Jesco FEDOS E 5 User manual

FEDOS E/DX
Piston Dosing Pump
Dosing
Conveying
Control
Liquids
Gases
Systems
Operating Manual
Read this operating manual before using the equipment.
To be retained for future reference.
EN 02

Contents
1. General and Safety Instructions................................................................................................................................3
2. General .......................................................................................................................................................................7
2.1 Proper intended use .......................................................................................................................................... 7
2.2 Structure of the dosing pump............................................................................................................................. 7
3. Function .....................................................................................................................................................................8
4. Dimensioned drawings..............................................................................................................................................9
5. Technical data..........................................................................................................................................................10
5.1 Electric motor data .......................................................................................................................................... 12
5.2 Technical data, ATE servomotor FEDOS E (optional)............................................................................................ 13
6. Delivery characteristic curves ................................................................................................................................14
7. Installation ...............................................................................................................................................................15
7.1 General information ......................................................................................................................................... 15
7.2 Installation location.......................................................................................................................................... 16
7.3 Electrical connection of the dosing pump .......................................................................................................... 16
7.4 Wiring diagrams for ATE servomotor for stroke length adjustment....................................................................... 18
7.5 Level monitoring.............................................................................................................................................. 19
7.6 Pressure control and safety valves.................................................................................................................... 19
7.7 Injection nozzle installation............................................................................................................................... 20
7.8 Installation example......................................................................................................................................... 20
8. Operation..................................................................................................................................................................21
8.1 Stroke length adjustment ................................................................................................................................. 21
8.2 FEDOS DX operating elements.......................................................................................................................... 21
8.3 Switching on/off .............................................................................................................................................. 21
8.4 Operating mode selection ................................................................................................................................ 21
8.5 Alarm.............................................................................................................................................................. 22
8.6 Other settings.................................................................................................................................................. 23
8.7 Factory setting ................................................................................................................................................ 23
8.8 Connections and cable assignments................................................................................................................. 23
9. Start-up....................................................................................................................................................................25
9.1 Start up of FEDOS E with ATE servomotor.......................................................................................................... 25
10. Shutdown ...............................................................................................................................................................26
10.1 Disposal of old equipment.............................................................................................................................. 26
Device revision ............................................................................................................................................................26
11. Maintenance ..........................................................................................................................................................27
11.1 Lubrication.................................................................................................................................................... 27
11.2 Maintenance of the bearings.......................................................................................................................... 27
11.3 Maintenance of the ATE servomotor (optional) ................................................................................................. 27
11.4 Replacing the piston ...................................................................................................................................... 27
11.5 Valves........................................................................................................................................................... 29
12. Explosion-proof dosing pumps .............................................................................................................................32
12.1 General......................................................................................................................................................... 32
12.2 Special conditions.......................................................................................................................................... 32
13. Troubleshooting .....................................................................................................................................................33
14. Spare parts.............................................................................................................................................................34
15. External vent (optional) .........................................................................................................................................40
Index.............................................................................................................................................................................41
Declaration of no objection.........................................................................................................................................42
Warranty claim.............................................................................................................................................................43
CE declaration of conformity......................................................................................................................................44
2 | Operating Manual FEDOS E/DX | Contents

1. General and Safety Instructions
1.1 General
This operating manual contains basic instructions to be followed during installation, operation and mainte-
nance. It is therefore essential for the assembler and the relevant technical personnel/operating company
to read this operating manual prior to installation and start-up. It must remain accessible at the place of
installation of the system for reference at all times.
Besides the general safety instructions in this "Safety" section, the special safety instructions in the other
sections are also to be followed.
1.2 Identification of safety instructions in the operating manual
Failure to follow the safety instructions in this operating manual may result in personal injury or damage to
the environment and the system. Safety instructions are identified by the following symbols:
DANGER!
Indicates an immediate danger.
Failure to follow this instruction will lead to death or extremely serious injuries.
WARNING!
Indicates a potentially hazardous situation. Failure to follow this instruction may lead to death or severe
injury.
CAUTION!
Indicates a potentially hazardous situation. Failure to follow this instruction may lead to minor injury or dam-
age to property.
ATTENTION! or NOTICE!
Failure to follow these safety instructions may endanger the machine and its functions.
IMPORTANT!
This refers to additional information to facilitate operation and ensure the smooth running of the equipment.
Information attached directly to the dosing pump, such as
• cable markings
• markings for fluid connections
must be followed without fail and must remain fully legible at all times.
1.3 Personnel qualifications and training
The personnel employed for operation, maintenance, inspection, and installation must be suitably qualified
for this work. The responsibilities, areas of competence and personnel supervision must be clearly defined
by the operating company. Personnel who do not have the required know-how must be duly trained and
instructed. If necessary, this can also be done by the manufacturer/supplier on behalf of the operating
company. In addition, the operating company must ensure that the personnel are fully familiar with, and
have understood the contents of this operating manual.
1.4 Important safety instructions
When installing and using this electrical device, basic safety precautions should always be followed, includ-
ing the following:
ATTENTION!
Read and follow all instructions! Keep this operating manual for future reference!
WARNING!
To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at
all times.
General and Safety Instructions | Operating Manual FEDOS E/DX | 3

WARNING!
Risk of electric shock. Connect the device only to a socket outlet with earthing contact protected by a
ground fault circuit interrupter (GFCI). Consult a qualified electrician if you are uncertain whether the socket
is protected by a GFCI.
Do not bury the cable. Secure cable to avoid damage by lawn mowers, hedge trimmers and other equip-
ment.
WARNING!
To reduce the risk of electric shock, replace the cable immediately if damaged.
WARNING!
To reduce the risk of electric shock, do not use extension lead to connect unit to electric supply; use an
appropriately located socket outlet.
1.5 Hazards due to failure to follow safety instructions
Failure to follow the safety instructions may endanger not only persons, but also the environment and the
device. Failure to follow the safety instructions may invalidate any damage claims.
The following hazards in particular may result:
• Failure of major equipment functions
• Failure of required maintenance and repair methods.
• Danger to persons due to electrical, mechanical and chemical effects.
• Danger to the environment due to leakage of hazardous substances.
1.6 Safety awareness at work
The safety instructions contained in this operating manual must be observed. The operating company is
responsible for ensuring compliance with local safety regulations. Faults that may affect safety must be
repaired immediately.
1.7 Safety instructions for the operating company/operator
Leakages of hazardous substances (e.g. aggressive, poisonous) must be disposed of in such a way that they
do not pose a risk to persons and the environment. Legal requirements must be observed.
Risks from electric current must be excluded (for further details, refer to the VDE1) regulations and regula-
tions of the local public utilities).
1) German Association for Electrical, Electronic & Information Technologies
Separate regulations must be observed if the FEDOS E is operated in potentially explosive atmospheres.
The operating company must determine the explosion hazard (area classification) and select the appropriate
equipment. Further information can be found in paragraph 7.1 (Installation), paragraph 7.4 (Electrical con-
nection) and section 12 (Explosion-proof dosing pumps).
1.8 Safety instructions for inspection, maintenance and installation work
The operating company must ensure that all maintenance, inspection and installation work is carried out by
authorised and duly qualified personnel, who have read and understood this operating manual.
Any work on the machine must only be carried out after it has been brought to a complete stop. Always
follow the procedure specified in the operating manual for shutting down the dosing pump/system.
Dosing pumps or systems which convey hazardous media must be decontaminated.
All safety and protective equipment must be reattached and activated immediately after the work has been
completed.
CAUTION!
Particular caution is required during repair work with the operation of the FEDOS E in potentially explosive
atmospheres. Due to the risk of sparking, care must be taken to prevent metal parts or tools knocking
against one another. When repairing, it is better to move the dosing pump out of the area with a potentially
explosive atmosphere.
4 | Operating Manual FEDOS E/DX | General and Safety Instructions

Those points specified in chapter 7.2 "Installation location" and section 9. "Start-up" must be observed
before setting into operation.
1.9 Unauthorised modification and production of spare parts
The device may only be modified or converted in consultation with the manufacturer. Use only the manufac-
turer's spare parts and accessories. Otherwise the warranty is invalidated.
1.10 Inadmissible operating practices
Any methods of operation which contradict chapter 2 "Proper intended use" are inadmissible and will result
in the expiry of all liability claims.
1.11 Dosing of chemicals
CAUTION!
When working on dosing systems, the local accident prevention regulations must be observed and the
specified personal protective equipment must be worn. The following standard protective clothing is recom-
mended, depending on the hazardousness of the metered medium:
Protective clothing Protective gloves Protective goggles
It is recommended that all persons responsible for the installation and maintenance of piping systems,
hoses and accessories wear this protective clothing.
Before working on the dosing pump and system, disconnect it from the mains power supply and prevent it
from being switched on.
CAUTION!
Any chemical still present in the dosing head may spray out when the voltage supply is reconnected. This
may lead to chemical or other burns to the face and hands. Dosing lines must always be connected before
switching on again.
The chemical resistance of the construction materials in the pump must be verified before dosing aggres-
sive media!
The pump dosing head and the system connections and lines may be under pressure. Working on the dos-
ing system requires special safety precautions and is allowed only for suitably trained personnel:
CAUTION!
Chemical may spray out. This may lead to chemical or other burns. Always release the pressure before
starting work on the dosing pump.
Before working on the dosing head, valves and connections, flush the dosing pump with a harmless medium
(water in most cases), to avoid unintentional contact with the metered medium.
The piston area must remain open for control reasons and may be dangerous if accessed directly.
CAUTION!
Stroke movement of the piston! There is a risk of crush injuries to hands. Do not reach into the piston area!
Work in the piston area may therefore only be carried out with the dosing pump switched off.
WARNING!
Never look into the open end of a clogged line or valve. Chemicals may emerge unexpectedly and cause
chemical or other burns to face and hands.
Before start-up, all screw connections must be inspected for correct tightness and leak-tightness, and must
be re-tightened using an appropriate tool if necessary.
General and Safety Instructions | Operating Manual FEDOS E/DX | 5

CAUTION!
If connections at the dosing head are loosened during operation, for venting or other reasons, leaking
chemicals must be removed properly. Only in this way is it possible to effectively avoid the risk of injuries
caused by chemicals and corrosion at the dosing pump.
ATTENTION!
If changing the chemical, check the materials in the pump and other system parts for chemical resistance. If
there is a danger of chemical reaction between the different media, clean thoroughly beforehand.
IMPORTANT!
To operate the pump, mount the fan cowl in order to ensure sufficient cooling of the motor.
The protection class of the control unit is only ensured if the connection ports are protected by caps or the
standard connectors are inserted.
DANGER!
Risk of burns. Shock wave: parts may fly off and cause fatal injury. FEDOS DX must not be used in poten-
tially explosive atmospheres under any circumstances.
CAUTION!
Under certain operating conditions, the drive motor of the DX version might heat up considerably. This may
cause burns to the hands. To avoid unintentional contact, provide an appropriate safety device.
WARNING!
Lethal voltage!
Proceed with caution when carrying out adjustment work on the inside of the ATE servomotor (optional for
FEDOS E). Connections and internal limit switches might be live. Additional limit switches in the ATE drive
may be under voltage (live) even when the auxiliary voltage is switched off. After installing the ATE servomo-
tor or before start-up, re-attach the cover.
1.12 Transportation
No special devices are required for transportation of the dosing pumps. However, it is advisable to choose a
transport method appropriate for the weight of the dosing pumps (e.g. transport trolley). If transporting with
the oil drained, the dosing pump should preferably be placed in the horizontal position. Otherwise, stability
must be ensured by screwing it onto the transport frame.
1.13 Scope of delivery
IMPORTANT!
Carefully unpack the dosing pump and any accompanying accessories ordered, so that small parts are not
left inside the packaging. Compare the delivery content with the delivery note immediately. If there are any
discrepancies, determine the cause.
The following are part of the scope of delivery:
• Dosing pump FEDOS E or DX
• Suction and discharge side connections
• Gear oil
• 2x cables (for FEDOS DX)
• Operating Manual
• ATE servomotor (optional)
• Separate fan (optional)
6 | Operating Manual FEDOS E/DX | General and Safety Instructions

2. General
2.1 Proper intended use
The device is intended for the following purpose only: the conveying and dosing of chemicals.
Operating safety is guaranteed only if the device is used for its intended purpose. All other types of use are
prohibited and will invalidate the warranty. The operating conditions described in chapter 5 "Technical Data"
must be observed!
2.2 Structure of the dosing pump
c
a
h
b
i o p q
g
k
n
m
l
f
e
j
aDosing head
bSuction side valve
cDischarge side valve
eStroke length adjustment
fStroke length adjustment lock
gMotor terminal box (FEDOS E voltage supply)
hOil inlet
iOil outlet
jControl unit (FEDOS DX)
kOperating panel with display
l"External switch-off" contact
m"Level input" contact
n"External control" contact
oVoltage supply (FEDOS DX)
pMotor connection
qFault signalling relay
General | Operating Manual FEDOS E/DX | 7

3. Function
Piston dosing pumps of the FEDOS series are used in industry, in the process engineering sector, as well as
in water conditioning and the treatment of waste water.
FEDOS E
The FEDOS E is used when no control is required for constant dosing. For this the voltage supply is connect-
ed directly to the terminal box of the motor. To adapt the dosing capacity the stroke length can be adjusted
manually from 0 … 100%, or the motor speed is controlled by means of a separate frequency converter.
The FEDOS E is optionally available with remote electrical stroke-length adjustment (ATE servomotor).
The FEDOS E can be operated in Zone 1 potentially explosive atmospheres if the corresponding drive is
taken into account. Further information can be found in section 12.
FEDOS DX
The "intelligent" FEDOS DX is used if the dosing pump is to be integrated in controls or automatic control
systems. It enables versatile adaptation to a variety of different control signals and system monitoring
equipment. The signals required for external activation of the dosing pump can be from simple potential-
free N.O. contacts of water meters or controllers, or analogue 0/4 … 20 mA signals. For contact actuation
(pulse control), the stroke frequency can be adapted by division or multiplication. For internal operation (own
stroke), the dosing pump can be adjusted continuously between 0 and max. 142 strokes/min, depending on
version.
Principle of operation
aPiston rod
bReturn spring for suction stroke
cTappet plate
dDrive cam
eStroke limiting cam
Like the roller bearings, the worm gear set of the
single-speed gear runs in an oil bath. Dosing takes
place when the rotation of the drive cam dcauses
movement of the piston rod a. The suction stroke
is produced by the return movement due to spring
force. The stroke length is adjusted by limiting the
tappet return movement using a manually adjust-
able cam disk (stroke limiting cam e) as stop. The
adjustment range is from 0 to 100%.
a b c
d
e
min.
max.
max.
8 | Operating Manual FEDOS E/DX | Function

4. Dimensioned drawings
D
Dimensional drawing FEDOS E/DX
E/DX)A L
1 … 2 125 25
5 … 30 114 25
Motor W
EMG 353
ATB 373
VEM 364
ATEX version 474
All dimensions in mm
184~
50 60
Dimensional drawing FEDOS E with ATE servomotor
Dimensioned drawings | Operating Manual FEDOS E/DX | 9

5. Technical data
FEDOS E/DX 01 03 06 1 21) 51) 81) 171) 301)
Delivery rate at max.
pressure
l/h 0,17 0,31 0,63 1,42 2,13 4,8 8,5 17 31,5
Stroke volume ml/
stroke
0,11 0,25 0,25 0,56 1 2 3,7
Max. pressure bar 40 25
max. pressure 3) bar 100 80 - -
Stroke frequency rpm 26 48 95 142
Piston-Ø mm 4 6 9 12 17 23
Stroke length mm 9
Suction lift mbar 800
max. supply pressure
∑static + dynamic
mbar 500
max. ambient tempera-
ture2)
°C 40
Power output E (3~) W 50 250
Power output DX (1~) W 120
Weight kg 11 16
1) E/DX 2…30 not for 60Hz operation, special sizes E/DX 2A … 30A available for 60 Hz operation.
The details about delivery rate and stroke frequency are also applicable for 60 Hz operation.
2) Media temperature 60 °C, short time 80 °C.
3) High-pressure version
Dimensioning of the lines
The following approximate values are applicable for the dimensioning (maximum length) of suction and
pressure lines:
• 2 m for peak flow velocity of 0.5 … 0.7 m/s
• 10 m for peak flow velocity of 1.0 … 1.5 m/s
(without pulsation damper or suction pressure regulator, and without overdimensioning of the line).
This is applicable to chemicals with a maximum viscosity of 20 mPAS (the highest viscosity is at lowest
system temperature, for example in case of delivery in winter) and with a maximum density of 1100 kg/m³.
The maximum flow velocity is calculated as follows: Q x π / A (Q = flow rate, A = line diameter).
For all other chemicals and installation situations please refer to the seminar documents of the manufactur-
er "Kleine Einführung in die Dosiertechnik" (Short introduction into dosing technology) or to other applicable
guidelines from specialist literature on fluid dynamics (i.e. Kalide ISBN 3-446-13092-6).
Avoid overloading of the pump, the piping or the instruments.
10 | Operating Manual FEDOS E/DX | Technical data

Control unit (FEDOS DX) Standard version CSA version
Power supply 95 … 264 V AC, 48 … 63 Hz
Connection 1.8 m cable,
3-wire, 0.75 mm2
Shock-proof plug
1.8 m cable,
3-wire, 0.75 mm2
UL/CSA connector
Power consumption (without motor) 10 W
ISO class F
Protection class IP 55*
Max. admissible ambient temperature 40 °C
Digital display 3-digit display for stroke frequency and level status
LEDs for functional display in operation (green)
fault (red)
external control (green)
Plastic film keypad 4 keys for programming and operation
Weight 0.8 kg
Inputs
External shut-off External switch off for dosing pump, provided by the
customer, by
potential free contact (normally closed, N.C.),
3.5 mm jack socket (M12x1 plug optional)
Level input Connection of accessories (e.g. suction line with level
switch)
5 V DC voltage, low level alert and main alarm,
Contact: normally closed, N.C.
3.5 mm jack socket (M12x1 plug optional)
External control pulse input or analogue input
RCA socket
(M12x1 plug optional)
3-pin socket
Pulse input potential-free contact (normally closed, N.C.) provided by
operating company
5 V DC voltage
Pulse length min. 30 ms
Multiplication/division of pulses 1 / 2 / 4 / 8 / 16 / 32 / 64
Analogue input 0/4 … 20 mA signal **
Working resistance: 150 Ohm
Outputs
Fault signalling relay voltage-free changeover contact,
max. 250 V AC, 2.5 A or max. 30 V DC, 2.5 A,
Cable connection
*if connection ports are protected by caps, or standard connectors are inserted.
**1 If several dosing pumps are connected in series with 4 … 20 mA control, an additional device (splitter) is necessary.
Technical data | Operating Manual FEDOS E/DX | 11

5.1 Electric motor data
FEDOS DX 01…30 E 01…2 E 5…30
Standard motor,
type
AF 63/4B-7R ECS63K4 DAS 63 S4 DAS 63 K4
Speed rpm 1390 1650 1400
Voltage V 1~ 230 120 230/400
Nominal
current
A 1,15 2,2 0,5 0,95
Power
output
kW 0,12 0,05 0,25
Frequency Hz 50 60 50
Protection class IP 55 IP 55
ISO class F F
Explosion-proof motors for FEDOS E
FEDOS E (ATEX) 01…30 01…30
Type KPER63K4 F63CTV/a4
Explosion protection increased safety
EExeIIT3
EXdellCT4 pressure-
resistant enclosure
Speed rpm 1370 1410
Voltage V 1~ 230/400 230/400
Nominal
current
A 0,83/0,48 1,0/0,6
Power
output
kW 0,12 0,18
Frequency Hz 50 50
Protection class IP 55 IP 55
ISO class F F
12 | Operating Manual FEDOS E/DX | Technical data

5.2 Technical data, ATE servomotor FEDOS E (optional)
Reversible servomotor with self-locking step-down gear. Connections via cable glands. Angle of rotation
limited by two internal limit switches.
Servomotor NK 1510 NK 1510-PMR-NK
Part No. 79466 79468 79467 79469
FEDOS E E4 ... 380
Voltage 230 V AC,
50/60 Hz
115 V AC,
50/60 Hz
230 V AC,
50/60 Hz
115 V AC,
50/60 Hz
Power consumption 7 VA
Regulation
time
50 Hz 45 s
60 Hz 39 s
Regulation bevel 270° ⇔0...100%
Protection class IP 65
Ambient temperature -15 ... +60 ℃
Weight 2.5 kg
Inputs
Control 3-point step control 0(4) ... 20 mA
Working resistance
at 0/4...20 mA
- 250 Ω
Outputs
Position feedback signal for
remote display
0...1000 Ohm, max. 2 W 0(4) ... 20 mA
0(2) ... 10 V
See the enclosed operating instructions for the ATE servomotor for further technical data.
Technical data | Operating Manual FEDOS E/DX | 13

6. Delivery characteristic curves
The delivery characteristic curves refer to water at 20 °C (68 °F) and a suction lift of 0.5 m. The medium
(density and viscosity) and temperature cause the delivery rate to change. Dosing pumps must therefore be
gauged in litres for the application. At 60 Hz operation, values are increased by a factor of 1.2.
0
1
2
3
4
5
6
7
8
9
012345678910
l/h
Hubeinstellung
FEDOS E/DX 01...8
E/DX 01-1
E/DX 2
E/DX 5
E/DX 8
0
5
10
15
20
25
30
35
0 1 2 3 4 5 6 7 8 9 10
l/h
Hubeinstellung
FEDOS E/DX17...30
E/DX 17
E/DX 30
14 | Operating Manual FEDOS E/DX | Delivery characteristic curves

7. Installation
7.1 General information
Local rules and regulations must be taken into account when selecting a dosing pump for designing a
system, and for installation and operation. This applies to the selection of the appropriate materials for the
dosing pump, the handling of chemicals, and electrical installation.
Before installing the pump in areas with a potentially explosive atmosphere, the dosing pump must be
checked to ensure that it meets the minimum requirements set by the applicable explosion protection
regulations. For this purpose, the data on the dosing pump rating plate must be compared with the local
requirements.
The technical specifications of the dosing pump (section 5) must also be taken into consideration, and the
system designed accordingly (e.g. pressure loss for pipe dimensions i.e. nominal diameter and length).
The designer and operating company are responsible for ensuring that the entire system, including the
dosing pump, is designed in such a way that no lasting damage occurs to system equipment or buildings in
the event of chemical leakage due to the failure of wearing parts (e.g. wear of the packing) or burst hoses.
If the chemical system represents a potential source of danger, the installation must be designed in such
a way that no unreasonable consequential damage occurs, even if the dosing pump fails. We therefore
recommend installing leakage monitors and collecting pans.
CAUTION
The FEDOS E/DX may not be used for dosing combustible and flammable fluids. For constructional reasons
piston pumps are not leakage-free. This must be taken into account in the design of the process and the
plant.
To increase dosing accuracy and ensure functional reliability, we recommend installing additional valves and
accessories. These include pressure control valves, pressure relief valves, leakage monitors and low level
indicators, as shown in the installation examples.
Always use appropriate tools for installation work. To avoid damage, never apply excessive force.
IMPORTANT!
To prevent seizing, threaded stainless steel parts (e.g. dosing head and valves) must be lubricated before
being assembled (e.g. with PTFE spray).
ATTENTION!
Check the lubricant for compatibility with the chemical.
7.1.1 Installation of FEDOS E with ATE servomotor
The ATE servomotor is connected to the dosing pump and adjusted at the factory. When installing, sufficient
installation space of at least 150 mm must be provided in order to allow later maintenance.
The electrical connection of the ATE drive must be made in accordance with locally applicable requirements
and may only be carried out by technical personnel. The wiring diagrams (chapter 7.4) show the standard
connection variant.
Cable type and cross-section must be chosen according to the motor data.
The cable passage through the housing must be made professionally. We recommend using gland con-
nections with strain-relief clamp. The required protection class must be ensured by professional-standard
installation of the electrical connections.
ATTENTION!
Note that the ATE servomotor can only be actuated when the main drive motor of the dosing pump is run-
ning. This means that the ATE servomotor must be locked electrically. Otherwise, the adjusting eccentric will
suffer excessive wear, or be destroyed.
Installation | Operating Manual FEDOS E/DX | 15

7.2 Installation location
The installation location of the dosing pump must be easily accessible by operating and service personnel.
ATTENTION!
Ambient temperatures above 40 °C are not permitted. Radiant heat from apparatus and heat exchangers
must be shielded so that heat from the dosing pump can be dissipated sufficiently. Avoid exposure to direct
sunlight. If the dosing pump is installed outside, provide a roof to protect it from the effects of weather.
Install the pump so that the suction and discharge valves are in vertical position. To ensure stability, the
dosing pump must be screwed onto an appropriate surface. The system piping must not exert any force on
the connections and valves of the dosing pump. To avoid dosing errors at the end of the process, the dosing
pump must be locked electrically and hydraulically.
7.3 Electrical connection of the dosing pump
The electrical connection of the dosing pump must be made according to local rules and regulations and
may only be carried out by qualified technical personnel. Cable type and cross-section of the supply lines
must be chosen according to the motor data. The cable passage to the motor terminal box must be made
professionally. We recommend using gland connections with strain-relief clamp. The required protection
class must be ensured by professional-standard installation of the electrical connections.
For external switch-off of the dosing pump, see paragraph 8.3.
ATTENTION!
Dosing pumps with explosion-proof motors must be installed and commissioned by specialists qualified
to work with equipment intended for use in potentially explosive atmospheres. The user is responsible for
ensuring that explosion-proof motors are connected correctly. Both the motor and the dosing pump must be
grounded to prevent electrostatic discharges.
DANGER!
Risk of burns. Shock wave: parts may fly off and cause fatal injury. FEDOS DX must not be used in a poten-
tially explosive atmosphere under any circumstances. The electrical connection of the dosing pump must be
made according to local rules and regulations and may only be carried out by qualified technical personnel.
NOTE!
The dosing pump must be plugged into a grounded power outlet.
The 230 V AC version of the FEDOS DX is connected by a shockproof earthing-pin plug. The 115 V AC ver-
sion is equipped with a UL/CSA plug.
NOTE!
Signal cables must not be laid parallel to high-voltage current lines or mains cables. Lay supply and signal
lines in separate channels. An angle of 90° is required at line crossings. If signal lines are more than 2
meters long, shielded cables must be used.
ATTENTION!
To avoid premature wear of the gear, always ensure the correct rotation direction of the motor: counter-
clockwise (to the left), looking toward the fan wheel.
16 | Operating Manual FEDOS E/DX | Installation

7.3.1 Drive motor connection
IMPORTANT!
Note the data on the motor rating plate
Connection FEDOS Phases Motor sup-
plier
Note
W2 U2 V2
U1 V1 W1
L1 L2 L3 PE
E 3~ All Y-connection (Standard)
W2 U2 V2
U1 V1 W1
L1 L2 L3 PE
3~ All Delta connection
FEDOS E three-phase motors
Connection FEDOS Phases Motor supplier Note
Z1
TB2
U2
U1 Z2
TB1
L N PE
CB E 1~ ATB
U1
Z1
U2 PE
C
12345
T1 L N
T2
Z2
1~ EMG 230 V AC
or 120 V AC (CSA)
FEDOS E alternating current motors
Connection FEDOS Motor supplier
U2
V2
U1
W2
L2 Stop L1 Run PEN
W1 V1
L
C
Temp.
DX ATB
Installation | Operating Manual FEDOS E/DX | 17

Connection FEDOS Motor supplier
U1
Z1
U2 PE
CL
12345
T1 L1 L2 N
T2
Z2
Run Stop
DX EMG
FEDOS DX alternating curent motors
FEDOS DX Control unit Standard version CSA version
L1 RUN BR (brown) BK (black)
L2 STOP BK (black) RD (red)
N BU (blue) or GY (grey) WH (white)
PE GN/YE (green/yellow) GN/YE (green/yellow)
Connection between FEDOS DX control unit and motor
7.4 Wiring diagrams for ATE servomotor for stroke length adjustment
See the accompanying operating instructions for the ATE servomotor.
18 | Operating Manual FEDOS E/DX | Installation

7.5 Level monitoring
If a level monitor is connected, the jack plug has to be covered by a plastic sleeve in order to maintain the
protection class. The required sleeve is part of the level monitor (also in combination with a suction line).
With the level monitor connected, the dosing pump stops if the chemical level in the supply tank is low, in
order to prevent air bubbles from entering the suction line and the dosing head. The red LED is lit. As soon
as the level contact closes again, the dosing pump restarts.
The level sensor must be designed as a max. N.O. contact.
FEDOS is equipped with a 2-stage level monitor. When the first contact breaks (low level alert), the red LED
begins to flash. The dosing pump continues to operate. The fault signalling relay is actuated. The dosing
pump only stops when the second contact breaks (main alarm). The red LED is lit continuously.
The "low level alert" function is not available when using a 2-pin connector and a simple float switch.
NOTE!
A dummy plug (Part No. 29115) must be attached if a float switch is not connected. The dosing pump is
delivered with a dummy plug already attached. If a float switch is to be connected, the dummy plug has to
be removed before inserting the jack plug.
7.6 Pressure control and safety valves
Pressure control valves are used to optimise the dosing process. They are used:
• to increase the dosing accuracy in the case of fluctuating backpressure.
• when the dosing lines are long, in order to prevent excess delivery, since the accelerated medium
continues moving due to its own inertia even after the delivery stroke has ended.
• to prevent siphoning, if the supply pressure is higher than system pressure.
Pressure relief and safety valves are used for overload protection of the dosing pump and the associated
valves and lines. They prevent inadmissible pressure rises in the delivery side system of the dosing pump;
for example, if shutoff valves close while the pump is running, or if the injection nozzle is clogged.
7.7 Injection nozzle installation
Injection nozzles are used to inject the metered medium into the main flow, while at the same time acting
as non-return valve. The injection nozzle is usually mounted from the top into the main line. Mounting from
below is recommended only for media that have a tendency to crystallise, in order to prevent air bubbles
from being trapped in.
For media that tend to contaminate the injection nozzle, we recommend installing an injection nozzle that
can be shut off and removed for maintenance purposes.
a
b
a Injection nozzle mounted from above, b Injection nozzle mounted from below (for media that tend to crystallise)
Installation | Operating Manual FEDOS E/DX | 19

1
2
3
4
5
6
7
8
7.8 Installation example
aDosing pump
bSuction line
cElectrical agitator
dTank
ePressure relief valve
f Diaphragm shutoff valve
g Injection nozzle
h Pulsation damper
20 | Operating Manual FEDOS E/DX | Installation