Advantage Controls MicroTron A Series User manual
1
Manual
MicroTron
Series A
Chemical Metering Pump
Installation
Maintenance
Repair
Manual
Advantage Controls
4700 Harold Abitz Dr.
Muskogee, OK 74403
Phone: 800-743-7431
Fax: 888-686-6212
www.advantagecontrols.com
2
Series A Pump
Instruction & Maintenance Manual
Table of Contents
Contents Page
I. Introduction ................................................................................3
Model Numbering.......................................................................3
II. Unpacking ..................................................................................4
III. Safety Considerations................................................................4
A. Chemical Compatibility .....................................................4
B. Safety Equipment and Preparation...................................4
IV. Installation..................................................................................4
A. Location ............................................................................4
B. Electrical ...........................................................................5
C. Plumbing...........................................................................5
V. Start-Up......................................................................................7
A. Front Panel Description ....................................................7
B. Run Mode Explanation .....................................................8
C. Set-Up Mode Explanation.................................................8
D. Password Protection.........................................................8
E. Priming the Pump .............................................................8
F. Adjusting Feed Rate .........................................................8
G. Stroke Length ...................................................................9
H. Calculating Output ............................................................9
VI. Control Options ..........................................................................9
A. Standard Control...............................................................9
B. 4-20mA Input Programming..............................................9
C. Selectable Timers .............................................................9
1. Recycle Timer Programming ...................................9
2. Pulse Timer Programming .....................................10
3. Biocide Pump Programming..................................10
VII. Set-Up Menus ..........................................................................10
VIII. Maintenance ............................................................................13
A. Diaphragm Replacement ................................................13
B. Suction and Discharge Check Valve Replacement ........13
C. Liquid End Diagram ........................................................14
D. Pump Replacement Parts...............................................15
IX. Trouble Shooting Guide ...........................................................16
X. Warranty and Factory Service Policies ....................................17
3
I. Introduction
This manual covers all facets of operation of the Advantage MicroTron™ pump, including unpacking,
mounting, electrical and plumbing connection, and start-up. Safety, maintenance and repair, warranty, and
factory information is also provided. Please read this manual completely before proceeding. Observe safety
protocols and heed all warnings and precautions.
Model Numbering
particular pump. Your pump may be supplied with one or more of the options described in this manual.
To determine what features apply to your pump, check the model number label located on the pump.
Model Number Example A 1 30 X 1 – K V C 1 - S
Pressure Rating
1 = 110 and 150 psi
2 = 250 psi
Gallon Per Day Rating
30 = 30 gallons per day at 110 psi
15 = 15 gallons per day at 150 psi
17 = 17 gallons per day at 250 psi
Control Options
X = Strokes per minute or hour (standard)
M = 4-20mA Input
T = Selectable Timers - Pulse, 28-Day, Recycle
Voltage
1 = 120 volt - 50/60 Hz - .35A with USA plug (standard)
2 = 240 volt - 50/60 Hz - .65A no plug
3 =
4 = 12 volt dc
Pump Head Material
K = Kynar
S = Stainless
Seat Material
V = Viton (standard)
F =
H = Hypalon
Check Ball
C = Ceramic (standard)
D = Ceramic/single on discharge (pressure relief)
S=Stainless
Tubing Connections
1 = 3/8” PE, 75-200 psi (standard)
2 = ¼” PE, 250 psi models (standard)
P = ¼” MNPT
V =
Special Options
E = External Stop
H =
S = 3-function injection valve
R = No stroke length adjustment knob
4
II. Unpacking
The MicroTron™ pump has been shipped as a complete package, ready for installation.
If the shipping carton shows any signs of damage, notify the shipping company immediately
upon receipt. Advantage Controls cannot be held responsible for damage from shipping.
Unpack the carton and insure the following items are present:
2. Suction, discharge and priming tubing 5. Instruction manual
3. Foot valve and weight
III. Safety Considerations
NOTE: All MicroTron™ pumps are primed with water before leaving the factory. If the
solution to be pumped is not compatible with water, disassemble the pump uid end before
use. After disassembly, thoroughly dry the pump head, valves, and seals before pump is
reassembled and used.
A. Chemical Compatibility
MicroTron™ metering pumps are designed to work with most liquid chemicals depending upon
your pump’s liquid end materials of construction. A chemical resistance chart is available for
compatibility questions, contact Advantage Controls service department at 1-800-743-7431.
B. Safety and Preparation
Always wear the proper protective clothing and gear when working around chemicals and
chemical metering pumps. Safety glasses, gloves, and aprons are critical in preventing accidental
exposure to dangerous chemicals. Liquids under pressure can present a special hazard when
a line or seal is punctured resulting in the spraying of chemical many yards away. If a chemical
the chemical being used.
IV. Installation
A. Location
Select a mounting location convenient to the chemical supply as well as a source of power
for the pump. Do not install the pump in a location where the ambient temperature exceeds
120 degrees F (50o
the pump. While the MicroTron™ pump is suitable for most outdoor installations, do not use
the standard poly tubing in direct sunlight. If you must mount pump in direct sunlight or under
Accessory item R00225 (plastic mounting bracket) is recommend for a secure installation.
5
B. Electrical
1. The Standard MicroTron™ pump has a voltage regulated internal power supply capable
of operating in the range of approximately 95 to 135 VAC. Use a supply voltage of 100 to
120 VAC for best results. The 3-wire grounded plug must be used in a 3-wire wall plug.
2. With a 240-volt option, the MicroTron™ pump has a voltage regulated internal power
supply capable of operating in the range of approximately 195 to 260 VAC. Use a
supply voltage of 210 to 250 VAC for best results.
CAUTION: Never remove ground wire from plug!
C. Plumbing
1. Tubing Connections
The MicroTron™ pump uses carefully matched components to achieve a predictable
unaltered. Do not attempt to reduce tubing size. All tubing connections should be
double checked to insure against leakage. If hazardous chemicals are being pumped, use
shielding around discharge tubing.
NOTE: When cutting lengths of tubing for your installation, ensure a clean, square
cut. Use short lengths of tubing and as few connections as possible.
2. Tubing Nuts
Do not use a wrench or pliers
Be
sure to observe applicable local plumbing codes.
WARNING: Clear exible tubing is not intended for pressurized use.
3. Tubing Connections
3/8"
1/4"
TUBING MUST SLIP OVER NIPPLE
1/4" TUBING
ADAPTER
IMPORTANT
THE END OF THE TUBING
MUST EXTEND 1/4" BEYOND ADAPTOR
6
4. Suction Lift vs Flooded Suction Applications
Suction Lift Installation
Mount the MicroTron™ pump around the top of the solution tank, not to exceed 5 feet
from pump to bottom of tank.
Flooded Suction
This installation is recommended for very low outputs, solutions that gasify and/or high
viscosity solutions. Priming is easier and loss of prime is reduced. Failure of the pump
diaphragm or rupture of the solution tubing can cause loss of solution in the tank.
Suction lift Flooded Suction Not recommended
5. Wall Mounting
The pump head must be kept in a vertical position for proper operation. The head can
be removed and rotated 90oif needed to keep the inlet and outlet valves in a vertical
position.
6. Foot valve installation
A weight is provided to hold the tubing and foot valve in a vertical position at the
bottom of the tank. Do not allow the foot valve to lay horizontally in the chemical
container. This defeats the action of the valve and causes the pump to lose prime.
Keep suction tubing reasonably short and avoid high spots or bends.
7. Injection valve installation
line. To work properly, this valve must be mounted within 45 degrees of vertical (see
drawing). One end of the injection valve is 1/2” MNPT. Install this end into the piping
head.
7
8. Optional Three Function Valve.
Anti-siphon feature allows metering of liquids “downhill” or into the suction side of a
circulating pump. It provides protection against an accidental application of suction
anti-siphon action.
Back pressure function permits metering into atmospheric discharge (open container)
without overpumping.
Line check
9. Priming / Degassing Valve Connection
Connect the clear poly tubing to the outlet of the bleed or priming valve. Position the
priming valve built into the head. Clear poly tubing should be connected to the outlet of
this valve, the other end of the tube should be placed in the chemical container above
V. Start-Up
A. Front Panel Description
80
20
30
40 50 60
70
90
100
PULSE POWER
Press ENTER to test
Press MENU to access settings
MENU
ENTER
80
20
30
40 50 60
70
90
100
POWER PULSE
Press ENTER to test
Press MENU to access settings
MENU
ENTER
All Model R pumps come with the following standard panel
features:
• 1x16-backlit LCD display
• Pulse or Stroke indicator light
• Up and Down arrow keys for setting
adjustments
• MENU key to enter and exit pump set-up
• ENTER key to save desired adjustments
NOTE: When installation is made into a
line with zero pressure or when
pumping into an open vessel, use the
optional three function injection valve
which provides back pressure and
anti-syphon capabilities.
8
B. Run Mode Explanation
The readout will display one of two modes, Run mode and Set-up mode. Run mode is
displayed only while the pump is in normal operation. The display will show the pump speed
setting.
Manual activation of the relay output and pump stroking can be activated by pressing the
ENTER key while the pump is in the run mode. This will manually activate both functions of
the unit for 3 minutes. After three minutes the unit goes back to automatic.
If the ENTER key is pressed during the 3-minute test, it will revert to automatic.
C. Set-Up Mode Explanation
To enter Set-up mode, press MENU. Notice that a cursor appears on the screen signifying that
keys until the desired setting appears, then press ENTER to advance. Continue pressing
ENTER to toggle past the other displays. When all settings are made, press MENU to return
to run mode, and save settings.
D. Password Protection
Option T allows for a built in four-digit password to prevent unauthorized changes.
Entering Setup Mode when a password has been set - Press Menu and enter the correct
four-digit password using the up and down arrow keys followed by Enter. Once the password has
been entered correctly the Setup Mode menus can be accessed. A code of 0000 disables the
password.
Set a new password by pressing the Menu key to enter the Setup Mode. Press ENTER until
the display shows “Password: 0000” then use the up and down keys followed by the ENTER
key to set each of the four digits to the desired value.
E. Priming the Pump
1. Settings
Plug in pump, set stroke knob to 100%.
2. Priming/Bleed valve
Do not over tighten bleed valve. Damage may occur.
3. To prime the Advantage A pump, simply press the ENTER key while the pump
is in Run mode. This allows the pump to stroke at the maximum STROKES/MIN
setting.
F. Adjusting Feed Rate
The A pump allows for an exact number of strokes to be set and read on the front panel
LCD meter. It is adjustable from 0 to 125 strokes per minute (0 to 160 for 55 GPD).
In addition, for applications requiring very low outputs the speed can be set in strokes per
hour from 1 to 125.
9
G. Stroke Length
The stroke length can be adjusted on all MicroTron™ pumps. This adjustment is a
mechanical adjustment made using the large knob on the control panel. To avoid damage to
the pump, this adjustment should only be made while the pump is running at a high stroking
rate.
Always start adjusting your pump’s output down by reducing the pump’s stroking speed or
frequency. By leaving the stroke length as long as possible you decrease any chance of
loosing prime.
H. Calculating Output
A pump’s output per minute can be determined by dividing the maximum rated gallons per
day by 1440 (minutes per day). For example, a 30 gallons per day (gpd) pump at a maximum
stroke length and speed setting of 125 strokes per minute (spm) will pump 0.000167 gallons
per stroke (gps).
30 ÷ 1440 = 0.0208 gpm ÷ 125 spm = 0.000167
With this value and the pump’s speed setting (strokes per minute) you can calculate your
pump’s output at it’s rated pressure. A 30 gpd pump set at 50 strokes per minute:
50spm x .000167gps x 1440 (minutes per day) = 12.02 gallons per day
Reducing the stroke length will reduce the pump’s output again. If the example pump above
had it’s stroke length reduced to 50% the 12.02 gallons per day output is reduced to 6.01.
(example: 12.02 gpd x 0.50 = 6.01 gpd)
A higher product viscosity will reduce the output. Pressures lower than the pump’s rating can
increase the output.
VI. Control Options
A. Standard Control (Basic A Pump) - See Menu Map on Page 10
Pumps continuously with speed and length adjustments.
B. 4-20mA Input (Option M) - See Menu Map on Page 12
Option M allows the pump to accept a 4-20mA signal input to control the pump’s stroking
rate or speed from an external control device. The pump can be programmed for number
of strokes per minute at two milli-amps points on a 4-20 scale. The maximum setting is 125
strokes per minute.
C. Selectable Timers
1. Recycle Timer - See Menu Map on Page 11
The recycle timer allows the pump to run based on set cycle times. The on time is adjustable
10
2. Pulse Timer and Flowmeter Input - See Menu Map on Page 11
Pulse timer allows the pump to run based on signals from an external dry contact switch closure.
Incoming pulse rate must not exceed 1,800 pulses per minute. There are four selections for a
pump with this option selectable on the MENU page EXT= which is short for external. Press
to select the desired external pulse function from the selections below. Press the ENTER key
to set the desired pulse function.
With screen showing Timer: MLTIPL BY the pump strokes based on multiplying each
incoming pulse by 1 to 9999. With the screen set for Timer: DIVIDE BY it strokes based
The pump will store strokes (a maximum of 65,000 divided by the set multiply factor) to be
made if contacts come in faster than the pumps stroking. If the stored number of strokes
exceeds the maximum any additional strokes are lost.
3. Biocide or Event Timer - See Menu Map on Page 11
Biocide or event timers allow the pump to feed chemical based on a 28-day timer for the daily,
weekly, or monthly addition of chemicals. The unit has four programmable timers labeled P1,
P2, P3, and P4.
VII. Set-Up Menus
10
hours and 59 minutes. Ex. An on time of 15 minutes and an off time of 15 minutes will cycle
the pump on 15 minutes and off 15 minutes repeatedly.
2. Pulse Timer and Flowmeter Input - See Menu Map on Page 11
Pulse timer allows the pump to run based on signals from an external dry contact switch
closure. There are four selections for a pump with this option selectable on the MENU page
EXT= which is short for external. Press to select the desired external pulse function from
the selections below. Press the ENTER key to set the desired pulse function.
With screen showing Timer: MLTIPL BY the pump strokes based on multiplying each
incoming pulse by 1to 9999. With the screen set for Timer: DIVIDE BY it strokes based
on dividing each in coming pulse. For example, if the pump is told to divide by five it will
count five incoming external pulses and then stroke one time.
The pump will store strokes (a maximum of 65,000 divided by the set multiply factor) to be
made if contacts come in faster than the pumps stroking. If the stored number of strokes
exceeds the maximum any additional strokes are lost.
3. Biocide or Event Timer - See Menu Map on Page 11
Biocide or event timers allow the pump to feed chemical based on a 28-day timer for the daily,
weekly, or monthly addition of chemicals. The unit has four programmable timers labeled P1,
P2, P3, and P4.
VII. Set-Up Menus
125 Strokes/Min
Reset Counter? N
Model Axxx
MENU MAP
Use the ARROW keys to change
options and the ENTER key to
continue to next menu item.
Software version 8.2.a
Prime ALM:020STR
Grayed out menu items are
available only when FloTracker
option is enabled.
FT: 003.33 ML/P
11
11
125 Strokes/Min
Set Clock? N
Reset Counter? N
Model AxxxT
MENU MAP
Timer: No Timer
New Pass: 0000
Use the ARROW keys to change
options and the ENTER key to
continue to next menu item.
Software version 8.1.h
FT: 003.33 ML/P
Grayed out menu items are
available only when FloTracker
option is enabled.
Prime ALM: 020STR
Other Timer Options
Timer: Pulse
WM: 00000 Gal/P
WM: Gals/Pulse
Timer Mode: VOL
Accum:000 Pulses
Tmr Mode: Timed
Accum:000 Pulses
On Time mm:ss
Reset Meter: No
Duration 0000 ML
Limit mm:ss
Timer: Mltipl by
Mltiply by: 0000
Timer: Divide by
Divide by: 0000
Timer: Recycle
On Time mm:ss
Duration 0000 ML
Off Time hh:mm
Timer: 28 Day
P1 All Days
P1 All Weeks
P1 Strt 12:00 pm
P1 Mode: Timed
P1 Length hh:mm
P1 Mode: Volume
P1 Length 000 mL
P1 Limit hh:mm
12
12
125 Strokes/Min
Length = 100%
Pressure = 150PSI
Reset Counter? N
Calibrate? No
Calibrate? Yes
60 Strks = 00.0mL
Model A Option M (4-20mA Input)
MENU MAP
4-20mA= ON
Low Input = 04
Hi Input = 20
04mA = OFF Str
20mA = 125 Str
Use the ARROW keys to change
options and the ENTER key to
continue to next menu item.
Prime ALM:020STR
FT:003.33 ML/P
Grayed outmenu items are
available only when FloTracker
option is enabled.
13
VIII. Maintenance
The Advantage MicroTron™ pump is designed for long service life with minimum maintenance.
If for any reason, maintenance is necessary or desireable, the MicroTron™ pump is easily
maintained.
Before any maintenance or service is performed, observe the following precautions:
1. Disconnect the MicroTron™ pump from power source.
2. Drain chemical from discharge tubing.
3. Disconnect discharge tubing from pump.
from chemical container.
5. Observe relevant safety protocols when handling parts which have been in contact with
hazardous chemicals.
A. Diaphragm Replacement
4. Unscrew the diaphragm from the pump shaft in a counter-clockwise direction.
Be careful that diaphragm support ring does not fall out.
5. Do not allow sharp or abrasive objects to come in contact with pump parts.
6. Inspect end of shaft to assure that threads are in good condition. Replace shaft bellows
if necessary. No further disassembly is recommended.
7. Screw new diaphragm onto pump shaft until it bottoms out on shoulder of shaft.
It is not necessary to tighten further.
9. Reconnect plumbing and power. Prime the pump.
B. Suction and Discharge Check Valve Replacement
1. Disconnect suction tubing from pump.
5. Remove check valve from suction side pump and replace.
9. Reconnect plumbing and power. Prime the pump.
NOTES: 1. Tighten pump head screws after pump’s initial week of operation.
2. When installing check valves, remember that the seats are always installed
at the bottom.
14
C. Liquid End Diagram
OR
2
OR
OR
5
14
8
9
10
4
3
OR
15
13
12
6
11
1
7
Item Description
1 Complete Head Kit
2 Injection Valve
3 Foot Valve
4 Suction Valve
5 Discharge Valve
6 Bleed Valve Assembly
7 Pump Head
8 Pump Diaphragm
9 Support Ring
10 Shaft Seal
11 Head Bolts
12 Priming Tube
13 Suction Tubing
14 Discharge Tubing
15 Weight
Complete Head Kit
includes items:
4,5,6,7,8, and 11
15
D. Replacement Parts
Getting the right materials of construction for your spare parts is easy. Using positions 7-10 of the
pump model number, example: A130X1-KFCV.Find the assembly needed and add the codes of
Part Assemblies
Item Description Part Number
1....................... Complete Head Assembly 110 psi....................................... CKR-1- __ __ __ __
......................... Complete Head Assembly 150 & 250 psi ............................... CKR-2- __ __ __ __
2....................... Injection Valve Assembly .............................................................. INJ- __ __ __ __
Optional ....... 3-Function Injection Valve............................................................ 3FV- __ __ __ __
3....................... Foot Valve Assembly .................................................................. FTV- __ __ __ __
4....................... Suction Valve Assembly.............................................................. SUC- __ __ __ __
5....................... Discharge Valve Assembly............................................................DIS- __ __ __ __
6....................... Priming Valve Assembly ...............................................................PRI- __ __ __ __
Body Seat Ball Connection
K- Kynar V- Viton C- Ceramic 1
S- 316 Stainless F D- Single 2
H- Hypalon S- Stainless 3
K
P
U
V
Single Parts
12...............Priming Tubing ....................................................................... R00255
13........................................................................ R00255
................... ............................................................. R00122
................... ............................................................ R00097
14............... ......................................................... R00122
................... ......................................................... R00267
15...............Weight, Suction Tubing ........................................................... R00139
16
IX. Trouble Shooting
PROBLEM CAUSE REMEDY
Pump does not achieve
or maintain prime
Air trapped in suction line
Foot valve contaminated or improperly
installed
Excessive lift
Worn or contaminated check valves
Split or pinch in suction tube
Low chemical level
Straighten suction line so as to eliminate
high spots.
Inspect foot valve screen and assure that
foot valve is in a vertical position below
Maximum suction lift is 5 feet with water or
heavier liquids such as acids. Mount pump
in a lower position relative to the chemical
container.
restriction. Conversely, if any leakage occurs,
pump will suck air and fail to prime.
Clean or replace as necessary.
Inspect suction tube through its full length
to assure that there are no splits at the
connections or other restrictions. Move
any objects or equipment which impinges
upon suction tube or reroute as required to
assure a smooth transition from foot valve
to pump.
Stroke adjustment set too low
Worn or contaminated check valves
Obstruction in suction line
Clogged foot valve screen
Output (system) pressure too high
Diaphragm worn or torn
Electronic failure
Check operation of stroke limiter knob.
If pump delivers too low adjustable rate,
check settings. Readjust as required.
Inspect, clean or replace as necessary.
Check suction line for obstructions, clogging,
kinks or pinch points.
Clean or replace foot valve screen.
Relocate the injector to a lower pressure part
of the the system.
Replace diaphragm, making sure that it is
screwed on fully to shoulder of shaft.
Consult dealer or factory.
17
Failure or lack of antisiphon valve
Excessive stroke rate
Improper stroke length
Inspect or add anti-siphon valve. This is
caused when system is in a vacuum condition
suction which feeds systems at very low
pressures.
Lower the stroke rate if adjustable on your
pump.
Reduce stroke length.
Pump will not pump System pressure too high
Diaphragm improperly installed
Check valves worn or clogged
Check system pressure to assure that it
is within system rated paramaters of the
pressure.
Make sure that diaphragm is screwed fully
unto shaft.
Clean or replace as required.
Pump will not run not
plugged in
Pump not turned on or not plugged in
Electronic failure
Check outlet with meter to assure that correct
or voltage is present and that power supply
cord is in good condition and plugged in.
Consult dealer or factory.
Excessive noise Pump not primed
No output pressure
Prime pump.
Add an anti-siphon valve to provide 25 PSI
restriction on pump discharge.
X. Manufacturer’s Product Warranty
Advantage Controls warrants units of its manufacture to be free of defects in material or
workmanship. Liability under this policy extends for 24 months from date of installation. Liability is limited
to repair or replacement of any failed equipment or part proven defective in material or workmanship upon
manufacturer’s examination. Removal and installation costs are not included under this warranty.
Manufacturer’s liability shall never exceed the selling price of equipment or part in question.
Advantage disclaims all liability for damage caused by its products by improper installation,
maintenance, use or attempts to operate products beyond their intended functionality, intentionally or
otherwise, or any unauthorized repair. Advantage is not responsible for damages, injuries or expense
incurred through the use of its products.
The above warranty is in lieu of other warranties, either expressed or implied. No agent of ours is
authorized to provide any warranty other than the above.
30 Day Billing Memo Policy
Advantage Controls maintains a unique factory exchange program to ensure uninterrupted service
with minimum downtime. If your unit malfunctions, call 1-800-743-7431, and provide our technician with
Model and Serial Number information. If we are unable to diagnose and solve your problem over the phone,
a fully warranted replacement unit will be shipped, usually within 48 hours, on a 30-Day Billing Memo.
This service requires a purchase order and the replacement unit is billed to your regular account for
payment. The replacement unit will be billed at current list price for that model less any applicable resale
discount. Upon return of your old unit, credit will be issued to your account if the unit is in warranty. If the unit
is out of warranty or the damage not covered, a partial credit will be applied based upon a prorated
replacement price schedule dependent on the age of the unit. Any exchange covers only the controller
or pump. Electrodes, liquid end components and other external accessories are not included.
18
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