Initiative Engineering edose MEGA User manual

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INITIATIVE FORMAT NO-IE/DD/15(1)
REV. DATE- 22.02.19
REV. NO.- O1
OPERATION ANDMAINTENANCE MANUAL
MEGA

• Backlit LCD Display
• User-friendly knob linked with digital display for adjusting dosing frequency with facility of password lock
• Built-in ARV with separate discharge point to prevent chemical spill on hands
• Diaphragm made of solid PTFE to ensure maximum life
• 4-20 Input (Optional)
• Level switch Interlock (Optional)
• IP 65 certified
Dosing rate 40Lph @ 3 Kg/Cm²
Suction/Discharge tubing 8/10 mm
Frequency Up to 120 spm
Electrical 230 (± 10)V AC, 50 Hz
• Metering pump
• Suction/discharge tubing (3 meter)
• Foot valve with strainer
• Injection valve (NRV)
NOTE: Available in PVDF for Sulfuric Acid
Scope of Supply
Installation (Dosing Pump)
Features
Specifications (Dosing Pump)
Scope of Supply

 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.
 Pump is to be protected from sun and rain. If outdoor installation is unavoidable, provide a canopy
over the pump. Pump should be acce5sible for routine maintenance and should not be subjected to
ambient temperature above 50° C
 Flooded suction-: The pump is mounted at the base level of the storage tank. This installation is most
trouble free and is recommended for low flow output and high viscosity solutions. Since suction
tubing is filled with solution, priming is accomplished quickly and chance of losing prime is reduced.
Suction lift-: When suction lift is less than 1.5 meter for solutions having a specific gravity of water.
For denser solutions consult factory.
The foot valve act as a check valve to keep the pump primed in suction lift applications,
 Thevalveisdesignedtosubmergeinthesolutiontankordrumandmustsitinaverticalposition at
the bottom. Position approximately 2 inches off the bottom if the tank or drum contains sediment.

Injection valve prevents back flow from the main line. When installing the injection valve, be
 sure to position it in vertical so that the valve enters the bottom of the pipe line.
Mount the pump on a tank/surface using mounting bracket and nut-bolts provided
Tighten the nut-bolts properly.
Do not install the pump under direct sun light.
Place the pump above the liquid to be dosed within maximum limit of 1.5meter suction lift.
The discharge point marked with arrow should be always faces upwards.
The suction nipple will be on the lower side with the suction tubing being immersed completely in
the dosing liquid.
 After cut ng an appropriate length of tubing, connect tubing to injection valve and then backto
the discharge side of the pump head.
Use the remaining tubing on the discharge side and connect the back injection
valve to the injection pipe into which dosing is to be done.
Connect the nozzle on the pump to the injection valve.
Plug the pump.
Install the pump in a dry environment and mount it on a tank/surface using the mounting brackets and
nut-bolts provided.
Place the pump above the liquid to be dosed within a maximum limit of 1.5 meter suction lift.
The discharge point (marked with arrow) should always be facing upward. The suction nipple will be on the
lower side with the suction tubing being immersed completely in solution.
Cut the suction tubing to the desired length and attach suction filter to it. Ensure that suction filter is
placed vertical and always immersed completely in solution.
Use the remaining tubing on the discharge side and connect the back pressure/injection valve to the injection pipe
into which dosing is to be done. Connect nozzle on pump to the injection valves.
Plug the pump into a 230 Volts AC electrical outlet
Installation (Dosing Pump)
Installation (Dosing Pump)

Switch on the mains power supply to the pump.
PresstheON/OFFkeytostartthepump.
Turnthefrequency knob fullyclockwiseso thatthedisplay shows099(Thisisthemaximumfrequencysettingofthe
pump).Make surealltheairisprimed outofthesystembyopeningthebleedvalveuntil liquidflows outina
continuous stream.Close bleed valve.
Pumpisnowinoperation.
Adjust the knob to the desired percentage frequency to achieve required dosing flow.
Note-
By pressing the button once, the strokes per minute (spm) value is displayed.
Pressing a second time displays the input voltage.
Press once again toshow the percentage dosing.
Startup
Typical mounting set up schematic

Dosing
LPH
40
Mechanical
Data
Turn Down Ratio
10:1
Maximum Dosing
Capacity
l/h
43
GPH
11.36
Minimum Dosing
Capacity
l/h
GPH
Maximum Operating
Pressure
Kg/cm²
3
PSI
43
Maximum Stroke
Frequency
strokes/min.
120
Stroke Volume
ml
5.6
Accuracy of
Repeatability
%
±2
Maximum Suction
Lift During
Operation
meter
1.5
Min. / Max. Liquid
Temperature
⁰C
5 to 50
Suction / Discharge
Tubing
mm
8/10
Electrical
Data
Voltage
V
230 ± 10%
Frequency
Hz
50-60
Length of Main
Cable
meter
2
Maximum Power
Consumption
W
Electric Safety Class
II
Enclosure Class
IP 65
Pollution Degree
3
Sound
Pressure
Maximum Sound
Pressure
dB
‹80
Technical Specifications

GA Drawing
1.
SUCTION VALVE
2.
DISCHARGE VALVE
3.
DOSING HEAD
4.
AIR RELEASE VALVE
5.
MOUNTIING BRACKET
6.
FREQUENCY KNOB
7.
PCB HOUSING

Edose Dosing Head Exploded View
Product Drawing

Part List
NRV BALLHOUSING
DOSING HEAD ‘O’ RING (O 76X3.5 VT)

Problem
Possible Causes
Trouble Shooting
Excessive Pump
Output
Syphoning
Little or no pressure at injection
point Excessive strokes per minute
Move injection point to a
pressurized point Make sure
injection check valve
installed properly Consult
factory
Pump will not
prime/loss priming
Pump not turned on or plugged in
No demand as per the set point.
Foot valve not in vertical position
in the tank. Pump suction lift is too
high Suction tubing is curved or
coiled inside the tank Air trap in
suction tubing
No solution in the tank/container
Airlock on suction side
Turn on the pump/plug in
Prime the pump in manual mode
Foot valve must be vertical
Maximum suction lift is 5 feet.
Suction tubing must be vertical
Untighten the air bleed valve, run
the pump till air trap is out then
tighten. Refill the container/tank
and re-prime Check tubing for
pinholes, cracks, replace if
necessary
Low output or
failure to pump
against pressure
Pump maximum pressure rating
exceeded by injection Worn seal
rings & balls Ruptured diaphragm
Tubing run on the discharge side
may be too long
Clogged foot valve strainer
Injection pressure cannot exceed
pump rated pressure Check &
replace Check & replace Longer
tubing may create frictional losses
sufficient to reduce pump pressure
rating Clean or replace
Trouble Shoot

Essential Safety Requirement
Install the pump in any shaded place away from direct sunlight.
The pump can not be used fin sub-merged condition.
Before starting work on the pump, the pump must be disconnected from the power supply. The
system must be pressure less!
Make sure that any chemicals that are released from the pump or any damaged lines do not causes
damages to system parts.
Before switching on the main supply, the tubing cap (both suction and discharge valve assembly)
should be tightened to dosing head properly so that the metering liquid can not spray out from the
dosing head in working condition and put operator’s in risk. The dosing medium/liquid is pressurized
and can be harmful to health and the environment.
When working with chemicals, the accident pretension regulations applicable at the installation site
should be applied (e.g. wearing protection clothing's). Observe the chemical manufacturer's safety
data sheet and safety instructions when handling chemicals.
The dosing medium must be a liquid, Observe the freezing and boiling point of the dosing media.The
resistance of the parts which comes into contact with the dosing medium, such as the dosing head,
PTFE ball and washer, glass ball, ‘O’ ring, ball bush, pipe lines, ball seal and suction filter assembly,
NRV body etc. , depends on the medium, media temperature and operating pressure. Ensure that the
parts come contact with the dosing medium are resistance to the dosing medium under operating
temperature and pressure, see the data booklet.
Ensure voltage is within range specified for the pump i.e., 230±20% V
Electrical connection should be made between Live –Neutral and Not live-Ground
Avoid giving supply from the same line as heavy electrical equipment.
Do not operate the pump with a damage/break diaphragm. Operating with damaged diaphragm can
lead to dosing liquid entering pump housing. In case of diaphragm breakage immediately separate
the pump from the power supply. Make sure the pump cannot be put back into the operation by
accident. In case of diaphragm breakage use the following step to dismantle diaphragm (refer fig of
Edose and Edose Neo Dosing Head overview):
1. Make the system pressure less
2. Empty the dosing head before maintenance and flush it, if necessary
3. Set the frequency knob to 0%.
4. Switch off mains supply.
5. Take suitable steps to ensure that the returning liquid is safely collected.
6. Dismantle the suction and discharge tubing and check whether tubing is blocked, soiled or
damaged. Replace if necessary
7. Dismantle NRV body in suction and discharge side.
8. Remove the ball bush and o ring from NRV body. Check their safety for wear and damage. If
necessary, replace them.
9. Unscrew the PCB housing and remove it.
10. Remove the spring fitting washer and nut and PTFE washer.
11. Loosen the screws on dosing head and remove the screws.
12. Remove the diaphragm washer, plunger washer and diaphragm o ring from diaphragm-
plunger assembly.
13. Dismantle the diaphragm-plunger assembly
14. Check the diaphragm. If necessary, replace it.