AdBlue CDI-H27 User manual

CDI-H27 AD BLUE PUMP
Before Installing And Use Please Read The Instruction Manual Carefully
USER MANUAL

SECTION
1
2
3
4
5
6
7
8
9
10
SECTION 1 SAFETY INSTRUCTIONS
This instruction manual contains essential information that must be observed during
installation, operation and servicing. It is therefore important that the installer and
the responsible technician/operator read this instruction manual before the
equipment is installed and put into operation. The manual must always be available
at the location where the pump or the plant is installed. Failure to observe the safety
instructions can lead to the loss of all warranty.
In this instruction manual, safety information is distinctly labelled with particular
symbols. Disregarding this Information can be dangerous.
ATTENTION
General danger to people
DANGER - ELECTRIC SHOCK RISK
Warning of electrical voltage
QUALIFICATION AND TRAINING OF PERSONNEL
All personnel involved with the operation, servicing, inspection and installation of the
equipment must be suitably qualified for this work and must have studied the
instruction manual in depth to ensure that they are sufficiently conversant with its
contents. The supervision, competence and areas of responsibility of the personnel
must be precisely regulated by the operator. If the personnel do not have the
necessary skills, they must be instructed and trained accordingly.
SAFETY CONSCIOUS WORKING
The safety instructions in this instruction manual, the existing national regulations
regarding accident prevention, and any internal working, operating and safety
regulations must be followed
SAFETY INSTRUCTIONS FOR THE USER
All legal regulations, local directives and safety regulations must be followed. Legal
regulations must be observed
WARRANTY
ELECTRICAL CONNECTION
DIMENSIONAL DRAWING
DISASSEMBLY AND DISPOSAL
TROUBLE SHOOTING
MAINTENANCE
OPERATION
INSTALLATION
APPLICATION
SAFETY INSTRUCTIONS
DESCRIPTION
CDI-H27 AD BLUE PUMP

SAFETY INSTRUCTIONS FOR INSTALLATION, INSPECTION AND MAINTENANCE
WORKS
As a basic principle, works may only be carried out to the equipment when it is shut
down. Pumps or plant that convey harmful substances must be decontaminated. All
safety and protection components must be re-fitted and/or made operational
immediately after the works have been completed. Their effectiveness must be
checked before restarting, taking into account the current regulations and
stipulations.
UNAUTHORISED MODIFICATIONS, MANUFACTURE OF SPARE PARTS
The equipment may only be modified or altered in agreement with the manufacturer.
The use of original spare parts and accessories approved by the manufacturer is
important for safety reasons. The use of other parts can result in liability for
consequential damage being rescinded. All materials in contact with water have been
tested and approved, therefore only original replacement parts should be used.
UNAUTHORISED OPERATING METHODS
The operational safety of the supplied equipment is only guaranteed if the
equipment is used for its intended purpose. The limiting values given in the
“Technical Data” section may not be exceeded under any circumstances
INSTRUCTIONS REGARDING ACCIDENT PREVENTION
Never work alone. Always wear a hard hat, safety glasses and safety shoes and, if
necessary, a suitable safety belt. Before carrying out welding works or using electrical
devices, check to ensure there is no danger of explosion.
For the sake of your health, be sure to pay meticulous attention to cleanliness
wherever you are working. Make sure that there are no toxic gases in the working
area
Observe the relevant occupational health and safety regulations and keep first aid
materials available.
In some cases, the pump and the pumping medium may be hot and could cause
burns. For installations in areas subject to explosion hazards, special regulations
apply!
DANGER - ELECTRIC SHOCK RISK
230v Pumps - The pump must only be connected to sockets that have been installed
properly in accordance with the regulations and are protected with safety switch
(RCD,30mA)
Only qualified electricians may carry out electrical works to the pump or the controls
Always pull out the mains plug before carrying out any work on the pump
Check the rubber hose for mechanical or chemical damage. A damaged or kinked
hose must be replaced.

SECTION 2 APPLICATION
The CDI-H27 pump is a five chamber positive displacement diaphragm pump.
Designed for pumping AD Blue (AUS32-DEF-ADBLUE) with no solid suspended
particles, fibres or abrasive materials. NOT FOR PUMPING PETROL!
DANGER
Never use the pump for flammable and/or explosive liquids
Improper use of the pump can lead to physical injury and/or material damage.
Improper use of the product will render the warranty null and void
SOUND PRESSURE LEVEL
The sound pressure level is below 70dB (LpA) on all models
TRANSPORT AND STORAGE
On delivery, check that the electric pump has not been subject to damage during
transport; in this case notify the retailer immediately. Check procedure phases -
check the exterior of the packaging - remove all product packaging material - inspect
the product for possible damaged parts - contact the retailer if any defects are found.
Use the original packaging to return the product to the retailer in the event of
defects; otherwise dispose of all packaging materials according to current local
standards
If after use the pump will be stored away for a long period, wash the pump body out
with clean water. Ad Blue if left in the pump body will crystalise and may cause
problems on next use
DANGER
Handle the product in observance of current accident prevention standards
During storage, protect the product from humidity, dust, heat sources, mechanical
damage and external contaminants in order to conserve the quality of the water
subsequently placed in contact with the pump

SECTION 3 INSTALLATION
Install the pump on a flat surface and secure to prevent movement during start-up
and operation, ensuring that there are no obstructions to the regular flow of cooling
air delivered by the motor fan. Clean the pump prior to installation if left unused for
prolonged periods of time
Ensure that the installation site is sufficiently sized to enable assembly of the pump
on the system and future maintenance operations. Ensure that the pump installation
room or site is not subject to the risk of flooding by the leakage of liquids or other
events that may cause submersion of the pump itself.
ATTENTION
To avoid breakdown of the system with the risk of physical injury, use pipelines,
connectors and accessories suited to the maximum operating pressure values
All pipeline connections must be made by qualified personnel in conformity with
current local standards.
To avoid the need to drain the system in the event of pump maintenance, the
installation of a shutoff valve is recommended, on the suction and delivery pipelines
If the pump remains in operation with the delivery valve closed, the liquid will start to
overheat. Never use the pump with the shutoff valve closed on the delivery side
The pump should be installed in such a way to avoid the risk of air pockets in the
body or pipelines, in particular on the suction side of the pump
Pipelines and valves must be correctly sized according to the installation. Pipelines
must not cause excessive mechanical stress on pump suction or delivery with
excessive loads and torque values
If flexible hoses are used, fit a semi-rigid pipe on suction to avoid the risk of shrinkage
due to negative pressure on suction
It is recommended to fit a filter on the inlet of the suction pipeline where the pump is
used for pumping AD Blue from a tank
Periodically check the condition of the filter and regularly clean or replace this
element

Correct pump installation is essential to ensure priming
Position the pump in the vicinity of the well or tank to ensure that the suction pipe is
as short as possible. In this way, the priming time is reduced, above all in the case of
large differences in height between the liquid and suction point.
Use a pipeline that is at least the same diameter as that of the pump suction port and
no longer than 2 metres vertical
To avoid the formation of air vortexes, immerse the suction pipe by at least 0.5m in
the liquid to be pumped. Install a foot valve with filter at the end of the suction pipe
or check valve on the suction port in the case
Ensure complete sealing of the suction pipe including all connections
Do not run the pump dry for more than 10 minutes. This can cause damage to the
pump components
Operating conditions with duty cycles longer than 20 minutes can cause the motor
temperature to rise. Allow the pump and motor to cool for 20 minutes
The by-pass valve allows the pump to continue with the dleivery outlet closed but
only for short periods. Maximum 3 minutes. To avoid damaging the pump make sure
it is switched off after use
Use wide bends on the suction section

SECTION 4 ELECTRICAL CONNECTION
DANGER - ELECTRIC SHOCK RISK
Ensure that the rated voltage and frequency correspond to those of the specifications
of the mains power available.
The electrical connection must be made according to current local standards.
Before any intervention on the pump - 230v pumps, disconnect the electrical mains.
Low voltage pumps - Disconnect from the low voltage power source. Ensure that the
electrical power supply cannot be restored inadvertently.
The electrical cables must be protected, in particular from high temperatures,
vibrations and impact, which could cause mechanical or chemical damage.
The electrical power line (230v pumps) must be fitted with a short circuit protection
device, and a residual current device RCD with high sensitivity (30mA)
The electric power line (230v) must be fitted with an external main switch with a
contact opening gap compliant with current local standards.
SINGLE PHASE MOTORS
The single phase motors are protected against temperature and current overload by
means of thermal cutout devices in the winding. The motor protection is reset
automatically on elapse of the time required for the electric motor to cool down.
ELECTRICAL CONNECTIONS
230v model is supplied with a 1.5m power cable and plug
Low Voltage DC models are supplied with 1.5m power cable and clamps

SECTION 5 OPERATION
ATTENTION
The pump must never be operated with the shut off valve on the delivery side closed.
The discharge valve must be opened as soon as the pump has been started up, to
prevent damage to the latter by an excessive increase in liquid temperature
Use the electric pump according to the performance specifications as stated on the
data plate. Before using the pump, read application chapter for a proper use
Always avoid operation of the pump with the upline shut off valve closed (suction
side). Dry running of the pump can lead to over heating and damage to the pump
itself.
Never run the pump with the shut off valve downline (delivery side) completely
closed. In this case, the water in the system reaches very high temperatures, with the
risk of damage to equipment and scalding in the event of liquid escaping. In this
situation, turn off the pump and leave the system to cool.
Operating with duty cycles longer than 20 minutes can cause the motor temperature
to arise and damage the motor. For each running time of 20 minutes, switch off the
pump and allow the motor to cool for 20 minutes.
If an automatic nozzle is installed on the delivery line when first starting the pump
note that is may be difficult to prime because of air trapped in the hose. Open the
trigger so air can escape

SECTION 6 MAINTENANCE
DANGER - ELECTRIC SHOCK RISK
Before any intervention on the pump, disconnect the electrical power supply. Ensure
that the electrical power supply cannot be restored inadvertently
ATTENTION
Refer to safety instructions
In normal conditions, the electric pumps do not require any scheduled maintenance.
With a view to prevention of possible faults, it is recommended to periodically check
the pressure delivered and current absorption. A reduction in pressure is
symptomatic of pump wear. An increase in current absorption is symptomatic of
abnormal mechanical friction in the pump
Special maintenance may be required to clean the pump if it not used for prolonged
periods (e.g. for an entire season) it should be drained completely rinsed with clean
water and stored in a dry location

SECTION 7 TROUBLESHOOTING GUIDE
ATTENTION
Refer to safety instructions
THE PUMP DOES NOT WORK
No power supply - Turn off the switch and check that no electrical connections are
loose or defective
Check the mains voltage (230v)
Check the DC low voltage (12v / 24v)
Fuse blown - Check that the cables and relative connections are not defective and
replace the fuse if necessary
The 230v single phase motor thermal cut out has tripped this is reset automatically
once the motor has cooled
Motor overload cut out has tripped - Check that the cables and relative connections
are not defective, check that the pump is not blocked mechanically, or whether the
pump motor winding is damaged
THE PUMP STOPS AFTER A SHORT INTERVAL OF OPERATION DUE TO A TRIPPED
MOTOR PROTECTION DEVICE
Excessive current absorption check the operating condition of the pump
If foreign bodies are present, blocking hydraulics = clean the hydraulic components
The 230v single phase motor thermal cutout has tripped = this is reset automatically
once the motor has cooled; check installation conditions
Thermal cutout protection setting or fuses not suitable = check protection devices
with respect to rated current of pump
Power cable damaged = replace component
THE PUMP STARTS UP BUT DOES NOT DELIVER LIQUID
The pump takes in air, check the liquid level, operation of the foot valve and the
suction pipeline, check connections are air tight
PUMP PERFORMANCE IS REDUCED
Pipelines obstructed check pipelines, check valves
Suction pipe is partially obstructed with impurites, clean suction pipe
Leak from suction pipe, repair or replace

SECTION 8 DISASSEMBLY AND DISPOSAL
DANGER - ELECTRIC SHOCK RISK
Before any intervention on the pump, disconnect the electrical mains. Ensure that
the electrical power supply cannot be restored inadvertently
Disconnect the pump electrically from the system according to safety standards
Open the tap nearest to the pump to decrease the system's pressure
Before disassembly, close the shutoff valves on the delivery side, and if present also
close the shutoff valve on the suction side
This product or any part of the latter must be disposed of in accordance with local
standards using the public or private waste collection authorities as required
SECTION 9 DIMENSIONAL DRAWINGS
CDI-H27 230v
CDI-H27 12v & 24v

SECTION 10 WARRANTY
Conditions of Warranty Terms
Products are covered by Warranty relating to manufacturing defect or failing and/or
those of the material used. The components subject to fair wear and tear, such as
bearings, seal housing bushes, seals and o rings are not covered under the
manufactures warranty.
The Warranty right starts from the date of sale and must be certified by the sale’s
receipt and is covered for 12 months (1 Year) from sale against fault of manufacture.
The warranty is not accepted in case of:
Failures due to wrong treatment or operation.
Failures due to wrong implementation or storage.
Failure due to wrong hydraulic or electrical connections or installations.
Failures due to by a lack of an adequate protection.
Failures to reasons of force of nature or other uncontrollable factors.
Failures due to abrasive, or corrosive liquids or different from those allowed.
The use of the item beyond the limits indicated on the plate or in wrong conditions.
Failures due to lack of maintenance.
Failures due to incorrect user’s actions.
Failure due to wear and tear in certain applications.
In case of pumps the warranty is void if they have not been installed with accurate
motor over load protection.
The Warranty consists of repair or replacement by the service centre or supplier at
their discretion for the defective pump or parts.
The Warranty is a return to base warranty. Faulty or defective pumps will need to be
inspected at the service centre or supplier before repair or replacement is issued.
Pumps found to be not covered under warranty will be assessed and quoted for
repair.
ONLY FOR EU COUNTRIES Do not dispose of electric tools together with household
waste material! In observance of European Directive 2002/96/EC on waste electrical
and electronic equipment and its implementation in accordance with national law,
electric tools that have reached the end of their life must be collected separately and
returned to an environmentally compatible recycling facility