Defoamer Metering System Installation Instructions Product Documentation/Service Bulletins...Defoamer Metering System Installation Instructions 8 / 14 SB00027_A Step 2 Using the nuts

CONFIDENTIAL

Microseparator™ Coolant Management Systems

bazell technologies™www.bazell.com +1 925.603.0900

Service BulletinSB00027 Rev A

Approvals

Engineering Ronald Kappesser

Manufacturing Chris Bazell 10-7-2014

Name Signature Date

Defoamer Metering System Installation Instructions


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IntroductionThe installation of the defoamer metering system varies by system type. To install it on your system go to the appropriate section. In all cases, the installation should be done with the system powered down to avoid risk of shock or damage to equipment

HC2/3/V‐TwinUltra

MechanicalInstallation

AssemblyIf the metering system is shipped unassembled, then it needs to be put together. If your system comes pre-assembled you may skip to step 2.

Step1As shown in figure 1, the pump mounting bracket attaches to the shelf using 4 #10-32 screws. After installing the #10-32 screws, install the supplied grommet and install the supplied #8-32 screws and acorn nuts to the bracket. The #8-32 screws should be screwed into the bracket then the acorn nuts should be tightened onto the screws to make the screw heads stick out the right length for the metering pump. Use Locktite 242 or similar thread locker for all threads.

Figure 1 - Bracket Assembly

Acorn Nut

10-32 Screw

Shelf

Bracket

Grommet


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Step2Install the metering pump to the pump to the assembled pump mounting bracket as shown in figure 2.

Figure 2 Pump Installation


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Step3Hang the metering system on the side of the tank in a convenient location. Use a nearby bolt and the supplied clip to secure the metering system in place.

Figure 3 - Metering System Installation

Step4: Modify bottle to install tube 1/4" tube fitting as shown in on the last page of this document.

Clip


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Step5: Install tubing as shown:

Route Tube to Clean Side of Tank


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ElectricalInstallationWARNING: The tank junction box contains high voltages that can kill or injure you. If you are uncomfortable working with electrical wiring, have this step done by a qualified electrician. Ensure that Power is disconnected from the system. Trim the metering pump cord to length and wire the metering pump in the following way: Green to GND White to 2 Black to 0:10A Note that on some systems 0:10A is labeled as 7T2

Figure 4 - Junction Box Wiring

White

Green

Black


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HC1/HC6

InstallationOptionsThe bottle bracket may be installed in one of two ways depending on your requirements. If the standard location of the metering pump is acceptable, then skip to step 3. Otherwise, follow the procedure below.

Step1Remove the m12 power connector from the existing metering pump Remove the screws holding the metering pump in place

Figure 5 m12 Connector and Mounting Screw Location

m12 connector

mounting screws


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Step2Using the nuts included with your kit, install the pump Re-route existing m-12 cable to the pump or order a new cable if needed.

Step3Modify bottle to install tube 1/4" tube fitting as shown in on the last page of this document.

Step4Hang bottle off the side of the tank in a convenient location and secure with supplied fender washer and bracket as shown in figure #

Figure 6 Mounting Bracket Installation

Fender Washer

Mounting Bracket


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Step5If not relocating the metering pump, just connect the 1/4" tubing to from the metering pump to the bottle. If the metering pump is mounted on the bottle shelf, then connect the tubing as shown below. Also reconnect the m12 power cable at this time.

ICS/ICSPro

MechanicalInstallation The metering system for the ICS and ICS Pro is shipped assembled.

Step1Hang the bracket on the clean side of the tank as shown and install the bracket clip using the supplied fender washer.


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Step2Modify the defoamer bottle per the instructions on the last page of this document and route the hose from the pump to the clean side of your tank.

Figure 7 - Installed mounting Clip


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ElectricalInstallationWARNING: The tank control panel contains high voltages that can kill or injure you. If you are uncomfortable working with electrical wiring, have this step done by a qualified electrician.

Step1Route the 9 pin control cable from back of pump into control panel.

Step2Disconnect one of the 3 leads going to the feed pump and place the current switch around that lead then reconnect it. Secure the current switch in place with a zip tie. Then reconnect the lead to the motor starter.

Step3Connect the red wire on the current switch to the gray wire on the 9 pin control cable and connect the black wire on the current switch to the blue wire on the control cable using wire nuts and electrical tape.

Step4Plug the pump into 110V AC power.

Step5After installation, but before its first use the metering pump needs to be set up for use. This involves 3 steps:

A. Setting the tubing diameter

B. Setting the pump to run triggered by the current switch

C. Setting the dosing rate

Figure 8 - Current Sensing Switch Installation


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Figure 9 Front Panel of Metering Pump

Step5A‐SettingthetubingdiameterTo set the tubing diameter turn off the pump using the switch on the back. Then hold down the Diameter key on the front panel while the pump powers up. Set the diameter to the inside diameter (in inches) of the tube you are using (usually 1/16).

Step5B‐Settingthepumptoruntriggeredbycurrentswitch1. To set the trigger mode press the diameter/setup key until it displays 'othr'

2. Press any arrow key to select

3. Press the diameter/setup key again until ttl displays

4. Press any arrow key to select

5. TR:xx should display where xx is the current setting. Use the keys to select FH

Now the pump will start pumping when it sees the current at the current switch and stop when it doesn't. NOTE: the pump only senses transitions from on to off and back, so if the current switch is triggered when the trigger mode is set, the pump will not begin pumping until the current switch stops sensing current and then senses it again, so it is best to change the setting when the triggering system (such as the ICS) is off.

Step5C‐SettingthedosingrateYou can set the dosing rate by using the arrow keys under the displayed number. If you need to move the decimal point to get a lower dosing rate then press and hold the left-most arrow key. It will scroll past 9 to 0 and then the decimal point will start moving to the right. Keep holding the key and it will cycle through to the leftmost position. Our recommended initial dosing rate of Lohfoam 10 is 0.017 ml/min for and ICS or ICS Pro, but you may need to raise or lower this depending on your system.

BasicOperation

StartingandstoppingthepumpOnce the pump is set up, you should not need to interact with it. As long as the red pumping light is lit, the pump is pumping, even if the rate display displays 'off'. If the red light is blinking, the program is paused. If it is blinking and your system is running, you can resume the pumping program by pressing start. The start will also allow you to manually start the pump.


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PrimingthepumpWhen changing the bottle, it is necessary to prime the pump. To do so, press and hold the start button until fluid has completely filled the tubes.


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ModifyingLohfoam10bottleformeteringsystem

Step1Measure the bulkhead fitting supplied with the metering system.

Step2Remove lid and drill a hole in the lid that is the large enough to fit the bulkhead fitting. Install the bulkhead fitting into the cap.

Step3Trim the supplied piece of semi-rigid tubing to the same 1/4" [4mm] shorter than the bottle and straighten it. Then install the tube into the bottom of the push to connect fitting.

Step4Put the cap back inside the bottle. The end of the tube should be about 1/8" off the bottom of the bottle. If it is closer or further then adjust the position of the bulkhead fitting to get the position right. You may reuse the cap on your next bottle of defoamer.

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Defoamer Metering System Installation Instructions Product Documentation/Service Bulletins...Defoamer Metering System Installation Instructions 8 / 14 SB00027_A Step 2 Using the nuts