Knight Equipment PMP-800 Installation Manual
INSTRUCTION MANUAL
INTRODUCTION
The PMP Plus Series peristaltic and electric diaphragm metering pump
systems are designed to dispense a variety of cleaning, sanitizing,
lubrication and water treatment chemicals. Positive, accurate metering of
liquids can be triggered manually or by a process control signal.
The PMP Plus Series offers a range of variable speed controlled flow rates
with 30 PSI peristaltic or 100 PSI electric diaphragm pump and a standard
multi-function pump controller with selectable feed modes including limittimer, repeating cycle timer, relay/direct feed and push button activation.
Variable speed control of the pump flow rate can be set manually or by a
remote 4—20mA input from a process control. PMP Plus is built with
Knight’s field proven, long-life pumps. The moisture-sensitive motor and
controller are enclosed in a corrosion-resistant, watertight, powder-coated
case that stands up well for indoor applications.
KEY FEATURES / BENEFITS
Auto-Start or Optional Manual Button Activation
Watertight, Secure Locking Enclosure
Long-Life Peristaltic or Electric Diaphragm Pumps (―EDP‖)
Water Resistant Case w/―D‖ Shaped Silicone Gasket
Long Lasting Squeeze Tubes and Valves Seals
Variable Speed Control
4—20mA speed control input to vary pump delivery volume with process
―Batch Feed‖ mode (Timer)
―Repeat Cycle‖ mode
Programmable Pump Delay
Wide Range of Flow Rates
Microprocessor, Push Button Programming
Pumps Pressure from 30 to 100 PSI
Pressure Switch option
Pump Lockout Option
APPLICATIONS
FOOD & BEVERAGE PROCESSING PLANTS: CIP Sanitizer Injection, COP
Dosing, Bucket Fill, Conveyor Lube, Cart Washer, Water Treatment, Odor
Control Misting
PMP-EDP Series
PMP-900 Series
DAIRY: Pipeline Cleaning/Sanitizing, Teat Dip Chemical, Wash Pen
Chemical Injection
INDUSTRIAL: General Cleaning, Machinery Lubrication, Cooling Towers,
Boilers
TRANSPORTATION: Car Wash Stations
0900815 Rev: B (01/12) Page 1 of 24
Remote Activator
CAUTION: Wear protective clothing and eyewear when dispensing chemicals or
other materials. Observe safety handling instructions (MSDS) of chemical mfrs.
CAUTION: To avoid severe or fatal shock, always disconnect main power when
servicing the unit.
CAUTION: When installing any equipment, ensure that all national and local
safety, electrical, and plumbing codes are met.
Page 2 of 24 0900815 Rev: B (01/12)
RECOMMENDED OPERATING PARAMETERS
Pump Model Duty Cycle Maximum Pump Run
PMP-800 Models 50% 5 Minutes 10 Feet (3 Meters) 30 PSI (2 Bar)
PMP-900 Models 50% 5 Minutes 10 Feet (3 Meters) 30 PSI (2 Bar)
PMP-EDP Models 70% 60 Minutes 15 Feet (4.5 Meters) 100 PSI (6.9 Bar)
NOTE: The duty cycles and maximum pump run time specified above can be exceeded, however in doing so the life
of the squeeze tube, roller block and motor may be reduced.
Time
Maximum Lift
(Suction)
Maximum Head
Pressure
SPECIFICATIONS
Enclosure: Powder coated stainless steel.
Pump Drive: Variable DC.
Squeeze Tube and Valve Seal Materials: Material available for most chemical applications.
Control: Limiting timer, repeating cycle timer, or relay mode.
Dimensions: PMP Plus-800: 9.3‖H x 5.8‖W x 5‖D (23.6cm x 14.7cm x 12.7cm)
PMP Plus-900: 13.6‖H x 8‖W x 7.5‖D (34.5cm x 20.3cm x 19.1cm)
PMP Plus EDP:13.6‖H x 8‖W x 7.5‖D (34.5cm x 20.3cm x 19.1cm)
Pollution Degree II
Installation category I
Altitude 2000m
Humidity 5 to 95%
Electrical supply 115VAC/60HZ, 230VAC/60HZ, 230VAC/50HZ, 2A
For Indoor Use Only
Temperature 5C to 40C
Mains supply voltage fluctuations are not to exceed 10% of the nominal supply voltage
The unit shall not be positioned so that it is difficult to operate the power disconnecting means
Protection is impaired if the product is used in a manner not specified by the manufacturer
Replacement Fuse for 115V/230V model: 2Amp, 250V, 6.3x32mm, Fast-Acting
PROGRAMMING SETTINGS
Operating
Mode
KTM 14—240 VAC/VDC 0—12 min 42 sec 0—12 min 42 sec Select Select
CT 14—240 VAC/VDC 0—12 min 42 sec 0—255 min 0—12 min 42 sec Select Select
Relay 14—240 VAC/VDC 1 sec to continuous
4—20 mA External Input (PLC)
0900815 Rev: B (01/12) Page 3 of 24
Signal Input Pump ―ON‖ Time Pump ―OFF‖
Time
Delay On Time On First Off First
THEORY OF OPERATION
The PMP Plus chemical metering systems come standard with a unique microcontroller that provides extreme
versatility of use. The multi-function pump controller varies the speed of the pump to provide accurate, precise
injections for almost any chemical batch feed application, repeat cycle injection, pumped misting applications and
direct closed loop injection. The integral circuit board has dual dip switch program/mode selectors that provide the
following operations:
KTM Mode (Timer) Dip Switch#5— This pump ―Limit Timer‖ control is designed to control the run time of the pump
with the press of a button or input of a signal from a powered switch or remote controller. The water proof control
cabinet is normally mounted near the delivery point for the chemical, convenient for operators. Typical delivery points
include Gerry cans, buckets, floor scrubbers, portable foamers or other receptacles. For applications where remote
triggers such as a CIP or Conductivity control signal are used, the controller can be installed close to the signal
source. The signal-input circuit accepts input voltages from 14-240 VAC. The MFSC board also has a ―Relay Mode‖
feature that allows the pump to run from a 14 – 240V signal (for as long as the signal is present) or while the push
button is held down. Using the relay mode with the push button is well suited for manual feed applications.
CT Mode (Repeat Cycle) Dip Switch#5 — This pump ―Cycle Timer‖ triggers a continuous On-Off feed cycle anytime
power is applied to the power input. For continuous chemical applications such as conveyor or track lubrication, the
Repeat Cycle Timer Mode will feed from 0-12 minutes of ON time, with an OFF time from 0-255 minutes off.
INSTALLATION—PERISTALTIC MODELS
(1) Check voltage of installation with a voltmeter and compare with voltage inputs of pump unit before mounting.
Application of incorrect voltage will permanently damage unit and is not covered under warranty.
(2) Mount unit on wall or shelf in a convenient location near both injection point and chemical supply. Do not mount
unit in direct path of steam. This can short circuit and permanently damage your system.
(3) Install power leads. Most systems include a power cord for easy connection. Variable speed systems have an
internal transformer which steps down the incoming voltage. Rigid or flexible conduit should be used to ensure
safety and continued operation without shorts. The green ground wire must be applied to ground. Failure to do
so will void warranty.
(4) Install braided tubing between the discharge (right) tube side of the peristaltic pump and the injection point. Use
the provided stainless steel hose clamps and barb fittings to secure braided tubing to squeeze tube.
(5) Install braided tubing between the suction (left) tube side and the barb fitting on the PVC pickup tube provided.
Use the provided stainless steel hose clamps and barb fittings to secure braided tubing to squeeze tube.
INSTALLATION—ELECTRIC DIAPHRAGM MODELS
(1) Check voltage of installation with a voltmeter and compare with voltage inputs of pump unit before mounting.
Application of incorrect voltage will permanently damage unit and is not covered under warranty.
(2) Mount unit on wall or shelf in a convenient location near both injection point and chemical supply. Do not mount
unit in direct path of steam. This can short circuit and permanently damage your system.
(3) Install power leads. Most systems include a power cord for easy connection. Rigid or flexible conduit should be
used for all 115 and 230 VAC installations to ensure safety and continued operation without shorts. The green
ground wire must be applied to ground. Failure to do so will void warranty.
(4) Install vinyl hose between the discharge (right) tube side of the pump and the injection point. Use hose clamps to
secure tubing to fittings. For all hose routing, avoid any sharp bends which may crimp tubing and restrict flow. As
an alternative, use 90 elbow fittings, but only if absolutely necessary.
(5) Install vinyl hose between the suction (left) tube side and the PVC product pickup tube provided.
PRIMING THE PUMP
(1) Locate the dip-switch pack on the lower left corner of the circuit board; set switch #2 to RUN, set switch #4 to
RELAY, and switch #7 to SIGNAL.
(2) Press and hold the Start button until the chemical line is fully primed, then release the button.
(3) When finished priming, set switch #4 to TIMER (unless you intend to use relay mode).
Page 4 of 24 0900815 Rev: B (01/12)
PROGRAMMING KTM (TIMER) MODE
Pump Run Time: (max run time is 12 minutes and 42 seconds)
(1) Locate the dip-switch pack on the lower left portion of the circuit board — set switch #2 to Program, set switch #3
to RUN TIME and set switch #7 to Signal MODE.
(2) Using a measuring cup or beaker, press Start switch and release when pump starts. Let the pump run until
desired amount of chemical is dispensed then press Start switch again to stop. The run time is now programmed.
Repeat step if new volume is required.
(3) Set mode switch #2 to RUN MODE.
Delay Time: (max delay time is 12 minutes and 42 seconds)
(1) Locate the dip-switch pack on the lower left portion of the circuit board — set switch #7 to SIGNAL, set switch #3
to DELAY TIME and set switch #2 to PROGRAM MODE.
(2) Press Start switch and release when the LED begins flashing. When the desired delay time has passed, press
the Start switch again. The delay time is now programmed. Repeat step if new delay time is required.
(3) Set mode switch #2 to RUN MODE.
Lock-Out Time: (max lock-out time is 255 minutes) See Dip Switch located on right side of circuit board.
This feature defeats consecutive dispensing of product for a pre-determined interval. Select a combination of
switches 1 – 8 to program total lock-out time.
Example: For 10 minute lock-out, set switches #2 and #4 to ON with all other switches OFF.
For maximum lock-out (255 min) set all switches ON.
For no lock-out, set all switches OFF.
OPERATION—KTM (TIMER) MODE
Manual activation: Press the Start button for 1 full second. The unit will begin counting down the delay time (if used)
and will then run the pump for the amount of time programmed. Once the lock-out time expires (if used) the pump will
be ready to restart.
Signal activation: When the signal input on the circuit board receives a 14-240VAC trigger signal for at least 5
seconds, the delay time (if used) will begin counting down. Then the pump will run for the amount of time
programmed. Once the lock-out time expires (if used) the pump will be ready to restart.
RELAY MODE
(1) Locate the dip-switch pack on the lower left corner of the circuit board; set switch #2 to RUN, set switch #4 to
RELAY.
(2) Set switch #1 to POT for the pump speed to be controlled by the on-board potentiometer. If the pump speed will
be controlled by a 4—20 mA signal, then set switch #1 to 4—20 mA.
(3) Set switch #7 to SIGNAL if you want the pump to activate for as long as an external trigger signal is present, or
for as long as the manual button is depressed. Set switch #7 to POWER-UP if you want the pump to run for as
long as main power is on (no signal required).
DISABLING THE START BUTTON
There is a jumper marked ―JP1‖ on the circuit board that can be used to prevent manual activation in certain
applications, or to allow manual activation by remote push-button only. This jumper only affects the on-board start
button. A remote start button, or trigger signal, can always be used to activate the pump.
When the jumper is ON, the on-board start button is functional.
When the jumper OFF, the on-board start button is disabled.
0900815 Rev: B (01/12) Page 5 of 24
OPERATING MODES
Dip Switch #1 (Pot—4-20 mA)
Select Pot for potentiometer pump speed control (on board)
Select 4-20 mA for installations where automatic process controlled flow rates are required
Dip Switch #2 (Program—Run Mode)
Program mode explained in previous pages
Run Mode is selected after programming has been completed
Dip Switch#6 (On First—Off First)
In the On First position the system will execute the dispense time function for Timer or Repeat Cycle mode when
power is first applied. If a Delay time is programmed the LED will flash until Delay time is elapsed before the pump
starts.
In the Off First position the system will execute the ―off‖ time function for Repeat Cycle mode when power is first
applied.
Dip Switch #7 (Signal—Power Up)
The signal input feature is particularly useful for CIP and other control interface applications. The signal input circuitry
will accept any signal voltage in the range of 14 – 240V. Check the signal voltage with a meter before connecting to
the circuit board.
In the Power Up position allows the pump to be powered by the main power source and run when main power is
applied to the system.
In the Signal position the system requires an input signal from a process control or any voltage signal with an
effective range of 14 –240 VAC
PROGRAMMING CT (REPEAT CYCLE) MODE
Locate dip switch #5 and select CT Mode
Maximum ON time is 12 minutes and 42 seconds.
Maximum OFF time is 255 minutes.
Setting “OFF” Time
Power should be off when changing this setting. The off time is set by selecting a combination of switches 1 – 8. All
switches that are turned ON will be added up to determine the total off time. For example, if you wish to set a 20
minute off time, set switches #3 and #5 to ON with all other switches OFF.
For maximum off time (255 min) set all switches ON.
The off time resets and begins counting down again the next time the pump runs.
Setting “ON” Time
(1) Ensure that power is on. Be aware that the pump may run briefly — this is normal as the pumps are tested at the
factory during final QC inspection.
(2) Locate the dip-switch pack on the circuit board — set switch #2 to PROGRAM.
(3) Using a measuring cup or beaker, press Start switch and release when pump starts. Let the pump run until
desired amount of chemical is dispensed then press Start switch again to stop. The on time is now programmed.
(4) Set mode switch #2 to RUN MODE.
Page 6 of 24 0900815 Rev: B (01/12)
SPEED CONTROL
Pump Speed Control is accomplished by manually adjusting pump speed to a desired output speed/concentration
using the circuit board mounted potentiometer or by a dedicated 4-20mA input signal from a PLC. Many CIP process
controls and wash circuit programs are able to output variable signals that regulate the injection of sanitizers and
other process chemicals to achieve targeted PPM concentrations that match fresh water flow rates or desired batch
dose volumes. A simple two wire 4-20mA connection (+/-) from the PLC will run the pump at the rated speed (see
charts on the following pages) and vary the flow rate as the control signal changes in amplitude.
NOTE: DIP switch #8 is used on 24V board configurations only, and is intended to maximize performance with 800
Series pumps. This switch allows you to select EPDM or Viton as the type of squeeze tube used with the pump.
CONNECTING A START SWITCH
A remote, or case mounted, start switch can be connected to the circuit board for manual activation of the pump. See
the diagram below and the wiring diagrams on pages 13—18 that show where the start switch should be connected.
Timer Activation: The start switch will activate the programmed feed time for KTM mode (see KTM MODE
on page 5 for further details).
Relay Mode: The start switch will run the pump for as long as the switch is depressed (see RELAY MODE
on page 5 for further details)
REMOTE START
SWITCH INPUT
PUMP POWER
INPUT
(NOT USED ON
800 SERIES)
TRIGGER
SIGNAL INPUT
SPEED
CONTROL
SIGNAL
INPUT
CIRCUIT
BOARD
POWER
INPUT
PUMP
OUTPUT
SPEED CONTROL
POTENTIOMETER
EPDM VITON
CONFIGURATION
DIP SWITCHES
(#8 ONLY USED
FOR 800 SERIES)
DIP SWITCHES
FOR LOCKOUT OR
CYCLE TIME
START SWITCH
0900815 Rev: B (01/12) Page 7 of 24
Pump Speed Data .4 gpm Electric Diaphragm
Current
(ma)
Voltage
(vdc)
Flow (gal/
min)
115VAC 230VAC
Flow (oz/
min)
Flow (L/
min)
Flow (ml/
min)
Flow (gal/
min)
Flow (oz/
min)
Flow (L/
min)
Flow (ml/
min)
3.00 0.72 0.000 0.000 0.000 0 0.000 0.000 0.000 0
3.60 0.864 0.000 0.000 0.000 0 0.000 0.000 0.000 0
4.20 1.008 0.040 5.072 0.150 150 0.048 6.087 0.180 180
4.80 1.152 0.096 12.342 0.365 365 0.116 14.878 0.440 440
5.40 1.296 0.144 18.429 0.545 545 0.177 22.655 0.670 670
6.00 1.44 0.199 25.530 0.755 755 0.248 31.785 0.940 940
6.60 1.584 0.248 31.785 0.940 940 0.301 38.548 1.140 1140
7.20 1.728 0.299 38.210 1.130 1130 0.361 46.156 1.365 1365
7.80 1.872 0.332 42.437 1.255 1255 0.427 54.610 1.615 1615
8.40 2.016 0.367 47.001 1.390 1390 0.489 62.556 1.850 1850
9.00 2.16 0.395 50.552 1.495 1495 0.510 65.261 1.930 1930
9.60 2.304 0.419 53.595 1.585 1585 0.535 68.473 2.025 2025
10.20 2.448 0.446 57.146 1.690 1690 0.567 72.531 2.145 2145
10.80 2.592 0.466 59.682 1.765 1765 0.590 75.574 2.235 2235
11.40 2.736 0.483 61.880 1.830 1830 0.612 78.279 2.315 2315
12.00 2.88 0.499 63.909 1.890 1890 0.630 80.646 2.385 2385
12.60 3.024 0.515 65.937 1.950 1950 0.650 83.182 2.460 2460
13.20 3.168 0.524 67.121 1.985 1985 0.663 84.873 2.510 2510
13.80 3.312 0.535 68.473 2.025 2025 0.680 87.071 2.575 2575
14.40 3.456 0.544 69.657 2.060 2060 0.692 88.593 2.620 2620
15.00 3.6 0.556 71.179 2.105 2105 0.703 89.945 2.660 2660
15.60 3.744 0.567 72.531 2.145 2145 0.712 91.129 2.695 2695
16.20 3.888 0.575 73.545 2.175 2175 0.716 91.636 2.710 2710
16.80 4.032 0.581 74.391 2.200 2200 0.724 92.650 2.740 2740
17.40 4.176 0.590 75.574 2.235 2235 0.733 93.834 2.775 2775
18.00 4.32 0.594 76.082 2.250 2250 0.738 94.510 2.795 2795
18.60 4.464 0.602 77.096 2.280 2280 0.741 94.848 2.805 2805
19.20 4.608 0.606 77.603 2.295 2295 0.745 95.356 2.820 2820
19.80 4.752 0.613 78.449 2.320 2320 0.793 101.442 3.000 3000
20.40 4.896 0.617 78.956 2.335 2335 0.794 101.611 3.005 3005
Page 8 of 24 0900815 Rev: B (01/12)
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