BWT Medo XB4 Series User manual

Installation and operating manual EN
Medo XB / 2016-08 / © BWT Wassertechnik GmbH/Printed in Germany
Medo® XB
Metering pumps
Types: XB 4, XB5
Changes reserved!

Table of contents
1 Identity code ................................................................................... 4
2 About this pump............................................................................... 6
3 Safety chapter................................................................................. 7
4 Storage, transport and unpacking................................................. 11
5 Overview of equipment and control elements............................... 13
5.1 Overview of equipment......................................................... 13
5.2 Control elements................................................................... 14
5.2.1 Pulse Control Switch.......................................................... 14
5.2.2 Stroke length adjustment knob........................................... 14
5.2.3 Multifunctional switch......................................................... 14
5.2.4 Functional and Fault Indicators.......................................... 15
5.2.5 "External control" terminal.................................................. 15
5.2.6 "Level Switch" terminal....................................................... 15
6 Functional Description................................................................... 16
6.1 Liquid End............................................................................. 16
6.2 Drive Unit.............................................................................. 16
6.3 Capacity................................................................................ 16
6.4 Self-Bleeding......................................................................... 16
6.5 Operating Modes .................................................................. 16
6.6 Functions............................................................................... 16
6.7 Relays................................................................................... 17
6.8 Hierarchy of Operating Modes, Functions and Fault Sta‐
tuses...................................................................................... 17
7 Electrical Installation...................................................................... 18
7.1 Supply Power Connection..................................................... 18
7.2 Description of the Terminals................................................. 18
7.2.1 "External Control" Terminal................................................ 18
7.2.2 "Level Switch" Terminal..................................................... 19
7.3 Relays................................................................................... 20
7.3.1 "Fault Indicating Relay" Output (Identity Code 1 + 3 or 4 +
5)........................................................................................ 20
7.3.2 Output for Other Relays (Identity Code 4 + 5)................... 21
8 Operation....................................................................................... 22
8.1 Manual.................................................................................. 22
8.1.1 Capacity............................................................................. 22
8.1.2 Functions............................................................................ 22
8.1.3 Extern Contact................................................................... 23
8.2 Remote Operation................................................................. 23
9 Troubleshooting............................................................................. 24
9.1 Faults without a fault alert..................................................... 24
9.2 Fault alerts............................................................................ 24
9.3 Warning Alerts....................................................................... 25
9.4 All Other Faults..................................................................... 25
10 Decommissioning.......................................................................... 26
11 Technical data............................................................................... 28
11.1 Performance data................................................................ 28
11.2 Accuracy............................................................................. 29
11.2.1 Standard Liquid End......................................................... 29
11.2.2 Self-Bleeding Liquid End.................................................. 30
11.3 Viscosity.............................................................................. 30
11.4 Material Data....................................................................... 30
11.5 Electrical data...................................................................... 31
Table of contents
2

11.6 Ambient Conditions............................................................. 31
11.6.1 Temperatures................................................................... 31
11.6.2 Climate............................................................................. 32
11.7 Protection class and Safety Requirements......................... 33
11.8 Sound Pressure Level......................................................... 33
11.9 Shipping weight................................................................... 33
12 Decontamination declaration......................................................... 34
Table of contents
3

1 Identity code
Product range Medo , Version b
XB4 Type Performance
bar l/h
1000 10 0.74
1601 16 1.10
1602 16 2.20
1604 16 3.60
0708 7 7.10
0413 4 12.30
0220 2 19.00
XB5
2504 25 2.90
1008 10 6.80
0713 7 11.00
0420 4 17.10
0232 2 32.00
Material of dosing head/valves
PP Polypropylene/PVDF. With the self-bleeding version (SEK): polypropylene/polypropylene
NP Clear acrylic/PVDF. With the self-bleeding version (SEK): Clear acrylic/PVC
PV PVDF/PVDF
TT PTFE/PTFE
SS Stainless steel 1.4404/1.4404
Material of seals/diaphragm
T PTFE/PTFE coated
E EPDM/PTFE coated, only for PP and NP self-bleeding (SEK)
B FPM-B/PTFE coated, only for PP and NP self-bleeding (SEK)
S Diaphragm additionally with FPM coating for media containing silicate
Dosing head version
0 without bleed valve, without valve spring only for TT, SS and type 0232
1 without bleed valve, with valve spring only for TT, SS and type 0232
2 with bleed valve, without valve spring only for PP, PV, NP not for type 0232
3 with bleed valve, with valve spring only for PP, PV, NP not for type 0232
4 version for higher-viscous media only for PVT, type 1604, 2504, 0708, 1008, 0413,
0713, 0220, 0420
9 self-bleeding (SEK) only for PP/NP, not for types 1000 and 0232
Hydraulic connector
0 Standard connection in line with technical data
5 Connector for 12/6 tube, discharge side only
9 Connector for 10/4 tube, discharge side only
Design
Identity code
4

Product range Medo , Version b
0 Standard
Logo
0 with BWT logo
Electrical connection
U 100-230 V ± 10 %, 50/60 Hz
Cable and plug
A 2 m European
B 2 m Swiss
C 2 m Australian
D 2 m USA
1 2 m open end
Relay
0 No relay
1 fault indicating relay (NC) (change-over relay)
3 fault indicating relay (NO) (change-over relay)
4 as 1 + pacing relay, (ONE each)
5 as 3 + pacing relay, (ONE each)
Accessories
0 No accessories
1 with foot and injection valve, 2 m PVC suction
line, 5 m metering line
Control type
0 no lock
1 with lock: manual operation locked when
external cable plugged in
Control versions
0 Standard
Options
00 no options
Identity code
5

2 About this pump
This solenoid metering pump is equipped with all adjustment and activa‐
tion functions for modern water treatment and the dosing of chemicals. It
has pulse step-up and pulse step-down compared with the preceding
model. This enables it to adapt more precisely to external signal genera‐
tors. The result is the simpler and more precise adjustment of chemical
consumption to the actual need. It also has a 10 percent increase in effi‐
ciency and energy efficiency over the preceding model. The Medo can be
simply adjusted during operation.
Properties of the device
About this pump
6

3 Safety chapter
The following signal words are used in these operating instructions to
identify different severities of a hazard:
Signal word Meaning
WARNING Denotes a possibly hazardous sit‐
uation. If this is disregarded, you
are in a life-threatening situation
and this can result in serious inju‐
ries.
CAUTION Denotes a possibly hazardous sit‐
uation. If this is disregarded, it
could result in slight or minor inju‐
ries or material damage.
The following warning signs are used in these operating instructions to
denote different types of danger:
Warning sign Type of danger
Warning of a dangerous area
Warning of dangerous electrical voltages.
Warning of unexpected startup.
nThe pump may only be used to meter liquid metering chemicals.
nThe pump may only be started up after it has been correctly installed
and commissioned in accordance with the technical data and specifi‐
cations contained in the operating instructions.
nObserve the general limitations with regard to viscosity limits, chem‐
ical resistance and density - see also BWT resistance list (In the
product equipment catalogue or at www.bwt.de )!
nAny other uses or modifications are prohibited.
nThe pump is not intended for the metering of gaseous media or solids.
nThe pump is not intended for the metering of combustible media
without suitable protective equipment.
nThe pump is not intended to meter explosive media.
nThe pump is not intended to meter radioactive media.
nThe pump is not intended for exterior applications without use of suit‐
able protective equipment.
Explanation of the safety information
Warning signs denoting different types of
danger
Correct and proper use
Safety chapter
7

nThe pump should only be operated by trained and authorised per‐
sonnel, see the following "Qualifications" table.
nYou are obliged to observe the information contained in the operating
instructions at the different phases of the device's service life.
WARNING!
Warning about personal and material damage
The pump can start to pump, as soon as it is connected to
the mains voltage.
– Install an emergency cut-off switch in the pump power
supply line or integrate the pump in the emergency cut-
off management of the system.
WARNING!
Risk of electric shock
A mains voltage may exist inside the pump housing.
– If a knock-out opening has been knocked-out, (for a
relay or module), then the pump must only be operated
with the knock-out opening closed.
– If the pump housing has been damaged, you must dis‐
connect it from the mains immediately. It may only be
returned to service after an authorised repair.
WARNING!
Fire danger
Combustible media may only be transported using stainless
steel dosing heads. In exceptional cases where this is not
possible, PTFE with carbon can be used, whereby our TT_
versions are manufactured from this conducting plastic.
Here, the operator is urged to take special care due to the
low mechanical strength.
WARNING!
Warning of hazardous or unknown feed chemical
Should a hazardous or unknown feed chemical be used, it
may escape from the hydraulic components when working
on the pump.
– Take appropriate protective measures before working on
the pump (protective eyewear, protective gloves, ...).
Read the safety data sheet on the feed chemical.
– Drain and flush the liquid end before working on the
pump.
CAUTION!
Warning of feed chemical spraying around
Feed chemical can spray out of the hydraulic components if
they are manipulated or opened due to pressure in the liquid
end and adjacent parts of the system.
– Disconnect the pump from the mains power supply and
ensure that it cannot be switched on again by unauthor‐
ised persons.
– Depressurise the system before commencing any work
on hydraulic parts.
Safety notes
Safety chapter
8

CAUTION!
Warning of feed chemical spraying around
An unsuitable feed chemical can damage the parts of the
pump contacted by the chemical.
– Take into account the resistance of the material con‐
tacted by the chemical when selecting the feed chem‐
ical.
CAUTION!
Warning of feed chemical spraying around
The metering pump can generate a multiple of its rated pres‐
sure. If a discharge line is blocked, hydraulic parts may burst.
– Correctly install a back pressure valve in the discharge
line behind the metering pump.
CAUTION!
Danger of personnel injury and material damage
The use of untested third party parts can result in personnel
injuries and material damage.
– Only fit parts to metering pumps, which have been
tested and recommended by BWT.
CAUTION!
Danger from incorrectly operated or inadequately maintained
pumps
Danger can arise from a poorly accessible pump due to
incorrect operation and poor maintenance.
– Ensure that the pump is accessible at all times.
– Adhere to the maintenance intervals.
NOTICE!
Danger from incorrect dosing
Should a different liquid end size be fitted, this will change
the dosing behaviour of the pump.
– Have the pump reprogrammed in the works.
NOTICE!
Warning of illegal operation
Observe the regulations that apply where the device is
installed.
In an emergency either press the customer installed emergency-off switch
or disconnect the pump according to the emergency-off management of
your system!
If feed chemical escapes, also depressurise the hydraulic system around
the pump. Observe the safety data sheet for the feed chemical.
Information in the event of an emergency
Safety chapter
9

Activity Qualification level
Storage, transport, unpacking Instructed personnel
Installation, installation of hydraulic
system
Technical personnel
Electrical installation Electrician
operation Instructed personnel
Maintenance, repair Technical personnel
Decommissioning, disposal Technical personnel
Troubleshooting Technical personnel, electrician,
instructed personnel
Electrician
Electricians are deemed to be people, who are able to complete work on
electrical systems and recognise and avoid possible hazards independ‐
ently based on his/her technical training and experience, as well as knowl‐
edge of pertinent standards and regulations.
Electricians should be specifically trained for the working environment in
which the are employed and know the relevant standards and regulations.
Electricians must comply with the provisions of the applicable statutory
directives on accident prevention.
Instructed personnel
The instructed personnel have been instructed by the operator in a training
session about the tasks allocated to them and potential hazards with incor‐
rect and improper conduct.
Technical personnel
Technical personnel are deemed to be people, who are able to complete
the tasks allocated to them and recognise and avoid hazards independ‐
ently based on his/her technical training and experience, as well as knowl‐
edge of pertinent regulations.
The sound pressure level is < 70 dB (A)
at a maximum stroke length, maximum stroke rate, maximum back pres‐
sure (water) according to:
DIN EN ISO 3743-1
Qualification of personnel
Sound pressure level
Safety chapter
10

4 Storage, transport and unpacking
WARNING!
The transporting of pumps which have been used with radio‐
active feed chemicals is forbidden!
They will also not be accepted by BWT!
WARNING!
Only return metering pumps for repair in a cleaned state and
with a flushed liquid end - refer to the section on decommis‐
sioning! Should safety precautions nevertheless be neces‐
sary, in spite of carefully emptying and cleaning the pump,
the requisite information must be completed in the Declara‐
tion of Decontamination Form!
The Decontamination Declaration constitutes an integral part
of an inspection / repair order. A unit can only be inspected
or repaired when a Declaration of Decontamination Form is
submitted that has been completed correctly and in full by an
authorised and qualified person on behalf of the pump oper‐
ator.
The "Decontamination Declaration Form" can be found in the
Appendix.
NOTICE!
Danger of material damage
The device can be damaged by incorrect or improper storage
or transportation!
– The device should only be stored or transported in a well
packaged state - preferably in its original packaging.
– The packaged unit should also only be stored or trans‐
ported in accordance with the stipulated storage condi‐
tions.
– The packaged unit should be protected from moisture
and the ingress of chemicals.
Personnel: nTechnical personnel
Data Value Unit
Minimum storage and transport tempera‐
ture
-20 °C
Maximum storage and transport tempera‐
ture
+60 °C
Maximum air humidity * 95 % rel.
humidity
* non-condensing
Safety notes
Ambient conditions
Storage, transport and unpacking
11

Compare the delivery note with the scope of supply:
nMetering pump with mains power cable
nConnector kit for tube/pipe connection
nProduct-specific operating instructions with EC Declaration of Con‐
formity
nOptional accessories if ordered
Scope of supply
Storage, transport and unpacking
12

5 Overview of equipment and control elements
5.1 Overview of equipment
1 2 3
P_BE_0013_BWT
Fig. 1: Complete overview
1 Control unit
2 Drive unit
3 Liquid end
a
b
c
d
e
f
P_BE_0008_SW
Fig. 2: Overview of liquid end (PV)
a Discharge valve
b Backplate
g Dosing head
d Bleed valve
e Bypass hose nozzle
f Suction valve
Overview of equipment and control elements
13

5.2 Control elements
1
2
3
4
5
7
8
9
6
P_BE_0011_BWT
Fig. 3
1 Pulse Control Switch
2 Stroke length adjustment knob
3 Fault indicator (red)
4 Warning indicator (yellow)
5 Operating indicator (green)
6 Multifunctional switch
7 "External control" terminal
8 Relay connection (optional)
9 "Level Switch" terminal
5.2.1 Pulse Control Switch
In Extern Contact operating mode via the pulse control switch a single
contact (at the "external control" terminal) can be used to trigger a series
of strokes or to support an incoming series of contacts.
5.2.2 Stroke length adjustment knob
The stroke length adjustment knob can be used to adjust the stroke
length.
5.2.3 Multifunctional switch
The multifunctional switch can be used to set the following functions, oper‐
ating modes and stroke rate.
The operating modes that can be set are:
nTest (priming function)
nStop
nExtern (Contact)
nManual (setting stroke rate in 10 % increments)
Overview of equipment and control elements
14

5.2.4 Functional and Fault Indicators
The fault indicator lights up if the liquid level in the chemical feed container
falls below the second switching point of the level switch (20 mm residual
filling level in the chemical feed container).
This LED flashes in the event of an undefined operating mode.
The warning indicator lights up if the fluid level in the chemical feed con‐
tainer falls below the first switching point of the level switch.
The operating indicator lights up if the pump is ready for operation and
there are no fault or warning alerts. It goes out quickly as soon as the
pump has performed a stroke.
5.2.5 "External control" terminal
The "external control" terminal is a five-pole panel terminal.
It enables the following functions and operating modes to be used:
nPause
nExternal contact
nAuxiliary frequency (external frequency changeover)
The two- and four-pole cables used to date can continue to
be used. The "Auxiliary frequency" function can, however,
only be used with a five-pole cable.
5.2.6 "Level Switch" terminal
A 2-stage level switch with pre-warning and end switch-off can be con‐
nected.
Fault indicator (red)
Warning indicator (yellow)
Operating indicator (green)
Overview of equipment and control elements
15

6 Functional Description
6.1 Liquid End
The dosing process is performed as follows: The diaphragm is pressed
into the dosing head; the pressure in the dosing head closes the suction
valve and the feed chemical flows through the discharge valve out of the
dosing head. The diaphragm is now drawn out of the dosing head; the dis‐
charge valve closes due to the negative pressure in the dosing head and
fresh feed chemical flows through the suction valve into the dosing head.
One cycle is completed.
6.2 Drive Unit
The diaphragm is driven by an electromagnet, which is controlled by an
electronic controller.
6.3 Capacity
The capacity is determined by the stroke length and the stroke rate.
The stroke length is adjusted by the stroke length adjustment knob within
a range of 0 ... 100 %. A stroke length of between 30 ... 100 % (SEK type:
50 ... 100 %) is recommended to achieve the specified reproducibility!
Data Value Unit
Recommended stroke length, standard
type
30 ... 100 %
Recommended stroke length, SEK type 50 ... 100 %
The stroke rate can be set within a range of 10 ... 100 % using the multi‐
functional switch.
6.4 Self-Bleeding
Self-bleeding liquid ends (SEK types) are capable of independent priming
when a discharge line is connected and diverting existent air pockets via a
bypass. During operation they are also capable of conveying away gases
which are produced, independently of the operating pressure in the
system. It is also possible to dose precisely in a depressurised state due
to the integral back pressure valve.
6.5 Operating Modes
The operating modes are selected by means of the multifunctional switch.
As soon as the stroke rate has been set by the multifunctional switch, the
pump finds itself in "Manual" operating mode. 100 % corresponds to 180
strokes/min.
The "Extern" operating mode is described below in the "Operation"
chapter.
6.6 Functions
The functions are described below in the "Operation" chapter.
"Manual" operating mode
"Extern" operating mode:
Functional Description
16

6.7 Relays
The pump has two connector options.
The relay can close a connected power circuit, in the event of for an alarm
buzzer, in the event of fault or warning indicating alerts, such as a level
warning.
The relay can be retrofitted through a knock-out opening in the pump foot -
refer to Retrofitting Relays and Ordering Information in the Appendix.
This combined relay can generate a contact with each stroke from its
pacing relay in addition to its function as a fault indicating relay.
The relay can be retrofitted through a knock-out opening in the pump foot -
refer to Retrofitting Relays and Ordering Information in the Appendix.
6.8 Hierarchy of Operating Modes, Functions and Fault Statuses
The different operating modes, functions and fault statuses have a dif‐
ferent effect on if and how the pump reacts.
The following list shows the order:
1. - Test (priming)
2. - Fault, Stop, Pause
3. - Auxiliary frequency (external frequency changeover)
4. - Manual, Extern Contact
Comments:
re 1 - "Priming" can take place in any mode of the pump (providing it is
functioning).
re 2 - "Fault", "Stop" und "Pause" stop everything apart from "Priming".
re 3 - The stroke rate of "Auxiliary frequency" always has priority over the
stroke rate specified by an operating mode in 4.
Fault indicating relay option
Fault indicating and pacing relay option
Functional Description
17

7 Electrical Installation
WARNING!
Risk of electric shock
There may be live voltage in the inside of the pump.
– Disconnect the mains cable on the pump from the mains
power supply before working on it.
WARNING!
Risk of electric shock
This pump is supplied with a grounding conductor and a
grounding-type attachment plug.
– To reduce the risk of electric shock, ensure that it is con‐
nected only to a proper grounding-type receptacle.
NOTICE!
Material damage possible by power surges
Should the pump be connected to the mains power supply in
parallel to inductive consumers (such as solenoid valves,
motors), inductive power surges can damage the controller
when it is switched off.
– Provide proprietary contacts for the pumps and supply
with voltage via an auxiliary contactor or relay.
Personnel: nElectrician
Install the pump technically correctly and in accordance with the
operating instructions and applicable regulations.
7.1 Supply Power Connection
Connect the pump to the mains power supply using the mains cable.
Should the pump be connected to the mains in parallel to inductive con‐
sumers (e.g. solenoid valves, motor), the pump must be electrically iso‐
lated when these consumers are switched off.
nSupply the pumps with voltage via an auxiliary contactor or relay with
proprietary contacts for the pump.
nShould this not be possible then a varistor (part no. 710912) or an RC
gate, 0.22 µF / 220 Ω (part no. 710802) should be connected in par‐
allel.
7.2 Description of the Terminals
7.2.1 "External Control" Terminal
The "external control" terminal is a five-pole panel terminal. It is compatible
with two- and four-pole cables.
The "Auxiliary Frequency" function can only be used with a five-pole cable.
Parallel connection to inductive con‐
sumers
Electrical Installation
18

Electrical interface for pin 1 "Pause" - pin 2 "Extern Contact" - pin 5 "Auxil‐
iary frequency"
Data Value Unit
Voltage with open contacts 5 V
Input resistance 10 kΩ
Max. pulse frequency 25 pulse/s
Minimum pulse duration 20 ms
Activation via:
nzero volt connection contact (load: 0.5 mA at 5 V) or
nsemi-conductor switch (residual voltage < 0.7 V)
Pin Function 5-wire cable 2-wire cable
1 Pause brown bridged at pin 4
2 Extern Contact white brown
3 - blue -
4 Ground mass black white
5 Auxiliary Fre‐
quency
grey -
Refer to the Description of Functions for the hierarchy of
functions and operation modes.
The pump does not work if:
nthe cable is connected and pin 1 and pin 4 are open.
The pump works if:
nthe cable is connected and pin 1 and pin 4 are connected.
nno cable is connected.
The pump performs one or more strokes if:
nPin 2 and pin 4 are connected to each other for at least 20 ms. Pin 1
and pin 4 then also have to be connected to each other.
The pump works at a preset stroke rate if:
nPin 5 and pin 4 are connected to each other. Pin 1 and pin 4 then also
have to be connected to each other. The auxiliary frequency is fac‐
tory-preset to maximum stroke rate.
7.2.2 "Level Switch" Terminal
A 2-stage level switch with pre-warning and end switch-off can be con‐
nected.
1
54
2
3
P_BE_0014_SW
Fig. 4: Assignment on the pump
2
45
1
3
P_BE_0015_SW
Fig. 5: Assignment on the cable
"Pause" function
"Extern Contact" operating mode
"Auxiliary frequency" operating mode:
Electrical Installation
19

Electrical interface
Data Value Unit
Voltage with open contacts 5 V
Input resistance 10 kΩ
Activation via
nzero volt connection contact (load: 0.5 mA at 5 V) or
nsemi-conductor switch (residual voltage < 0.7 V)
Pin Function 3-wire cable
1 Ground mass black
2 Minimum pre-warning blue
3 Minimum end switch-
off
brown
7.3 Relays
7.3.1 "Fault Indicating Relay" Output (Identity Code 1 + 3 or 4 + 5)
A fault indicating relay can be ordered as an option - refer to Ordering
Information in the Appendix. It is used to emit a signal when there is a fault
with the pump and with "Liquid level low, stage 1" warning alert and
"Liquid level low stage 2" fault alert.
A cut-off relay works when there are fault alerts from the pump and in the
event of the "Liquid level low stage 2" fault alert.
The fault indicating relay can be retrofitted and is operational once
attached to the relay board - refer to "Retrofitting Relays" in the Appendix.
Electrical interface
Data Value Unit
Maximum contact load at 230 V and 50/60
Hz:
8 A
Minimum mechanical lifespan: 200 000 Switching
cycles
To pin VDE cable Contact CSA cable
1 white NO (normally open) white
2 green NC (normally closed) red
4 brown C (common) black
3
21
P_BE_0016_SW
Fig. 6: Assignment on the pump
3
12
P_BE_0017_SW
Fig. 7: Assignment on the cable
2
3
1
4
P_BE_0019_SW
Fig. 8: Assignment on the pump
Identity code 1 + 3
Electrical Installation
20