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ITC DOSTEC-AC Original Manual

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DOSTEC-AC
ENGLISH

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  • Page 1 DOSTEC-AC ENGLISH...
  • Page 2 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 Select stroke frequency in % (flow) 4.1.4.3 Select stop mode...

  • Page 3: Safety Rules

    4.4 Monitor 4.4.1 Real Time 4.4.2 Counters 4.4.3 Info Unit 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 5.5.2 Flow detector 5.5.3 Pressure sensor 5.5.4 Pulse output isolator 5.5.5 Additional ventilation 115 / 230V 6.- START UP AND REGULATION...

  • Page 4: General Description

    1.- GENERAL DESCRIPTION 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).

  • Page 5: Packing And Storage

    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...

  • Page 6: Technical Features

    3.- TECHNICAL FEATURES SS Mode (Slow Suction) Max. *Max. FLOW PRESSURE *Suction lift FLOW viscosity viscosity CODE mPas mPas Piston 500 (E) 1200 73-AC3P44-P110_X 1500 (E) 73-AC3P44-P95_X 2000 (E) 73-AC3P44-P77_X 73-AC2 800 (C) P44-P77_M 73-AC1 2000 (E) 73-AC3P43 -P77_X 73-AC2 1500 (C) P44-P61 _M 73-AC1...
  • Page 7 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 Cylinder P.P. / PVDF / SS316 Valve (body) P.P.
  • Page 8 FLOW-PRESSURE GRAPHICS DIAPHRAGM PUMP AC1-AC2 73-AC_D21-D69 73-AC_D11-D69 15 - 10 - 2,5- 3,5 - 13 - 11 - 1,5- Bars Bars 73-AC_D33-D69 14.5- 55 - 73-AC_D31-D69 52.5-- 13.5- 50 - 25 - 47.5-- 12.5- 45 - 11.5- 20 - 42.5- 40 - Bars Bars...
  • Page 9 73-AC_D43-D95 73-AC_D42-D115 290- 200- 52,5- 190- 270- 47,5- 180- 250- 170- Bars Bars 73-AC_D43-D115 340- 320- 300- Bars DIAPHRAGM PUMP AC3 73-AC3D33-D142 73-AC3D42-D142 480- 84.5- 320- 130- 460- 80.5- 305- 130- 440- 76.5- 290- 120- 420- 110- 72.5- 275- 400- 105- 68.5- 260-...

  • Page 10: Inputs And Outputs

    Inputs and outputs • Analogue input 0/4-20mA • Serial port RS-485 ModBus • External pulse input • 4-20mA output for register and monitoring • Remote on/off input • Pulse output for register, monitoring and • Level sensor input (pre-empty) 2nd pump control •...

  • Page 11: Lcd Screen Description

    LCD SCREEN DESCRIPTION Advanced Dosing Function Program blocked 1 0 0 0240 % Flow Level 1 Level 2 1 4 4 Strokes/min l / h Flow failure Leakage ON / OFF MODE Overpressure Pulse loss Configuration Alarm Monitor Mode 4.1 Operating Mode menu 4.2 Configuration menu 0 0 0 0 0 0...

  • Page 12: Operating Modes

    4.1 OPERATING MODES 4.1.1. Manual mode This operation mode allows a manual regulation of dosing flow. 0 0 0 0 0 0 0240 0240 Manual MODE: Proportional 0 0 0 Analog 0 0 0 l / h l / h Batch ModBus MODE...
  • Page 13 PROPORTIONAL X:Y Select the number of pump strokes 0001 Change values with and confirm with 0001 Q = 025 % M = 005 pulses PROPORTIONAL X:Y Select the pump speed in % Change values with and confirm with 0001 0001 For X: 1 configuration Q must be lower than 50% M = 005 pulses PROPORTIONAL X:Y...
  • Page 14 Select ON if you want to do a proportional dosing with a PROPORT. volume limit. The pump will stop when it reaches the maximum Set Point 000,05 volumen to be dosed. Stop Pump Change values with and confirm with Stop Vol (1) 03,6 Set the desired maximum volume.

  • Page 15: Batch Mode

    ANALOG INPUT Select the mA Input to second point INPUT Change values with and confirm with 00,0 mA = 16,0 mA 100 % ANALOG INPUT Select the flow in % for the second point in mA SPAN Change values with and confirm with 4 mA 000 %...

  • Page 16: Batch Mode Settings

    Batch mode settings BATCH MODE Start Man. Manual: press to start the pump Flow 000 % Stop Stroke BATCH MODE Start Ext.: start the pump throught remote input Flow 000 % Stop Stroke BATCH MODE Start Time Time: start the pump through a timer by introducing a frecuency Flow 000 % (00:00:01 - 23:59:59)
  • Page 17 BATCH MODE Time: set the runtime before stop Start Man. Flow 050 % Stop Time BATCH MODE Change values with Start Man. Flow 050 % and confirm with Stop 00 : 00 : 10 Volume 333,33 l Configuration modes view Volumen to dose 01,379 l Start :...

  • Page 18: Modbus Mode

    4.1.5 ModBus mode 0 0 0 0 0 0 0240 0 240 MODE: Manual Proportional 0 0 0 Analog 0 0 0 l / h l / h l / h Batch ModBus MODE Command Address Name Value Read 00 00 Dosing Flow Integer Read...

  • Page 19: Remote Activation

    4.1.5.1 Remote activation LEVEL 2 4-20mA PULSE REMOTE LEVEL 1 STOP + 24 17 18 RUN (factory default) 17 18 4.1.5.2 Test priming function 4.2 CONFIGURATION 4.2.1 Pump Calibration 0 0 0 0240 CONFIGURATION PUMP CALIBRATION PUMP CALIBRATION TEST TIME 0 0 0 DOSING MODE l / h...
  • Page 20 PUMP CALIBRATION Change values with and confirm with TEST TIME ENT to start PUMP CALIBRATION PUMP CALIBRATION Introduce the value in the unit PROGRESS Dosed volume and confirm with 03,333 Strokes Speed P. 0415 Max.Curr. 04,5 Press to finish the calibration process PUMP CALIBRATION Dvol: dosed volume DVol...
  • Page 21 4.2.2.2 Low Flow The Low Flow mode (LF) allows to pause the dosing during the discharge cycle, extendind the dosing time and therefore reducing the flow up to 1%. The other modes allow to reduce the flow up to 10%. DOSING MODE Mode: Low Flow...

  • Page 22: Flow Limit

    4.2.3 Set up 4.2.3.1 Dosing pump Technical features of the dosing pump 0 0 0 SET UP 0240 CONFIGURATION DOSING PUMP 0 0 0 PUMP CALIBRATION UNITS l / h DOSING MODE FLOWMETER SET UP LOCK CODE IN / OUT MODE MODBUS Flow of the pump...
  • Page 23 4.2.3.2 Units Select the units for flow, pressure and proportion 0 0 0 SET UP 0240 CONFIGURATION DOSING PUMP PUMP CALIBRATION 0 0 0 UNITS DOSING MODE l / h FLOWMETER SET UP LOCK CODE IN / OUT MODBUS MODE UNITS Change units LITERS / GALONS with Flow...
  • Page 24 FLOWMETER FLOWMETER Change values with FREQUENCY : FREQUENCY : HIGH and confirm with 010.77 / puls 010.77 puls / TIME Q=0 : TIME Q=0, Time without receiving pulses necessary to identify as dlow zero. 4.2.3.4 Lock code 0 0 0 SET UP 0240 CONFIGURATION...
  • Page 25 MODBUS ADDRESS Address: Change values with and confirm with Baudrate: 9600 Data Bits: Parity: Stop Bits: MODBUS ADDRESS Address: Change values with and confirm with Baudrate: 9600 Data Bits: Parity: Stop Bits: MODBUS ADDRESS Address: Change values with and confirm with Baudrate: 9600 Data Bits:...
  • Page 26 FLOW DETECTOR IN Strokes Pump Change values with and confirm with 4.2.4.3 Pulse output Configuration of the volume/pulse to monitor the pump flow 0 0 0 0240 CONFIGURATION INPUTS PRESSURE PUMP CALIBRATION 0 0 0 FLOW DETECTOR l / h DOSING MODE OUTPUTS SET UP...

  • Page 27: Level Alarm

    4.3 ALARMS If there is an alarm, the appropiate icon will be blinking on the main screen. If the cause of the alarm stops, the icon will remain fixed on the screen. To clear the alarm icon is necessary to stop and start the pump by pressing the “ENT” key. The safety time is 5 seconds before activating any alarm.
  • Page 28 LEVEL 1 PRE EMPTY LEVEL 2 EMPTY Switch on the Alarm Level relay when the alarm is on Alarm Alarm Level relay and confirm with Level 2 relay Stop pump Stop pump LEVEL 1 PRE EMPTY LEVEL 2 EMPTY Stop the pump when the alarm is on Alarm Alarm and confirm with...
  • Page 29 LEVEL 1 PRE EMPTY DIAPHRAGM LEAKAGE Switch on the Alarm Level relay when the alarm is on Alarm Alarm Level relay and confirm with Relay out Stop pump Stop pump DIAPHRAGM LEAKAGE Stop the pump when the alarm is on Alarm and confirm with Relay out...
  • Page 30 Analogue input value (mA) External pulse input value (Hz) INPUTS 0/4-20mA Pressure sensor input value (BAR/PSI) Pulse Hz External pulse input value (ON-OFF) Press Bar Pulse x:y Remote activation input Remote Number of strokes per minute St/min Pulse Flow Flow detector input value Analog output value (mA) OUTPUTS 0/4-20mA...

  • Page 31: Installation

    5.- INSTALLATION 5.1.- GENERALITIES To install this pump it is advisable to choose places protected from water, away from heat sources and with air renewal. Place the pump vertically over a totally rigid surface to achieve a proper lubrication of all inner elements. Anticipate which will be the room you will need to comfortably do the basic maintenance and install / uninstall the pump.

  • Page 32: Electrical Connection

    Ventilation 24Vdc Inputs Outputs ENCODER LEAKAGE PRESSURE FLOW VENTILATION RS-485 12 V MN+ MN- +2 4 +5 V H 4-20mA PULSE REMOTE LEVEL 1 LEVEL 2 4-20mA PULSE ALM LEVEL Pulse input 4-20mA ITC Flowmeter ITC controllers Quick external plug...
  • Page 33 WIRING Inputs FUNCTION DETAIL Encoder +12vdc Encoder Encoder Encoder Encoder Flow detector Flow detector Leakage detector Leakage detector Pressure transmitter +24v dc Pressure transmitter Pressure transmitter Analogue mode input 4-20mA Analogue mode input 4-20mA Proportional mode pulse input Pulse Proportional mode pulse input Remote activation / Batch mode Dry contact Remote activation / Batch mode...

  • Page 34: Hydraulic Installation

    5.4.- HYDRAULIC INSTALLATION 5.4.1- Installation examples 10 11 Avoid suctioning the undiluted particles from the bottom of the tank. 2 Filter. It is important to install a filter (150 micron) in the suction pipe. 3 Level sensor 4 Agitator 5 Make sure to collect any liquid leakage from the cylinder’s vent/drain hole in a proper container.

  • Page 35: Suction Pipe

    5.4.2.- Recomendations for the correct installation SUCTION PIPE Long suction pipe: L>2m (6.5ft) RECOMENDED PIPE SIZE Øint L < 2 m L < 5 m AC1/ 2 1000 Ø 1000 Q max (l/h) Air in suction pipe DISCHARGE PIPE Long discharge pipe: L>5m (16 ft) RECOMENDED PIPE SIZE Øint L <...
  • Page 36 5.5.- ACCESSORIES 5.5.1- Diaphragm leakage detector The diaphragm leakage detector is a conductivity sensor which is able to detect conductive liquids, with a minimum conductivity of 0.05mS. The pump must be provided with the specific diaphragm flange to hold the leakage detector. Ø...
  • Page 37 5.5.4- Pulse output isolator The pulse output isolator allows to safely connect any dispositive to an pulse output. The pulse output is a drycontact. The pulse output isolator is not necessary when this output connects with a pulse input of another Dostec AC.
  • Page 38 27-051 AC3 PISTON 28054 29321 66344 (x4) 62352 (x4) 71304 71139 (2,4c/min) 71107(2c/min) 71137(1c/min) 62451 71309 (x4) 71308 61337 71151 71306 71-031 62129 64310 71124 61336 61-011-F 64412 61-855-P 62166(x4) 71314 61-131-/C (P110) 61-134-/C (P95) 61-136-/C (P77) 71123 61137 (P110) 61138 (P95) 63424 (P77) 71130.1-P...
  • Page 39 29061 (AC2) 60301 66334 66344 60109 60315 60333 71-030 (c15-7,5) 71111(c15-7,7) 71-029 (c10-5) 71112(c10-5) 60314 60110(c15-7,7) 71127(c10-5) 29-036 29-035 71184(15mm) 71187(10mm) 71138 (2,4c/min) 71188(7,5mm) 71106(2c/min) 71189(5mm) 71310 71136(1c/min) 71310 71307 71303 71311 71185.1 60156 71313(x4) 71186 62166(x4) 60300 60304(x3) 65466 29-059.1 29-057.1 61-875-P...
  • Page 40 LIST OF PARTS AC3 (Piston) CODE DESCRIPTION UNITS 28054 Electric motor 1,2Kw 6P 110/190 3ph 80/100 B14 29321 Seal motor T80 Maraz 29620 Control board AC 29622 Power board 230V AC 33429 Screw M4x20 Din 912 a-2 38301 Screw M3x8 Din7985 A2 60109 Regulator knob Dostec 60110...
  • Page 41 71129 Ring plate for piston cylinder D160 71151 Block D50 Ac3 71184 Eccentric shaft 15 encoder Ac3 71185.1 Block lid D50 encoder 71186 Magnet for encoder base D50 71187 Eccentric shaft 10 encoder Ac3 71188 Eccentric shaft 7,5 encoder Ac3 71189 Eccentric shaft 5 encoder Ac3 71303...
  • Page 42 27-051 AC3 DIAPHRAGM 28054 29321 66344 (x4) 62352 (x4) 71304 71139 (2,4c/min) 71107(2c/min) 71137(1c/min) 62451 71309 (x4) 71308 61337 71151 71306 71-032 62166(x4) 62129 64310 61-011-F 61336 63331(x4) 61-855-P 71217 (D142) 71218 (D163) 71221 (D142) 71222 (D163) 71226 (D142) 71225 (D163) 71214.1 -P/F (D142) 71215.1-P/F (D163)
  • Page 43 29061 (AC2) 60301 66334 66344 60109 60315 60333 71-030 (c15-7,5) 71111(c15-7,7) 71-029 (c10-5) 71112(c10-5) 60314 60110(c15-7,7) 29-036 71127(c10-5) 29-035 71184(15mm) 71187(10mm) 71138 (2,4c/min) 71188(7,5mm) 71106(2c/min) 71189(5mm) 71310 71136(1c/min) 71310 71307 71303 71185.1 71311 60156 71313(x4) 71186 62166(x4) 60300 60304(x3) 29-059.1 65466 29-057.1 61-875-P...
  • Page 44 LIST OF PARTS AC3 (Diaphragm) CODE DESCRIPTION UNITS 28054 Electric motor 1,2Kw 6P 110/190 3ph 80/100 B14 29321 Seal motor T80 Maraz 60109 Regulator knob Dostec 60110 Regulator guide p1,5mm Dostec 60156 Magnet for encoder d6x2.5 60300 Oil peep hole 60301 Regulator knob plug 60304...
  • Page 45 71214.1-P/F Cylinder diaphragm ring plate D142 71215.1-P/F Cylinder diaphragm ring plate D163 71217 Diaphragm flange D142 71218 Diaphragm flange D163 71221 Base membrana D142 71222 Base membrana D163 71225 Diaphragm D163 71226 Diaphragm D142 71303 Wedging piece Din 6885-a (8x7x25) 71304 Screw M6x10 Din 913 8.8 71306...
  • Page 46 27-050 AC1/2 PISTON 28053 29319 62352(x4) 60118 (144c/min) 60116 (120c/min) 60117 (60c/min) 60137 (36c/min) 60138 (22c/min) 63213 63212 60111 60319 60320(x5) 60312 63124 60151 60302(x4) P.E. / Ceramic 60-014 64412 62-132 / 62-143 (D24) 60-023(500L) 62-133 / 62-144 (D34) 60-125 / 62-145 (D49) 60-126 / 62-146 (D61) 60-127 (D77) 62129...
  • Page 47 29060 (AC1) 29061 (AC2) 60301 66334 66344 60109 60318 60315 60333 60-022 (p1,5) 60-021 (p0,9) 60108(p1,5) 60209(p0,9) 60314 29-036 60110(p1,5) 29-035 60112(p0,9) 60119 (144c /min 60305 60115 (120c/min) 60114 (60c/min) 60133 (36c/min) 62453 60134 (22c/min) 61305 62453 60154.1 60156 60158 63212(x4) 62451 60300...
  • Page 48 LIST OF PARTS AC1/2 (Piston) Code Description Units 28053 Motor 230Kw AC1/2 29118 Motor adapter for inverter 0,5Hp 110V 29319 Seal motor Marax T71 60108 Regulation rod 15 Dostec 60109 Regulator knob Dostec 60110 Regulator guide p1,5mm Dostec 60111 Pinion bumper Dostec 60112 Dostec guide regulator p0,9mm 60114...
  • Page 49 62-143 Piston 50 l/h - s M20 lock ceramic 62-144 Piston 100 l/h - s M20 lock ceramic 62-145 Piston 200 l/h - s M20 lock ceramic 62-146 Piston 300 l/h - s M20 lockceramic 62300 O-ring 19x3 FPM 62352 Screw M6x12 Din 933 A2 62451 Bearing 6202 zz...
  • Page 50 27-050 27-051 AC1/2 DIAPHRAGM 28054 29307 (x4) 29118 29318 62352(x4) 60118 (144c/min) 60116 (120c/min) 60117 (60c/min) 60137 (36c/min) 60138 (22c/min) 63212 63213 60111 60320(x5) 60319 63124 60312 60151 60302(x4) 60313 60-015 67104.2-P/F (D69) 67104-I (D69) 62129 62-859-P (6x12) 62-857-P (3/4) 64310 63125 63125...
  • Page 51 29060 (AC1) 29061 (AC2) 60301 66334 66344 60109 60318 60315 60333 60-022 (p1,5) 60-021 (p0,9) 60108(p1,5) 60209(p0,9) 60314 29-036 29-035 60110(p1,5) 60112(p0,9) 60119 (144c /min 60305 60115 (120c/min) 60114 (60c/min) 60133 (36c/min) 62453 60134 (22c/min) 61305 62453 60154.1 60156 60158 63212(x4) 62451 60300...
  • Page 52 LIST OF PARTS AC1/2 (Diaphragm) Code Description Units 28053 Motor 230Kw AC1/2 29118 Motor adapter for inverter 0,5Hp 110V 29129 Advanced Control case 29131 Advanced Control lid 29132 Case seal DOSTEC AC 29202 Lexan Dostec AC 29307 Screw M4x15 Din 7991 29312 O-ring 32x2 FPM 29315...
  • Page 53 61324 Bearing 6206zz (30x62x16) EF 62119 Cylinder spacer D40/MF 62129 Bellow FPM 62300 O-ring 19x3 FPM 62352 Screw M6x12 Din 933 A2 62451 Bearing 6202 zz 62453 Retaining ring 15 Din 471 63124 filler plug 63125 3/8” drain plug 63212 Screw M5x12 Din 912 A2 63213 Washer 18x5x2,5 F5...

  • Page 54: Priming Valves

    VALVES 6X12 (60 l/h max.) AISI 316 PP / PVDF Suction Discharge Discharge Suction 60-858-P 60-859-P 60-809.1-I 60-808.1-I 60-808.1-F 60-809.1-F 62310 60811.1-I 62310 60811.1-P/F 60813.1-I 60813.1-P/F 60877 64351 64348 (Boro) 60877 60308 60812.1-I 60308 62310 60812.1-P/F 60810.1-I 60810.1-P/F 62310 60810.1-I 60813.1-P/F 60810.1-P/F 60813.1-I...

  • Page 55: Periodical Maintenance

    MAINTENANCE Ensure the following points before any maintenance operation: The pump is stopped and disconnected from the electric supply. There is no pressure neither inside the head nor in the discharge pipe. It is advisable to empty the head before opening it. The staff in charge of the maintenance will use the adequate protection equipment in order to manipulate the dosed liquid.
  • Page 56 - Check with a voltmeter incoming INPUT VOLTAGE TOO HIGH OVERVOLTAGE voltage SHORTCIRCUIT INTERNAL SHORTCIRCUIT - Contact ITC Technical Service MOTOR PHASE FAILURE PHASE FAILURE - Check the wiring between motor and electronic card AL-2 TEMPERATURE - Check the wiring of the additional...

  • Page 57: Electrical Wiring

    MN+ MN- 4-20mA PULSE ALM LEVEL Violet Black LEVEL 2 4-20mA PULSE REMOTE LEVEL 1 + 24 Yellow Blue White 230V ENCODER wiring Violet Black 12v F1 F2 S - Yellow White Blue Pulse input 4-20mA ITC flowmeter ITC controllers...

  • Page 58: Ec Conformity Declaration

    EC CONFORMITY DECLARATION I.T.C S.L.. Vallès, 26 Polígono Industrial Can Bernades-Subirà 08130 Santa Perpètua de Mogoda Declares that all models DOSTEC AC products, identified by a serial number and year of manufacture, strictly fulfill 2006/042/CE,low voltages directives D2014/35/UE, and electromagnetic compatibility directivess D2014/30/UE, as long as installation, use and maintenance are carried out following the prevailing regulation and following the instructions contained in the handbook.

  • Page 60: Original Manual

    Original manual Ed:19/07/19 EN C/ Vallès, 26 Pol. Ind. Can Bernades - Subirà P.O. Box 60 08130 Santa Perpètua de Mogoda BARCELONA Tel. 93 544 30 40 Fax 93 544 31 61 e-mail: itc@itc.es www.itc-dosing-pumps.com...

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