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Related Manuals for Idex PULSAFEEDER DGF1
Summary of Contents for Idex PULSAFEEDER DGF1
- Page 1 DIGITAL GLYCOL FEEDER DGF1, DGF2 OPERATING INSTRUCTIONS P/N: 72-900-24 Rev J (06-22-07) STANDARD PUMP OPERATION 27101 Airport Road Punta Gorda, FL 33982 Telephone (941) 575-3800 Manufactures of Quality Pumps, Fax: (941) 575-4085 Controls and Systems (800) 333-6677 www.pulsa.com...
- Page 2 FACTORY SERVICE POLICY Your Digital Glycol Feeder (DGF) is designed to make-up lost glycol in a closed loop system. If you are experiencing a problem with your DGF consult the trouble-shooting guide. If the problem is not covered or cannot be solved, please contact your local Pulsafeeder Representative or our Technical Service Department at (800) 333-6677 for further assistance.
- Page 3 Copyright Copyright ©1999 Pulsafeeder, Inc. All rights reserved. Information in this document is subject to change without notice. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or any means electronic or mechanical, including photocopying and recording for any purpose other than the purchaser’s personal use without the written permission of Pulsafeeder, Inc.
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Page 4: Table Of Contents
Table of Contents 1. I .............................1 NTRODUCTION Systems and Options......................2 2. I ............................3 NSTALLATION Assembly..........................3 2.1.1 Tools Required For Assembly..................3 2.1.2 Pre–Assembly ........................5 2.1.3 Location ..........................6 2.1.4 Plumbing...........................6 2.1.5 Mounting The Tank ......................7 2.1.6 Mounting The Controller ....................8 2.1.7 Installing The Level Wand....................9 2.1.8 Connecting The Pressure Switch...................10 2.1.9... - Page 5 Conventions For the remainder of this bulletin, the following Conventions are in effect. A WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE EQUIPMENT AND THE PERSONNEL OPERATING IT PAY CLOSE ATTENTION TO ANY WARNING Notes are general information meant to make operating the equipment easier. Tips have been included within this bulletin to help the operator run the equipment in the most efficient manner possible.
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Page 6: Introduction
1. Introduction The Digital Glycol Feeder (DGF), is designed to make-up for lost glycol in a closed loop system. It accomplishes this by monitoring system pressure. When system pressure drops below a set pressure (indicating glycol loss), the pump activates and restores the lost glycol, bringing the system pressure back to the proper operating level. -
Page 7: Systems And Options
Systems and Options The Glycol Feeder for Closed Loop Systems includes: • control unit in a NEMA type 4X enclosure • 55 gallon polyethylene tank and stand Refer to Figure 2 – Options List, for Glycol Feeder options. Figure 2 – Options List... -
Page 8: Installation
2. Installation Assembly If your DGF is shipped to you unassembled, perform the following: (If you ordered the assembled version go to section 2.2 – Electrical Wiring.) AILURE TO FOLLOW THESE WARNINGS AND ASSEMBLY INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH •... -
Page 10: Pre-Assembly
Figure 3 – Glycol Feeder Assembly 2.1.2 Pre–Assembly 1. Unpack all cartons and inspect for damage. If shipping damage is found, save all packaging and notify the carrier immediately. Lay out and identify all parts. Parts List: Item : Tank Plumbing Stack. Item : Controller mounted on a bracket with two-cover mounting screws attached. -
Page 11: Location
Figure 4 – Parts ListLocation 1. Locate a space approximately 3’ x 3’ that is convenient to system piping and to an electrical outlet or power source. 2. Place the tank stand in the installation location with the front (pump head/wet end side) facing out. -
Page 12: Mounting The Tank
2.1.4 Mounting The Tank 1. Turn the tank upside down and screw the plumbing stack assembly into the adapter attached to the bottom of the tank. Tighten until snug plus 1/4 turn. Orient as shown in Figure 6 – Tank Installation below. 2. -
Page 13: Mounting The Controller
Mounting The Controller 1. Loosen the screws mounted to the back of the controller mounting bracket. DO NOT REMOVE! 2. Set the controller on the tank cover so that the holes in the front of the controller bracket slide over the two screws mounted to the top of the tank cover. 3. -
Page 14: Installing The Level Wand
Refer to the Molex/Heat shrink sleeving procedure shown below while making the connections outlined in sections 2.1.7, and 2.1.8. Find Mating Connections. Slide heat shrink sleeving over one of the connectors. 3 Assemble the connectors together. 4 Slide heat shrink over connection. Shrink sleeving and secure each end with a cable tie as shown. -
Page 15: Connecting The Pressure Switch
2.1.7 Connecting The Pressure Switch 1. Connect the cable from the pressure switch to the three position cable on the back of the controller marked “PRESSURE SWITCH #1”. Repeat steps 2.1.8, 2.1.9, and 2.1.10 if you have a dual loop system. The second switch is connected to the cable marked “PRESSURE SWITCH #2”. - Page 16 Figure 9 – Primary Connections...
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Page 17: Electrical Wiring
Electrical Wiring The procedure you will use to make the electrical connections is dependent on the option package you select (refer to Figure 2 – Options List). 2.2.1 115VAC Pre-Wired Unit Connections 2.2.1.1 Dual AC Alarm Connection Figure 10 – Dual AC Alarm Connection 1. - Page 18 2.2.1.2 Dual Dry Contact Connection Figure 11 – Dual Dry Contact Connection 1. Plug the 2-wire Molex connector tagged Level Wand into its mate on the end of the PVC wand (low liquid level switch). 2. Plug the 2-wire Molex connector tagged Pressure Switch #1 into its mate on the end of the associated pressure switch attached to the closed loop system.
- Page 19 2.2.1.3 Dry Contact – AC Alarm Connection Figure 12 – Dry Contact – AC Alarm Connection 1. Plug the 2-wire Molex connector tagged Level Wand into its mate on the end of the PVC wand (low liquid level switch). 2. Plug the 2-wire Molex connector tagged Pressure Switch #1 into its mate on the associated pressure switch attached to the closed loop system.
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Page 20: 115Vac/230Vac Conduit Connections
2.2.2 115VAC/230VAC Conduit Connections If your application requires 230VAC, or you did not order the 115VAC unit pre-wired, you will hard wire the electrical connections as shown in the following paragraphs (refer to Figure 13 – Main Circuit Board below for terminal locations). 2.2.2.1 Getting Around The Main Circuit Board The Main Circuit board shown below (Figure 13 –... - Page 21 2.2.2.1.1 DGF Inputs (J14) The inputs to the DGF are pre-wired at the factory and are connected to main circuit board at J14, via a pre-wired harness with Molex connectors. Figure 14 – DGF Inputs 1. Plug the 2-wire Molex connector tagged Level Wand into its mate on the end of the PVC wand (low liquid level switch).
- Page 22 2.2.2.1.2 Dry Contact #1 Or AC Output #1 1. The Dry Contact #1 connection is made to J34 pins 1, 2 or 3. 2. The AC Output #1 connection is made to J34 pins 2 or 3, 4, & 5. (The N.O.
- Page 23 2.2.2.1.3 Connecting The Pump(s) 1. If you have a single pump system, connect Pump #1 to J2-3, J3-3 & J6-3 as shown in Figure 16 – Pump Wiring Connections. This connection will allow the pump to energize when the corresponding pressure switch trips. If you have a dual pump system, connect pump #2 to J2-1, J3-1 &...
- Page 24 2.2.2.1.4 Connecting The Audible Alarm 1. Connect the Audible Alarm by connecting the alarm’s Red wire to J5 and the alarm’s Black wire to J6. Figure 17 – Audible Alarm Hook up This connection will be made at the factory when the option is selected.
- Page 25 2.2.2.1.5 Connecting main power (“Non-CE” approved) 1. Connect the main power to J4 pins 1, 2, & 3 as shown in Figure 18 – Main Power Connections below. Figure 18 – Main Power Connections (Non-CE) Approved AC P HE SUPPLIED OWER VOLTAGE MUST MATCH THE MARKED VOLTAGE RATING POSITION IN THE OPTIONS LIST...
- Page 26 2.2.2.1.6 Connecting main power (“CE” approved) 1. Connect the main power to the line filter using the wire nuts that were provided with your Digital Glycol Feeder as shown in Figure 19, Main Power Connections (CE) Approved below: a) Brown = Hot b) Blue = Return c) Green/Yellow = Ground Figure 19 –...
- Page 27 Connection of: Terminal Block Lead Color U.S. International Inputs Multiple Multiple J34-1 Dry Contact #1 (Alarm Option) J34-2 N.O. Black Black J34-3 N.C. Black Black J28-1 White White Dry Contact #2 (Alarm Option) J28-2 N.O. Black Black J28-3 N.C. Black Black J34-2 N.O.
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Page 28: Glycol Feeder System
3. Glycol Feeder System User Interface The User Interface is shown below (Figure 20). Figure 20 – User Interface The User Interface consists of the following: − Pump key (AUTO, FORCED ON, FORCED OFF) − Alarm key (AUTO, FORCED ON, FORCED OFF) −... -
Page 29: Start Up & Calibration
If a relay is in the FORCED OFF mode and power is lost, the relay will still be in the FORCED OFF state when the unit is powered up again. Start Up & Calibration This section defines the procedure for starting your Digital Glycol Feeder for the first time. 1. - Page 30 Figure 21 – Start-up Component Location 8. Observe the Pressure LED. a) If the LED is RED, adjust the Pressure Switch Range Adjustment Screw (refer to Figure 22) counter-clockwise until the Pressure LED goes out (refer to Figure 20). b) If the LED is out, adjust the Pressure Switch Range Adjustment Screw clockwise until the LED is RED.
- Page 31 c) While observing the Pressure Gauge, slowly turn the Pressure Relief Valve counter- clockwise until you see liquid flow or the pressure drops. Keep track of the number of turns, as they will be used at a later step. The Pressure LED should illuminate RED. The Pressure gauge will show the pump start pressure.
- Page 32 Figure 23 – Optional Low Pressure Switch...
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Page 33: Operation
4. Operation The DGF feeds glycol by monitoring the re-circulating glycol system pressure. When the pressure drops below the set pressure point, the pump operates until the set pressure point is reached. The DGF will continue to feed glycol until the glycol level falls below the Tank Level Monitor switch. -
Page 34: Specifications
5. Specifications Environment Operating Temperature: 0°C to 50°C (32°F to 122°F) Storage Temperature: -20°C to 60°C (-20°F to 140°F) Enclosure Rating: NEMA 4X Figure 24 – General Layout: DGF1AEACXA... -
Page 35: Power Requirements
Power Requirements 1. 115/230 VAC 50/60 Hz. Factory configured. ±10% 2. On 115V units, Alarm power is fused at the input with a 10-amp Time-Lag 5x20 glass fuse [located on the main circuit board] (Pulsafeeder Part # 05-052-17) in line with the main power cable. -
Page 36: Outputs
Outputs 5.4.1 Pump 1. One (DGF1) or two (DGF2) AC pigtail plugs come out of the back of the enclosure for use with each accompanying pump. The pigtails will be wired Normally Open (NO) which will provide power to the pump when the Pressure Switch is activated (Pressure Low). The relays have a 16 amp at 120VAC and 8 amp at 230VAC contact rating. -
Page 37: Trouble Shooting
6. Trouble Shooting Symptom Action No power light. Verify power from the source. Check fuse. If necessary, for a 115VAC system, replace the 10-amp Time-Lag 5x20 Glass Fuse. (Pulsafeeder Part #: 05-052-17) If necessary, for a 230VAC system, replace the 5-amp Time-Lag 5x20 Glass Fuse. -
Page 38: Maintenance
7. Maintenance EMOVE POWER FROM THE CONTROLLER BEFORE ANY ATTEMPT AT CLEANING IS MADE 7.1 Cleaning If your Glycol Feeder Controller requires cleaning, a mild soap or detergent can be used on the face and enclosure. Use only a mild soap or detergent to ensure that the overlay is not damaged in any way. -
Page 39: Pump Information
8. Pump Information Drive The pump is driven directly from the electric motor shaft by means of a flexible coupling. An aluminum adapter connects the pump to the motor. The adapter is a type “C–Face”. Suction Lift A rotary gear pump is capable of lifting water on the suction side as high as 20 feet. Though gear pumps are self-priming, a foot valve is recommended. -
Page 42: Notes
Notes:... -
Page 43: Appendixa - Reference Charts
Appendix A – Reference Charts Reference Chart % Propylene Glycol Weight % Volume % Refractive Boiling Point °ƒ Propylene Propylene Freeze Index Degree Point °ƒ Glycol Glycol 77°ƒ Brix @ 760MM Hg 19.4 19.9 1.3565 15.4 213°ƒ 20.4 19.0 1.3575 16.0 21.4 18.0... - Page 44 Reference Chart % Ethylene Glycol Weight % Volume % Refractive Boiling Point °ƒ Ethylene Ethylene Freeze Index Degree Point °ƒ Glycol Glycol 77°ƒ Brix @ 760MM Hg 18.1 17.0 1.3525 13.0 216°ƒ 19.2 16.5 1.3536 13.7 20.1 16.0 1.3546 14.3 21.0 14.0 1.3555...
- Page 45 STANDARD PRODUCTS OPERATION EUROPEAN UNION Pulsafeeder, Inc. Warren Rupp Europe Limited 27101 Airport Rd. PO Box 91 Punta Gorda, FL 33982 Washington NE37 1YH England www.pulsa.com Telephone: 0191 419 0999 Fax: 0191 418 3500...