Blue-White FLEXFLO A1 Series User manual

Peristaltic Metering Pump
®
www.blue-white.com
[email protected]
[email protected]
Series A1

Page 2 ®
FLEXFLO A1
1.0
Introduction
4
1.1 Available Models
4
2.0
Engineering Specifications
5
3.0
Materials of Construction
6
3.1 Wetted Components
6
3.2 Non-Wetted Components
6
4.0
Features
7
4.1 Agency Listings
7
5.0
Installation
8
5.1 Mounting Location
8
5.2 Wall Mounting
9
5.3 Installing Injection Fitting and Strainer
10
5.4 Programming FVS (Flow Verification Sensor)
10
6.0
Touchpad Layout
11
6.1 IO Connection
12
7.0
Programming 4-20mA Input
14
8.0
Power Connections
15
9.0
Output Adjustment
16
10.0
Tube Failure Detection (TFD+)
16
10.1 Confirming Chemical Detection
16
11.0
Pump Maintenance
17
11.1 Routine Inspection and Maintenance
17
11.2 Cleaning and Lubricating the Pump
17
12.0
Tube Replacement
18
12.1 Provided Tool
18
12.2 Tube Removal
18
12.3 Tube Installation
20
13.0
Firmware Update
22
14.0
Replacement Parts List
24
14.1 Exploded View
25
15.0
Accessories
26
16.0
Troubleshooting
28
17.0
Warranty
29
APPENDIX A: ACRONYMS
30
APPENDIX B: MODEL NUMBER MATRIX
31

READ THE OPERATING MANUAL PRIOR TO INSTALLATION AND USE.
Page 3
®
FLEXFLO A1

®
Congratulations on purchasing Blue-White’s FLEXFLO Series A1 peristaltic metering pump (a peristaltic meter-
ing pump is a type of positive displacement pump used for pumping a variety of fluids).
®
The FLEXFLO Series A1 peristaltic metering pump is pre-configured for the tubing that is shipped with it.
NOTE: It is recommended that the pump have a one-hour break-in period before calibrating the new tube.
NOTE: The tubing has an identification number printed on the tube for easy re-ordering.
NOTE: The pump was pressure-tested at the factory with clean water before it was shipped, so there may be
trace amounts of clean water in the pre-installed tube assembly. This is part of Blue-White’s stringent
quality assurance process.
1.1 Available Models
1.0 INTRODUCTION
Page 4 ®
FLEXFLO A1
NOTES:
*Data pertains to both “T” and “M” connection types for A1F and A1V Models
Tube Model
Feed Rate
Maximum Pressure
PSI (bar)
Maximum
Temperature
°F (°C)
GPH
LPH
A1-1*
0.001 - 1.09
0.002 - 4.13
65 (4.50)
130 (54)
A1-3*
0.003 - 5.60
0.011 - 21.2
50 (3.45)
130 (54)
A1-6*
0.001 - 1.35
0.003 - 5.14
100 (6.89)
185 (85)
A1-7*
0.002 - 4.17
0.008 - 15.8
50 (3.45)
185 (85)
A1-8*
0.002 - 3.09
0.006 - 11.7
50 (3.45)
130 (54)

2.0 ENGINEERING SPECIFICATIONS
1
Maximum Working Pressure (Excluding pump tubes)
100 PSI (6.89 bar)
Maximum Fluid Temperature
O O
185 F (85 C)
Maximum Viscosity
5000 centipoise
Maximum Suction Lift
30 ft. of water at sea level (14.7 atm psi)
Ambient Operating Temperature
O O O O
14 F to 125 F (-10 C to 52 C)
Ambient Storage Temperature
O O O O
-40 F to 158 F (-40 C to 70 C)
Operating Voltage
115V60Hz 1 PH (0.6A max.)
220V50Hz 1 PH (0.3A max.)
230V60Hz 1 PH (0.3A max.)
230V50Hz 1 PH (0.3A max.)
240V50Hz 1 PH (0.3A max.)
Power Cord Options
115V60Hz = NEMA 5/15 (USA)
230V60Hz = NEMA 6/15 (USA)
220V50Hz = CEE 7/VII (EU)
240V50Hz = AS 3112 (Australia/New Zealand)
230V50Hz = BS 1363/A (UK)
Motor
Brushless DC, 50W.
Duty Cycle
Continuous
Motor Speed Adjustment Range
2,000:1 (0.5% - 100%) Max rpm = 65 rpm
Enclosure
®
NEMA 4X (IP66), Valox (PBT) & PA12
Maximum Overall Dimensions
7.25” W x 9” H x 10” D (18.5 W x 22.9 H x 25.2 D cm)
Product Weight
6 lb. (2.7 Kg)
Approximate Shipping Weight
13 lb. (5.9 Kg)
Approximate Shipping Dimensions
10.5” W x 13.75” H x 11” D (26.7 W x 35 H x 28 D cm)
Page 5
®
FLEXFLO A1

3.0 MATERIALS OF CONSTRUCTION
3.1 Wetted Components
3.2 Non-Wetted Components
Pump Tube Assembly
Tubing
® ® ®
Flex-A-Prene , Flex-A-Thane , Flex-A-Chem
Adapter Fittings
PVDF
Injection / Back-Flow Check Valve
Body & Insert
PVDF
Check Ball
Ceramic
Spring
Hastelloy C-276
Ball Seat O-Ring
TFE/P
Static Seal O-Ring
FKM
Ancillary Items Provided
Suction Tubing
3/8” OD x 1/4” ID x 5’ Clear PVC
Discharge Tubing
3/8” OD x 1/4” ID x 5’ Polyethylene (LLDPE)
Suction Strainer
Polypropylene
Weight
Ceramic
Enclosure
®
Valox (PBT) & PA12
Pump Head
®
Valox (PBT)
Pump Head Cover
Polycarbonate
Permanently lubricated sealed motor shaft support ball
bearing.
Cover Screws
Stainless steel, polypropylene cap
Roller Assembly
Rotor
®
Valox (PBT)
Rollers
Nylon
Roller Bearings
Bronze
TFD System Sensor
Polysulfone (PES)
Power Cord
3 conductor, SJTW-A water-resistant
Tube Installation Tool
GF nylon
Mounting Brackets and Hardware
316 stainless steel screws
GF nylon bracket
Page 6 ®
FLEXFLO A1

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, Low Voltage Directive 2014/35/EU,
EN 60335-2-41, EMC Directive 2014/30/EU & EN 55014-1, EN 55014-2.
4.0 FEATURES
Symbol
Description
Warning (Risk of electric shock)
Caution (Refer to the user’s guide)
Ground, Protective Conductor Terminal
!
Page 7
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FLEXFLO A1
>Tube Failure Detection (TFD+) senses tube failure and shuts off the pump. No false triggering.
>Heavy duty display shield protects pump controls.
>Remote Start/Stop, which is one non-powered dry contact closure.
>Compatible with Blue-White’s output Flow Verification Sensor (FVS) system.
>Relay outputs include a single 250V/3A and a single solid state.
>Self-priming (even against maximum line pressure), which means no required bypass valves, and it cannot
vapor lock or lose prime.
>SCADA Inputs include: 4-20mA
4.1 Agency Listings
ENCLOSURE RATING
NEMA 4X Constructed for either indoor or outdoor use to provide a degree of protection to personnel against incidental
contact with enclosed equipment; to provide a degree of protection against falling dirt, rain, sleet, snow,
windblown dust, splashing water, and hose-directed water; and that will be undamaged by external formation
of ice on enclosure.
IP66 No ingress of dust; complete protection against contact. Water projected in powerful jets against enclosure
from any direction shall have no harmful effects.

5.0 INSTALLATION
Page 8 ®
FLEXFLO A1
5.1 Mounting Location
1. Choose an area located near the chemical supply tank, chemical injection point, and electrical supply. Also,
choose an area where the pump can be easily serviced.
2. Finding a secure surface and using the provided mounting hardware, mount the pump close to the injection
point. Keep the inlet (suction) and outlet (discharge) tubing as short as possible. Longer discharge tubing
increases back pressure at pump head.
NOTE: Mounting the pump lower than the chemical container will gravity-feed chemical into it. This “flooded
suction” installation will reduce output error due to increased suction lift. A shut-off valve, pinch-clamp, or
other means to halt gravity-feed to the pump must be installed during servicing.
NOTE: Install a back flow prevention check valve at the discharge side of the pump to prevent the system fluid
from flowing back through pump during tube replacement or during tube rupture.
NOTE: It is recommended to have a pressure relief valve at the discharge side of the of pump to prevent
premature wear and damage to the pump tube, in the event that the discharge line becomes blocked.
NOTE: The does not require back pressure. Keep the discharge pressure as low as possible to maximize pump
the tube life.
All diagrams are strictly for guideline purposes only. Always consult an expert before installing
metering pump on specialized systems. Metering pump should be serviced by qualified persons
only.
Always wear protective clothing, face shield, safety glasses and gloves when working on or near
your metering pump. Additional precautions should be taken depending on solution being
pumped. Refer to MSDS precautions from your solution supplier.
Risk of chemical overdose. Be certain pump does not overdose chemical during backwash and
periods of no flow in circulation system.
Be sure that installation does not constitute a cross connection with drinking water supply.
Check your local plumbing codes.
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.
The pump should be supplied by an isolating transformer or RCD (operating current less or
equal 30 mA).
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION

5.2 Wall Mounting
1. Using the provided #10 self-tapping screws, mount the bracket to a secure wall that is located where it can be
easily serviced.
#10 Self-Tap
(2 X)
4.50 in.
[11.43 cm]
Wall Mount Bracket (Side View) Mounted Pump (Front View)
2. Lower the pump so that the tab on the wall mount is inserted into the slot located on the back of the pump. The
pump will now be secured to the wall mount bracket.
Wall Mount Tab
Wall mount slot
Wall Mount (Side View) Mounted Pump
Page 9
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FLEXFLO A1

Pipe Tee
1/2” male NPT
1/4” male NPT
Weight,
Ceramic
Suction tubing, PVC
3/8" (0.95 cm) O.D. X
1/4” (0.64 cm) I.D.
Strainer,
Polypropylene
PVDF
Spring, Hastelloy C-276
Polypropylene
O-ring, TFE/P (optional EP)
Ball, Ceramic
O-ring, TFE/P (optional EP)
Polypropylene
Injection nose
may be trimmed
(removed) when
injecting into
small pipe.
Install upward
for best results.
5.3 Installing Injection Fitting and Strainer
Assemble the injection fitting and strainer per the figures below.
NOTE: Install upward for best results.
NOTE: The injection nose may be trimmed (removed) when injecting into a small pipe.
Proper eye and skin protection must be worn when installing and servicing the pump.
INJECTION FITTING AND STRAINER FOR 1/4” (0.64 CM) I.D. CONNECTION END MODELS
Discharge Injection Fitting / Check Valve
Suction Tubing and Strainer
CAUTION
!
5.4 Programming FVS (Flow Verification Sensor)
Directions
1
Confirm that pump is in the OFF position
2
Press and hold FVS button
3
Toggle up/down arrow until desired
trigger time is shown (seconds)
4
Press and hold FVS button to set
NOTE: Alarm Delay Time range 1-20 seconds
Page 10 ®
FLEXFLO A1
3
1
2

Page 11
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FLEXFLO A1
6.0 TOUCHPAD LAYOUT
Item Number
Item
1
LED/LCD Readout
2
Start & Stop Key
3
Lock-Out Key
4
Prime Key
5
Flow Verification Sensor (FVS) Key
6
Remote Start/Stop Key
7
Up Key
8
Rate Display Key
9
Down Key
10
Manual Speed Adjust
11
4-20mA
1
2
3
4
5
6
11
10
9
8
7
3
4
2
9
7
5
6
8
1

6.1 IO Connection
Risk of electric shock - All wiring must be insulated and rated 60V minimum.
WARNING
Page 12 ®
FLEXFLO A1
Pump (Right Side Panel)
Item Number
Item
1
USB-C Connector
2
M12 Input Connector 1 (Included with A1V ONLY)
3
M12 Input Connector 2
4
M12 Output Connector
2
4
3
M12 connectors not included with product.
Blue-White Industries requires any A-Type M12 connector with 5 position female sockets
1

Page 13
®
FLEXFLO A1
P4
P1
P2
P3
P5
PIN
Function
Specifications
Reference
P1
4-20mA Input (+)
120 Ohm Impedance, Non powered
loop
(+) Positive
P2
4-20mA Input (-)
120 Ohm Impedance, Non powered
loop
(-) Negative
P3
Not Used
P4
Not Used
P5
Not Used
PIN
Function
Specifications
Reference
P1
Remote Start / Stop
N.O. Dry Contact Closure
Open = Stop
Gnd = Run
P2
Ground
DC Ground
0 VDC
P3
FVS (+)
15 VDC @ 60 mA
To power FVS sensor
P4
FVS (-)
DC Ground (0 VDC)
FVS Ground Input
P5
FVS (Signal)
Input Signal
Input for FVS Signal
M12 Input Connector 1
M12 Input Connector 2
M12 Output Connector
PIN
Function
Specifications
P1
Motor On Out (+)
SS(+) Contact Out
Solid State
P2
Motor On Out (-)
SS(-) Contact Out
Solid State
P3
N.O.
Relay Out, N.O. Contact
3 Amp @ 250 VAC
P4
COM
Relay Out, COM Contact
P5
N.C.
Relay Out, N.C. Contact
6.2 M12 Connector
- Included with A1V ONLY

7.0 4-20mA Input
Proper eye and skin protection must be worn when installing and servicing the pump.
CAUTION
!
Directions
1
Confirm that pump is in the OFF position
2
Press 4-20mA Input button
1
7.1 Selecting 4-20mA input mode
Directions
1
Confirm that pump is in the OFF position.
2
Press and hold 4-20mA Input button.
3
MIN mA light will illuminate. Use arrow
keys to toggle min mA value for the pump
to operate at
4
Press 4-20mA Input button for MIN %
Speed light to illuminate
5
Use arrow keys to toggle MIN % Speed
value for the pump to operate.
6
Press 4-20mA Input button for MAX mA
light to illuminate.
7
Use arrow keys to toggle MAX mA value
for the pump to operate.
8
Press 4-20mA Input button for MAX %
Speed light to illuminate.
9
Use arrow keys to toggle MAX % Speed
value for the pump to operate.
10
Press and hold 4-20mA Input button to exit
programming mode.
13
7.2 Programming 4-20mA input mode
2
2
Page 14 ®
FLEXFLO A1

Page 15
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FLEXFLO A1
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.
>Use the voltage for which the power cord is rated.
>Do not strap together control (input/output) cables and power cables.
>When there is a power interruption, the pump, which has an auto-restart feature, will restore the pump to the
operating state it was in when the power was lost.
>POWER: 115V60Hz (0.6A max.), 220V50Hz (0.3A max.), 230V60Hz (0.3A max.), 230V50Hz (0.3A max.),
240V50Hz (0.3A max.)
NOTE: Contact a licensed electrician when there is doubt regarding the electrical installation.
Electrical connections and grounding (earthing) must conform to local wiring codes.
8.0 POWER CONNECTIONS
Ensure to connect the pump to the proper supply voltage. Using the incorrect voltage will damage
the pump and may result in injury. The voltage requirements is printed on the pump serial label.
WARNING
WARNING
WARNING

9.0 OUTPUT ADJUSTMENT
The speed of the pumping mechanism is adjustable from 0.5 to 100 % motor speed (0.03 RPM to 65 RPM).
10.0 TUBE FAILURE DETECTION (TFD+)
The pump is equipped with a Enhanced Tube Failure Detection (TFD+) system,
which is designed to stop the pump and provide an output alarm in the event
the pump tube should rupture, and a chemical enters the pump head.
This TFD+ system can detect the presence of many chemicals, including
sodium hypochlorite (chlorine), hydrochloric (muriatic) acid, sodium hydroxide,
oils based polymers, water based polyers, and many others. The system will
not be triggered by water (rain, condensation, etc.) or silicone oil (roller lubri-
cant).
NOTE: If the system has detected a chemical, the pump tube must be
replaced, and the pump head and roller assembly must be thoroughly
cleaned. Failure to clean the roller assembly will void the warranty.
NOTE: If the TFD+ alarm is triggered, the pump will stop, and close an alarm
output.
Fluid
Tubing failure
10.1 Confirming Chemical Detection
To determine if a chemical will be detected by the system:
1. Remove the pump head cover, and the pump tube and roller assembly.
2. Place a small amount of chemical in the bottom of the pump head that is enough to cover the sensors.
3. Reinstall only the pump head cover.
4. Turn on the pump by pressing the START button.
NOTE: If the TFD+ system detects a chemical, the pump will stop after a two-second confirmation period.
NOTE: If the TFD+ system does not detect a chemical, the pump will continue to operate after the
confirmation period.
5. Carefully clean the chemical out of the pump head. Ensure to remove all the chemical traces from the sensor
probes.
6. Reinstall the roller assembly and tubing.
7. Reinstall the pump head cover.
8. Press the START button to clear the alarm condition.
9. Restart the pump.
Page 16 ®
FLEXFLO A1

Page 17
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FLEXFLO A1
11.0 PUMP MAINTENANCE
Always wear protective clothing, face shield, safety glasses and gloves when working on or
near your metering pump. Additional precautions should be taken depending on the
solution being pumped. Refer to MSDS precautions from your solution supplier.
11.1 Routine Inspection and Maintenance
The pump requires minimal maintenance. However, the pump and all the accessories should be checked weekly,
especially when pumping chemicals. Inspect all the components for signs of leaking, swelling, cracking,
discoloration, or corrosion. Immediately replace worn out or damaged components.
Cracking, crazing, or discoloration during the first week of operation are signs of a severe chemical attack. If this
occurs, perform the following steps:
1. Immediately remove the chemical from the pump.
2. Determine which parts are being attacked.
3. Replace the damaged parts with parts that have been manufactured using more suitable materials.
4. After servicing, operate the pump to verify normal operation.
NOTE: The manufacturer does not assume responsibility for damage to a pump that has been caused by a
chemical attack.
11.2 Cleaning and Lubricating the Pump
> The pump will require occasional cleaning, and it will depend on the severity of service.
> When changing the pump tube assembly, the pump head chamber, the roller assembly, and the pump head
cover should be wiped of any dirt and debris.
> Clean the motor shaft with a clean towel, and then apply a small amount of grease to the shaft. This will help
prevent the rotor from sticking to the motor shaft.
> Periodically, or when necessary, grease the pump head cover bearing. Apply a small amount of grease
(Aeroshell aviation grease #5 or equivalent).
> 100% silicone lubrication may be used on the roller assembly.
> Periodically clean the injection fitting /check valve assembly, especially since injecting fluids, like sodium
hypochlorite, can calcify. These lime deposits and other buildups can clog the fitting, increase back pressure,
and interfere with the check valve operation.
> Periodically clean the suction strainer.
CAUTION
!

The pump tube assembly will eventually become non-operational if it is not regularly inspected and replaced. The
tube life is affected by many factors, such as the type of chemical being pumped, the amount of back pressure,
the motor revolutions per minute (RPM), and temperature.
Use extreme caution when replacing the pump tube. Do not place your fingers near the
rollers.
12.0 TUBE REPLACEMENT
Prior to service, pump clean water through the pump and suction / discharge line to remove
any chemical.
Always wear protective clothing, face shield, safety glasses and gloves when working on or
near your metering pump. Additional precautions should be taken depending on solution
being pumped. Refer to MSDS precautions from your solution supplier.
Use the provided Tube Installation Tool to leverage tubing into the pump head. Do not use
your fingers.
Safety first. Remove the pressure. Relieve (remove) the system pressure on the
discharge and suction side of the pump. Failure to do so will cause the solution to squirt
when disconnecting the tube connections.
12.2 Tube Removal
1. Disconnect the system plumbing from the pump tube
adapters.
2. Press the Start/Stop key to stop the pump.
3. Remove the three black thumb screws from the front of
the pump head cover by unscrewing counterclockwise.
Remove the pump head cover by pulling straight out.
12.1 Provided Tool
Tube Installation Tool
90002-278
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
Page 18 ®
FLEXFLO A1

6. Press the Start/Stop key to stop the pump.
Page 19
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FLEXFLO A1
4. Set the motor speed to 10%. Press the Start/Stop key to start the pump.
5. With the pump running, pull the inlet (suction) fitting out of the pump head. Guide the tube counterclockwise
away from the rollers. Pull the outlet (discharge)fitting out of the pump head.

3. Stretch the tube slightly and insert the outlet (discharge) fitting into the upper retaining slot of the pump head.
Pull the outlet fitting out of the pump head.
12.3 Tube Installation
Page 20 ®
FLEXFLO A1
NOTE: Thoroughly clean the pump head and rotor. The rotor can be removed by pulling it straight out. After
cleaning, push the rotor back on the shaft.
1. Set the motor speed to 10%. Press the Start/Stop key to start the pump.
2. Insert the inlet (suction) side of the pump tube fitting into the lower retaining slot of the pump head. Carefully
guide the pump tube into the pump head.