Omega Products FPUDT600 Installation Manual

User’s Guide

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DIAPHRAGM INJECTOR

MODEL FPUDT600

Operating Manual

OMEGAnet Online Service Internet e-mail Omega.com info@omega.com

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U.S.A.: One Omega Drive, P.O. Box 4047

ISO 9001 Certified Stamford, CT 06907-0047

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Canada: 976 Bergar

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For immediate technical or application assistance:

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Customer Service: 1-800-622-2378 / 1-800-622-BEST Engineering Service: 1-800-872-9436 / 1-800-USA-WHEN

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Service Europe:

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TEL: +31 (0)20 3472121 FAX: +31 (0)20 6434643 Toll Free in Benelux: 0800 0993344 E-mail: sales@omega.fr

Czech Republic: Frystatska 184, 733 01 Karvina, Czech Republic

Tel: +420 (0)59 6311899 FAX: +420 (0)59 6311114 Toll Free: 0800-1-66342 e-mail: info@omegashop.cz

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TEL: +33 (0)1 61 37 2900 FAX: +33 (0)1 30 57 5427 Toll Free in France: 0800 466 342 E-mail: sales@omega.fr

Germany/Austria: Daimlerstrasse 26, D-75392 Deckenpfronn, Germany

TEL: +49 (0)7056 9398-0 FAX: +49 (0)7056 9398-29 Toll Free in Germany: 0800 639 7678 E-mail: info@omega.de

United Kingdom: One Omega Drive, River Bend Technology Centre ISO 9002 Certified Northbank, Irlam, Manchester

M44 5BD United Kingdom TEL: +44 (0)161 777 6611 FAX: +44 (0)161 777 6622 Toll Free in United Kingdom: 0800-488-488 E-mail: sales@omega.uk

It is the policy of OMEGA Engineering, Inc. To comply with all worldwide safety and EMC/EMI regulations that apply. OMEGA is constantly pursuing certification of its products to the European New Approach Directives. OMEGA will add the CE mark to every appropriate device upon certification.

The information contained in this document is belived to be correct, but OMEGA accepts no liability for any erroes it contains, and reserves the right to alter specifications without notice. WARNING: These products are not designed for usein, and should not be used for, human applications.

FPUDT600

TABLE OF CONTENTS

SECTION HEADING PAGE

1 Introduction 2

2 Specifications 2

3 FPUDT600 Features 3

4 How to install the FPUDT600 3

4.1 Mounting location 3

4.2 Electrical connections 5

4.3 How to install the tubing and fittings 6

5 How to operate the FPUDT600 8

5.1 Adjusting the Pump Output - Standard Models 8

5.2 Adjusting the Pump Output - Fixed cycle timer Models 8

5.3 Measuring the pump’s output - volumetric test 9

6 How to maintain the FPUDT600 9

Page 2

6.1 Routine inspection and cleaning 9

6.2 How to clean the FPUDT600 9

1.0 Introduction

Thank you for purchasing the FPUDT600 positive displacement metering pump. The FPUDT600 is designed to inject chemicals into piping systems. All models are equipped with a top mounted mechanical flow rate adjustment knob. Optional on/off cycling timers are available.

2.0 Specifications

Maximum Working Pressure 125 psig / 8.6 bar*

Maximum Fluid Temperature 130 F / 54 C

Output Accuracy +/- 10% of maximum (water @ 70 F, 0 psig, and 5’ suction lift)

Ambient Temperature Range 14 to 110 F / -10 to 43 C Enclosure Zinc - Metal Duty Cycle Continuous Maximum Viscosity 1,000 Centipoise Maximum Suction Lift up to 10 ft. water Power Requirements 115V60Hz 45 Watts

Dimensions 6-1/2” high x 6-1/2” wide x 5-3/4” deep Weight 8 lb.

o o

o

o o

220V50Hz 45 Watts 230V60Hz 45 Watts 24V60Hz 45 Watts

Page 3

3.0 FPUDT600 Features

!

Double-ball ceramic check valves.

!

PVDF (Kynar) valve assemblies.

!

Viton o-rings.

!

High outlet pressure capability of 125 PSIG.*

!

Easy access, side mounted mechanical feed rate adjustment.

!

Ball bearing supported motor drive shaft.

!

Permanently lubricated ball bearing motor.

!

27:1 adjustment turn down ratio.

!

Easy servicing.

!

Includes suction tube foot valve & strainer, suction tube weight, suction tubing, discharge tubing and injection fitting with internal back-flow check valve and mounting hardware.

* Most models.

4.0 How To Install the FPUDT600

Become familiar with the parts shown

Junction box

Pump

head

FPUDT600

Top valve

fitting

Output

adjustment

(cam cover not shown)

Bottom valve

fitting

CAUTION: PROPER EYE AND SKIN PROTECTION MUST BE WORN

WHEN INSTALLING AND SERVICING THE FPUDT600

Note: All diagrams are strictly for guideline purposes only. Always consult an expert before installing the FPUDT600 into specialized systems. The FPUDT600 should be serviced by qualified persons only.

4.1 Mounting Location

Choose an area located near the chemical supply tank, chemical injection point and electrical supply. Install the pump where it can be easily serviced.

!

Mount the pump to a secure surface or wall using the enclosed hardware. Wall mount to a solid surface only. Mounting to drywall with anchors is not recommended.

!

Keep the outlet (discharge) tubing as short as possible. Longer tubing increases the back pressure at the pump head.

!

Do not mount the pump directly over your chemical container. Chemical fumes may damage the unit. Mount the pump off to the side or at a lower level than the chemical container.

!

Mounting the pump lower than the chemical container will gravity feed the chemical into the pump. This “flooded suction” installation can reduce the time required to prime the pump. Install a shut-off valve, pinch clamp or other means to halt the gravity feed to the pump during servicing.

!

Your solution tank should be sturdy. Keep the tank covered to reduce fumes.

!

Be sure your installation does not constitute a cross connection with the drinking water supply. Check your local plumbing codes.

FPUDT600

Page 4

6-3/4”

171.5mm

6-1/4”

158.8mm

5-5/16”

134.9mm

FIG. 4.1 DIMENSIONAL DRAWING

1. Strainer

2. Circulation Pump

3. Filter

4. Heater

5. Check Valve

6. Flowmeter

7. Injector FPUDT600

8. Solution Tank

9. Injection Fitting

10. Return Line

l

o

oP

FPUDT600

Pumping unit

Discharge

Tube

55

44

33

22

11

00

Chemical Container

¼

" "

& ½

Suction Tube

(vertical)

N

P

T

I

n e r

j c

to

FIG. 4.2 TYPICAL INSTALLATION

7

5

3

2

11

3

1010

5

4

6

9

7

8

FIG. 4.3 SWIMMING POOL INSTALLATION

Stud

55

44

33

22

11

00

Stud Mount

55

44

33

22

11

00

Masonry

FIG. 4.4 WALL MOUNTING

Page 5

4.2 Electrical Connections

4.2.1 Input Power Connections

Be certain to connect the pump to the proper supply voltage. Using the incorrect voltage will damage the pump and may result in injury. The voltage requirement is printed on the pump serial label.

Note: When in doubt regarding your electrical installation, contact a licensed electrician.

The FPUDT600 is supplied with a junction box for field wiring.

JUNCTION BOX MODELS -To reduce the risk of electric shock, be certain that a grounding conductor is connected to the green grounding screw located in the junction box.

FPUDT600

MOTOR LEADWIRES

INPUT

VOLTAGE

115V 60Hz

220V 50Hz

230V 60Hz

BLACK or YELLOW

BLUE or YELLOW

BLACK or YELLOW

24V 60Hz

* Yellow leadwire : thermally protected motor Black or Blue leadwire: standard impedance protected motor

Hot

AC

Input

Power

Common

Earth Ground (green)

HOT

LEADWIRE

BLUE

NEUTRAL

LEADWIRE

*

BLUE

BROWN

RED

WHITE

Hot

Neutral

Ground (green)

GROUND

LEADWIRE

GREEN

AC MOTOR

FIG. 4.5 WIRING DIAGRAM - STANDARD MODELS

FPUDT600

Common

Hot Earth Ground (green)

Power Cord

Page 6

Cycle Adjustment Potentiometer

120VAC

220/230 VAC

HOT LOAD

Timer Board

AC MOTOR

Neutral Hot

FIG. 4.6 WIRING DIAGRAM - FPUDT600 -T MODELS

4.3 How To Install the Tubing and Fittings

CAUTION: PROPER EYE AND SKIN PROTECTION MUST BE WORN

WHEN INSTALLING AND SERVICING THE FPUDT600

4.3.1 Inlet Tubing - Locate the inlet fitting of the pump head, see fig 4.7. Remove the tube nut. Push the

clear PVC suction tubing onto the compression barb of the fitting. Use the tube nut to secure the tube. Hand tighten only.

4.3.2 Footvalve/Strainer -Trim the inlet end of the suction tubing so that the strainer will rest in a vertical position, approximately one inch from the bottom of the solution tank. This will prevent sediment from clogging the strainer. Loss of prime may occur if the footvalve is permitted to lay on the bottom of the solution tank in a horizontal position. Slip the ceramic weight over the end of the suction tube. Press the footvalve/strainer into the end of the tube. Secure the ceramic weight to the strainer. Drop the strainer into the solution tank.

4.3.3 Outlet Tubing - Locate the outlet fitting of the pump head, see fig 4.7. Remove the tube nut. Push the rigid outlet (discharge) tubing onto the compression barb of the fitting. Use the tube nut to secure the tube. Hand tighten only.

Trim the other end of the outlet tube leaving only enough slack to connect it to the Injection/Check valve Fitting (FIG. 4.9). Increasing the length of the outlet tube increases the back pressure at the pump head, particularly when pumping viscous fluids.

Keep the inlet and outlet tubes as short as possible.

Page 7

Discharge Tube (Opaque P.E.)

Tube Nut

FPUDT600

Footvalve Adapter

Suction Tubing

FIG. 4.7

Outlet Adapter

Pump Head

Inlet Adapter

Tube Nut

Suction Tubing (clear PVC)

FootValve

Ceramic Weight

FootValve Assembly

Must be installed in

a vertical position.

DO NOT LAY ON SIDE!

FIG. 4.8 FOOTVALVE ASSY.

O-Ring

Ceramic Ball

O-Ring

Footvalve Body

Footvalve Strainer

4.3.4 Injection/Check Valve Fitting Installation - The Injection/Check valve fitting is designed to install

directly into either 1/4” or ½” female pipe threads. This fitting will require periodic cleaning, especially when injecting fluids that calcify such as sodium hypochlorite. These lime deposits and other build ups can clog the fitting increasing the back pressure and interfering with the check valve operation. See section 6.0.

Install the Injection/Check valve directly into the tee fitting. Do not install the fitting into a pipe stud and then into the tee. The solution must inject directly into the flow stream.

Use Teflon thread sealing tape on the pipe threads. Push the opaque outlet (discharge) tubing onto the compression barb of the Injection/Check valve fitting. Use the tube nut to secure the tube. Hand tighten only.

FIG. 4.9

INJECTION/CHECK VALVE

TEE INSTALLATION AND EXPLODED VIEW

Page 8

5.0 How To Operate The FPUDT600

5.1 Adjusting the Pump Output

The FPUDT600 flow rate can be adjusted within a range of approximately 10%-100% of maximum output (27:1 turndown ratio) by means of a mechanical, cam type mechanism. The mechanism adjusts the pump’s stroke length to 1 of 27 settings within the flow range. The pump’s output is affected by the pressure of the system , the amount of suction lift, and the viscosity of the fluid being injected into the pump must be over-sized to allow for these factors. Sizing the pump to allow adjustment within the midrange is preferred to maintain accuracy. Consult the factory for individual pump model output curve data.

To adjust the pump output:

1. Make sure the pump is off before adjusting.

2. Loosen the wing nut.

3. Turn adjusting knob so the pointer is on the desired setting. Note: pump less chemical at first, then re-adjust.

4. While holding the knob, tighten the wing nut to keep the knob at the desired setting. Note: wing nut must be tight.

Adjustment Knob

66

55

44

33

22

11

00

Wing Nut

FIG. 5.1 Adjustment Cam

5.2 Priming The Pump

Each pump is factory tested with water. The test water is sealed in the pump head keeping the valves wet to aid in priming. If the valves have dried or priming is difficult due to back pressure, do the following:

1. Remove the opaque discharge tubing from the top valve fitting in the pumphead.

2. Remove the top and bottom valve fittings and immerse in water to wet the valves. Reinstall the fittings.

3. With the discharge tubing removed, start the pump. Stop the pump when the fluid enters the pumphead.

4. Attach the discharge tubing to the top valve fitting.

5. Be sure the footvalve/strainer is attached to the suction tubing and is installed in a vertical position.

If your installation is at high altitude, priming may be more difficult since the atmospheric pressure is decreased. When the suction line is dry, the diaphragm may not create enough pull. If this is the case, do the following:

1. Remove the clear suction tube from the bottom valve fitting and fill completely with water.

2. While the pump is running, attach the tube (filled with water) to the bottom valve fitting.

3. When the fluid enters the pumphead, place the foot valve in the solution tank.

4. Be sure the footvalve/strainer is attached to the suction tubing and is installed in a vertical position.

Page 9

5.3 Measuring the Pump’s Output - Volumetric Test.

This volumetric test will take into account individual installation factors such as line pressure, fluid viscosity, suction lift, etc. This test is the most accurate for measuring the injector’s output in an individual installation.

1. Be sure the Injection Fitting and Footvalve/Strainer is clean and working properly.

2. With the injector installed under normal operating conditions, place the Footvalve/Strainer in a large

graduated cylinder.

3. Fill the graduated cylinder with the solution to be injected and run the injector until all air is removed from the suction line and the solution enters the discharge tubing.

4. Refill the graduated cylinder, if necessary, and with the Footvalve completely submerged in the solution, note the amount of solution in the graduated cylinder.

5. Run the injector for a measured amount of time and note the amount of fluid injected. A longer testing time will produce more accurate results.

5.4 Timer Equipped Model

1.The pause control knob adjusts the cycle timer’s time on. The FPUDT600 standard cycle time is set at

one minute. (+-10%) Other cycle lengths are available.

2. To adjust the amount of time on,turn the pause control knob to the correct setting. ½ equals

approximately 30 seconds on. 3/4 equals approximately 45seconds on, etc.

FPUDT600

6.0 How to Maintain the FPUDT600

6.1 Routine Inspection and Maintenance

The FPUDT600 requires very little maintenance. However, the pump and all accessories should be checked regularly. This is especially important when pumping chemicals. Inspect all components for signs of leaking, swelling, cracking, discoloration or corrosion. Replace worn or damaged components immediately.

Cracking, crazing, discoloration and the like during the first week of operation are signs of severe chemical attack. If this occurs, immediately remove the chemical from the pump. Determine which parts are being attacked and replace them with parts that have been manufactured using more suitable materials. The manufacturer does not assume responsibility for damage to the pump that has been caused by chemical attack.

6.2 How to Clean the FPUDT600

The FPUDT600 will require occasional cleaning, especially the Injection fitting, the Footvalve/Strainer, and the pump head valves. The frequency will depend on the type and severity of service.

When changing the diaphragm, the pump head chamber should be wiped free of any dirt and debris.

]

Periodically clean the injection/check valve assembly. Dirt and other build ups can clog the fitting, increase the back pressure and interfere with the check valve operation. See section 4.3.4. FIG. 4.9.

]

Periodically clean the suction strainer. FIG. 4.8.

]

Periodically inspect the air vents located on the back of the motor compartment. Clean if necessary.

FPUDT600

Page 10

FPUDT600

11

27

12

Optional

Exploded View

1

25

13

14

15

26

16

28

4

15

2

3

17

18

19

20

T.I. Anti siphon valve fitting

Threaded Anti siphon valve, ¼ & ½” N.P.T.

22

8

9

10

21

23

4

24

3

25

5

6

7

Page 11

FPUDT600 Parts List

Catalog No. Description Amount Reqd.

1. C-395-6V Injection / anti-syphon valve 6 PSI, Viton® 1

C-395-6E Injection / anti-syphon valve 6 PSI, EP (optional) 1

2. C-335-6 Discharge Tubing 3/8 OD, 5ft. Opaque Poly-E 1

3. C-330-6 Tube nut 2

4. K-568V-4 Bullet valve (double ball), Viton®, 4 pack set 2

K-568V-10 Bullet valve (double ball), Viton®, 10 pack set 2

K-569E-4 Bullet valve (double ball), EP, 4 pack set (optional) 2

K-569E-10 Bullet valve (double ball), EP, 10 pack set (optional) 2

5. C-334-6 Suction tubing 3/8” OD, 5ft. Clear PVC w/ indicator 1

6. C-346 Ceramic weight 1

7. C-345V Foot valve / strainer Poly-Pro, Viton® 1

C-345E Foot valve / strainer Poly-Pro, EP (optional) 1

8. C-535 Heavy duty molded pump head 1

9. C-504HD Screw, HD Pump head 10-32 X 1-1/4” 4

10. C-535FC Pump head cover, Chem-Feed logo 1

11. C-628 Cover Screw 6-32 X 2-3/4” Steel 2

12. C-608P Motor Cover 1

13. C-625 Motor screw 8-32 X 2-1/2” 2

14. C-612F Rotor Fan 1

15. C-612PB Rotor Bearing 2

16. C-616PN Rotor w/ Spacers 1

17. C-618P-14 Gearbox Assembly, 14 RPM 1

C-618P-30 Gearbox Assembly, 30 RPM 1

C-618P-45 Gearbox Assembly, 45 RPM 1

C-618P-60 Gearbox Assembly, 60 RPM 1

C-618P-125 Gearbox Assembly, 125 RPM 1

C-618P-250 Gearbox Assembly, 250 RPM 1

18. C-301 Motor Mount 1

19. C-624 Motor Mount Screw 10-32 X ½ ” 4

20. C-325 Cam S/A FPUDT600 1

21. C-304 Yoke w/ Bearing 1

22. C-406T Diaphragm Teflon coated, EP 1

23. 90011-155 Screw 6-32 X 3/8” 1

24. 90002-201 Cam Cover 1

25. C-560-6V Bullet Valve Adapter, Viton® O-ring 2

C-560-6E Bullet Valve Adapter, EP O-ring 2

26. 90007-515 ½” Aluminum Chase Nipple 1

27. C-308J Junction Box Complete w/Cover and Gasket 1

28. C-615P-1 Stator S/A 115V / 60Hz, blue-black (lead wires) 1

C-615P-2 Stator S/A 230V / 60Hz, red-black (lead wires) 1

C-615P-3 Stator S/A 220V / 50Hz, brown-blue (lead wires) 1

C-615P-4 Stator S/A 24V / 60Hz, blue-white (lead wires) 1

C-615P-6 Stator S/A 230V / 60Hz, red-yellow (lead wires) 1

C-615P-8 Stator S/A 220V / 50Hz, brown-yellow (lead wires) 1

C-615P-9 Stator S/A 115V / 60Hz, blue-yellow (lead wires) 1

FPUDT600

RETURN REQUESTS / INQUIRIES RETURN REQUESTS / INQUIRIES

MADEMADE

ININ

USAUSA

OMEGA warrants this unit to be free of defects in materials and workmanship and to give satisfactory

service for a period of from date of purchase. OMEGA Warranty adds an additional one

service for a period of 13 months from date of purchase. OMEGA Warranty adds an additional one

(1)month grace period to the normal one to cover handling and shipping time.

(1)month grace period to the normal one (1) year product warranty to cover handling and shipping time.

This ensures that OMEGA’s customers receive maximum coverage on each product. If the unit should

malfunction, it must be returned to the factory for evaluation. OMEGA’s Customer Service Department will

issue an Authorized Return (AR) number immediately upon phone or written request. Upon examination by

OMEGA, if the unit is found to be defective it will be repaired or replaced at no charge. However, this

WARRANTY is void if the unit shows evidence of having been tampered with or shows evidence of being

damaged as a result of excessive corrosion; or current, heat, moisture, or vibration; improper specification;

misapplication; misuse or other operating conditions outside of OMEGA’s control. Components which wear

or which are damaged by misuse are not warranted. These include contact points, fuses, and triacs.

OMEGA is glad to offer suggestions on the use of it’s various products. Nevertheless, OMEGA only

warrants that the parts manufactured by it will be as specified and free of defects.

OMEGA MAKES NO OTHER WARRANTIES OR REPRESENTATIONS OF ANY KIND WHATSOEVER,

EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE AND ALL IMPLIED WARRANTIES INCLUDING

ANY WARRANTY OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.

LIMITATION OF LIABILITY: The remedies of purchaser set forth herein are exclusive and the total

liability of OMEGA with respect to this order, whether based on contract, warranty, negligence,

indemnification, strict liability or otherwise, shall not exceed the purchase price of the component

upon which liability is based. In no event shall OMEGA be liable for consequential, incidental or

special damages.

13 months

WARRANTY/DISCLAIMER

(1) year product warranty

Every precaution for accuracy has been taken in the preparation of this manual; however, OMEGA

ENGINEERING, INC. Neither assumes responsibility for any omissions or errors that may appear nor

assumes liability for any damages that result from the use of the products in accordance with the

information contained in this manual.

SPECIAL CONDITION

SPECIAL CONDITION: Should this equipment be used in or with any nuclear installation or activity,

purchaser will indemnify OMEGA and hold OMEGA harmless from any liability or damage whatsoever

Direct all warranty and repair requests/inquiries to the OMEGA ENGINEERING Customer Service

Department. BEFORE RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN

AUTHORIZED RETURN (AR) NUMBER FROM OMEGA’S CUSTOMER SERVICE DEPARTMENT (IN

ORDER TO AVOID PROCESSING DELAYS). The assigned AR number should then be marked on the

outside of the return package and on any correspondence.

FOR WARRANTY RETURNS, please have FOR NON WARRANTY REPAIRS OR The following information available CALIBRATION, consult OMEGA for

1. P.O. Number under which the product current repair/calbration charges. Have was PURCHASED. Information before contacting OMEGA.

2. Model and serial number of the product 1. P.O. Number to cover the COAST of under warranty, and the repair/ calibration.

3. Repair Instructions and/or specific 2. Model and serial number of product, Problems relative to the Product. and

3. Repair instructions and/or specific Problems relative to the product

OMEGA’s policy is to make running changes, not model changes, whenever an improvement is

possible. This affords our customers the latest in technology and engineering.OMEGA is a

reduced to any electronic medium or machine-readable form, in whole or in part, without written

consent of OMEGA ENGINEERING, INC.

: Should this equipment be used in or with any nuclear installation or activity,

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