Marco 164 622 15-US User manual

10/05/17 Rev.04
© S.p.A.
INSTRUCTIONS FOR USE
SELF-PRIMING ELECTRIC PUMP
FOR TRANSFERRING VARIOUS LIQUIDS
164 622 15-US - UP6/E 12/24V

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AIR VENT VALVE ACTIVATION
When starting the pump, or when emptying the tank, slightly open the small valve
in order to let the air out and facilitate the priming.
As soon as the pump is operating close the small valve.
ELECTRONIC PRESSURE SENSOR
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ELECTRONIC PRESSURE SENSOR WORKING DIRECTIONS
The electronic pressure sensor, through the use of a microprocessor, controls the
pump's speed to obtain the needed flow rate, with the following advantages:
- Noise reduction during operation
- The optimization of current consumption
- A strong reduction of electrical noise, thanks to the slow speed ramp up and
ramp down of the motor.
- A longer life for the whole system, thanks to less wear of pump parts
compared to conventional mechanical pressure switches.
The pressure sensor system is equipped with two LEDs: one blue and one multicolored
(red, green, and yellow).
During normal operation, the blue LED will:
- Turn on if there's liquid in the hoses.
- Turn off when there's no liquid in the hoses.
- Flash when in priming mode. The first time it senses water it keeps flashing
for 10 seconds to make sure that the water is being pumped correctly and
continuously.
If the pump goes more than five times from “priming” to “no liquid” (blue led off)
the circuit turns everything off anyway, to protect the motor and the gears from
running without liquid.
The multicolored LED signals:
- With solid yellow LED, that the pressure in the hoses is not the required
pressure, but the pump is trying to reach it.
- With solid green LED, that the pump has reached the target pressure, there
is still liquid demand, but the pump's speed won't be changed because the
flow rate is constant.
- With flashing green LED, the pump has reached the target pressure and
there is no liquid demand, it's in stand-by with the motor off.
- With solid or slowly flashing red LED, the motor has been short circuited,
something may have blocked the gears or there could be a problem in the
connection between the pump and circuit. The red LED flashes for 30
seconds, after which the pump is re-fed up to a maximum of 3 attempts.
On the fourth attempt, the LED remains solid red, the pump is off and should
be checked for possible permanent damage. To reset this warning you need
to reboot the circuit or press the Reset button on the control panel, if present.
(follows)
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- With fast flashing red LED, the pump is being overloaded (due to viscous
liquids or gears overheating). While the pump is running, the speed is reduced
to keep the current up to the nominal value for 30 seconds, period after which
the circuit tries to release again the motor to its normal operating speed.
If an overload happens again, the circuit tries three time to lower the speed
and it turns the pump off. Please check that the liquid being pumped is correct
for the chosen pump and that the gears move freely without problems.
To reset this warning you have to reboot the circuit or press the Reset button
on the control panel, if present.
There are two warnings that use both LEDs:
- Red and blue LED that blink alternatively, signal that the pump has run one and
a half minute without liquid and the motor has been stopped for this reason. To
reset this warning you have to reboot the circuit or press the Reset button on the
control panel, if present.
- Yellow and blue LED that blink together indicate that the power supply is
providing the wrong voltage. Please check to have the correct wire section for
the power supply and a charged battery, if present.
- Steady red and blinking Blue indicate that the pump has run for more than two
hours at very low speeds and that the motor has been stopped to prevent
overheating. To reset this warning you have to reboot the circuit or press the
Reset button on the control panel, if present.
An accumulator of at least ½ liter is recommended in case of rigid or short pipes, in order
to increase even more the system's life.
Please mind that no pressure regulators or additional check valves are suggested on
pump's line, as those may interfere with the electronic pressure sensor.
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PRODUCT DESCRIPTION
TECHNICAL DETAILS
APPLICATIONS
FLUIDS ALLOWED / NOT ALLOWED
There are numerous fields of applications for the pump, however only exclusively with the
allowed liquids mentioned:
Ø
boats, camper
ØWater pressure systems
ØTransfer of light weight lube oils, antifreeze
Main use as automatic pump for freshwater and sanitary water systems on
Self-priming gear pump, integrated check valve and electronic pressure sensor: to be used
as automatic pump. Nickel-plated brass body, PTFE gears, stainless-steel shaft and lip seal.
The electronic pressure sensor is preset at 36.3 psi.
Tab.1 EN
CODE TYPE VOLT WIRE SIZE (**)
AWG 14
(*) Internal tube 16 mm-0,65 in / (**) Length up to 6.6 ft
A 20
FUSE FLOW RATE (*) PRESSURE WEIGHT
IP 67 Protection
gpm 6,9 psi 36,3 lb 7,9164 622 15-US UP6/E 12/24
Tab.2 EN
FRESH WATER (max 40 °C-104 °F)
PETROL (GASOLINE) •
FLAMMABLE LIQUIDS with PM< 38 °C-100 °F •
LIQUIDS WITH VISCOSITY > 20 cSt •
FOODSTUFF LIQUIDS •
CORROSIVE CHEMICAL PRODUCTS • •
SOLVENTS • •
ISO 8846 Compliant Device
INJURY TO
PERSONNEL
DAMAGE TO SEALS
OK
NO
FKM Lip Seal
LIQUIDS
DANGERS
WARRANTY EXPIRES IF MAX FLUID
TEMPERATURE IS EXCEEDED
FIRE / EXPLOSION
MOTOR
OVERHEATING
FOODSTUFF LIQUID
CONTAMINATION
PUMP CORROSION
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TRANSPORTATION AND HANDLING
INSTALLATION
PRELIMINARY CHECKS
POSITIONING
AMBIENT CONDITIONS
TEMPERATURE: RELATIVE HUMIDITY:min.-10°C 14°F-max.60°C 140°F max. 90 %
OPERATING CYCLE
Under conditions of high operating pressures (eg. with closed or blocked outlet, excessive
length of the delivery circuit and/or excessive pressure due to accessories), it can be
subjected to elevated stresses and overheating and therefore should not be used for
prolonged periods under such conditions.
Due to limited weight and dimensions the pump does not require the use of any special
handling or lifting equipment. When handling manually, normal personal protective gear
should be worn (safety shoes with toe piece, etc.). The pump is carefully packed prior to
shipment. Upon receiving, the packaging should be inspected for damages and the pump
stored in a dry area.
It is recommended that the use of the pump be according to normative safety standards
and also as per the precautions listed below.
The pump can be mounted in any position. Fix the pump utilizing suitable diameter
screws corresponding to the holes.
Check that there has been no damage to the pump during transportation or storage. Both
inlet and outlet ports should be carefully cleaned removing possible dust or residual
packaging material. Verify that the available electrical power supply corresponds to the
specification requirements.
WARNING: the above indicated temperature ranges are applicable to all components
of the pump and these limits must be respected in order to avoid any possible damage
or malfunctioning.
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To ensure the correct directional flow of the fluid as indicated by the arrow on the top plate, it is
necessary to connect the positive pole (+) of the battery supply to the red wire on the motor
end-cap and the negative pole (-) to the black wire. Electrical connections must be made
using adequate terminal blocks and connectors ensuring a tight fitment of the electrical
cables. Bad wiring can cause power losses and/or overheating of the cabling itself.
Ø
Ø
Ø
Prior to making any tube/hose connections, check that the inlet ports have no end
caps;
Do not position the pump at a excessive height with respect to the minimum level of
the fluid to be transferred. Damage may occur if this height is exceeded as the pump
may not draw fluid. Make sure that the outlet tube is empty and without chokes;
Avoid choking the inlet or outlet tubes so that efficiency is optimized.
The use of an inlet filter is recommended especially with fluids containing impurities
(mesh ASTM no. 35).
Utilize tubes and connection pieces that are resistant to the fluid types handled and
avoid any possible environmental dispersion.
Ø
Ø
In this case frequent cleaning and maintenance of the filter is
advisable. The standard filter withstands a maximum positive pressure of 0.5 bar.
The electrical installation of the pump must include a protection fuse which is suitably rated
as indicated on the motor label.
Always mount the anti vibration rubber fittings supplied with the pump kit. Their usage
ensures a consistent reduction in noise and vibration levels. Electrical cabling size should
depend on the distance between pump and battery power supply (see Tab.1 EN). The use of
undersized cabling can cause overheating of the electrical wiring and subsequent fire
hazard. There will also be a voltage drop at the motor terminals with a consequent reduction
in efficiency. The flow rate value indicated on the motor label is obtained with internal tube
diameter indicated on Tab.1 EN. Tubes with inferior diameters will cause an increase in
current with potential risk of motor overheating.
WARRANTY EXPIRES IF NO FUSE IS UTILIZED
WARNING: it is the responsibility of the installation technician to ensure a correctly
designed circuit installation fitted according to regulations. Environmental risks must
be taken into account with the installation.
WARNING: DUE TO THE EMI FILTER THE PUMP IS NOT SUITABLE FOR
SWITCHING APPLICATIONS
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TROUBLESHOOTING
WHY THE PUMP WILL NOT PRIME ITSELF?
CHECK POINTS IF THE PUMP HAS STOPPED OR WILL NOT START
GOOD PRACTICES ENSURING A WELL FUNCTIONING PUMP
Ø
Ø
Ø
Ø
Ø
Check the effectiveness of the battery power supply (voltage activity);
Check if the fuse has blown;
Check for any foreign matter present in the pump body. To do this, disconnect the
power supply and unscrew the four fixing screws, remove the front cover plate and
inspect the chamber. Replace the cover plate in the same initial position after
inspection;
Avoid running the pump dry for more than a few minutes. Pumps found defective
that have run dry in the absence of fluid are not covered by warranty;
The average life span of the motor commutator brushes is approximately 2500
hours under normal operating conditions. Stoppages are possible due to brush
wear and tear after such a time period.
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Ø
The pump is fitted at an excessive height above the fluid level
The pump has run dry for too long a period
Long periods of inactivity. In this case it is advisable to add liquid directly into the
chamber before start-up
Air leak at the suction pipe due to the following reasons, possible cuts in the pipe,
inadequate hose clamps, malfunctioning of the filter due to defective/worn seals or
filter clogged
Air leak at the front plate cover due to the following reasons, loose fixing screws,
poor effectiveness of the seal
Faulty electrical cable connections
Presence of obstructions or restrictions in the suction or delivery pipes or the use of
special devices(eg. automatic spray pistol or aqua-stop)
Presence of liquid loops in the outlet tube
ØDirty bypass valve (VP45 series)
If it is expected that the pump will not be used for a period of at least 30 days, especially in the
case of usage with water, it is advisable to run fresh water through it and to then loosen the
front plate screws. Upon re-use, run the pump briefly (a few seconds) and tighten the screws
again. Check under conditions of maximum operating pressure that the motor current value
is within the motor label specifications.
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NORMAL MAINTENANCE
INDICATORS THAT THE PUMP IS FUNCTIONING CORRECTLY
TO OPEN THE PUMP
ENVIRONMENTAL DISPOSAL
WARRANTY
PACKAGING ENVIRONMENTAL DISPOSAL
Ø
Ø
Ø
Check frequently and keep the inlet filter clean.
Check every month the chamber and keep clean from any foreign matter.
Check every month that electrical wiring is in good condition.
ØReplace the rubber impeller every season or every 500 hours (for UP1 series).
Ø
Ø
Ø
Temperature of body and motor frame is within 60°C and 70°C (140 °F - 158 °F);
Regular flow and constant noise levels;
Amp-draw within the limits indicated in the diagrams.
Ø
Ø
It is recommended that a specialized service technician be consulted for any
repair work or the replacement of worn out internal components, exclusively with
original spare parts;
During the warranty period, only by authorized Marco S.p.A. personnel, failing
which the warranty will expire.
Do not dispose of pumps into household waste: pumps that are no longer usable, must
be collected separately and and disposed of in an enviromentally correct manner.
The user is invited to effect a proper waste separation, in order to facilitate the recycling
of the materials of which the packing is composed.
1) The Warranty period is 2 years from date of purchase on production of the
appropriate sales invoice.
2) Should the original sales invoice not be available, then the 2 year warranty
period will be valid from production date.
3) The Warranty becomes null and void in the case of incorrect utilization or
disregard of the instructions contained herein.
4) The Warranty only covers original production defects.
5) The Warranty does not cover any related installation costs involved.
6) Transport costs are refundable only in the case where warranty has been duly
accepted by Marco Spa and they will be limited to the actual shipment costs
between Marco Spa warehouse and the client's delivery address.
7) No credit notes or replacement items will be issued prior to the receipt and
proper testing of any Marco goods that are deemed faulty.
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EXPLODED VIEW
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DIMENSIONS
mm pollici / inches
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DIAGRAMS
FLOW RATE DIAGRAM
AMPERE-DRAW DIAGRAM
0
2
4
6
8
10
0 10 20 30 40
psi
gpm
0
5
10
15
20
0 10 20 30 40
psi
A
12V
24V
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EN 55014-1 Electromagnetic compatibility.
Requirements for household appliances,
electric tools, and similar apparatus.
Part 1: Emission.
This declaration is given under the sole responsibility of:
MARCO S.P.A.
Via Mameli 10 - 2501 Cas enedolo - Brescia - Italy 4 t
Tel. [phone] Fax [phone]
EN 55014-2 Electromagnetic compatibility.
Requirements for household appliances,
electric tools, and similar apparatus.
Part 2: Immunity.
is in conformity with the Directive 2014/30/EU (ex. 2004/108/EC) relating to electromagnetic compatibility.
This declaration is valid for all products which are produced in accordance with the technical documentation which
is a part of this declaration. For verification of conformity with regard to the Electromagnetic Compatibility the
following standards are applied:
We confirm that the product:
E.C. DECLARATION OF CONFORMITY
164 622 15 - UP6E 12/24V Electronic Gear pump
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Property of MARCO S.p.A reproduction prohibited. All rights reserved.
For further information visit our web site - www.marco.it
Marco S.p.A Via Mameli 10 - 25014 Castenedolo (Brescia) – Italy
tel. [phone] / Fax [phone]