Jesco MIDIDOS E, MIDIDOS E 24, MIDIDOS E 48, MIDIDOS E 72, MIDIDOS E 120 Operation & Maintenance Instructions Manual
MIDIDOS E
Operation &
Maintenance Instructions
Read these operation and maintenance instructions
before start up!
To be held for future reference.
Dosing
Conveying
Control
Li quids
Ga ses
Sy stems
2
3
Content
1. Safety ......................................................................................................................................................................................................4
1.1 General ..................................................................................................................................................................................................4
1.2 Kennzeichnung von Hinweisen in der Betriebsanleitung .........................................................................................................................4
1.3 Qualification and training of personnel ...................................................................................................................................................5
1.4 Important safety instructions ..................................................................................................................................................................5
1.5 Hazards due to non-compliance with safety instructions ........................................................................................................................5
1.6 Safe operation .......................................................................................................................................................................................6
1.7 Safety instructions for the owner/operator .............................................................................................................................................6
1.8 Safety instructions for inspection-, maintenance-, and installation work.................................................................................................6
1.9 Unauthorized modifications and production of spare parts .....................................................................................................................6
1.10 Impermissible modes of operation .......................................................................................................................................................6
1.11 Dosierung von Chemikalien..................................................................................................................................................................7
1.12 Scope of delivery .................................................................................................................................................................................8
2. General ....................................................................................................................................................................................................9
3. Function...................................................................................................................................................................................................9
4. Technical data ........................................................................................................................................................................................10
5. Mechanical handling capacity performance curves ................................................................................................................................10
6. Measurement drawing ...........................................................................................................................................................................12
7. Installation .............................................................................................................................................................................................13
7.1 General information .............................................................................................................................................................................13
7.2 Installation location ..............................................................................................................................................................................13
7.3 Drainage discharge ..............................................................................................................................................................................14
7.4 Pressure sustaining and safety valves ..................................................................................................................................................14
7.5 Injection nozzles ..................................................................................................................................................................................15
7.6 Electrical connection ............................................................................................................................................................................15
7.7 Installation example ............................................................................................................................................................................17
8. Stroke length setting ..............................................................................................................................................................................17
9. Start up.................................................................................................................................................................................................18
10. Shutdown ............................................................................................................................................................................................19
11. Maintenance ........................................................................................................................................................................................19
11.1 Lubricants .........................................................................................................................................................................................19
11.2 Maintenance of storage .....................................................................................................................................................................19
11.3 Replacing the diaphragm ...................................................................................................................................................................20
11.4 Valves ................................................................................................................................................................................................22
12. Spare parts list MIDIDOS E 24...72 .......................................................................................................................................................26
12. Spare parts list MIDIDOS E 120 ............................................................................................................................................................28
13. Troubleshooting ...................................................................................................................................................................................30
14. Declaration of conformity .....................................................................................................................................................................32
15. Declaration of harmlessness ................................................................................................................................................................33
16. Warranty ..............................................................................................................................................................................................34
4
1. Safety
1.1 General
This Operation & Maintenance Manual contains basic information to be noted during
installation, operation and maintenance. It is therefore essential that the contractor read
the manual before installing and commissioning the pump/system as well as by the
relevant operating personnel/owner of the pump/system. It must remain accessible at
the dosing pump/system for reference at all times.
In addition to the general safety instructions under this main heading of Safety, the special safety precautions outlined another section must also be observed.
1.2 Warning symbols used in this Operation & Maintenance Manual
This Operation & Maintenance Manual contains vital information, which may endanger
people, the environment and the dosing pump/system if disregarded. These statements
are identified by the following symbols:
DANGER!
Refers to an imminent danger.
Non-compliance can lead to death or serious injury.
WARNING!
Refers to a potentially hazardous situation. Non-compliance can lead to death or serious
injury.
CAUTION!
Refers to a potentially hazardous situation. Non-compliance can lead to minor injury or
property damage.
NOTICE!
or
INFORMATION!
Appear in conjunction with safety instructions, which may endanger the pump/system
and its operation if disregarded.
IMPORTANT!
Draws attention to supplementary information to make the work easier and ensure trouble free operation.
Markings that are affixed directly to the pump, such as
• Cable markings
• Markings for process fluid connections
must be observed without fail and remain fully legible at all times.
5
1.3 Qualification and training of personnel
The personnel employed for installation, operation, inspection and maintenance work
must be qualified to do so. The areas of responsibility, competence and supervision of
the personnel must be precisely defined by the owner. Personnel who do not have the
required knowledge must be duly rained and instructed. If necessary, this training can
also be provided by the manufacturer/supplier on behalf of the dosing pump’s owner. In
addition, the owner of the system must ensure that the relevant personnel are fully familiar with and have understood the contents of this Operation & Maintenance Manual.
1.4 Important safety instructions
When installing and using this electrical equipment, basic safety precautions should
always be followed, including the following:
READ AND FOLLOW ALL INSTRUCTIONS!
WARNING!
To reduce risk of injury, do not permit children to use this product unless they are closely
supervised at all times.
WARNING!
Risk of electric shock. Connect only to a grounding type receptacle protected by a
ground-fault circuit-interrupter (GFCI). Contact a qualified electrician if you cannot verify
that the receptacle is protected by a GFCI.
Do not bury the cord. Locate the cord to minimize abuse from lawn mowers, hedge
trimmers, and other equipment.
WARNING!
To reduce the risk of electric shock, replace damaged cord immediately.
WARNING!
To reduce the risk of electric shock, do not use an extension cord to connect the unit to
the electricity supply; provide a properly located outlet.
SAVE THESE INSTRUCTIONS!
1.5 Hazards due to non-compliance with safety instructions
Failure to comply with safety instructions may endanger not only people, but also the
environment and the dosing pump/system. Non-compliance with the safety instructions can lead to the loss of all entitlement to damages.
WARNING!
WARNING!
WARNING!
WARNING!
6
The following hazard in particular may arise:
• Danger to people due to electrical, mechanical and chemical effects.
• Failure of dosing pump/system functions.
• Failure of specified methods for maintenance and repair.
• Danger to the environment due to leakage of hazardous substances.
1.6 Safe operation
The safety instructions in this Operation & Maintenance Manual must be observed.
The owner is responsible for ensuring the compliance with local safety regulations.
1.7 Safety instructions for the owner/operator
• Leakages (e.g. due to ruptures in the lining) of hazardous substances (e.g. toxic or
abrasive) must be discharged in such a way as to exclude all danger to people and
the environment. Statutory regulations must be observed.
• Danger due to electric current must be excluded (for further details, refer to the
German VDE standards as well as local regulations or chapter 1.4).
1.8 Safety instructions for inspection-, maintenance-, and installation
work
The owner must ensure that all inspection, maintenance and installation work is undertaken by authorized and duly qualified personnel who have also studied this Operation
& Maintenance Manual.
The dosing pump must always come to a complete stop before starting any work on the
pump. The procedure specified in this Operation & Maintenance Manual for shutting
down the Dosing/pump/system must be observed without fail.
Dosing pumps or systems in contact with potentially harmful media must be decontaminated.
All safety mechanisms and guards must be refitted and reactivated as the work is completed.
The instructions outlined in chapter 7.2 “Installation location” and 9. “Start up” must be
observed before starting the pump/system.
1.9 Unauthorized modifications and production of spare parts
The dosing pump may only be modified or converted in consultation with the manufacturer. Genuine spare parts and accessories authorized by the manufacturer ensure
greater safety. The use of other parts can void the liability for the subsequent consequences.
1.10 Impermissible modes of operation
The operational safety of the pump supplied can only be guaranteed when it is used in
conformity with its intended use as specified in our contracts, especially in our order
confirmation. The limit values specified in these documents must not be exceeded
under any circumstances.
7
1.11 Dosing of chemicals
CAUTION!
• When working on dosing systems, the accident prevention regulations applicable
on-site must be observed and the specified personal protective clothing is recommended, depending on the hazard associated with the metered medium:
Googles Protective gloves Protective suit
• It is recommended that all people responsible for the installation and maintenance of
piping, hoses and accessories should wear this protective clothing.
• Before working in the dosing pump and plant, disconnect it from the power supply
and protect it from reconnection.
CAUTION!
• Any chemicals still present in the dosing head may spray out when the power supply
is reconnected. This may lead to caustic or other burns to the face and hands. The
dosing lines must always be reconnected before starting the pump up again.
• The chemical resistance of the pump’s materials of construction must be verified
before dosing with aggressive media!
• The dosing pump’s dosing head as well as connections and lines of the system may
be under pressure. Work carried out on the dosing system requires special safety
precautions and may be carried out only by instructed technical personnel.
CAUTION!
• Chemicals may spray out. This may lead to caustic or other burns. Always release
the pressure from the dosing pump system before starting work on the pump.
• Flush the pump with a harmless medium (mainly water) before working on the dosing head, valves and connections in order to avoid unintentional contact with the
dosing medium.
WARNING!
• Never look into the open end of a clogged line or valve.
Chemicals may emerge unexpectedly and cause caustic or other burns to hand and
face
• Before start up, all connections must be inspected for correct tightness and, if necessary, must be further tightened using the appropriate tools.
CAUTION!
• If connections at the dosing head are loosened during operation for venting or other
reasons, the leaked chemicals must be removed professionally. This is the only way
CAUTION!
CAUTION!
CAUTION!
CAUTION!
CAUTION!
8
to avoid the danger of physical injury and corrosion at the dosing pump. Leaking
chemicals may also damage the diaphragm pump at its mounting points.
CAUTION!
• When changing the chemical medium, check whether the pump and the system’s
materials of construction are chemically resistant. If there is danger of a chemical
reaction between different media, a thorough cleaning is first mandatory.
IMPORTANT!
• After adjusting the stroke length, the locking screw must be retightened. Otherwise
the adjusting knob may change its position. Thus causing irregular flow rates.
CAUTION!
• The base area of the dosing pump must be kept clear to allow sufficient air circulation to cool the motor down. If there is a danger of fluid collecting underneath the
base of the pump, the pump must be elevated.
DANGER!
• Fire hazard. Pressure surge: catapulting parts could kill you. MIDIDOS E must not be
used under any circumstances in an explosive environment.
1.12 Scope of delivery
IMPORTANT!
Please unpack the dosing pump and ordered accessories with great care in order not to
miss any small parts. Immediately compare the scope of delivery with the delivery note.
The cause of any discrepancies must be determined.
CAUTION!
CAUTION!
IMPORTANT!
DANGER!
IMPORTANT!
9
2. General
Dosing pumps are used to add chemicals in various processes. As leak free diaphragm
dosing pumps with a dosing range of between max. 2 l/h and 120 l/h the MIDIDOS E has
a broad field of application.
The MIDIDOS E is supplied as a simple dosing pump with the dosing head mounted on
the left hand side.
The motor is connected directly into a terminal box. The electrical power is supplied
through a three-phase motor. Operation with alternating voltage is likewise possible
with the use of an operating capacitor. To adapt the dosing performance the stroke
length can be set manually between 0 – 100%.
3. Function
The gearbox is based on a single level worm-wheel transmission. The gear parts as
well as the storage are greased for life. The dosing stroke functions through a cam that
the membrane moves over a spring-loaded tappet. The siphon is reached through a
spring-loaded position.
Legend
1 Retaining spring for the siphon
2 Stroke limiter eccentric cams
3 Eccentric drive cam
4 Impact plate
5 Diaphragm rod
x
a e d
b
c
drive eccentric continues to run free until the plunger plate is reached again.
10
4. Technical data
MIDIDOS E 24 E 48 E 72 E 120
Flow rate [l/h] - max. pressure [bar] 24 - 10 48 - 10 72 - 6 114 - 4
max. pressure at 1~ mode [bar] 10 5 3 2
Hub frequency [1/min] 48 96 142 96
Hub volume [ml/Hub] 8.5 8.5 8.5 20.8
Diaphragm-Ø [mm] 64 64 64 90
Suction lift [mbar] 700 700 700 300
Double ball valve in pipe diameter DN6 DN6 DN6 DN10
max. environment temperature [°C] 45 (with PVC max. 40)
max. medium temperature [°C] 50 (wth PVC max. 35)
Motor specifications 3-Phase 400V / 50Hz - 440V/60Hz - 0,05kW
- 0,5A
Motor specifications 1 -Phase 230V/50Hz - 0,05kW - 0,85A
Weight of plastic model [kg] 7 7 7 8
5. Mechanical handling capacity performance curves
The performance curves of the handling capacity are at 20°C (68°F) for water. Media
(specific gravity and viscosity) and temperature change the handling capacity. Therefore
dosing pumps have to be litered out when used.
MIDIDOS E24
0
5
10
15
20
25
30
35
0 1 2 3 4 5 6 7 8 9 10
l/h
10 bar
2 bar
Stroke adjustment
11
MIDIDOS E24
0
5
10
15
20
25
30
35
0 1 2 3 4 5 6 7 8 9 10
Hubeinstellung
l/h
MIDIDOS E48
0
10
20
30
40
50
60
0 1 2 3 4 5 6 7 8 9 10
l/h
10 bar
2 bar
10 bar
2 bar
MIDIDOS E24
0
5
10
15
20
25
30
35
0 1 2 3 4 5 6 7 8 9 10
Hubeinstellung
l/h
MIDIDOS E72
0
10
20
30
40
50
60
70
80
90
0 1 2 3 4 5 6 7 8 9 10
l/h
MIDIDOS E48
0
10
20
30
40
50
60
0 1 2 3 4 5 6 7 8 9 10
Hubeinstellung
l/h
10 bar
2 bar
10 bar
2 bar
6 bar
2 bar
MIDIDOS E120
0
20
40
60
80
100
120
140
0 1 2 3 4 5 6 7 8 9 10
l/h
0
5
0 1 2 3 4 5 6 7 8 9 10
Hubeinstellung
MIDIDOS E72
0
10
20
30
40
50
60
70
80
90
0 1 2 3 4 5 6 7 8 9 10
Hubeinstellung
l/h
MIDIDOS E48
0
10
20
30
40
50
60
0 1 2 3 4 5 6 7 8 9 10
Hubeinstellung
l/h
10 bar
2 bar
6 bar
2 bar
4 bar
2 bar
Stroke adjustment
Stroke adjustment
Stroke adjustment
12
6. Measurement drawing
31
136
q
305~ (~359)
153~ (~252)
187~ (~297)
258~ (~284)
130~ (~145)
35211
100
q
9
O
47
175~
Dimensions for MIDIDIS E 120 in parenthesis.
13
7. Installation
7.1 General information
For the selection of a dosing pump when designing a system as well as for the installation and operation, local rules and regulations must be obeyed. This applies to the selection of appropriate materials of construction for the pump, the handling of chemicals
and the electrical installation.
Likewise the technical data of the dosing pump (chapter 4) must be taken into consideration. The system must be designed accordingly/properly (e.g. loss of pressure in the
piping, depending on nominal diameter and length).
The designer and the operator are responsible for ensuring that the whole system including the dosing pump is constructed in such a way that neither plant equipment nor
buildings are damaged in the case of chemical leakage due to the failure of wear parts
(e.g. a rupture in the dosing membrane) or burst tubing. If the chemical system poses
great potential danger, the installation must be carried out in such a way that that no unreasonably high consequential damages occur, even if the dosing pump fails. Therefore
we recommend the installation of leakage probes and containment tanks.
The draining pipe of the dosing head must be visible in order for a diaphragm failure
to be detected. The flow from the drainage pipe must be routed downwards without
obstacles.
To increase the dosing accuracy and to ensure the functional reliability, we recommend
the use of additional accessories. These include, amongst others, backpressure valves,
relief valves, leakage probes and low level indicators, as shown in the installation examples.
Always use appropriate tools for the installation of plastic connecting parts. To avoid
damage, never apply excessive force.
IMPORTANT!
Plastic parts (especially parts made out of PVC) can be tightened and loosened with
greater ease if the thread is first lubricated with Vaseline or silicon grease.
NOTICE!
The compatibility of the lubricant with the dosing chemicals must be verified.
7.2 Installation location
The installation location of the dosing pump must be easily accessible for the operating
and service staff. When installing the dosing pump below the level of the process fluid,
care must be taken to ensure that chemical leakages due to a broken diaphragm cannot
cause any damage for example – collection pan, leakage sensor.
Further more it is possible to install the pump direct to the dosing supply tank.
The maximum environment temperature permissible for the dosing pump must be observed (see technical specifications). Heat radiation from the apparatus and heat exchanges must be shielded from radiation heat, so that the dosing pump can sufficiently
emit it own heat. Direct sunlight must be avoided. When the dosing pump is installed in
the open, a canopy is provided as protection the effect of the weather.
The dosing pump is to be erected with the suction and pressure valves in an upright
IMPORTANT!
CAUTION!
14
position. To guarantee its stability, the pump must be screwed appropriately into the
ground.
The system’s piping must not put any force on the dosing pump’s connections or valves.
To avoid backfiring dosing after the process end, an electrical and hydraulically locking
device is provided on the dosing pump.
7.3 Drainage discharge
NOTICE!
Released gases can destroy the dosing pump’s transmission!
The drainage as well as the leakages from the separate chamber must slope downwards, i.e. to go in a descent to the collection tank. Under no circumstances is the
drainage pipe to go direct through the lidded receptacle back to the medium; otherwise
the released gases can infiltrate the dosing pump’s transmission. The drainage pipe
must be directed only to a gas free collection tank (in a decline) or it has to be lead
on a decline to a collection funnel over which it then has to end with enough distance
in between. The leakages can then be directed back via the funnel through the tank
cover. Moreover possible leakages are detected with greater ease from the gap to the
collection funnel.
7.4 Pressure sustaining and safety valves
Pressure sustaining valves are accessories for optimizing the dosing process. They are
used:
• to increase the dosing accuracy in the presence of fluctuating back pressure
• with long dosing lines in order to prevent excess delivery, as the accelerated medium
continues moving on account of its own inertia even when the delivery stroke has
already ended.
• to prevent siphoning when the suction pressure is higher than the pressure system.
NOTICE!
15
Safety and pressure relief valves protect the dosing pump and the associated accessories and lines from overloads. They prevent an impermissibly high increase of pressure on
the discharge side of the dosing pump that may be caused for example by the accidental
closing of valves whilst the pump is in operation or by a clogged injector.
The PENTABLOC is a combi-accessory that combines, amongst others, the function of
a pressure-sustaining valve as well as being a safety valve. Furthermore, the functions
such as anti-siphon, pressure-relief and flow indicator and monitor are also integrated.
7.5 Injection nozzles
Injection nozzles are used to mix the metered process fluid into a main stream and
simultaneously fulfill a non-return function. The injection nozzle is usually installed in
the main line from above. Installation from below is only recommended in the case of
media with a tendency to crystallize. Thus entrapped air is able to leave.
In the case of media with a tendency to contaminate the injector, it is advisable to use
an injector that can be dismantled for maintenance and shut off.
Injection fitting mounted from above
Injection fitting mounted from
below (for media with a tendency to crystallize)
7.6 Electrical connection
• The electrical connection of the dosing pump must be made according to the local
rules and regulations and may only be carried out by technical experts.
• The type of cable and supply pipe’s cross section of the cable must be chosen in
accordance with the engine’s data.
• The connection of the cable to the engine terminal box must be carried out correctly.
We recommend a plug socket screw joint with strain relief.
• The required level of protection is guaranteed by the correct installation of the electrical connector.
• To avoid incorrect dosing after the process ends an electrical and hydraulic locking
device is provided for the dosing pump.
16
Electrical connection data
(variants on request)
Pump sizes
MIDIDOS
voltage
[V]
output
[Watt]
electricity
[A]
E 24...120 400/230 50 0,50/0,87
50 Hz
440/254 80 0,46/0,80
60 Hz
400/230 80 0,42/0,73
60 Hz
230/1-Phase 50 0,85
50 Hz
Connection system for the driving motor
• supply of three-phase current
• alternating current supply with motor in the stonecutter circuit
• special connector-variant
Other electrical connectors are to be taken from the separately shown circuit diagrams.
W2
U2
V2
U1 V1 W1
L1 L2 L3 PE
W2
U2
V2
U1 V1 W1
L1 L2 L3 PE
W2
U2
V2
U1 V1 W1
L1 L2 L3 PE
W2
U2
V2
U1 V1 W1
L1 L2 L3 PE
Y-Schaltung
-Schaltung
W2
U2
V2
U1 V1 W1
L1 N PE
W2
U2
V2
U1 V1 W1
L1 N PE
Y-circuit ∆-circuit
clockwise counterclockwise
17
7.7 Installation example
Legend
1. MIDIDOS E
2. Electric agitator
3. Chemical tank
4. Pulsation dampener
5. Pressure relief valve (safety valve)
6. Diaphragm stop-valve
7. Injection nozzle
8. Stroke length setting
CAUTION!
The pump’s stroke length is to be moved only when the motor is running!
Set the stroke length as follows:
1. Loosen the mounted screw of the setting knob anti-clockwise (around to the left)
2. Set the stroke length to the desired value according to the capacity performance
curves (chapter 5)
3. Under the retention of the stroke length setting, tighten the mount screw again.
g f e
d
a
b
c
CAUTION!
18
9. Start up
NOTICE!
Personal protective equipment as specified by on-site regulations must be worn at all
times while working on the dosing pump!
Goggles Protective gloves Protective suit
1. Before starting up the dosing pump all the stages for “Installation” in chapter 7 have
to be carried out. The safety advice must be adhered to.
2. The dosing pump is connected externally to the installed control system.
3. The manual performance setting should be set at maximum stroke length for improved suction. During the initial suction it should run without contra-flow pressure. For
this purpose the installation of a relief valve on the pressure side of the dosing pump
is recommendable.
4. If a suction aid is installed this has to be filled up with chemical beforehand. In case
the dosing pump does not have suction, loosen the pressure valves and fill the dosing head with fluid when the pump is turned off. With safe media the dose medium
itself can be used, other a neutral medium that does not disturb the process. (In
many cases water is suitable).
WARNING!
Chemicals can spray out. This may lead to caustic or other burns. Ensure that the line
is not under pressure before disconnecting it.
Mount discharge valve, switch on the dosing pump and allow it to prime again.
5. If a venting facility is integrated in the dosing head or is available as a separate unit,
open it whilst the dosing pump is running until the liquid escapes, then close it. In
the case of effervescent media allow the process fluid to flow continuously (approx.
1 drop per 1...3 strokes)
6. If the ideal setting has been set, then the desired handling capacity is carried out at
the adjusting knob (see chapter 8). The first time it is filled use the capacity performance curves (chapter 5). Depending on the installation and the chemicals used this
value may change and has to be verified under operation conditions.
7. The manufacturer of the dosing equipment is not responsible for damages due to
excessive or low flow rates resulting from faulty dosing pump settings or insufficient
and incorrect installation of peripheral accessories and fittings.
CAUTION!
WARNING!
19
10. Shutdown
Before starting any maintenance and before prolonged downtime, drain the chemical
from the pump and rinse it out with a neutral medium.
CAUTION!
Excess chemicals must be disposed of in accordance with local rules and regulations.
Note the applicable accident prevention regulations and wear personal protective clothing.
Goggles Protective gloves Protective suit
CAUTION!
Next the dosing pump must be disconnected from the power supply and secured to
prevent unauthorized restarting.
CAUTION!
The pressure must be relieved before disconnecting the discharge line from the pump
discharge valve so that chemicals will not spray out.
It is advisable to loosen the discharge and suction check valves in order to drain the
dosing head.
11. Maintenance
Dosing pumps are produced according to the highest quality standards and have a
long service life. Nevertheless some parts are subject to wear and tear caused by its
running (e.g. diaphragm, valve seats, valve balls). To ensure a long operating life, visual
inspection is recommended regularly. Periodic maintenance protects the dosing pump
and system from unexpected downtime.
11.1 Lubricants
The diaphragm-dosing pump is designed to be maintenance friendly. The dosing pump’s
transmission is greased for life with a molybdenum-disulfide. Nonetheless the grease
has to be renewed after approx. 5000 hours of operation when under heavy operational
use such as under high environment temperatures and long running times. For this
purpose you can use for example: “Molykote BR 2 plus” or „OKS400“.
NOTICE!
The dosing pump motor is not to be greased with oil!
11.2 Maintenance of storage
The motor shaft storage are ball holdings caulked and greased for life. The other antifriction bearings in the transmission as well as the plain bearing of the diaphragm insert
are greased with the operational lubricant.
NOTICE!
CAUTION!
CAUTION!
CAUTION!
20
11.3 Replacing the diaphragm
CAUTION!
Chemicals may spray out this may lead to caustic or other burns. The dosing pump head
must always be depressurized and rinsed with water or another suitable medium before
starting any work on the dosing pump.
CAUTION!
Legend
1. Dosing head
2. Diaphragm
3. Supporting plate
(with the MIDIDOS E 24, 48
and 72)
4. Diaphragm chamber
6. Diaphragm insert
7. Motor
Changing the diaphragm
1. Remove the dosing head (1) with a suitable tool (Allen key SW 10 or. SW13 for
E120). picture 1
2. The dosing pump is set whilst the motor
is running at zero-capacity, whereby the
diaphragm (2) is secured into its stop
position.
3. Turn the pumps off.
4. Diaphragm (2), take its edge and turn
it anti-clockwise. So that the support
plate (3) behind the diaphragm is also
moved. Picture 2.
IMPORTANT!
Der Stützpilz c muss vor Einbau einer neuen Membrane von Chemikalien gereinigt
werden, weil die Membrane sonst von der
Rückseite attackiert werden kann.
1
2
3
4
6
7
a
b
c
d
f
g
IMPORTANT!
Picture 1
Picture 2
21
5. The diaphragm rod has to be greased
with Molykote Longterm W2, only in
the area of the bulkhead receptacle and
along the diaphragm thread.
6. The supporting plate (3) is turned onto
the arched side of the diaphragm and
pushed onto the thread support of the
new diaphragm. Picture 3
7. Screw the new diaphragm (2) onto the
support plate (3) clockwise, until it locks
firmly onto the diaphragm rod. The
smooth side of the supporting plate is
then screwed onto the end of the diaphragm rod. Picture 4
8. Install the dosing head (1). Tighten the
screws crossways, e.g. upper left, lower
right, upper right, lower left. A tightening
torque of 2 Nm is required for the dosing head screws on the MIDIDOS E24...
E72 and 6 Nm for the MIDIDOS E120.
Picture 5
IMPORTANT!
The diaphragm will not provide a tight seal
if the tightening torque is too low. The dosing head may be damages if the tightening
torque is too high.
9. After the connection of the dosing pipe,
the dosing pump is started up as described in the “start up” section (chapter 9)
If the diaphragm is excessively worn, it
can lead to the possible causes described in “trouble shooting” (chapter 13).
IMPORTANT!
7
Picture 3
Picture 4
Picture 5
22
11.4 Valves
The dosing pump valves have to be cleaned on a regular basis.
CAUTION!
Chemicals may spray out causing caustic as well as other burns. Before working on the
pump, release any pressure and wash with water or another suitable medium.
NOTICE!
Unclean valves will reduce the dosing accuracy.
NOTICE!
These valves are supplied without valve stops. The internal pieces could fall apart when
unscrewed.
Double-ball valve DN6 (MIDIDOS E24…E72)
Pressure valve suction valve
CAUTION!
NOTICE!
NOTICE!
a
b
c
d
e
f
c
d
e
f
g
g
d
e
f
c
b
c
d
e
f
a
Legend
1. 0-ring
2. *valve casing
3. 0-ring
4. *ball guide
5. *valve ball
6. valve seat*
7. 0-ring
*not included in
spare parts.
23
Spring-loaded valves DN6 (MIDIDOS E24…E72)
Pressure valve suction valve
a
b
c
d
e
f
g
d
e
f
c
b
g
h
h
a
Legend
1. 0-ring
2. *valve casing
3. 0-ring
4. *ball guide
5. *valve ball
6. valve seat*
7. 0-ring
8. spring
*not included in spare parts.
24
Double ball valve DN 10 (MIDIDOS E120)
Pressure valve suction valve
a
b
c
d
e
f
h
d
e
f
g
g
d
e
f
b
c
d
e
f
a
b
h
b
Legend
1. 0-ring 2. 0-ring 3. *valve casing 4. *ball guide
5. *valve ball 6. valve seat* 7. 0-ring 8. spring
*not included in spare parts.
25
Spring-loaded valves DN 10 (MIDIDOS E120)
Pressure valve Suction valve
a
b
c
d
e
f
h
g
g
d
i
c
e
f
a
i
h
b
Legend
1. 0-ring 2. 0-ring 3. *valve casing 4. *ball guide
5. *valve ball 6. valve seat* 7. 0-ring 8. O-ring
9. spring
*not included in spare parts.
26
12. Spare parts list MIDIDOS E 24...72
MIDIDOS E 24...72
h
Diaphragm 81465
i
Support plate 28977
g
Dosing head including screws
Material Order no.:
PVC 23909
PP 34661
PVDF 33330
Stainless steel 1.4571 23911
d
d
b
a
c
d
d
d
d
a
c
d
a
c
f
e
h
g
i
27
Spare parts for MIDIDOS E 24...72 with double balls/valves
Consisting of:
a
balls
c
valve seats
d
O-ring
h
diaphragm
Material Order no.:
PVC/Glas/FPM 28275
PVC/Glas/CSM 28274
PP/Glas/FPM 35567
PP/Glas/CSM 35346
PVDF/PTFE/FPM 35756
Stainless steel / FPM 28277
e
Double ball valve DN6 komplett
Material Order no.:
Suction valve pressure valve
PVC/Glas/FPM 18185 18186
PVC/Glas/CSM 18187 18188
PP/Glas/FPM 35199 35200
PP/Glas/CSM 34670 34671
PVDF/PTFE/FPM 33337 33338
Stainless steel / FPM 19176 19177
Spare parts for MIDIDOS E 24...72 with spring-loaded valves
Consisting of:
a
balls
b
spring
c
valve seats
d
O-ring
h
diaphragm
Material Bestell-Nr:
PVC/Glas/FPM 27815
PVC/Glas/CSM 27814
PP/Glas/FPM 37496
PP/Glas/CSM 37497
PVDF/PTFE/FPM 37495
Stainless steel / FPM 27821
f
Spring-loaded valves Ventile DN6 complete
Material Order-no.:
Suction valve pressure valve
PVC/Glas/FPM 25162 27517
PVC/Glas/CSM 25161 27516
PP/Glas/FPM 35260 35261
PP/Glas/CSM 34810 34811
PVDF/PTFE/FPM 38231 38233
Stainless steel / FPM 23408 23409
28
12. Spare parts list MIDIDOS E 120
MIDIDOS E 120
h
Diaphragm 81466
g
Dosing head inclusive of screws
Material Order-no.:
PVC 38306
PP grey 38178
Stainless steel 1.4571 32890
PVDF 32892
d
d
b
a
c
d
d
d
d
a
c
d
a
c
f
e
h
g
29
Spare parts for MIDIDOS E 120 with double ball valves
Consisting of:
a
balls
c
valve seats
d
O-rings
h
Diaphragm
Material Order-no.:
PVC/Glas/FPM 38196
PVC/Glas/CSM 38197
PP/Glas/FPM 28301
PP/Glas/CSM 28300
Stainless steel / FPM 28303
PVDF/PTFE/FPM 38310
e
Double ball valve DN10 complete
Material Order-no.:
Suction valve pressure valve
PVC/Glas/FPM 34173 34174
PVC/Glas/CSM 34171 34172
PP/Glas/FPM 26842 27357
PP/Glas/CSM 26841 27356
Stainless steel / FPM 27652 27655
PVDF/PTFE/FPM 34078 34079
Spare parts for MIDIDOS E 120 with spring-loaded valves
Consisting of:
a
balls
b
spring
c
valve seats
d
O-rings
h
diaphragm
Material Order-no.:
PVC/Glas/FPM 38198
PVC/Glas/CSM 38199
PP/Glas/FPM 28305
PP/Glas/CSM 28304
Stainless steel / FPM 28307
PVDF/PTFE/FPM 28312
f
Spring-loaded valve DN10 complete
Material Order-no.:
Suction valve pressure valve
PVC/Glas/FPM 34177 34178
PVC/Glas/CSM 34175 34176
PP/Glas/FPM 25707 27354
PP/Glas/CSM 26845 27353
Stainless steel / FPM 25797 27654
PVDF/PTFE/FPM 38308 38309
30
13. Troubleshooting
Problem Cause Recommended action
Dosing pump not delivering or
output too low.
Valves are leaking or blocked. Clean check valves and bleed dos-
ing head. See also chapter 9.
Valves are incorrectly installed. Assemble valves again
Ensure that the valve balls are above
the valve seats.
Suction valve or suction pipe
leaking or blocked.
Clean and seal the suction pipe.
Suction level too high. - Set the dosing pump to “intake”.
- Install the pulsation dampener on
the suction.
- Install priming aid
Viscosity too high. - Install spring-loaded valves
- Enlarge the pipe cross section
- Use a special dosing head.
>> Contact Lutz-Jesco
No existing stroke motion. Dosing pump set on 0 strokes. Correctly adjust the pump stroke
length.
Loaded spring broken Replace springs.
Interrupted supply flow/tension Turn on line voltage.
Numerous ruptures
in the diaphragm
missing support plate.
See chapter 11 “maintenance”
Install a new diaphragm with sup-
porting plate. When changing the
diaphragm check if the diaphragm
rod has been attacked by the me-
dium sprayed through.
The diaphragm is not properly
screwed to the to the diaphragm
rod.
Screw the new diaphragm up to
the stop limit. The supporting plate
must then be affixed inbetween the
diaphragm and diaphragm rod..
Backpressure too high
(Measured at the pressure connection of the dosing pump).
Check the system. Clean out
blocked injection nozzle. Stop pres-
sure surges due to too long piping
from the installation of the pulsation
dampener.
Check function of safety valves.
Media sedimentin dosing head Flush out dosing head.
The dosing pump delivers too
much
(Dosing pump levers through)
Suction side pressure too high. Install pressure relief valve or a suc-
tion pressure regulator.
Stroke stop shifted. Reset the strokes.
31
Dosing pump powers strength
noises.
Defective anti-friction bearings. Replace the gear-box.
Gear-box without molybdenum-
disulfide.
e.g. renew with Molycote.
Motor throbs but doesn’t draw
in.
Wrong connection Check electrical connection
condensator defective, wrong
size or wrongly connected.
Eventual condensator correctly
clamped on or replaced.
Pressure too high. Check process.
If the problem cannot be solved with the support of the above instructions, return the dosing pump to the
factory or contact our Customer Service for further assistance. Repairs will be carried out promptly.
32
EG – Declaration Of Conformity
We hereby clarify, Lutz-Jesco GmbH
Am Bostelberge 19
D-30900 Wedemark
that the product described in the following complies with the relevant fundamental safety and
hygiene requirements and the EC regulations mentioned below due to the concept and design
of the models sold by us.
If the product is modified without our consent, this declaration is no longer valid.
Product description: Diaphragm-dosing pump
Model designation: Minidos A, Mididos E, Memdos TM, Memdos M, Memdos
ML, Memdos E, Memdos MR, Memdos GMR
Relevant EC regulations: EC- Low voltage Directive (73/23/EEC)
EC-Machine Directive (98/37/EC)
Applied harmonized EN 292 – 1 and EN 292 – 2 Machine safety
standards, especially: EN 809,
Pumps and Pump systems for fluids,
technical safety requirements
Date, Manufacturer’s signature: 2006/10/01 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signatory’s details: Mr. Lucjan Gogolin, Head of Technical Office
This declaration is no assurance of characteristics in the sense of the product liability law.
The safety notes in the operating instructions must be observed.
14. Declaration of conformity
This declaration is no assurance of characteristics in the sense of the product liability law.
The safety notes in the operation & maintenance instructions must be observed.
33
Please copy and send in with your apparatus!
15. Declaration of harmlessness
Declaration of harmlessness
(please fill out a separate form for each appliance – e.g. pump or accessory)
We forward the following dosing equipment for repairs:
Type (dosing pump or accessory): ____________________________________________________
Part-no.: _______________________________________________________________________
Order-no.: ______________________________________________________________________
Delivery date: ___________________________________________________________________
Reason for repair: ________________________________________________________________
______________________________________________________________________
Medium used: ____________________________________ Properties: irritant: yes/no
corrosive: yes/no
We hereby certify that the machine has been thoroughly cleaned inside and out before its dispatch and that
it is free from health risk chemical, biological and radioactive materials as well as having been drained of
oil. *)
If Lutz-Jesco find it necessary to carry out further cleaning work, we accept the charge will be made to us.
We certify that the aforementioned information is correct and complete and that the unit is dispatched in
compliance with legal requirements.
Company / address: Phone:
Fax:Fax:
E-Mail:
Customer-number:
Contact person:
________________________ ____________________________
Date Signature / stamp
*) If not applicable please cross out!
Please send with the unit and display Lutz-Jesco GmbH, Am Bostelberge 19
anon the outer packaging. 30900 Wedemark, Germany
34
16. Warranty
Please copy and send with MIDIDOS E!
If the dosing pump breaks down within the period of warranty, please return the MIDIDOS E in a cleaned
condition with the complete warranty application, filled out.
Sender
Company: ........................................................................Phone:........................................ Date: .......................................
Address: .............................................................................................................................................................................
Contact person: ..................................................................................................................................................................
Lutz-Jesco order-no.: .......................................................Delivery date: .............................................................................
MIDIDOS type: .................................................................Serial no.: ...................................................................................
Nominal capacitynominal pressure:.....................................................................................................................................
Description of fault: ............................................................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
Type of fault:
1. Mechanical fault 2. Electrical fault
- premature wear - loose connections such as plug connector or cable
- wear parts - operating elements (e.g.. switches/buttons)
- breakage/other damage - electronics - corrosion
- damage in transit
3. Leaks . 4. No or inadequate suction
- connections - defective diaphragm
- dosing head - other
Service conditions of the dosing pump
Point of use / system designation: ......................................................................................................................................
Accessories used (Suction line, PDS, etc.): .........................................................................................................................
..........................................................................................................................................................................................
..........................................................................................................................................................................................
Commissioning (date): .......................................................................................................................................................
Duty peroid (approx. operating hours): ...............................................................................................................................
Please describe the specifics of the installation and provide a simple diagram with details of the material, diameter, length
and levels.
35
Lutz-Jesco GmbH
Am Bostelberge 19
30900 Wedemark
Germany
Tel.: +49 5130 5802-0
Fax: +49 5130 5802-68
E-Mail: info@lutz-jesco.de
Internet: www.lutz-jesco.de
24h-Hotline:
+49 5130 580 280
Austria
Lutz-Jesco GmbH
Aredstraße 29/212
2544 Leobersdorf
Austria
Telefon: +43 2256 62180
Fax: +43 2256 6218062
E-Mail: info@lutz-jesco.at
Internet: www.lutz-jesco.at
Niederlande
Lutz-Jesco Nederland B.V.
Nijverheidstraat 14 C
2984 AH Ridderkerk
Netherlands
Telefon: +31 180 499460
Fax: +31 180 497516
E-Mail: info@lutz-jesco.nl
Internet: www.lutz-jesco.nl
USA
Lutz-JESCO America Corp.
55 Bermar Park
Rochester, NY 14624
USA
Telefon: +1 585 426-0990
Fax: +1 585 426-4025
E-Mail: mail@jescoamerica.com
Internet: www.jescoamerica.com
East Asia
Lutz-Jesco
East Asia Sdn Bhd
Taman Perindustrian Jaya
47200 Petaling Jaya
Malaysia
Telefon: +603 78454812
Fax: +603 78458413
E-Mail: info@lutz-jescoasia.com
Internet: www.lutz-jescoasia.com
Middle East
Lutz-Jesco Middle East FZE
P.O. Box 9614
SAIF-Free Zone Center
Sharjah
UAE
Telefon: +971 6 5572205
Fax: +971 6 5572230
E-Mail: kudchikar@jesco.de
Internet: www.jescome.com
Best.-Nr. E MIDIDOS E-A
© Lutz-Jesco GmbH 11.06
Printed in Germany
Ungarn
Lutz-Jesco Üzletág
Vasvári P. u. 9.
9024 Györ
Hungary
Telefon: +36 96 523046
Fax: +36 96 523047
E-Mail: s.dudas@lutz-jesco.hu
Internet: www.lutz-jesco.hu
Großbritannien
Lutz-Jesco (GB) Ltd.
Gateway Estate
West Midlands Freeport
Birmingham B26 3QD
Great Britain
Telefon: +44 121 782 2662
Fax: +44 121 782 2680
E-Mail: summers@jesco.de
Internet: www.lutz-jesco.de
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