ITC DOSmart AC User manual

ENGLISH

INDEX
1 GENERAL DESCRIPTION 4
2 PACKING AND STORAGE 5
3 TECHNICAL SPECIFICATIONS 6
FLOW AND PRESSURE GRAPHS 8
4 INSTALLATION 9
4.1 GENERAL 9
4.2 ELECTRICAL CONNECTION 10
4.3 HYDRAULIC INSTALLATION 12
4.3.1 Installation examples 12
4.3.2 Installation recommendations 13
4.4 ACCESSORIES 14
4.4.1 Diaphragm leakage detector 14
4.4.2 Pressure sensor 14
4.4.3 Pulse output isolator 14
5 OPERATION 15
5.1 OPERATING MODES 17
5.1.1 Manual mode 17
5.1.2 Proportional mode 17
5.1.3 Analogue mode 19
5.1.4 Batch mode 20
5.1.5 ModBus mode 23
5.2 CONFIGURATION 24
5.2.1 Pump calibration 24
5.2.2 Dosing mode 24
5.2.3 Setup 26
5.2.4 Inputs/outputs 30

5.3 ALARMS 32
5.3.1 Level alarm 1 32
5.3.2 Level alarm 2 32
5.3.3 Flow fault alarm 33
5.3.4 Diaphragm leakage alarm 34
5.3.5 Overpressure alarm 34
5.4 MONITOR 35
5.4.1 Real time 35
5.4.2 Counters 35
5.4.3 Info Unit 36
6 START-UP AND REGULATION 37
7 MAINTENANCE 38
Exploded view 38
Periodic Maintenance: 42
Troubleshooting: Possible cause and solution 43
Electrical Wiring 45
CE DECLARATION OF CONFORMITY 47
WARRANTY 47
To avoid personal injury risks and damage to the environment, and to ensure proper
equipment operation, personnel responsible for installing, commissioning and maintaining the
equipment must follow the instructions in this manual, with special attention to the detailed
recommendations and warnings. The specic instructions for the use of the chemicals to be
dosed must also be followed.
SAFETY INSTRUCTIONS

4
Product description
1GENERAL DESCRIPTION
DOSmart AC is a series of dosing pumps with a step motor and advanced control functions to automate
.
This series of pumps is characterized by high precision, extensive regulation (1:3000) and high suction
up to 16 bar. The choice of the correct head material between PP, PVDF and stainless steel allows the
dosing of any commonly used chemical in the water treatment, chemical, food and agriculture industries.
Operating modes
ed.
Analogue: dosing proportional to a 0/4-20 mA analogue signal.
te.
Proportional to pulses: dosing by cycles, proportional to input pulses.
Dosing by volume: dosing of a given volume. Manual, remote or timed activation.
emote or timed activation.
ModBus: Dosing control via ModBus RTU protocol.
Code formulation
MOTOR
STA: 100-240 Vac
STD: 24 Vdc
DIAMETER
D50: ø 50 mm
D69: ø 69 mm
HEAD
P: PP
I: AISI316
F: PVDF
VALVE-BALL
B: PP - Boron.
I: AISI316 - AISI316
F: PVDF -Boron.
CONNECTION
L: 6x12 (6x8 PVDF)
M: 3/4”
REDUCER
3: Reduction i=3
4: Reduction i=4
5: Reduction i=4.85
STROKE
0: 2 mm
1: 4.5 mm
55 - STA F30 - D50 P B L
VELOCITY
F: Fast
S: Slow

5
Product description
2 PACKING AND STORAGE
The original packaging is designed to allow the equipment to be transported and stored without damage,
provided this takes place in dry, ventilated spaces away from heat sources.
The packing contains:
- DOSmart AC dosing pump
- Instruction manual
- Connection accessories for 4x6, 6x8, 6x12, 10x12 conduit

6
Product description
3TECHNICALSPECIFICATIONS
Flow max. at P max.l/h 1.5 4 8 13 25 40 60
gph 0.40 1.05 2.10 3.40 6.60 10.50 15.80
Max. pressure bar 16 12 8 7 5 3 2
psi 232174 116 100 72 44 29
Diaphragm diametermm 50 50 50 50 50 69 69
Stroke mm 2 2 2 4.5 4.5 4.5 4.5
Cycles/min 40 82 143 92 164 113 164
Volume/cycle at Pmaxml 0.63 0.82 0.93 2.36 2.54 5.92 6.08
Adjustment range1:3000 1:3000 1:3000 1:3000 1:3000 1:3000 1:3000
ml/h 0.50 1.34 2.66 4.34 8.32 13.33 20.00
gph
Slow suction max. l/h 1.12 3 6 9.75 18.75 30 45
gph 0.30 0.79 1.59 2.58 4.96 7.94 11.90
Slow suction max. ml/h 0.75 2 4 6.5 12.5 20 30
gph 0.20 0.53 1.06 1.72 3.31 5.29 7.94
Max. suction head in
operationm 6 6 6 6 6 5 3
Max. suction head,
priming with empty
head
m 2 2 2 3 3 3 3
Max. viscosity, std.
valve (and minimum
DN pipe)
mPa.s 100 10 200100200200100
Max. viscosity, M
valve with spring (and
DN15 pipe)
mPa.s 300030003000300021002000600
Max. viscosity, M
valve SS1with spring
(and DN15 pipe)
mPa.s 3000300030003000300030001800
Max. viscosity, M
valve SS2with spring
(and DN15 pipe)
mPa.s 3000300030003000300030001800
Valve connections4x64x66x8/6x12 6x8/6x12 10x12 10x12 10x12
Recommended
minimum pipe DN
(water and up to
L=2 m)
mm 4 4 6 6 10 10 10
SUC L=2 m mm 4 4 6 6 10 10 15
SUC L=5 m mm 4 4 10 10 15 15 20
P max. suctionbar 1 1 1 1 1 1 1
Ambient T max.°C/°F0…45 C / 32…113 F
T max. average °C/°FPP: 0…50C / 32…122 F; PVDF: -10…50C / 14…122 F; AISI316:
-10…60 / 14…140 F
Noise leveldB(A) < 60
ProtectionIP65
Weightkg 4.5 kg/10 lb
Voltage V100-250 Vac/22-30 Vdc
Frequency Hz 50/60 Hz
Power W 32
Current A 0.14 A (230 Vac)/0.24 A (110 Vac)/1 A (24 Vdc)
55-STA... / 55-STD... S50-D50 F50-D50 F30-D50 F51-D50 F31-D50 F41-D69 F31-D69

7
Product description
Inputs/outputs
• Analogue input 0/4-20 mA
• External pulse input
• Remote activation input (on/o󰀨)
• Level sensor input (pre-warning)
• Level sensor input (alarm)
• Leak detector input
• Flow detector input
• Pressure sensor input
• RS-485 ModBus serial port
• 4-20 mA logging and monitoring output
• Log output, monitoring and control of second
pulse pump
• Alarm output (relay)
• Level alarm output (relay)
DIMENSIONS
267
18383
253
248
296
172
143

8
FLOW AND PRESSURE GRAPHS
Pressure compensation activated
Pressure compensation deactivated
64 -
62 -
60 -
58 -
l/h
Bar
2
10
F31-D69
16 -
14 -
12 -
18 -
l/h
Bar
6
4
2
0
F51-D50
l/h
Bar
39 -
40 -
41 -
42 -
43 -
44 -
3
2
10
F41-D69
8 -
9 -
7 -
10 -
11 -
12 -
13 -
14 -
l/h
Bar
6 -
8
6
4
20
F30-D50
10
8
6
4
20 12
F50-D50
23 -
24 -
25 -
26 -
27 -
28 -
29 -
l/h
Bar
0
F31-D50
24 153
2 -
3 -
1 -
4 -
5 -
l/h
Bar
0 -
10
8
6
4
20 12 14 16
S50-D50
5 -
6 -
4 -
7 -
8 -
9 -
l/h
Bar
3 -
0,5 1,5
0,5 1,5 2,5
7
5
3
1

9
Installation
4 INSTALLATION
4.1 GENERAL
It should be installed in a place protected from water, away from heat sources and with renovation of air.
Fix the pump on a rigid horizontal surface. Provide enough space to comfortably perform basic
maintenance and facilitate installation and removal.
Fix the pump to the chosen at surface using 4 screws
(See drawing).
81
234
129
5.8
81
234
129

10
Installation
4.2 ELECTRICAL CONNECTION
The electrical protection of the motor must be installed and adjusted on the basis of its
nominal current (thermomagnetic circuit breaker) . (See connection).
A device for disconnection in case of emergency must be installed.
The equipment must be protected against false starts.
12VF 1F 2S - +-MN+M N- 24 +-
13 14 15 16 17 18 19 20 21 22 23 24 25 26
A
BI N -I N -I N -I N -2 4 AB
27 28 29 30 31 32 33 34 35 36
+2 4 C NO - +5 V H L -
37 38 39 40 41 42 43 44 45 46
+
-I N -N O NC CN O NC C
P
12
-
ENCODER
Inputs Outputs
External quick connectors
Flow Leakage Pressure
Red Blue Yellow
ENCODER
1 2 3 4 5 6 7 8 10 11 12
FLOW LEAKAGE PRESSURE VENTILATION RS-485
4-20 mA PULSE PULSE ALM LEVEL ALM REMOTE LEVEL 1 LEVEL 2 4-20 mA
4-20 mA
ITC controllers
Pulse input
ITC owmeter
Remote activation
Level sensors
Brown Brown Brown Black White White Blue Blue
12345
Black Grey
1REMOTE
2REMOTE
3LEVEL 1
4LEVEL 2
5COMMON
110-250 Vac
Remote
Q - pulse 4-20
24 Vdc

11
Installation
NFUNCTION DETAIL
Inputs
1Encoder +12 Vdc
2Encoder F1
3Encoder F2
4Encoder S
5Encoder (-)
6Flow detector (+)
7Flow detector (-)
8Leak detector (+)
9Leak detector (-)
10 Pressure transmitter +24 Vdc
11 Pressure transmitter (+)
12 Pressure transmitter (-)
13 4-20 mA input analogue mode (+)
14 4-20 mA input analogue mode (-)
15 Proportional pulse input mode Pulses
16 Proportional pulse input mode (-)
17 Remote Voltage free contact
18 Remote Voltage free contact
19 Level sensor 1 Voltage free contact
21 Level sensor 2 Voltage free contact
22 Common level sensor Voltage free contact
Outputs
33 RS-485 +5 Vdc
34 RS-485 H(B)
35 RS-485 L (A)
36 RS-485 (-)
37 4-20 mA monitor output (+) Not isolated
38 4-20 mA monitor output (-) Not isolated
39 Monitor pulse output Signal. Not isolated
40 Monitor pulse output (-) Not isolated
41 Level 2 alarm output NO
42 Level 2 alarm output NC
43 Level 2 alarm output Common (max. 5 A 250 Vac)
44 Alarm output NO
45 Alarm output NC
46 Alarm output Common (max. 5 A 250 Vac)
WIRING

12
Installation
4.3 HYDRAULIC INSTALLATION
4.3.1 Installation examples
7
12
h
1
2
5
6
3
4
h
8910 11
125
6
7
12
1. To avoid undissolved particles, never suck the product to be injected from the bottom of the tank.
2. Filter. It is essential to install a lter (150 micron) in the suction piping.
3. Level sensor
4. Agitator
5. For the evacuation of leaks through the leak detection orice in the diaphragm loss collars, a hose
or pipe made of material compatible with the product to be dosed must be connected to the bottom of
the cylinder, and the liquid must be collected in a safe place.
6. Priming and drain valve built into the pump.
7. Pressure relief valve. Install a pressure relief valve in a bypass as close as possible to the pump in
order to protect the pump and the installation from possible overpressure. This bypass should pipe the
liquid to a safe place.
8. Pulsen dampener
9. Pressure gauge.
10. Pressure maintenance valve.
11. Flowmeter
12. Injection check valve

13
Installation
4.3.2 Installation recommendations
Long discharge: L> 5 m (16 ft)
Long suction: L> 2 m (6.5 ft)
Air in suction
Siphon
DISCHARGE
SUCTION
L
Ø
L
Ø
h
*
p>h
*
PIPE SIZE
Øint L ≤ 2 m L ≤ 5 m
4 4 4
613 -
10 60 13
15 -40
20 -60
Q max. (l/h)
PIPE SIZE
Øint L ≤ 2 m L ≤ 5 m
4 4 4
613 13
10 60 40
15 -60
Q max. (l/h)
Q max. (l/h)

14
Installation
4.4 ACCESSORIES
4.4.1 Diaphragm leakage detector
The diaphragm leakage detector is an electrical conductivity sensor capable of detecting the presence of
liquid when its conductivity is 0.05 mS or higher. The pump must be provided with the specic diaphragm
ange for housing the detector.
Fit detector Ref. 29-056 in the lower opening of the diaphragm and
connect pins 8-9 as shown in the drawing.
Diaphragm Ø Diaphragm leakage detector kit
50 29-068-P
69 29-063-P
4.4.2 Pressure sensor
The pressure sensor protects the pump from working in overpressure conditions, when the pressure
alarm is activated. Connect the 4-20 mA 10 bar pressure sensor Ref. 18705 as shown in the drawing.
18705
1 = 24
2 = +
1
24 +-
10 11 12
PRESSURE
2
4.4.3 Pulse output isolator
38 39 40 41
27 28 29 31 32 33 34
The pulse output isolator allows any device to be securely
connected to a pulse output.
The pulse output is a voltage free output. The isolator is not
necessary when the output is connected to a 38 39 40 41 pulse
input of another DOSmart AC.
MN+M N-
89
LEAKAGE
-+
29-056

15
Installation
5 OPERATION
The electric motor transmits power via a reducer, consisting of a pinion (A) and an eccentric crown (B)
that drives a connecting cam (C) onto which the diaphragm (D) is screwed. Spring (F) is compressed
during the suction cycle, thus storing energy which is released during the discharge cycle.
By varying the speed of the motor and depending on the operating mode selected in the Control Unit, the
equipment will regulate the ow to the desired value with a maximum variation of 1:3000.
SYSTEM DESCRIPTION
LCD screen
Keyboard
Exit without conrming /
Validate/Run/Stop
Increase/decrease value
Scroll left
Scroll right/test
ESC
ENT
Inputs/outputs
Control
unit
B
A
C
D
F
Injection
valve
Suction valve
Head
Box
Bleed valve

16
Installation
off
l
%
l / h
1 4 4
1 0 0
SS1
MODE
25.0
LCD DISPLAY DESCRIPTION
Menus
%
l / h
0 0 0
0 0 0
MODE
%
l / h
0 0 0
0 0 0
MODE
%
l / h
0 0 0
000
MODE
%
l / h
0 0 0
0 0 0
MODE
5.1 Operating mode menu 5.2 Conguration menu
5.3 Alarms menu 5.4 Monitor menu
Advanced dosing function
% ow
Programming locked
Flow rate fault
Level 1
Leakage
Level 2
Overpressure
Loss of pulse
Manual
Level 1
Pump calibration
Proportional
Level 2
Dosing Mode
Analogue
Flow rate
Standard (ST)
Batch
Leakage
Pressure
Slow Suction 1 (SS1)
Slow Suction 2 (SS2)
Set Up
In/Out
Dosing pump
Pressure Input
Units
Flow detector
Inputs
Real time
Flowmeter
Pulse output
Counters
Lock code
Outputs
4-20 mA out
Info Unit
ModBus
Monitor motor
Cycles/min
ON/OFF
MonitorAlarmSetupMode
25.0
25.0 25.0
25.0

17
Installation
Inputs
Outputs
Monitor motor
5.1 OPERATING MODES
5.1.1 Manual mode
This mode allows manual adjustment of the dosing ow rate.
5.1.2 Proportional mode
This mode allows dosing to be proportional to a pulsed input. Use X:Y mode to establish a ratio of input
pulses (X) to pump cycles (Y). Use the %/ppm mode for proportional dosing.
Proportional mode settings
5.1.2.1 X:Y pulses
The pump will cycle Y times after receiving X input pulses. The pump speed can be adjusted manually.
%
l / h
0 0 0
0 0 0
MODE
MODE: Manual
Proportional
Analog
Batch l / h
Mo
%
0 0 0
0 0 0
off
l
l / h
M
%
3 1
4 4
ENT ENT
ENT
Increase/decrease ow
Start/stop the pump
The pump will start if the Remote Activation input is activated.
Proportional to a pulse input from a owmeter
1. X:Y for low frequency pulses (0,005-30 Hz)
2. %/ppm for high frequency owmeters (1-300 Hz)
%
l / h
0 0 0
0 0 0
MODE
MODE: Manual
Analog
Batch
Proportional l / h
10
m3/h
o
%
0 0 0
0 0 0
Proportional
% / PPM Flowmet.
X:Y Pulse
ENT
ENT
0001 :
Q = 025 %
M = 005 pulses
0001
PROPORTIONAL X:Y
25.0
25.0
25.0
25.0
7.75
Select the number of input pulses
Change by pressing and validate by pressing ENT

18
Installation
Start/stop the pump
The pump will start if the Remote Activation input is activated.
5.1.2.2 %/ppm Flowmeter
By entering a proportion value (%/ppm) and with a pulse input from a owmeter, the pump will regulate its
speed to dose the ow according to the desired proportion.
ENT
0001 : 0001
Q = 025 %
M = 005 pulses
PROPORTIONAL X:Y
0001 0001
:
PROPORTIONAL X:Y
Q = 025 %
M = pulses005
0001 0001
:
Q = %
M = 005 pulses
025
PROPORTIONAL X:Y
PROPORT. %
Set Point 000,05
Stop Pump OFF
PROPORT. %
Set Point 000,05
Stop Pump OFF
ENT
ENT
* For the setup of units (%/ppm) see Units in the Conguration section
* For owmeter setup. See the Conguration section
l / h
60.0
l
%
2 5
3 6
6.25
12 150
l / h
30
m3/h
l
%
6 2
8 9
15.5
Select the number of pump cycles
Change by pressing and validate by pressing ENT
Select pump speed in %
Change by pressing and validate by pressing ENT
For Y=1 Q must be set at less than 50%
Select the maximum number of pulses in memory
Change by pressing and validate by pressing ENT
Proportionality value in % or ppm
Change by pressing and validate by pressing ENT
Select OFF to perform proportional dosing with no volume
limit.
Change by pressing and validate by pressing ENT
Instantaneous water ow rate
Pressing ENT will casue the ON/OFF indicator to toggle to
ON and the pump will start if the Remote Activation input of
is activated

19
Installation
5.1.3 Analogue mode
This mode allows dosing proportional to an analogue 0/4-20 mA input.
PROPORT. %
Set Point 000,05
03,6
Stop Pump
Stop Vol (1)
ON
PROPORT. %
Set Point 000,05
03,6
Stop Pump
Stop Vol (1)
ON
150
l / h
00,0
l / h
03,6
l / h
30
m3/h
l
%
6 2
8 9
Volume to be dosed
volume dosed
By pressing ENT the ON/OFF indicator will change to ON and
the pump will start if the Remote Activation input is activated.
The pump will stop when it reaches the maximum volume set.
ENT ENT
%
l / h
0 0 0
0 0 0
MODE
x2 MODE: Manual
Proportional
Batch
Analog
1
l / h
00mA
o
%
0 0 0
0 0 0
5.1.3.1 Analogue mode settings
ANALOG INPUT
INPUT
16,0 mA = 100 %
00,0 mA = %067
ANALOG INPUT
INPUT
16,0 mA = 100 %
00,0 mA %067
25.0 25.0
Select mA input for the rst point
Change by pressing and validate by pressing ENT
Select ON to perform proportional dosing with a volume limit.
The pump will stop when it reaches the ENT maximum volume
to be dosed.
Change by pressing and validate by pressing ENT
Set the desired maximum volume.
Change by pressing and validate by pressing ENT
Select the ow in % for the rst point in mA
Change by pressing and validate by pressing ENT

20
Installation
Examples:
1: 4 mA=0% 2: 4 mA=100% 3: 4 mA=0% 4: 12 mA=0%
20 mA=100% 20 mA=0% 12 mA=100% 20 mA=100%
Examples 3 and 4 can be combined into two pumps when both are controlled with the same mA signal to
start a second pump as supplementary ow.
5.1.4 Batch mode
This mode allows batch dosing. Various activation options may be chosen (manual, external, time), and
an end of the work cycle dened by number of cycles/volume or by time. In any of the operating modes,
the speed of the pump can be dened in %.
ANALOG INPUT
INPUT
16,0 mA = 100 %
= %067
ANALOG INPUT
4 mA = 000 %
SPAN
20 mA = %100
l / h
2
8.0mA l
%
2 5
3 6 Start / stop the pump
The pump will start if the Remote Activation input is activated
ENT
%
100
41 22 0 mA
%
100
41 22 0 mA
%
100
41 22 0 mA
%
100
41 22 0 mA
ENT ENT
%
l / h
0 0 0
0 0 0
MODE
x2 MODE: Manual
Proportional
Analog
ModBus
Batch
01,600 l
00,000 l
o
%
0 0 0
0 0 0
6.25
25.0
Select the ow rate in % for the second point in mA
Change by pressing and validate by pressing ENT
Select mA output for the second point
Change by pressing and validate by pressing ENT