manual FEDOS E/DX | 21

Key Display Description Key Display Description

Mode +▼INT Manual control Mode +▼64.1 Pulse control

1.64 Pulse control

▼

1.32

▼

1.16

▼

1.8

▼

1.4

▼

1.2

▼

Manual control

The dosing pump delivers a constant ﬂow of chemical per unit time, regardless of the process. To set this operating mode, proceed as follows:

1. Press the "Mode" and ▲ or ▼ key simultaneously until INT is displayed.

2. Release the "Mode" key. The current stroke frequency is displayed (strokes/min)

3. Use the ▲ and ▼ keys to change the stroke frequency

Pulse control

The dosing pump delivers a constant ﬂow of chemical per input pulse. A maximum of 64 pulses are bufferstored, if the pulse rate exceeds the processing speed. To set the pulse multiplication/division, simultaneously press the "Mode" and ▲ or ▼ keys until one of the following values is displayed:

• for a ratio of 1:1, i.e. the dosing pump executes one dosing stroke after each pulse,

• 1.2 to 1. 64 for pulse multiplication or

• 2.1 to 64. 1 for pulse division

The "Extern" indicator is lit. Settings for pulse multiplication and division: 1, 2, 4, 8, 16, 32 and 64.

Example

1. 64 The dosing pump executes 64 dosing strokes after each pulse.

64. 1 The dosing pump executes one dosing stroke after 64 pulses.

32.1

▼

16.1

▼

8.1

▼

4.1

▼

2.1

▼

1.1

▼

4.20 Analogue control

▼

0.20

▼

Analogue control

The dosing pump delivers a quantity of the chemical proportional to the input signal. To set the operating mode, press the "Mode" and ▲ or ▼ keys simultaneously until one of the following values is displayed:

• 0. 20 for 0 … 20 mA signal or

• 4. 20 for 4 … 20 mA signal

When the "Mode" key is released, the stroke frequency corresponding to the current is displayed. The "Extern" indicator is lit. If the current is greater than 20 mA (display: OVL) or less than 4 mA (display: E-I), the alarm indicator is lit, the fault signalling relay switches and the dosing pump stops. The stroke frequency of the dosing pump is proportional to the input signal.

8.5 Alarm

The dosing pump allows monitoring of the dosing process. An alarm is indicated visually on the display and transmitted by the fault signalling relay.

Alarm LED Alarm relay Pump Display

Level pre-alarm ﬂashes switches continues to operate Number of strokes Level main alarm is lit switches stops E - L

Internal error

22 | Operating Manual FEDOS E/DX | Operation

The dosing pump carries out a self-check which switches off the pump, if no stroke has been executed two seconds after startup of the motor (e.g. in the case of excessively high backpressure) or if the stroke sensor does not work (display E-2). The alarm is reset by pulling out the mains plug.

The functions of the LEDs and built-in fault signalling relay are shown in the following table:

Condition LED 1ONLED 2

Extern

LED Alarm

Fault signalling relay

Display

R0 RW R1

Voltage supply absent closed Dosing pump running



closed Number of

strokes Dosing pump off (by ON/OFF switch) closed OFF Dosing pump off (by external contact) Low level alert



*) ﬂashes closed Number of



closed OFF

strokes Level main alarm Dosing pump fault (proximity switch,



closed E - L



closed E - 2



stroke sensor) Dosing pump fault (current < 4 mA)

*) LED 2 lights up in operating modes 1.1 - 1.64; 0…20 mA and 4… 20 mA

 

closed E - I

8.6 Other settings

8.6.1 Maximum number of strokes

The Mode and I/O keys are held depressed while applying the voltage and the maximum number of strokes of the dosing pump is set with the keys ▼ and ▲. When the "Mode" key is released, normal operation starts.

8.6.2 Alarm relay

In the default setting the relay is without current in the case of error and OFF. If the keys "Mode" and ▲ are held depressed while the voltage is applied (display RE0), the relay is without current in the case of error and OFF, with the keys "Mode" and ▼ the relay picks up in the event of error (display RE1).

8.7 Factory setting

• The initial status of the FEDOS DX is "OFF".

• Depending on the technical speciﬁcations, the maximum stroke frequency is preset (see section 5).

• In case of a fault or "OFF", the fault signalling relay is not picked up.

8.8 Connections and cable assignments

Control unit FEDOS DX Standard version CSA version

L1 RUN Motor BR (brown) BK (black)

L2 STOP BK (black) RD (red) N BU (blue) or GY (grey) WH (white) PE GN/YE (green/yellow) GN/YE (green/yellow) L Power supply

N BU (blue) or GY (grey) WH (white) PE GN/YE (green/yellow) GN/YE (green/yellow) R0 Break contact Fault signalling

Rw Changeover

contact

R1 Make contact BK (black) BK (black)

230 V AC, 50/60 Hz or 120 V AC, 50/60 Hz

relay (1.5 m cable)

R0 RW R1 Fault

R0 RW R1 Operation

BR (brown) BK (black)

BR (brown) RD (red) BU (blue) or GY (grey) WH (white)

Operation | Operating Manual FEDOS E/DX | 23

Connection Connector Housing Cable

External

shut-off

Level input 3.5 mm jack

External control RCA Socket

3.5 mm jack plug

M12 x 1, A coded (optional)

plug

M12 x 1, A coded (optional)

Socket

a b

2.5 m 3-wire (cable included in delivery)

a Input (+) b Ground (GND)

Plug

1 = input (+) BN (brown) 2 = ground (GND) WH (white)

Socket

ab c

Manufacturer's accessories

a Main alarm b Low level alert c Ground (GND)

Plug

1 = low level alert

2 = main alarm WH (white) 3 = ground (GND) BU (blue)

RD (red) BK (black) / WH (white)

RD (red) WH (white) BK (black)

BN (brown)

a b

1.5 m 2-wire (cable included in delivery)

a Input (+) b Ground (GND)

CSA version Plug

1.5 m, 3-wire (cable included in delivery) 1 = input (+) BN (brown) 2 = - BK (black) 3 = ground (GND) BU (blue)

M12 x 1, B coded (optional)

NOTE!

The protection class of the control unit is only ensured if the connection ports are protected by caps or the standard connectors are inserted.

24 | Operating Manual FEDOS E/DX | Operation

Plug

1 = ground (GND) BN (brown) 2 = pulses WH (white) 3 = pulses BU (blue) 4 = ground (GND) BK (black)

BN (brown) WH (white)

9. Start-up

CAUTION!

The personal protective equipment speciﬁed by the applicable accident prevention regulations must be worn whenever working on the dosing pump/system!

Protective clothing Protective gloves Protective goggles

1. All the work described under "Installation" (Section 7) must be carried out before starting the dosing pump.

2. Fill the dosing pump with the oil supplied. For oil grade and quantity, see section 11.1.

3. The FEDOS E dosing pump is switched on by an externally installed control system. The FEDOS DX has its own control. The initial status of the FEDOS DX is OFF. Electrical connection and the control types are explained in section 8, FEDOS DX operating controls.

4. The manual capacity adjustment should be set to maximum stroke for better priming. During the initial priming, there should be no backpressure. For this purpose, we recommend installing a relief valve on the discharge side of the dosing pump.

5. If a priming aid has been installed, this must be ﬁlled with chemical ﬁrst. If the dosing pump does not prime, switch off the dosing pump, unscrew the discharge valve and ﬁll the dosing head with ﬂuid. If non-hazardous, the medium itself can be used; otherwise use a neutral medium that will not disturb the process. (In many cases, water can be used.)

WARNING!

Chemical may spray out. This may lead to chemical or other burns. Ensure that the discharge line is depressurised before disconnecting.

Then reinstall the discharge valve, switch on the dosing pump and allow it to prime. (A priming aid is

recommended. See example installations.)

6. If there is a vent valve integrated in the dosing head or installed as a separate ﬁtting, open it while the dosing pump is operating until ﬂuid comes out. Then close it again. In the case of outgassing media, allow the ﬂuid to ﬂow off continuously (about 1 drop per 1 - 3 strokes). The escaping ﬂuid ﬂows through a hose back into the tank.

7. When correct operation has been established, set the desired delivery rate using the adjusting knob (see section 8.1) or the remote control adjustment. For an initial approximation, refer to the delivery characteristic curves (Section 6).

NOTE!

Depending on the installation and the chemicals used, these values may differ and must be checked under operating conditions.

8. The manufacturer of the dosing equipment is not responsible for damage due to excessive or insufﬁcient ﬂow rates at the dosing pump or incorrect or faulty installation of peripheral ﬁttings.

9.1 Start up of FEDOS E with ATE servomotor

Switch on the main drive motor of the dosing pump. An electrical interlocking system then allows ATE drive adjustment. To check the direction of rotation, send short control pulses to the ATE servomotor. If the direction of rotation is wrong, adjust its direction as described in the ATE servomotor operating instructions. To check the limit stop of the integrated limit switches, the ATE servomotor must be moved to the end position. The factory-set angle of rotation is 270°. If required, the maximum delivery rate can be changed by limiting the angle of rotation. To do this, the trigger cams of the limit switches are moved.

Start-up | Operating Manual FEDOS E/DX | 25

10. Shutdown

Before starting any maintenance work or before long downtimes, drain the chemicals from the dosing pump and rinse it thoroughly with a neutral medium.

CAUTION!

Excess chemicals must be disposed of properly. Observe the applicable accident prevention regulations and wear personal protective equipment.

Protective clothing Protective gloves Protective goggles

CAUTION!

The dosing pump must be disconnected from the voltage supply and secured to prevent it being restarted.

CAUTION!

Before disconnecting the discharge line from the pump discharge valve, release the pressure so that chemicals do not spray out.

The discharge and suction valves should be unscrewed in order to drain the dosing head.

10.1 Disposal of old equipment

If the equipment is being disposed of, it should be washed thoroughly. Residual chemicals should be disposed of properly. The equipment was manufactured in accordance with the ROHS guideline and the waste electrical equipment legislation. The manufacturer will take care of disposal if the equipment is returned free of charge. It should not be disposed of as domestic waste!

Device revision

This operating manual applies to the following devices:

Device Revision

FEDOS E/DX 01…30 06/2004

It contains all the technical information required for installation, start-up and maintenance. Should you have any questions or require further information regarding this operating manual, please contact the manufacturer or its ofﬁcial national representative.

26 | Operating Manual FEDOS E/DX | Shutdown

11. Maintenance

These dosing pumps are produced to the highest quality standards, and have a long service life. Nevertheless some parts are subject to wear caused by operation (e.g. piston, valve seats, valve balls). Regular visual inspections are therefore necessary in order to ensure a long operating life. Regular maintenance will protect the dosing pump from operation interruptions. The manufacturer recommends maintenance once per year, provided the local regulations do not specify more frequent maintenance.

11.1 Lubrication

The piston dosing pump FEDOS E/DX requires little maintenance. The dosing pump gear is lubricated with gear oil of viscosity class ISO-VG460 according to DIN 51519 (corresponds to SAE 140 according to DIN 51512). The initial ﬁlling supplied must be replaced after about 500 operating hours. Subsequent oil changes should be carried out every 5,000 operating hours. The ﬁlling capacity is about 0.25 l for gears. The actually quantity of gear oil required can be determined by checking the min.-max. markings of the oil-measuring stick.

ATTENTION!

FEDOS DX: To avoid damaging the proximity switch inside the gear housing, the dosing pump must be switched off before removing the oil dipstick.

11.2 Maintenance of the bearings

The upper bearing of the pinion shaft is a sealed and permanently lubricated ball bearing. The other rolling bearings in the gearing, and the plain bearings of the diaphragm rod, are lubricated by the gear oil. The oil also performs a heat dissipation function.

All bearings must be examined for wear after 5000 hours of operation. The service life of the rolling bearings depends on the applied loads. If the dosing pump is operated at maximum load, bearings must be replaced after 5,000 hours of operation.

11.3 Maintenance of the ATE servomotor (optional)

The ATE servomotor comes with lifetime lubrication ex factory. Nevertheless, regular inspections are recommended if the drive is operated in tough operating conditions, for example in high ambient temperatures or continuous operation. To re-lubricate the ATE gear, use molybdenum disulphite, for example "Molykote BR2plus" or "OKS400".

11.4 Replacing the piston

CAUTION!

Chemical may spray out. This may lead to chemical or other burns. The dosing pump must always be depressurised and rinsed with water or a suitable medium before starting any work on the dosing pump.

a Dosing head with discharge and suction valve

b Support ring c Supporting disk d Packing rings

e Gland f Gland connection g Piston

Fig. 11.1: Dosing head FEDOS E/DX

Maintenance | Operating Manual FEDOS E/DX | 27

CAUTION!

The piston can be replaced as follows:

1. Switch off the pump!

2. Loosen the clamping screws at the clamping ﬂange with an appropriate tool (open-end spanner SW10). (see Fig. 1)

3. Loosen the gland connection ? (see ﬁg. 11.1) with an appropriate tool. With two cotter pin drives d6 inserted into two opposite bores in the gland connection, the connection can easily be loosened. (see Fig. 2)

NOTE!

To loosen the gland connection and the piston, the following assembly kits are available (consisting of cotter pin drives and open jaw wrenches): FEDOS E/DX 01…2 (A/N 37850), FEDOS E/DX 5…8 (A/N 37851) and FEDOS E/DX 17…30 (A/N 37852)

4. The dosing head a is withdrawn from the holder in an axial direction.

IMPORTANT!

Slight rotary movements of the dosing head make dismantling easier.

5. The piston g is unscrewed from the piston rod with the help of 2 open jaw wrenches. Use one openend spanner to ﬁx the piston rod and the other to unscrew the piston from the piston rod. Grease the thread of the new piston with Molykote DX. The new piston g is now screwed into the piston rod. (see Fig. 3)

6. To replace the packing d, unscrew the gland connection f completely from the dosing head. Remove the gland e and the supporting disc c. The defective packing is removed using a packing worm. Alternatively, a hook can be used to remove the old packing.

7. Clean the packing area. Install the new packing rings d with staggered gaps and observe the correct sequence of support ring, supporting disc, packing rings and another supporting disc (see ﬁg. 4). Install the gland hand-tight. (see Fig. 5)

CAUTION!

The packing material must be coordinated to the purpose of use (system pressure) and the chemical (chemical resistance).

8. The dosing head a is now pushed in alignment with the piston g and the seating ﬂange and ﬁxed in the ﬁnal position with the attachment screws.

IMPORTANT!

Make sure that the valves are aligned vertically. (see Fig. 4)

9. Carefully tighten the gland connection f, to start the bedding-in process of the new packing. For this purpose the dosing pump is run dry ﬁrst without connection to the medium. After a few strokes the gland is tightened once more.

10. After connecting the dosing lines, the pump is started as described in the section entitled Startup. For this the packing is to be prestressed further using the gland connection, until a minimum leakage occurs.

ATTENTION!

If prestressing is too strong, the return movement of the piston might be restrained. In this case slightly loosen the gland stud again.

11. If the piston wear is excessively high, try to ﬁnd out the reason. For the possible causes, please refer to "Troubleshooting" (Section 14).

28 | Operating Manual FEDOS E/DX | Maintenance

11.5 Valves

The dosing pump valves must be cleaned regularly.

NOTE!

When screwing the valves into the dosing head, observe the tightening torque of 2 Nm ±20 %.

CAUTION!

Chemical may spray out. This may lead to chemical or other burns. The dosing pump must always be depressurised and rinsed with water or a suitable medium before starting any work on the dosing pump.

NOTE!

Dirty valves will affect the dosing accuracy.

Maintenance | Operating Manual FEDOS E/DX | 29

Valves DN 3 / DN 4, FEDOS E/DX 01…2

Saugventil

Druckventil

Double-ball valves Suction valve Discharge valve

a * O-ring b Ball guide DN3 c *Valve ball DN3 d *Valve seat DN3 e *Flat gasket f Ball guide DN4 g *Valve ball DN4 h *Valve seat DN4 i * O-ring j *Valve body k *Flat gasket

* included in the spare parts kits.

30 | Operating Manual FEDOS E/DX | Maintenance

Valves DN 6, FEDOS E/DX 5 … 30

Saugventil

Druckventil

Saugventil

Druckventil

Double-ball valves Spring-loaded valves Suction valve Discharge valve Suction valve

Discharge valve

a * Flat gasket b Ball guide c *Valve ball d *Valve seat e Valve body f *Compression spring

(g additional O-rings, for high-pressure only) * included in the spare parts kits

Maintenance | Operating Manual FEDOS E/DX | 31

12. Explosion-proof dosing pumps

12.1 General

The FEDOS E explosion-proof dosing pump is an electro-motor-driven, explosion-proof piston dosing pump of equipment category 2, group II.

In combination with an explosion-proof motor (Ex II 2 G E Ex e II T3 or Ex II 2 G E Ex d/de IIB/IIC T4) it is used for dosing ﬂuids in Zone 1 potentially explosive atmospheres. The dosing pump carries the Ex mark "Ex II 2 G c k T4 03 ATEX D085".

ATTENTION!

The dosing pump is not intended for dosing gaseous media or solids.

DANGER!

Risk of burns. Shock wave: parts may ﬂy off and cause fatal injury. FEDOS DX must not be used in potentially explosive atmospheres under any circumstances.

12.2 Special conditions

The minimum requirements for the zone classiﬁcation must be ensured if using the dosing pump in areas with a potentially explosive atmosphere. The dosing pump itself and the motor must meet the minimum requirements.

CAUTION!

The FEDOS E may not be used for dosing combustible and ﬂammable ﬂuids.

32 | Operating Manual FEDOS E/DX | Explosion-proof dosing pumps

13. Troubleshooting

Problem Possible cause Remedy

Dosing pump not delivering or output too low.

No stroke movement observed

Dosing pump delivery rate too high

Heavy leakage at piston

Dosing pump very noisy.

Motor hums and does not start.

Alarm states indicated by red LEDs on the display.

The dosing pump switches off automatically.

If the problem cannot be solved with the above remedies, please return the dosing pump to the factory or contact our AfterSales Service for further assistance. Repairs will be carried out immediately.

Valves leaking or blocked. Clean the valves and vent the dosing pump.

See also "Start-up" Tighten the screw connections.

Valves incorrectly installed. Reassemble the valves.

Ensure that the valve balls are located above the valve seats.

Suction valve or suction line

Clean or seal the suction line.

leaking or blocked. Suction lift too high. - Set the dosing pump at the inlet.

- Install the pulsation damper on the suction side.

- Install a priming aid.

Viscosity too high. - Install spring-loaded valves.

- Increase the pipe diameter.

- Use special dosing head >> Contact manufacturer

Dosing pump set to zero stroke. Set the stroke length adjusting knob cor-

rectly. Diaphragm return spring broken. Replace the spring. Power supply interrupted. Switch on power supply. Pressure on suction side too

high (pump siphoning). Packing not tightened strong

Install a pressure control valve on the

discharge line.

Tighten gland stud carefully. enough.

Piston has longitudinal grooves due to normal wear.

Excessive wear due to abrasive

Replace piston and packing.

14. Spare parts

Genuine spare parts authorized by the manufacturer ensure greater safety. Wearing parts for the FEDOS E/DX are available as a spare parts set.

14.1 Spare parts list FEDOS E/DX 01 … 06

34 | Operating Manual FEDOS E/DX | Spare parts

Spare parts for FEDOS E/DX 01…06

Item Description Material Order No.

Piston

Piston for high-pressure 29227 Packing ring PTFE/silk PTFE/silk 81014

Packing ring PTFE/Aramid for high-pressure PTFE/Aramid 81725 Supporting disk PVDF 31712

Drive E/DX 01 35743 Drive E/DX 03 35744

Drive E/DX 06 35715 Control unit Europa 34897 Control unit CSA 35187

Control unit M12x1 35565

Stainless steel

29232

Spare parts set for FEDOS E/DX with double ball valves

Consisting of:

a Flat gaskets b Balls DN3 c Balls DN4 d Valve seats DN3 e Valve seats DN4 f O-rings g Piston h Packings i Supporting disk

j Double-ball valves, complete

Material Order No.

Stainless steel / ceramic / PTFE 35274 35275

k Dosing head complete

Material Order No. Order No.

1.4571/PTFE-silk/PVDF 29234 29704

Material Order No. Order No.

Stainless steel/PTFE 33611 38608

Suction valve Discharge valve

01..06 up to 40 bar

01…06

High-pressure

01…06 High-pressure

Spare parts | Operating Manual FEDOS E/DX | 35

14.2 Spare parts list FEDOS E/DX 1 … 2

36 | Operating Manual FEDOS E/DX | Spare parts

Spare parts for FEDOS E/DX 1…2

Description Material Order No.

g Piston Piston for high pressure

h Packing ring PTFE/silk Packing ring PTFE/Aramid for high pressure

i Supporting disc

l Drive E/DX 1

Drive E/DX 2

m Control unit Europa Control unit CSA Control unit M 12x1

Stainless steel

PTFE/silk

PTFE/Aramid

PVDF 31713

10602 99520

81046

81726

35715 35714

34897 35187 35565

Spare parts set for FEDOS E/DX

with double ball valves

Consisting of: Material Order No. Order No.

a Flat gaskets

b Balls DN3

c Balls DN4

d Valve seats DN3

e Valve seats DN4

f O-rings

g Piston

h Packings

i Supporting discs

j Double-ball valves, complete

Material Order No.

Stainless steel / ceramic / PTFE 35274 35275

k Dosing head complete

Material Order No. Order No.

1.4571/PTFE-silk/PVDF 37500

1.4571/PTFE-Aramid/PVDF 37540

PTFE

Ceramic

1.4401

Ceramic

1.4571

PTFE

1.4571

PTFE-silk

PVDF

Suction valve Discharge

up to 40 bar High-pres-

1..2

up to 40 bar

37689 37689

valve

sure

1..2

High-pres-

sure

Spare parts | Operating Manual FEDOS E/DX | 37

14.3 Spare parts list FEDOS E/DX 5 … 30

Spare parts for FEDOS E/DX 5 8 17 30

Description Material Order No.

e Piston

Stainless

10616 10622 10632 10652

steel

e Piston for high-pressure

f Packing ring

f Packing ring for high-pres-

PTFE/silk 81257 81023 81025 81027

PTFE/Aramid 81711 81693 - -

37896 38655 - -

sure

g Supporting disk

h Drive E

i Control unit Europa

i Control unit CSA

i Control unit M12x1

PVDF 34643 31715 31717 31719

35714

34897

35187

35565

38 | Operating Manual FEDOS E/DX | Spare parts

Spare parts set for FEDOS

E/DX 5 E/DX 8 E/DX17 E/DX30

with double ball valves

Consisting of: Material Order No.: Order No. Order No. Order No.

a Flat gaskets

b Valve balls

c Valve seats

e Piston

f Packings

g Supporting disk

1.4401

1.4571

PTFE-silk

PVDF

29949 29950 29951 29953

Spare parts set for FEDOS

E/DX 5 E/DX 8 E/DX17 E/DX30

with spring-loaded valves

Consisting of: Material Order No. Order No. Order No. Order No.

a Flat gaskets

b Valve balls

c Valve seats

d Compression spring

e Piston

f Packings

g Supporting disk

j Double-ball valves, complete

Material Order No.

Stainless steel/AF 26967 26968 Stainless steel /

AF/FPM* Stainless steel /

AF/EPDM*

l Dosing head complete

1.4401

1.4571

Hastelloy

37692 37693 37694 37695

1.4571

PTFE-silk

PVDF

k Spring-loaded valves, complete

Material Order No.

Suction valve

Discharge valve

Stainless steel/AF 28775 28776

37971 37972

Stainless steel / AF/FPM*

37973 37974

Stainless steel / AF/EPDM*

*) with additional O-rings for high-pressure

E/DX 5 E/DX 8 E/DX17 E/DX30

Suction valve

38382 38383

37978 37979

for

Material Order No.: Order No.: Order No.: Order No.: Stainless steel / PTFE-silk 23316 23317 23318 23320 Stainless steel / PTFE-silk* - 37183 - Stainless steel / PTFE-Aramid* 37897 - - -

*) for high-pressure

Discharge valve

Spare parts | Operating Manual FEDOS E/DX | 39

15. External vent (optional)

L1 L2 L3 PE L1 L2 L3 PE

W2 U2 V2

U1 V1 W1

W2 U2 V2

U1 V1 W1

L1 L2 L3 PE

W2 U2 V2

U1 V1 W1

Functional description of vent motors

The fan cowl and fan blade of the drive motor are removed and replaced by the extended fan cowl with integrated fan. The fan has a direct mains connection, and therefore delivers the maximum quantity of cool air to protect the motor against overheating at all speeds. Separate fans can be operated over a wide voltage range, according to the technical data below. They can be connected to three-phase or alternating current power supply, if connected according to the instructions. For single-phase operation, an operating capacitor is included in the terminal box (see electrical wiring diagram). The fan motors work according to the direction of rotation. The air ﬂow must be directed towards the motor.

Special versions available

• Extended fan cowl (for operation with tachogenerator or motor brake)

• Alternative mounting bracket

• Different fan cowl diameter

Technical data

Motor size 63 71 80 90 100 112 Air ﬂow rate m3/h 47 60 88 169 208 295 Power consumption W 27 30 28,5 86 86 84,5 Speed at 50 Hz (rpm) 2910 2870 2790 2880 2830 2770 Sound pressure level dB(A) 47 51 55 58 59 61 Protection class IP 66 Dimen-

sions (mm)

Nominal motor current (A) 3~, 200...290 V, delta 0,092 0,095 0,090 0,28 0,27 0,27

3~, 346...500 V, Y 0,06 0,06 0,05 0,06 0,06 0,06

1~, 230 V 0,075 0,081 0,090 0,19 0,21 0,23 Part No. Motor supplier ATB 47000200 47000201 47000202 47000203 47000204 47000205 Motor supplier VEM - 47000101 47000100 - - Motor supplier Siemens - - 47000303 - - -

Height 185 190 195 205 210 215

Diameter 126 143 160 176 196 220

Electrical wiring diagram

W2 U2 V2

U1 V1 W1

L1 L2 L3 PE

3~ Y-connection 3~ delta connection 1~ Steinmetz connection

L1 L2 L3 PE

40 | Operating Manual FEDOS E/DX | External vent (optional)

W2 U2 V2

U1 V1 W1

W2 U2 V2

U1 V1 W1

L1 N PE

Index

Alarm ...........................................................................22

Alarm relay ...................................................................23

Analogue control ...........................................................22

Approximation initiator ...................................................27

Area with a potentially explosive atmosphere ..................15

Bearings .......................................................................27

Cable assignments ........................................................23

Chemical leakage .........................................................15

Control unit ...................................................................11

Delivery characteristic curves ........................................14

Diaphragm replacement ................................................27

Dimensioned drawings ....................................................9

Dosing head ...................................................................7

Dosing of chemicals ........................................................5

Electric motor data ........................................................12

Explosion-proof .............................................................32

Explosion-proof motors ..................................................12

Factory setting ..............................................................23

Fault ............................................................................33

Function .........................................................................8

Injection nozzle .............................................................20

Installation ....................................................................15

Installation example ......................................................20

Installation location .......................................................16

Level input ....................................................................21

Level monitoring ...........................................................19

Lubrication ...................................................................27

Maintenance .................................................................27

Manual control ..............................................................22

Max. number of strokes .................................................23

Oil inlet...........................................................................7

Oil outlet.........................................................................7

Selection of operating mode ..........................................21

Operation .....................................................................21

Pressure control and safety valves .................................19

Protective clothing...........................................................5

Pulse control.................................................................22

Revision .......................................................................26

Separate fan .................................................................40

Servomotor ...................................................................13

Shutdown .....................................................................26

Spare parts ...................................................................34

Start up ........................................................................25

Structure of the dosing pump...........................................7

Switching on/off ............................................................21

Technical data ..............................................................10

Troubleshooting ............................................................33

Valves ..........................................................................29

Wiring diagram for electronics .......................................23

Wiring diagram for the drive motor .................................17

Y-connection .................................................................17

Index | Operating Manual FEDOS E/DX | 41

Declaration of no objection

When sending in for repair, please copy this form, ﬁll in and send along with each device!

Declaration of No Objection - Form

(please ﬁll in one form for each device and attach it to the outside of the device)

We are returning the following device for repair:

Device and device type: .............................................................................................................

Part No.: ...................................................................................................................................

Order No.: ................................................................................................................................

Date of delivery: ........................................................................................................................

Reason for repair: .....................................................................................................................

Medium conveyed

Description: ...............................................................................................................................

Properties: .................................................................................................................................

Irritant: Yes/No*) Corrosive: Yes/No*) *) Please delete as appropriate!

We hereby certify that the product has been cleaned thoroughly on the inside and outside before shipment, that it is free from hazardous chemical, biological, or radioactive substances and that the oil has been drained. *)

If the manufacturer ﬁnds it necessary to carry out further cleaning work, we will accept the related costs.

We conﬁrm that the above statements are correct and complete and that the device is being shipped according to legal requirements.

Company: ..................................................................................................................................

Address: ....................................................................................................................................

.................................................................................................................................................

Telephone: .................................................................................................................................

Fax: ...........................................................................................................................................

E-mail: ......................................................................................................................................

Customer No.: ...........................................................................................................................

Contact person: .........................................................................................................................

Date, signature, stamp: ..............................................................................................................

42 | Operating Manual FEDOS E/DX | Declaration of no objection

Warranty claim

Please copy and enclose with the unit. If the device fails during the warranty period, please clean it and return, accompanied by the completed warranty claim form.

Sender

Company: ......................................................................... Telephone: .................................. Date: .................................

Address: ........................................................................................................................................................................

Contact person: .............................................................................................................................................................

Manufacturer order No.: .................................................... Date of delivery: ....................................................................

Device type: ...................................................................... Serial number:.......................................................................

Nominal delivery rate:/Nominal pressure: .........................................................................................................................

Fault details: .....................................................................

Type of fault:

1. Mechanical fault 2. Electrical fault Premature wear Loose connections such as connectors or cables Wearing parts Controls (e.g. switches / buttons) Breakage/other damage Electronics Corrosion Damage in transit

3. Leaks 4. No or inadequate operation Connections Diaphragm defective Dosing head Other

Operating conditions of the device

Application site / site description: .....................................................................................................................................

Accessories used if any: ..................................................................................................................................................

......................................................................................................................................................................................

Setup (date): ...................................................................................................................................................................

Runtime (approx. number of operating hours): ...................................................................................................................

Please indicate the speciﬁc features of the installation and enclose a simple sketch showing materials, diameters, lengths and heights.

Warranty claim | Operating Manual FEDOS E/DX | 43

CE declaration of conformity

2006/42/EG

Descrizione del prodotto:

Direttive UE:

Conformità completa:

Direzione Tecnica

CE-Kolben_Dosierpumpe-V02

EU-Konformitätserklärung

Der Unterzeichnete Lutz-Jesco GmbH, Am Bostelberge 19, 30900 Wedemark, bestätigt, dass die nachfolgend bezeichneten Geräte in der von uns in Verkehr gebrachten Ausführung die Anforderungen der harmonisierten EU-Richtlinien, EU-Sicherheitstandards und produktspezifischen Standards erfüllen. Bei einer nicht mit uns abgestimmten Änderung der Geräte verliert diese Erklärung ihre Gültigkeit.

(EN) EU Certificate of Conformity

The undersigned Lutz-Jesco GmbH, Am Bostelberge 19, 30900 Wedemark. hereby certifies that, when leaving our factory, the units indicated below are in accordance with the harmonised EU guidelines, EU standards of safety and product specific standards. This certificate becomes void if the units are modified without our approval.

(FR) Certificat de conformité aux directives européennes

Le constructeur, soussigné: Lutz-Jesco GmbH, Am Bostelberge 19, 30900 Wedemark, déclare qu’à la sortie de ses usines le matériel neuf désigné ci-dessous était conforme aux prescriptions des directives européennes énoncées ci-après et conforme aux règles de sécurité et autres règles qui lui sont applicables dans le cadre de l’Union européenne. Toute modification portée sur ce produit sans l’accord express de Jesco supprime la validité de ce certificat.

(ES) Declaración de conformidad de la UE

El que subscribe Lutz-Jesco GmbH, Am Bostelberge 19, 30900 Wedemark, declara que la presente mercancía, objeto de la presente declaración, cumple con todas las normas de la UE, en lo que a normas técnicas, de homologación y de seguridad se refiere, En caso de realizar cualquier modificación en la presente mercancía sin nuestra previa autorización, esta declaración pierde su validez.

(NL) EU-overeenstemmingsverklaring

Ondergetekende Lutz-Jesco GmbH, Am Bostelberge 19, 30900 Wedemark, bevestigt, dat het volgende genoemde apparaat in de door ons in de handel gebrachte uitvoering voldoet aan de eis van, en in overeenstemming is met de EU-richtlijnen, de EU-veiligheidsstandaard en de voor het product specifieke standaard. Bij een niet met ons afgestemde verandering aan het apparaat verliest deze verklaring haar geldigheid.

(HU) EG (EK)– Egyezőségi nyilatkozat

A Lutz-Jesco GmbH, Am Bostelberge 19, 30900 Wedemark ezúton kijelenti, hogy a szóban forgó termék annak tervezése és szerkezeti

módja, valamint forgalomba hozott kivitele alapján a vonatkozó alapvető biztonság technikai és egészségügyi követelményeknek és az alábbi felsorolt EG –irányelveknek minden szempontból megfelel. A terméken engedélyünk nélkül végrehajtott módosítások következtében jelen

nyilatkozat érvényét veszíti.

Bezeichnung des Gerätes:

Description of the unit:

Désignation du matériel:

Descripción de la mercancía:

Omschrijving van het apparaat:

A termék megnevezése:

Typ / Type / Tipo / Típusjelölés:

FEDOS TK

FEDOS K

FEDOS E

REKOS KR

KARDOS KN

KARDOS N

Kolben-Dosierpumpe

Piston Metering Pump

Pompes doseuses à piston

Bombas dosificadoras de piston

Plunjerdoseerpomp

Dugattyús adagolószivattyúk

EU-Richtlinie / EU directives/ Directives européennes / Normativa UE / EU-richtlijnen / Vonatkozó EG-irányelvek

2006/95/EG

Harmonisierte Normen / harmonized standards / Normes harmonisées / Estándares acordemente / Toegepaste normeringen / Hatályos normák

EN ISO 12100-1 : 2003

EN ISO 12100-2 : 2003

EN 809 : 1998

i.V. Dipl. Ing. Klaus Albert

Lutz-Jesco, Wedemark, 01.02.2008

Technische Leitung / Technical Departement Manager / Direction technique /

Dirección Técnica / Hoofd technische dienst / Műszaki irodavezető

CE-Kolben_Dosierpumpe-V02

2004/108/EG

EU-Konformitätserklärung

Descrizione del prodotto:

Direttive UE:

Conformità completa:

Direzione Tecnica

CE-Kolben_Dosierpumpe-DX-V02

(EN) EU Certificate of Conformity

(FR) Certificat de conformité aux directives européennes

(ES) Declaración de conformidad de la UE

(NL) EU-overeenstemmingsverklaring

(HU) EG (EK)– Egyezőségi nyilatkozat

A Lutz-Jesco GmbH, Am Bostelberge 19, 30900 Wedemark ezúton kijelenti, hogy a szóban forgó termék annak tervezése és szerkezeti

nyilatkozat érvényét veszíti.

Bezeichnung des Gerätes:

Description of the unit:

Désignation du matériel:

Descripción de la mercancía:

Omschrijving van het apparaat:

A termék megnevezése:

Typ / Type / Tipo / Típusjelölés:

FEDOS DX

Kolben-Dosierpumpe DX

Piston Metering Pump DX

Pompes doseuses à piston DX

Bombas dosificadoras de piston DX

Plunjerdoseerpomp DX

Dugattyus adagolószivattyúk DX

EU-Richtlinie / EU directives/ Directives européennes / Normativa UE / EU-richtlijnen / Vonatkozó EG-irányelvek

2006/95/EG

2006/42/EG

Harmonisierte Normen / harmonized standards / Normes harmonisées / Estándares acordemente / Toegepaste normeringen / Hatályos normák

EN ISO 12100-1 : 2003

EN ISO 12100-2 : 2003

EN 809 : 1998

EN 50081-1 : 01.92

EN 50081-2 : 08.93

EN 50082-1 : 01.92

EN 50082-2 : 03.95

i.V. Dipl. Ing. Klaus Albert

Lutz-Jesco, Wedemark, 01.02.2008

Technische Leitung / Technical Departement Manager / Direction technique /

Dirección Técnica / Hoofd technische dienst / Műszaki irodavezető

CE-Kolben_Dosierpumpe-DX-V02

94/9/EG

EU-Konformitätserklärung

Descrizione del prodotto:

Direttive UE:

Conformità completa:

Direzione Tecnica

CE-Kolben_Dosierpumpe-Ex-V02

(EN) EU Certificate of Conformity

(FR) Certificat de conformité aux directives européennes

(ES) Declaración de conformidad de la UE

(NL) EU-overeenstemmingsverklaring

(HU) EG (EK)– Egyezőségi nyilatkozat

A Lutz-Jesco GmbH, Am Bostelberge 19, 30900 Wedemark ezúton kijelenti, hogy a szóban forgó termék annak tervezése és szerkezeti

nyilatkozat érvényét veszíti.

Bezeichnung des Gerätes:

Description of the unit:

Désignation du matériel:

Descripción de la mercancía:

Omschrijving van het apparaat:

A termék megnevezése:

Typ / Type / Tipo / Típusjelölés:

Fedos E - EX

Explosionsgeschützte Kolben-Dosierpumpe

Explosion proofed Piston Metering Pump

Pompes doseuses à piston EX

Bombas dosificadoras de piston EX

Explosieveilige Membraandoseerpomp EX

Dugattyus adagolószivattyúk robbanásbiztos kivitelben EX

EU-Richtlinie / EU directives/ Directives européennes / Normativa UE / EU-richtlijnen / Vonatkozó EG-irányelvek

2006/95/EG

2006/42/EG

Harmonisierte Normen / harmonized standards / Normes harmonisées / Estándares acordemente / Toegepaste normeringen / Hatályos normák

EN ISO 12100-1 : 2003

EN ISO 12100-2 : 2003

EN 809 : 1998

EN 13463-1 : 2001

ATEX-Registrier-Nr. :

Fedos E: Ex II 2 G c k T4 04 ATEX D041

i.V. Dipl. Ing. Klaus Albert

Lutz-Jesco, Wedemark, 01.02.2008

Technische Leitung / Technical Departement Manager / Direction technique /

Dirección Técnica / Hoofd technische dienst / Műszaki irodavezető

CE-Kolben_Dosierpumpe-Ex-V02

Notes

Notes | Operating Manual FEDOS E/DX | 47

Lutz-Jesco GmbH

Am Bostelberge 19 30900 Wedemark Germany

Telephone: +49 5130 5802-0 Fax: +49 5130 580268 info@lutz-jesco.com www.lutz-jesco.com/de

Austria

Lutz-Jesco GmbH

Aredstraße 7/2 2544 Leobersdorf Austria

Telephone: +43 2256 62180 Fax: +43 2256 6218062 info@lutz-jesco.at www.lutz-jesco.at

USA

Lutz-JESCO America Corp.

55 Bermar Park Rochester, NY 14624 USA

Telephone: +1 585 426-0990 Fax: +1 585 426-4025 mail@jescoamerica.com www.jescoamerica.com

Great Britain

Lutz-Jesco (GB) Ltd.

Gateway Estate West Midlands Freeport Birmingham B26 3QD Great Britain

Telephone: +44 121 782 2662 Fax: +44 121 782 2680 info@lutz-jesco.co.uk www.lutz-jesco.co.uk

East Asia

Lutz-Jesco East Asia Sdn Bhd

6 Jalan Saudagar U1/16 Hicom Glenmarie Industrial Park 40150 Shah Alam /Selangor Malaysia

Telephone: +603 5569 2322 Fax: +603 5569 1322 info@lutz-jescoasia.com www.lutz-jescoasia.com

Netherlands

Lutz-Jesco Nederland B.V.

Nijverheidstraat 14 C 2984 AH Ridderkerk Netherlands

Telephone: +31 180 499460 Fax: +31 180 497516 info@lutz-jesco.nl www.lutz-jesco.nl

Middle East

Lutz-Jesco Middle East FZE

P.O. Box 9614 SAIF-Free Zone Center Sharjah UAE

Telephone: +971 6 5572205 Fax: +971 6 5572230 info@jescome.com www.jescome.com

Hungary

Lutz-Jesco Üzletág

Vasvári P. u. 9. 9024 Györ Hungary

Telephone: +36 96 523046 Fax: +36 96 523047 info@lutz-jesco.hu www.lutz-jesco.hu

Jesco FEDOS E 5, FEDOS DX 5, FEDOS E 8, FEDOS DX 17, FEDOS E 30 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. General and Safety Instructions

2. General

2.1 Proper intended use

2.2 Structure of the dosing pump

3. Function

4. Dimensioned drawings

5. Technical data

5.1 Electric motor data

5.2 Technical data, ATE servomotor FEDOS E (optional)

6. Delivery characteristic curves

7. Installation

7.1 General information

7.2 Installation location

7.3 Electrical connection of the dosing pump

7.4 Wiring diagrams for ATE servomotor for stroke length adjustment

7.5 Level monitoring

7.6 Pressure control and safety valves

7.8 Installation example

8. Operation

8.1 Stroke length adjustment

8.2 FEDOS DX operating elements The operating panel has two green LEDs for operation and external control, one red LED for

8.3 Switching on/off

8.4 Operating mode selection

8.5 Alarm

8.6 Other settings

8.7 Factory setting

8.8 Connections and cable assignments

9. Start-up

9.1 Start up of FEDOS E with ATE servomotor

10. Shutdown

10.1 Disposal of old equipment

Device revision

11. Maintenance

11.1 Lubrication

11.2 Maintenance of the bearings

11.3 Maintenance of the ATE servomotor (optional)

11.4 Replacing the piston

11.5 Valves

12. Explosion-proof dosing pumps

12.1 General

12.2 Special conditions

13. Troubleshooting

14. Spare parts

15. External vent (optional)

Index

Declaration of no objection

Warranty claim

CE declaration of conformity