Jesco MAGDOS LK Operating Instructions Manual

Download

Dosing

Conveying

Control

Liquids Gases Systems

Original Operating Instructions

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump

MAGDOS LK

Operating Instructions

Read the Operating Instructions!

The user is responsible for installation and operation related mistakes!

Contents

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Contents

1 Notes to the Reader ............................................................ 4

1.1 General non-discrimination ...................................................... 4

1.2 Explanation of signal words ...................................................... 4

1.3 Explanation of warning signs .................................................... 4

1.4 Identiﬁcation of warnings ......................................................... 4

1.5 Identiﬁcation of instructions for action ...................................... 5

2 Safety ................................................................................. 6

2.1 General warnings .....................................................................6

2.2 Hazards due to non-compliance with the safety instructions .....7

2.3 Safe operation .........................................................................7

2.4 Personal protective equipment .................................................7

2.5 Personnel qualiﬁcation .............................................................7

3 Appropriate and intended use ...........................................8

3.1 Notes on product warranty .......................................................8

3.2 Intended purpose .....................................................................8

3.3 Device revision ........................................................................8

3.4 Principles ................................................................................8

3.5 Prohibited dosing media ...........................................................8

3.6 Foreseeable misuse .................................................................8

4 Product Description ......................................................... 10

4.1 Properties ..............................................................................10

4.2 Scope of delivery ...................................................................10

4.3 Structure of the dosing pump .................................................10

4.4 Function description ..............................................................11

4.5 Nameplate .............................................................................11

5 Technical Data ..................................................................12

5.1 Delivery capacity data ............................................................12

5.2 Operating conditions and limits ..............................................12

5.3 Electrical data ........................................................................13

5.4 Other data .............................................................................13

6 Dimensions ......................................................................14

6.1 MAGDOS LK with dosing head made of PVC, PP or PVDF .........14

6.2 MAGDOS LK with dosing head made of stainless steel (1.4571) ...

7 Installing the Dosing Pump .............................................. 15

7.1 Set up information .................................................................15

7.2 Installation examples .............................................................15

8 Hydraulic installation ....................................................... 16

8.1 Dimensioning of the system ...................................................16

8.2 System piping ........................................................................17

8.3 Aligning the dosing head ........................................................17

8.4 Hydraulic connections ............................................................17

8.5 Connecting a leakage drain ....................................................19

8.6 Connecting the dosing head venting facility ............................19

8.7 Hydraulic accessories ............................................................20

9 Electrical installation ....................................................... 26

9.1 Principles ..............................................................................26

9.2 Description of connection sockets ..........................................26

10 Control .............................................................................. 29

10.1 Operator controls of the control unit ......................................29

10.2 Explanation of menu navigation ............................................29

10.3 Explanation of the menu icons ..............................................29

10.4 Menu settings at initial commissioning .................................30

10.5 Main menu ..........................................................................30

10.6 System setup .......................................................................30

10.7 Information about the dosing pump ......................................33

11 Operation ..........................................................................34

11.1 Commissioning the dosing pump..........................................34

11.2 Operating modes .................................................................36

11.3 External On/Off via Release input ..........................................39

11.4 Decommissioning the dosing pump ......................................39

11.5 Shutting down in an emergency ...........................................40

11.6 Storage ...............................................................................40

11.7 Transportation......................................................................40

11.8 Disposal of old units .............................................................40

12 Maintenance ....................................................................41

12.1 Maintenance intervals ..........................................................41

12.2 Tighten up dosing head bolts ................................................42

12.3 Change the diaphragm .........................................................42

12.4 Clean suction and discharge valves ......................................42

13 Troubleshooting ............................................................... 43

13.1 Type of fault .........................................................................43

14 Spare parts ....................................................................... 46

14.1 Diaphragm spare parts kits ..................................................46

14.2 Dosing head spare parts kits including valves .......................46

15 Delivery characteristic curves ......................................... 47

16 Menu structure of the Control Unit ..................................48

16.1 Program start.......................................................................48

16.2 System setup .......................................................................48

16.3 Main menu ..........................................................................51

17 Appendix .......................................................................... 53

17.1 Default settings....................................................................53

18 EC Declaration of Conformity ........................................... 54

19 Declaration of harmlessness ........................................... 55

20 Warranty application .......................................................56

Index ......................................................................................57

Notes to the Reader

General non-discrimination

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

1 Notes to the Reader

These Operating instructions contain the information and rules of behav iour necessary for safe and correct operation of the MAGDOS LK dosing pump.

Follow these principles:

nRead the entire Operating instructions prior to commissioning the unit. nEnsure that everyone who works with or on the dosing pump has read

the operating instructions and follows them.

nKeep the operating instructions for the entire service life of the dosing

pump.

nPass on the operating instructions to any subsequent owner of the

dosing pump.

1.1 General non-discrimination

In these operating instructions, only the male gender is used where grammar allows gender allocation. The purpose of this is to make the text easy to read. Men and women are always referred to equally. We would like to ask female readers for understanding of this text simpliﬁ cation.

1.2 Explanation of signal words

Different signal words in combination with warning signs are used in these Operating instructions. Signal words illustrate the gravity of possible injuries if the risk is ignored:

Signal word Meaning

DANGER

Refers to imminent danger. Ignoring this sign may lead to death or the most serious injuries.

WARNING

Refers to a potentially hazardous situation. Ignoring this sign might lead to death or the most serious injuries.

CAUTION

Refers to a potentially hazardous situation. Ignoring this sign may lead to light injuries or damage to property.

NOTICE

Refers to a danger which, if ignored, may compromise the unit or its function.

Tab. 1: Explanations of signal words

1.3 Explanation of warning signs

Warning signs represent the type and source of a danger:

Warning sign Type of danger

General danger zone

Danger of electric shock

Danger of caustic or other burns.

Danger of explosions

Danger of magnetic radiation

Danger of automatic start up

Danger of damage to machine or compromised function.

Tab. 2: Explanations of warning signs

1.4 Identiﬁcation of warnings

Warnings are intended to help you recognise risks and avoid negative consequences.

This is how warnings are identiﬁed:

Warning sign

SIGNAL WORD

Description of danger.

Consequences if ignored.

ðThe arrow signals a precautionary measure to be taken to

elim inate the danger.

Notes to the Reader

Identiﬁcation of instructions for action

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

1.5 Identiﬁcation of instructions for action

This is how pre-conditions for action are identiﬁed:

üPre-condition for action which must be met before taking action.

This is how instructions for action are identiﬁed:

èSeparate step with no follow-up action.

1. First step in a series of steps.

2. Second step in a series of steps.

4Result of the above action.

üAction completed, aim achieved.

Safety

General warnings

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

2 Safety

2.1 General warnings

The following warnings are intended to help you to eliminate the dangers that can arise while handling the dosing pump. Risk prevention measures always apply regardless of any speciﬁc action.

Safety instructions warning against risks arising from speciﬁc activities or situations can be found in the respective sub-chapters.

DANGER

Danger to life due to electric shock!

Wrongly connected or located cables or damaged ones can injure you.

ðConnect the device only to a socket outlet with earthing contact

protected by a ground fault circuit interrupter (GFCI).

ðReplace damaged cables without delay. ðDo not use extension cables. ðDo not bury cables. ðSecure cables to avoid being damaged by other equipment.

DANGER

Danger to life through explosions!

When using dosing pumps without ATEX certiﬁcation in a potentially explosive area, explosions can occur that result in fatal injuries.

ðNever use the MAGDOS LK dosing pump in potentially explosive

areas.

WARNING

Caustic burns or other burns through dosing media!

After connecting the mains supply, residual dosing media in the dosing head can spray out.

ðBefore connecting the mains supply, connect the dosing lines. ðCheck that all the screw connections have been tightened

cor rectly and are leak-proof.

WARNING

Caustic burns or other burns through dosing media!

While working on the dosing head, valves and connections, you may come into contact with dosing media.

ðUse sufﬁcient personal protective equipment. ðRinse the dosing pump with a liquid (e.g. water) which does not

pose any risk. Ensure that the liquid is compatible with the dosing medium.

ðRelease pressure in hydraulic parts. ðNever look into open ends of plugged pipelines and valves.

WARNING

Caustic burns or other burns through dosing media!

The materials of the dosing pump and hydraulic parts of the system must be suitable for the dosing medium that is used. Should this not be the case, the dosing media may leak.

ðMake sure that the materials you are using are suitable for the

dosing medium.

ðMake sure that the lubricants, adhesives, sealants, etc. that you

use are suitable for the dosing medium.

WARNING

Danger due to magnetic radiation for people with pace makers!

During operation solenoid diaphragm dosing pumps emit a stray magnetic ﬁeld. If you do not keep far enough away, the function of a pacemaker can be negatively affected.

ðPeople with pacemakers must always keep at least 50 cm away

from the dosing pump..

CAUTION

Increased risk of accidents due to insufﬁcient qualiﬁcation of personnel!

Dosing pumps and their accessories may only be installed, operated and maintained by personnel with sufﬁcient qualiﬁcations. Insufﬁ cient qualiﬁcation will raise the risk of accidents.

ðEnsure that all action is taken only by personnel with sufﬁcient and

corresponding qualiﬁcations.

ðPrevent access to the system for unauthorised persons.

Safety

Hazards due to non-compliance with the safety instructions

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

CAUTION

Danger of personal injury and material damage!

Changing dosing media can lead to unpredictable reactions.

ðThoroughly clean the dosing pump and appropriate sections of

the plant to avoid chemical reactions.

2.2 Hazards due to non-compliance with the safety instructions

Failure to observe the safety instructions can pose a risk not only to the personnel, but consequentially to the environment and the unit.

The speciﬁc consequences can be:

nFailure of vital functions of the dosing pump and the system, nfailure of required maintenance and repair methods, ndanger for individuals through dangerous dosing media, ndanger to the environment through substances leaking from the

system.

2.3 Safe operation

Besides the safety instructions speciﬁed in these Operating instructions, further safety rules apply and must be followed:

nAccident prevention regulations, nsafety and operating provisions, nsafety provisions for handling dangerous substances (mostly the

safety data sheets to dosing media),

nenvironmental protection provisions, napplicable standards and legislation.

2.4 Personal protective equipment

Based on the degree of risk posed by the dosing medium and the type of work you are carrying out, you must use corresponding protective equipment. Read the Accident Prevention Regulations and the Safety Data Sheets to the dosing media ﬁnd out what protective equipment you need.

As a minimum, the following protective equipment is recommended:

Protective clothing Protective gloves Goggles

Corresponding protective equipment must be used during these tasks:

nCommissioning, nworking on the dosing pump while running, ndecommissioning, nmaintenance work, ndisposal.

2.5 Personnel qualiﬁcation

Any personnel who work on the dosing pump must have appropriate special knowledge and skills.

Anybody who works with the dosing pump must meet the conditions below:

nAttendance at all the training courses offered by the owner, nPersonal suitability for the respective job, nSufﬁcient qualiﬁcation for the respective job, nTraining in handling of the dosing pump, nKnowledge of safety equipment and the way this equipment

func tions,

nKnowledge of these Operating instructions, particularly of safety

instructions and sections relevant for the job,

nKnowledge of fundamental regulations regarding health and safety

and accident prevention.

All persons must generally have the following minimum qualiﬁcation:

nTraining as specialists to carry out work on the dosing pump

unsu pervised,

nSufﬁcient training that they can work on the dosing pump under the

supervision and guidance of a trained specialist.

These Operating instructions differentiate these user groups:

2.5.1 Expert staff

Expert staff are able, thanks to their professional training, knowledge and experience as well as knowledge of the respective provisions, to do the job allocated to them and recognise and/or eliminate any possible dangers by themselves.

2.5.2 Trained persons

Trained persons have been trained by the operator into the tasks they are supposed to perform and into the dangers stemming from improper behaviour.

In the table below you can check what qualiﬁcations are the pre-condition for the respective tasks. Only people with appropriate qualiﬁcations are allowed to perform these tasks!

Qualiﬁcation Activities

Expert staff

nAssembly nHydraulic installations nElectrical installations nMaintenance nRepairs nCommissioning nDecommissioning nDisposal nTroubleshooting

Trained persons

nStorage nTransportation nControl nTroubleshooting

Tab. 3: Personnel qualiﬁcation

Appropriate and intended use

Notes on product warranty

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

3 Appropriate and intended use

3.1 Notes on product warranty

Any non-designated use of the product can compromise its function or intended protection. This leads to invalidation of any warranty claims!

Please note that liability is on the side of the user in the following cases:

nThe dosing pump is operated in a manner which is not consistent with

these Operating instructions, particularly the safety and handling instructions and the chapter entitled „Appropriate and intended use“.

nIf people operate the product who are not adequately qualiﬁed to carry

out their respective activities,

nNo original spare parts or accessories of Lutz-Jesco GmbH are used, nUnauthorised changes are made to the device by the user, nThe user uses different dosing media than those indicated in the

order,

nThe user does not use dosing media under the conditions agreed with

the manufacturer such as modiﬁed concentration, density, temperature, contamination, etc.

3.2 Intended purpose

The MAGDOS LK dosing pump is intended for the following purpose: the conveying and dosing of liquids.

3.3 Device revision

This operating manual applies to the following devices:

Device Month / year of

manufacture

Firmware

MAGDOS LK 03/2015 onwards 1.49 onwards

Tab. 4: Device revision

3.4 Principles

nBefore delivery, the manufacturer inspected the dosing pump and

operated it under speciﬁc conditions (with a speciﬁc dosing medium with a speciﬁc density and temperature, with speciﬁc pipe dimensions, etc.) Since these conditions vary at every installation location, you must calibrate the dosing pump after delivery. For information on the calibration procedure refer to “Calibrating the dosing pump“ (see page35). For details on the approximate values and the capacity of the dosing pump, refer to the chapter entitled “Delivery characteristic curves“ (see page45).

nInformation on the usage and environment (see “Technical Data“ on

page12) applies.

nAny restrictions regarding the viscosity, temperature and density of

dosing media must be followed. You must only use dosing media at temperatures above freezing point or below the boiling point of the respective medium.

nThe materials of the dosing pump and hydraulic parts of the system

must be suitable for the dosing medium that is used. In this connection, note that the resistance of these components can change in dependence on the temperature of the media and the operating pressure.

Information on the suitability of materials combined with different dosing media can be found in the Chemical Resis tance List of Lutz-Jesco GmbH. The information in this resistance list is based on information from the material manufacturers and on expertise obtained by Lutz-Jesco from handling the materials. As the durability of the materials depends on many factors, this list only constitutes initial guidance on selecting material. In all cases, test the equipment with the chemicals you use under operating conditions.

nThe dosing pump is not intended for outdoor use unless appropriate

protective measures have been taken.

nAvoid leaks of liquids and dust into the casing and avoid direct

expo sure to sunlight.

nYou must never operate dosing pumps in a potentially explosive

atmosphere if they do not have corresponding nameplates or an appropriate EC Declaration of Conformity for potentially explosive atmospheres.

3.5 Prohibited dosing media

The dosing pump must not be used for these media and substances:

nGaseous media, nradioactive media, nsolid substances, ncombustible media, nall other media that are not suitable for delivery using this dosing

pump.

3.6 Foreseeable misuse

Below, there is information about the applications of the dosing pump or associated equipment that are not considered to be intended use. This chapter is intended to allow you to detect possible misuse in advance and to avoid it.

Foreseeable misuse is assigned to the individual stages of the product lifetime:

3.6.1 Faulty assembly

nUnstable or unsuitable bracket nDosing pump bolted wrongly or loosely

3.6.2 Faulty hydraulic installation

nSuction and pressure lines dimensioned incorrectly nUnsuitable connection of the pipes due to wrong material or

unsuit able connections.

nSuction and pressure lines mixed-up nDamage to threads due to them being tightened too much nBending of pipelines nNo free return ﬂow of the pressure relief valve nExcessive demand due to the pressure differences between the

suction and discharge valves

Appropriate and intended use

Foreseeable misuse

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

nThrough-suction at installation without back-pressure valves nDamage due to undamped acceleration mass forces nExceeding the admissible pressure on the suction and discharge sides nUsing damaged parts

3.6.3 Faulty electrical installation

nConnecting the mains voltage without a protective earth nUnsecured mains or one that does not conform to standards nNot possible to immediately or easily disconnect the power supply nWrong connecting cables for mains voltage nDosing pump accessories connected to wrong sockets nProtective earth removed

3.6.4 Faulty commissioning

nCommissioning with damaged plant nShut-off valves closed at commissioning nClosed suction or pressure line, e.g. due to blockages nPersonnel was not informed before commissioning nSystem was recommissioned after maintenance without all the

protective equipment and ﬁxtures, etc. being reconnected.

nInadequate protective clothing or none at all

3.6.5 Faulty operation

nProtective equipment not functioning correctly or dismantled nModiﬁcation of the dosing pump without authority nIgnoring operational disturbances nElimination of operational disturbances by personnel without

adequate qualiﬁcations

nDeposits in the dosing head due to inadequate purging, particularly

with suspensions

nBridging the external fuse nOperation made more difﬁcult due to inadequate lighting or machines

that are difﬁcult to access

nOperation not possible due to dirty or illegible display of the dosing

pump

nDelivery of dosing media for which the system is not designed nDelivery of particulate or contaminated dosing media nInadequate protective clothing or none at all

3.6.6 Faulty maintenance

nCarrying out maintenance during ongoing operation nCarrying out work that is not described in the operating instructions nNo adequate or regular inspection of correct functioning nNo replacement of damaged parts or cables with inadequate

insula tion

nNo securing against reactivation during maintenance work nUsing cleaning materials that can cause reactions with the dosing

media

nInadequate cleaning of the system nUnsuitable purging medium nUnsuitable cleaning materials nCleaning materials left in system sections

nUsing unsuitable cleaning equipment nUsing the wrong spares or lubricants nContaminating the dosing medium with lubricant nInstalling spares without following the instructions in the operating

manual

nBlocking venting oriﬁces nPulling off sections of the plant nContamination at installation without a dirt trap nMixing up the valves nMixing up the sensor lines nNot reconnecting all the lines nDamaging or not installing all the seals nNot renewing seals nNot paying attention to safety data sheets nInadequate protective clothing or none at all

3.6.7 Faulty decommissioning

nNot completely removing the dosing medium nDismantling lines while the dosing pump is running nDevice not disconnected from the power supply nUsing the wrong dismantling tools nInadequate protective clothing or none at all

3.6.8 Faulty disposal

nIncorrect disposal of dosing media, operating resources and other

materials

nNo labelling of hazardous substances

Product Description

Properties

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

4 Product Description

4.1 Properties

The MAGDOS LK is a Solenoid-Diaphragm Dosing Pump that is used when precise dosing results are required.

They are characterized by the following properties:

nOutput range from 0.5 to 15 l/h, up to 16 bar, nReproducible dosing precision of w 2%, nIntegrated automatic dosing head venting facility (except with

stain less steel (1.4571) dosing heads),

nSuitable for highly aggressive or poisonous dosing media, nOperating modes: Manual mode and Pulse input, nGraphic display: 128 x 64 px, 1.5“, monochrome, illuminated, nMenu languages: English, German, French, Spanish, Portuguese,

Dutch,

nFour multifunction keys for operator inputs, nFloor- and wall-mounting options, nRelease code and security code, nCalibration option, nEco-Mode energy-saving mode, nConnections: M12x1 connector, A-coded

4.2 Scope of delivery

Please compare the delivery note with the scope of delivery. The following items are part of the scope of delivery:

n MAGDOS LK dosing pump, nOne set each of hose clamping connections for the suction and

discharge sides for hoses with diameters of 4/6 mm, 6/9 mm and 6/12 mm (made of PVC, PP and PVDF),

n3 covering caps for electrical connections (mounted on the dosing

pump),

nMains cable, nOperating Manual, nInspection report and test certiﬁcate (optional), nAccessory kit (optional).

4.3 Structure of the dosing pump

4.3.1 General Overview

Fig. 1: Overview of MAGDOS LK dosing pump

No. Description

Dosing head

Drive unit

Control unit

4.3.2 Dosing head

Fig. 2: Dosing head

No. Description

Valve and connection on the discharge side

integrated dosing head venting facility (plastic version only)

Arrow indicating the direction of throughﬂow of the dosing medium (plastic version only)

Valve and connection on the suction side

Product Description

Function description

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

4.3.3 Control elements

Fig. 3: Controller of MAGDOS LK dosing pump

No. Description

Graphic display

Multifunction keys on the contol unit for operator inputs

Connection sockets for external operation or connecting acces sories

Mains cable for power supply

Tab. 5: Designation of components

4.4 Function description

Dosing pumps are positive displacement pumps. They are used if precisely deﬁned delivery of a medium is necessary. A constant volume per stroke or time is delivered.

The system delivers or meters the dosing medium by means of a repeated sequence of suction strokes followed by pressure strokes. This results in a pulsing ﬂow.

If the dosing pump is in the suction stroke phase, the diaphragm is pulled into the rear ﬁnal position. Due to the resulting vacuum in the dosing head, the discharge valve closes, the suction valve opens and dosing medium ﬂows from the suction line into the dosing head.

If the dosing pump is in the pressure stroke phase, the diaphragm is moved into the front ﬁnal position. Due to the pressure in the dosing head, the suction valve closes and the dosing medium ﬂows through the discharge valve from the dosing head into the pressurised pipe.

4.5 Nameplate

There is information on the equipment about safety or the product‘s way of functioning. The information must stay legible for the duration of the service life of the product.

Fig. 4:

Material: Max. XXX l/h at bar Max. XXX l/h at bar IP XX, XXX V, XXXX Hz, XX W

Lutz-Jesco GmbH 30900 Wedemark Germany

XX/XXXX

S/N: XXXXXXXXXXP/N:

Made in Germany

*102A12345678*

*12345678012345*

MAGDOS LK

d e

MAGDOS LK nameplate

No. Description

Product, type, nominal size

Part number

Type of material of dosing head/ type of material of seals

Maximum delivery capacity at average pressure

Maximum delivery capacity at maximum pressure

Protection class

Voltage supply

Frequency

Power consumption

WEEE label

Label showing conformity with applicable European directives

Month / year of manufacture

Serial number

Tab. 6: Nameplate

f g h i

Technical Data

Delivery capacity data

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

5 Technical Data

5.1 Delivery capacity data

Please note that some of this data only represents guide values. The actual capacity of a dosing pump depends on various factors. For approximate values of the delivery capacity at different pressures, refer to “Delivery characteristic curves“ (see page45).

Information Value

MAGDOS LK size

05 1 2 4 6 10 15

Delivery capacity at max. back pressure

l/h 0.36 0.76 1.9 3.4 6.2 9.0 13

ml/stroke 0.05 0.05 0.2 0.32 0.57 0.83 0.87

Max. back pressure bar 16 8 6 3

Max. delivery pressure in Eco-Mode 1* bar 10 6 4 2

Delivery capacity at average back pressure

l/h 0.54 1.1 2.3 3.8 6.8 10 15

ml/stroke 0.08 0.08 0.24 0.35 0.63 0.92 1

Average back pressure bar 8 4 3 1

Max. stroke frequency RPM 120 250 160 180 250

Suction head for non-gassing media (suction line ﬁlled)

mWS 5 3 2

Tab. 7: Output data

* In the case of operation in Eco-Mode energy saving mode, the delivery capacity is 5-10 % less than in normal mode (with the same back pressure). If necessary, recalibration may be necessary (see “Calibrating the dosing pump“ on page 35).

5.2 Operating conditions and limits

Information Value

MAGDOS LK size

05 – 15

Permitted ambient temperature °C 0 – 45 (0 – 40 with PVC parts)*

Relative humidity % Max. 90

Max. sound pressure level (depressurised) dB(A) 68 – 75

Max. sound pressure level (at test pres sure) dB(A) 65 – 70

Max. supply pressure mbar 800

Viscosity limits mPas 300** / 1000***

Adjustable dosing range % 0 – 100

Tab. 8: Operating conditions and limits

* Use of dosing pumps at ambient temperatures of under 5 °C has to be checked individually. In those cases please contact the manufacturer.

** With a viscosity of ~300 mPas and above, you must use spring-loaded valves.

*** If the viscosity is above 1000 mPas, this must be checked individually and the stroke frequency must be between 50 and 100 strokes/min.

Technical Data

Electrical data

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

5.2.1 Permitted temperature of the medium

Information Value MAGDOS LK (all sizes)

Dosing head made of PVC °C 0 – 35

Dosing head made of PP °C 0 – 60

Dosing head made of PVDF °C 0 – 80

Dosing head made of stainless steel (1.4571) °C 0 – 80

Tab. 9: Permitted temperature of the medium

5.3 Electrical data

Information Value

MAGDOS LK size

05 1 2 4 6 10 15

Voltage supply 230 V AC ± 10 %, 50/60 Hz or

115 V AC ± 10 %, 50/60 Hz (refer to name plate)

Power consumption W 8 13 19 25 22

Max. current consumption during dosing stroke

at 115 V AC

1,8 2,3 2,5 2,3

at 230 V AC 0,9 1,1 1,4 1,2

Eco-Mode 1

Power consumption W 6 9 14 16 18 17

Max. current consumption during dosing stroke

at 115 V AC

1,6 1,9 2,2 2,3 2,0

at 230 V AC 0,8 0,9 1,0 1,1 0,9

Tab. 10: Electrical data

5.4 Other data

Information

Value

MAGDOS LK size

05 1 2 4 6 10 15

Weight (with dosing head made of PVC, PP or PVDF)

kg ~ 3.2

Weight (with dosing head made of stain less steel (1.4571))

kg ~ 4.3

Diameter of diaphragm mm 24 33 39

Electrical cable m 1.8 m (with mains plug)

Protection class IP65 (with covering caps on the connections)

Insulation class F

Valve connection G 5/8 external

Valve size DN3 DN4

Tab. 11: Other data

Dimensions

MAGDOS LK with dosing head made of PVC, PP or PVDF

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

6 Dimensions

6.1 MAGDOS LK with dosing head made of PVC, PP or PVDF



 







 









 

Fig. 5: Dimensioned drawing of MAGDOS LK with dosing head made of PVC, PP or PVDF (all dimensions in mm)

Connection Material Size Nominal diameter L

Hose clip PVC / PP / PVDF

4/6 mm DN4 31

1/4x3/8” 1/4“ 34

6/9 mm

DN6

6/12 mm DN6 15

6.2 MAGDOS LK with dosing head made of stainless steel (1.4571)



 







 









 

Fig. 6: Dimensioned drawing of MAGDOS LK with dosing head made of stainless steel (1.4571) (all dimensions in mm)

Connection Material Size Nominal diameter L

Hose clip Stainless steel (1.4571) / PVDF 4/6 mm DN4 50

Hose clip Stainless steel (1.4571) / PVDF 6/9 mm DN6 54

Installing the Dosing Pump

Set up information

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

7 Installing the Dosing Pump

DANGER

Danger to life due to electric shock!

Electrically conductive liquid can enter pump housings, cable screw connections and mains connectors.

ðMake sure that all protective measures comply at least with the

requirements of protection class IP65.

ðAlways set up the dosing pump such that water cannot enter the

housing.

CAUTION

Danger of personal injury and material damage!

A dosing pump that is difﬁcult to access represents a danger due to incorrect operation and faulty maintenance.

ðInstall the dosing pump such that it is accessible at all times.

7.1 Set up information

When installing, follow the basic principles below:

nThe valves must be vertical: Discharge valve at top, suction valve at

bottom. in this connection, pay attention to the arrow on the dosing head. The dosing head must be aligned such that the arrow points vertically upwards.

nYou should install the dosing pump at a convenient height for

opera tion.

nIt must not be installed under the ceiling. nThe frame of foundation for ﬁxing the dosing pump must not be

subjected to jolts. The pump must be vibration-free and stable.

nThere must be enough free space in the area of the dosing head and

the suction and discharge valves for these parts to be easily disman tled if required. The entire space requirement for installation and maintenance is approximately 1 m².

nThe distance from the sides of the dosing pump to the wall or other

dosing pumps or equipment must be at least 3 cm. There must be a guaranteed ﬂow of circulating air.

nThe maximum ambient temperature must be complied with, see

“Operating conditions and limits” on page12. If necessary, radiated heat from surrounding equipment must be screened.

nAvoid exposure to direct sunlight. nThe dosing pump is not intended for use out of doors unless

appro priate protective measures have been taken to prevent dust and water from entering the housing.

nFor the dimensions of the fastening holes, refer to “Dimensions“ (see

page14).

nThe tightening torque for the fastening bolts is 1.5 - 2 Nm.

7.2 Installation examples

7.2.1 Installation on a wall bracket

Fig. 7: Installation on a wall bracket

To reduce the structure-borne noise, the dosing pump is bolted to the wall bracket using rubber elements. The materials necessary for this are included with the wall bracket.

7.2.2 Installation on the wall

Fig. 8: Installation on the wall

The dosing pump can be mounted to the ﬂoor or directly to the wall without the need for additional elements. Turn the dosing head appropriately to ensure the ﬂow direction of the medium through the dosing head.

Hydraulic installation

Dimensioning of the system

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

8 Hydraulic installation

In this chapter, you will ﬁnd information about the hydraulic parts of a system that you should install or that can install additionally. In many cases, you must install hydraulic accessories to be able to use all the functions that the dosing pump MAGDOS LK offers, to guarantee func tional safety or to achieve a high level of dosing precision.

WARNING

Caustic burns or other burns through dosing media!

The materials of the dosing pump and hydraulic parts of the system must be suitable for the dosing medium that is used. Should this not be the case, the dosing media may leak. Depending on the type and hazardousness of the dosing medium, this can result in injury.

ðMake sure that the materials you are using are suitable for the

dosing medium.

ðMake sure that the lubricants, adhesives, sealants, etc. that you

use are suitable for the dosing medium.

WARNING

Caustic burns or other burns through dosing media!

If there is a diaphragm rupture, the dosing medium can escape in an uncontrolled way. Depending on the type and hazardousness of the dosing medium, this can result in injury.

ðInstall a leakage drain.

WARNING

Caustic burns or other burns through dosing media!

The dosing pump can generate a pressure that is many times the rated one. A blocked pressure line can lead to dosing medium escaping. Depending on the type and hazardousness of the dosing medium, this can result in injury.

ðInstall pressure relief valves.

CAUTION

Danger of personal injury and material damage!

High peak pressures can lead to piping vibrating and cause them to snap. This can result in injury due to uncontrollable piping or escap ing dosing media.

ðInstall pulsation dampeners.

NOTICE

Damage to drives due to overloading

The pressure conditions between the suction and discharge sides must be balanced; otherwise, overloading can result. This can lead to uncontrolled dosing processes, damage to the plant pipework and to the dosing pump.

ðEnsure that the pressure on the discharge side is at least 1 bar

greater than on the suction side.

NOTICE

Locking of threads

Stainless steel and plastic parts (particularly those made of PVC) that are bolted together in a detachable connection (e.g. the dosing head and the valves) can lock. This makes them difﬁcult to release.

ðBefore bolting, grease the corresponding parts with a lubricant

(e.g. PTFE spray). Ensure that the lubricant is compatible with the dosing medium.

8.1 Dimensioning of the system

nThe dosing pump’s technical data (see “Technical Data“ on page12)

must be taken into account and the plant’s layout must be set up appropriately (e.g. pressure loss when rating the lines with regard to their nominal diameter and length).

nYou must design the entire plant and its integrated dosing pump such

that escaping dosing medium due to the failure of wearing parts such as the diaphragm, or to burst hoses does not lead to permanent damage to parts of the system or the premises.

nThe leakage opening of the dosing head must be visible so that you

can detect a diaphragm failure. It must be possible for the outﬂow from the leakage drain to be on a free downwards gradient.

nIf you use hazardous dosing media, the installation must be designed

such that no disproportionately high consequential damages arise due to dosing media escaping.

nTo avoid dosing errors after the end of the process, the dosing pump

must be locked hydraulically.

nTo allow you to easily inspect the pressure conditions in the system,

you should provide connections for pressure gauges close to the suction and discharge valves.

Hydraulic installation

System piping

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

8.2 System piping

nThe system piping must not exert any force on the connections and

valves of the dosing pump.

nThis means that steel piping should be connected to the dosing pump

by means of ﬂexible pipe sections.

nThe nominal diameters of the pipework and the installed ﬁttings

should be rated the same as or greater than the nominal diameters of the dosing pump‘s suction and discharge valves.

nThe suction line should be kept as short as possible. nYou should avoid intertwined hoses. nAvoid loops, since air bubbles can collect.

8.3 Aligning the dosing head

Fig. 9: Aligning the dosing head

When connecting the dosing lines to the dosing pump, you must observe the direction of through-ﬂow (see arrow b).The dosing head must be aligned vertically.

The suction valve c must always point downwards. Accordingly, arrow b and pressure valve f always point upwards. This is irrespective of the positioning of the dosing head to the drive.

8.4 Hydraulic connections

8.4.1 Connecting hose clips

Choose the hose connection according to the condition of the hose (material, inner diameter, wall thickness) in order to ensure maximum pressure resistance.

8.4.1.1 Sizes 4/6 and 6/9

4/6

6/9

Fig. 10: Hose clips 4/6 and 6/9 (internal and external diameters in mm)

Perform the following working steps:

1. Cut the hose a to length neatly and at an exact right angle.

2. Place a gasket that is suitable for the dosing medium between the

connection e and the valve.

3. Screw the connecting piece e to the dosing pump‘s valve using the

union nut b.

4. Thread the union nut c and the clamping ring d onto the hose.

5. Plug the hose a all the way in to the grommet of connection piece

6. Push the clamping ring d onto the grommet of connection piecee

and screw it to the union nut c.

7. Carry out the same procedure with the connection to the dosing

pump‘s other valve.

üHose clip connected.

Hydraulic installation

Hydraulic connections

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

8.4.1.2 Size 6/12

Fig. 11: Hose clip 6/12 (internal and external diameter in mm)

Size 6/12 hose clips only have a union nut. It clamps the hose onto the grommet of the connection piece and at the same time fastens on the dosing pump‘s valve.

Perform the following working steps:

1. Cut the hose a to length neatly and at an exact right angle.

2. Place a gasket that is suitable for the dosing medium between the

connection d and the valve.

3. Push the union nut b and the cutting ring c over the hose a.

4. Press the end of the hose a onto the grommet of connection

pieced. You can do this more easily by moistening the end of the hose on the inside or applying some lubricant to the grommet in the cone area. You should push at least two thirds of the hose onto the grommet of the connection piece.

5. Push the cutting ring c over the hose a into the cone area on the

grommet of connection piece d.

6. Screw the union nut b onto the valve of the dosing pump.

üHose clip connected.

8.4.2 Making the bonded connection

Fig. 12: Bonded connection

Perform the following working steps:

1. Cut the PVC tube to length.

2. Push the union nut a onto the tube.

3. Stick the bonded coupling sleeve b to the tube (follow the

instruc tions of the adhesive manufacturer).

4. Screw the union nut a onto the valve of the dosing pump. Use a

gasket that is suitable for the dosing medium.

üBonded connection made.

8.4.3 Making the cemented connection

Fig. 13: Cemented connection

Perform the following working steps:

1. Cut the tube to length.

2. Cut the thread b onto the end of the tube.

3. Push the union nut a onto the tube.

4. Seal the thread b. When choosing your sealing material, take into

account its resistance to material, temperature and pressure.

5. Screw the union nut a onto the valve of the dosing pump. Use a

gasket that is suitable for the dosing medium.

üCemented connection made.

Under normal conditions, you only need to screw the hydraulic connections ﬁnger-tight. However, due to the mate rial settling, the pre-tension of the screw connection can slacken. This means that you must re-tighten the screw connection before carrying out commissioning.

Hydraulic installation

Connecting a leakage drain

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

8.5 Connecting a leakage drain

Lutz-Jesco GmbH dosing pumps are produced to the highest quality standards and have a long service life. However, some parts are subject to operational wear. This is the case particularly with the diaphragms that are continuously subjected to forces during the suction and discharge strokes and to the effects of the dosing medium.

If a diaphragm ruptures, the dosing medium starts to leak. This leakage is drained via the leakage opening. On the ﬂange of the dosing head, there are three openings for this purpose. Depending on the alignment of the dosing pump, the leakage is drained via the downward opening.

Fig. 14: Openings of the leakage drain

NOTICE

Damage to drives due to effervescent media

If a hose is connected to the leakage drain and it is routed back into the dosing tank, effervescent media can enter the drive and damage it.

ðCollect the leakage in a collecting pan. ðAs an alternative, you can route the leakage back to to the dosing

tank using a funnel. You should install the funnel at an adequate distance from the leakage opening.

8.6 Connecting the dosing head venting facility

The MAGDOS LK dosing heads have an integrated dosing head venting facility (except for dosing heads made of stainless steel).

For the procedure when venting, refer to “Venting the dosing pump” on page34.

Fig. 15: Dosing head venting facility with hose connection

Perform the following working steps:

1. Connect a 4/6 hose to the dosing head venting facility.

2. Route the other end of the hose into the dosing tank or a collecting

tank.

üDosing head venting facility connected.

Hydraulic installation

Hydraulic accessories

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

8.7 Hydraulic accessories

The following chapter is intended to give you an overview of installation options.

Please note that these operating instructions are no substitute for the instructions supplied with the accessories in each case. The corresponding documentation supplied with the product applies to safety information and provides exact instructions on assembly.

8.7.1 Injection nozzle

If the pressure line enters a main line, it is advisable to install an injec tion nozzle.

Injection nozzles have three main functions:

nDosing the medium into a main line, nPreventing ﬂowback into the pressure line through a non-return valve.

Notes on assembly:

nDouble-ball injection nozzles must be installed into the main line

vertically from the bottom. You can install hose and spring-loaded injection nozzles any way you like.

nWith dosing media that tend to crystallize, it is advisable to carry out

installation into the main line from the bottom. This prevents air bubbles from being trapped.

nMany dosing media tend to contaminate the injection nozzles, which

can lead to blockages. In cases like this, it is advisable to install an injection nozzle that is easy to dismantle and block off.

Fig. 16: Installation with an injection nozzle

No. Description

Main line

Injection nozzle with shut-off valve

Pressure relief valve

Chemical tank

Pressure line

MAGDOS LK dosing pump

Wall bracket

Shutoff valve

Suction line

Tab. 12: Designation of components

8.7.2 Contact Water Meter

The contact-type water meter measures the throughﬂow in a pipe and sends a pulse to the dosing pump, which then starts dosing. This means that ideal proportional dosing is also possible with large throughﬂow ﬂuctuations.

The Contact Water Meter connects to connection socket 2 (see “Connection socket 2“ on page27).

You determine the ratio of throughﬂow and executed strokes of the dosing pump in „Pulse input“ mode, (see “Water meter“ on page37).

Fig. 17: MAGDOS LK installation on contact-type water meter

Hydraulic installation

Hydraulic accessories

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

8.7.3 Pressure relief valve

Pressure relief valves have an important safety function for protecting the dosing pump and the associated pipes and ﬁttings.s The dosing pump can generate a pressure that is many times the rated one. A blocked pressure line can lead to dosing medium escaping.

An inadmissibly high pressure can occur if:

nthe shut-off valves are closed even though the dosing pump is

running,

npipes block.

At an appropriate pressure, a pressure relief valve opens a bypass line and protects the system in this way from pressures that are too high.

Notes on assembly:

nThe line for returning dosing medium from the pressure relief valve

must be routed to the dosing tank or to a collecting pan.

nThe pressure in the dosing tank must not be too high so that it is

possible to accommodate the returned dosing medium.

nAs an alternative, the system can return dosing medium into the

suction line in front of the dosing pump. In this case, there must not be a non-return valve or a foot valve in the suction line.

nYou should install the pressure relief valve as close as possible to the

dosing head.

Fig. 18: Installation with pressure relief valve – returning to the suction line

Fig. 19: Installation with pressure relief valve – returning to the dosing tank

No. Description

Main line

Injection nozzle with shut-off valve

Pressure relief valve

Chemical tank

Pressure line

MAGDOS LK dosing pump

Wall bracket

Shutoff valve

Suction line

Tab. 13: Designation of components

Hydraulic installation

Hydraulic accessories

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

8.7.4 Back-pressure valve

Back-pressure valves are necessary if:

nthere are considerably ﬂuctuating system pressures, nthe pressure on the suction side is higher than on the discharge side

or if you intend to carry out dosing into depressurized lines.

In cases like this, if you do not use a back-pressure valve, imprecise dosing results will occur or overloading will result. The back-pressure valve solves these problems by generating a deﬁned, constant back pressure.

In some circumstances, a back-pressure valve is unnecessary if you use a hose injection nozzle and if the back pressure that it generates is adequate.

Fig. 20: Installation with a back-pressure valve

No. Description

Main line

Injection nozzle with shut-off valve

Back-pressure valve

Pressure relief valve

Chemical tank

Tab. 14: Designation of components

No. Description

Pressure line

MAGDOS LK dosing pump

Wall bracket

Shutoff valve

Suction line

Tab. 14: Designation of components

8.7.5 Pulsation dampener

Pulsation dampeners have the following functions:

nDamping pulsating delivery ﬂows for processes that require

low-pulsation dosing,

nReducing the throughﬂow resistance with long pipelines.

When installed on the suction side:

nDamping of acceleration mass forces and with this reduction of wear

on the dosing pump.

nPreventing cavitation (pull-off of the liquid column) due to too high

acceleration.

However, pulsation dampeners also have important safety functions, since they prevent pressure peaks from arising that lead to piping vibrating and cause them to snap.

This problem can occur:

nwith the high amplitudes of the vibrations, nwhen using long pipes (the severity of the pulsation increases with the

length of the pipe),

nwhen using rigid piping instead of elastic hoses.

Notes on assembly:

nYou should carry out assembly in the direct vicinity of the location

where you want to damp the pressure peaks (directly in front of the suction valve or directly behind the discharge valve).

nPulsation dampeners should be installed with throttle valves or

back-pressure valves installed directly behind them. By setting the valves appropriately, you can further-optimise damping of the pulsations.

nTo prevent unnecessary pipe friction losses, you should lay the

connecting line straight and in accordance with the rated width of the pulsation dampener.

nYou must separately fasten relatively large pulsation dampeners and

ones with hose connections.

nPipelines must not transfer any mechanical tensions onto the

pulsa tion dampener.

Hydraulic installation

Hydraulic accessories

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Fig. 21: Installation with a pulsation dampener

No. Description

Main line

Injection nozzle with shut-off valve

Pulsation dampener

Chemical tank

Pressure line

MAGDOS LK dosing pump

Wall bracket

Suction pulsation dampener

Suction line

Shutoff valve

Tab. 15: Designation of components

8.7.6 Priming aid

Priming aids are particularly advisable:

nin the case of dosing pumps with small volumetric displacements per

stroke or with low stroke length settings,

nwith high uction heads, nwith highly dense dosing media, nat priming for the ﬁrst time due to dry valves and air in the suction line

and the dosing head,

nin dosing systems with frequent downtimes.

Further advantages resulting from priming aids:

npreventing cavitation in the suction line, ngas removal, noptical dosing control with small amounts, nsmoothing of the suction ﬂow.

Fig. 22: Installation with a priming aid

No. Description

Main line

Injection nozzle with shut-off valve

Priming aid

MAGDOS LK dosing pump

Wall bracket

Tab. 16: Designation of components

Hydraulic installation

Hydraulic accessories

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

No. Description

Chemical tank

Suction line

Tab. 16: Designation of components

8.7.7 Level monitoring

Level monitoring of suction-side feeding of the dosing medium to prevent the tank being sucked dry and to ensure that it can be topped up again in good time.

Fig. 23: Installation with a level monitoring system

No. Description

Main line

Injection nozzle with shut-off valve

Pressure line

MAGDOS LK dosing pump

Chemical tank

Suction line with level monitoring

Tab. 17: Designation of components

8.7.8 Dosing of suspensions

When dosing suspensions, the dosing head must be rinsed regularly to prevent depositing. To do this, you install a feed line for the rinsing medium (water) in the suction side installation.

Fig. 24: Dosing of suspensions

No. Description

Main line

Injection nozzle with shut-off valve

Pressure line

Chemical tank

MAGDOS LK dosing pump

Wall bracket

Suction line

Shutoff valve

Line for rinsing the dosing head

Tab. 18: Designation of components

Hydraulic installation

Hydraulic accessories

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

8.7.9 Suction pressure regulator

A suction pressure regulator may be necessary if the suction-side installation of the system demonstrates a varying suction pressure or supply pressure:

nDosing pumps that are installed above dosing tanks deliver less as the

tank empties, since the suction head increases.

nDosing pumps that are installed below dosing tanks deliver less as the

tank empties, since the positive delivery pressure reduces.

Further problems that can occur:

nGreater wear on the dosing pump, e.g. diaphragm rupture due to the

effects of heavy forces with particularly high tanks and high-density dosing media.

nIdling of the dosing tank in the case of a diaphragm rupture or pipe

breakage.

nImpermissibly high forces in the pump transmission that occur when

dosing pumps receive the dosing medium directly from the pressure line.

nReduced performance or destruction of ﬁttings due to cavitation with

long suction lines.

Installing a suction pressure regulator is a remedy for the problems above. The suction pressure regulator is opened by the dosing pump‘s suction pressure. This ensures that no dosing medium can ﬂow if the dosing pump is not running or no vacuum can be generated following a pipe fracture.

Notes on assembly:

nWhen using a large suction pressure regulator, you should provide a

pulsation dampener on the suction side.

Fig. 25: Installation with a suction pressure regulator

No. Description

Main line

Injection nozzle with shutoff valve

Pressure line

Chemical tank

MAGDOS LK dosing pump

Wall bracket

Suction line

Suction pressure regulator

Shutoff valve

Tab. 19: Designation of components

Electrical installation

Principles

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

9 Electrical installation

DANGER

Danger to life due to electric shock!

If there is an electrical accident, you must disconnect the dosing pump from the mains as quickly as possible.

ðInstall an emergency stop switch or integrate the dosing pump into

the plant safety concept.

CAUTION

Danger of automatic start up!

The dosing pump does not have an ON/OFF switch and may start to pump as soon as it is connected to the mains supply. This means that dosing medium can escape. Depending on the type and hazardousness of the dosing medium, this can result in damage to property or to injury.

ðInstall an emergency stop switch or integrate the dosing pump into

the plant safety concept.

NOTICE

Damage due to wrong mains voltage

The dosing pump can be damaged if you connect it to the wrong mains voltage.

ðObserve the information on the mains supply that is given on the

nameplate.

NOTICE

Insufﬁcient electromagnetic compatibility

When you connect the dosing pump to a socket without an attached protective earth, it is not possible to guarantee the interference radiation and interference immunity according to EMC regulations.

ðOnly connect the dosing pump to sockets with an attached

pro tective earth.

9.1 Principles

nAccording to the model the dosing pump either has a 230 V AC or a

115 V AC power supply unit.

nThe electrical connection comply with local regulations. nThe dosing pump must be plugged into a grounded power outlet. nTo avoid dosing errors at the end of the process, the dosing pump

must be locked electrically.

nThe dosing pump must not be operated by switching the mains

voltage on or off.

nSignal cables must not be laid parallel to high-voltage current lines or

mains cables. You must route supply and signal lines in separate channels. An angle of 90° is required at line crossings.

9.2 Description of connection sockets

Fig. 26: Connection sockets 1 - 3

Inputs Connection socket

Release input 1

Pulse input 2

Level input 3

Tab. 20: Inputs of the control unit

Outputs Connection socket

Stroke feedback output alternative: Alarm optocupler output

Tab. 21: Outputs of the control unit

Electrical installation

Description of connection sockets

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

9.2.1 Connection socket 1

Connection socket 1 is equipped with an optocupler output and a switching input. The optocupler can be conﬁgured for stroke feedback or a fault message. The connections and switch data are listed in the following tables.

Pin M12x1

(A-coded)

Assignments Connection Cable colour*

Optocoupler collector (+)

Brown BN

2 Optocoupler

emitter (-)

White WH

Ground (GND)

Blue BU

4 External On/Off Black BK

Tab. 22: Connection socket 1

* Applies to cable colours of cables from Lutz-Jesco GmbH. No liability is accepted for cables from other manufacturers.

Pin Function

Optocupler (Pin 1&2) max. 30V DC, max. 5mA

Release input (Pin 3&4) Potential-free contact

Opener NC or closer NO, Freely programmable

Tab. 23: Technical data connection socket 1

9.2.1.1 Stroke feedback output

At the stroke feedback output, the dosing pump reports back each executed stroke to the pulse input of another dosing pump. In this way, it is possible to network several dosing pumps and to trigger synchro nized dosing strokes.

The stroke feedback output can continue to be used e.g. to evaluate the signal in a PLC (stroke counting for batch mode).

Fig. 27: Synchronization of several dosing pumps by means of stroke feedback and pulse

control

9.2.1.2 Fault reporting optocupler

The optocupler will notify dosing pump faults upon activation of this function. The message can be evaluated e.g. with a PLC.

For information on how to set the function of the release input, see 10.6.3 „Set “Alarm output” menu item“ on page 31.

9.2.1.3 Release input

Using the Release input, it is possible to start or stop the dosing pump externally.

For information on how to set the function of the release input, see 10.6.5 „Set “Release input” menu item“ on page 31.

9.2.2 Connection socket 2

9.2.2.1 Pulse input

The pulse input makes it possible to control the delivery capacity by means of pulses. The system regulates the delivery capacity by means of the dosing pump‘s stroke frequency and number of strokes in dependence on the number of pulses and the pulse spacing.

nProvided potential-free contact nFor potential-free NO contact, e.g. a contact-type water meter nPulse length min. 4 ms

For information on setting the Pulse input operating mode, see page 36.

Pin M12x1

(A-coded)

Assignments Connection Cable colour*

Pulses

Brown BN

2 - White WH

3 Ground (GND) Blue BU

4 - - - Black BK

Tab. 24: Connection socket 2

* Applies to cable colours of cables from Lutz-Jesco GmbH. No liability is accepted for cables from other manufacturers.

9.2.3 Connection socket 3

9.2.3.1 Level input

Connection for level monitoring of a dosing tank (e.g. a suction line with a ﬂoat switch).

nAlert and main alarm nPotential-free contact nProgrammable NC or NO contact

Electrical installation

Description of connection sockets

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

For more details on installing the level monitoring system, see page 24.

For information on setting the Level input function, see page 30.

Pin M12x1

(A-coded)

Assignments Connection Cable colour*

Pre-alarm

Brown BN

2 Main alarm White WH

3 Ground (GND) Blue BU

4 - - - Black BK

Tab. 25: Connection socket 3

* Applies to cable colours of cables from Lutz-Jesco GmbH. No liability is accepted for cables from other manufacturers.

Control

Operator controls of the control unit

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

10 Control

10.1 Operator controls of the control unit

Fig. 28: Operator controls of the control unit

No. Explanation

Graphic display

Four multifunction keys

Tab. 26: Operator controls of the control unit

You operate the MAGDOS LK dosing pump using the four multifunction keys below the display. The keys have different assignments depending on where you are located at any one time in the menu structure. The system shows the respective functions of the keys at the bottom of the display:

Manual mode

Menu Stop- +

Liter

0.00

Fig. 29: Function assignments of the multifunction keys

In this example, the ﬁrst key from the left has the Menu function; the second one has the - function; the third one has the + function and the fourth one has the Stop function.

The + and - selection keys as well as the

and keys have a repeat function, i.e. if you keep them pressed down, the system automatically repeats the key function.

The display brightness reduces 45 seconds after your last input.

Two minutes after your last input, the control unit goes back to the start screen of the selected operating mode in each case.

The dosing pump does not have an ON/OFF switch. After being disconnected from the power supply, the dosing pump starts in the operating mode and conﬁguration that you selected last..

10.2 Explanation of menu navigation

Fig. 30:

Manual mode

Menu Start- +

Liter

100%

0.06

Representation of the control unit on the display

No. Explanation

Calculated delivery capacity (units per day or hour)

Designation of active operating mode

Symbol for level monitoring

Symbol for the active operating mode

Symbol for external ON/OFF

Variable assignment of the four menu keys on the dosing pump

Bar for representing the stroke frequency or delivery capacity

Tab. 27: Explanation of menu navigation

10.3 Explanation of the menu icons

10.3.1 Level monitoring

Symbol Meaning

Dosing tank full

Dosing tank at minimum (alert)

Dosing tank empty (main alarm)

Tab. 28: Explanation of the menu icons – Level monitoring

10.3.2 Operating modes

Symbol Meaning

Manual mode

Pulse input

Tab. 29: Explanation of the menu icons – Operating modes

Control

Menu settings at initial commissioning

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

10.3.3 Release input

Symbol Meaning

Active and open

Active and closed

Tab. 30: Explanation of the menu icons – Release input

10.3.4 Release code

Symbol Meaning

Password protection active

Tab. 31: Explanation of the menu icons – Release code

10.4 Menu settings at initial commissioning

On ﬁrst connecting the dosing pump to the mains or resetting it to the factory default setting, it is automatically in the Language menu (menu6.3). The system prompts you to specify the menu language.

Language

Deutsch

English

Back

6.3

↓

Fig. 31: Menu 6.3 Language

1. Use the or key to choose a language.

2. Press OK.

4The dosing pump displays menu 6, Setup system.

3. Press Menu.

4The dosing pump displays menu 1 Main menu.

4. Press Back.

4The dosing pump displays the start screen. In the factory default

setting, the Manual mode operating mode is preset and saved with a stroke frequency of 0% (no dosing).

Fig. 32: Start screen of the dosing pump after initial commissioning

10.5 Main menu

èPress Menu.

4The dosing pump displays menu 1 Main menu.

Diaphragm change

Venting

Back

Operating mode

↓

Fig. 33: Main menu

The main menu lists the main functions of the MAGDOS LK dosing pump:

nOperating mode (see “Operating modes” on page35), nVenting (see “Venting the dosing pump” on page34), nScaling (see “Scaling the delivery capacity” on page34), nCalibration (see “Calibrating the dosing pump” on page35), nSystem setup (see “System setup” on page29), nInfo (see “Information about the dosing pump” on page32),

For a complete overview of the control unit's menu structure, see page 46.

10.6 System setup

In the System setup menu item, you conﬁgure all the dosing parameter‘s general parameters that do not depend on an operating mode.

1. Press Menu.

2. Use the

or key to choose the System setup menu item and

press OK.

4The dosing pump displays the System setup menu.

Level input

Units

Setup

Language

↓

Fig. 34: System setup menu

10.6.1 Set "Language" menu item

1. Use the or key to choose the Language menu item and press

Setup.

You can choose from the following options:

nEnglish (factory default setting), nDeutsch, nFrancais, nEspanol, nPortugues, nNederlands,

2. Use the

or key to choose a language and press OK.

üThe language is set.

Manual mode

Menu Stop- +

Liter

0.00

Control

System setup

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

10.6.2 Set "Units" menu item

Manual mode

Start-+

100%

0.06

Liter

Fig. 35: Display of the unit of delivery capacity

1. Use the or key to choose the Units menu item and press

Setup.

You can choose from the following units:

nLitres/Day, nLitres/Hr. nUSgal/Day (American gallons), nUSgal/Hr. (American gallons), nI.gal/Day (Imperial gallons), nI. gal / Hr. (Imperial gallons), nml/Min.

2. Use the

or key to choose the desired unit and press OK.

üThe unit is set.

10.6.3 Set “Alarm output” menu item

Faults to the dosing pump can be notiﬁed externally using the fault reporting function. This can be performed using the fault reporting optocupler at the socket 1. When activating the fault reporting optocupler in the menu, the function “Stroke feedback” is not applicable.

See section 9.2.1.2 „Fault reporting optocupler“ on page 27 for connection.

The optocupler only switches with the supply voltage on.

Situation Output

Optocoupler

function

Alarm Pins 1/2(socket 1)

N.O

no open

yes closed

N.C.

no closed

yes open

Tab. 32: Conﬁguration of alarm optocoupler

10.6.4 Set "Level input" menu item

Level monitoring of the dosing medium feed on the suction side with two alarm stages: Alert and main alarm

For more details on installing the level monitoring system, see “Level monitoring” on page24.

For information on the connection, see “Level input” on page27.

1. Use the

or key to choose the Level input menu item and press

Setup.

You can choose from the following options:

nNot active (factory default setting), nAlarm = contact (issues an alarm when the ﬂoat contact is closed), nAlarm = open (issues an alarm when the ﬂoat contact is open;

setting for standard Lutz-Jesco GmbH level monitoring systems).

2. Use the

or key to choose the desired function and press OK.

ü"Level input" is set.

The system displays the selected setting of the level input as an icon on the start screen of each operating mode. For an explanation of the icons, see page 28.

10.6.4.1 "Level input" conﬁguration

Status Display Level input

Dosing pump

Alarm =

contact

Alarm = open

Tank full

Running

Tank at

minimum

(alert)

Running

Tank empty

(main alarm)

Stopped

Tab. 33: Level input conﬁguration

10.6.5 Set "Release input" menu item

Option of starting or stopping the dosing pump externally.

For information on the connection, see “Release input” on page27.

For information on starting and stopping the dosing pump, see “External On/Off via Release input” on page38.

1. Use the

or key to choose the Release input menu item and

press Setup.

You can choose from the following options:

Control

System setup

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

nNot active (factory default setting), nRun = contact (enables the dosing pump if both contacts are

closed),

nRun = contact (enables the dosing pump if both contacts are open).

2. Use the

or key to choose the desired function and press OK.

ü"Release input" is set.

The system displays the selected setting of the Release input as an icon on the start screen of each operating mode. For an explanation of the icons, see page 29.

10.6.6 Activating the Release code

If the Release code is activated, the dosing pump is protected against unauthorized access. You can only create settings after you enter the correct Release code.

WARNING

Caustic burns or other burns through dosing media!

If the Release code is activated, operation of the dosing pump is blocked. If a dosing pump has been started without the Release code being entered, it can only be stopped by means of the power supply. In unfavourable cases, if the user has inadvertently acti vated or forgotten the release code, the dosing pump cannot be quickly stopped and injuries may result.

ðInstall an emergency stop switch or integrate the dosing pump into

the plant safety concept.

You can set any Release code you like from 0000 to 9999.

1. Use the

or key to choose the Release code menu item and

press Setup.

4The dosing pump displays menu 6.10 Release code.

Release code

4 3 2 1 Off

Back

6.10

Next - +

Fig. 36: Release code

2. Use the + and - keys to set a value of 0 to 9 for the ﬁrst digit of the

code and then press Next.

3. Proceed as described under point 2 for the other digits.

4. Choose the last item Off and press +.

5. Press Back.

4The Release code is activated. The dosing pump displays the

corresponding symbol:

Manual mode

Liter

day

0.0%

0.00

Fig. 37: Start screen with activated Release code

10.6.6.1 Entering the Release code

Once you press any key, you must enter the Release code. If you enter the code correctly, you have 120 seconds in which to operate the dosing pump. When the 120 seconds have elapsed, you must re-enter the

Release code, even if you are in the middle of making another entry

(this does not include settings in the menus).

Release code

1 1 1 1

Back

8.1

- +

Fig. 38: Entering the Release code

1. Use the + and - keys to set a value of 0 to 9 for the ﬁrst digit of the

code and then press Next.

2. Proceed as described under point 1 for the other digits.

3. After entering all the digits, press OK.

4If your input is correct, the dosing pump displays the start screen.

If you have forgotten the code, please contact Lutz-Jesco GmbH.

10.6.6.2 Deactivating the Release code

1. Press Menu.

2. Use the

or key to choose the System setup menu item and

press OK.

3. Use the

or key to choose the Release code menu item and

press Setup.

4. Keep pressing Next until On is selected.

5. Press -.

6. Press Back.

üRelease code deactivated.

10.6.7 Deactivating the safety code

Protects the System setup menu from unauthorized access. In the factory default setting, the code is not activated.

You can set any Safety code you like from 0000 to 9999.

1. Use the

or key to choose the Safety code menu item and

press Setup.

4The dosing pump displays menu 6.11 Safety code.

Safety code

1 2 3 4 Off

Back

6.11

Next - +

Fig. 39: Safety code

2. Use the + and - keys to set a value of 0 to 9 for the ﬁrst digit of the

code and then press Next.

3. Proceed as described under point 2 for the other digits.

4. Choose the last item Off and press +.

Control

Information about the dosing pump

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

5. Press Back.

4The Safety code is activated. You must enter it when accessing

the System setup menu.

10.6.7.1 Entering the safety code

Safety code

1 1 1 1

8.2

- +

Fig. 40: Entering the safety code

1. Use the + and - keys to set a value of 0 to 9 for the ﬁrst digit of the

code and then press Next.

2. Proceed as described under point 1 for the other digits.

3. After entering all the digits, press OK.

4If your input is correct, the dosing pump displays the System

setup menu.

If you have forgotten the code, please contact Lutz-Jesco GmbH.

10.6.7.2 Deactivating the safety code

1. Press Menu.

2. Use the

or key to choose the System setup menu item and

press OK.

3. Enter the correct Safety code and press OK.

4. Use the

or key to choose the Safety code menu item and

press Setup.

5. Keep pressing Next until On is selected.

6. Press -.

7. Press Back.

üThe safety code is deactivated.

10.6.8 Set „Factory setup“ menu item

Resets the dosing pump‘s control unit settings to the factory default setting.

1. Use the

or key to choose the Factory setup menu item and

press Setup.

2. Press OK.

4The dosing pump displays the Language menu (menu 6.3); see

also “Menu settings at initial commissioning” on page29.

üThe dosing pump is reset to the factory setup setting.

10.6.9 Set „Eco-Mode“ menu item

Setting energy-saving mode. Doing this changes the power consump tion, the delivery capacity and the delivery pressure; see also “Technical Data” on page12.

1. Use the

or key to choose the Eco-Mode menu item and press

Setup.

You can choose from the following options:

nOff (factory default setting), nEco-Mode 1.

2. Use the

or key to choose the desired function and press OK.

4The system displays the selected Eco-Mode on the start screen

after the respective operating mode.

Fig. 41: "Slow Motion 1" mode display in manual mode

10.7 Information about the dosing pump

In the Info menu item, you can ﬁnd a wide range of information about your dosing pump.

1. Press Menu.

2. Use the

or key to choose the Info menu item and press OK.

4The dosing pump displays menu 7.1 Info 1.

Info 1 Strokes / min 180 Capacity 3.80 l/Std Calibration 3.80 l/Std

7.1

Fig. 42: Display of menu Info 1

3. Keep pressing Next to get to subsequent Info menus.

The Info menus display the following information:

Menu Information

Info 1

nMaximum strokes/minute nMaximum delivery capacity in l/hr nCalibrated delivery capacity in l/hr

Info 2

nStroke volume at factory setting in ml nStroke volume after calibration in ml

Info 3

nRunning time of the dosing pump in hrs. nTotal strokes of the dosing pump carried out

Info 4

nSoftware version and date of updating nPart number nSerial number

Info 5

nPower supply voltage nPower frequency

Info 6

Assignment of connection socket 1

Info 7

Assignment of connection sockets 2 and 3

Tab. 34: Explanation of the Info menus

4. Press Menu to exit the Info menu.

Manual mode Eco 1

Menu Stop- +

Liter

0.00

Operation

Commissioning the dosing pump

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

11 Operation

WARNING

Caustic burns or other burns through dosing media!

After connecting the mains supply, residual dosing media in the dosing head can spray out.

ðBefore connecting the mains supply, connect the dosing lines. ðCheck that all the screw connections have been tightened

cor rectly and are leak-proof.

WARNING

Caustic burns or other burns through dosing media!

While working on the dosing head, valves and connections, you may come into contact with dosing media.

ðUse sufﬁcient personal protective equipment. ðRinse the dosing pump with a liquid (e.g. water) which does not

pose any risk. Ensure that the liquid is compatible with the dosing medium.

ðRelease pressure in hydraulic parts. ðNever look into open ends of plugged pipelines and valves.

CAUTION

Danger of personal injury and material damage!

Dosing medium can escape if you loosen connections on the dosing head, e.g. for venting, during operation.

ðFollow the safety data sheet of the dosing medium. ðClean the dosing pump if dosing medium escapes. ðDispose of the dosing medium correctly.

CAUTION

Increased risk of accidents due to insufﬁcient qualiﬁcation of personnel!

Dosing pumps and their accessories may only be installed, operated and maintained by personnel with sufﬁcient qualiﬁcations. Insufﬁ cient qualiﬁcation will raise the risk of accidents.

ðEnsure that all action is taken only by personnel with sufﬁcient and

corresponding qualiﬁcations.

ðPrevent access to the system for unauthorised persons.

CAUTION

Danger of personal injury and material damage!

Changing dosing media can lead to unpredictable reactions.

ðThoroughly clean the dosing pump and appropriate sections of the

plant to avoid chemical reactions.

CAUTION

Danger of automatic start up!

ðStop the dosing pump before disconnecting it from the mains

supply.

ðEnsure that the dosing pump has been installed correctly before

connecting it to the mains supply.

11.1 Commissioning the dosing pump

Precondition for action:

üThe dosing pump has been assemble and installed in accordance

with “Installing the Dosing Pump“ (see page15), “Hydraulic instal lation“ (see page16) and “Electrical installation“ (see page26).

üAll the mechanical fastenings have been inspected to ensure

adequate load-bearing capacity.

üThe dosing head screws have been tightened with the correct torque

(see “Tighten dosing head bolts“ on page40).

üAll the hydraulic sections have been inspected to ensure they are

adequately leak-proof and that the throughﬂow direction is correct.

üThe dosing pump has been set in accordance with “Menu settings at

initial commissioning“ (see page29) and, if necessary, the other settings in menu “System setup“ (see page29) have been carried out.

üPersonnel have read all the operating instructions and understood

them completely.

For initial commissioning, it is advisable to use water as the dosing medium to check that the system is leak-proof and that the dosing pump is functioning correctly. Check ﬁrst whether undesirable reactions could occur between the actual dosing medium and the water.

Operation

Commissioning the dosing pump

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Perform the following working steps:

1. Open the shut-off valves on the suction and discharge sides if

present.

2. Plug in the dosing pump‘s mains plug to the power supply.

3. Vent the dosing pump, (see “Venting the dosing pump“ on page34).

4. Scale the delivery capacity of the dosing pump, if necessary (see

“Scaling the delivery capacity“ on page34).

5. Calibrate the dosing pump (see “Calibrating the dosing pump“ on

page35).

6. Select an operating mode and start the dosing pump in accordance

with the instructions in the chapter entitled “Operating modes“ (see page35).

4The dosing pump primes. if it does not prime enough, use a priming

aid, (see “Priming aid“ on page23).

At initial commissioning, it is advisable to prime the pump without back pressure. For this purpose, we recommend installing a relief valve on the discharge side of the dosing pump.

üThe dosing pump is commissioned.

11.1.1 Venting the dosing pump

Fig. 43: Dosing head venting facility with vent screw

Precondition for action:

üThe dosing head venting facility connected has been connected in

accordance with the chapter entitled “Connecting the dosing head venting facility“ (see page19).

Perform the following working steps:

1. Open the vent screw by one complete turn (looking onto the dosing

head, anti-clockwise).

2. Press Menu.

3. Use the

or key to choose the Venting menu item and press OK.

4. Press the Start key and keep it pressed.

4The dosing pump starts delivery at the highest stroke frequency.

5. Release Start key as soon as there is a continuous throughﬂow

from the dosing head venting facility with no air bubbles.

4The dosing pump stops delivery.

6. Close the vent screw.

üThe dosing pump is vented.

If you are using effervescent media, allow them to ﬂow out continuously. Open the vent screw such that about one drop per 1–3 strokes escapes.

11.1.2 Scaling the delivery capacity

You can use the Scaling function to adjust the MAGDOS LK ﬂexibly to the local conditions during the start-up. Sometimes, a dosing pump model selected during the planning phase turns out to be too big. To minimise the risk of overdosing, the delivery capacity can be limited or scaled.

The reduced delivery capacity applies to all operating modes of the dosing pump. The setting is retained even after an interruption to the power supply.

Perform the following working steps:

1. Press Menu.

2. Use the

or key to choose the Scaling menu item and press OK.

3. Use the + and - keys to set the desired delivery capacity in l/h and

press OK.

4The bar that indicates delivery capacity is now displayed in two

parts.

Manual mode

Menu Stop- +

Liter

day

75.0%

90.0

Fig. 44: Display with scaled delivery capacity

The meaning of the bars is as follows:

Bar Meaning

top The scaled delivery capacity value (part of the

delivery capacity in the factory setting)

bottom The current delivery capacity expressed as a

percentage of the scaled delivery capacity

üDelivery capacity scaled.

To reverse scaling, set the delivery capacity in the Scaling menu to the value 0 or to the maximum possible value.

Operation

Operating modes

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

11.1.3 Calibrating the dosing pump

In dependence on the dosing medium you are using and the existing delivery pressure, you must match the theoretical delivery capacity with that which is actually measured. You use the Calibration function to do this.

Precondition for action:

üThe plant sections on the discharge side of the dosing pump have

been installed correctly and are ready for operation.

Perform the following working steps:

1. Fill the metering container with the dosing medium.

2. Hold the end of the dosing pump‘s suction line in the metering

container.

3. Vent the dosing pump, (see “Venting the dosing pump“ on page34).

4. Press Menu.

5. Use the

or key to choose the Calibration menu item and press

OK.

4The dosing pump displays menu 5 Calibration.

Calibration

Capacity 100 %

Start

- +

Fig. 45: Menu 5 Calibration

6. Use the + and - keys to set the percentage value of the delivery

capacity with which you want to carry out calibration. Setting range 10% - 100%.

7. Press Start.

4The dosing pump starts delivery and displays the number of

executed strokes.

8. Press Finish as soon as you have achieved a measurable value in

the metering container.

4The dosing pump stops and displays the theoretical value of the

delivery rate in ml.

Calibration

Capacity 5.67ml

5.3

- +

Factory setup +0.0%

Fig. 46: Menu 5.3 Calibration

9. Read off the actual delivery rate from the metering container and use

the + and - keys to correct the displayed delivery capacity. Adjustment range: -50% – +50%

10. Press OK.

üThe dosing pump is calibrated.

11.2 Operating modes

The MAGDOS LK dosing pump offers the following operating modes:

nManual operation - Manual setting of the delivery capacity, nPulse input - Controlling the stroke frequency and number of

strokes in dependence on the number of pulses and the pulse spacing,

11.2.1 Manual mode

CAUTION

Danger of automatic start up!

If the dosing pump is in manual mode with a speciﬁed stroke fre quency, it retains the stroke frequency even after you disconnect if from the mains and then reconnect it. This means that dosing medium can escape. Depending on the type and hazardousness of the dosing medium, this can result in injury.

ðStop the dosing pump before disconnecting it from the mains

supply.

ðEnsure that the dosing pump has been installed correctly before

connecting it to the mains supply.

11.2.1.1 Selecting the operating mode

1. Press Menu.

2. Use the

or key to choose the Operating mode menu item and

press OK.

3. Use the

or key to choose the Manual mode menu item and

press OK.

4The dosing pump displays the start screen of Manual operation

mode.

Manual mode

Menu Stop- +

Liter

0.00

Fig. 47: Start screen of Manual operation

11.2.1.2 Starting the dosing pump

4. Press the + key to increase the stroke frequency by 1%.

4The dosing pumps starts dosing immediately. The system

auto matically calculates the resulting delivery capacity and displays it.

5. Use the + and - keys to set the desired stroke frequency.

üDosing pump has started.

11.2.1.3 Stopping the dosing pump

èPress Stop.

4The system displays the „Stop“ signal and Stop changes to

Start. Press Start to restart the dosing pump.

üDosing pump has stopped.

Operation

Operating modes

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Pressing Menu does not interrupt dosing! You do not stop the dosing pump until you change to a different operating mode using the menu.

11.2.2 Pulse input

In the Pulse input operating mode, the system regulates the stroke frequency and the number of strokes in dependence on the number of pulses and the pulse spacing of the pulse signal that is connected at the pulse input (see “Connection socket 2” on page27).

11.2.2.1 Selecting the operating mode

1. Press Menu.

2. Use the

or key to choose the Operating mode menu item

and press OK.

3. Use the

or key to choose the Pulse input menu item and

press OK.

4The dosing pump displays the current conﬁguration of this operating

mode's parameters (Menu 3.31).

Pulse input 1 Impulse = 1 Stroke Memory = 1 Stroke

Menu Mode

3.31

OKSetup

Fig. 48: Parameters of the operating mode

4. Press OK.

4The dosing pump displays the start screen of Pulse input mode.

Pulse input

Menu Reset Start

Liter

0.00

Setup

Fig. 49: Start screen of Pulse input

11.2.2.2 Choosing the pulse input mode

You can choose from the following modes in Pulse input operating mode:

Type Explanation

Strokes

Transmission and reduction of the number of pulses compared to the number of strokes

Output

Delivery of a ﬁxed output per pulse

Water meter

Operation on a contact-type water meter

Tab. 35: Explanation of pulse input modes

The system marks the currently active mode by displaying

(On) after the menu item. In the factory default setting, the Strokes mode is preselected: Strokes (On).

1. Press Setup.

4The dosing pump displays the current conﬁguration of this operating

mode's parameters (Menu 3.31).

2. Press Mode.

3. Use the

or key to choose a language and press OK.

4The dosing pump displays the current conﬁguration of this operating

mode's parameters (Menu 3.31).

4. Press OK.

4The dosing pump displays the start screen of Pulse input mode.

11.2.2.3 Pulse input modes

The parameters that you can set are different depending on the mode.

Strokes

The Strokes pulse input mode offers the following conﬁguration options:

Parameter Explanation

Strokes per pulse

Speciﬁes the required number of strokes that the dosing pump carries out per pulse. in this connection, the system determines the stroke frequency on a dynamic basis based on the time between the last two pulses. Stroke frequency = number of strokes/pulse spacing Default settings: 1 stroke Setting range: 1 - 999 strokes.

Pulses per stroke

Speciﬁes the required number of pulses that must be connected to the input to trigger a stroke. Default setting: 1 pulse Setting range: 1 - 999 pulses.

Stroke buffer

The strokes that have still to be executed are saved in the stroke buffer. If stroke multiplication is set, the system writes all the strokes belonging to one pulse into the stroke buffer. With each pulse, the number of strokes in the accumulator increases; with each executed stroke, it decreases. The limit of the stroke buffer must be raised to save pulse requests that arrive during execution of the strokes from the previous pulse request. If the number of requested strokes exceeds the stroke buffer capacity, the system issues a „stroke buffer maximum“ message. Default setting: 1 stroke Setting range: 1 - 999 strokes.

Tab. 36: Strokes conﬁguration type

In the case of pulse multiplication, you must increment the stroke buffer manually. Otherwise, you can conﬁrm the conﬁguration by pressing OK.

Operation

Operating modes

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

You can conﬁgure parameters Strokes per pulse and Pulses per

stroke at the same time to deﬁne an exact number of strokes for a

number of pulses. in this connection, the system determines the stroke frequency on a dynamic basis based on the time between the last two pulses.

Example:

If you set „7 strokes per pulse“ and „3 pulses per stroke“, the dosing pump carries out 7 strokes per 3 input pulses.

Output

The Output pulse input mode offers the following conﬁguration options:

Parameter Explanation

Output

Speciﬁes the required output per pulse in ml. The output is calculated from the dosing pump‘s stroke volume after calibration and the automatically calculated ratio of the number of strokes to the number of pulses. The value that is displayed in brackets indicates the number of strokes and pulses (number of strokes/number of pulses).

stroke buffer

See „stroke buffer“ mode under “Strokes” on page36.

Tab. 37: Output conﬁguration mode

The delivery capacity depends on the dosing pump‘s delivery pressure. To display the delivery capacity correctly, you must calibrate the dosing pump, see page 35.

Water meter

The Water meter pulse input mode offers the following conﬁguration options:

Parameter Explanation

Output

Speciﬁes the delivered output of the dosing pump per cubic metre (m3) throughﬂow of the water meter in ml. The value corresponds to the throughﬂow amount per pulse. Since the dosing pump only controls the output via the stroke frequency, you must set the cycle between the water meter pulse and the dosing pump‘s stroke. The value that is displayed in brackets indi cates the number of strokes that must be trig gered per number of water meter pulses. (Number of strokes/number of pulses).

Stroke buffer

See „stroke buffer“ mode under “Strokes” on page36.

ml/pulse

Speciﬁes the water meter‘s throughﬂow amount per pulse in ml.

l/pulse

Speciﬁes the water meter‘s throughﬂow amount per pulse in l.

m3/pulse

Speciﬁes the water meter‘s throughﬂow amount per pulse in m

Maximum

Speciﬁes the water meter‘s maximum through ﬂow amount in m

/hr.

Tab. 38: Water meter conﬁguration mode

Operation

External On/Off via Release input

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

On the basis of the water meter‘s values (ml/pulse, l/pulse or m3/

pulse) and the delivered dosing capacity (output) , the dosing pump

automatically determines the stroke frequency. If the dosing pump‘s maximum output is exceeded during a fast sequence of pulses, the system issues a warning message.

If you enter contradictory parameters, the system displays this when you try to save them (Menu 3.41). It is not possible to activate the operating mode without correcting the parameters.

11.2.2.4 Conﬁguring the pulse input mode

1. Press Setup.

4The dosing pump displays the current conﬁguration of this operating

mode's parameters (Menu 3.31).

2. Press Setup.

3. Use the

or key to choose a parameter of the mode and press OK.

4. Press the + key to increment the parameter's value or the - key to

decrement it.

5. Press OK.

4The dosing pump displays the current conﬁguration of this operating

mode's parameters (Menu 3.31).

6. Press OK.

4The dosing pump displays the start screen of Pulse input mode.

11.2.2.5 Starting the dosing pump

Precondition for action:

üThe dosing pump has been connected in accordance with the

chapter entitled “Pulse input“ (see page27).

1. Press Start.

2. Apply a pulse to the dosing pump‘s pulse input.

4The dosing pumps starts dosing immediately. The system

auto matically calculates the resulting delivery capacity and displays it.

üDosing pump has started.

11.2.2.6 Stopping the dosing pump

èPress Stop.

üDosing pump has stopped.

11.2.2.7 Clearing the stroke buffer

èPress Reset.

4All the strokes in the accumulator that are still pending are deleted.

The dosing pump stops; however, it is still active and waiting for the next pulse.

üThe stroke buffer has been cleared.

11.3 External On/Off via Release input

Regardless of the selected operating mode, you can start or stop the MAGDOS LK dosing pump by means of the closed switching contact on the Release input.

If you set the function (see “Set „Release input“ menu item“ on page30), the system displays in the selected operating mode the symbol for conﬁguration of the Release input (see also “Explanation of the menu icons” on page28).

Analog input

Start

Liter

0.00

Setup

Fig. 50: Start screen of Analog input with icon for open contact

11.3.1 Starting the dosing pump

If Run = contact is set:

èClose the switching contact on the Release input.

üDosing pump has started.

If Run = open is set:

èOpen the switching contact on the Release input.

üDosing pump has started.

11.3.2 Stopping the dosing pump

If Run = contact is set:

èOpen the switching contact on the Release input.

üDosing pump has stopped.

If Run = open is set:

èClose the switching contact on the Release input.

üDosing pump has stopped.

11.4 Decommissioning the dosing pump

Perform the following working steps:

1. Stop the dosing pump in accordance with the selected operating

mode.

2. Unplug the dosing pump‘s mains plug from the power supply.

3. Disconnect all electrical connections.

4. Depressurize all the hydraulic parts in the system.

5. Unplug all the hydraulic connections on the dosing pump.

6. Empty the dosing head.

7. Remove any residual dosing medium from the dosing head by

ﬂushing the system with a washing agent. Ensure that the washing agent is compatible with the dosing medium.

üDosing pump is decommissioned.

Operation

Shutting down in an emergency

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

11.5 Shutting down in an emergency

nIn an emergency, you must immediately disconnect the dosing pump

from the mains supply or activate the Emergency Stop switch installed in the plant.

nDepending on the type of incident, you must depressurized the

hydraulic connections or locked to prevent dosing medium from escaping.

nYou must follow the safety data sheet of the dosing medium.

11.6 Storage

Storing the dosing pump correctly extends its service life. You should avoid negative inﬂuences like extreme temperatures, high humidity, dust, chemicals, etc.

Ensure ideal storage conditions where possible:

nthe storage place must be cold, dry, dust-free and generously

venti lated,

nTemperatures between + 2°C and + 40°C (with PP and PVDF dosing

heads, between + 2°C and + 60°C),

nRelative humidity must not exceed 90%.

11.7 Transportation

Perform the following working steps:

nThe unit should be thoroughly cleaned. Any dangerous dosing media

must be additionally neutralised and decontaminated.

nAll accessories should be dismantled. nAll openings should be closed, so that no foreign objects can get into

the system.

nThe dosing pump must be shipped in suitable packaging, ideally in

original packaging.

Should the unit be sent back to the manufacturer, please follow chap ters “Declaration of harmlessness“ (see page52) and “Warranty appli cation“ (see page53).

11.8 Disposal of old units

nThe waste unit must be thoroughly cleaned. Any dangerous dosing

media must be additionally neutralised and decontaminated.

nAny residual dosing media must be removed in a professional manner. nThe dosing pump must be disposed of in accordance with applicable

local laws and regulations. The unit does not belong to household waste!

nAs the disposal regulations may differ from country to country in the

European Union, please consult your supplier if necessary.

Maintenance

Maintenance intervals

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

12 Maintenance

Lutz-Jesco dosing pumps are produced to the highest quality standards and have a long service life. Nevertheless, some of their parts are subject to wear due to operation (e.g. diaphragms, valve seats, valve balls). This means that regular visual inspections are necessary to ensure a long operating life. Regular maintenance will protect the dosing pump from operation interruptions.

DANGER

Danger to life due to electric shock

Live parts can inﬂict fatal injuries.

ðBefore carrying out any maintenance work, always disconnect the

dosing pump from the power supply.

ðSecure the dosing pump from accidental power-up.

WARNING

Caustic burns or other burns through dosing media!

While working on the dosing head, valves and connections, you may come into contact with dosing media.

ðUse sufﬁcient personal protective equipment. ðRinse the dosing pump with a medium (e.g. water) which does not

pose any risk.

ðRelease pressure in hydraulic parts. ðNever look into open ends of plugged pipelines and valves.

WARNING

Caustic burns or other burns through dosing media!

After connecting the mains supply, residual dosing media in the dosing head can spray out.

ðBefore connecting the mains supply, connect the dosing lines. ðCheck that all the screw connections have been tightened

cor rectly and are leak-proof.

CAUTION

Danger of personal injury and material damage!

The dosing pump can generate a pressure that is many times the rated one. The dosing medium can escape in the case of material failure or wear on the dosing head, the connection pipe or the seals that are used.

ðCarry out maintenance work at the recommended intervals.

CAUTION

Increased risk of accidents due to insufﬁcient qualiﬁcation of personnel!

Dosing pumps and their accessories may only be installed, operated and maintained by personnel with sufﬁcient qualiﬁcations. Insufﬁ cient qualiﬁcation will raise the risk of accidents.

ðEnsure that all action is taken only by personnel with sufﬁcient and

corresponding qualiﬁcations.

ðPrevent access to the system for unauthorised persons.

12.1 Maintenance intervals

This table gives you an overview of maintenance work and the intervals at which you must carry it out. The next few chapters contain instruc tions for carrying out this work.

Maintenance work to be carried out

Frequency

Check that piping is seated ﬁrmly Regularly

Check that suction and discharge valves are seated ﬁrmly

Regularly

Clean suction and discharge valves Regularly

Check that electrical connections are not damaged

Regularly

Tighten dosing head bolts

nRegularly nBefore initial commissioning nEach time you replace the

diaphragms

Check diaphragms for leakage due to rupture

Regularly

Check that the installed accessories are functioning correctly

Regularly

Check the dosing pump for unusual noises during operation, unusual temperatures or smells

Regularly

Tab. 39: Maintenance information and maintenance intervals

Maintenance

Tighten up dosing head bolts

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Maintenance work to be carried out

Frequency

Replace parts that are subject to wear (diaphragms, valves, seals, etc.)

if you detect unacceptable wear

Rinse out and clean the dosing pump

nbefore changing diaphragms nbefore decommissioning for

a long period of time

nafter feeding aggressive,

adhesive, crystallising or contaminated liquids

Tab. 39: Maintenance information and maintenance intervals

12.2 Tighten up dosing head bolts

èTighten the dosing head bolts in diagonally opposite sequence with a

torque wrench.

The necessary torque is 180 Ncm.

12.3 Change the diaphragm

Fig. 51: Exploded view of the diaphragm and dosing head

12.3.1 Dismount the old diaphragm

Precondition for action:

üYou have disconnected the dosing pump from the mains supply. üYou have depressurised the hydraulic sections of the plant. üYou have rinsed the dosing pump using a safe medium (e.g. water).

Perform the following working steps:

1. Screw out the four screws e on the dosing head using a suitable

tool (SW 3 Allen key) and take off the dosing head d.

2. Use pliers to bend the edge of the diaphragm c slightly upwards

and screw it out counter-clockwise.

12.3.2 Install a new diaphragm

Precondition for action:

üYou have thoroughly cleaned the diaphragm rod b and the

diaphragm ﬂange a so that the new diaphragm is not affected by dosing medium residues.

üYou have slightly greased the diaphragm thread c (e.g. using

Molykote Longterm W2).

1. Screw the diaphragm manually c in the clockwise direction until it

safely contacts into the diaphragm rod.

2. Bring the dosing head into position and insert the screws. First

tighten the screws ﬁnger-tight. After this, tighten the screws in diagonally opposite sequence, e.g. top left and bottom right and top tight and bottom left.

NOTICE

Damage to the dosing head/leakiness of the diaphragm

If you tighten the screws too much, this can lead to the dosing head being damaged. However, not tightening the screws enough leads to the diaphragm being leaky and correct functioning being affected.

ðTighten the screws to a torque of 180 Ncm.

üDiaphragm change ﬁnished.

It may be necessary to recalibrate the dosing pump after replacing the diaphragm or other spare parts on it. For more information, refer to page 35.

12.4 Clean suction and discharge valves

Contaminated valves affect the dosing preceision and this means that you should clean the valves on a regular basis.

With dosing heads made of plastic, when replacing a valve you must replace the complete dosing head (see “Spare parts“ on page44).

Troubleshooting

Type of fault

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

13 Troubleshooting

See below the troubleshooting instructions to the unit/system. If you cannot eliminate the fault, please consult with the manufacturer on further measures or return the dosing pump for repair.

13.1 Type of fault

13.1.1 Dosing pump not delivering or output too low

Possible cause Remedy

Wrong type of dosing pump selected

èCheck the dosing pump‘s

tech nical data and if necessary select a type with a higher delivery capacity.

Valve leaking or blocked

èClean the valve and vent the

dosing pump.

èTighten the screw connections.

Valve installed incorrectly

èReassemble the valve. Ensure

that the valve balls are located above the valve seats.

Valve damaged (e.g. valve balls)

èRemove the damaged parts or

install a new valve.

Suction line is leaking

èSeal the leak locations or replace

the parts.

Suction line is blocked (e.g. screen in foot valve)

èClean the suction line

Shut-off valves closed

èOpen the shut-off valves Inspect

the dosing pump for possible damage.

Suction head too high

èSet the dosing pump to feed or

reduce the suction head.

èInstall a priming aid.

Viscosity too high

èPossibly reduce the concentra tion

of the dosing medium or increase the temperature.

èInstall spring-loaded valves.

èIncrease the pipe diameter.

Current supply interrupted

èReconnect the current supply

The dosing pump‘s electrical data does not match that of the mains supply

èCheck the electrical installation.

Eco-Mode set (driving power reduced)

èSwitch off Eco-Mode.

Tab. 40: Type of fault: Dosing pump not delivering or output too low

Possible cause Remedy

System back pressure too high (measured at discharge connection of dosing pump)

èClean blocked injection nozzle.

èInstall pulsation dampeners to

reduce pressure peaks if pipes are too long.

èCheck function of safety valves.

Tab. 40: Type of fault: Dosing pump not delivering or output too low

13.1.2 Dosing pump does not prime

Possible cause Remedy

Valve leaking or blocked

èClean the valve and vent the

dosing pump.

èTighten the screw connections.

Valve installed incorrectly

èReassemble the valve. Ensure

that the valve balls are located above the valve seats.

Valve damaged (e.g. valve balls)

èRemove the damaged parts or

install a new valve.

Suction line is leaking

èSeal the leak locations or replace

the parts.

Suction line is blocked (e.g. screen in foot valve)

èClean the suction line

Shut-off valves closed

èOpen the shut-off valves Inspect

the dosing pump for possible damage.

Suction head too high

èSet the dosing pump to feed or

reduce the suction head.

èInstall a priming aid.

Viscosity too high

èPossibly reduce the concentra tion

of the dosing medium or increase the temperature.

èInstall spring-loaded valves.

èIncrease the pipe diameter.

Current supply interrupted

èReconnect the current supply

Dry the valves

èDampen the dosing head and the

valves

èVent the dosing head.

Air in the suction line with simultaneous pressure on the discharge valve

èVent the dosing head or the lines.

Tab. 41: Type of fault: Dosing pump does not prime

Troubleshooting

Type of fault

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

13.1.3 Delivery rate varies

Possible cause Remedy

Valve leaking or blocked

èClean the valve and vent the

dosing pump.

èTighten the screw connections.

Valve damaged (e.g. valve balls)

èRemove the damaged parts or

install a new valve.

Suction line is leaking

èSeal the leak locations or replace

the parts.

Suction line is blocked (e.g. screen in foot valve)

èClean the suction line

Viscosity too high

èPossibly reduce the concentra tion

of the dosing medium or increase the temperature.

èInstall spring-loaded valves.

èIncrease the pipe diameter.

The dosing pump‘s electrical data does not match that of the mains supply

èCheck the electrical installation.

Suction side pressure too high (pump siphoning)

èInstall a back-pressure valve in

the pressure line.

Pressure peaks due to accel eration with long suction lines

èInstall a suction pressure

regu lator.

Imprecise dosing due to changeable positive and negative suction heads

èInstall a suction pressure

regu lator.

System back pressure too high (measured at discharge connection of dosing pump)

èClean blocked injection nozzle.

èInstall pulsation dampeners to

reduce pressure peaks if pipes are too long.

èCheck function of safety valves.

Tab. 42: Type of fault: Delivery rate varies

13.1.4 No stroke movement observed

Possible cause Remedy

Diaphragm return spring broken.

èContact the manufacturer.

Current supply interrupted

èReconnect the current supply

The dosing pump‘s electrical data does not match that of the mains supply

èCheck the electrical installation.

Tab. 43: Type of fault: No stroke movement observed

Possible cause Remedy

Pressure peaks due to accel eration with long suction lines

èInstall a suction pressure

regu lator.

System back pressure too high (measured at discharge connection of dosing pump)

èClean blocked injection nozzle.

èInstall pulsation dampeners to

reduce pressure peaks if pipes are too long.

èCheck function of safety valves.

Tab. 43: Type of fault: No stroke movement observed

13.1.5 Dosing pump delivery rate too high

Possible cause Remedy

Suction side pressure too high (pump siphoning)

èInstall a back-pressure valve in

the pressure line.

Pressure peaks due to accel eration with long suction lines

èInstall a suction pressure

regu lator.

Tab. 44: Type of fault: Dosing pump deliver y rate too high

13.1.6 Diaphragm is torn or tears too often

Possible cause Remedy

Shut-off valves closed

èOpen the shut-off valves Inspect

the dosing pump for possible damage.

Pressure peaks due to accel eration with long suction lines

èInstall a suction pressure

regu lator.

The materials are not suitable for the dosing medium being used

èCheck the resistance of the

materials.

Diaphragm not screwed up to the end stop on the diaphragm rod

èScrew a new diaphragm up to the

end stop.

System back pressure too high (measured at discharge connection of dosing pump)

èClean blocked injection nozzle.

èInstall pulsation dampeners to

reduce pressure peaks if pipes are too long.

èCheck function of safety valves.

Media sediment in dosing head

èClean the dosing head.

Tab. 45: Type of fault: Diaphragm is torn or tears too often

Troubleshooting

Type of fault

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

13.1.7 Loud noises on the dosing pump

Possible cause Remedy

The drive magnet‘s stop dampener is worn-out

èContact the manufacturer.

Tab. 46: Type of fault: Loud noises on the dosing pump

Spare parts

Diaphragm spare parts kits

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

14 Spare parts

Fig. 52: Spare parts kits (dosing head made of plastic)

Fig. 53: Spare parts kits (dosing head made of stainless steel (1.4571))

Required kits for a complete service:

n1 diaphragm spare parts kit, n1 dosing head spare parts kit including valves.

14.1 Diaphragm spare parts kits

Diaphragm spare parts kit containing:

n1 diaphragm a, n1 set of dosing head screws c.

Diaphragm kit Type

Part No.

LK 05, LK 1 39121

LK 2, LK 4 39122

LK 6, LK 10, LK 15 39123

14.2 Dosing head spare parts kits including valves

Dosing head spare parts kits including screws containing:

nDosing head b, nValves, n1 set of dosing head screws c.

PVC Type

Part No.

Glass/PVDF/FPM (ball/seat/seals)

LK 05, LK 1 38981

LK 2, LK 4 38982

LK 6, LK 10, LK 15 38983

PP Type

Part No.

Glass/PVDF/FPM (ball/seat/seals)

LK 05, LK 1 38978

LK 2, LK 4 38979

LK 6, LK 10, LK 15 38980

PVDF Type

Part No.

PTFE/PVDF/FPM (ball/seat/seals)

LK 05, LK 1 38984

LK 2, LK 4 38985

LK 6, LK 10, LK 15 38986

Stainless steel

(1.4571)

Type

Part No.

Stainless steel (1.4571) / stainless steel (1.4571) / FPM (ball/seat/seals)

LK 05, LK 1 39942

LK 2, LK 4 39943

LK 6, LK 10, LK 15 39944

Delivery characteristic curves

Dosing head spare parts kits including valves

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

15 Delivery characteristic curves

This Chapter is intended to give you an idea of the delivery capacity that the dosing pump can achieve at speciﬁc back pressures. These delivery capacities were determined on the manufacturer's test stands. They apply at 20 °C (68 °F) for water, at 100% stroke frequency. The delivery capacity depends on the medium (density and viscosity) and temperature. Since these conditions vary at every installation location, you should calibrate the dosing pump.

0 2 4 6 8 10 12 14 16

LK 4

LK 2

LK 1

LK 05

Delivery capacity [l/h]

Pressure [bar]

Fig. 54: Delivery capacity diagrams of MAGDOS LK 05 - 4

Fig. 55:

0 2 4 6 8

LK 6

LK 10

LK 15

Delivery capacity [l/h]

Pressure [bar]

Delivery capacity diagrams of MAGDOS LK 6 - 15

Menu structure of the Control Unit

Program start

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

16 Menu structure of the Control Unit

16.1 Program start

Language

Deutsch

English

Back

6.3

↓

Magdos

LK 4

Language

Francais

Deutsch

Back

6.3

↓

Language

Espanol

Francais

Back

6.3

↓

Language

Portugues

Espanol

Back

6.3

↓

Language

Netherland

Portugues

Back

6.3

↓

Language

Nederlands

Portuges

Back

6.3

↓

Level input

Units

Setup

Language

↓

Calibration

Venting

Back

Operating mode

↓

System setup (see the next chapter)

Main menu (see page 48)

16.2 System setup

Language

Deutsch

English

Back

6.3

↓

Language

Francais

Deutsch

Zurück

6.3

↓

Language

Espanol

Francais

Zurück

6.3

↓

Language

Portugues

Espanol

Zurück

6.3

↓

Language

Nederlands

Portugues

Zurück

6.3

↓

Language

Nederlands

Portugues

Zurück

6.3

↓

Alarm output

Units

Setup

Language

↓

Menu structure of the Control Unit

System setup

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Alarm output

Units

Setup

Language

↓

Level inpit

Alarm output

Setup

Units

↓

Units

Litres / h

Litres / day

Back

6.4

↓

Units

USgal / day

Litres / h

Back

6.4

↓

Units

USgal / h

USgal / day

Back

6.4

↓

Units

I.gal / day

USgal / h

Back

6.4

↓

Units

I.gal / h

I.gal / day

Back

6.4

↓

Units

ml / min

I.gal / h

Back

6.4

↓

Units

ml / min

I.gal / h

Back

6.4

↓

Alarm output

Optocoupler N.O.

not active

Back

6.5

↓

Alarm output

Optocoupler N.C.

Optocoupler N.O.

Back

6.5

↓

Alarm output

Optocoupler N.C.

Optocoupler N.O.

Back

6.5

↓

Release input

Level input

Setup

Alarm output

↓

Level input

Alarm = contact

not active

Back

6.6

↓

Level input

Alarm = open

Alarm = contact

Back

6.6

↓

Level input

Alarm = open

Alarm = contact

Back

6.6

↓

Menu structure of the Control Unit

System setup

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Safety code

Release code

Setup

Release input

↓

Release code

4 3 2 1 Off

Back

6.10

- +

Release code

1 2 3 4 Off

Back

6.10

- +

Factory setup

Safety code

Setup

Release code

↓

Safety code

4 3 2 1 Off

Back

6.11

- +

Safety code

1 2 3 4 Off

Back

6.11

- +

Eco-Mode

Factory setup

Setup

Safety code

↓

Eco-Mode

Setup

Factory setup

↓

Factory setup

Confirm reset!

Back

6.12

Eco-Mode

Eco-Mode 1

Off

Back

6.13

↓

Eco-Mode

Eco-Mode 1

Off

Back

6.13

↓

User code

Release input

Setup

Level input

↓

Release input

Run = contact

not active

Back

6.8

↓

Release input

Run = open

Run = contact

Back

6.8

↓

Release input

Run = open

Run = contact

Back

6.8

↓

Menu structure of the Control Unit

Main menu

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

16.3 Main menu

Pulse input

Manual mode

↓

Manual mode

Pulse input

↓

Manual mode

Pulse input

↓

Manual mode

Menu Start- +

Liter

100%

0.06

Scaling

Venting

Back

1OKOperating mode

↓

Pulse input 1 Impulse = 1 Stroke Memory = 100 Strokes

3.31

OKSetup

Stroke buffer

Pulses / stroke

Back

3.32

Setup

Strokes / pulse

↓

Stroke buffer

Pulses / stroke

Back

3.32

Setup

Strokes / pulse

↓

Stroke buffer

Pulses / stroke

Back

3.32

Setup

Strokes / pulse

↓

Strokes / pulse

1 Stroke

Back

3.33

- +

Pulses / stroke

1 Impulse

Back

3.34

- +

Stroke buffer

1 Stroke

Back

3.35

- +

Pulse input

Menu Start

Liter

0.00

SetupReset

Mode

Water meter

Capacity

Back

3.36

Strokes (On)

↓

Pulse input 1 Impulse = 1 Stroke Memory = 100 Strokes

3.31

OKSetup

Mode

Water meter

Capacity (On)

Back

3.36

Strokes

↓

Pulse input

0.038 ml / Impulse Memory = 1 Stroke

3.31

OKSetup

Stroke buffer

Back

3.32

Capacity

↓

Capacity

0.038 ml / Impulse (110/1024)

Back

3.37

- +

Stroke buffer

1 Stroke

Back

3.35

- +

Pulse input

Menu Start

Liter

0.00

SetupReset

Mode

Pulse input

0.038 ml / Impulse Memory = 1 Stroke

3.31

OKSetup

Mode

Stroke buffer

Back

3.32

Capacity

↓

Menu structure of the Control Unit

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Calibration

Venting

Back

Operating mode

↓

Pulse input

Back

Manual operation

↓

Water meter

0.1 l / Pulse

Back

3.38

- +

Water meter (On)

Output

Back

3.36

Strokes

↓

Output

0.038 ml / Pulse (110/1024)

Back

3.37

- +

Stroke buffer

1 Stroke

Back

3.35

- +

Pulse input

378.3 ml / m3 Memory = 1Stroke Max: 10.0 m3 / h

3.31

OKSetup

Mode

Pulse input

378.3 ml / m3 Memory = 1Stroke Max: 10.0 m3 / h

3.31

OKSetup

Mode

ml / Imp. (on)

Stroke buffer

Back

3.32

Output

↓

ml / Imp. (on)

Stroke buffer

Back

3.32

Output

↓

l / Imp.

ml / Imp. (on)

Back

3.32

Stroke buffer

↓

m3 / Imp.

l / Imp.

Back

3.32

ml / Imp. (on)

↓

Maximum

m3 / Imp.

Back

3.32

l / Imp.

↓

Maximum

m3 / Imp.

Back

3.32

l / Imp.

↓

Water meter

100 ml / Pulse

Back

3.38

- +

Water meter

0.1 m3 / Pulse

Back

3.38

- +

Water meter

max. 10.0 m3 / h

Back

3.39

- +

Scaling

Venting

Back

Operating mode

↓

Info

System setup

Back

Calibration

↓

Info

Back

System setup

↓

Venting

Press Start !

Start

Venting

Pump running !

Start

System setup

Calibration

Back

Scaling

↓

Calibration

Capacity 100 %

Start

- +

Calibration

No. of strokes 14

5.1

Finish

Calibration

Capacity 5.67ml

5.3

- +

Factory setup +0.0%

Info 1 Strokes / min 180 Capacity 3.80 l/h Calibration 3.80 l/h

7.1

Info 2 Factory setup 0.352 ml Calibration 0.532 ml / Stroke

7.2

Info 3 Runtime 0 h Strokes 24

7.3

Info 5 U: 233 V F: 49 Hz

7.5

Info 7 Connection 2: Pulse input (+BN / -WH) 3: Level input

7.7

Info 6 Connection 1: Strokes (+BN / -WH) 1: Release input (+BK / -BU)

7.7

Info 4 SW V 1.26 09.07.12 P.Nr. 10231004 S.Nr. 3100401

7.4

Scaling

10.8 l/h

Back OK

- +

Calibration

Scaling

Back

Venting

↓

See “System setup” on page 46.

Appendix

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

17 Appendix

17.1 Default settings

Preset operating mode Manual mode (delivery capacity0%)

Parameter Factory setting Own setting

Language English

Units Litres/hr.

Level input Not active

Diaphragm rupture Not active

Release input Not active

Release code Off

Safety code Off

Eco-Mode Off

Pulse input

Type Strokes

Strokes p. pulse 1 stroke

Pulses p. stroke 1 pulse

Stroke buffer 1 stroke

Output 64/64

Unit ml/pulse

Maximum 10 m3 /hr.

Tab. 47: Default settings

EC Declaration of Conformity

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

18 EC Declaration of Conformity

(DE) EG-Konformitätserklärung

Hiermit erklären wir, dass das nachfolgend bezeichnete Gerät aufgrund seiner Konzipierung und Bauart sowie in der von uns in Verkehr gebrachten Ausführung den einschlägigen grundlegenden Sicherheits- und Gesundheitsanforderungen der aufgeführten EG-Richtlinien entspricht. Bei einer nicht mit uns abgestimmten Änderung am Gerät verliert diese Erklärung ihre Gültigkeit.

(NL) EU-overeenstemmingsverklaring

Ondergetekende Lutz-Jesco GmbH, 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.

(FR) Déclaration de conformité CE

Nous déclarons sous notre propre responsabilité que le produit ci-dessous mentionné répond aux exigences essentielles de sécurité et de santé des directives CE énumérées aussi bien sur le plan de sa conception et de son type de construction que du modèle que nous avons mis en circulation. Cette déclaration perdra sa validité en cas d’une modiﬁcation effectuée sur le produit sans notre accord explicite.

(PT) Declaração de conformidade CE

Declaramos pelo presente documento que o equipamento a seguir descrito, devido à sua concepção e ao tipo de construção daí resultante, bem como a versão por nós lançada no mercado, cumpre as exigências básicas aplicáveis de segurança e de saúde das directivas CE indicadas. A presente declaração perde a sua validade em caso de alteração ao equipamento não autorizada por nós.

(EN) EC Declaration of Conformity

We hereby certify that the device described in the following complies with the relevant fundamental safety and sanitary requirements and the listed EC regulations due to the concept and design of the version sold by us. If the device is modiﬁed without our consent, this declaration loses its validity.

(ES) Declaración de conformidad CE

Por la presente declaramos que, dados la concepción y los aspectos constructivos del modelo puesto por nosotros en circulación, el aparato mencionado a continuación cumple con los requisitos sanitarios y de seguridad vigentes de las directivas de la U.E. citadas a continuación. Esta declaración será invalidad por cambios en el aparato realizados sin nuestro consentimiento.

2006/42/EG, 2004/108/EG

Die Schutzziele der Niederspannungsrichtlinie 2006/95/EG wurden gemäß Anhang I, Nr. 1.5.1 der Maschinenrichtlinie 2006/42/EG eingehalten.

The protective aims of the Low Voltage Directive 2006/95/EC were adhered to in accordance with Annex I, No. 1.5.1 of the Machinery Directive 2006/42/EC.

EG-Richtlinien: EC directives:

EN ISO 12100, EN 809, EN 61000-6-2, EN 61000-6-3Harmonisierte Normen:

Harmonized standards:

Lutz-Jesco GmbH

Dokumentationsbevollmächtigter: Authorized person for documentation:

Bezeichnung des Gerätes:

Descripción de la mercancía:

Description of the unit:

Omschrijving van het apparaat:

Désignation du matériel:

Designação do aparelho:

Magnet-Membrandosierpumpe

Bomba dosiﬁcadora magnética de membrana

Solenoid diaphragm dosing pump

Magneet Membraandoseerpomp

Pompe doseuse à membrane magnétique

Bomba doseadora de membrana magnética

MAGDOS LK 05 – 15Typ:

Type:

Heinz Lutz Geschäftsführer / Chief Executive Ofﬁcer Lutz-Jesco GmbH Wedemark, 01.03.2014

Lutz-Jesco GmbH Am Bostelberge 19 30900 Wedemark Germany

Declaration of harmlessness

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

19 Declaration of harmlessness

Copy the Declaration of harmlessness and complete it separately for each unit. Enclose one copy to the unit you are sending. Please send the declaration of harmlessness to us also in advance per fax or e-mail!

Declaration of no objection

Please fill out a separate form for each appliance!

We forward the following device for repairs:

Device and device type: ................................................................ Part-no.:...................................................................................

Order No.:..................................................................................... Date of delivery: .......................................................................

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

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

Dosing medium

Description: .................................................................................. Irritating:

Yes No

Properties: .................................................................................... Corrosive:

Yes No

We hereby certify, that the product has been cleaned thoroughly inside and outside before returning, that it is free from hazardous material (i.e. chemical, biological, toxic, flammable, and radioactive material) and that the lubricant has been drained.

If the manufacturer finds it necessary to carry out further cleaning work, we accept the charge will be made to us.

We assure that the aforementioned information is correct and complete and that the unit is dispatched according to the legal requirements.

Company / address:...................................................................... Phone:......................................................................................

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

..................................................................................................... Email:.......................................................................................

Customer No.:............................................................................... Contact person: ........................................................................

Date, Signature:............................................................................

Warranty application

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

20 Warranty application

Index

Warranty Application

Please copy and send it back with the unit!

If the device breaks down within the period of warranty, please return it in a cleaned condition with the complete warranty application, filled out.

Sender

Company: ............................................................................................................... Phone: .................................. Date: ..........................

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

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

Manufacturer order no.: .......................................................................................... Date of delivery: .........................................................

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

Nominal capacity / nominal pressure: .........................................................................................................................................................

Description of fault:.....................................................................................................................................................................................

Service conditions of the device

Point of use / system designation:...............................................................................................................................................................

Accessories used (suction line etc.):............................................................................................................................................................

Commissioning (date): ................................................................................................................................................................................

Duty period (approx. operating hours): ........................................................................................................................................................

Please describe the specific installation and enclose a simple drawing or picture of the chemical feed system, showing materials of construction, diameters, lengths and heights of suction and discharge lines.

Index

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Index

Accessories .....................................................................................20

Appropriate and intended use ............................................................8

Back-pressure valve ........................................................................22

Bonded connection ..........................................................................18

Calibrating the dosing pump ............................................................35

Calibration .......................................................................................35

Cemented connection ......................................................................18

Change the diaphragm ....................................................................40

Clearing the stroke buffer ................................................................38

Commissioning the dosing pump .....................................................33

Connection sockets ..........................................................................26

Contact Water Meter ........................................................................20

Control .............................................................................................28

Control elements .............................................................................11

Declaration of harmlessness ............................................................52

Decommissioning the dosing pump .................................................38

Default settings

List of default settings ................................................................50

Delivery capacity data ......................................................................12

Delivery characteristic curves .......................................................... 45

Device revision ..................................................................................8

Diaphragm

Spare parts kits ..........................................................................44

Dimensioned drawing ......................................................................14

Dimensioning of the system .............................................................16

Dimensions ......................................................................................14

Disposal of old units ........................................................................38

Dosing head

Aligning the dosing head ............................................................17

Spare parts .................................................................................44

Structure ....................................................................................10

Dosing head venting facility .............................................................19

Dosing media

Permitted temperature of the medium ........................................13

Prohibited dosing media ...............................................................8

EC Declaration of Conformity ...........................................................51

Eco-mode

Setting .......................................................................................32

Technical Data ............................................................................12

Electrical installation ........................................................................26

Electric data ....................................................................................13

Expert staff ........................................................................................7

External On/Off via Release input .....................................................38

Factory default setting

Resetting to factory default setting .............................................32

Foreseeable misuse ...........................................................................8

Function description ........................................................................11

Hazards due to non-compliance with the safety instructions ..............7

Hose clip ..........................................................................................17

Hydraulic connections ......................................................................17

Hydraulic installation .......................................................................16

Information about the dosing pump ..................................................32

Initial commissioning

Menu settings .............................................................................29

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

Inputs of the control unit ..................................................................26

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

Electrical ....................................................................................26

Hydraulic ....................................................................................16

Installing the Dosing Pump ..............................................................15

Instruction for action

Identiﬁcation .................................................................................5

Intended purpose ...............................................................................8

Language ........................................................................................29

Leakage drain ..................................................................................19

Level input

Conﬁguration of the control unit ..................................................30

Connection .................................................................................27

Level monitoring ..............................................................................24

Explanation of the icons ..............................................................28

Main menu ......................................................................................29

Maintenance ....................................................................................39

Maintenance intervals ......................................................................39

Manual operation .............................................................................35

Menu icons ......................................................................................28

Menu navigation

Explanation .................................................................................28

Menu settings at initial commissioning ............................................29

Menu structure of the Control Unit ...................................................46

Nameplate .......................................................................................11

Notes to the Reader ...........................................................................4

Operating conditions and limits ........................................................12

Operating modes .............................................................................35

Explanation of the icons ..............................................................28

Operation .........................................................................................33

Index

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Operator controls of the control unit .................................................28

Output (pulse input mode) ................................................................37

Outputs of the control unit ...............................................................26

Personal protective equipment ...........................................................7

Personnel qualiﬁcation .......................................................................7

Piping ..............................................................................................17

Pressure relief valve ........................................................................21

Priming aid ......................................................................................23

Product description ..........................................................................10

Product warranty ...............................................................................8

Protective equipment

Personal protective equipment ......................................................7

Pulsation dampener .........................................................................22

Pulse input

Connection .................................................................................27

Operating mode ..........................................................................36

Pulse input modes ...........................................................................36

Release code ...................................................................................31

Release input

Conﬁguration of the control unit ..................................................30

Connection .................................................................................27

Explanation of the icons ..............................................................29

Safe operation ...................................................................................7

Safety ................................................................................................6

Safety code ......................................................................................31

Scaling the delivery capacity ............................................................34

Scope of delivery .............................................................................10

Set up information ...........................................................................15

Shut down .......................................................................................38

Shutting down in an emergency .......................................................38

Signal words

Explanation ...................................................................................4

Spare parts ......................................................................................44

Start-up ...........................................................................................33

Storage ............................................................................................38

Stroke feedback output ....................................................................27

Strokes (pulse input mode) ..............................................................36

Structure of the dosing pump ...........................................................10

Suspensions ....................................................................................24

System piping ..................................................................................17

System setup ...................................................................................29

Technical Data .................................................................................12

Temperature

Permitted ambient temperature ..................................................12

Permitted temperature of the medium ........................................13

Tighten dosing head bolts ................................................................40

Trained person ...................................................................................7

Transportation ..................................................................................38

Troubleshooting ...............................................................................41

Units ................................................................................................30

Venting ............................................................................................34

Venting the dosing pump .................................................................34

Wall assembly .................................................................................15

Wall bracket ....................................................................................15

Warnings

General warnings .........................................................................6

Identiﬁcation .................................................................................4

Warning signs

Explanation ...................................................................................4

Warranty application ........................................................................53

Water Meter .....................................................................................20

Water meter (pulse input mode) .......................................................37

BA-10221-02-V03

Stepper Motor-driven Diaphragm Dosing Pump MAGDOS LK

Operating Instructions

Headquarters

Lutz-Jesco GmbH

Am Bostelberge 19 30900 Wedemark Germany

Tel.: +49 5130 5802-0 Fax: +49 5130 580268

E-mail: info@lutz-jesco.com Website: www.lutz-jesco.de

Netherlands

Lutz-Jesco Nederland B.V.

Nijverheidstraat 14 C 2984 AH Ridderkerk Netherlands

Tel.: +31 180 499460 Fax: +31 180 497516

E-mail: info@lutz-jesco.nl Website: www.lutz-jesco.nl

Hungary

Lutz-Jesco Üzletág

Vasvári P. u. 9. 9024 Györ Hungary

Tel.: +36 96 523046 Fax: +36 96 523047

E-mail: info@lutz-jesco.hu Website: www.lutz-jesco.hu

USA

Lutz-JESCO America Corp.

55 Bermar Park Rochester, N.Y. 14624 USA

Tel.: +1 585 426-0990 Fax: +1 585 426-4025

E-mail: mail@jescoamerica.com Website: www.lutzjescoamerica.com

East Asia

Lutz-Jesco East Asia Sdn Bhd

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

Tel.: +603 55692322 Fax: +603 55691322

E-mail: info@lutz-jescoasia.com Website: www.lutz-jescoasia.com

Austria

Lutz-Jesco GmbH

Aredstraße 7/2 2544 Leobersdorf Austria

Tel.: +43 2256 62180 Fax: +43 2256 6218062

E-mail: info@lutz-jesco.at Website: www.lutz-jesco.at

Middle East

Lutz-Jesco Middle East FZE

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

Tel.: +971 6 5572205 Fax: +971 6 5572230

E-mail: info@jescome.com Website: www.jescome.com

Great Britiain

Lutz-Jesco (GB) Ltd.

Gateway Estate West Midlands Freeport Birmingham B26 3QD Great Britain

Tel.: +44 121 782 2662 Fax: +44 121 782 2680

E-mail: info@lutz-jesco.co.uk Website: www.lutz-jesco.co.uk

Product Range Lutz Pumpen GmbH

P.O. Box 1462 • D-97864 Wertheim

www.lutz-pumpen.de

Product Range Lutz-Jesco GmbH

P.O. Box 100164 • D-30891 Wedemark

www.lutz-jesco.com

Centrifugal Pumps

Products for the disinfection of swimming pool water based on salt water electrolysis and domestic water technology

The Lutz-Jesco App for iPads is available from the iTunes App Store. Additional information can be found at www.lutz-jesco.com

Barrel and Container Pumps

Dosing Pumps

Measuring and Control Equipment

Double Diaphragm Pumps

Standard Plus

Chemical Centrifugal Pumps

Flow Meters

Chlorinators Disinfection

Jesco MAGDOS LK Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual