Dover All-Flo PSG 72000-00 Owner's manual

IOM
INSTALLATION OPERATION
& MAINTENANCE
BATCH CONTROLLER
72000-00

ALF-14020-E-02 All-Flo2
TABLE OF
CONTENTS
SECTION 1 WARNINGS, DANGERS AND CAUTIONS 3
SECTION 2 PRINCIPLES OF OPERATION 4
SECTION 3 INSTALLATION 5-6
SECTION 4 BATCH SET UP 7
SECTION 5 SPECIFICATIONS 8

ALF-14020-E-02 All-Flo3
READ THESE WARNINGS AND SAFETY PRECAUTIONS PRIOR
TO INSTALLATION OR OPERATION. FAILURE TO COMPLY WITH
THESE INSTRUCTIONS COULD RESULT IN PERSONAL INJURY
AND OR PROPERTY DAMAGE. RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE.
WARNING Prior to servicing the pump and controller,
ensure that the air and fluid lines are closed and disconnected. While
wearing personal protective equipment, flush, drain and process liquid
from the pump in a safe manner.
WARNING When removing the end cap using compressed
air, the air valve end cap may come out with considerable force. Hand
protection such as a padded glove or rag should be used to capture
the end cap.
CAUTION Use caution when mounting the cycle counter in
areas where wash down occurs.
CAUTION For the speed controller, do not use zero as a
speed and always observe signal polarity and current limits.
CAUTION Disconnect all power sources before opening
control module.
This product can expose you to chemicals
including Nickel, Chromium, Cadmium, or Cobalt, which are known
to the State of California to cause cancer and/or birth defects or other
reproductive harm. For more information, go to www.P65Warnings.ca.gov.
CAUTIONS — READ FIRST!
WARNING
CAUTION
= Hazards or unsafe practices which
could result in severe personal injury,
death or substantial property damage
= Hazards or unsafe practices which
could result in minor personal injury,
product or property damage.
SECTION 1
WARNING

ALF-14020-E-02 All-Flo4
SECTION 2
PRINCIPLES OF OPERATION
The 72000-00 controller is engineered to provide control of the number
of times a solenoid pump fully discharges both liquid chambers, referred
to as a “cycle”, in a batching application. It also controls the speed that
the pump cycles, how many “Batches” are in an operation, and the
interval of time between batches. This allows for greater control and
repeatability of your All-Flo pump. The pump speed can be adjusted
using the buttons on the controller’s keyboard and preset batch
operations can be made to ensure a quick set up.
72000-00 BATCH CONTROLLER
All-Flo’s solenoid pumps use the compressed air to displace fluid in the
same way as a standard Air Operated Double Diaphragm (AODD) pump
while using electric pulses to control the pump speed. The use of a
solenoid pump allows the user to have more control over the operation.
The solenoid pump uses an electrical pulse to energize the solenoid
valve attached to the air end of the pump. These electronic pulses are
sent in the form of a square wave (Figure 1).
The energized pulses move the solenoid valve connecting the different
ports changing how the air flows. In Figures 2 and 3, port 1 denotes the
connection to the air supply, ports 2 and 4 denote the ports leading the
air chambers, and ports 3 and 5 denote the ports that are open to the
atmosphere.
While the solenoid is de-energized, the valve sits at its standard position,
allowing pressurized air from the air supply (port 1) into one of the
air chambers of the pump (port 2). The other air chamber (port 4) is
connected the exhaust (port 5), discharging any pressurized air in that
chamber.
When the pulse is received, the solenoid energizes and moves the valve
to its energized position (Figure 3).
While the solenoid is energized, the pressurized air from the air supply
(port 1) flows into the air chamber of the pump (port 4). The other air
chamber (port 2) is connected the exhaust (port 3), discharging any
pressurized air in that chamber.
This pulsating energized and de-energized states mimics the air flow
cycle cause by the pilot sleeve in the standard pump. The faster these
pulses are applied, the quicker the pump operates.
ALL-FLO’S SOLENOID CONTROLLED PUMPS
FIGURE 3
ENERGIZED
SOLENOID POSITION
FIGURE 2
DE-ENERGIZED
SOLENOID POSITION
FIGURE 1
SQUARE WAVE
Energized
De-energized

ALF-14020-E-02 All-Flo5
SECTION 3
INSTALLATION
The 72000-00 controller requires 100 volts AC (220 volts AC is also available) to power. It delivers 12 volts DC
to the pump. The appropriate 12-volt DC solenoid pump is needed to be used with this controller. This system
is programmed using the keypad on the cover and can be remotely paused or stopped using dry contact via a
Switch terminal on the circuit bord. This controller should be mounted close to pump in a dry and safe place.
The enclosure is NEMA 4X, but All-Flo advises to avoid hosing the unit.
72000-00 BATCH CONTROLLER
1. Selection Indicator: The LCD screen shows the
current batch or program you are running. This
will change based on which preprogrammed
batch is selected for your operation.
2. Speed: The LCD readout shows the time interval
between strokes. The stroke interval is shown
in strokes per seconds. The range for this cycle
counter is 0.1 to 3,600 Seconds/Stroke.
3. Run: This button will give the signal to the
solenoid on the pump to start the application you
have selected.
4. Batch: This button cycles through the preset
batch operations saved on the cycle counter.
Hitting this button should change the readout of
the LCD screen shown at point 1.
5. Constant: This button is used to set the pump to
run constantly. To achieve this, press this button
and then the run button shown as point 3.
6. Pause: This button will momentarily stop the
operation that is being run. This will not remove
the current count of the batch operation.
7. Set: This button is used to program the batch
operations that are to be saved on the cycle
counter. Hitting this button multiple times
will cycle through the batch’s programable
information like speed, duration, and time
between batches.
8. Stop: This button will stop the operation that is
being run. Hitting this button during the batch
process will not allow the batching process to be
continued from the point the stop button was hit.
The batch operation would need to start from the
beginning.
9. Up/Down: These buttons are used when setting
the preset batch information.
KEYPAD FUNCTIONS

ALF-14020-E-02 All-Flo6
SECTION 3
A. The Display control changes the contrast on
the LCD display. You will probably never touch
it unless the temperature around the unit is
unusually high or low. If there is no information
on the display, someone probably fiddled with the
control. Bring it full counterclockwise and then
back off until you have the desired contrast.
B. The Solenoid output provides 12 volts DC for
the pump’s integral solenoid. You must use the
correct pump solenoid for the pump to operate
properly.
C. The Switch terminal connects the control
switches to the system. You can remotely Run,
Pause and Stop the system by connecting
remote momentary dry contacts to the propriate
terminals.
D. The 110 VAC (also available in a 220 volt version)
input is the only way to power the unit. Make
sure the connections are neat and that for safety
reasons no conductor is exposed. This is the only
location on the circuit board where more than 12
volts is present.
INTERNALS

ALF-14020-E-02 All-Flo7
SECTION 4
BATCH SET UP
1. Enter the Batch you wish to program (Batch 1,
Batch 2 or Batch 3) by hitting the Set button (7)
to enter Setup mode and display the number of
Cycles per batch.
A PUMP STROKE IS ONE CHAMBER
A PUMP CYCLE IS BOTH CHAMBERS
2. Hit Set again and set the pump speed in Sec/
Stroke.
3. Hit the Set button again display the number of
batches in this program (zero makes the batch
run an infinite number of times).
4. Hit Set again to display the hours, minutes and
seconds between batches using the Set button
between each segment.
5. Lastly, hit the Set one more time to get out of the
programming mode.
6. To program the other batches, press the batch
button until the desired batch is displayed and
repeat the process.
7. To set the Constant speed, press the Set button
when the unit is displaying that it is in the
“Constant” mode.
8. Use the Up and Down buttons (9) to set the speed,
and then press the Set button (7) to escape the
programming mode.
9. To run the system when the batch mode is
selected, momentarily press the Run button (3).
To stop the pump, momentarily push the Stop
button (8).
10. To stop the unit but be able to pick up where you
left off, press the Pause button (6). You can then
press either the Pause (6) or Run (3) buttons to
start back up.
11. To run the pump constantly, first press the Const
button (5) to get into the proper mode and then
press the Run (3), Pause (6), and Stop (8) buttons
in the same way as the Batch mode.

ALF-14020-E-02 All-Flo8
5
SECTION
Dimensions:
Weight:
Enclosure Construction:
Power Consumption:
Voltage Requirement:
Voltage Output (to Solenoid):
Operating Temperature Range:
Speed Range:
Number of Batches:
SPECIFICATIONS
6-2/4˝ Height x 4-3/4˝ Width x 2-1/4˝ Depth
1-1/2 lbs
NEMA 4x with Sealing Gland for Cable and Boot for Switch
12 Watts
120VAC
12VDC 750ma Maximum (the pump’s solenoid must operate on 12VDC)
40°F to 100°F
0.1 to 3,600 Seconds/Strokes
Three separate, plus a “Constant Run” preset
72000-00 BATCH CONTROLLER

PSG®reserves the right to modify the information and illustrations contained in this document without prior notice. This is a non-contractual document.
PSG
22069 Van Buren Street
Grand Terrace, CA 92313-5651 USA
P: [phone] F: [phone]
all-o.com
All-Flo is committed to the pursuit of designing and manufacturing the
highest quality product available to industry. Since the beginning in
1986, All-Flo engineers have used their extensive knowledge of today’s
engineered materials, advanced air system logic and manufacturing
techniques to develop the superior group of lube-free, air-operated
diaphragm pumps found in this catalog. Every pump is performance
engineered and quality built to provide trouble-free service under the
toughest conditions.
Where Innovation Flows
ALF-14020-E-02