Blue-White A-100N Peristaltic Injector Pump User Manual

MODEL A-100N
Peristaltic Injector Pump
Operating Manual
Models A-100NA, A-100NC, A-100NS, A-100NF, A-100NX

Introduction

Congratulations on purchasing the A-100N Peristaltic Metering Pump. The A-100N is designed to inject chemicals into piping systems. The pump has been tested by NSF International for use with 12 ½% Sodium Hypochlorite.
This manual covers the following feed rate adjustment mechanisms:

1. Fixed Cycle Timer – (Models A-100NA, A-100NC, A-100NS) The fixed speed pumping mechanism is turned on and off by an electronic timer.
   The total cycle time is factory set. The on-time cycle is adjustable from 5% through 100% of the total cycle time. Model A-100NA has a 1 minute cycle with a 60 second adjustable on-time. Model A-100NC has a 5 second cycle with a 5 second adjustable on-time. Model A-100NS (ideal for spa and hot tub chlorination) has a 1 minute cycle with a 6 second adjustable on-time.
   (Custom cycles are available from the factory).

2. Variable Speed Controller – (Model A-100NF) The speed of the pumping mechanism is adjustable from 5% through 100%.

3. Fixed Feed Rate – (Model A-100NX) No adjustment control.

Specifications

Maximum Working Pressure
Maximum Fluid Temperature
Ambient Temperature Range
Duty Cycle
Maximum Solids
Maximum Viscosity
Maximum Suction Lift
Power Requirements
Dimensions
Weight| 100 psig / 6.9 bar (most models)
130 F / 54 C
14 to 110 F / -10 to 43 C
Continuous
50% by volume
5,000 Centipoise
up to 30 ft. water
115V60Hz (0.51A max.)
220V50Hz (0.66A max.)
230V60Hz (0.56A max.)
240V50Hz (0.59A max.)
6-1/8” H x 10-1/8” W x 9” D
8 lb.
---|---

Features

• Peristaltic Pump Tube does not require valves.
• Self priming under maximum pressure. Cannot vapor lock.
• High outlet pressure capability of 100 psig (most models).
• High inlet suction lift capability of 30 feet.
• Patented Tube Failure Detection (TFD) system.
• Patented pump tube assembly design.
• Includes Flow Verification System (FVS) – sensor sold separately.
• Open collector (sinking 50mA max) alarm output. (30V DC max)
• Corrosion proof Valox housing.
• Tamper resistant electronic control panel cover.

Your pump pack

Your pump package should contain the following:

1 – Injector pump with 2 pump tube assemblies
1 – suction tube strainer
1 – ceramic tubing weight
1 – 5’ Length of clear PVC suction tubing
1 – 5’ Length of opaque LLDPE discharge tubing
1 – Injection fitting with internal back-flow check valve
1 – Mounting hardware kit
1- Shroud (Weather proof cover see page 6)

Installation

CAUTION : Proper eye and skin protection must be worn when installing and servicing the pump.
øNote : All diagrams are strictly for guideline purposes only. Always consult an expert before installing the pump into specialized systems. The pump should be serviced by qualified persons only.

5.1 Mounting Location
Choose an area located near the chemical supply tank, chemical injection point and electrical supply. Although the pump is designed to withstand outdoor conditions, a cool, dry, well ventilated location is recommended.
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.

• Mount the pump close to the injection point. Keep the outlet (discharge) tubing as short as possible. Longer tubing increases the back pressure at the pump tube.

• Your solution tank should be sturdy. Keep the tank covered to reduce fumes. Do not mount the pump directly over your tank. 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 will reduce output error due to increased suction lift. You must install a shut-off valve, pinch clamp or other means to halt the gravity feed to the pump during servicing.

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

• Be sure to install a back-flow prevention check valve.

• An anti-syphon valve is not required. syphoning cannot occur.

A-100N
INJECTOR MOUNTING

TYPICAL INSTALLATION

Wall or shelf mount away from the top of the solution tank. Chemical fumes can damage the unit.

PARTS LOCATOR DRAWING

* Slide both top & bottom clamps to the left only far enough to open the control cover.

This Shroud is designed to weather proof this Peristaltic Pump. If the pump is wall mounted the shroud is not necessary and will still be considered weather proof.

5.2 Optional circuit board signal connection installation – The pump includes three optional external signal connections:

• FVS – FLOW VERIFICATION SENSOR INPUT
  Accepts a pulse signal from an optional Blue-White sensor confirming that fluid is passing through the pump. Triggers the AL alarm output if fluid is not detected.

• AL – ALARM OPEN COLLECTOR OUTPUT
  The output (purple wire) sinks to DC ground when an alarm condition exists. 6-30Vdc collector voltage. 50mAdc maximum sinking current.

• MA – MOTOR ACTIVE OPEN COLLECTOR OUTPUT
  The output (brown wire) sinks to DC ground when the motor is deenergized. 6-30Vdc collector voltage. 50mAdc maximum sinking current.

All signal wires must be connected to the circuit board, located inside the pump enclosure, using connector plug wiring assemblies. A liquid-tight connector must be installed in the pump enclosure wall and the signal wires passed through the liquid-tight connector and secured. See pages 8 & 9 for wiring details.

1. Remove the rear enclosure panel.
2. Remove knock-out using a screwdriver.
3. Trim edge with a knife and remove sharp edges.
4. Install the provided liquid-tight connector.
5. Connect the connector plug to the circuit board.

A-100N

CIRCUIT BOARD SIGNAL CONNECTIONS

OPEN COLLECTOR OUTPUT SCHEMATICS

5.3 Input Power Connections
WARNING : Risk of electric shock.

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.
The pump is supplied with either a ground wire conductor and a grounding type attachment plug (power cord) or a junction box for field wiring.
POWER CORD MODELS -To reduce the risk of electric shock, be certain that the power cord is connected only to a properly grounded, grounding type receptacle. JUNCTION BOX MODELS -To reduce the risk of electric shock, be certain that a grounding conductor is connected to the green grounding conductor located in the junction box.
POWER: 115V60Hz (0.51A max.), 220V50Hz (0.66A max.), 230V60Hz (0.56A max.), 240V50Hz (0.59A max.)
Note : When in doubt regarding your electrical installation, contact a licensed electrician.

MOTOR LEADWIRES

INPUT
VOLTAGE| HOT
LEADWIRE| NEUTRAL
LEADWIRE| GROUND
LEADWIRE
---|---|---|---
I I 5VAC 60Hz| YELLOW| BLUE| GREEN
220VAC 50Hz| YELLOW| BROWN| GREEN
230VAC 60Hz| YELLOW| RED| GREEN
90VDC| (+) RED| _ (-) BLACK| GREEN

CIRCUIT BOARD SIGNAL IN/OUT CONNECTIONS

FVS – FLOW VERIFICATION SENSOR INPUT
Accepts a pulse signal from an optional Blue-White sensor confirming that fluid is passing through the pump. Triggers and alarm output if fluid is not detected.| RED (+ 20VDC) BLACK (-)
YELLOW (signal)
TFD – TUBE FAILURE DETECTION SYSTEM INPUT Monitors a pair of sensors in the pumphead. Triggers an alarm
output if fluid with a conductivity of greater than 500 micro-seimens is detected. Typical chemicals include chlorine, acid, caustic.
The system will not detect water or silicone lubricating oil.| GRAY & GRAY
AL – ALARM OPEN COLLECTOR OUTPUT
The output (purple wire) sinks to DC ground when an alarm condition exists.
6-30Vdc collector voltage. 50mAdc maximum sinking current.| PURPLE (+) & BLACK (-)
MA- MOTOR ACTIVE OPEN COLLECTOR OUTPUT The output (brown wire) sinks to DC ground when the motor is de-energized.
6-30Vdc collector voltage. 50mAdc maximum sinking current.| BROWN (+) & BLACK (-)

A-100N

WIRING DIAGRAM – Model A-100NA & A-100NCWIRING DIAGRAM – Model A-100NS

WIRING DIAGRAM – Model A-100NF

5.4 How To Install the Tubing and Fittings
CAUTION : Proper eye and skin protection must be worn when installing and servicing the pump.

• Inlet Tubing – Locate the inlet fitting of the Pump Tube. 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.
• Strainer – Trim the inlet end of the suction tubing so that the strainer will rest approximately two inches from the bottom of the solution tank. This will prevent sediment from clogging the strainer. Slip the ceramic weight over the end of the suction tube. Press the strainer into the end of the tube. Secure the ceramic weight to the strainer. Drop the strainer into the solution tank.
• Outlet Tubing – Locate the outlet fitting of the Pump Tube. Remove the tube nut. Push the opaque outlet (discharge) tubing onto the compression barb of the fitting.
  Use the tube nut to secure the tube. Hand tighten only.

Keep outlet tube as short as possible.

• Injection/Check Valve Fitting Installation – The Injection/Check valve fitting is designed to install directly into either 1/4” or 1/2” female pipe threads. This fitting will require periodic cleaning, especially when injecting fluids that calcify such as sodium hypochlorite. See section 7.0.
• Install the Injection/Check valve directly into the piping system. To prevent trapped gasses, install the fitting in an upward direction. Use PTFE 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.

How to Adjust The Output

6.1 Fixed Cycle Timer Models -The pumping mechanism is turned on and off by an electronic cycle timer. The total-time cycle is factory preset and is not user adjustable. The on-time cycle is adjustable from 5% to 100% of the total cycle time (model A-100NS timers adjust from .5 to 6 seconds with total time cycle of 60 seconds).
Example: If the total-time cycle is 60 seconds and the on-time cycle is adjusted for 25 percent, the pump will run for 15 seconds and turn off for 45 seconds (60 second total cycle). This cycle is repeated until either the power switch is turned off, the cycle time is changed or the input power is disconnected from the pump. To adjust the pump output –

• Slide the slide clamps to the left only far enough to open the control panel door.
• Turn the adjustment knob to the desired percentage of on-time per cycle.
  Note: When power is applied to the pump, the A-100N will either automatically begin to pump, or maintain power-off status, depending on the power switch status.

6.2 Variable Speed Model -The speed of the pumping mechanism is adjustable from 5 % through 100%.
To adjust the pump output –

• Slide the slide clamps to the left only far enough to open the control panel door.
• Turn the adjustment knob to the desired percentage of speed.

6.3 TFD (Tube Failure Detection) – The pump is equipped with a Tube Failure Detection System which is designed to stop the pump and provide an open collector (sinking) output signal in the event the pump tube should rupture and chemical enters the pump head. This patented system is capable of detecting the presence of a large number of chemicals including Sodium Hypochlorite (Chlorine), Hydrochloric (muriatic) Acid, Sodium Hydroxide, and many others. The system will not be triggered by water (rain, condensation, etc.) or silicone oil (roller and tubing lubricant).
If the system has detected chemical, the pump tube must be replaced and the pump head and roller assembly must be thoroughly cleaned.
Confirm Chemical Detection – To determine if your chemical will be detected by the system, remove the pump tube and roller assembly. Place a small amount of the chemical in the bottom of the pump head – just enough to cover the sensors. Turn on the pump. If the TFD system detects the chemical, the pump will stop after a five second confirmation period. If the TFD system does not detect the chemical, the pump will continue to run after the confirmation period. Carefully clean the chemical out of the pump head being sure to remove all traces of chemical from the sensor probes. Turn the power switch off and on to reset the pump.
Open Collector Alarm Output – An open collector (sinking) output signal is provided with the TFD system. (See page 6).
6.4 (FVS) Flow Verification System The pump is equipped with a Flow Verification System which is designed to stop the pump and provide an open collector (sinking) output signal in the event the sensor does not detect chemical during pump operation. This could indicate a clogged injection fitting, empty chemical solution tank, worn pump tube, loose tubing connection, etc.
The system features an alarm delay time of 6 seconds which allows the pump to clear any gasses that may have accumulated during stopped operation. The pump will stop, and the alarm mode activated, if no pulses are received by the pump and the alarm delay time period has ended. Turn the power switch off and on to clear the alarm and restart the pump. The Flow Verification Sensor is sold as an optional accessory.
Confirm the FVS flow range – The Flow Verification Sensor (FVS) will only function within its operating range. Sensor model FV-100-6V has an operating range of 30-300 ml/min (1-10 oz/min). If the pump’s output is less than 30 ml/min (0.5 ml/sec), the sensor will not detect chemical and a signal will not be sent to the pump.

SENSOR
MODEL
NUMBER| OPERATING
FLOW RANGE
(ml/min)
---|---
FV-100-6V| 100-1000
FV-200-6V| 30-300
FV-300-6V| 300-3000
FV-400-6V| 200-2000
FV-500-6V| 500-5000
FV-600-6V| 700-7000

Install the FVS Flow Sensor – The Flow Verification Sensor (FVS) should be installed on the inlet (suction) side of the pump tube. The sensor includes a PVC tubing insert, located inside the sensor’s female thread connection, that is designed to seal the sensor onto the pump tube inlet adapter. Thread the sensor onto the pump tube until the tubing insert is snug against the pump tube inlet fitting – do not over-tighten.
Connect the red/white (+), black (-), and bare (signal) wires from the sensor to the red (+), black (-), and yellow (signal) wires on the plug connector.
Knock-out the liquid-tite connector mounting hole on the side of the pump enclosure and install the liquid tight connector. Route the wires through the connector and tighten the connector nut. Plug the connector onto the circuit board at the pins marked “FVS”. See page 6.

Open Collector Alarm Output – An open collector (sinking) output signal is provided with the FVS system. (See page 6).

How to Maintain the Pump

CAUTION : Proper eye and skin protection must be worn when installing and servicing the pump.

7.1 Routine Inspection and Maintenance
The pump requires very little maintenance. However, the pump and all accessories should be checked weekly. 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.
7.2 How to Clean and Lubricate the Pump
The pump will require occasional cleaning and lubricating. The amount will depend on the severity of service.

• When changing the pump tube assembly, the pump head chamber, roller assembly and pump head cover should be wiped free of any dirt and debris.
• The pump head cover bearing may require grease periodically. Apply a small amount of grease (Aeroshell aviation grease #5 or equivalent) when necessary.
• Although not necessary, 100% silicone lubrication may be used on the roller assembly.
• Periodically clean the injection/check valve assembly, especially when injecting fluids that calcify such as sodium hypochlorite. These lime deposits and other build ups can clog the fitting, increase the back pressure and interfere with the check valve operation.
• Periodically clean the suction strainer.
• Periodically inspect the air vents located under the motor compartment and on the rear panel. Clean if necessary.

7.3 How to Replace the Pump Tube
The pump tube assembly will eventually break if not replaced. The tube has been designed for a minimum service life of 500 hours. However, the life of the tube is affected by many factors such as the type of chemical being pumped, the amount of back pressure, the motor RPM, temperature and others. The pump tube assembly must be inspected and replaced regularly.
Remove the Old Pump Tube – The pump roller assembly spins in a counter clockwise direction. The pump head inlet (suction) side is located at the bottom of the pump and the outlet (discharge) is located at the top of the pump head.

Release any pressure that may be in the discharge tubing.
Disconnect the suction and discharge tubes from the pump tube.
Remove the pump head cover.
With the pump running, pull the inlet fitting out of the pumphead. Guide the tube counter clockwise away from the rollers. Pull the outlet fitting out of the pump head.

Install the New Pump Tube – Be sure the pump head chamber is clean and free of any debris.
Remove and inspect the roller assembly. Be sure the rollers spin freely. If required, apply a small amount of grease to the pump head cover bearing.
With the pump running, insert the inlet (suction) side of the Pump Tube fitting into the pump head.
Carefully guide the Pump Tube into the pump head. Stretch the tube slightly and insert the outlet (discharge) fitting into the upper retaining slot in the pump head.
Place the clear cover on the pump head and secure with three screws.
Tip! Apply silicone lubrication to outside of Flex-A-Thane tube for longer tube life.

REPLACEMENT PARTS DRAWING

Limited Warranty

Your Blue-White product is a quality product and is warranted for a specific time from date of purchase (proof of purchase is required). The product will be repaired or replaced at our discretion. Failure must have occurred due to defect in material or workmanship and not as a result of operation of the product other than in normal operation as defined in the product manual. Warranty status is determined by the product’s serial label and the sales invoice or receipt. The serial label must be on the product and legible. The warranty status of the product will be verified by Blue-White or a factory authorized service center.
FLEX-FLO® A100N pumps are warranted for 1 year from date of purchase (proof of purchase is required). Pumps will be repaired or replaced at our discretion.

What is not Covered

• Tubes and Rollers – They are wearable and require periodic replacement
• Pump removal, or re-installation, and any related labor charge.
• Freight to the factory, or service center
• Pumps that have been tampered with, or in pieces.
• Damage to the pump that results from misuse, carelessness (such as chemical spills on the enclosure), abuse, lack of maintenance, or alteration that is out of Blue-White control.
• Pumps damaged by faulty wiring, power surges, or acts of nature.

Blue-White does not assume responsibility for any loss, damage, or expense directly or indirectly related to or arising out of the use of its products. Failure must have occurred due to defect in material or workmanship and not as a result of operation of the product other than in normal operation as defined in the pump operation manual.
The warranty status is determined by the pump’s serial label and the sales invoice or receipt. The serial label must be on the pump and be legible. The warranty status of the pump will be verified by Blue-White or a factory authorized service center.

Procedure for In-Warranty Repair
Warranty service must be performed by the factory or an authorized service center. Contact the factory or local repair center to obtain a RMA (Return Material Authorization) number. It is recommended to include foot strainer and injection/check valve fitting since these devices may be clogged and part of the problem. Decontaminate, dry, and carefully pack the product to be repaired. Please enclose a brief description of the problem and proof of purchase. Prepay all shipping and insurance cost. COD shipments will not be accepted.
Damage caused by improper packaging is the responsibility of the sender. When InWarranty repair is completed, the factory pays for return shipping to the dealer or customer.
Product Use Warning
Blue-White products are manufactured to meet the highest quality standards in the industry.
Each product instruction manual includes a description of the associated product warranty and provides the user with important safety information. Purchasers, installers, and operators of Blue-White products should take the time to inform themselves about the safe operation of these products. In addition, Customers are expected to do their own due diligence regarding which products and materials are best suited for their intended applications. Blue- White is pleased to assist in this effort but does not guarantee the suitability of any particular product for any specific application as Blue- White does not have the same degree of familiarity with the application that the customer/end user has. While Blue-White will honor all of its product warranties according to their terms and conditions, Blue-White shall only be obligated to repair or replace its defective parts or products in accordance with the associated product warranties. BLUE-WHITE SHALL NOT BE LIABLE EITHER IN TORT OR IN CONTRACT FOR ANY LOSS OR DAMAGE WHETHER DIRECT, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL, ARISING OUT OF OR RELATED TO THE FAILURE OF ANY OF ITS PARTS OR PRODUCTS OR OF THEIR NONSUITABILITY FOR A GIVEN PURPOSE OR APPLICATION.

Chemical Resistance Warning
Blue-White offers a wide variety of wetted parts. Purchasers, installers, and operators of Blue-White products must be well informed and aware of the precautions to be taken when injecting or measuring various chemicals, especially those considered to be irritants, contaminants or hazardous. Customers are expected to do their own due diligence regarding which products and materials are best suited for their applications, particularly as it may relate to the potential effects of certain chemicals on Blue-White products and the potential for adverse chemical interactions.
Blue-White tests its products with water only. The chemical resistance information included in this instruction manual was supplied to Blue-White by reputable sources, but Blue-White is not able to vouch for the accuracy or completeness thereof. While Blue-White will honor all of its product warranties according to their terms and conditions, Blue-White shall only be obligated to repair or replace its defective parts or products in accordance with the
associated product warranties.
BLUE-WHITE SHALL NOT BE LIABLE EITHER IN TORT OR IN CONTRACT FOR ANY LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL, ARISING OUT OF OR RELATED TO THE USE OF
CHEMICALS IN CONNECTION WITH ANY BLUE-WHITE PRODUCTS.

AUTHORIZED SERVICE CENTERS
To find an authorized service center near you, please call Blue-White Industries at 714-893-8529 or e-mail us at customerservice@blue-white.com

Users of electrical and electronic equipment (EEE) with the WEEE marking per Annex IV of the WEEE Directive must not dispose of end of life EEE as unsorted municipal waste, but use the collection framework available to them for the return, recycle, recovery of WEEE and minimize any potential effects of EEE on the environment and human health due to the presence of hazardous substances. The WEEE marking applies only to countries within the European Union (EU) and Norway. Appliances are labeled in accordance with European Directive 2002/96/EC.
Contact your local waste recovery agency for a Designated Collection Facility in your area.

5300 Business Drive
Huntington Beach, CA 92649
USA
Phone:714-893-8529 FAX: 714-894-9492
E mail:sales@blue-white.com or customerservice@blue-white.com
Website:www.blue-white.com

References

• white.com is for sale | www.brandforce.com
• Blue-White - Fluid metering solutions made simple™

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>