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Blue-White FLEXFLO A5 Series Operating Manual

Peristaltic metering pump
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Peristaltic Metering Pump
Series A5

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Summary of Contents for Blue-White FLEXFLO A5 Series

  • Page 1 ® Peristaltic Metering Pump Series A5...

  • Page 2: Table Of Contents

    Page 2 ® FLEXFLO A5 Introduction 10.0 Industrial Protocols What’s in the box 10.1 Control and Status Mapping for Profibus and EtherNet/IP Storage and Handling Engineering Specifications 10.2 Control and Status Mapping for Modbus Output vs fluid viscosity Materials of Construction 10.3 EtherNet/IP Wetted Components...
  • Page 3 ® Page 3 FLEXFLO A5 READ THE ENTIRE OPERATING MANUAL PRIOR TO INSTALLATION AND USE. +1 (714) 893 - 8529 sales@blue-white.com customerservice@blue-white.com 5300 Business Drive Huntington Beach, CA 92649...
  • Page 4 Please Note: Your new pump has been pressure tested at the factory with clean water before shipping. You may notice trace amounts of clean water in the pre-installed tube assembly. This is part of our stringent quality assurance pro- gram at Blue-White Industries. For more information please visit us at: www.blue-white.com For videos and tutorials please visit as at: https://www.blue-white.com/resources/videos...

  • Page 5: Introduction

    Contact factory if pump or components have sustained damage. Shipping damage is not covered under warranty and will be addressed according to Blue-White freight terms and policy. If the pump will not be installed at time of arrival, store the pump in original packaging indoors in an air conditioned environment.

  • Page 6: Engineering Specifications

    Page 6 ® 2.0 Engineering Specifications FLEXFLO A5 ENGINEERING SPECIFICATIONS 65 psig (4.4 bar) Maximum Working Pressure (excluding pump tubes) NOTE: See individual pump tube assembly maximum pressure ratings. 185 °F (85 °C) Maximum Fluid Temperature (excluding pump tubes) NOTE: See individual pump tube assembly max.

  • Page 7: Output Vs Fluid Viscosity

    ® Page 7 2.0 Engineering Specifications FLEXFLO A5 OUTPUT VERSUS FLUID VISCOSITY Fluid viscosity and motor RPM both have an effect on fluid output. Please contact factory for charts and information for your application. All testing was conducted with a three foot suction lift.

  • Page 8: Materials Of Construction

    Page 8 ® Materials of Construction FLEXFLO A5...

  • Page 9: Features

    ® Page 9 Features FLEXFLO A5 Agency Listings This pump is ETL listed to conforms to the following: UL Standard 778 as a motor operated water pump. CSA Standard C22.2 as process control equipment This pump complies to the Machinery Directive 2006/42/EC, BS, EN 60204-1, Low Voltage Directive 2014/35/EU BS EN 61010-1, EMC Directive 2014/30/EU, BS EN 50081-1/BS EN 50082-1.

  • Page 10: Installation

    Page 10 ® Installation FLEXFLO A5 CAUTION The pump should be serviced by qualified persons only. If equipment is used in a manner not specified in this manual, the protection provided by the equipment may be impaired. This appliance is not intended for use by persons (including children) with reduced physical, CAUTION sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for...
  • Page 11 ® Page 11 Installation FLEXFLO A5 Pump Dimensions...

  • Page 12: Input Power Connections

    Page 12 ® Installation FLEXFLO A5 Input Power Connections WARNING Risk of electric shock – cord connected models are supplied with a grounding conductor and grounding-type attachment plug. To reduce risk of electric shock, be certain that it is connected only to a properly grounded, grounding-type receptacle. WARNING Electrical connections and grounding (earthing) must conform to local wiring codes.

  • Page 13: Wiring Terminals And I/O Schematics

    INPUT #2 CMOS (-) NEGATIVE WARNING: INPUT: (+) POSITIVE RED (+) FVS SYSTEM DO NOT ALLOW BARE BLUE-WHITE (FLOW VERIFICATION (-) NEGATIVE INPUT #1 FVS SENSOR SENSOR) INPUT #1 P1 AND P2 FV SENSOR ONLY SIGNAL BLACK (-) WIRES TO TOUCH...

  • Page 14: Layout

    APP SCREEN LAYOUT Note: Scroll right to see more options. Not all App Settings are available in Local Only or Remote Only Modes. Put pump in OFF mode to access all App Settings. Blue-White Icon Home Screen Page Indicator (1 of 2)

  • Page 15: M12 Connectors

    ® Page 15 Layout FLEXFLO A5 M12 Connector Pump (Rear Upper Panel) Input Connector 2 Output Connector 1 Input Connector 1 USB-C Output Connector 4 Output Connector 2 Output Connector 3 IO Connection Pump (Rear Lower Panel) ON/OFF Ethernet/ Modbus Power Supply Profibus...
  • Page 16 Page 16 ® Layout FLEXFLO A5 M12 Connector M12 Input/Output Connector See page 13 for wiring instruction M12 Profibus Connector M12 Input Connector 1 ** Warning - Do not let P1 and P2 wires touch! Will damage electronics. Function Specifications Reference P1** Remote Start/Stop...
  • Page 17 ® Page 17 Layout FLEXFLO A5 M12 Output Connector 3 Function Specifications Reference Not Used Not Used .8 Amp Max @ 30VDC N.O. Contact Closure Output #3, N.O. Contact 1 Amp @ 125 VAC .8 Amp Max @ 30VDC N.C. Contact Clsoure Output #3, N.C.

  • Page 18: Startup

    Page 18 ® Startup FLEXFLO A5 Powering On The Pump The A5 is equipped with a rocker switch to power ON/OFF the pump. Ensure that the power cord is securely plugged into the corresponding power source before powering on the pump. “I”...

  • Page 19: Welcome Screen

    ® Page 19 Startup FLEXFLO A5 Welcome Screen The first time the pump is powered on, or after a factory reset, the pump will boot up to the Welcome Screen. Follow the onscreen instructions to configure your A5 pump. Refer to section 11 of this manual to change any of these options after you have finished the initial configuration.

  • Page 20: Input Setup

    Page 20 ® Input Setup FLEXFLO A5 Manual Speed Adjust This input mode allows the user to set a specific speed and the pump will run at that speed until stopped. There are up and down arrows on the home screen to incrementally adjust the speed of the motor.
  • Page 21 ® Page 21 Input Setup FLEXFLO A5 4-20mA Input This input mode allows the user to set a range of mA input signals to a given motor speed, flow rate or rpm. Used to remotely control the pump with an incoming 4-20mA signal. Four points on the slope must be defined: 1) a low mA value 2) an output rate at the low mA value...

  • Page 22: Frequency Input

    Page 22 ® Input Setup FLEXFLO A5 Frequency Input This input mode is used to remotely control the pump with an incoming high speed frequency signal. Four points on the slope must be defined: 1) a low Hz value 2) an output rate at the low Hz value 3) a high Hz value 4) an output rate at the high Hz value Default settings:...

  • Page 23: Pulse Input

    ® Page 23 Input Setup FLEXFLO A5 Pulse Input This input mode allows the user to trigger the pump to dispense a measured amount of chemical (Amount Per Trigger) over a specific period of time (Pump On Time), after a specific number of pulses (Pulses Count Trigger).
  • Page 24 Page 24 ® Input Setup FLEXFLO A5 Remote Start/Stop This input mode is used to remotely start and stop the pump using “Closed” or “Open” signal. Primary Remote Switch - Used to Start/Stop the pump Secondary Remote Switch - Used in conjunction with a pressure switch or level switch (M12 Input Connector 2) - Will stop pump if closed.

  • Page 25: Set Fvs (Flow Verification System)

    FVS requires a sensor that is connected to the inlet of the pump to monitor the fluid input. Blue-White offers two flow verification sensors: The MS6 &...

  • Page 26: Prime The Pump

    Page 26 ® Input Setup FLEXFLO A5 Prime This mode allows the user to prime the pump at 100% motor speed for sixty seconds. After the prime is complete the pump will remain in this mode ready to be primed again. To exit: select another input method.

  • Page 27: Auto Prime

    ® Page 27 Input Setup FLEXFLO A5 Auto-Prime This mode will allow the user to prime the pump remotely using the dry contact. Both prime duration and percent motor speed is configurable. (This feature uses the P1 contact on Input #2 connector. Note: Can not be used if using Secondary Contact Input) Default settings: 60 Seconds at 100% Motor Speed To Enable Auto-Prime (While in “REMOTE ONLY”...

  • Page 28: Manual Cycle Adjust

    Page 28 ® Input Setup FLEXFLO A5 Manual Cycle Adjust This input mode allows the user to run the pump at a set motor speed (Pump Speed) for a set amount of time (Duty Time) after which the pump will pause for a set amount of time (Cycle Time).

  • Page 29: Dispensing

    ® Page 29 Input Setup FLEXFLO A5 8.10 Dispensing This input mode allows the user to dispense a set amount of fluid (in milliliters) at a set rate (Motor % Speed). Default settings: Amount Per Dispense = 1,000 mL Motor % Speed = 50% To Enable Dispensing (While in “LOCAL ONLY”...

  • Page 30: Time Of Day

    Page 30 ® Input Setup FLEXFLO A5 8.11 Time of Day This mode allows the user to run the pump at a specific motor speed for a specific length of time beginning at a specific time of day. Three values to be defined: 1) Percent Motor Speed 2) Run time (in minutes) 3) Time of Day that the pump will turn on...

  • Page 31: Revolution Alarm

    ® Page 31 Input Setup FLEXFLO A5 8.12 Revolution Alarm This mode will allow the user to set an alert once a set number of revolutions has been reached. One of the primary factors effecting tube life is the number of revolutions the tube has operated.

  • Page 32: Passcode

    Default settings: Pump will lockout after 30 seconds To Input a Passcode: Open the App Drawer Open Settings Open Passcode Enable Passcode Select User Passcode and Confirm by pressing Save create new a six digit code. Lost password? Email customerservice@blue-white.com to have your password reset...

  • Page 33: Local Only Mode (Via Quick Tab Setting)

    ® Page 33 FLEXFLO A5 8.14 Local Only Mode This mode will allow the user to put the pump into a state where all remote input signals are disabled. The pump may only be operated and run manually (Manual Speed Adjust) at the pump.

  • Page 34: Output Setup

    Page 34 ® Output Setup FLEXFLO A5 Set 4-20mA Output This output sends a configurable 4-20mA. This feature can be used to control other pumps (in sync / proportionally), data logging systems, and other external devices for plant automation. Four points on the slope must be defined: 1) a low mA value 2) an output rate at the low mA value 3) a high mA value...

  • Page 35: Frequency Output

    ® Page 35 Output Setup FLEXFLO A5 Frequency Output This output sends a configurable high speed frequency signal. This feature can be used to control other pumps (in sync / proportionally), data logging systems, and other external devices for plant automation. Four points on the slope must be defined: 1) a low Hz value 2) an output rate at the low Hz value...
  • Page 36 Page 36 ® Output Setup FLEXFLO A5 Relay & Contacts This feature is used to assign alarms to relay & contact closures Four values to be defined: 1) Contact #1 2) Contact #2 3) Contact #3 4) Relay Output To Enable Relay & Contacts: Open the App Drawer Select Outputs Select Relay &...

  • Page 37: Industrial Protocols

    ® Page 37 10.0 Industrial Protocols FLEXFLO A5 10.1 Control and Status Mapping Version 4 : February 20, 2024 Terminology: TFD/DFD = Tube/Diaphragm Failure Detection FVS = Flow Verification System LSB = Least Significant Byte MSB = Most Significant Byte...
  • Page 38 Page 38 ® 10.0 Industrial Protocols FLEXFLO A5 10.2 Control and Status Mapping Ethernet IP and Profibus DP...
  • Page 39 ® Page 39 10.0 Industrial Protocols FLEXFLO A5 10.1 Control and Status Mapping Ethernet IP and Profibus DP...

  • Page 40: Control And Status Mapping For Modbus Tcp

    Page 40 ® 10.0 Industrial Protocols FLEXFLO A5 10.2 Control and Status Mapping Modbus...
  • Page 41 ® Page 41 10.0 Industrial Protocols FLEXFLO A5 10.2 Control and Status Mapping Modbus...
  • Page 42 Page 42 ® 10.0 Industrial Protocols FLEXFLO A5 10.2 Control and Status Mapping for Modbus TCP...

  • Page 43: Ethernet/Ip

    ® Page 43 10.0 Industrial Protocols FLEXFLO A5 10.3 EtherNet/IP This is used to configure the EtherNet/IP Four values to be defined: 1) IP Address 2) Subnet Mask 3) Gateway 4) Always On (Connection will remain active even when mode is inactive/OFF) To Enable EtherNet/IP: Open the App Drawer Select Industrial Protocols...

  • Page 44: Modbus Tcp

    Page 44 ® 10.0 Industrial Protocols FLEXFLO A5 10.4 Modbus TCP/IP This is used to configure the Modbus TCP/IP Three values to be defined: 1) IP Address 2) Subnet Mask 3) Gateway 4) Always On (Connection will remain active even when mode is inactive/OFF) To Enable Modbus TCP: Open the App Drawer Select Industrial Protocols...

  • Page 45: Profibus Dp

    ® Page 45 10.0 Industrial Protocols FLEXFLO A5 10.5 Profibus DPV2 This is used to configure the Profibus Three values to be defined: 1) Bus Address 2) Baud Rate 3) Watchdog Time 4) Always On (Connection will remain active even when mode is inactive/OFF) To Enable Profibus: Open the App Drawer Select Industrial Protocols...

  • Page 46: Tubing

    Page 46 ® 11.0 Tubing FLEXFLO A5 11.1 Tube Info This feature will display information regarding the tubing within the pump including: · Tube type · Tube installation date · Tube run time & revolutions · Current maximum tube flow rate To View The Tube Info: Tap on the Tube Info text in the Tube info will be displayed...

  • Page 47: Tube Calibration

    ® Page 47 11.0 Tubing FLEXFLO A5 11.2 Tube Calibration This feature allows the user to calibrate the pump’s indicated flow rate to the system To Calibrate Your Tube: On the home screen select the Enter values: Select Start to begin Calibration Icon ·Pump Speed (RPM) ·Run Time (seconds)

  • Page 48: Settings

    Page 48 ® 12.0 Settings FLEXFLO A5 12.1 Pump Name This is to change the name of the pump that is displayed on the home screen. To Input Pump Name: Open the App Drawer Open Settings Open System Select “Pump Name” Enter desired Pump Name Confirm by pressing OK...

  • Page 49: Unit Of Volume

    ® Page 49 12.0 Settings FLEXFLO A5 12.2 Unit of Volume This is to change the units of volume that is displayed. To Input Units of Volume: Open the App Drawer Open Settings Open System Select Unit of Volume Select desired Units of Volume Confirm by pressing OK ·...

  • Page 50: Unit Of Time

    Page 50 ® 12.0 Settings FLEXFLO A5 12.3 Unit of Time This will change the Unit of Time that is displayed for the flow rate To Input Unit of Time: Open the App Drawer Open Settings Open System Select Unit of Time Select Desired Time Confirm by pressing OK ·Minutes (mL &...

  • Page 51: Chemical Name

    ® Page 51 12.0 Settings FLEXFLO A5 12.4 Chemical Name This is used to change the Chemical Name that is displayed on the home screen. To Input a Chemical Name: Open the App Drawer Open Settings Open System Select “Chemical Name” Enter desired Chemical Name Confirm by pressing OK...

  • Page 52: Max Motor Rpm Cut-Off

    Page 52 ® 12.0 Settings FLEXFLO A5 12.5 Max Motor RPM Cut-off This will limit the maximum speed (RPM) that the pump can run, regardless of run mode. To Input the Max Motor RPM: Open the App Drawer Open Settings Open System Select Max Motor RPM Cut-off Select Desired RPM...

  • Page 53: Language

    ® Page 53 12.0 Settings FLEXFLO A5 12.6 Set Language This setting is used to change the system language. To Input a Language: Open the App Drawer Open Settings Open System Select Locale Select Desired Language Confirm by pressing OK ·English ·Deutch ·Español...

  • Page 54: Pump Rotation Direction

    Page 54 ® 12.0 Settings FLEXFLO A5 12.7 Pump Rotation Direction This setting is used to change the rotational direction of pump. In most applications, the tube will fail by developing a small leak in the outlet side (pressure side) of the tube assembly.

  • Page 55: Resume Operation Upon Start-Up

    ® Page 55 FLEXFLO A5 12.0 Settings 12.8 Resume Operation on Start-Up This setting is used to choose whether to resume operation in the same state prior to turning off pump, or after power interruption. Note: Pump will require approx. 30 seconds for initialization before resuming operation. Default settings: Enabled Disabled = Pump will be stopped at Start-Up To Modify Setting:...

  • Page 56: Factory Reset

    Factory Reset This setting is used to factory reset the pump. This will erase all of the configurations and restore the pump to it’s original configuration when it left Blue-White factory. To Conduct A Factory Reset: Open the App Drawer...

  • Page 57: 12.10 System Time

    ® Page 57 FLEXFLO A5 12.0 Settings 12.10 System Time This setting is used to change the local time that is displayed. To Input The System Time: Select the Time in the upper Select Desired Hour Select Desired Minute right hand corner Select AM or PM Confirm by pressing OK...

  • Page 58: Display Flow Rate, Rpm, Speed, Input

    Page 58 ® 12.0 Settings FLEXFLO A5 12.11 Display Flow Rate / RPM / % Motor Speed / Remote input (4-20 mA input / Hz / Pulses) To change the display between Flow Rate, RPM, % Motor Speed, or Remote input (4-20 mA, Hz frequency, or # of pulses), press the display where value is shown.

  • Page 59: System

    ® Page 59 13.0 System FLEXFLO A5 13.1 SYSTEM INFORMATION This is to view the System Information Information to be displayed: ·Pump Name ·Serial Number ·Model ·Chemical Name ·I/O Port Firmware Version ·Firmware Version ·Motor Firmware Version ·System Build ·Industrial Protocol Firmware Version ·Manufactured Data &...

  • Page 60: Firmware Update

    Firmware Update ® To update the firmware for your pump you first need to download and install Blue-Central which is available at: https://www.blue-white.com/resources/ To Update The System Firmware: Plug pump into a computer via Select firmware tab and select The firmware upgrade box will USB A to USB C cable and “Start Upgrade”.

  • Page 61: Pump Maintenance

    100% silicon lubrication may be used on the roller assembly. Refer to www.blue-white.com/resources/videos for roller assembly maintenance video instructions. Periodically clean the back flow prevention check valve assembly, especially when injecting fluids that calcify such as sodium hypochlorite.
  • Page 62 Page 62 ® 14.0 Pump Maintenance FLEXFLO A5 CAUTION Prior to service, pump clean water through the pump and suction / discharge line to remove chemical. CAUTION Always wear protective clothing, face shield, safety glasses and gloves when working on or near your metering pump.

  • Page 63: Pump Maintenance

    ® Page 63 14.0 Pump Maintenance FLEXFLO A5...
  • Page 64 Page 64 ® 14.0 Pump Maintenance FLEXFLO A5 14.4 Tube Replacement / Tube Replacement Kit Assembly Instructions The M5 pump comes with a Dual Tube Assembly installed. The Tube Assembly includes two tubes, a suction manifold, and a discharge manifold. (See Spare Parts pages for details) When tube replacement is needed, either: 1.

  • Page 65: Tube Installation

    ® Page 65 14.0 Pump Maintenance FLEXFLO A5 14.5 Tube Break-In and Pump Head Cover Assembly When replacing NPP/NLL tubes, a “break-in” procedure is required to ensure proper start-up. 1. Before installing the bearing bracket, install first A-side roller only. Lock spider to hold roller in place.

  • Page 66: Tube Break-In And Roller Installation

    Page 66 ® 14.0 Pump Maintenance FLEXFLO A5 14.5 Tube Break-In and Pump Head Cover Assembly (Continued) 6. Install bearing bracket and spacers. Once spacer is in place insert and tighten each bearing bracket screw using a 3/8” allen wrench at 21ft-lbs torque setting. 7.

  • Page 67: Tube Assembly Care And Use Guide

    Blue-White only. Use of tubing not manufactured by Blue-White will affect the pump's performance, may damage the pump, and will void the warranty. • Blue-White Tube Assemblies are designed to function in a specific pump model. Verify that the Tube Assembly used is compatible with the pump before installing.

  • Page 68: Tfd (Tube Failure Detection)

    Page 68 ® 14.0 Pump Maintenance FLEXFLO A5 14.7 This pump is equipped with a Tube Failure Detecting System which is designed to stop the pump and provide an output alarm (see Output menu) in the event pump the tube should rupture and chemical enters the pump head.

  • Page 69: Predictive Tube Failure

    ® Page 69 FLEXFLO A5 14.8 Predictive Tube Failure Detection (TFD) This pump is equipped with a Predictive Tube Failure Detection feature that uses tube replace- ment history to let the operator know when a tube failure may occur. This feature must be activated in the Settings Tab.

  • Page 70: Replacement Parts

    Page 70 ® 15.0 Replacement Parts List FLEXFLO A5 15.1 Replacement Parts...

  • Page 71: Tube Selection Matrix

    ® Page 71 15.0 Replacement Parts List FLEXFLO A5 15.2 Tube Matrix...

  • Page 72: Accessories

    Page 72 ® 16.0 Accessories FLEXFLO A5 16.0 ACCESSORIES ® The following accessories are available for the A5 FLEXFLO Peristaltic Metering Pump. Please visit Blue- white.com for more information. All accessories are sold separately. KIT-M12 KIT-M12 WIRING INSTRUCTIONS DIAGRAM PIN # WIRE COLOR Kit contains: Two M12 PIN 1...

  • Page 73: Troubleshooting And Error Codes

    ® Page 73 16.0 Accessories FLEXFLO A5 17.0 TROUBLESHOOTING AND ERROR CODES The below is a list of common pump issues and error codes. We recommend contacting the factory for support if issues persist or if there are further questions on pump operation. Frequently, a Firmware Update is required when support is requested.
  • Page 74 Page 74 ® FLEXFLO A5 17.0 TROUBLESHOOTING AND ERROR CODES The below is a list of Error Codes. Frequently, a Firmware Update is required when support is requested. Reference the Firmware Update section for details on updating firmware. Do not attempt to open the pump or service internal electrical components.

  • Page 75: Warranty

    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.

  • Page 76: 19.0 Certificate Of Conformance

    Page 76 ® FLEXFLO A5 19.0 CERTIFICATE OF CONFORMANCE...
  • Page 77 ® Page 77 FLEXFLO A5 NOTES:...

  • Page 78: Appendix A: Acronyms

    Page 78 ® FLEXFLO A5 APPENDIX A: ACRONYMS Return Material Authorization °C Celsius Revolutions per minute °F Fahrenheit Steam-in-place Alternating current Solid state Unit of pressure TFD+ Enhanced Tube Failure Detection Clean-in-place TFE/P Tetrafluoroethylene propylene Centimeters Underwriters Laboratories Cash on Delivery United States Depth Volt...

  • Page 79: Appendix B: Model Number Matrix

    ® Page 79 FLEXFLO A5 APPENDIX B: Model Number Matrix Model Number Matrix Model Number FLEXFLO ® Peristaltic metering pump Power Cord (operating voltage user selectable 115V/240 VAC 50/60Hz) 115V / 60Hz, power cord NEMA 5/15 plug (US) 220V / 50HZ, power cord CEE 7/VII plug (EU) No Power Cord Inlet/Outlet Connection Size, Connection Type, Connection Material 1.5”...
  • Page 80 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. www.blue-white.com sales@blue-white.com customerservice@blue-white.com P.N.

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