Ecolab MIKRO-MASTER 300 User manual

MIKRO-MASTER 300
INSTALLATION AND OPERATION MANUAL
18182/0307/0405 Copyright Ecolab Inc. 2005 9403-2067
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i
MIKRO-MASTER 300
INSTALLATION AND OPERATION MANUAL
Section 1.0 PREFACE............................................................................................................................. 1
Section 2.0 INTRODUCTION .................................................................................................................. 1
Section 3.0 SPECIFICATIONS ............................................................................................................... 2
3.1 Dimensions .............................................................................................................................. 2
3.2 Services Requirements ............................................................................................................ 2
3.3 Equipment Supplied ................................................................................................................. 2
3.4 Equipment Not Supplied .......................................................................................................... 2
Section 4.0 INSTALLATION PROCEDURES ......................................................................................... 3
Section 5.0 START-UP PROCEDURES ................................................................................................. 5
Section 6.0 TROUBLESHOOTING.......................................................................................................... 6
Section 7.0 REPLACEMENT PARTS ..................................................................................................... 7
TABLE OF CONTENTS

This manual has been written to present the basic installation
and operational characteristics of the Mikro-Master 300. This
manual applies, in its entirety, to current units.
Guidelines will be suggested in reference to the preferred
method of installation, however, the variety of equipment and
the surrounding physical environment will dictate the actual
installation of the
Mikro-Master 300.
WARNING - These installation and servicing in-
structions are for use by qualified personnel only.
The installation must be made in accordance with
local plumbing codes.
1.0 PREFACE 2.0 INTRODUCTION
1
The Mikro-Master 300 dispenser is a water driven meter,
proportioning sanitizer/lube system which offers ease of in-
stallation and accurate concentration control. The piston
pump injects product from the shipping container into a
mixing chamber which is connected in-line with the spray
outlets. The flow meter contains an impellar which provides
long life over a wide range of accuracies. The flow meter has
a straight reading is U.S. gallons. The dispensing system is
designed to provide positive metering and dispensing for
sanitizing and lube applications.
As liquid flows through the flow meter, a magnetic pick-up,
external to the flow stream, senses each rotation of the
lightweight, high speed rotor. These high speed pulses are
transmitted to the programmable divider mounted above the
flow meter. The programmable divider is preset to accumu-
late any number of these high speed rotor pulses (up to
9,999) for triggering to stroke the pump.
As flow continues, the programmable divider continues to
accumulate high speed pulses, and again triggers a stroke of
the pump as soon as the preset number is accumulated.
When the flow rate increases, pulse accumulation becomes
faster and the pump stroke frequency increases in proportion.
When flow stops, the pump stops.

3.0 SPECIFICATIONS
3.1 Dimension
• Height: 22" (55 cm)
• Length: 48" (121.9 cm)
• Width: 8" (20.3 cm)
3.2 Services Required
• Water Supply
Minimum - 10 psi (.69 bar)
Maximum - 90 psi (6.2 bar)
• Water Volume
Minimum - 1/2 gal./min. (1.89 liters/min.)
Maximum - 20 gal./min. (75.6 liters/min.)
• Equipment Water Temperature
Minimum - 32°F (0°C)
Maximum - 130°F (54.4°C)
• Electrical 120VAC, 50/60Hz, 1 AMP
3.3 Equipment Supplied
The Mikro-Master 300 dispenser is supplied with a backflow
preventer. This backflow preventer should be installed just
before the shut-off valve to the flow meter. The mixing cham-
ber is a water filter that is internally modified to allow maxi-
mum mixing of the water and the chemical before going to the
distribution system.
3.4 Equipment Not Supplied
Inlet and outlet shut-off valves are not supplied with the
installation kit. If a pressure regulator is necessary, it should
be installed at the inlet to the back flow preventer. A water filter
housing without cartridge, a mounting bracket and a stainless
steel water filter cartridge are available if needed. (See
optional installation items under Lube Systems in the Repair
Parts Manual.) This filter should be connected into the input
water supply line.
2
Installation Diagram
W
H
L

Figure 2
Figure 1
Figure 3
4.0 INSTALLATION PROCEDURES
WARNING - THESE INSTALLATION AND SERVICE IN-
STRUCTIONS ARE FOR USE BY QUALIFIED PERSONNEL
ONLY. THE INSTALLATION MUST BE IN ACCORDANCE
WITH THE LOCAL PLUMBING CODES.
1. Remove the water manifold assembly from the shipping
carton and mount on the wall immediately adjacent to the
water line using the screws and wall anchors provided,
refer to Figure1. Keep in mind that the flow meter manifold
assembly must be mounted horizontally. For the best
results, it should be mounted at the lowest horizontal point
in the pipeline.
NOTE - If the pipeline is not adjacent to a wall, remove
the base from the flow meter manifold assembly and
mount it directly into the pipeline. Insure that the pipe-
line is adequately supported for the extra weight of the
manifold assembly.
2. Install anti-siphon valve and shut-off valve (optional) up-
stream (inlet) of the flow meter manifold assembly,
refer to
Figure 2. Make sure that the orifice size of the valve is at
least as large as the nominal size of the flow meter. Plumb
the inlet, which is the inlet through the flow meter, on the
left-hand side of the manifold assembly
3. Locate an area on the wall that is convenient to both the
chemical injection point and the 120VAC/60Hz electrical
supply. Mount the pump shelf slightly below the level of
the flow meter pulser assembly so that the head of the
pump is below the injection point on the manifold assem-
bly mixing chamber (this is to keep air in the line from the
pump to the injection point to a minimum), refer to Figure
3. Mount the pump on a shelf using the stainless steel
mounting bar, nuts and washers provided. For conven-
ience, the pump can be mounted so the head is either to
the right or left of the injection point on the flow meter
manifold assembly.
4. Plug the cable connector from the programmable divider
into the receptacle located under the control panel of the
pump, refer to Figure 4.
3
MOUNTING
SCREWS
MIKRO-MASTER MANIFOLD
ASSEMBLY
BACKFLOW
PREVENTER
CLOSE
NIPPLE
NUT
WASHER
MOUNTING
BAR
PUMP
SHELF
MOUNTING
SCREWS
LMI
PUMP
OPTIONAL
SHUT-OFF
VALVE

Figure 4
Figure 5
Figure 6
NOTE - insure pump is mounted close enough to flow
meter manifold assembly for the length of cable con-
nector wire available from the programmable divider.
5. Using the drum probe, 1/2" (12.7mm) tubing and fittings
provided, plumb the drum probe to the bottom connector
on the pump head,
refer to Figure 5.
NOTE - For products that gas off, do not use the drum
probe. The tubing should be flexible and as short as
possible. The product drum must be placed directly
under the pump.
Using the 1/2" (12.7 mm) tube and hose clamp provided,
plumb the output port, which is the one on the top of the
anti-siphon valve on the pump, to the injection point on the
mixing chamber of the manifold assembly. Connect the
pump to 120VAC/60Hz electrical supply.
Connect 1/4" (6.4 mm) tubing, which is provided to the
tubing nut on the anti-siphon valve on the pump head, and
run it back to the drum or the drain. This is for pressure
relief during priming.
6. Place the pump switch in the INTERNAL position. As the
pump is running, set the stroke length knob at 60% (all
dosage ratio calculations are based on 60% stroke length),
refer to Figure 6.
Set the speed control switch on the pump at 100% and
with the pump switch in the internal position, grasp the
black and yellow knob on the pump anti-siphon valve and
pull outward on both until the product rises in the suction
tube and starts to come out the 1/4" (6.4 mm) bypass tube.
(Priming is best accomplished with the speed switch set
on 100%). The pump is now primed.
SET THE SELECTOR SWITCH ON THE PUMP TO THE
EXTERNAL POSITION.
4
PUMP CONTROL
PANEL
OUTPUT
TUBING
DRAIN
TUBING
DRUM PROBE
TUBING
ANTI-SIPHON
VALVE
INJECTION
POINT
YELLOW
KNOB
BLACK
KNOB
SPEED
CONTROL
PUMP
SWITCH
STROKE
LENGTH FROM
PRODUCT
TO DRAIN
PROGRAMMABLE
DIVIDER
PUMP TO
PROGRAMMABLE
DIVIDER
CONNECTION

6.0 START-UP PROCEDURES
5
Figure 7
ANTI-SIPHON
VALVE DIVIDER
NUMBERS
MIXING
CHAMBER
PRODUCT
TUBING
DRAIN
TUBING
PROGRAMMABLE
DIVIDER
FLOW METER
INLET VALVE
(OPTIONAL)
The dosage ratio is an amount of chemical solution to be
added or injected into an amount of water using the same unit
of measure. Dosage ratios are determined by setting the
divider number of the programmable divider.
1. To set the divider number, remove the clear window on the
divider. Set thumb wheel switches to divider number
determined on the chart located at the right. Divider num-
bers are precalculated for each sanitizer/lube listed and
could vary slightly up or down depending on external
conditions.
2. Turn on the water supply to the unit and open the input
valve (optional). When water flows through the flow meter,
the pump will start pumping, allowing solution to the spray
outlets.
IMPORTANT - THE PUMP SHOULD NOT BE ALLOWED
TO STROKE MORE THAN 80 STROKES PER MINUTE
AS DAMAGE TO THE PUMP WILL RESULT.
3. Check the dosage ratio. If the concentration is too high, set
the programmable divider number up slightly. If the con-
centration is too low, set the divider number down slightly.
DOSAGE DIVIDER NO.
PRODUCT RATIO SETTING
Mikro-Klene DF 1.00 oz. per 10 gal. 40
Bevro-Klene 1.00 oz. per 10 gal. 40
Bac-Flush 1.00 oz. per 52 gal. 117
K-San 1.00 oz. per 2 gal. 8
Mandate 1.00 oz. per 6 gal. 24
Ster-Bac 1.00 oz. per 4 gal. 16
P3 Oxonia Active 1.00 oz. per 3 gal. 10
Fas-Trac (1%) 1.28 oz. per 1 gal. 3
Fas-Trac (.5%) .64 oz. per 1 gal. 6
Klenz-Glide 1 (1%) 1.28 oz. per 1 gal. 3
Klenz-Glide 1 (.5%) .64 oz. per 1 gal. 6
Klenz-Glide 5 (1%) 1.28 oz. per 1 gal. 3
Klenz-Glide 5 (.5%) .64 oz. per 1 gal. 6
Klenz-Glide 10 (1%) 1.28 oz. per 1 gal. 3
Klenz-Glide 10 (.5%) .64 oz. per 1 gal. 6
Klenz-Glide 20 (1%) 1.28 oz. per 1 gal. 3
Klenz-Glide 20 (.5%) .64 oz. per 1 gal. 6
Klenz-Glide 30 (1%) 1.28 oz. per 1 gal. 3
Klenz-Glide 30 (.5%) .64 oz. per 1 gal. 6
Klenz-Glide PL (1%) 1.28 oz. per 1 gal. 3
Klenz-Glide PL (.5%) .64 oz. per 1 gal. 6
Lubri-Klenz (1%) 1.28 oz. per 1 gal. 3
Lubri-Klenz (.5%) .64 oz. per 1 gal. 6
Lubri-Klenz LF (1%) 1.28 oz. per 1 gal. 3
Lubri-Klenz LF (.5%) .64 oz. per 1 gal. 6
Replace clear window to activate programmable
divider.
IMPORTANT - THE DIVIDER WILL NOT OPERATE
UNLESS WINDOW IS IN PLACE.

PROBLEM
Mikro-Master 300 does not operate.
Pump does not stroke.
Pump strokes too fast (80 strokes per
minute is maximum to avoid damage
to the pump).
Pump will not prime or will not pump
product.
Pump will not pump against system
pressure.
7.0 TROUBLESHOOTING
CAUSE OR FAILURE MODE
No 120VAC power.
Internal - OFF - External switch on
pump in OFF position.
No water flow through the system.
Interconnecting cable between the flow
meter and the pump is disconnected or
loose.
Water flow through the system is less
than 1/2 gpm.
The programmable divider's plastic
window is not installed or is loose.
Internal - OFF - External switch on
pump in OFF position
Divider number on programmable
divider is set at a high dosage ratio.
Flow meter faulty.
Pump is faulty.
Interconnecting cable between the flow
meter and pump is disconnected or
loose.
Divider number of programmable
divider is set at a low dosage ratio
number.
Ceramic valve balls in pump head bad
or missing.
Teflon seal rings bad or missing.
Coupling nuts on pump leaking or
cracked.
Diaphragm is leaking or cracked.
Pressure release cap assembly or anti-
siphon cap assembly on anti-siphon
valve faulty or cracked.
Suction drum probe faulty.
Improper installation where system
pressure exceeds 70 psi (4.8 bar).
ACTION
Check power source to pump.
Place switch in External position.
Check and correct as necessary.
Check and correct as necessary.
Increase water flow through the
system to more than 1 gpm.
Install window or tighten mounting
screw as necessary.
Place switch in External position.
Set divider number down.
Replace sensor.
Replace pump.
Check and correct as necessary.
Set divider number up.
Replace faulty or missing balls from
spare parts kit.
Replace faulty or missing seal rings
from spare parts kit.
Replace leaking or cracked coupling
nuts from spare parts kit.
Replace leaking or cracked diaphragm
from spare parts kit.
Replace pressure release cap
assembly or anti-siphon cap assembly
from spare parts kit.
Replace suction drum probe.
Install pressure regulator to Mikro-
Master 300 system.
6

MIKRO-MASTERSECTION:
7
REPLACEMENT PARTS MIKRO-MASTER 300
5
8
10
11
12
13
18
SEE DETAIL
"B"
12
6
7
9
20
DETAIL B (MM-300 Conversion Kit)
3
22
4
SEE DETAIL
"A"
21
14
15
16
17
DETAIL A
21
26*
25
26*
25
12
12
12
12
12
12
13
13
13
13
13
1
1INCLUDED WITH KIT REF. NO. 19
2INCLUDED WITH KIT REF. NO. 23
3INCLUDED WITH KIT REF. NO. 24

REF.
NO. PART NO. DESCRIPTION
1 8524-1511 BACKFLOW PREVENTER 3/4 FPT
2 #8495-0179 WATER METER (INCLUDES REF.
NO. 3)
3 8480-5969 SENSOR ASM
4 8524-4044 CHECK VALVE 3/4" FPT DELRYN
5 8480-5951 PROGRAMMABLE DIVIDER
6 8730-1149 HOSE CLAMP, IDEAL 6207 SS
7 8578-5236 HOSE END ELBOW, 3/8ID X 1/4 MPT
POLYP
8 8603-3016 COUPLING, 1/4 304 SS
9 8524-3038 CHECK VALVE, 1/4MPT SS
10 9401-9072 MIXING CHAMBER
11 8730-1032 HOSE CLAMP, 11/16 TO 1-1/4 SS
12 8501-5774 PLASTIC TUBE, 7/8 ID PVC CLEAR
13 9403-7538 WALL MOUNT BASE
14 8842-0088 NUT 10-32 HEX MACHINE SCREW SS
15 8852-2602 LOCKWASHER #10 EXT SHK/PRF SS
16 9403-9294 BAR,PUMP HOLD DOWN
17 #8460-4495 METERING PUMP, LMI 721
18 9219-0214 PLASTIC TUBE, 1/4 OD X 10 FT. POLY-
FLO
19 18480-3717 SPARE PARTS KIT INCLUDES:
ANTI-SIPHON CAP ASM
PRESSURE RELIEF CAP
BALL, CERAMIC
SEAL RING, TEFLON
COUPLING NUT, POLYP
DIAPHRAGM
CLAMP RINGS SST
REF.
NO. PART NO. DESCRIPTION
20 9403-1077 MM-300 METER CONVERSION KIT
21 8480-7734 PUMP HEAD ONLY
22 8511-1706 NIPPLE, 3/4 X 7
23 28480-3857 4-FUNCTION VALVE KIT
24 38480-3840 SUCTION VALVE KIT
25 8480-3719 CLAMP RING 1/2 SST
*8480-3720 SEAL RING TEFLON
*8480-3721 SEAL RING HYPALON
•8531-0100 THUMB-TROL PLASTIC NOZZLE
•8310-9108 ADHESIVE BACK CABLE TIE
MOUNT
•8310-9041 CABLE TIE, 3/16 X 7-3/8 POLYP
•9403-2067 INSTALLATION AND OPERATION
MANUAL
•9403-1000 PRESSURE REGULATOR
W/ GAUGE (OPTIONAL)
# PARTS MUST BE RETURNED TO BELOIT
• ITEM NOT SHOWN
* USE HYPALON IN ALL APPLICATIONS EXCEPT POAA'S
AND MANDATE PLUS - THEN USE TEFLON
8
MIKRO-MASTERSECTION:
REPLACEMENT PARTS MIKRO-MASTER 300
26