Dover All-Flo PSG 72100-00 Owner's manual

IOM
INSTALLATION OPERATION
& MAINTENANCE
BATCH CONTROLLER
72100-00

ALF-14021-E-01 All-Flo2
TABLE OF
CONTENTS
SECTION 1 WARNINGS, DANGERS AND CAUTIONS 3
SECTION 2 PRINCIPLES OF OPERATION 4
SECTION 3 INSTALLATION 5
SECTION 4 BATCH SET UP 6
SECTION 5 SPECIFICATIONS 7

ALF-14021-E-01 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-14021-E-01 All-Flo4
SECTION 2
The 72100-00 controller works by adjusting the time interval between
the signals sent to the solenoid controlled AODD pump. These signals
dictate when the pump will discharge one of the fluid chambers of
the pump. This discharge of a single fluid chamber is referred to as a
“stroke”. The 72100-00 controller is engineered to provide speed control
of a solenoid-controlled pump that is linearly proportional to a 4-20 ma
signal. The signal can be set to have a speed range of 1 to 499 Strokes/
Minute.
You must use the appropriate pump solenoid when using a 72100-00
controller. The system requires 110 volts AC to power it and delivers 12
volts DC to the pump solenoid. The system can be operated using the
toggle switch on the cover of the unit or by connecting a “SPDT center-
off” switch (or a set of dry-contacts) remotely. The connections for
remote usage are a terminal strip, also on the circuit board. The system
uses Strokes/Minute units which are very useful in estimating fluid
delivery rates and permit linear calculations.
72100-00 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
PRINCIPLES OF OPERATION

ALF-14021-E-01 All-Flo5
SECTION 3
INSTALLATION
The 72100-00 controller requires 100 volts AC (220 volts AC is also available) to power and 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 is a dry and safe place. The enclosure is NEMA 4X, but All-
Flo advises to avoid hosing the unit. The unit always comes up in a 4-20 mode and is ready to run seconds after
power is applied.
72100-00 BATCH CONTROLLER
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. Just bring it full counterclockwise and
then back off until you have the desired contrast.
B. The Setup Keypad has the Set key in the center
and four keys with arrows around it. They are for
right, left, up and down. The right and left move
the cursor on the display accordingly and the
up and down change the values high- lighted by
the cursor accordingly. They are only used to set
the unit up. Once you have “dialed in” the unit,
you prob- ably won’t be using them and they are
inside the unit, out of harm’s way.
C. 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.
D. The 4-20 ma input gets hooked into the control
loop. You must observe the proper polarity for the
controller to work properly and to protect it from
damage. If you connect the 4-20 input to a current
source of greater magnitude you may damage the
A/D converter in the system so pay attention the
maximum current in the loop.
INTERNALS
E. The Switch terminal connects the control switch
to the system. If the Run terminal (blue wire) and
the Common terminal (black) are connected, the
system reads 4-20 ma. If the Jog (yellow) and
the Common (black) are connect- ed, the system
will run the pump at the average of the high and
low speeds programmed. Never connect all three
wires together; you won’t hurt anything, but you
will confuse the processor and the system won’t
function properly. You can disconnect the unit’s
switch and connect any dry contact set that can
function as a SPDT switch. So, relays, switches
and even PLCs are possible as control devices.
F. The 110 VAC input is the only way to power the
standard unit (220 VAC and 12 VDC versions
are available by specifying) Just 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.

ALF-14021-E-01 All-Flo6
SECTION 4
BATCH SET UP
1. Hit the Set button to enter Setup mode and then
adjust the values and move the cursor (using the
left and right arrow buttons) and raise or lower
the values (using the up and down arrow buttons)
until you have all the values where you want
them.
2. Hit the Set button again to get out of Setup mode.
3. The practice of using the 4-20 Signal to Stop
the Pump should Be set Using 4ma as “off” By
default and 5ma as the slowest Speed or 20ma
as “off” in the reverse setup. Putting a zero as a
speed can sometimes create math problems for
the processor.
4. The System is now ready to Run (or Jog).
5. The sensor supplying the loop current, the 72100-
00 unit, the pump, and even the fluid (“heads” And
viscosity) and the air supply to the pump all have
tolerances on their performance. The exact flows
will need to be dialed in.
6. To run the system, flip the switch to the right. The
display will tell you the loop current and the pump
speed.
7. To run the pump, to purge it, prime it, or simply
to pump a little product; flip the switch to the left.
The unit will display the pump speed which is the
average of the setup high and low speeds.
NOTE: DO NOT USE ZERO AS A SPEED & ALWAYS
OBSERVE SIGNAL POLARITY & CURRENT LIMITS
72100-00 BATCH CONTROLLER
The pump manufacturer supplies information about
the delivery of fluid per pump stroke (emptying of one
chamber), but factors like inlet and outlet head, inlet
air pressure and flow delivery, viscosity and cavitation
all effect the volumetric flow. Dividing the desired
flow rate by the displacement per stroke will provide
the estimated desired pump speed. Since there are
many factors that can change the displacement per
stroke, the exact speed will need to be dialed in.
CALCULATING VOLUMETRIC DELIVERY

ALF-14021-E-01 All-Flo7
SECTION 5
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 to 499 Strokes/Minute
Three separate, plus a “Constant Run” preset
72100-00 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-14021-E-01