ITC DOSTEC-AC Instructions de fonctionnement

ENGLISH

DOSTEC-AC

INDEX

1. GENERAL DESCRIPTION

2. PACKING AND STORAGE

3. TECHNICAL FEATURES

4. OPERATION

4.1 Operating modes

4.1.1 Manual mode

4.1.2 Proportional mode

4.1.2.1 Pulse

4.1.2.2 % / PPM Flowmet

4.1.3 Analogue mode

4.1.3.1 Analogue mode settings

4.1.4 Batch mode

4.1.4.1 Select start mode

4.1.4.2

4.1.4.3 Select stop mode

4.1.5 ModBus mode

4.1.5.1 Remote activation

4.1.5.2 Test priming function

4.2 Configuration

4.2.1 Pump calibration

4.2.3 Set up

4.2.3.1 Dosing pump

4.2.3.2 Units

4.2.3.3 Flowmeter

4.2.3.4 Lock code

4.2.3.5 ModBus

4.2.4 IN /OUT

4.2.4.1 Pressure input

4.2.4.2 Flow detector

4.2.4.3 Pulse output

4.2.4.4 4-20mA output

4.2.2 Dosing Mode

4.2.2.1 Standard

4.2.2.2 Low Flow

4.2.2.3 Slow Suction

4.2.2.4 Low Pulsation

Select stroke frequency in % (flow)

4.3 Alarm

4.3.1 Level alarm 1

4.3.2 Level alarm 2

4.3.3 Flow failure alarm

4.3.4 Diaphragm leakage alarm

4.3.5 Overpressure alarm

SAFETY RULES

5.- INSTALLATION

5.1 Generalities

5.2 Block

5.3 Electrical connection

5.4 Hydraulic connection

5.4.1 Installation examples

5.4.2 Recomendations for correct installation

5.5 Accessories

5.5.1 Diaphragm leakage detector

6.- START UP AND REGULATION

7.- MAINTENANCE

Parts list AC3 piston

Parts list AC3 diaphragm

Parts list AC1/2 piston

Parts list AC1/2 diaphragm

Periodical maintenance

Problems: causes and solutions

Electrical wiring

CE APPROVAL DECLARATION

WARRANTY

5.5.5 Additional ventilation 115 / 230V

5.5.4 Pulse output isolator

5.5.3 Pressure sensor

5.5.2 Flow detector

4.4 Monitor

4.4.1 Real Time

4.4.2 Counters

4.4.3 Info Unit

To avoid personal or enviromental damages and to guarantee a proper

operation of the equipment, the staff in charge of the installation, set up and

maintenance of the equipment must follow the instructions of this manual,

specially those recommendations and warnings explicitly detailed. In addition,

specific instructions for the chemical products to be dosed should be followed.

1.- GENERAL DESCRIPTION

It is made up as follows:

Motor

Advanced Control

Unit (ACU)

Encoder

Additional ventilation

Block

Suction valve

Cylinder

Injection valve

Dostec AC is a diaphragm or piston dosing pump with advanced control for an

accurate and efficient automatic dosing.

This series allows many dosing possibilities depending on the chosen head.

The flow range covers from 3 to 1200 l/h (317 gph) up to pressures of 20 bar

(290 psi). The correct selection of head's materials, PP, PVDF or S.S., makes

this pump suitable for the most chemicals products used in water treatment,

chemical industry, food and beverage and agriculture.

Operation modes

Manual: manual flow adjustment through the keyboard

Analogue: dosing flow proportional to a 0/4-20mA signal

Proportional to flow: proportional dosing to a water flow

Proportional to pulses: stroke frequency proportional to input pulses

Batch control, by volume: Dosing a defined volume, after a manual, remote or

time pre-set start.

Batch control, by time: Dosing for a defined time, after a manual, remote or

time pre-set start.

ModBUs: dosing control through ModBus RTU protocol

2.- PACKING AND STORAGE

Code formulation

P: PP -

C: PP - Ceramic

I : AISI316 - Ceramic

F: PVDF - Ceramic

T: PTFE - Ceramic

PEUHMW

3/4"

X: 1”1/4

Y: 1”1/4 NTP

L: 6x12 (6x8 PVDF)

AC1: 0.43 KW 110V

AC2: 0.43 KW 230V

AC3: 1.2 KW 230V

P24: 24 mm

P34: 34 mm

P49: 49 mm

P61: 61 mm

P77: 77 mm

P95: 95 mm

P110: 110 mm

D69: 69 mm

D95: 95 mm

D115: 115 mm

D142: 142 mm

D163: 163 mm

DIAMETER CYLINDER-PISTON CONNECTION

73 - AC2 P 4 4 - P61 P B M

VALVE-BALL

P: PP - Soda.

B: PP - Boro.

I: SS316 - SS316

F: PVDF - Boro.

T: PTFE - Boro.

1: 26 Strokes/min.

2: 43 Strokes/min.

3: 72 Strokes/min.

4: 144 Strokes/min.

FREQUENCY

HEAD

1: 4,5 mm

2: 7,5 mm

3: 9 mm

4: 15 mm

STROKE

MOTOR

P: Piston

D: Diaphragm

The original packing is prepared so that carriage and storing of the product do

not cause any damage to the product, as long as this is done far from heat

sources and in dry, ventilated spaces.

The packing contains:

- DOSTEC-AC dosing pump

- Handbook

- Oil: AC1/2 250 m3

AC3 700 m3

3.- TECHNICAL FEATURES

20bars models only with ceramic piston.

Models with_L include priming valve.

*Suction lift when the dosing head and suction pipe are full. Tested with water at 20ºC

** Lift for viscous products: (A)= 60-P-AIMN-IIMC / (B)= 62-P-AIMN-IIMC / (C)= 62-P-AIXN-IIXC / (E)= 62-P-AIXN-IIXC

73-AC3P44-P110_X

73-AC3D44-D163_X

73-AC3D43-D142_X

73-AC3P44-P95_X

73-AC3D43-D163_X

73-AC3D42-D142_X

73-AC3D33-D142_X

73-AC3P44-P77_X

73-AC3P43 -P77_X

P44-P77_M

73-AC2

73-AC1

CODE FLOW

l/h GPH l/h GPHbar PSI m ft mPas mPas

PRESSURE

Piston

Diaphragm

*Suction lift Max.

viscosity

*Max.

viscosity

FLOW

SS Mode (Slow Suction)

1200

900

600

400

317

238

159

106

5,5

7,5

4,5

109

160

174

1,5

600

450

300

200

159

120

500 (E)

1500 (E)

2000 (E)

800 (C)

2000 (E)

D42-D115_M

73-AC2

73-AC1

D43-D95_M

73-AC2

73-AC1

D43-D69_M

73-AC2

73-AC1

D41-D69_L

73-AC2

73-AC1

D21-D69_L

73-AC2

73-AC1

P44-P61 _M

73-AC2

73-AC1

P44-P34 _M

73-AC2

73-AC1

P34-P24 _L

73-AC2

73-AC1

P14-P24 _L

73-AC2

73-AC1

P11-P24 _L

73-AC2

73-AC1

P44-P49 _M

73-AC2

73-AC1

D43-D115_M

73-AC2

73-AC1

D42-D95_M

73-AC2

73-AC1

D42-D69_M

73-AC2

73-AC1

D31-D69_L

73-AC2

73-AC1

D11-D69_L

73-AC2

73-AC1

P44-P24 _M

73-AC2

73-AC1

P33-P24 _L

73-AC2

73-AC1

P13-P24 _L

73-AC2

73-AC1

360

240

120

10,5

1044

624

498

373

301

251

249

173

144

11,4

6,5

63,4

31,7

7,9

4,7

2,7

1,6

0,8

276

165

132

45,6

9,6

1,7

5 73

10 145

14510

5 72

725

10 145

8116

10 145

15 217

217

145

102

20/15

102

160

217

4 13

9 30

180

120

5,2

1,5

522

312

249

186,5

150,5

125,5

124,5

86,5

41,5

9,5

5,7

3,2

7,9

3,9

2,4

1,4

0,8

0,4

138

82,5

39,5

22,8

4,8

2,5

1,5

0,85

1500 (C)

2000 (C)

1500 (B)

2000 (A)

400 (E)

1300 (E)

2000 (E)

2000 (C)

2000 (E)

2000 (C)

400 (B)

1500(B)

2000 (A)

DIMENSIONS

Diaphragm

Piston

D163

D142

306 400 154 180 270 150 155 90 mm

12 15.7 6 7 10.6 5,9 6.1 3,5 in

AC3

AC2 /1

D115

D95

D69

A B D G HC E F

429 490 241 285 210 212 122 mm

16.8 19.3 9.5 11.2 8.2 8.3 4.8 in

230

A B D E G HC F

395 270 241 210 212 122 mm

15.5 19.3 9.5 11.2 8.2 8.3 4.8 in

490 285

10.6

394 490 250 241 285 210 212 122 mm

15.5 19.3 9.8 9.5 11.2 8.2 8.3 4.8 in

270 400 204 180 270

10.6 15.7 8 7 10.6

150 155 90 mm

5,9 6.1 3,5 in

270 400 184 180 270

10.6 15.7 7.2 7 10.6

150 155 90 mm

5,9 6.1 3,5 in

274 400 154 180 270 150 155 90 mm

10.6 15.7 6 7 10.6 5,9 6.1 3,5 in

D163

D142

422 155 mm

16.6 6.1 in

AC3

D115

D95

D69

A E

525 205 mm

9.9 8.1 in

A E

490 225 mm

19.3 8.8 in

489 215 mm

19.2 8.4 in

386 180 mm

15.1 7.1 in

386 170 mm

15.1 6.7 in

390 155 mm

15.3 6.1 in

AC2 /1

Optional assembly

ELECTRIC CURRENT: As specified in the motor plate

POWER: 0.43 KW (0.58 Hp)

1.2 KM (1.6 Hp)

PROTECTION: IP-55

MATERIALS: Piston PEUHMW / Ceramic / SS316

Diaphragm P.T.F.E. Elastomer base reinforced with fiber

Retention FPM

Cylinder P.P. / PVDF / SS316

Valve (body) P.P. / PVDF / SS316

Valve (ball) Soda lime / Borosilicate / SS316

AMBIENT TEMPERATURE: 0...45ºC

MEDIA TEMPERATURE: PP: 0...50ºC

PVDF: -10...50ºC

SS: -10...60ºC

RELATIVE HUMIDY MAX.: 95% (without condensation)

NOISE LEVEL dB(A): minor than 70

WEIGH: AC3: 24 KG (53 lb)

AC2/1: 13 Kg (29lb)

FLOW-PRESSURE GRAPHICS

6 -

8 -

10 -

l/h

GPH

10 Bars

212 14

145 PSI

116

29 174 203

1,5-

2 -

2,5-

13 -

l/h

GPH

4 -

3 -

3,5 -

15 -

11 -

10 Bars

212 14

145 PSI

116

29 174 203

Bars

6543

110

PSI

87725843

29 101

130

116 145

GPH l/h

GPH

40 -

l/hGPH

14-

13-

12-

11-

10-

50 -

Bars

PSI

29 174 203

812

145116

73-AC_D41-D69

25 -

20 -

l/hGPH

Bars

PSI

29 174 203

812

145116

-73-AC_D31-D69

73-AC_D21-D69

73-AC_D11-D69

Bars

6543

110

PSI

87725843

29 101

130

116 145

19-

20-

21-

22-

23-

24-

65 -

75 -

GPH l/h

70 -

18-

80 -

85 -

90 -

73-AC_D42-D69

90 -

80 -

85 -

22-

23-

24-

25-

26-

27-

28-

29-

95 -

100 -

105 -

110 -

73-AC_D43-D69

l/h

145-

175-

155-

Bars

6543

PSI

87725843

29 101

14 116

165-

GPH

46-

38-

40-

42-

44-

73-AC_D42-D95

DIAPHRAGM PUMP AC1-AC2

Bars

6543

110

PSI

87725843

29 101

130

116 145

GPH l/h

GPH

45 -

40 -

42.5-

11-

11.5-

12-

12.5-

13-

13.5-

14-

14.5-

47.5--

50 -

52.5--

55 -

73-AC_D33-D69

l/h

GPH

Bars

6543

PSI

87725843

29 101

14 116

85 -

22.5-

23.75-

25-

90 -

95 -

100-

26.25-

27.5-

73-AC_D33-D95

Bars

543

PSI

725843

l/h

GPH

73-AC_D43-D115

150-

160-

170-

40-

42.5-

45-

DIAPHRAGM PUMP AC3

25Bars

490-

520-

580-

l/h

GPH

130-

135-

145-

150-

155-

160-

165-

170-

5843

29 72

550-

610-

PSI

810

130116 145

101

25Bars

l/h

29 72 PSI

710

130

116101 145

l/h

620 -

660 -

700 -

GPH

170-

180-

190-

200-

210-

220-

5843

Bars

PSI

8772 101

L/H

432 5 Bars

1120-

1160-

1240-

1200-

l/h

GPH

270-

5843

29 72PSI

1080-

280-

290-

300-

310-

320-

73-AC3D44-D163

25Bars

l/h

29 72 PSI

420-

440-

710

130

116101 145

380-

400-

GPH GPH

100-

105-

140-

1040-

245-

260-

275-

64.5-

68.5-

72.5-

290-

305-

320-

76.5-

80.5-

84.5-

460-

480-

110-

120-

130-

73-AC3D42-D142

73-AC3D33-D142

73-AC3D43-D142

640-

740 -

780 -

820 -

73-AC3D43-D163

Bars

543

PSI

725843

l/h

GPH

Bars

543

PSI

725843

l/h

GPH

73-AC_D43-D115

73-AC_D42-D115

l/h

GPH

Bars

6543

PSI

87725843

29 101

14 116

170-

45-

47,5-

50-

180-

190-

200-

52,5-

55-

73-AC_D43-D95

270-

250-

290-

65-

70-

75-

300-

320-

340-

80-

85-

90-

L/H

432 5 Bars

560-

580-

620-

600-

l/h

GPH

135-

5843

29 72PSI

540-

140-

145-

150-

155-

160-

73-AC3D34-D163

520-

LDC Screen

4.- OPERATION

SYSTEM DESCRIPTION

2Keyboard

ENT

ESC

Inputs and outputs

• Analogue input 0/4-20mA

• External pulse input

• Remote on/off input

• Level sensor input (pre-empty)

• Level sensor input (empty)

• Leakage detector input

• Flow detector input

• Pressure sensor input

• Serial port RS-485 ModBus

• 4-20mA output for register and monitoring

• Pulse output for register, monitoring and

2nd pump control

• Alarm output (relay)

• Level alarm output (relay)

The rotational motion of the motor is transmitted by the gear box, that consists of

two major components, the pinion (A) and the ring gear (B. The pinion and the ring

gear are linked to an axis with an eccentric bearing (C) that pushes the shaft (D)

which is throated to the diaphragm or the piston (E). The return movement is

made by the spring (F).

A high resolution encoder (G) checks the instantaneous position and speed and

allows the Advanced Control Unit to do a close loop adjustment for torque and

rotation speed.

By changing the motor speed and according to the operation mode selected in the

Advanced Control Unit, the dosing pump adjusts the flow to the required value

within the range from 10 to 100% of the rated flow.

Confirm

Exit without confirm

Increase / reduce value

Move left

Move right / Test max. speed

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