AQUAVIVA Kompact Series Dosing Pumps Instruction Manual

KOMPACT DPT
INSTALLATION MANUAL AND COMMISSIONING GUIDE FOR THE
KOMPACT SERIES DOSING PUMPS

PACK CONTENTS:

A. Opaque tube for connecting the output from the pumpto the point of injection
B. Transparent tube for connecting the bleeder valve for manual priming
C. Injection fitting
D. Tube connection kit
E. Foot filter
F. Wall fixing bracket
G. Anchor bolts for fixing the wall bracket
H. Pump body screws protection caps
I. Instruction Manual
FOR SPECIFIC HYDRAULIC FEATURES SEE THE LABEL ON THE PUMP
The dosing pump consists of a control section containing the electronics and the magnet, and a hydraulic section, which is always in contact with the liquid to be dosed.
Check the main specifications of your pump on the data plate

1. Control panel
2. Dosing head
3. Valve for priming the pump
4. Delivery connection
5. Suction connection
6. Support for base-plate (optional)

It is advisable to check the chemical compatibility between the product to be dosed and the materials with which it will come into contact.

MATERIALS USED TO MAKE THE HEAD OF THE PUMP

• Casing: PVDF-T
• Valve: PVDF-T
• Balls: Ceramic
• Membrane: PTFE

TECHNICAL SPECIFICATIONS

• Weight: 1,5 Kg
• Power supply: 100 ÷ 240 Vac (50-60 Hz) – 24Vac/dc
• Power consumption: 19W @ 100 ÷ 240 Vac – 12W @ 24 Vac/dc
• Fuse: 2A (100 ÷ 240 Vac) / 3,15 (24V); 250V; T 5×20
• Protection class: IP65

READ CAREFULLY THE FOLLOWING WARNINGS BEFORE PROCEEDING TO INSTALL OR CARRY OUT MAINTENANCE ON THE PUMP.
WARNING: ALWAYS DISCONNECT THE POWER SUPPLY BEFORE PROCEEDING TO INSTALL OR CARRY OUT MAINTENANCE ON THE PUMP.
WARNING: WE RECOMMEND INSTALLING THE PUMP IN A VERTICAL POSITION TO ENSURE PROPER OPERATION.
WARNING: PRODUCT INTENDED FOR PROFESSIONAL USE ONLY, BY QUALIFIED PERSONNEL.
WARNING: THE MAINTENANCE OF THE PUMP MUST BE CARRIED OUT BY QUALIFIED AND AUTHORIZED PERSONNEL.

• H2SO4 SULPHURIC ACID Before dosing chemicals that could react with water it is necessary to dry all the internal hydraulic parts.
• The ambient temperature must not exceed 40°C. The relative humidity must be lower than 90%. The pump protection class is IP65. Do not install the pump in a place where it would be in direct sunlight.
• Secure the pump firmly into place in order to avoid excessive vibrations.
• The power-supply voltage available in the system and the working pressure must be compatible with those indicated on the pump label.

WIRING CONNECTIONS

Input A
Power supply 100 ÷
240Vac (50-60 Hz) or 24Vac/dc
The pump should be connected to a power supply complying with the indications shown on the label on the pump side. Failure to comply with the limits indicated may cause damage to the pump.
These pumps have been designed to absorb minor over voltages However, in order to prevent any damage to the pump it is always preferable to avoid connecting it to the same source of power as electrical equipment that generates high voltages.
The connection to the three-phase 380V line MUST always be made solely between phase and neutral. No connections should be made between phase and earth.

HYDRAULIC CONNECTIONS

1. Injection point
2. Injection coupling
3. Gasket
4. Washer holder
5. Pipe clamp
6. Ring nut
7. Delivery pipe (rigid)
8. Delivery coupling
9. Pumping body
10. Bleeding valve
11. Suction coupling
12. Suction hose (soft)
13. Foot filter
14. Bleeding valve coupling

Drilling template for the wall bracket After about 800 hours of operation, tighten the bolts of the pump body by using a tightening torque of 3 Nm.
In making the hydraulic connections it is necessary to comply with the following instructions:

• The BOTTOM FILTER should be installed at a distance of about 5-10 cm from the bottom, in order to avoid clogging;
• The installation with the pump below the liquid level is recommended for pumps with very low flow rates. In particular when dosing products that have a tendency to develop gases (ex: sodium hypochlorite, hydrazine, hydrogen peroxide…)
• If it is necessary to use tubes longer than those supplied with the installation kit, they must always have the same dimensions as those supplied with the pump. If the DELIVERY PIPE is exposed to direct sunlight, it is recommended the use of a black UV-resistant pipe;
• It is advisable for the INJECTION POINT to be placed higher than the pump or the tank.;
• The INJECTION VALVE supplied with the pump, should always be installed at the end of the dosing-flow delivery line.

STARTING UP THE PUMP

Once you have checked all the above operations, you are ready to start the pump.
Priming

• Start the pump
• Open the priming coupling by turning the knob anticlockwise and wait for the liquid to flow out of the hose connected to it.
• Once you are sure that the pump is completely filled with liquid you can close the coupling and the pump begins to dose.

TROUBLESHOOTING

The pump is running regularly but the
dosage was interrupted| The valves are clogged| Clean the valves or replace them if it’s not possible to remove the deposits
Eccessive intake height| Position the pump or the tank so as to reduce the intake height
The liquid is too viscous| Reduce the intake height or use a pump with a higher flow rate
Insufficient flow rate| Leaky valves| Check the tightness of the nuts
The liquid is too viscous| Reduce the intake height or use a pump with a higher flow rate
Partial clogging of the valves| Clean the valves or replace them if it’s not possible to remove the deposits
Irregular pump flow rate| Transparent PVC tube for delivery| Use the opaque PE tube for delivery
The diaphragm is breaking| Excessive back pressure| Check the system pressure. Check if the injection valve is clogged. Check if there is a clogging between the discharge valves and the injection point.
Operation without liquid| Check the presence of the foot filter (valve)
The diaphragm is not fixed properly| If the diaphragm has been replaced, check its proper tightening
The pump does not turn on| Insufficient power supply| Check if the values on the plate of the pump correspond to those of the electrical network.

Control panel – KOMPACT DPT

| To access the programming menu. (Press and hold down simultaneously for at least 3 seconds).
---|---
| To start and stop the pump.
To disable the display notification in case of active level alarm condition (only alarm function), flow alarm condition and memory.
In programming mode it functions as “enter”, to confirm the access and the changes within the various menu levels.
| To “escape” the various menu levels. Before exiting the programming mode you will be prompted to save the changes.
Prolonged pressure displays the screen for the flow sensor calibration.
+ to change the contrast.
| To scroll the menus or change the parameters in programming mode.
In Batch, Timer mode, simulating the external trigger can start the dosage.
Prolonged pressure enables the priming.
| Green LED flashes while dosing.
Red LED turns on in case of various alarm conditions.

Electrical connections

2
3| Not used
4| – Frequency signal input (water meter pulse-sender)
– External trigger input E85
5
6
7| Pole +| 4-20 mA input
Input impedance: 200 ohm
8| Pole _
9| – Remote control input (start-stop)
– Pause signal input
10
11| Level control probe input
12
S| Dip switch to manage the type of input frequency signal

Dip switch position and connections for frequency signals input mode

KOMPACT DPT Programming Menu

Press the keys for more than three seconds to access the programming mode. Press the key to scroll the menu items then press the key to access the options. Whenever a menu item is editable, it flashes.
y default, the pump is set for constant mode. The pump automatically returns to operating mode after 1 minute of inactivity. In this case, the data entered will not be saved. Press the key to exit the programming levels. When you exit the programming mode, the display shows: to confirm your choice.

Setting the language

Press to access the item, and then press to set the language.
Press to confirm and return to the main menu.

Paragraph 1 – Manual dosage

pressing simultaneously.

Display during operation Paragraph 2 – Proportional Dosage to a 0/4-20 mA signal

| The pump proportionally doses at a signal of (0)4-20 mA. By default, the pump interrupts the dosage at 4 mA and doses at the maximum set frequency when it receives 20 mA. These two values can be modified during programming. The maximum frequency can be modified during operation by pressing simultaneously to modify the flow rate.
To view the current reading for the mA input, scroll the menu items to In mA.
For an input signal of less than 0.2 mA the alarm LED turns on to indicate the absence of signal.

Display during operation

| The pump proportionally doses at a signal of 20-4(0) mA. By default, the pump interrupts the dosage at 20 mA and doses at the maximum set frequency when it receives 4 mA. For an input signal of less than the minimum value – 0.2mA (fixed threshold) (Ex. 4-0.2= 3.8mA) the alarm LED turns on to indicate that the minimum value has been exceeded, but the pump continues to dose at the maximum frequency. These two values can be modified during programming. The maximum frequency can be modified during operation by pressing simultaneously to modify the flow rate.
To view the current reading for the mA input, scroll the menu items to In mA.
For an input signal of less than 0.2 mA the alarm LED turns on to indicate the absence of signal and the pump interrupts the dosage.

Display during operation Paragraph 4 – Proportional to External Impulses (multiplication)

| The pump doses proportionally to an external signal (ex: water meter pulse- sender). For every signal received, the pump runs the programmed “n” number of strokes. The pump automatically sets the dosage frequency, adapting it to the time that passes between two successive signals. It is possible to set the time (timeout) in seconds, beyond which the pump resets the interval counter in order to avoid dosages over excessively long periods of time. The pump has a memory function which detects the reception of a signal during the dosage. If set to Off, it only detects the signal; if set to On, it detects and memorizes the impulses, then executes them when has finished receiving the signals.
The “n” value can be changed during operation by pressing simultaneously.

Display during operation Paragraph 5 – Proportional to External Impulses (division)

| The pump doses proportionally to an external signal (ex: water meter pulse- sender). For every “n” signals received, the pump runs a stroke. The “n” value can be set during programming. By programming the “n” value, you set the % of maximum dosage; during operation this value can be modified by pressing simultaneously.

Display during operation Paragraph 6 – Proportional to External Impulses (batch dosage)

| The pump doses proportionally to an external signal (ex: water meter pulse-sender). In this case, you can set the quantity to be dosed in mL and the period of time necessary to complete the dosage.
The dosage can be started manually by pressing or through a remote command.
You can press to interrupt the dosage. The dosage already made can be reset to zero by pressing or restarted by pressing again.
The quantity to be dosed can be modified during operation by pressing simultaneously to modify the flow rate.

Display during operation Paragraph 7 – Proportional to External Impulses (ppm dosage)

| The pump doses proportionally to an external signal (ex: water meter pulse-sender) by automatically calculating the ratio between the input signals and the pump strokes according to the programmed ppm value. The data to be inserted are the ppm value, the pulses/liter ratio (or liter/pulse) of the counter and the concentration of the product to be dosed.
The dosage frequency can be modified during operation by pressing simultaneously.

Display during operation Paragraph 8 – Timed Dosage (Frequency signal input “TRIGGER” activated)

| After receiving the set Trigger signal, the pump doses a quantity that can be programmed in mL. It is possible to set a delay time before dosage (Delay) and an interval between subsequent dosages (Interval) as shown on the diagram:For example, by setting the interval Interv.= 0 you will get a system in which the programmed quantity is dosed after each TRIGGER signal (with the eventual delay set):You can start the dosage by pressing the + key, which practically simulates the Trigger signal.
The Trigger signal can be set to N. Open (it is activated when the input is switched from open to closed mode) or to N. Closed (it is activated when the input is switched from closed to open mode).
The Trigger signal is locked during the dosage (its reception is neither stored nor managed).
The Pause input (Remote Control) cannot be programmed and its activation locks the dosage, while the subsequent deactivation makes the system wait for the Trigger signal for a new dosage.
The dosage frequency can be modified during operation by pressing simultaneously.

Display during operation Paragraph 8 – Timed Dosage (Frequency signal input “TRIGGER” not activated)

| The pump doses a programmed quantity in mL. It is possible to set a delay time (Delay) for the pump start up and an interval between subsequent dosages (Interval) as shown on the diagram:The Delay and Interv. times are in dd.hh.mm format (days.hours.minutes)
The Pause input can be programmed in three different modes:
1. Freeze Time: with the pause activated, the system stops the current time count and restarts the count when the pause is deactivated
2. Pause Dosing: with the pause activated, the system continues to count the time and stops the dosage.
3. Restart Timer: with the pause activated, the system stops the dosage and when the pause is deactivated the count restarts
from the beginning.
The dosage frequency can be modified during the pump operation by pressing simultaneously.

Display during operation Paragraph 9 – Weekly timed dosage You can program 10 dosages for the entire week. Press from “Weekly Dos.” to enter the programming mode in order to program the dosages.

1. Number of program: press to modify and then press to confirm.
2. Dosage schedule: press to modify and then press to confirm.
3. Quantity to be dosed: press  to set the value in “mL” and then press to confirm.
4. Dosing time, i.e. the period of time (in seconds) in which the quantity previously programmed will be dosed: press  to set the value in seconds and then press to confirm.
5. Setting the dosage relay: press to modify the values and then press to confirm; in “Off” mode the relay does not stay off (open); in “after” mode, the relay is closing when the dosage is activated and stays closed, when the dosage is finished, for a period of time (in seconds) that you can set by pressing the key and then confirm by pressing the key. In “before” mode, the relay is closing before the dosage activation time, for a period of time (in seconds) that you can set by pressing the key and then confirm by pressing the key.
6. Activation days, i.e. the days in which you want the set program to be active (start time, quantity, dosage time and relay operation mode). Press to modify the option, then press to activate/deactivate the dosage, then press to change the day of the week. Press to confirm and automatically pass to the next program.
   If you need to configure the new program, repeat the above procedure, otherwise press to return to the main menu.
   On the main menu the next step is to set the clock; press to modify the option, then press to set the values and then press to confirm. In sequence, you can set the day, the hour and the minute. Of course, the day and the time set are those to which the programming will refer.

Paragraph 10 – Setting the Maximum Flow Rate

(% or frequency) is used as the standard measurement unit when displaying the flow rate.
Press to access the item, and then press to set the value. Press to confirm and return to the main menu.

Paragraph 11 – Flow Rate Calibration

| On the main menu appears the memorized cc/stroke value.
You can perform the calibration in two modes:
MANUAL – insert manually the cc/stroke value using the key and then confirm with the key.
AUTOMATIC – the pump runs 100 strokes, which are started by pressing the key, and at the end of the strokes insert
the amount aspirated by pump using the key and confirm with the key.
The data entered will be used for the calculation of the flow rates.

Paragraph 12 – Statistics

| On the main menu is displayed, in hours, the operating time of the pump; press to access other statistics:
– Strokes = the number of strokes performed by the pump
– Q.ta (L) = the quantity dosed from the pump expressed in liters; this information is calculated based on the memorized cc/stroke value
– Power = the number of pump activations
– Reset = press to reset the counters, select (YES) or (NO), then press to confirm.
Press to return to the main menu.

Paragraph 13 – Password

all the setup parameters, but every time you try to change the settings you will be prompted for the password.
The flashing line indicates the editable number; press to select the number (from 1 to 9), then press to select the number to modify, and then press to confirm. By setting “0000” (default), the password will be eliminated.

Paragraph 14 – Flow Alarm

| Allows you to activate (deactivate) the flow sensor.
Once activated (On) by pressing the key, you can set the number of signals the pump requires before starting the alarm (by setting the Time = 0 s on the next menu) or the priming (by setting the Time different from 0 s in the next menu). Press and the number will start to flash, than press to set the value.
Press to confirm then press to return to the main menu.
In the Time menu you can set the time over which the pump, not having received the flow signal for the set number of signals, will start priming before starting the alarm. If during the priming the pump receives again the flow signal, it will return to normal operation. For the time = 0 s, after the set number of signals, the pump will start immediately the alarm, without performing the priming. To set and modify the time:
press and the number will start to flash, than press to set the value. Press to confirm then press to return to the main menu.
Only in Batch mode you can activate the Recovery mode. The pump repeats the number of strokes not detected by the flow sensor. Press to access the request of the maximum number of signals that the pump can recover before starting the alarm. Press
and the number will start to flash, than press to set the value. Press to confirm then press to return to the main menu.

Paragraph 15 – Level Alarm

| Allows you to set the pump for the level alarm activation, with dosage operation interruption (Stop), or simple activation of the alarm signal without dosage operation interruption.
Press to access the item, then press to set the alarm type. Press to confirm. Press to return to the main menu.

Paragraph 16 – Flow Rate Measurement Unit Display

Press to access the item, then press to set the type of unit, L/h (Liter/hour), Gph (Gallons/hour), mL/m (milliliters/minute) or standard (% or frequency, according to the settings). Press to confirm and return to the main menu.

Paragraph 17 – Setting the Pause

By default, the system is set to Normally Open.
Press to access the item, and then press to set the value (N. OPEN or N. CLOSED).
Press to confirm and return to the main menu.

Alarms

with the
memory function set to Off| Press the key.
“Mem” icon flashing| The pump receives one or more impulses during the dosage with the
memory function set to On| When the pump finishes receiving external impulses, it returns the
memorized strokes
Alarm LED on “Flw” icon flashing| Flow alarm activated, the pump has not received from the flow sensor the programmed number of signals.| Press the key.
Parameter Error| Internal CPU communication error.| Press the key to restore the default parameters.

EM00136457

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