UGSI Chemical Feed Encore MB, Operation & Maintenance Manual

Page 1: ...Operations Maintenance Manual Encore MB ME Diaphragm Dosing Pump MANUAL NO CF 450 410 001 IM 1114 ...

Page 2: ...from shipment whichever occurs first to provide Seller with prompt written notice of any claims of breach of the Limited Warranties Continued use or possession of the Product after expiration of the warranty period shall be conclusive evidence that the Limited Warranties have been fulfilled to the full satisfaction of Buyer and user unless Buyer has previously provided Seller with notice of a brea...

Page 3: ...3 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 4: ...ipe 20 7 4 Electrical connection of the pump 20 7 5 Wiring diagrams for ATE servo motor for stroke length adjustment 23 7 6 Level control 24 7 7 Back pressure and safety valves 24 7 8 Injection nozzle installation 24 7 9 Installation example 25 8 Operation 26 8 1 Stroke length adjustment 26 8 2 Encore MB operating elements 26 8 3 Switching on off 26 8 4 Operating mode selection 26 8 5 Alarm 27 8 6...

Page 5: ...afety instructions may endanger the machine and its functions IMPORTANT This indicates additional information that makes work easier and ensures trouble free operation Information attached directly to the dosing pump such as cable markings markings for fluid connections must be followed without fail and must remain fully legible at all times 1 3 Personnel qualifications and training The personnel ...

Page 6: ...the operating company operator Leakages of dangerous substances e g aggressive toxic for example due to a broken diaphragm must be suitably drained away so that they do not cause danger to persons or the environment Statutory regulations must be observed Dangers due to electric current must be prevented for further details refer to the VDE1 regulations and regulations of the local power supply com...

Page 7: ...r assembly and maintenance of piping hoses and accessories should wear this protective equipment Before working on the dosing pump and system disconnect it from the mains supply and prevent it from being switched on CAUTION Any chemical still present in the dosing head may spray out when the power supply is reconnected This may lead to chemical or other burns to the face and hands Dosing lines mus...

Page 8: ...y device WARNING Lethal voltage Adjustment work inside the ATE servomotor optional for Encore ME must be carried out carefully Connections and internal limit switches might be live Additional limit switches might be live even when the auxiliary voltage is switched off ATE servomotor After installation work on the ATE servomotor or before start up re attach the cover 1 12 Transportation No special ...

Page 9: ...be observed 2 2 Structure of the dosing pump c a h b d i o p q g k n m l f e j a Dosing head b Suction side valve c Discharge side valve d Drain pipe e Stroke length adjustment f Stroke length adjustment lock g Motor terminal box Encore ME power supply h Oil inlet i Oil outlet j Control unit Encore MB k Operating panel with display l External switch off contact m Level input contact n External con...

Page 10: ...core MB allows adaptation to a large variety of different control signals and system monitoring equipment The signals required for external activation of the dosing pump can be from simple potential free closing contacts of water meters or con trollers or analogue 0 4 20 mA signals For contact actuation pulse control the stroke frequency can be adapted by division or multiplication For internal op...

Page 11: ...6 4 65 3 74 8 74 1 4 x 3 8 tubing 1 4 FNPT 0 51 50 6 02 4 09 9 21 0 51 75 76 6 02 4 09 9 21 0 66 110 156 9 68 4 60 10 19 0 86 All dimensions in inches Dimensional drawing Encore ME 4 0 156 ATE ATEX Motor 473 5 11 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 12: ...260 10 94 5 82 12 48 18 46 approx 0 86 ME 300 380 12 51 6 04 12 59 18 46 approx 0 86 24 88 MB 300 380 12 51 6 04 12 59 18 46 approx 0 86 Dimension L for glue in connection internal ø 0 78 all dimensions in inches Dimensional drawing Encore ME 160 380 ATE 12 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 13: ...roke volume ml stroke 36 5 51 2 Max pressure psig 150 125 Stroke frequency4 SPM 85 114 114 Diaphragm ø in 4 72 5 90 Stroke length in 0 39 Suction lift ft H2 0 8 6 Max inlet pressure psi 7 25 Max ambient temperature 3 F 104 Power output ME 3 W 370 Power output MB 1 W 250 Weight Plastic ME lbs 37 47 41 88 MB lbs 52 91 57 32 Weight Stainless steel ME lbs 57 32 70 54 MB lbs 72 75 85 98 1 Special sizes...

Page 14: ...ut Connection of accessories e g suction line with level switch 5 V DC voltage pre alarm and main alarm Connection Contact normally closed N C 0 13 in jack socket M12x1 plug optional External control Pulse input or analogue input RCA socket M12x1 plug optional 3 pin socket Pulse input potential free contact normally closed N C provided by operating company 5 V DC voltage Pulse length min 30 ms Mul...

Page 15: ...oltage V 3 230 400 Nominal current A 0 86 0 5 1 5 0 9 1 75 1 0 2 8 1 6 Power output kW 0 05 0 25 0 37 0 55 Frequency Hz 50 Protection class IP 55 ISO class F PTC thermistor optional Explosion proof motors for Encore ME Encore ME 4 156 160 380 4 156 160 380 Type KPER63K4 KPER71G4 F63CTV a4 F71CTV b4 Explosion protection increased safety EExeIIT3 EXdellCT4 pressure resistant enclosure Speed rpm 244 ...

Page 16: ...AC 50 60 Hz 115 V AC 50 60 Hz Power consumption 7 VA Regulation time 50 Hz 45 s 60 Hz 39 s Regulation bevel 270 0 100 Protection class IP 65 Ambient temperature 15 60 Weight 5 5 lbs Inputs Control 3 point step control 0 4 20 mA Working resistance at 0 4 20 mA 250 Ω Outputs Position feedback signal for remote display 0 1000 Ohm max 2 W 0 4 20 mA 0 2 10 V See the enclosed operating instructions for ...

Page 17: ...y and viscosity and temperature cause the delivery rate to change Dosing pumps must therefore be gauged in litres for the application At 60 Hz operation values are increased by a factor of 1 2 Power output data apply to 50 and 60 Hz operation 17 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 18: ...ing pump for 50 Hz operation only Power output data apply to 50 and 60 Hz operation Dosing pump for 50 Hz operation only 18 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 19: ... pipe of the dosing head must be visible so that a diaphragm rupture can be detected Drainage should be able to flow freely downward through the drain pipe To increase dosing accuracy and ensure functional reliability we recommend installing additional valves and accessories These include back pressure valves pressure relief valves leakage monitors and low level indicators as shown in the installa...

Page 20: ... any leakages at the gap to the collecting funnel ATTENTION If a leakage monitor is installed in an area with a potentially explosive atmosphere the electrical connection must be intrinsically safe The drive motor must be electrically interlocked to prevent additional medium escaping if a leak occurs 7 4 Electrical connection of the pump The electrical connection of the dosing pump must be made ac...

Page 21: ...ft looking toward the fan wheel 7 4 1 Drive motor connection IMPORTANT Note the data on the motor rating plate Connection Encore Phases Motor supplier Note W2 U2 V2 U1 V1 W1 L1 L2 L3 PE ME 4 156 ME 160 380 3 All Y connection Standard W2 U2 V2 U1 V1 W1 L1 L2 L3 PE ME 4 156 ME 160 380 3 All Delta connection Encore ME three phase motors Connection Encore Phases Motor supplier Note Z1 TB2 U2 U1 Z2 TB1...

Page 22: ... 4 5 T1 L1 L2 N T2 Z2 Run Stop MB 4 156 EMG U2 Z1 U1 Z2 L2 Stop L1 Run PE N MB 160 380 VEM Encore ME alternating current motor Encore ME control unit Standard version CSA version L1 RUN BR brown BK black L2 STOP BK black RD red N BU blue or GY grey WH white PE GN YE green yellow GN YE green yellow Connection between Encore MB control unit and motor 22 Diaphragm Dosing Pump Encore MB ME Operating I...

Page 23: ...g diagrams for ATE servo motor for stroke length adjustment See the accompanying operating instructions for the ATE servomotor 23 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 24: ...in the presence of fluctuating back pressures when the dosing lines are long in order to prevent excess delivery since the accelerated medium continues moving due to its own inertia even after the delivery stroke has ended to prevent siphoning if the supply pressure is higher than system pressure Pressure relief and safety valves are used for overload protection of the dosing pump and the associat...

Page 25: ... g h b d c f e Dosing pump Suction line Electric agitator Tank Pressure relief valve Diaphragm shutoff valve Injection nozzle Pulsation damper 25 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 26: ...trol connection Mode key operating mode selection Selection keys I O key ON OFF switch Display k Power supply l Motor connection m Warning alarm relay connection For connection assignments see 8 8 8 3 Switching on off The dosing pump is switched on off using the I O key When disconnected the display shows OFF When the contact is opened for external switch off the dosing pump is also switched off T...

Page 27: ...or is lit Settings for pulse multiplication and division 1 2 4 8 16 32 and 64 Example 1 64 The dosing pump executes 64 dosing strokes after each pulse 64 1 The dosing pump executes one dosing stroke after 64 pulses Analogue control The dosing pump doses proportionally to the input signal To set the operating mode press the Mode and or keys simultaneously until one of the following values is dis pl...

Page 28: ...um pump stroke frequency using keys and When the Mode key is released normal operation starts 8 6 2 Warning alarm relay connection Relay not activated in case of fault or OFF When voltage is applied press and hold Mode and keys Display RE0 Relay activated in case of fault or OFF When voltage is applied press and hold Mode and keys Display RE1 8 7 Factory setting The initial status of Encore MB is ...

Page 29: ...N brown 2 Main alarm WH white 3 Ground GND BU blue f External control RCA Socket 4 9 ft 2 wire cable included in delivery Input BN brown Ground GND WH white CSA version Plug 4 9 ft 3 wire cable included in delivery 1 input BN brown 2 BK black 3 ground GND BU blue M12 x 1 B coded optional Plug 1 ground GND BN brown 2 pulses WH white 3 pulses BU blue 4 ground GND BK black NOTICE The protection class...

Page 30: ...tart priming A priming aid is recommended See installation examples 6 If there is a vent valve integrated in the dosing head or installed as a separate fitting open it while the dosing pump is operating until fluid comes out Then close it again In the case of outgassing media allow the fluid to flow off continuously about 1 drop per 1 3 strokes The escaping fluid flows through a hose back into the...

Page 31: ...tion valves 10 1 Disposal of old equipment If the equipment is being disposed of it should be washed thoroughly Residual chemicals should be disposed of properly The equipment was manufactured in accordance with the ROHS guideline and the waste electrical equipment legislation The manufacturer will take care of disposal if the equipment is returned free of charge It should not be disposed of as do...

Page 32: ...oil dipstick ATTENTION Encore MB To avoid damage to the approximation initiator the dosing pump must be switched off before taking out the oil dipstick 11 2 Maintenance of the bearings The upper bearing of the pinion shaft is a sealed and permanently lubricated ball bearing In the Size I Encore MB ME up to MB ME 150 this function is also performed by the drive side motor bearing The other roller b...

Page 33: ...rely into the diaphragm rod grease the thread This causes the flat side of the support plate if present to be pressed against the end of the diaphragm rod 7 The dosing pump stroke is now set to maximum while the motor is running Switch off the motor The diaphragm is now seated in the groove of the dia phragm flange 8 Fit the dosing head at the front Tighten the screws alternately e g top left bott...

Page 34: ...spray out This may lead to chemical or other burns The dosing pump must always be depressurized and rinsed with water or a suitable medium before starting any work on the dosing pump NOTICE Dirty valves will affect the dosing accuracy DN4 valves DN4 valves are pre assembled and can be unscrewed from the dosing head as a single unit To disassemble the valves use a screwdriver with a 39 in bit Valve...

Page 35: ...rge valve Suction valve Discharge valve Suction valve O ring b Valve body Flat gasket Ball guide e Valve ball f Valve seat O ring Valve plug Gasket Pressure spring included in the spare parts set 35 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 36: ...ischarge valve Suction valve Discharge valve Suction valve Flat gasket b Valve body Flat gasket Ball guide e Valve ball f Valve seat Flat gasket Pressure spring included in the spare parts set 36 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 37: ...ge valve Suction valve Discharge valve Suction valve Flat gasket b Flat gasket Valve body Ball guide e Valve ball f Valve seat Flat gasket Flat gasket Pressure spring included in the spare parts set 37 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 38: ...ever be used in areas with a potentially explosive atmosphere 12 2 Special conditions The minimum requirements for the zone classification must be ensured if using the dosing pump in areas with a potentially explosive atmosphere The dosing pump itself and the motor must meet the minimum requirements 12 3 Dosing of flammable media If dosing flammable fluids all metal parts in the suction and discha...

Page 39: ...must be clamped firmly between diaphragm and diaphragm rod System back pressure too high measured at discharge connec tion of dosing pump Inspect the system Clean blocked injection nozzle Install pulsa tion dampers to reduce pressure spikes if pipes are too long Check that safety valves are working see installation example Media sediment in dosing head Clean the dosing head Dosing pump very noisy ...

Page 40: ...65 j Support plate EJ28977 k Control unit Encore MB EU version EJ34897 CSA version EJ35187 Encore Size 1 Spare parts Description MB ME 110 156 MB ME 160 260 MB ME 300 380 h Dosing head with screws PP EJ34979 EJ23722 EJ34953 Stainless steel EJ32890 EJ23728 EJ34952 other materials on request i Diaphragm PTFE coated EJ81466 EJ81467 EJ81468 Conductive PTFE for ATEX version EJ81796 EJ81793 EJ81794 k Co...

Page 41: ... Stainless steel PTFE EJ29751 EJ37339 Complete valves for Encore MB ME 4 26 Material Double ball valve Spring loaded valve Suction valve Discharge valve Suction valve Discharge valve PVC Glass FPM EJ20890 EJ20891 EJ25087 EJ25088 PVC Glass EPDM EJ33497 EJ33498 EJ33499 EJ33500 PP Glass FPM EJ35605 EJ35606 EJ35262 EJ35263 PP Glass EPDM EJ34647 EJ34648 EJ34733 EJ34809 PVDF PTFE PTFE EJ28111 EJ28112 EJ...

Page 42: ...M EJ35346 EJ37497 Stainless steel AF EJ27808 EJ27820 Complete valves for Encore MB ME 50 76 Material e Spring loaded valve f Double ball valve Suction valve Discharge valve Suction valve Discharge valve PVC Glass FPM EJ25162 EJ27517 EJ18185 EJ18186 PVC Glass CSM EJ25161 EJ27516 EJ18187 EJ18188 PP Glass FPM EJ35260 EJ35261 EJ35199 EJ35200 PP Glass CSM EJ34810 EJ34811 EJ34670 EJ34671 Stainless steel...

Page 43: ...17 PP Glass CSM EJ28300 EJ28304 Stainless steel AF EJ28302 EJ28306 Complete valves for Encore MB ME 110 156 Material f Double ball valve e Spring loaded valve Suction valve Discharge valve Suction valve Discharge valve PP Glass FPM EJ26842 EJ27357 EJ25707 EJ27354 PP Glass CSM EJ26841 EJ27356 EJ26845 EJ27353 Stainless steel AF EJ29694 EJ29659 EJ29696 EJ29697 43 Diaphragm Dosing Pump Encore MB ME Op...

Page 44: ...J28317 EJ28313 EJ28321 PP Glass CSM EJ28308 EJ28316 EJ28312 EJ28320 Stainless steel AF EJ28310 EJ28318 EJ28314 EJ28322 Complete valves for Encore MB ME 160 260 MB ME 300 380 Material f Double ball valve e Spring loaded valve Suction valve Discharge valve Suction valve Discharge valve PP Glass FPM EJ26842 EJ27357 EJ25707 EJ27354 PP Glass CSM EJ26841 EJ27356 EJ26845 EJ27353 Stainless steel AF EJ2969...

Page 45: ...15 Declaration of harmlessnes When sending for repair please copy fill out and send along with each device 45 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 46: ...ture wear Connections connectors or cables loose Wear parts Operating controls e g switches push buttons Breakage other damage Electronics Corrosion Damage in transit 3 Leaks 4 No or inadequate function Connections Diaphragm defective Dosing head Other Operating conditions of the equipment Location description of installation Accessories used if any Start up date Running time approx operating hour...

Page 47: ...17 CE Declaration of conformity 47 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 48: ...48 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 49: ...control 24 Level input 26 Level pre warning 24 Lubrication 32 M Maintenance 32 Manual control 27 Media temperature 13 N Max number of strokes 28 O Oil inlet 9 Oil outlet 9 Selection of operating mode 26 Operation 26 P Performance curves 17 Principle of operation 10 Protective clothing 7 Pulse control 27 R Revision 31 S Scope of delivery 8 Servomotor 16 Shutdown 31 Spare parts 40 Spare parts sets 4...

Page 50: ...19 Notes 50 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 51: ...51 Diaphragm Dosing Pump Encore MB ME Operating Instructions CF 450 410 001 IM 1114 ...

Page 52: ...Encore MB ME Diaphragm Dosing Pump MANUAL NO CF 450 410 001 IM 1114 CF 450 420 001 IM 1114 ...