CONTROLAUTOMATICO

INSTITUTO POLITCNICO NACIONAL ESCUELASUPERIORDEINGENIERIAMECANICAYELECTRICA
UNIDADPROFESIONALADOLFOLPEZMATEOS
CONTROL AUTOMTICO DE FLUJOS QUMICOS PARA EL ACONDICIONAMIENTO DEL SECADOR YANKEE

T E S I S

QUE PARA OBTENER EL TTULO DE: INGENIERO EN CONTROL Y AUTOMATIZACIN
PRESENTAN:
IVAN HERNNDEZ GARCA JOS LUIS HERNNDEZ PEREA
ASESORES:
M. EN C. PEDRO F. HUERTA GONZLEZ ING. JESS HERNNDEZ MUOZ
MXICO, D.F. 2010
NDICE
Objetivo General............................................................................................................................1 Objetivos Especficos.....................................................................................................................2 Introduccin....................................................................................................................................3 CAPITULO I Marco Terico...........................................................................................................4 1.1 Descripcin general del proceso de fabricacin de papel tissue.......................................5 1.1.1. Descripcin del proceso de secado......................................................................10 1.1.2. Descripcin del proceso de crepado....................................................................10 1.1.3. Descripcin del proceso de acondicionamiento del secador Yankee.............. 12 1.2 Conceptos de crepado.......................................................................................................16 1.2.1. Definicin de crepado...........................................................................................16 1.2.2. Geometra de crepado..........................................................................................18 1.2.3. Qumica del crepado.............................................................................................22 1.2.3.1. Caractersticas de qumicos adhesivo, release, monofosfato...................22 1.3 Sistema Yankee Spray......................................................................................................24 1.3.1. Diseo de regadera Yankee Spray......................................................................24 1.3.1.1. Seleccin de espreas para regadera yankee spray.................................25 1.3.2. Clculo de slidos depositados en la superficie del secador yankee..................26 1.4 Definicin de control automtico...26 CAPITULO II Antecedentes.........................................................................................................28 2.1 Sistema Yankee spray actual...........................................................................................32 2.1.1 Dimensiones de regadera Yankee spray................................................................33 2.2 Planteamiento del problema, Filosofa de control............................................................34 2.2.1 Anlisis del problema..............................................................................................34 2.2.2 Diagrama Porque-Porque (Causa - Raz)..............................................................38 2.3 Justificacin.......................................................................................................................39 2.3.1 Consecuencias en la produccin............................................................................39 2.3.1.1 Prdida por generacin de merma...................................................................47
CAPITULO III Desarrollo (Propuesta de solucin).....................................................................50 3.1 Diseo Propuesto de regadera Yankee..........................................................................51 3.2 Seleccin de Hardware.....................................................................................................52 3.2.1 Determinacin de tipo de bombas..........................................................................54 3.2.2 Determinacin de protocolo de comunicacin........................................................56 3.2.3 Configuracin de HMI.............................................................................................57 3.2.4 Fuente de alimentacin..........................................................................................58 3.2.5 Gabinetes...............................................................................................................58 3.2.6 Conexiones.............................................................................................................59
3.3 Seleccin de Software......................................................................................................60 3.3.1 Configuracin de comunicacin..............................................................................60 3.3.2 Configuracin de HMI............................................................................................ 60 3.4 Actividades para el Plan de Mantenimiento....................................................................60
CAPITULO IV Anlisis Costo Beneficio.......................................................................................61
4. 1 4. 2 4. 3 4. 4
Presupuesto..................................................................................................................62 Anlisis de Costos.........................................................................................................62 Beneficios obtenidos.....................................................................................................62 Rendimiento de la inversin ROI...................................................................................63
CAPITULO V Conclusiones.........................................................................................................64 5.1 Conclusiones.................................................................................................................65 5.2 Observaciones..............................................................................................................66
Fuentes de Consulta...................................................................................................................66 Anexos.........................................................................................................................................66
Objetivo General. Controlar la dosificacin de los flujos qumicos: resina, release y monofosfato, para el recubrimiento de la superficie del secador yankee de la mquina de papel No. 3 de Planta Ecatepec Tissue de SCA Mxico y Centroamrica S.A de C.V. por medio de bombas dosificadoras con seal de 4-20mA.
INGENIERA EN CONTROL Y AUTOMATIZACIN
Objetivos Especficos. Determinar el diseo de la regadera Yankee Spray. Determinar la capacidad y el tipo de bombas para la dosificacin de qumicos. Determinar la conexin de bombas y configuracin de comunicacin al sistema de control (Total Plant Solution, Sistema de control distribuido, marca Honeywell). Configurar la pantalla para monitoreo y control de los flujos de qumicos en interfase hombre mquina (HMI) del TPS. Establecer Plan de mantenimiento del Sistema Yankee Spray.
Introduccin
En el desarrollo de este proyecto se analiz que existen diversos problemas en la funcionalidad del papel durante el proceso de enrollado y en el rea de conversin, es decir, el papel se revienta con gran facilidad. El problema de reventadas y conceptos como tronadas, patinadas, bobinado flojo, orilla floja, se deben a una gran combinacin de variables que pueden afectar en el proceso de fabricacin de papel tissue. Al estudiar el proceso de fabricacin de papel tissue, encontramos que uno de los procesos fundamentales, es el acondicionamiento del secador Yankee, esto es, suministrar una mezcla de qumicos a travs de una regadera, para formar una capa que recubre la superficie del secador yankee, la cual permite tomar la hoja de papel de la zona de prensado a la zona de secado, adems de poder lubricar el yankee y disminuir la friccin entre la superficie del secador y las cuchillas de corte, crepado y limpieza, y poder despegar la hoja para realizar el procesos de enrollado. Se realiz el anlisis porqu, de la falta de acondicionamiento del secador yankee e identificamos que el sistema de dosificacin de qumicos para realizar la mezcla del recubrimiento, se encuentra en condiciones desfavorables, las bombas se encuentran en condiciones ambientales expuestas a altas temperaturas, con una ubicacin de alta inseguridad, la operacin de las bombas para el control de los flujos qumicos se realiza de manera manual. Por lo que dentro de este proyecto se realiza la propuesta de automatizacin de lazo abierto de los flujos qumicos para el recubrimiento del secador yankee. La automatizacin del acondicionamiento del yankee se realiz a travs del control con el que cuenta la planta actualmente, el cual es el Total Plant Solution (TPS) de Honeywell. El desarrollo del proyecto, es controlar los cambios de dosificacin de los qumicos a travs de la Interfase Hombre Mquina del TPS. Esto es mediante una seal de 4 20 mA que manejan las bombas dosificadoras de cada qumico, y visualizarlas en la HMI de control para que la ejecucin del control sea ms rpida y efectiva y as disminuir las prdidas de produccin por falta de acondicionamiento del secador yankee.
Capitulo I Marco Terico. 1.1 Descripcin general del proceso de fabricacin de papel tissue. Materias primas (Fibras) Todo papel se produce con fibras de origen vegetal (celulosa), las que luego de ser dispersadas en una mezcla acuosa, se entrelazan en un proceso de formacin en hmedo y luego se secan para formar una hoja continua la cual es enrollada para poder luego ser procesada en la conversin de productos finales. Las fibras pueden tener distintos orgenes tales como madera de pino, eucaliptus, lamos y otros, as como de subproductos de otras fibras vegetales tales como la caa de azcar. Estas pueden obtenerse como fibras vrgenes (celulosas), las cuales tpicamente pueden ser de fibras largas provenientes del pino o fibras cortas provenientes de distintas variedades de eucaliptus. Otro origen de la fibras para el proceso de fabricacin de papel son las Fibras Secundarias o papeles viejos para reciclar los cuales contienen la celulosa con la cual fueron hechos originalmente ms otros elementos extraos a la celulosa que se agregaron para su uso final tal como recubrimientos plsticos, corchetes, adhesivos y lacas, tintas, etc., y que deben ser removidos en el proceso. Preparacin de las Pastas Las fibras ya mencionadas deben ser seleccionadas, preparadas y mezcladas de acuerdo a las caractersticas y usos que se requieran para cada producto especfico; as un papel para toallas de cocina, por ejemplo, tendr una mayor proporcin de fibras largas y un tratamiento de estas fibras que le otorgue una buena resistencia y absorcin , mientras que un pauelito de papel tendr una mayor proporcin de fibras de eucaliptus y un tratamiento de baja intensidad, para otorgarle una mxima suavidad . Las fibras son dosificadas y mezcladas con agua en una especie de juguera gigante llamada Pulper, donde son disgregadas formndose una pulpa que luego es procesada de acuerdo al origen de esas fibras. En el caso de las fibras vrgenes, que no contienen impurezas, estas pasan por unos filtros muy simples para retirar piedrecillas o contaminantes menores que pudiesen haberse adherido durante su transporte, y son enviadas directamente a los estanques de alimentacin de la Mquina Papelera para ser luego inyectadas a esta, solas o en mezcla con otras fibras.
En el caso de las Fibras Recicladas, luego de su disgregacin en el pulper, estas son procesadas en distintos equipos y etapas para retirar las distintas impurezas o elementos extraos que acompaan a las fibras: depuracin centrfuga para eliminar elementos pesados tales como clips, corchetes y arena ; depuracin en coladores presurizados (perforaciones y ranuras de distintos tamaos) para eliminar trocitos y grumos de plsticos , adhesivos, etc.; lavado y flotacin para eliminar tintas y cargas minerales . Una vez que las fibras han sido depuradas de los elementos extraos, la pulpa o pasta, est en condiciones de ser alimentada sola o en mezcla, al proceso de fabricacin del papel (mquina papelera). Fabricacin del Papel (Mquina Papelera) En la mquina papelera se procesa la mezcla escogida de las pastas ya descritas y se transforma en un gran rollo de papel (Jumbo Roll); si bien los conceptos generales de las mquinas para distintos tipos de papeles son similares, una mquina papelera tissue tiene caractersticas especiales ya que debe producir papeles muy livianos y que sean crepados para otorgarles la flexiblidad, suavidad y absorcin que requiere el producto final. Estas caractersticas se obtienen en la mquina con los siguientes procesos consecutivos y simultneos:
Formacin : Consiste en inyectar la mezcla de agua y fibras (pasta ) sobre una o ms mallas sin fin, en movimiento, donde gran parte del agua es retirada, dejando una trama de fibras que forman una hoja continua, pero todava bastante hmeda. Prensado: La hoja hmeda es transferida, siempre en movimiento, a un pao (especie de alfombra sin fin), que la transporta hacia las prensas, que son rodillos perforados (1 o 2) los cuales presionan la hoja contra un enorme cilindro secador (Yankee), extrayndole una gran cantidad de agua por este efecto. Secado: El secado final de la hoja se efecta con esta adherida al cilindro secador (Yankee), como combinacin del efecto del contacto con su superficie a mas de 100C (el yankee es calentado internamente con vapor a presin), y del soplado por su otro lado de aire caliente a 500 C por una campana o capota envolvente que rodea al Yankee. Todo este proceso dura slo un par de segundos ya que el papel viaja sobre el Yankee a una velocidad cercana a los 100 kilmetros por hora. Crepado y Enrollado: El crepado es un proceso clave para otorgar a la hoja de papel tissue caractersticas de flexibilidad, suavidad y absorcin que la diferencian de los papeles lisos y consiste en micro arrugas a travs de toda la hoja que se obtienen mediante una lmina crepadora que separa la hoja del Yankee en movimiento para que sta quede libre para ser enrollada en la ltima parte de la mquina; como la enrolladora gira a una menor velocidad que el cilindro Yankee, la hoja tiende a permanecer contra la lmina, generndose as las arrugas o crepado. La hoja crepada es finalmente enrollada
generndose una bobina de grandes dimensiones (tpicamente de 2 metros de dimetro y 2 toneladas de peso) a la que se le denomina Jumbo.
Figura 1.1 Diagrama General sobre el proceso de papel
Figura 1.2 BAM Bussines Activities Map, Fabricacin de Papel Tissue Mquina No. 3
1.1.1 Descripcin del proceso de secado. En una mquina de papel tissue de alta velocidad, el secado por evaporacin se transforma en un proceso de mucha trascendencia, porque es un solo secador, aunque el papel es de peso base muy bajo.
Figura 1.3 Ubicacin del secado por evaporacin Sistema Yankee
Una mquina de papel que utiliza un solo secador (el yankee) para secar el papel, puede diferenciarse de la que utiliza multi cilindros, por lo siguiente: a.- El yankee cumple la funcin de secado en una sola superficie. b.- Algunos grados de papel, como el tissue, son muy dbiles cuando est la hoja hmeda, y el yankee proporciona un excelente soporte para la hoja, pudindose utilizar aire a altas velocidades.
1.1.2 Descripcin del proceso de crepado. El yankee suele tener tres cuchillas: 1.- Cuchilla para separar la hoja del yankee, mientras se cambia la cuchilla de crepado 2.- Cuchilla de crepado. 3.- Cuchilla de control de espesor del recubrimiento del yankee.
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Figura 1.4 Ubicacin de Cuchillas para el proceso de crepado
El crepado imparte una cantidad tremenda de energa mecnica sobre la estructura de la hoja rompiendo y explotando los enlaces y arrugndose para dar las caractersticas de la hoja. Esta energa da calibre y suavidad.
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1.1.3 Descripcin del proceso de acondicionamiento del secador Yankee. Para que el yankee cumpla fielmente su cometido, es necesario que tenga una capa de recubrimiento sobre su superficie, para : a.- Evitar su deterioro. b.- Facilitar las labores que desarrollan sobre su superficie.
Figura 1.5 Imagen del Acondicionamiento la superficie del secador Yankee
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Influencia del recubrimiento del Yankee en las labores que se realizan sobre su superficie a.- Evita el desgaste acelerado de la cuchilla b.- Facilita la operacin de crepado. Importancia de homogeneidad en el recubrimiento del yankee Para mantener una adhesin correcta de la hoja de papel en toda la superficie del yankee, para: a.- Una ptima calidad b.- Una ptima eficiencia en la operacin de la mquina de papel. En el proceso de acondicionamiento del Yankee se realiza la preparacin de los qumicos que son dosificados a travs de una regadera para el recubrimiento de la superficie del secador Yankee. Existen dos tipos de sistema de preparacin de qumicos para el recubrimiento del secador yankee.
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Sistema de alimentacin en lnea

Pressure Equalize Mill
140
Regulador de Intercambiador de presin n presion
Mezcladores
Adhesi Mill Relea Adhesi
Yankee Dryer
filtros
purg
FIGURA 1.6 Sistema de alimentacin en lnea
Sistema de Alimentacin en lnea Ventajas Desventajas
Sistema cerrado limpio. Poca o nula contaminacin

bacteriolgica.
Recubrimiento no uniforme. No es
flexible. la presin de la lnea.
No hay contaminacin de polvo. Fcil mantenimiento.
Depende de
Equipo utilizado ampliamente papeles calidad media

TABLA 1.1 Tabla de ventajas y desventajas del sistema de alimentacin en lnea.
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Sistema de preparacin con tanque

vap
140 F
Control de presin
Intercambiador de calorr
Flotador para control de Nivel de agua. Linea de
Modifie r
3 bar or 40 PSI pressure
Relea
Yankee
filtros
Vlvula de retorno
FIGURA 1.7 Sistema de alimentacin por tanque
Sistema de Alimentacin con tanque Ventajas Desventajas
Presin constante. Flujo constante. Recubrimiento uniforme. Presin uniforme de regadera.
Se ensucia con facilidad. Puede formar microorganismos.
Tendencia alto costo de mantenimiento.
Flexible para cambios de concentracin. Se utiliza para grados de alta calidad y Premium.
TABLA 1.2 Tabla de ventajas y desventajas del sistema de alimentacin por tanque
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1.2 Conceptos de crepado. 1.2.1 Definicin de crepado. El crepado aumenta la superficie especfica del papel y abre las fibras, permitiendo mayor capacidad de absorcin y mayor flexibilidad que las de una hoja de papel corriente. El conocimiento del crepado, es la llave para poder hacer negocios en la industria del papel Tissue.
FIGURA 1.8 Funcin de la cuchilla de crepado
La funcin de la cuchilla de crepado es separar al papel de la superficie del yankee.
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FIGURA 1.9 Separacin de la hoja de la superficie del secador
Otra funcin no menos importante es la de estructurar el crepado del papel tissue. Separacin del papel de la superficie del secador Para que la hoja de papel sea separada del yankee, es necesario que la punta de la cuchilla venza las fuerzas que adhieren a la hoja a la superficie del secador yankee.
FIGURA 1.10 Acercamiento de la separacin de la hoja del secador
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La carga que se tiene en la punta de la cuchilla debe de tener una fuerza tal que enve al papel fuera del cilindro yankee. Condiciones de operacin de las cuchillas La calidad del papel tissue es funcin de la geometra de la cuchilla, por ello para una calidad homognea es necesario que esta condicin permanezca constante. 1.2.2 Geometra de crepado.
FIGURA 1.11 Geometra de Crepado
Si conocemos el bisel de la cuchilla y el desgaste de cuchilla, podemos saber toda la geometra de crepado. Relacin de geometra de crepado Angulo Pocket=90- ngulo portacuchilla+bisel cuchilla .........(Ecuacin 1) Angulo Pocket=ngulo de la hoja+ngulo de salida...............(Ecuacin 2) Para calcular el ngulo Pocket real debemos de conocer el ngulo de desgaste ya que siempre hay una defleccin en la cuchilla de crepado y se calcula: 90 - Angulo de desgaste + bisel de cuchilla(Ecuacin 3)
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Con un ngulo alto de crepado se incrementa la posibilidad de romper los enlaces de la fibra y de esta manera la suavidad se manifiesta en mayor grado, es decir, a mayor ngulo de bisel de la cuchilla se obtiene un mayor grado de suavidad del papel.
FIGURA 1.12 ngulo al de crepado
Consecuencia de un ngulo alto en la calidad del papel Cuando el ngulo de la cuchilla de crepado es alto, se reduce el impacto de la hoja sobre la punta de la cuchilla, dando un crepado ms fino. En estas condiciones la suavidad del tissue se beneficia, debido a que se rompen ms las uniones de las fibras en la hoja debido al borde de la cuchilla. Tericamente es muy fcil mantener una operacin eficaz y constante para la elaboracin de un papel tissue de alta calidad. Las condiciones ideales son difciles de manejar, pero sobre todo mantenerlas constantes y esto es el gran reto del productor de papel tissue. Para mantener la calidad constante del papel tissue, es necesario que los parmetros seleccionados tambin permanezcan constantes Defleccin de la cuchilla La accin de la cuchilla para levantar la hoja de la superficie del yankee se modifica, y esto se har ms acentuado en la medida que el bisel de la punta de la cuchilla sea mayor.
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FIGURA 1.13 Estado de la cuchilla a mayor presin.
Este problema puede conducir a que la cuchilla pierda tanto su poder de separar la hoja del secador y esta logre pasar enrollndose en el yankee. El punto final de esto nos lleva al cambio de cuchilla. El cambio de cuchilla va a estar en funcin de que la cuchilla soporte ms o menos tiempo de trabajo, pero lo real es que cada cambio de cuchilla el dao al yankee es ms acentuado. El cambio de cuchilla de realiza con e l fin de conseguir una calidad deseada en el papel tissue. Pero una cuchilla nueva tiene sus aspectos positivos pero tambin no solo afecta la superficie del secador sino que puede tambin levantar el recubrimiento. Cuando la cuchilla no penetra lo suficiente en el recubrimiento puede ocurrir: a.- La cuchilla rompe las fibras b.- Romper la hoja ocasionando una cada de gua.
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FIGURA 1.14 Consecuencias de una mala penetracin de la cuchilla en las fibras
El tener estos problemas, de operacin, en donde una cada de gua lleva a una prdida de produccin, la que es una prdida econmica, tambin adicionalmente acarrear efectos en la calidad del papel como por ejemplo en la resistencia a la traccin. Si la cuchilla penetra muy profundamente en el recubrimiento, puede ocurrir un dao a la superficie del yankee.
FIGURA 1.15 Consecuencias de una mala penetracin de la cuchilla en la superficie del secador
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1.2.3 Qumica del crepado. 1.2.3.1 Caractersticas de qumicos adhesivo, release, monofosfato. 1. La preparacin del recubrimiento para la superficie del secador yankee tiene 3 componentes bsicos, adhesivo, releases, y finos. 2. Algunas veces el recubrimiento incluye modificadores con bases rehumectables. 3. El adhesivo o resina pega la hoja al secador, puede ser que reticule o flmico. 4. El release controla la adhesividad de la hoja al secador y lubrica a la cuchilla crepadora. 5. Normalmente un recubrimiento (coating) contiene 50% de finos Los qumicos para el recubrimiento del yankee se pueden clasificar en naturales y sintticos: Los que se utilizan son los sintticos, adhesivo resina, release y finos como el monofosfato de amonio. Adhesivo, Resina Las resinas reticulables, son las que tienen un punto en donde son ms adhesivos, sus propiedades son: Los primeros adhesivos fueron componentes naturales de la pulpa, principalmente pitch y hemicelulosas. Ms tarde se dieron cuenta que la adhesin de la hoja puede mejorar adicionando resinas en la pasta. Muchas plantas que producan toallas cafs slo dependan de coating natural y de la resinas de resistencia en hmedo. La mayora de las resinas comerciales son de base epichlorohidrinas de resistencia en hmedo. Release Agente release o liberador. La mayora es en base a hidrocarburos. Mezclado con un recubrimiento orgnico, puede ayudar a: a.- La dureza del recubrimiento. b.- El espesor del recubrimiento. c.- La adhesin de la hoja sobre el recubrimiento. d.- Provee una barrera lubricante entre el recubrimiento y la cuchilla, lo que alarga su vida til. e.- Controla la adhesin de la hoja sobre el secador yankee f.- Controla el grosor del recubrimiento en le secador yankee
polyamidas -
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FOSFATO MONO AMONICO Esto formar una capa ms dura ya que contribuye en los slidos adicionados en el secador y evita la corrosin del secador. Fases dinmicas de la formacin del recubrimiento: a.- Entrecruzado b.- Transicin vtrea c.- Rehumedecimiento d.- Acoplamiento e.- Accin de la cuchilla f.- Curado total Una combinacin de un polmero con el agente release o liberador puede formar un recubrimiento dividido en tres regiones.
FIGURA 1.16 Capas formadas por el release
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1.3 Sistema Yankee Spray. 1.3.1 Diseo de regadera Yankee Spray.
FIGURA 1.17 Sistema Yankee-Spray
Secado ?
FIGURA 1.18 Regaderas para el acondicionamiento del secador (SYS)
Factores para definir el diseo de la regadera Yankee Spray Distancia de regadera a la superficie del secador. Presin de la regadera Alimentacin de coating Temperatura del agua Mantenimiento de boquillas Desgaste de boquillas Sistema de filtrado Cobertura 24
1.3.1.1 Seleccin de espreas para regadera yankee spray Geometra de la boquilla
FIGURA 1.18 Esquema de boquilla para regaderas
FIGURA 1.19 Vista lateral de regadera y boquilla
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Clculos para diseo de regaderas: A partir de la boquilla seleccionada se decide el tipo de cobertura de la regadera. Datos: ngulo de la boquilla = Flujo de agua= GPM Frmulas C= Distancia entre orificio de boquillas C=2Dtan Cantidad de Boquillas a cobertura sencilla: N= Ancho de Mquina/Distancia entre centro.(Ecuacin 4) Nmero de boquillas para una cobertura N N1= N*Cobertura..(Ecuacin 5) Flujo de regadera total Consumo=N1*Flujo de agua..(Ecuacin 6) 1.3.2 Clculo de slidos depositados en la superficie del secador yankee. Miligramos depositados en la superficie del secador Yankee mg=Flujo*slidos del producto qumico*1000/(Ancho Total*Velocidad de mquina)(Ecuacin 7)
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Capitulo II Antecedentes.
La mquina No. 3 de planta Ectaepec Tissue de la empresa SCA Mxico y Centroamrica, es la ms importante debido a la capacidad de produccin de 90 toneladas por da, adems del tipo de papel que se fabrica para el sector medio y alto de la sociedad. La planta Ecatepec Tissue se encuentra ubicada en Av. Prolongacin la Viga No. 220 Col. Jajalpa, Ecatepec Estado de Mxico.
FIGURA 2.1 Localizacin de Maq. 3 en Planta SCA
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Anteriormente la distribucin de los qumicos se encontraba de la siguiente manera.
RESINA 03PV094 R. Y. Aceite releaseccel 640-D R.Y. TANQUE DE YANKEE SPRAY MONOFOSFATO LQUIDO HIPOCLORITO
ANTIESPUMANTE 60403 RESINA KYMENE R. H. GAS NAFTA BLANCOPHOR R. BUCKMAN 699 SUAVISANTE BUSPERSE 46 A. S.
NALBRITE 2613 FLOT AID 638 CAT. TRATAMIENTO MICRO B. TRATAMIENTO MICRO B. BUSPERSE 2035 R. T. TANQUE PREPARACIN COLOR NEGRO ADHESIVO 513-064
FIGURA 2.2 Ubicacin de qumicos en la MAQ 3
En la figura 2.2 se muestra las condiciones de localizacin en la que se encontraban todos los tanques de almacenamiento de qumicos necesarios para la fabricacin del papel en la Maq. 3, solamente los que nos interesa son de los tres qumicos utilizados para el acondicionamiento del Yankee los cuales son: RESINA ACEITE RELEASE MONOFOSFATO LIQUIDO
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En la figura 2.3 se muestra el estado actual de estos tanques, los cuales estn expuestos o todo el desprendimiento de fibra que se produce y esto repercute directamente en la calidad de los qumicos. Por lo cual en capitulo III se propone una solucin a este problema.
FIGURA 2.3 Estado Actual de los Tanques de Quimicos
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2.1 Sistema Yankee spray actual. Se utiliza un sistema de alimentacin con tanque, el cual esta compuesto de la siguiente manera:
FIGURA 2.4 DTI Sistema Yankee Spray
31
2.1.1 Dimensiones de regadera Yankee spray. Las dimensiones de la regadera Yankee spray se encuentran de la siguiente manera: Dimensiones de regadera Yankee spray 1.- Distancia de la regadera con respecto a la superficie del secador Yankee 19 2.- Nmero de espreas =25 y tipo de boquillas= 80030 3.- Cobertura, triple 4.- Flujo de consumo total= 3 gal/min 5.- Presin de regadera Yankee spray 120 psi 6.- Flujo de resina= 80 a 90 mL/min 7.- Flujo de release= 40 a 100 mL/min 8.- Flujo de monofosfato= 15 a 30 mL/min 9.- Nivel de Tanque de mezcla de sistema yankee spray =75% 10.- Temperatura de la mezcla en tanque =???
FIGURA 2.5 Sistema Yankee Spray Actual
32
P=120psi Numero de espreas=25 Flujo=0.12gal/min Flujo Total=3.0 gal/min o 11.35 l/min ngulo de aspersin=80 Diametro de orificio=0.021 Cobertura=triple Distancia de Cobertura=19.5 a 11 de separacin del secador 2.2 Planteamiento del problema, Filosofa de control. 2.2.1 Anlisis del problema El recubrimiento del secador Yankee, como ya se ha mencionado es uno de los factores fundamentales para la fabricacin del papel tissue, ya que permite la funcin de toma de hoja de la zona de prensado al secador Yankee, interviene en el desarrollo de secado de la hoja de papel, permite el proceso de crepado y tiene la funcin de mantener en condiciones ptimas de lubricacin y disminucin de desgaste de la superficie del secador yankee. Actualmente se tiene el sistema de alimentacin con tanque del recubrimiento del secador yankee. Los productos que se dosifican son: resina, release y monofosfato, a travs de bombas.
Dosificacin de qumicos Producto qumico Monofosfato de Amonio N-03PV094 N-640D Punto de Consumo kg/da aplicacin maq1/maq2/maq3 Acondicionamiento del Secador (Yankee) Antioxidante Secador 0.06/0.065/0.02 del Secador Resina Secador 1.7/0.7/1.5 Secador Release Secador 1/0.7/0.75 Secador Funcin
TABLA 2.1 Tabla de valores de dosificacin de quimicos
Flujo ml/min
15-30 70-80 40-50
33
La forma de operar el sistema es a travs de las bombas dosificadoras de manera manual, esto es, el operador verifica los flujos de cada qumico con la ayuda de una probeta y cronmetro. El ajuste para cada flujo de qumico, es realizado con la perilla de Stroke y Rate de las actuales Bombas las cuales se muestra en la figura 2.6.
FIGURA 2.6 Bombas dosificadoras de qumicos Manuales
34
35
FIGURA 2.7 Diagrama PORQUE-PORQUE
2.2.2 Diagrama Porque-Porque (Causa - Raz). Se realiza el anlisis para encontrar las causas raz del problema mediante la herramienta de 5 porqus. Se puede observar que existen diversos elementos que intervienen para un buen desempeo del sistema de acondicionamiento del secador Yankee, tales como: 1.- Calidad de agua. 2.- Funcionalidad de filtracin 3.- Condiciones de instalacin de dosificacin de qumicos. 4.- Condiciones de seguridad y exposicin al ambiente de las bombas. La forma de operar el sistema Yankee spray, tiene alto riesgo por las condiciones de instalacin que se tiene tales como: 1.- Las tuberas de dosificacin se encuentran estructura de la mquina. colgantes por la
2.- Los tanques no tienen una seccin o lugar definido para su localizacin. 3.- Las bombas se encuentran sobre puestas en los contenedores de los qumicos y expuestas a altas temperaturas ambientales. 4.- Las conexiones elctricas se encuentran colgantes as como en un estado de inseguridad. 2.3 Justificacin. 2.3.1 Consecuencias en la produccin. Debido a que no se tiene un control en automtico el tiempo de respuesta para poder determinar el cambio y asegurar un ajuste en cualquiera de las variables de control, nos lleva a la generacin de merma por papel poroso, tiempos perdidos por no poder despegar la hoja de papel del secador yankee, por defectos de calidad de la caracterstica de elongacin, por rasgado en cambio de cuchilla, por desgaste de la cuchilla. Mediante el anlisis de la informacin de tiempos pedidos y prdidas en la produccin se realiza el histrico de Junio de 2008 a Septiembre del 2008.
36
PARETO DE PERDIDAS "JUNIO 2008"

TIEMPO ( MIN) %ACUM.
700
100.0%
90.0% 600 80.0%
500
70.0%
60.0% TIEMPO (MIN) 400 50.0% 300 40.0% % ACUM.
200
30.0%
20.0% 100 10.0%
0 A B C D E F G CAUSAS DE FALLA
0.0%
FIGURA 2.8 Diagrama de Pareto Junio 08
37
FALLAS
CLAVE
No DE VECE S
TIEMP O (MIN)
TIEMP O (HRS)
CAUS A
% ACUM.
% TOTA L
LIMPIEZA GENERAL DE MQUINA CAMBIO DE CUCHILLAS REVENTADAS DE LA HOJA DE PAPEL SE REALIZA LIMPIEZA CON GAS NAFTA A SECCIN TELA NO.2 POR IMPUREZAS (OPER) CAMBIO DE FABRICACIN CAMBIO DE ROLLOS DESACONDICIONAMIENTO DEL SECADOR VARIACIN DE FLUJO DE PASTA POR FALLA DE LA VALVULA (INST) SE REALIZA LIMPIEZA CON HIPOCLORITO A SECCIN FIELTRO (OPER) VARIACIN DE FLUJO DE PASTA BOTARSE QUEMADOR (ELE) (OPER)
A B C D E F G H I J K L M N
(ELE)
88 152 42 25 25 13 4 3 5 2 2 1 2 1 2 1 1 1 1 1 1 1 1
375
621 507 475 231 230 113 70 70 44 30 30 30 25 20 15 15 10 10 10 10 10 3 3

2582
10.35 8.45 7.92 3.85 3.83 1.88 1.17 1.17 0.73 0.50 0.50 0.50 0.42 0.33 0.25 0.25 0.17 0.17 0.17 0.17 0.17 0.05 0.05
43.03
O O O O O O O M O O M O M M M O M O O O M O O
24.1% 43.7% 62.1% 71.0% 79.9% 84.3% 87.0% 89.7% 91.4% 92.6% 93.8% 94.9% 95.9% 96.7% 97.3% 97.8% 98.2% 98.6% 99.0% 99.4% 99.8% 99.9% 100.0 %
24.1 % 19.6 % 18.4 % 8.9% 8.9% 4.4% 2.7% 2.7% 1.7% 1.2% 1.2% 1.2% 1.0% 0.8% 0.6% 0.6% 0.4% 0.4% 0.4% 0.4% 0.4% 0.1% 0.1%
PAPEL CON FRANJAS HMEDAS VARIACIN DE FLUJO DE PASTA POR FALLA DE LA VALVULA (INST) FALTA DE SUMINISTRO DE CONDENSADO (EXT) FALLA DE ACCIONAMIENTO DE LOS BRAZOS DE CARGA
O P Q R S T U V
PAPEL CON ARRUGA POR FIELTRO TAPADO EN LAS ORILLAS (OPER) PARA QUEMADORES PARA RESTABLECER GRA DE 10 TON. (ELE) ATASCARSE QUEMADORRES DESPUES DE METERLOS EN SERVICIO (OPER) VARIACIN DE FLUJO DE RELEASE (OPER) CAMBIO DE BOMBA DE RELEASE (OPER) BOTARSE REFINADOR MERMA POR MUESTRAS ACUMULACIN DE PASTA EN EL RODILLO TENSOR (OPER) (ELE)
ACUMULADO POR DIA (MIN)
ACUMULADO POR DIA (HR)
TOTA L TOTA L
100% 100% 100% 100%
375
43.03
43.03
TABLA 2.1 Tabla de fallas del mes de Junio 08
38
PARETO DE PERDIDAS "JULIO 2008"

TIEMPO (MIN) %ACUM.
700
100.0%
90.0% 600 80.0% 500
70.0%
60.0% TIEMPO (MIN) 400 50.0% 300 40.0% % ACUM.
200
30.0%
20.0% 100 10.0%
0 A B C D E F G H I J K L M N O P Q R S CAUSAS DE FALLA
0.0%
FIGURA 2.9 Diagrama de Pareto de Julio 08
39
FALLAS
CLAVE
No DE TIEMPO TIEMPO CAUSA VECES (MIN) (HRS)
% ACUM.
% TOTAL
LIMPIEZA GENERAL DE MQUINA CAMBIO DE CUCHILLAS REVENTADAS DE LA HOJA DE PAPEL SE REALIZA LIMPIEZA CON GAS NAFTA A SECCIN TELA NO.2 POR IMPUREZAS (OPER) CAMBIO DE FABRICACIN VARIACIN DE FLUJO DE PASTA POR FALLA DE LA VALVULA (INST) MALA TRANSFERENCIA DE LA HOJA DE PAPEL DEL FIELTRO AL SECADOR YANKEE (OPER) CAMBIO DE ROLLOS SE REALIZA LIMPIEZA CON HIPOCLORITO A SECCIN FIELTRO (OPER) DESCONECTAR CABLES DE CONTROL DE GRA PRUEBA DE PROCESO OCASIONA CARGAS BAJAS SOBRECALENTAMIENTO DEL SECADOR SE REALIZA LIMPIEZA CON SOSA CAUSTICA A SECCIN FIELTRO (OPER) FALLA DE ACCIONAMIENTO DE LOS BRAZOS PRIMARIOS DESACONDICIONAMIENTO DEL SECADOR APAGARSE FUEGO ALTO DEL QUEMADOR (ELE) ATORARSE CABLE CON ESTRACTOR DE MANDRILES BOTARSE ALUMBRADO DE TODA LA NAVE (ELE) REPARAR FILTRO DE UN HUIZACHE ACUMULADO POR DIA (MIN) ACUMULADO POR DIA (HR) (MEC) (ELE) (ELE) (ELE) (OPER)
A B C D E F G H I J K L M N O P Q R S
101 164 33 28 40 4 2 5 5 2 1 2 2 1 2 1 1 1 1
396
578 431 268 234 181 92 80 61 60 60 50 45 30 27 25 25 20 10 7

2284
9.63 7.18 4.47 3.90 3.02 1.53 1.33 1.02 1.00 1.00 0.83 0.75 0.50 0.45 0.42 0.42 0.33 0.17 0.12
38.07
O O O O O M O O O M O O O M O M M M M
25.3% 44.2% 55.9% 66.2% 74.1% 78.1% 81.6% 84.3% 86.9% 89.5% 91.7% 93.7% 95.0% 96.2% 97.3% 98.4% 99.3% 99.7% 100.0%
25.3% 18.9% 11.7% 10.2% 7.9% 4.0% 3.5% 2.7% 2.6% 2.6% 2.2% 2.0% 1.3% 1.2% 1.1% 1.1% 0.9% 0.4% 0.3% 100% 100%
TOTAL TOTAL
396
38.07
38.07
100% 100%
TABLA 2.2 Tabla de fallas de Julio 08
40
PARETO DE PERDIDAS "AGOSTO 2008"

TIEMPO (MIN) %ACUM.
700
100.0%
90.0% 600 80.0% 500
70.0%
60.0% TIEMPO (MIN) 400 50.0% 300 40.0% % ACUM.
200
30.0%
20.0% 100 10.0%
0 A B C D E F G H I J K L M N O P Q R CAUSAS DE FALLA
FIGURA 2.10 Diagrama de Pareto de Agosto 08
0.0%
41
FALLAS
CLAVE
No DE VECE S
TIEMP O (MIN)
TIEMP O (HRS)
CAUS A
% ACUM.
% TOTA L
LIMPIEZA GENERAL DE MQUINA CAMBIO DE CUCHILLAS REVENTADAS DE LA HOJA DE PAPEL SE REALIZA LIMPIEZA CON GAS NAFTA A SECCIN TELA NO.2 POR IMPUREZAS (OPER) CAMBIO DE FABRICACIN FALTA DE REDUCTOR DE BRAZOS PRIMARIOS, DAARSE CUA DEL COPLE (MEC) SE REALIZA LIMPIEZA CON HIPOCLORITO A SECCIN FIELTRO (OPER) VARIACIN DE FLUJO DE PASTA POR FALLA DE LA VALVULA (INST) DESACONDICIONAMIENTO DEL SECADOR MALA TRANSFERENCIA DE LA HOJA DE PAPEL DEL FIELTRO AL SECADOR YANKEE (OPER) CAMBIO DE ROLLOS DAARSE MOTOR DE BOMBA DE VACO (ELE) (OPER)
A B C D E F G H I J K L M N O P Q R
117 196 36 24 45 1 5 4 3 2 3 1 1 2 2 1 1 1
445
652 539 356 304 179 88 72 60 60 35 25 20 20 19 14 10 10 10

2473
10.87 8.98 5.93 5.07 2.98 1.47 1.20 1.00 1.00 0.58 0.42 0.33 0.33 0.32 0.23 0.17 0.17 0.17
41.22
O O O O O M O M O O O M O O O M M M
26.4% 48.2% 62.6% 74.8% 82.1% 85.6% 88.6% 91.0% 93.4% 94.8% 95.8% 96.6% 97.5% 98.2% 98.8% 99.2% 99.6% 100.0 %
26.4 % 21.8 % 14.4 % 12.3 % 7.2% 3.6% 2.9% 2.4% 2.4% 1.4% 1.0% 0.8% 0.8% 0.8% 0.6% 0.4% 0.4% 0.4%
HUMEDAD ALTA POR FALLA DEL EQUIPO DE MEDICIN
CAMBIO DE HUIZACHE DE CORTE POR TAPARSE (OPER) SE REALIZA LIMPIEZA CON GAS NAFTA A SECCIN TELA NO.1 POR IMPUREZAS (OPER) BOTARSE BOMBA DE VACO NO.4 A CAJAS DEL FIELTRO (ELE) BOTARSE QUEMADOR LADO HUMEDO (ELE) FALLA DE ACCIONAMIENTO DE BRAZOS PRIMARIOS (ELE)
TOTA L TOTA L
100% 100% 100% 100%
445
41.22 41.22
TABLA 2.3 Tabla de fallas de Agosto 08
42
FIGURA 2.11 Diagrama de Pareto de Septiembre 08
43
FALLAS
CLAVE
No DE VECE S
TIEMP O (MIN)
TIEMP O (HRS)
CAUS A
% % TOTA ACUM. L
LIMPIEZA GENERAL DE MQUINA CAMBIO DE CUCHILLAS REVENTADAS DE LA HOJA DE PAPEL CAMBIO DE FABRICACIN DESACONDICIONAMIENTO DEL SECADOR SE REALIZA LIMPIEZA CON HIPOCLORITO A SECCIN FIELTRO (OPER) CAMBIO DE ROLLOS SE REALIZA LIMPIEZA CON GAS NAFTA A SECCIN TELA NO.2 POR IMPUREZAS (OPER) ATASCARSE BOMBA HIDRAULICA DE TOLVA DE HIDRAPULPER DE FIBRA LARGA (MEC) BOTARSE BOMBAS DE VACO BOTARSE QUEMADOR (ELE) (ELE)
A B C D E F G H I J K
(OPER)
137 239 41 30 5 4 3 4 1 1 3 1 2 1
794 626 340 228 107 85 60 55 35 35 32 25 20 20
13.23 10.43 5.67 3.80 1.78 1.42 1.00 0.92 0.58 0.58 0.53 0.42 0.33 0.33
O O O O O O O O M M M O O O
31.3% 55.9% 69.3%
31.3 % 24.7 % 13.4 %
78.3% 9.0% 82.5% 4.2% 85.9% 3.3% 88.2% 2.4% 90.4% 2.2% 91.8% 1.4% 93.1% 1.4% 94.4% 1.3% 95.4% 1.0% 96.2% 0.8% 97.0% 0.8%
ACONDICIONAMIENTO POR ARRANQUE DE MQUINA AONDICIONAMIENTO DE FIELTRO HUMEDAD ALTA (OPER) (OPER)
L M N
AJUSTE DE CUCHILLAS DE CREPADO POR PROBLEMAS DE DESPEGUE DE LA HOJA DEL SECADOR (MEC) MALA TRANSFERENCIA DE LA HOJA DE PAPEL DEL FIELTRO AL SECADOR YANKEE (OPER) VARIACIN DE FLUJO DE PASTA POR FALLA DE LA VALVULA ATORARSE BRAZOS PRIMARIOS (MEC) (INST)
O P Q R S T
1 1 1 1 1 1
478
17 15 15 15 10 5
2539
0.28 0.25 0.25 0.25 0.17 0.08

42.32
M O M M O O
97.6% 0.7% 98.2% 0.6% 98.8% 0.6% 99.4% 0.6% 99.8% 0.4% 100.0 % 0.2%
RESISTENCIAS BAJAS POR AJUSTE DE DISCOS DEL REFINADOR (OPER) VARIACIN DE FLUJO DE PASTA POR FALLA DE LA VALVULA (OPER)
TOTA L TOTA L
100% 100% 100% 100%
478
42.32 42.32
TABLA 2.4 Tabla de fallas de Septiembre 08
44
2.3.1.1 Prdida por generacin de merma Podemos observar que el desacondicionamiento del secador en los paretos, es una causa que no tiene alto impacto, sin embargo al analizar porqu se presentan reventadas de hoja y porque se presentan en esa frecuencia el cambio de cuchillas. Se lleg a la conclusin que el correcto acondicionamiento del secador influye en gran medida al proceso del secado del papel y a la separacin de la hoja de papel del secador. El correcto acondicionamiento del secador influye en gran medida sobre la frecuencia con la que se debe realizar el cambio de cuchillas debido a que el acondicionamiento del secador tambin realiza la funcin de lubricante entre la superficie del secador y el filo de la cuchilla, ya que no hay que olvidar que son dos metales sometidos a una fuerza de friccin. Cuando el operador se ve en necesidad de realizar un cambio de cuchillas, no es factible realizar un paro temporal de la maquina para realizarlo y tampoco es factible omitir esta accin. Por lo cual en el momento que se realiza el cambio de cuchillas, es necesario, realizar un ajuste en la cuchilla de limpieza para que despegue todo el papel de la superficie del secador, pero este papel se pierde, en pocas palabras se convierte en merma y por mas que el operario lo haga en el menor tiempo posible se genera perdida por merma. Por esta razn es necesario bajar la frecuencia con la que se realiza este cambio. En la siguiente figura se muestra la grafica referente a la generacin de merma de los meses Julio, Agosto y Septiembre.
45
FIGURA 2.12 Diagrama de Pareto Comparativo Julio-Septiembre
46
En resumen de las prdidas ms importantes y considerando una afectacin del 10% de las principales causas por falta de acondicionamiento tenemos la siguiente tabla:
Histrico 2008 Unidades Junio Julio Agosto Septiembre min 70 25 60 107 min 51 43 54 62 min 48 27 36 34 min 169 95 150 203 m 3.3 3.3 3.3 3.3 m/min 1550 1550 1550 1550 Kg 0.0155 0.0155 0.0155 0.0155 Kg 13398.7425 7531.8375 11892.375 16094.3475 Ton 13.3987425 7.5318375 11.892375 16.0943475
Concepto Tiempo por desacondicionamiento 10% de tiempo por cambio de cuchillas 10% de tiempo por reventadas Tiempo total Ancho til Velocidad de la mquina Gramaje del papel Produccin total
Costo por tonelada Costo total prdida
MNX MNX
10,752.56 10,619.47 10,654.92 10,654.92 144070.721 79984.1348 126712.304 171483.985
Merma rechazada por calidad 15% de jumbos por papel picado Rasgado por cuchilla 10% de jumbos con reventadas Total Costo de merma Costo total por merma Total Total Acumulado
Ton Ton Ton Ton MNX MNX MNX MNX
0 2500 0
0.325 0.308 1.4 2.033 2500 5082.5
0.55 0.5 1.12 2.17 2500 5425
0.86 0.56 1.97 3.39 2500 8475
144070.721 85066.6348 132137.304 179958.985 144070.721 229137.356 361274.66 541233.646
TABLA 2.5 Tabla de Histricos Junio-Septiembre 08
47
48
Capitulo III Desarrollo (Propuesta de solucin). La propuesta de solucin es: 3.1 Diseo Propuesto de regadera Yankee
FIGURA 3.1 Sistema Yankee Spray Propuesto
Condiciones de operacin Propuestas P=120psi Numero de espreas=25 Flujo=0.12gal/min Flujo Total=3.0 gal/min o 11.35 l/min ngulo de aspersin=80 Diametro de orificio=0.021 Cobertura=triple Distancia de Cobertura=19.5 a 11 de separacin del secador
49
3.2 Seleccin de Hardware. 3.2.1 Determinacin de tipo de bombas. Se instalar bombas con comunicacin al sistema de control distribuido TPS, para monitoreo y control en lazo abierto del flujo de los qumicos para el recubrimiento del secador yankee. Se realizar la instalacin de las bombas en gabinetes Se colocaran los contenedores de los qumicos en un rea de condiciones reguladas con seguridad. El tipo de bombas que se determinaron usar para este proyecto son de la marca PULSATRON, despus de validar otras opciones Tcnico-Comerciales las cuales se muestran en a continuacin.
50
TABLADECOTIZACIONES Proyecto: Ubicacin: AutomatizaciondeAcondicionamientoSecadorYankeeMaq#3 EcatepecEdodeMex PlantaEcatepecTissueSCA 10Oct08 Fecha: GerentedeProyecto Ing.JoseLuisHernandezPerea Ing.IvanHernandezGarcia Proveedores Equippump DLLS P.U. Importe
NalcodeMexico DLLS P.U. Importe Cantidad Concepto BombaPulsatrondosificadorade 2 quimicos,paramonofosfato BombaPulsatrondosificadorade 2 quimicospararelease BombaPulsatrondosificadorade 3 quimicosparaadhesivo 1 Gabinete Materialvarios:tuberiatubingde inoxidablede3/8"hacialospuntosde dosificacinysuccin.Instalacinde arreglodeprobetasparatodoslas bombas.Arreglosdevalvulaspara bombasdetrabajoydestock 1
Matercon DLLS P.U. Importe
519.60 1,039.20 749.00 1,498.00 730.00 1,460.00
789.50 1,579.00 810.70 1,621.40 799.90 1,599.80
789.50 2,368.50 810.70 2,432.10 829.76 2,489.28 3,500.00 3,500.00 2,576.98 2,576.98 3,487.34 3,487.34
10,000.00 10,000.00 11,654.67 11,654.67 12,384.74 12,384.74
SUBTOTAL 18,486.70 SUBTOTAL 19,783.15 SUBTOTAL 21,421.16 IVA 2,773.01 IVA 2,967.47 IVA 3,213.17 TOTAL 21,259.71 TOTAL 22,750.62 TOTAL 24,634.33
TABLA 3.1 Comparativo de Cotizaciones de Proveedores
51
La seleccin de bombas se realiza mediante la capacidad que debe tener la bomba de dosificar los flujos determinados de cada qumico. La siguiente tabla nos permite seleccionar el modelo de la bomba de acuerdo a los requerimientos establecidos. MODELO LPA3MAPTC1500 , LPG4MAPTC1500
FIGURA 3.2 Bomba Dosificadora Serie MP
La razn por la cual se tom la decisin de utilizar estas bombas dosificadoras de flujo es debido a que actualmente ya se manejan unas bombas de control manual de esta marca, por lo cual se estara adquiriendo una misma marca para este tipo de equipo , lo cual ser de mayor conveniencia ya que se podra manejar a un mismo proveedor para la compra de refacciones o garanta de equipo e instalacin. Esto con el sentido de poder eficientar el tiempo de los trmites administrativos. Debido a la capacidad de cada bomba se determina el tipo y queda de la siguiente manera:
CANTIDAD MODELO LPA3MAPTC1500 1 LPG4MAPTC1500 3
DESCRIPCION
BOMBA DOSIFICADORA PARA MONOFOSFATO
BOMBADOSIFICADORAPARAADHESIVO,RELEASEyRESPALDO
TABLA 3.2 Tabla Modelos y Aplicaciones de bombas dosificadoras.
La siguiente tabla contiene las especificaciones de cada una de las bombas a utilizar. 52
TABLA 3.3 Especificaciones de Bombas
53
3.2.2 Determinacin de protocolo de comunicacin. En este diagrama se presenta la arquitectura que tiene el Sistema de control actual, Total Plant Solution (TPS).
FIGURA 3.3 Arquitectura de Toptal Plant Solution (TPS)
Las Bombas dosificadoras se comunicaron de 4-20mA hacia la HPM del centro de control existente en la planta para la Mquina 3, del HPM se comunica con las estaciones de monitoreo y estaciones de ingeniera por medio de Ethernet como se muestra en la figura 3.3 con el cual se realiz la configuracin del HMI que en este caso se dio de alta solamente un grupo especialmente para el proceso del acondicionamiento del Yankee. Para este proyecto la razn por la cual no se cotizo tarjetas analgicas adicionales para la realizacin del monitoreo y control del proceso de acondicionamiento es porque el TPS contaba con la capacidad de agregar ms elementos a sus tarjetas analgicas y posteriormente para la realizacin de futuros lazos de control.
54
3.2.3 Configuracin de HMI. La configuracin de la interfaz hombre mquina se realiza mediante la estacin de ingeniera, la cual se explica de la siguiente manera: 1.- Se selecciona la estacin de ingeniera.
FIGURA 3.4 Pantalla de Configuracin GUS
2.- Se configuran los tres elementos de acuerdo a los nmeros de tarjeta y posicin de entrada colocada.
FIGURA 3.5. Pantalla de Configuracin II GUS
55
3.- Se da propiedades de entrada y salida para realizar los ajustes de escalado de acuerdo a la seal analgica de 4 a 20 mA.
FIGURA 3.6. Pantalla de Configuracin III GUS
4.- Se guardan y se descargan los cambios, con lo cual tenemos una respuesta como se muestra en la siguiente figura.
FIGURA 3.7. Pantalla Respuesta GUS
3.2.4 Fuente de alimentacin. Debido a que slo es la integracin de las bombas dosificadoras al TPS, se cuenta con la fuente de alimentacin del sistema. La fuente de alimentacin de las bombas es de 115V. 3.2.5 Gabinetes. Se selecciona el gabinete de acero inoxidable para colocar las 4 bombas, 3 de dosificacin en tiempo real y una bomba para respaldo en caso de falla.
56
3.2.6 Conexiones. Las conexiones de cada una de las bombas se realiza de la siguiente manera:
FTA / Marshalling
24 V
J Box
HPM
GUS
4-20 mA
FT LT PT AT
25 0
IO P
C O N T R O L L E R
LCN NIM UCN
CARDFILE
FIGURA 3.7. Esquema de conexin al HPM
FIGURA 3.8 Esquema Bombas dosificadora
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3.3 Seleccin de Software. 3.3.1 Configuracin de comunicacin. Los instrumentos (4-20 mA) son conectados al HPM (APM, PM). Los algoritmos de control residen en los procesadores del HPM. Aplicaciones Complejas residen en el APP node.
3.3.2 Configuracin de HMI. Las estaciones de trabajo (GUS) leen/escriben data en tiempo real desde los HPM. Los histricos son almacenados en el PHD (Oracle), utilizados para tendencias y registro de alarmas
3.4 Actividades para el plan de mantenimiento
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Captulo IV Anlisis de Costos. 4.1 Presupuesto De acuerdo a la tabla TABLA 3.1 Comparativo de Cotizaciones de Proveedores, se determina como mejor opcin las bombas de la marca PULSATRON. El costo del proyecto es:
CANTIDAD 1 3 1 MODELO
LPA3MAPTC1500 LPG4MAPTC1500 Material y gabinete
DESCRIPCION
BOMBA DOSIFICADORA PARA MONOFOSFATO
BOMBADOSIFICADORAPARAADHESIVOYRELEASE
tuberia tubing de inoxidable de 3/8" hacia los puntos de dosificacin y succin. Un gabinete en acero inoxidable para 6 bombas para maquina 3 con arreglo de probeta. Instalacin de arreglo de probetas para todos las bombas. Arreglos de valvulas para bombas de trabajo y de stock Horas hombre y puesta en marcha del proyecto
P.U.(DOL) IMPORTE $ 519.60 $519.60 $ 789.50 $2,368.50 $13,500.00 $13,500.00
Ingeniera
$5,643.00 $5,643.00 TOTAL $22,031.10
TABLA 4.1 Tabla de Cotizacin del Proyecto.
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4.2 Anlisis de costo- beneficio Se propone reducir las prdidas en un 50%, es decir el ahorro de prdidas por cada mes ser con un impacto del 50% del total perdido en el histrico de Junio a septiembre del ao 2008. El promedio mensual de ahorro es de $70 027.00.
Propuesta Concepto Tiempo por desacondicionamiento 10% de tiempo por cambio de cuchillas 10% de tiempo por reventadas Tiempo total Ancho til Velocidad de la mquina Gramaje del papel Produccin total de reduccin al 50% del problema Unidades Junio Julio Agosto Septiembre min 35 12.5 30 53.5 min 25.5 21.5 27 31 min 24 13.5 18 17 min 84.5 47.5 75 101.5 m 3.3 3.3 3.3 3.3 m/min 1550 1550 1550 1550 Kg 0.0155 0.0155 0.0155 0.0155 Kg 6699.37125 3765.91875 5946.1875 8047.17375 Ton 6.69937125 3.76591875 5.9461875 8.04717375
Costo por tonelada Costo total prdida
MNX MNX
10752.5554 72035.3607
10619.4717 39992.0674
10654.92 63356.1521
10654.92 85741.9925
Merma rechazada por calidad 15% de jumbos por papel picado Rasgado por cuchilla 10% de jumbos con reventadas Total Costo de merma Costo total por merma Total Total Acumulado
Ton Ton Ton Ton MNX MNX MNX MNX
0 2500 0 72035.3607 72035.3607
0.325 0.308 1.4 2.033 2500 5082.5 45074.5674 117109.928
0.55 0.5 1.12 2.17 2500 5425 68781.1521 185891.08
0.86 0.56 1.97 3.39 2500 8475 94216.9925 280108.073
4.3 Beneficios obtenidos Los beneficios de la aplicacin de este proyecto se vern reflejados en los siguientes aspectos: Seguridad: Las condiciones de instalacin y monitoreo por parte del operador sern ms adecuadas, ya que se ubican los contenedores y bombas dosificadoras con una mejor distribucin. Calidad: La calidad del producto semi-terminado de papel, presenta una mejor convertibilidad y capacidad de enrollado tanto en el rea de mquinas de papel como en el rea de conversin. Produccin: Nos permite tener una mejor capacidad de respuesta para realizar ajustes en el acondicionamiento del secador yankee y no tener prdidas de tiempo por des acondicionamiento.
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4.4 Rendimiento de la inversin ROI

Total Tipo de cambio Total Costo total del Proyecto USD MNX MNX 22031.1 13.8 304,029.18 70,027.02 4.341598255
Ahorro Promedio por mes
Meses Tiempo de recuperacin de inversin TABLA 4.2 Rendimiento de inversin
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5.1 Conclusiones. La aplicacin de este proyecto se ha iniciado en el mes de noviembre por lo que los resultados del impacto econmico se deben ver reflejados en el mes de diciembre. Se realiza la propuesta de automatizacin de control de flujos qumicos en el cual la fundamentacin de costo beneficio econmico es de gran importancia, ya que con este tipo de anlisis se puede cuantificar de manera directa el impacto en la rentabilidad del negocio. De los objetivos establecidos se tiene que: Se modifica el diseo de la regadera Yankee Spray, para tener una mejor distribucin y asegurar la operacin, as como el cambio de cobertura de doble a triple. Se determina la capacidad y el tipo de bombas para la dosificacin de qumicos, con el proveedor Nalco para mantener el uso de estos equipos y as las refacciones puedan ser ms fcil de obtener. Se determina la conexin de bombas y configuracin de comunicacin al sistema de control (Total Plant Solition, Sistema de control distribuido, marca Honeywell)., ya que son 4 elementos los que se agregan con seal de 4 a 20 mA y esto no afecta debido a la capacidad que tiene el sistema TPS. Se configura la pantalla para monitoreo y control de los flujos de qumicos en interfase hombre mquina (HMI) del TPS. En el grupo 53 del TPS, donde se encuentra el sistema Yankee Spray. Para un mejor mantenimiento se coloca el gabinete de acero inoxidable en que se coloca la instalacin elctrica adecuada. Para el mantenimiento de las bombas se tiene una bomba respaldo o para cubrir cualquier falla de las otras, adems de que al existir una falla en el control se pueden operar en modo manual. Se establece un plan de mantenimiento del Sistema Yankee Spray, el cual implica: o Rutinas de limpieza de los filtros, 1 vez por turno. o Rutina de purga del Tanque de mezcla Yankee Spray, 1 vez por da. o Rutina de limpieza de espreas, cada paro programado.
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o Rutina de purga de bombas dosificadoras, 1 vez cada semana. o Mantenimiento a bombas dosificadoras, 1 bomba cada mes, (Hacer uso de bomba de respaldo, cambio de vlvulas e inspeccin de elementos elctricos y electrnicos. Los objetivos se cumplieron en un 90%, ya que la configuracin de HMI, fue propiamente realizada por el rea de Instrumentacin y del departamento de ingeniera de la Planta Ecatepc Tissue, ya que su personal se encuentra altamente capacitado en la configuracin de de elementos en el sistema Total Plant Solution (TPS). 5.2 Observaciones. Se observa que las condiciones de seguridad mejoran al tener una instalacin adecuada, el tiempo de respuesta para controlar problemas de enrollado mediante el ajuste del acondicionamiento del secador, es ms eficiente. Aunque la calidad del papel se ve influenciada por la gran variedad de combinaciones de las variables que intervienen en el proceso de fabricacin de papel, el tener automatizado el proceso de acondicionamiento del secador yankee, permite disminuir la influencia o afectacin de la modificacin de los parmetros de los flujos de qumicos.
Fuentes de Consulta Informacin recopilada de SCA Mxico y Centroamrica S.A de C.V Literatura de Pulpa y Papel de archivos generales del rea de capacitacin de SCA. Mxico y Centroamrica. Informacin de proveedores de qumicos, Nalco, Buckman etc. Visita de pginas como: www.papelnet.cl www.nalco.com www.pulsatron.com Anexos Manual de operacin de Bombas Series MP. Manual de Total Plant Solution de Honeywell
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Series MP
ELECTRONIC METERING PUMPS
Installation Operation Maintenance Instruction
READ ALL WARNINGS CAREFULLY BEFORE INSTALLING
SAFETY INSTRUCTIONS
When using chemical feed pumps, basic safety precautions should always be followed to reduce risk of fire, electric shock, and personal injury. Failure to follow these instructions could result in death or serious injury.
READ ALL INSTRUCTIONS *** : Secure chemicals and metering pumps, making them inaccessible to children and pets.
*** DO NOT PUMP FLAMMABLE LIQUIDS. *** Do not cut the plug or ground lug off the electrical cord. Consult a licensed electrician for proper installation or replacement. ** : Always wear protective clothing, including gloves and safety glasses, when working on or near chemical metering pumps.
** Inspect tubing regularly for cracking or deterioration and replace as necessary. (Always wear protective clothing and safety glasses when inspecting tubing.) ** Use CAUTION to keep fingers away from rotating parts. ** If pump is exposed to direct sunlight, use a U.V. resistant tubing. ** Follow directions and warnings provided from the chemical manufacturer. The user is responsible for determining the chemical compatibility with the chemical feed pump. ** Make sure the voltage on the pump name tag matches the installation voltage. If pump fails to start, check line voltage. ** Consult with local health officials and/or qualified water conditioning specialists when treating potable water. ** Always depressurize system prior to installation or disconnecting the metering pump tubing. ** If injection point is lower than the chemical tank and pump, install an anti-siphon valve. ** DO NOT MODIFY PUMP. This poses a potentially dangerous situation and will void the warranty. * * * * : All pumps are factory tested with water. Remove tubing and thoroughly dry if the chemical being pumped will react with water (for example sulfuric acid). Hand tighten plastic connections (Do not use wrench). Consult licensed plumber and electrician before installation to conform to local codes. NOTE: For accurate volume output, pump must be calibrated under all operating conditions.
TABLE OF CONTENTS
Page SAFETY INSTRUCTIONS ............................................................................................................................... 2 INTRODUCTION.............................................................................................................................................. 4 UNPACKING THE PUMP ................................................................................................................................ 5 PRECAUTIONS FOR OPERATION ................................................................................................................ 6 INSTALLATION, PIPING AND WIRING ......................................................................................................... 8 DESCRIPTION OF CONTROLS AND OPERATION..................................................................................... 12 CONTROL OPTIONS .................................................................................................................................... 13 RELAY SETTINGS ........................................................................................................................................ 14 ALARMS......................................................................................................................................................... 15 CONTROL REFERENCE SUMMARY........................................................................................................... 16 START-UP AND OPERATION ...................................................................................................................... 18 ADDITIONAL SETTINGS............................................................................................................................... 23 MAINTENANCE ............................................................................................................................................. 24 TROUBLESHOOTING ................................................................................................................................... 26 EXPLODED VIEW DRAWINGS..................................................................................................................... 27 PUMP SPECIFICATIONS.............................................................................................................................. 29 REPAIR SERVICE ......................................................................................................................................... 30
INTRODUCTION
These installation, operation and maintenance instructions cover your electronic metering pump. Refer to the pump nameplate to determine the actual model. PRINCIPLE OF OPERATION Diaphragm metering pumps are used to dispense chemicals or fluids. This is achieved by an electromagnetic drive mechanism (solenoid) which is connected to a diaphragm. When the solenoid is pulsed by the control circuit, it displaces the diaphragm which, through the use of check valves, moves the fluid out the discharge under pressure. When the solenoid is de-energized it returns the diaphragm and pulls more fluid into the pump head and the cycle repeats. The stroke rate of the pumps is controlled via the touchpad and present status is indicated by the LCD display. The stroke length is controlled via the stroke length knob. MATERIALS OF CONSTRUCTION The wetted materials (those parts that contact the solution being pumped) available for construction are Glass filled polypropylene, PVC, SAN, Hypalon, Viton, PTFE, 316 Stainless Steel, PVDF, Ceramic and Alloy C. These materials are very resistant to most chemicals. However, there are some chemicals, such as strong acids or organic solvents, which cause deterioration of some elastomer and plastic parts, such as the diaphragm, valve seats, or head. Consult Chemical Resistance Guide or Supplier for information on chemical compatibility. Various manufacturers of plastics, elastomers and pumping equipment publish guidelines that aid in the selection of wetted materials for pumping commercially available chemicals and chemical compounds. Two factors must always be considered when using an elastomer or plastic part to pump chemicals. They are: 1. The temperature of service: Higher temperatures increase the effect of chemicals on wetted materials. The increase varies with the material and the chemical being used. A material quite stable at room temperature might be affected at higher temperatures. 2. Material choice: Materials with similar properties may differ greatly from one another in performance when exposed to certain chemicals. MANUFACTURERS PRODUCT WARRANTY Pulsafeeder warrants all pumps and controllers of its manufacture to be free of defects in material or workmanship. Liability under this policy extends for 24 months from date of shipment from the factory. The manufacturers liability is limited to repair or replacement of any failed equipment or part which is proven defective in material or workmanship upon manufacturers examination. This warranty does not include removal or installation costs and in no event shall the manufacturers liability exceed the selling price of such equipment or part. The manufacturer disclaims all liability for damage to its products through improper installation, maintenance, use or attempts to operate such products beyond their functional capacity, intentionally or otherwise, or any other unauthorized repair. The manufacturer is not responsible for consequential or other damages, injuries or expense incurred through the use of its products. Above warranty is in lieu of any other warranty, whether expressed or implied. The manufacturer makes no warranty of fitness or merchantability. No agent of ours is authorized to provide any warranty other than the above. The European Union Warranty address is listed below, however, please note that the seller should be contacted first. Steigar 24 NL 1351 AB Almere Netherlands
EUROPEAN TECHNICAL FILE LOCATION PO Box 91 Washington NE37 1YH United Kingdom UNPACKING THE PUMP Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damages should be reported immediately to the carrier and to the seller of the equipment. The carton should contain: - Metering Pump - Clear Flexible Suction Tubing* - Stiff White Discharge Tubing* - Foot valve/Strainer Assy.* - Backpressure Injection Valve Assy. - One Instruction Book that you are now reading - Bleed Valve Assembly* (most models) *These items are included with the standard pump. Items may or may not be included depending on model.
Make sure that all items have been removed from the shipping carton before it is discarded.
PRECAUTIONS FOR OPERATION

Each Electronic Metering Pump has been tested to meet prescribed specifications and safety standards. Proper care in handling, installation and operation will help in ensuring a trouble free installation. Please read all these cautionary notes prior to installation and start-up of your metering pump. 1. Important: Pump must be installed and used with supplied back pressure/injection valve. Failure to do so could result in excessive pump output flow. 2. Handle the pump with care. Dropping or heavy impact causes not only external damage to the pump, but also to electrical parts inside. 3. Install the pump in a place where the ambient temperature does not exceed 40C (104F). The pump is water resistant and dust proof by construction and can be used outdoors, however do not operate the pump submerged. To avoid high internal pump temperatures, do not operate in direct sunlight. 4. Install the pump in a place convenient for its future maintenance and inspection, then fix it to prevent vibration. 5. Protective caps must be removed prior to installing tubing onto valve assemblies. Use tubing of specified size. Connect the tubing to the suction side securely to prevent the entrance of outside air. Make sure that there is no liquid leakage on the discharge side. 6. Be careful to check that the voltage of the installation matches the voltage indicated on the pump nameplate. Each pump is equipped with a three prong plug. Always be sure the pump is grounded. To disconnect, do not pull wire but grip the plug with fingers and pull out. Do not use the receptacle in common with heavy electrical equipment which generates surge voltage. It can cause the failure of the electronic circuit inside the pump. 7. Tampering with electrical devices can be potentially hazardous. Always place chemicals and pump installation well out of the reach of children. 8. Never repair or move the metering pump while operating. Always disconnect electrical power. For safety, always wear protective clothing (protective gloves and safety glasses) when working on or near chemical metering pumps. 9. An air bleed valve is available for most models with tubing connections. Air purges should be performed when the pump chamber contains no fluid at the time of start-up. As a safety measure, connect the return tubing to the air bleed valve and bypass fluid back to storage tank or a suitable drain. 10. Chemicals used may be dangerous and should be used carefully and according to warnings on the label. Follow the directions given with each type of chemical. Do not assume chemicals are the same because they look alike. Always store chemicals in a safe location away from children and others. We cannot be responsible for the misuse of chemicals being fed by the pump. Always have the material safety data sheet (MSDS) available for any fluid being pumped. 11. All pumps are pretested with water before shipment. Remove head and dry thoroughly if you are pumping a material that will react with water, (i.e. sulfuric acid, polymers). Valve seats, ball checks, gaskets, and diaphragm should also be dried. Before placing pump into service, extreme care should be taken to follow this procedure. 12. Valve cartridges are stamped to indicate fluid flow direction. Always install so that markings read from top to bottom, with the arrow pointing in the direction of flow. 13. When metering hazardous material DO NOT use plastic tubing, strictly use proper rigid pipe. Consult supplier for special adapters or valve assemblies. 14. Pump is NOT to be used to handle or meter flammable liquids or materials. 15. Standard white discharge tubing is not recommended for installations exposed to direct sunlight. supplier for special black tubing. Consult
16. Factory will not be held responsible for improper installation of pump, or plumbing. All cautions are to be read thoroughly prior to hook-up and plumbing. For all installations a professional plumber should be consulted. Always adhere to local plumbing codes and requirements.
17. When using pump with pressurized systems, make sure the pressure of the system does not exceed the maximum pressure rating on the pump nameplate. Be sure to de-pressurize system prior to hook up or disconnecting the metering pump. 18. Electronic power modules are equipped with automatic reset thermal overload devices and may reset unexpectedly. 19. The pump is designed to operate using a backpressure/injection valve. If the discharge point is below the liquid level of the source or if the discharge pressure is less than the suction pressure, siphoning may occur. To correct this condition, install an anti-siphon valve or other anti-siphon device. Check local regulations which may apply. (Ref. Figure G1). 20. If the power cord is unplugged or in the event of electrical power interruption while the pump is operating, the pump will remember its last operating state for years and will resume operation as before, whenever power is restored.
INSTALLATION, PIPING AND WIRING

The metering pump should be located in an area that allows convenient connections to both the chemical storage tank and the point of injection. The pump is water resistant and dust proof by construction and can be used outdoors, however do not operate submerged. Avoid continuous temperatures in excess of 40C (104F). To do otherwise could result in damage to the pump. MOUNTING Typical mounting arrangements are shown in Figures B to E. Important: Injection point must be higher than the top of the solution supply tank to prohibit gravity feeding, unless a suitable backpressure is always present at the injection point. Installation of an antisiphon valve will prohibit gravity feeding.
1.
For wall or shelf mounting, refer to Figure E. Connect suction tubing to suction valve of chemical pump. Suction valve is the lower valve. Tubing should be long enough so that the foot valve/strainer assembly hangs about 1-2 inches (2.5 - 5 cm) above the bottom of chemical tank. To keep chemical from being contaminated, the tank should have a cover. Flooded suction mounting (installing the pump at the base of the chemical storage tank, Figure C) is the most trouble free type of installation and is recommended for very low output requirements. Since the suction tubing is filled with chemical, priming is accomplished quickly and the chance of losing prime is reduced. To mount pump, drill 4 holes of .25in. (6.3 mm) diameter in the shelf as shown in the dimension drawing (Figure F). Attach pump securely using four #10 bolts and nuts.
2.
3.
The pump can be mounted to a wall as shown in Figure D. A wall mount bracket kit is available which includes all necessary hardware to mount the pump to the wall. Mounting the pump other than as shown in Figure D defeats the purpose of the housing drain. Mounting dimensions for the pump are provided in Figure F for reference. The pump can be mounted on top of a solution tank as shown in Figure E. Install chemical pump on the cover. Insert suction tubing through the center hole and cut tubing so foot valve/strainer hangs about 1 or 2 inches (2.5 - 5 cm) above the bottom of the tank. Mount the chemical pump rigidly by drilling four .25in. (6.3 mm) holes and using four #10 screws and nuts. USE AN ANTI-SIPHON VALVE IN THE DISCHARGE LINE whenever the fluid pressure in the discharge line is below atmospheric pressure. This can occur if the injection point is on the suction side of a water pump or against a "negative" head such as when feeding down into a well, SEE FIGURE G1.
4.
5.
PIPING 1. Use provided tubing of specified size for connection. Connect tubing securely to prevent leakage of chemical and the entrance of air. Since plastic nuts are used for fittings, they should not be tightened excessively i.e. hand tighten only. NPT suction and discharge valves must NOT be over tightened. Hold fittings in place while adding piping and fittings. NPT suction and discharge valves should only be tightened 25 to 35 in. lbs. (4.46 to 6.25 kg/cm). 2. If the air bleed valve assembly is being used, a return line (tubing) should be securely connected and routed back to the storage tank. To avoid possible injury from chemicals do not attempt to prime using a bleed valve without installing a return line. 3. To maintain metering performance, a backpressure/injection valve is provided. The injection valve must be installed in the discharge line. Best practice is to install the injection valve at the point of chemical injection. 4. If the discharge tubing is going to be exposed to direct sunlight, black tubing should be used instead of the standard white translucent tubing supplied with each pump. To obtain, contact supplier. 5. To prevent clogging or check valve malfunction always install a strainer assembly to the end of the suction tubing (Figure E). This foot valve/strainer assembly should always be installed 1 to 2 inches (2.5 - 5 cm) above the bottom of the chemical tank. This will help prevent clogging the strainer with any solids that may settle on the tank bottom. The chemical tank and foot valve/strainer should be cleaned regularly, to ensure continuous trouble free operation. If the chemical being pumped regularly precipitates out of solution or does not dissolve easily or completely (e.g. calcium hydroxide), a mixer should be used in the chemical tank. These are readily available in many motor configurations and mountings. To obtain, contact supplier. 6. A flooded suction (tank liquid level always at a higher elevation than the pump) is recommended when pumping sodium hypochlorite (NaOCI) and hydrogen peroxide (H2O2) etc. which are liable to produce air bubbles. Maintaining a low liquid temperature will also help eliminate this problem. 7. Pipe corrosion can result if dilution at the injection point does not occur rapidly. This problem is easily prevented by observing this simple rule: install injection fitting so that the end is in the center of the flow stream of the line being treated. Trim injector tip as required. See Figure H. Note: Extended injection assemblies are available for large water lines. Consult your supplier for more information.
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WIRING 1. : Risk of electrical shock. This pump is supplied with a three prong grounding type power plug. To reduce risk of electric shock, connect only to a properly grounded, grounding type receptacle.
2. The metering pump should be wired to an electrical source which conforms to those on the pump nameplate. (Applying higher voltage than the pump is rated for will damage the internal circuit.) 3. In the electronic circuit of the control unit, measures for surge voltage are made by means of surge absorbing elements and high voltage semiconductors. Nevertheless, excessive surge voltage may cause failure in some areas. Therefore, the receptacle should not be used in common with heavy electrical equipment which generates high voltage. If this is unavoidable, however, measures should be taken by (a) the installation of a surge absorbing element (varistor of min. surge resistance 2000A) to the power supply connection of the pump, or (b) the installation of a noise suppression transformer.
4. In the event of electrical power interruption during pump operation, the pump will remember its setting and automatically resume operation as before, whenever power is restored. If a manual reset is required to resume operation, the electrical circuit serving the pump must be suitably wired. Latching power relays which "drop out" upon loss of power, requiring manual reset, are typically used for this purpose. WELL PUMP SYSTEM INSTALLATION 1. Ensure that the metering pump voltage matches the voltage of the well pump. Typical well pump electrical circuits are shown in Figure J. All electric wiring should be installed in accordance to local electrical codes by a licensed electrician. 2. Install the backpressure/injection (Figure I) on the discharge side of the metering pump into a tee which is installed into the water line going to the pressure tank. Typical installations are found in figures G1, G2 and G3.
Pumps carrying the "ETL Sanitation' approval (tested to NSF standard 50) are listed for swimming pools, spas, and hot tubs, and when proper materials are selected, are capable of handling but not limited to the following chemical solutions: 12% ALUMINUM SULPHATE 5% SODIUM CARBONATE 10% SODIUM HYDROXIDE 2%CALCIUM HYPOCHLORITE 12.5% SODIUM HYPOCHLORITE 10% HYDROCHLORIC ACID
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DESCRIPTION OF CONTROLS AND OPERATION

INTRODUCTION The pump performs the following functions:
Selected Controls - Fixed Rate - External Pulse - Straight Pulses - Pulse Storage - Division - Multiplication - External Current Signal - 4-20 mA - 20-4 mA - Stroke Counting - Timed Operation (intervals) Display Alarms - Circuit Failure - Signal Loss - Full Count
- Pulse Overflow - Pulse Rate High
Relay Output (one selected at a time) - Relay Off - Pulse Overflow - Stop Function - Repeat Strokes - Current Signal Loss - Circuit Failure - Full Count
USING THE TOUCHPAD All adjustments and changes to pump operation (except stroke length) are made through the 6-button touchpad (figure L). Except for alarm conditions, the LCD display (figure K) always presents either the present operating condition or a prompt which must be answered in order to commence operation. There are two types of prompts: Prompts in the form of questions (marked with a flashing question mark) are used to navigate through the menu options. These prompts are answered by pressing either the or buttons. Prompts marked with alternating up and down arrows are always encountered when a numerical value must be selected (i.e., stroke rates, counts, run times, ratios). These prompts are answered by pressing either the or buttons to change the display value to the desired setting. After the desired value has been set in the display, press to accept this value and continue or press to return to the main menu. To stop the pump at any time, press the red resume operation as before, press the button. button. To
To display the present stroking rate as a percentage of the button. maximum rate of the pump at any time, press the Press any button to return to the normal display. Pressing the button while the pump is in operation will bring up the relay option menu. Pressing will allow scanning the relay output options. When the desired option is presented press the button, this will set the relay option and the screen will automatically return to the operating display.
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HELPFUL HINTS You can always get to where you want to go simply by accepting or rejecting choices presented. If you find yourself within a menu where you don't want to be, keep selecting No until you return to the main menu. If you go past the desired selection by mistake, keep selecting No and the pump will take you back to it. If you press an inappropriate button, you will be notified by a message which lasts for several seconds. A partly flashing display requires your response. A flashing question mark requires a Yes or No answer. Flashing arrows require an Up or Down numerical adjustment. To make large numerical adjustments quickly, hold down either the Up or Down arrow buttons. The value in the display will change at an increased rate. A fully flashing display is an alarm. If power is interrupted, the pump will automatically resume operating where it left off when power is restored. The pump will remember this for years while power is off.
CONTROL OPTIONS
FIXED RATE The pump operates continuously at the set rate over the span 1-100% of maximum.
EXTERNAL PULSE CONTROL - STRAIGHT PULSES Each pulse received from the external signal port causes the pump to immediately stroke once at a rate limited by the maximum rate of the pump, 125 strokes per minute. If any pulses are received at a faster rate, the Pulse Rate High alarm is triggered, during which the pump operates at its maximum rate and does not respond to the excess pulses. In the Pulse Storage option, any pulse frequency received which is at a higher rate than the pump can respond to (125 contacts per minute), will cause excess pulses to be accumulated in memory. The pump will work off the excess pulses at a rate of 125 strokes per minute when the signal level drops below the maximum rate. If the accumulation exceeds 9,999 pulses, memory storage capacity is exceeded and the Pulse Overflow alarm is triggered. During the Pulse Overflow condition the pump operates at 125 strokes per minute; when the incoming rate drops below 125 pulses per minute, normal Pulse Storage operation resumes, starting with a full memory.
EXTERNAL PULSE CONTROL - DIVISION The pump operates as described above except that incoming pulses are divided by a value from 1 to 999 prior to actuating the pump. For example, at a setting of 5, every fifth incoming pulse causes the pump to stroke once. The Pulse Storage option operates as described above. Pulse division makes it possible to "tune" the pump by adjusting its response to an external pulse signal, such as that from a flow meter, which is of too high a frequency to cause the desired feed by directly stroking the pump.
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EXTERNAL PULSE CONTROL - MULTIPLICATION The pump operates as described previously except that incoming pulses are multiplied by a value from 1 to 999 prior to actuating the pump and then worked off at a selected stroking rate. For example, at a multiplier of 5 and a stroking rate of 25%, each incoming pulse causes the pump to stroke five times at 25% stroking rate and then stop. During operation, the display shows the present value and the present count on a running basis. Unless Pulse Storage is in effect, additional external pulses received while responding to a previous pulse are ignored. This option is similar to Stroke Counting (see below) except that action is initiated automatically by one or more external pulses rather than once manually by the user. There is no Full Count alarm as in Stroke Counting since it is always possible to receive additional external pulses. The Pulse Storage option operates as described above.
EXTERNAL CURRENT SIGNAL CONTROL In the 4-20 mA (direct) option, the pump responds linearly to a current signal from the incoming signal port over the full operating span from 0% (4 mA) to 100% (20 mA). For example, a 12 mA signal causes the pump to operate at 50% of full. In the 20-4 mA (reverse) option, pump response is the reverse of the above: from 0% (20 mA) to 100% (4 mA). In both the 4-20 mA and 20-4 mA options, a Ratio from 1 to 99% can be applied to step down the response. For example, a 12 mA signal at a 50% ratio causes the pump to respond as if the signal were only 6 mA (50% of 12 mA). In all the above options, the Signal Loss alarm is triggered whenever the signal drops below approximately 2 mA for several seconds. The pump stops operating during the loss of signal condition, and automatically resumes normal operation when the signal is restored.
STROKE COUNTING The pump delivers a preset number of up to 9,999 strokes at a selected stroking rate. During operation, the display shows the preset value and the present count on a running basis. When the preset number of strokes has been delivered, the pump stops and the Full Count alarm is triggered. Pressing Yes when the Full Count alarm is displayed brings up the reset prompt. Continue pressing Yes to repeat the same stroking cycle or change the displayed values as they are presented to change the stroke count. This option is similar to External Pulse Control - Multiplication (see above) except that action is initiated once manually by the user rather than by one or more external pulses.
TIMED OPERATION* The pump operates for selected run times from 1 to 999 minutes (16.65 hours) at selected intervals from 1 to 999 hours (41.625 days) at a selected stroking rate. For example, the pump might be set to operate for 60 minutes every 168 hours (7 days), at a 50% stroking rate. During operation the pump displays the run time in minutes and the interval in hours. * Pumps with version numbers "B4" and "GB4" (displayed on power-up) use settings of seconds and minutes.
RELAY SETTINGS
The following relay output options can be brought up on the menu by pressing the Yes button while the pump is in an operating condition (Relay options vary with operating condition). Press the No button to scan through the options available. Only one relay output option may be selected. When the desired option is displayed, press the Yes button. This will set the relay for the chosen option and the display will automatically return to the previous operating display.
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RELAY OFF In all control options the relay remains open at all times. STOP FUNCTION In all control options the relay is normally open and closes while the Stop Function is activated through the stop port. CURRENT SIGNAL LOSS In any Current Signal control option, the relay is normally open and closes while the Signal Loss alarm is in effect. FULL COUNT In the Stroke Counting control option, the relay is normally open and closes while the Full Count alarm is in effect. PULSE OVERFLOW In any External Pulse control option with Pulse Storage, the relay is normally open and closes while the Pulse Overflow alarm is in effect. REPEAT STROKES In all control options, the relay is normally open and closes momentarily during each stroke of the pump. If the pump is equipped with a 24 VDC signal relay output, this function may be used to pace another externally paced pump. CIRCUIT FAILURE At all times, the relay is normally open and closes while the Circuit Failure alarm is in effect. The numbers which flash alternately with the alarm signal are for failure diagnosis at the factory.
ALARMS
Alarms are distinguished by a fully flashing display. CIRCUIT FAILURE At all times, pumping is disabled and the pump will no longer operate until repaired. SIGNAL LOSS In any Current Signal option, the Signal Loss alarm is triggered whenever the signal drops below approximately 2 mA for several seconds. The pump stops operating during the loss of signal condition and resumes normal operation when the signal is restored. This includes the 20-4 mA option, in which a low current (4 mA) signal normally calls for full pump output in order to prevent overfeeding in the event of signal loss. FULL COUNT In the Stroke Counting control option, when the preset number of strokes has been delivered and the pump stops, the Full Count alarm is triggered. PULSE OVERFLOW In the Pulse Storage option, when memory capacity is exceeded the Pulse Overflow alarm is triggered. The pump continues to respond to external signal pulses as if 9,999 pulses were in storage. PULSE RATE HIGH In any External Pulse Control option without Pulse Storage, receipt of any pulses at a faster rate than maximum pump stroking rate, 125 strokes per minute, the Pulse Rate High alarm is triggered. The pump continues to operate at its maximum rate and does not respond to the excess pulses.
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CONTROL REFERENCE SUMMARY

CONTROL OPTIONS Fixed Rate External Pulse Straight Straight Pulse Pulse-Store 9999 Fixed Rate 100%
Pulse Storage option Division Pulses ) 999
Pulse Storage option: Multiplication x999/999
) 999 Store 999

x999 Store 999
Pulse Storage option External Current 4-20 mA 4-20mA Signal
Ratio option 20-4 mA
4-20 Ratio 100%
20-4mA Signal 20-4 Ratio 100%
Ratio option Count Strokes Timed Interval
Count 9999/9999 999m Every 999h
OUTPUT RELAY OPTIONS Relay Off Stop Function Relay Off Relay-Stop Relay-No Signal
Current Signal Loss Full Count
Relay-Full Count Relay-Overflow Relay-Repeat Relay-Failure
External Pulse Overflow Repeat Strokes Circuit Failure
ALARMS (full flashing display) Circuit Failure Signal Loss Full Count Pulse Overflow Pulse Rate High Circuit Failure Signal Loss Full Count Pulse Overflow Pulse Rate High
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SETTINGS OPTIONS Settings? Flow Verify? Relay Output? Relay-Stop? Relay-Repeat? Rel-No Signal? Rel-Full Count? Relay-Overflow? Relay-Failure? Rel-Flow Vrfy? Relay-Off? Factory Init? Init Settings? Are You Sure? Volume-Units? Units = GPD? Reset Totals? Are You Sure? Calibrate Flow? Stroke = 100 Run Calib? Language? English? French? German? Spanish? Yes=On No=Off
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START UP AND OPERATION

POWER All metering pumps are available in 115 volts at 50/60 Hertz, single phase. Optionally 230 volts at 50/60 Hertz, single phase can be provided. Prior to start-up always check to insure that the pump voltage/frequency/phase matches that of the power supply. : If pump is fitted with a PVC pump head (7th position of model number is V. Note: PVC is gray, not black), uniformly hand tighten the four head screws before use (18-22 inch pounds / 3.21-3.93 kg/cm). Periodically tighten after installation.
PRIMING : When working on or around a chemical metering pump installation, protective clothing and gloves and safety glasses should be worn at all times. All pumps are tested with water. If the chemical to be pumped reacts when mixed with water (e.g. sulfuric acid, polymer) the pump head should be removed and dried thoroughly along with the diaphragm and valve seats. 1. 2. 3. Turn on the power to the pump. Operate the pump in the fixed rate control mode at 100% (full) rate. The green LED will light up and flash off each time the pump strokes. Adjust the stroke length knob to the 100% setting mark (for more information see Stroke Length Adjustment on the following page). If the discharge line is connected directly to a pressurized system it should be temporarily bypassed during priming of the pump. A bleed valve will simplify this operation by allowing easy bypass of the discharge fluid. All air must be purged from the pump head before the pump will pump against pressure. Air Bleed Operation: A) While pump is running, turn adjustment screw counterclockwise. B) Run with valve open until a solid stream of fluid comes out of the bypass tubing (1/4 x 3/8 supplied with valve), no air bubbles. C) Close air bleed valve by turning adjustment screw clockwise. 4. Chemical should reach the pump head after a few minutes of operation. If not, remove the discharge fitting and moisten the discharge valve area (ball check and valve seats) with a few drops of chemical being fed to the metering pump. For safety, always use protective clothing and gloves, wear safety glasses and use a proper container to hold the chemical. If the pump continues to refuse to prime, refer to Troubleshooting Section of these instructions. Turn the power on once more and adjust the pump flow to the desired rate (see Controlling Procedure below). Always check the calibration of the pump after start-up. Its best to calibrate the pump under your typical use conditions.
5. 6. 7.
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STROKE LENGTH ADJUSTMENT Stroke length can be controlled within 0 to 100% of the diaphragm displacement. (It should be controlled within 20 to 100% for practical use.) Stroke length can be set by means of the stroke length adjusting knob while the pump is in operation. Do not turn the knob while the pump is stopped.
Controlling Procedure (for fixed rate): Proper set points for stroke length should be determined after consideration of the pump and characteristics of the fluid. The following procedure is recommended from the viewpoint of pump performance. Note: The closer the stroke length is to 100%, the better the pump performance will be. A) B) Set the stroke length to 100%. Measure the output capacity. Adjust the stroke rate frequency to obtain the desired output. If adjustment by stroke rate alone does not bring the output low enough, the stroke length may be adjusted to lower the maximum output. C) Measure the output capacity to ensure that the required value is obtained. = = = = = = LMD4 100% 100% 21 GPD* 17 GPD 17 x 100 = 81% (approx.)* 21
Example Selected Model Set Stroke Length Set Stroke Rate Output Capacity (Rated Pressure) Desired Flow Adjust Stroke Rate to 81% Output Capacity
Thus to obtain the desired flow, stroke length is set at 100% and stroke rate is set at 81% i.e. output capacity = 0.81 x 21 = 17 GPD* * Check these values by measurement. Output capacity is higher when feeding against less than rated pressure.
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OPERATION BY EXTERNAL INPUT SIGNALS: The pump can be controlled by three types of input signals. All are fully isolated from AC input power and from Earth ground. The input socket connections are located at the bottom of the control panel face and the signal cords are provided with the pump. Remove rubber plugs to access plug sockets.
Stop Function: Operation of the pump can be stopped by an external signal input. When the external signal is input to the stop terminals, the red light goes on and operation of the pump is stopped. The stop function overrides all control options and input signals at other terminals. Previous operation resumes when the stop signal is removed. : Operation of more than one pump from the same contact closure will damage the pump circuits. When such operation is required, the pump circuits must be electrically isolated from one another by means of a multi-contact control relay or similar means.
Input signals should be no-voltage signals from relay contacts, etc. and the input of other signals is prohibited. (In case of relay contacts, electric resistance must be 100 ohms or below when ON and 1 Mega ohm or above when OFF). The stop function is commonly used in conjunction with a tank float switch. The float switch contacts are normally open but when the tank level falls past a certain point the contacts close and the pump stops. Signal cord is provided with the pump.
External Pacing Function: Pump stroking can be controlled by an external pulse signal through the external signal terminals while the pump is in one of the external pacing control modes. : Operation of more than one pump from the same contact closure will damage the pump circuits. When such operation is required, the pump circuits must be electrically isolated from one another by means of a multi-contact control relay or similar means.
After receiving an input signal, the pump generates the necessary power pulse to actuate the solenoid. The external signal input is debounced by the pump circuit. Input signals should be no-voltage signals from relay contacts, etc. and the input of other signals is prohibited. (In the case of relay contacts, electric resistance must be 100 ohms or below when ON and 1 Mega ohm or above when OFF). The pulse duration of the input signal must be 10 milliseconds or over and the frequency of input signal must not exceed 125 times/min unless accommodated by pulse division or pulse storage. Signal cord is provided with the pump.
4-20 mA / 20-4 mA Function: The pump stroking rate can be controlled by a 4-20 mA direct or an inverse current signal when in one of the current signal modes. The pump automatically adjusts stroking rate according to the signal level provided to the pump. Pumps may be wired in series to the current signal providing that the signal source is sufficient to handle the load (each pump has an impedance of 187 ohms). The pump responds to a straight (non-ratio) 4-20 mA signal as follows: (Figure N below shows straight response and response ratioed by 25, 50 and 75%): The pump responds to a 20-4 mA signal as follows. (Figure O below shows straight response and response ratioed by 25, 50 and 75%):
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The signal cord is provided with the pump and has the following polarity: White = Positive (+) Black = Common Signal input impedance is 100 ohms.
OUTPUT RELAY Each pump has the option of being provided with one of two separate normally open output relay options as described below. Relays close according to the option selected, and remain closed during the condition specified for the selected option except for the Repeat Strokes option.
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The Signal Level output relay option is via the output signal terminals on the pump control panel. It is designed to provide direct or inverted voltage output signals as shown in figure O. The voltage input must have a high-impedance characteristic and must not exceed 24 VDC. The pump circuit can source or sink a maximum current of 10 mA. The signal cord is provided with the pump and has the following polarity when connected to the pump terminals. White = Positive (+) Black = Common
The Power Level option is via the power relay cord which exits the pump below the control panel. The power level relay is a zero-crossing triac-type solid-state switch as seen in figure Q which is designed to switch AC current only and has the following ratings: Voltage Minimum = 12 VAC, 50/60 HZ Maximum = 250 VAC, 50/60 HZ Current minimum = 10 mAmps maximum = .5 Amps Power minimum = .12 watts (at 12 VAC) maximum = 120 watts (at 240 VAC)
* Load can be any device which meets the above voltage and current limits (i.e., lamp, alarm, siren, relay, etc.)
Do not apply power directly to the relay cord without a sufficient load to limit current as indicated above. Do not exceed the specified voltage rating. Excess current or voltage will damage the pump and cause fire and electrical shock hazards. Do not install any type of standard power plug to the relay cord.
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ADDITIONAL SETTINGS: Flow Verify? used in conjunction with the flow verification meter; to activate this option: Choose: Settings?, press YES Flow Verify?, press YES Yes=On No=Off?, press YES NOTE: Enabling flow verification on a pump with no flow meter will cause a flow failure. Factory Init? initializes the pump back to all original factory settings; to reinitialize the pump: Choose: Settings?, press YES Factory Init?, press YES Init Settings?, press YES Are You Sure?, press YES Volume-Units? allows the user to select how the flow data will be displayed (default is GPD); to change this setting: Choose: Settings?, press YES Volume-Units?, press YES Use the up and down arrow to choose GPD, GPH, or LPH. Choose YES when the desired unit is displayed. Reset Totals? resets the flow totals; to reset the totals: Choose: Settings?, press YES Reset Totals?, press YES Are You Sure?, press YES The display will read Reset Done, press YES to get back to the settings menu. Calibrate Flow? allows the user to calibrate the system to obtain accurate flow totals; to calibrate the system: Choose: Settings?, press YES Calibrate Flow?, press YES Stroke=100%, use arrow keys to set the stroke per the dial, press YES Run Calib?, press YES Run the pump for the desired amount of time while measuring the flow output. Press YES to stop the calibration period. Use the arrow keys to enter the measured flow in mL, press YES. The display will read Calibrated, press YES to return to the Settings menu. NOTE: If the stroke length is changed and the calibration is not re-run, the flow totals will not be accurate. Additional Relay Functions: Rel-Flow Vrfy? allows the relay to be activated if there is a flow failure. To set this option: Choose: Settings?, press YES Rel-Flow Vrfy?, press YES Language? allows the user to select English (default), German, Spanish or French; to set the language: Choose: Settings?, press YES Use the arrow keys to select the desired language, press YES.
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MAINTENANCE
: Before performing any maintenance or repairs on chemical metering pumps, be sure to disconnect all electrical connections and insure that all pressure valves are shut off and pressure in the pump and lines has been bled off. Always wear protective clothing, gloves and safety glasses when performing any maintenance or repairs on chemical metering pumps.
ROUTINE MAINTENANCE 1. Routinely check the physical operating condition of the pump. Look for the presence of any abnormal noise, excessive vibration, low flow and pressure output or high temperatures [when running constantly at maximum stroke rate, the pump housing temperature can be up to 160F (70C)] 2. For optimum performance, cartridge valves should be changed every 4-6 months. Depending on the application, more frequent changes may be required. Actual operating experience is the best guide in this situation. Repeated shortterm deterioration of valve seats and balls usually indicates a need to review the suitability of wetted materials selected for the application. Contact the supplier for guidance. 3. Check for leaks around fittings or as a result of deteriorating tubing e.g. when standard white translucent discharge tubing is exposed to direct sunlight. Take appropriate action to correct leak by tightening fittings or replacing components. 4. Keep the pump free of dirt/debris as this provides insulation and can lead to excessive pump temperatures. 5. If the pump has been out of service for a month or longer, clean the pump head/valve assemblies by pumping fresh water for approximately 30 minutes. If the pump does not operate normally after this purging run, replace cartridge valve assemblies.
DISASSEMBLY AND ASSEMBLY DIAPHRAGM REMOVAL 1. Flush pump head and valve assemblies out by running pump on water or other suitable neutralizing solution. Wash outside of pump down if chemical has dripped on pump. 2. Set stroke length of pump to 0% and unplug pump. 3. Disconnect tubing or piping from the pump. Remove the four pump head screws and then remove the pump head assembly. 4. Remove the diaphragm by grasping it at the outer edges and turning it counterclockwise until it unscrews from the electronic power module (EPM). Dont lose the deflection plate or diaphragm shims which are behind the diaphragm. Note shim quantity can be from 0 to 2. 5. Inspect diaphragm if it is intended to be used again. Look for indications of the TFE face being overstretched, (localized white areas) or the elastomer on the back of the diaphragm being worn. Excessive amounts of either condition require diaphragm replacement.
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DIAPHRAGM REPLACEMENT Refer to drawings in the back of the manual. 1. When replacing the diaphragm, its always a good idea to replace the valve cartridges and other worn parts. A kit is available from your supplier with all parts necessary to completely rebuild your pumps wet end. All your supplier needs to know is the KOPkit No. on your pumps nameplate to supply this kit. 2. Set pump stroke length to 0% and unplug the pump. 3. If you kept the shims from the original diaphragm or know the original quantity you can avoid Step #4 for shimming the diaphragm and go to Step #5. 4. Slide the diaphragm deflection plate onto the back of the diaphragm stud, radius side towards the diaphragm. Next slide two shims onto the diaphragm threaded stud and screw the diaphragm into the EPM unit. Refer to Figure R. Turn diaphragm clockwise until deflection plate and shims are tight against solenoid shaft, diaphragm stops turning. If there is a gap between the adaptor and diaphragm, repeat the procedure removing one shim each time until the diaphragm just touches the adaptor or is slightly recessed. 5. Apply grease to areas of the diaphragm that contact the deflection plate or radius on the adaptor. 6. Screw the diaphragm into the EPM units shaft with the deflection plate and appropriate number of shims in between. 7. Adjust stroke length to 50%. It is easier to do this if you temporarily turn the pump on. Place the pump head onto the adaptor with valve flow arrows pointing up and install and tighten pump head screws. Tighten screws until pump head pulls up against adaptor. 8. Adjust stroke length back to 100% for easier priming and place pump back into service.
VALVE REPLACEMENT 1. Flush pump to clean any chemical from pump head. 2. Unplug pump, release system pressure, and disconnect any tubing or piping. 3. Unscrew valve cartridges and discard. Also remove O-Rings down inside pump head. 4. Using new O-Rings, install new valve cartridges with stamped letters reading from top to bottom, and the arrow pointing in the direction of flow. Hand tighten only, do not use wrenches or pliers. This is especially important when the pump head is SAN material. 5. Reconnect tubing or piping and reinstall the pump. 6. Check for leaks around newly installed fittings.
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TROUBLESHOOTING
PROBLEM LOSS OF CHEMICAL RESIDUAL PROBABLE CAUSE 1. Pump setting too low. 2. Scale at injection point 3. Solution container allowed to run dry 1. Pump setting too high1. TOO MUCH CHEMCIAL 2. Chemical in solution tank is too rich REMEDY 1. Adjust to higher setting (pump must be operating during stroke length adjustment). 2. Clean injection parts with 8% muriatic acid or undiluted 3. Refill the tank with solution and prime. See start-up and operation section 1. Lower pump setting (pump must be operating to adjust stroke length knob). 2. Dilute chemical solution. NOTE: For chemical that reacts with water, it may be necessary to purchase a more dilute grade of chemical direct from chemical supplier. 3. Test for suction or vacuum at the injection point. If suction exists, install an anti-siphon valve. 1. Cut off end of tubing (about 1) and then replace as before 2. Consult your seller for alternate material. 1. Examine suction tubing. If worn at the end, cut approximately an inch off and replace 2. Clean valve seats if dirty or replace with alternate material if deterioration is noted 3. When pumping against pressure, the dial should be set above 20% capacity for a reliable feed rate 4. Solution must be above foot valve 5. Replace diaphragm as shown in the Maintenance Section. Check for pressure above rated maximum at the injection point. NOTE: Chemical incompatibility with diaphragm material can cause diaphragm rupture and leakage around the pump head. 6. Replace pump head as shown in Maintenance Section. Make sure fittings are hand tight only. Using pliers and wrench can crack pump head. Also, chemical incompatibility can cause cracking and subsequent leakage. 7. Bleed pump head, see Air Bleed Operation. 8. Connect wiring properly. Check fuse or circuit breaker 9. Take measures after investigation of cause 10. Contact supplier 1. Remove and replace or clean off any scale or sediment 2. Check seat and ball checks for chips, clean gently. If deformity or deterioration is noted, replace part with proper material. Resulting crystals can hold check valves open, therefore the valves must be disassembled and cleaned. Be sure to replace all parts as shown in the Parts Diagram at the end of the manual. 3. Refill the tank with solution and prime. See Start-Up and Operation section 4. Bleed gas, use flooded suction, maintain chemical at room temperature (approx. 20 F / 6 C). 1. Tighten hand tight. Replace gasket if hand tight does not stop leakage 2. Check gaskets and replace if broken or damaged 3. Consult your pump supplier for alternate material 1. Turn off all pressure valves, loosen outlet tubing connection at discharge point. Remove discharge valve cartridge. Dampen ball check and valve seats with a few drops of solution. Set pump dial to maximum rate. When pump is primed, reconnect all tubing connections. 2. Disassemble, loosen, clean and check for deterioration swelling. Reassemble and wet the valve assembly, then prime. See Start-Up Operation section. 3. Always prime pump with out dial set a maximum rated capacity 4. Decrease suction lift or pull vacuum on pump discharge until pump is primed 5. Loosen discharge valve to aid in priming, take necessary safety precautions or apply vacuum to pump discharge
LEAKAGE AT TUBING CONNECTIONS
3. Siphoning of chemical into well or main line. 1. Worn tube ends 2. Chemical attack 1. Leak in suction side of pump 2. Valve seats not sealing 3. Low setting on pump
4. Low solution level 5. Diaphragm ruptured FAILURE TO PUMP 6. Pump head cracked or broken
7. Pump head contains air or chlorine gas 8. Breakdown or disconnection of wiring 9. Voltage drop 10. Malfunction of electronic control board 1. Dirty check valve 2. Ball checks not seating or not sealing properly PUMP LOSES PRIME 3. Solution container allowed to run dry 4. Chemical outgassing 1. Loose fittings LEAKAGE AT FITTING 2. Broken or twisted gasket 3. Chemical attack 1. Too much pressure at discharge
2. Check valves not sealing PUMP WILL NOT PRIME
3. Output dials not set at maximum 4. Suction lift height too much 5. Pump equipped with spring loaded high viscosity valves
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Specifications
Pressure, MAX, PSI/BAR @ GPD/GPH/LPD Capacity, MAX, GPD/GPH/LPD @ PSI/BAR Reproducibility, % MAX Capacity Viscosity, MAX, CPS (1) Suction Lift @ 1 CPS, MAX, FT/M @ 3000 CPS Controls Status Display LED Indicator Lights, Panel Mount Stroke Frequency, MAX, SPM External Stroke Frequency Control, (Automatic) Stroke Frequency Turn Down Ratio Stroke Length Turn Down Ratio Output Relay (Signal Level Option) Output Relay (Power Option) Power Input Current Draw @ 115 VAC, AMPS Average Input Power @MAX SPM, Watts Circuit Board Protection Temperature, MAX, F/ C - Environmental (Shaded) 300/20 3/.13/11 500/20.8/1890 20/1.4 2 1000 10/3.1 (once primed) 3.5/1.1 6-Station Membrane Switch 16-Position LCD Dot Matrix Backlight Power On - Green Pulsing - Green Flashing Stop - Red 125 4-20 mADC, 20-4 mADC External Pacing 100:1 10:1 24 VDC, 10 mA 250 VAC, 50/60 HZ, .5A 115 VAC/50-60HZ/1ph 230 VAC/50-60HZ/1ph 1 130 Circuit Breaker (Panel Mount)
104/40
.25" ID X .38" OD Connections - Tubing (Suction & Discharge) .38" ID X .50" OD . .50" ID X .75" OD . .25" FNPT . - Piping (Suction & Discharge) .50" FNPT
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REPAIR SERVICE
Normally following the instructions in the previous sections of the manual will rectify any pump problems. If, however, after following these instructions the pump does not perform properly, it can be returned for repair. Please follow the instructions below: 1. Pump cannot be serviced properly if the original pump nameplate or data contained on the nameplate is not intact. 2. Thoroughly flush pump head and outside of pump with water or a suitable fluid to neutralize any residual chemical left in pump. 3. Include written explanation of the following: A) Problem B) Pumped Fluid Name Viscosity Fluid Temperature C) Pressure @ Discharge @ Suction or Suction Lift D) Environmental Temperature E) Electrical Service Volts Hz Phase F) Nameplate Data Series Serial # KOPkit # 4. Package the pump in the original box if available and send to the address specified by your pump supplier.
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Keep-On-Pumping kits that can save you time and money!

The manufacturer has built a reputation for superior reliability by supplying carefully-designed, highquality equipment. Even the best equipment, however, requires a minimal amount of maintenance. KOPkits are designed to guard against unnecessary downtime and assure you the highest level of efficient and uninterrupted service. KOPkits contain those recommended spare parts which will most likely require normal maintenance. A typical KOPkit includes Valve Cartridges with ORings, Head, Diaphragm, Secondary O-ring Seal, Head Screws, Washers and an exploded view drawing. KOPkits will save you money. When you need a part, youve got it! You can cut downtime and production loss from days to minutes. You also save by buying parts in KOPkit form compared with buying individual parts. Each KOPkit part is vacuum-sealed to keep it clean even when stored for long periods of time. A KOPkit is a troubleshooters best friend. In the event of a breakdown, it will put you back in business fast! Preventive maintenance will insure continuous high performance of your pump. Keep on pumping! Get all the money-saving and security benefits of KOPkits immediately.
Selecting a KOPkit
The KOPkit part number is displayed on the pump model label as shown. To order the proper KOPkit model, begin with the letter "K" followed by the 4th, 7th, 8th, 9th and the 10th digit of the pump model number.
L9404500-000 Revision A
PRINTED IN U.S.A.
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The beta pump series is a solenoid-driven, diaphragmtype metering pump featuring the following:
Microprocessor based Capacity range 0.19 - 8.4 gph (0.74 - 32 L/h) Continuous stroke length adjustment from 0 to 100% 10-setting stroke frequency adjustment from 10 to 100% Maximum stroke rate: 180 spm Repeatability +/- 2% when used according to operating instructions Liquid end materials: PP, PVC, Acrylic, PTFE, SS Auto degassing liquid ends High viscosity liquid ends External access to options 12-24 VDC low voltage option ProMinent solenoid-driven metering pumps consist of two main components: the pump drive unit and the liquid end. The beta series offers two drive (solenoid) sizes: beta/4 (BT4a) and beta/5 (BT5a). Operating principles and options are identical, and both units offer maximum backpressures up to 253 psig (17.5 bar). Capacity range for the beta/4 is 0.19 to 5 gph (0.74 to 19 L/h); beta/5 is 1.1 to 8.4 gph (4.1 to 32 L/h). Feed rate is determined by stroke length and stroking rate: stroke length can be varied from 0 to 100% with an adjustment ratio of 10:1. It is set manually by the adjustment knob on the front of the pump. Stroke rate can be adjusted in 10% increments between 10 and 100% via the multifunction switch. This switch is also used to select voltage-free On/Off external pulse contact, pump stop, or test (for priming).
The Drive Unit

Pump housing
Constructed of fiberglass-reinforced PPE plastic, with a NEMA 4x enclosure rating to protect against corrosion, dust and water. valve. When the magnetic field is de-energized, a spring returns the armature and diaphragm to their original position. This return movement draws chemical into the dosing head cavity through the suction valve. In the event of a diaphragm rupture, the liquid end has a weep hole on the bottom of the backplate to direct chemical out of the pump and away from the solenoid. An optional diaphragm failure monitor can be used to stop the pump and indicate a problem. The stroke-length adjusting mechanism is directly connected to the solenoid. Adjustment results in an accurate self-locking stroke length setting.
Solenoid drive
The drive unit houses a shortstroke solenoid with a maximum stroke length of 0.05" (1.25 mm). It is equipped with a noise suppressing mechanism for quiet operation and has only one moving part, the armature. Operating on pulse action, each pulse generates a magnetic field in the solenoid coil. This magnetic field moves the armature forward. At the end of the armature is the diaphragm. The diaphragm pushes into the dosing head cavity forcing chemical out of the discharge
CUTAWAY VIEW OF
PROMINENT BETA SOLENOID-DRIVEN METERING PUMP
The Diaphragm
The diaphragm is constructed of fabric-reinforced EPDM elastomer with a plastic core and a PTFEfacing. It is chemically resistant against virtually all process fluids and can be used over a wide temperature range. The beta pump is designed with the new-style convex diaphragm. The curved shape contributes to more precise metering and alleviates stress placed on the diaphragm by reducing liquid end dead volume.
1 2 3 4 5 6 7 8 9 10 11 12
HOUSING LIQUID END DIAPHRAGM BACKPLATE SOLENOID SOLENOID COIL SOLENOID AXLE ARMATURE COVER STROKE ADJUSTMENT SCREW STROKE ADJUSTMENT AXLE STROKE ADJUSTMENT KNOB
beta1
ProMinent
ProMinent beta Metering Pumps
ProMinent
The Liquid End

The beta metering pump liquid ends are available in five material versions: Polypropylene (PP) PVC (PC) Acrylic/PVC (NP) PTFE (TT) 316 Stainless steel (SS) Options include a manual bleed valve for easy priming and continuous bleeding of fluids that tend to off-gas (available with versions 1000-0713 PP, NP and PC liquid ends). Automatic degassing liquid ends are available for PP and NP versions (except 1000 and 0232). This newstyle liquid end discharges from the center and degasses from the top to prevent air build-up in the chamber. High viscosity PVDF liquid ends are available for pump versions 1005, 0708, 0413, 0220, 1605, 1008, 0713, and 0420. Their metering capacity is 10-20% less than standard pump versions and recommended viscosity is up to 3000 cPs. The HV liquid ends are not self-priming. Suction and discharge ports are equipped with double ball check valves for maximum repeatability.
Some liquid ends are interchangeable between the BT4a and BT5a (see table on page 4).
DISCHARGE
DISCHARGE
AUTODEGASSING
BLEED VALVE DISCHARGE
SUCTION
SUCTION
SUCTION
Liquid end without bleed valve
Liquid end with bleed valve
Auto-degassing liquid end
Power Supply
The beta metering pumps accept 100-115, 200-230 or a universal 100230 volt power supply +/- 10%, single phase, 50/60 Hz, with a 1.15 service factor. Performance is identical whether operated on 50 Hz or 60 Hz power. The power cord is detachable.
Fault Indicators
Three LED lights indicate operational status. A green light flashes during normal operation; a yellow light warns of low chemical; and a red light indicates lack of chemical or an operational error. A two-stage level switch is needed to maximize this feature.
Relay Outputs
Fault annunciating relay For low tank level (level switch), processor fault, and fuse/power supply failure. Pacing relay A contact closure is issued with every pump stroke (contact duration 150 ms). This allows a second ProMinent metering pump to be paced synchronously, or to totalize flow with an external stroke counter.
Recognized Available
STROKE LENGTH ADJUSTMENT KNOB FAULT INDICATOR (RED LED) WARNING INDICATOR (YELLOW LED) OPERATING STATUS (GREEN LED) MULTIFUNCTION SWITCH POWER INPUT EXTERNAL CONTROL LEVEL SWITCH OUTPUT
COMPONENTS ARE IDENTICAL ON THE BETA/4 AND BETA/5 PUMPS
AN EXTERNAL PANEL IN THE BASE OF THE PUMP ENABLES OPTIONAL RELAYS TO BE INSTALLED ON-SITE.
beta2
Maximum stroke length: Materials of construction Housing: Diaphragm: Liquid end options: Enclosure rating: Motor insulation class: Power supply: Check valves: Repeatability of the metering: Power cord: Relay cable (optional): Relay load Fault relay only (options 1 & 3): Fault and pacing relay (options 4 & 5):
0.05" (1.25 mm) Fiberglass reinforced PPE PTFE-faced EPDM with plastic core Polypropylene, PVC, Acrylic/PVC, PTFE, 316 SS NEMA 4X (IP 65) F 100-115 VAC, 200-230 VAC or 100-230 VAC, 1 phase, 50/60 Hz, +/- 10%; 12-24 VDC or 24VDC +/- 10% Double ball When used according to operating instructions, 2% under constant conditions and at minimum 30% stroke length 6 foot (2 m) 6 foot (2 m) Contact load: 250 VAC, 2 A, 50/60 Hz Operating life: > 200,000 switch functions Contact load: 250 VAC/DC, 2 A, 50/60 Hz Operating life: > 200,000 switch functions Residual impedance in ON-position (RDSOn): < 8 Residual current in OFF-position: <1A Maximum current: < 100 mA Maximum voltage: 24 VDC Switch functions: 15x109 Contact closure: 100 ms (for pacing relay)
Ambient temperature range: Max. fluid operating temperatures:
14F (-10C) to 113F (45C) Material Acrylic/PVC Polypropylene PVC PTFE 316 SS PVDF Constant 113F (45C) 122F (50C) 113F (45C) 122F (50C) 122F (50C) 149F (65C) Short Term 140F (60C) 212F (100C) 140F (60C) 248F (120C) 248F (120C) 212F (100C)
Average power drain at maximum stroking rate (Watts) / current drain at pump stroke (Amps) BT4a: BT5a: Service factor: Warranty: Industry standards: Valve threads: Standard Production Test: Max. solids size in fluid: Controlling contact (pulse):
17W / 0.7 A or 15 A (peak current for approx. 1 ms) 22W / 1.0 A or 15 A (peak current for approx. 1 ms) 1.15 2 years on drive, 1 year on liquid end UL recognized, CE available for U.S.A. and Canada NP, PP, PC, TT Versions: M20 x 1.5 (provided with tubing adapters) All pumps are tested for capacity at maximum pressure prior to shipment Pumps with 1/4" valves: 15 - Pumps with 1/2" valves: 50 With voltage free contact, or with semiconductor sink logic control (NPN), not source logic (PNP). With a residual voltage of <700 mV, the contact load is approximately 0.5 mA at +5 VDC. (Note: Semiconductor contacts that require >700 mV across a closed contact should not be used.) Pump ignores contacts exceeding maximum input rate, and will not remember. 20 ms max. 200 cPs for standard liquid end max. 500 cPs for bleed valve max. 50 cPs for auto-degassing metering pumps max. 3000 cPs for high viscosity
beta3
Necessary contact duration: Recommended Viscocity:
ProMinent
Specifications: beta
ProMinent
Technical Data: beta

Pump Version Capacity at Maximum Backpressure U.S. mL/ psig (bar) GPH (L/h) stroke Capacity at 1/2 Maximum Backpressure U.S. mL/ psig (bar) GPH (L/h) stroke Pre-Primed Suction Lift ft. (m) Suction/Discharge Max. Tubing Stroking Connectors** Rate O.D. x l.D. spm inches Shipping Weight (higher weights are for SS) lbs. (kg)
BT4a 1000 1601 1602 1005 0708 0413 0220 BT5a 1605 1008 0713 0420 0232*
145 (10) 253 (17.5) 253 (17.5) 145 (10) 101 (7) 58 (4) 29 (2)
0.19 (0.74) 0.29 (1.1) 0.55 (2.1) 1.1 (4.4) 1.9 (7.1) 3.2 (12.3) 5.0 (19.0)
0.07 0.10 0.19 0.41 0.66 1.14 1.76
73 (5) 126 (8.75) 126 (8.75) 73 (5) 50.5 (3.5) 29 (2) 14.5 (1)
0.21 (0.82) 0.37 (1.4) 0.66 (2.5) 1.32 (5.0) 2.22 (8.4) 3.75 (14.2) 5.52 (20.9)
0.08 0.13 0.24 0.46 0.78 1.31 1.94
19.6 19.6 19.6 19.6 19.6 9.8 6.5
(6) (6) (6) (6) (6) (3) (2)
180 180 180 180 180 180 180
1/4 x 3/16 1/4 x 3/16 1/4 x 3/16 1/2 x 3/8 1/2 x 3/8 1/2 x 3/8 1/2 x 3/8
6.4-7.9 6.4-7.9 6.4-7.9 6.8-8.6 6.8-8.6 6.8-8.6 7.3-9.7
(2.9-3.6) (2.9-3.6) (2.9-3.6) (3.1-3.9) (3.1-3.9) (3.1-3.9) (3.3-4.4)
253 (17.5) 145 (10) 101 (7) 58 (4) 29 (2)
1.1 (4.1) 1.8 (6.8) 2.9 (11.0) 4.5 (17.1) 8.4 (32.0)
0.38 0.63 1.02 1.58 2.96
126 (8.75) 73 (5) 50.5 (3.5) 29 (2) 14.5 (1)
1.29 (4.9) 2.19 (8.3) 3.46 (13.1) 5.04 (19.1) 9.56 (36.2)
0.45 0.76 1.21 1.77 3.35
19.6 19.6 13.1 9.8 6.5
(6) (6) (4) (3) (2)
180 180 180 180 180
1/2 x 3/8 1/2 x 3/8 1/2 x 3/8 1/2 x 3/8 1/2 x 3/8
9.9-11.7 9.9-11.7 9.9-11.7 10.4-12.8 11.2-14.6
(4.5-5.3) (4.5-5.3) (4.5-5.3) (4.7-5.8) (5.1-6.6)
With auto-degassing liquid ends BT4a 1601 1602 1005 0708 0413 0220 BT5a 1605 1008 0713 0420 253 (17.5) 253 (17.5) 145 (10) 101 (7) 58 (4) 29 (2) 0.16 (0.59) 0.37 (1.4) 0.95 (3.6) 1.74 (6.6) 2.8 (10.8) 4.3 (16.2) 0.06 0.13 0.33 0.61 1.00 1.50 126 (8.75) 126 (8.75) 73 (5) 50.5 (3.5) 29 (2) 14.5 (1) 0.21 (0.78) 0.45 (1.7) 1.05 (4.0) 1.98 (7.5) 3.3 (12.6) 4.7 (18.0) 0.07 0.16 0.37 0.69 1.17 1.67 5.9 6.9 8.8 6.5 6.5 6.5 (1.8) (2.1) (2.7) (2.0) (2.0) (2.0) 180 180 180 180 180 180 1/4 x 3/16 1/4 x 3/16 1/2 x 3/8 1/2 x 3/8 1/2 x 3/8 1/2 x 3/8 6.4 6.4 6.8 6.8 6.8 7.3 (2.9) (2.9) (3.1) (3.1) (3.1) (3.3)
253 (17.5) 145 (10) 101 (7) 58 (4)
0.87 (3.3) 1.66 (6.3) 2.77 (10.5) 4.12 (15.6)
0.31 0.58 0.97 1.44
126 (8.75) 73 (5) 50.5 (3.5) 29 (2)
1.00 (3.8) 1.98 (7.5) 3.2 (12.3) 4.6 (17.4)
0.35 0.69 1.14 1.61
9.8 (3) 9.8 (3) 8.2 (2.5) 8.2 (2.5)
180 180 180 180
1/2 x 3/8 1/2 x 3/8 1/2 x 3/8 1/2 x 3/8
9.9 9.9 9.9 10.4
(4.5) (4.5) (4.5) (4.7)
Above capacities and suction lift refer to pumps tested on water at 115 VAC, 60 Hz, and an ambient temperature of 70F (20C). Higher specific gravity fluids will reduce suction lift. Higher viscosity fluids will reduce capacity. Liquid ends for highly viscous media have 10-20% les metering capacity and are not self-priming. Standard connectors are 1/2" MNPT or 5/8" hose barb. Positive suction recommended. * Not available with bleed valve. ** SS versions use 1/4" female threads except models 0220, 0420, and 0232 which use 3/8" female threads.
Liquid end materials

Version PPE PPB PCE PCB NPE NPB PVT TTT SST Liquid End Polypropylene Polypropylene PVC PVC Acrylic Acrylic PVDF PTFE with carbon 316 Stainless steel Suction/Discharge valves Polypropylene Polypropylene PVC PVC PVC PVC PVDF PTFE with Carbon 316 Stainless Steel Seals EPDM Viton EPDM Viton EPDM Viton PTFE PTFE PTFE Valve balls Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic
Auto-degassing type with Hastelloy C valve spring and PVDF valve seat. Viton is a registered trademark of DuPont Dow Elastomers.
Interchangeable liquid ends

The following pump versions have interchangeable liquid ends: BT4a 1005 and BT5a 1605 BT4a 0708 and BT5a 1008 BT4a 0413 and BT5a 0713 BT4a 0220 and BT5a 0420
beta4
BT4a BT5a
Series: beta/ 4 version a beta/ 5 version a BT4a 1000 1601 1602 1005* 0708* 0413* 0220* BT5a 1605* 1008* 0713* 0420* 0232 Pump version:
*Versions available with high viscosity liquid ends
PP PC NP PV TT SS
Liquid end materials: Polypropylene PVC Acrylic/PVC PVDF (for high viscosity only) PTFE SS Seal: EPDM seals (PP, PC, NP) Viton seals (PP, PC, NP) PTFE seals (PVDF, TT, SS) 0 1 2 3 4 9
E B T
Viton is a registered trademark of DuPont Dow Elastomers
Liquid end version: W/o bleed valve, w/o springs (TT, SS and version 0232 PP/PC) W/o bleed valve, with springs (TT, SS and version 0232 PP/PC) With bleed valve, w/o springs (PP, PC, NP; except version 0232 PP/PC) Wtih bleed valve, with springs (PP, PC, NP; except version 0232 PP/PC) W/o bleed valve, with springs (for high viscosity only) With auto-degassing (PP, NP - except versions 1000, 0232) 0 6 Connection: Standard according to technical data 1/2" x 3/8" tube fittings Labeling: Standard, with logo M N U Electrical connection ( 10%): 12-24 VDC (versions 1000-0220) 24 VDC (versions 1605-0232) 115-230 V, 50/60 Hz A D U 1 Cable and plug with 6 ft (2 m) power cord, single phase: European plug N. American plug, 115 V N. American plug, 230 V Open ended (for low voltage options M and N) 0 1 3 4 5 Relay: Without relay Fault annunciating relay, drops out Fault annunciating relay, pulls in Option 1 + pacing relay Option 3 + pacing relay Accessories: Not included (for PVDF, TT, SS) Standard (for PP, PC, NP) Operating mode configuration: Standard operating mode With lock for one operating mode: external or manual Options: Standard
NOTE: Connector option 6 must be used on all pumps with standard 1/2" x 3/8" tubing connections, and it may be used on pumps with 1/4" x 3/16" tubing connectors. Use option 0 on all pumps with standard NPT connections and for high viscosity.
0 1
0 1
000
BT4a 1602
NP
1 beta5
000
ProMinent
Identity code: beta metering pumps
ProMinent
Dimensions: beta
Dimensions in inches (mm). Ranges given, actual dimension dependant on liquid end material.
B A
F E D
Pump BT4
A 3.6 (92) 4.0 (102)
B 3.1 (80) 3.1 (80)
C 5.8 (148) 6.3 (160)
D 3.5-4.2 (88-108) 3.5-4.3 (88-110)
E 2.8-3.3 (71-83) 2.8-3.3 (71-83)
F 5.2 (132) 5.7 (144)
G 6.1-7.4 (156-187) 6.7-8.5 (171-217)
H 0.5-0.6 (12-14) 0.5-0.6 (12-14)
BT5
With Auto-Degassing Liquid Ends
B A
F E D
A BT4 3.6 (92) 4.0 (102)
B 3.1 (80) 3.1 (80)
C 5.8 (148) 6.3 (160)
D 3.5-3.6 (89-92) 3.5-3.6 (89-91)
E 2.9-3.0 (74-76) 2.9-3.0 (74-76)
F 5.2 (132) 5.7 (144)
G 6.7-7.1 (171-181) 7.3-7.4 (186-187)
H 1.7 (44) 1.7 (44)
J 3.7 (95) 4.0 (101)
BT5
beta6
Description
Part No.
Accessory kits
Pump includes tubing, foot valve and injection valve as standard. Accessory kits for beta pumps with tube fittings, including 5 ft. (1.5 m) of suction tubing, 10 ft. (3 m) of discharge tubing, foot valve and injection valve. Tubing Size (in.) (select to fit pump) 1/4 x 3/16 1/4 x 3/16 1/4 x 3/16 1/4 x 3/16 1/2 x 3/8 1/2 x 3/8 1/2 x 3/8 1/2 x 3/8 Material Code PCB/NPB PPE PPB PCE/NPE PCB/NPB PPE PPB PCE/NPE Suction Tubing PE PE PE PE PVC PVC PVC PVC Discharge Tubing PE PE PE PE PE PE PE PE 7809401 7809403 7809405 7809422 7809402 7809404 7809406 7809423
PVC 1/2" x 3/8" suction tubing is pliable, allowing foot valve to sink. PE discharge tubing is rigid. Pressure ratings are: PVC: 7 psig PE: 100 psig.
Tubing, foot valves and injection valves for TT and SS pumps are not available as kits and must be ordered as separate items.
Auto-degassing accessories
Bypass line fold protector (for soft tubing only)
Fits on top of the beta and gamma/L auto-degassing liquid ends, used to prevent a fold in the bypass line which is fed back to the tank. This is required when using soft tubing, however rigid tubing is standard. for tubing size (mm) 1/4" x 3/16" (6 mm)
1001844
Right-angled PVC threaded connector

Connector for the beta and gamma/L auto-degassing liquid ends required when mounting multifunction valves; optionally used to direct discharge flow upwards. Angle union 90. Type PCB (PVC/Viton) 1003318 Type PCE (PVC/EPDM) 1003472
beta7
ProMinent
ProMinent beta Accessories
ProMinent
ProMinent beta Control cables
Description
Part No.
Control cables for beta

Universal control cable
For metering pump control via voltage-free contact for remote pause control. For beta with 5-pole round plastic connector and 5-wire cable with loose end. Universal control cable, 5-pole round connector, 5-wire, 6 ft. (2 m) Universal control cable, 5-pole round connector, 5-wire, 15 ft. (5 m) Universal control cable, 5-pole round connector, 5-wire, 30 ft. (10 m) 1001300 1001301 1001302
ON/OFF Control
BROWN and BLACK wires must be connected together via an ON/OFF contact or shorted together. When the contact is closed between the BLACK & BROWN wires, the pump will run. When the contact is open, the pump will stop. Note: If ON/OFF control is the only control feature being used, GREY, WHITE and BLUE wires are not used. BROWN: Remote On/Off (+) BLACK: GREY: WHITE: BLUE: Common Auxiliary Frequency External (+) Not Used
Pulse Control
Pulse control will allow the pump to run in proportion to a pulsing potentially free contact closure. Note: BROWN and BLACK wires have to be connected together via an ON/OFF contact or shorted together. GREY wire is not used and should be cut. BROWN: Remote On/Off (+) BLACK: GREY: WHITE: BLUE: Common Not used Pulse (+) Analog (+)
Auxiliary Frequency
Auxiliary frequency will default the pump to 100% stroking frequency regardless of which operating mode the pump is in. The pump defaults to this stroking frequency as long as a contact is closed between the black and grey wires of the universal control cable. Note: BROWN and BLACK wires must be connected together via an ON/OFF contact or shorted together. BROWN: Remote On/Off (+) BLACK: GREY: WHITE: BLUE:
beta8
Common Auxiliary Frequency Pulse (+) Analog (+)
Spare parts kits and Diaphragms

Complete liquid ends include pump head, valves, mounting screws, diaphragm and back plate. Spare parts kits include: PP, PC & NP Liquid Ends 1 Diaphragm 1 Suction Valve 1 Discharge Valve 1 Adapter Set 2 Valve Balls 1 Set Seals Liquid End Version BT4A 1000 PPE PPB PCE NPE PCB NPB TTT SST PPE PPB PCE NPE PCB NPB TTT SST PPE PPB PCE NPE PCB NPB TTT SST PPE PPB PCE NPE PCB NPB PVT TTT SST PPE PPB PCE NPE PCB NPB PVT TTT SST 1002057 1002065 1002365 1002193 1002358 1002201 1002345 1002557 1002058 1002066 1002366 1002194 1002359 1002202 1002346 1002558 1002059 1002067 1002367 1002195 1002360 1002203 1002347 1002559 1002060 1002068 1002368 1002196 1002361 1002204 1018072 1002348 1002560 1002061 1002069 1002369 1002197 1002362 1002205 1018073 1002349 1002561 1001644 1001652 1001713 1001713 1001721 1001721 1001737 1002549 1001645 1001653 1001714 1001714 1001722 1001722 1001738 1002550 1001646 1001654 1001715 1001715 1001723 1001723 1001739 1002551 1001647 1001655 1001716 1001716 1001724 1001724 1019066 1001740 1002552 1001648 1001656 1001717 1001717 1001725 1001725 1019067 1001741 1002553 792644 792646 792119 792119 792026 792026 809407 809424 792644 792646 792119 792119 792026 792026 809407 809424 792644 792646 792119 792119 792026 792026 809407 809424 792644 792646 792119 792119 792026 792026 1002267 809407 809424 1001437 1001436 1001435 1001435 1001434 1001434 1002267 809445 809497 740350 740351 740349 740349 740348 740348 809406 809423 740350 740351 740349 740349 740348 740348 809406 809423 740350 740351 740349 740349 740348 740348 809406 809423 740350 740351 740349 740349 740348 740348 1002267 809406 809423 1001441 1001440 1001439 1001439 1001438 1001438 1002267 809444 809496 1001441 1001440 1001439 1000244 1000244 1000244 1000244 1000244 1000244 1000244 1000244 1000245 1000245 1000245 1000245 1000245 1000245 1000245 1000245 1000246 1000246 1000246 1000246 1000246 1000246 1000246 1000246 1000247 1000247 1000247 1000247 1000247 1000247 1000247 1000247 1000247 1000248 1000248 1000248 1000248 1000248 1000248 1000248 1000248 1000248 1000249 1000249 1000249 TT Liquid Ends 1 Diaphragm 1 Suction Valve 1 Discharge Valve 1 Adapter Set 2 Valve Balls 1 Set Seals 2 Ball Seat Discs Complete Liquid End Spare Parts Kit SS Liquid Ends 1 Diaphragm 4 Valve Balls 1 Set Seals 4 Ball Seat Discs
Material Code
Spare Valves Only (adapter sets not included) Suction Discharge Diaphragm
Discharge Valve 1/4"
Suction Valve 1/4"
1601
C A Pump Version BT4a 1000 1601 1602 1005 0708 0413 0220 BT5a 1605 1008 0713 0420 0232 Dim A (mm) Dim C (mm)
1602
30 30 35 46 46 55 77
5.0 7.5 11.5 16.5 21.5 26.0 33.5
1005
46 46 55 77 91
16.5 21.5 26.0 33.5 46.0
0708
0413
PPE 1002062 1001649 1001437 PPB 1002070 1001657 1001436 PCE 1002370 1001718 1001435 (additional materials for 0413 on following page)
beta9
ProMinent
ProMinent beta BT4a Materials
ProMinent
ProMinent beta BT4a Materials (cont.)
Spare parts kits and Diaphragms

Liquid End Version BT4A 0413 (cont.) NPE PCB NPB PVT TTT SST PPE PPB PCE NPE PCB NPB PVT TTT SST 1002198 1002363 1002206 1018084 1002350 1002562 1002063 1002071 1002371 1002199 1002364 1002207 1018085 1002351 1002563 1001718 1001726 1001726 1019069 1001742 1002554 1001650 1001658 1001719 1001719 1001727 1001727 1019070 1001754 1002555 1001435 1001434 1001434 1002267 809445 809497 1001437 1001436 1001435 1001435 1001434 1001434 1002267 809445 1002547 1001439 1001438 1001438 1002267 809444 809496 1001441 1001440 1001439 1001439 1001438 1001438 1002267 809444 1002548 1000249 1000249 1000249 1000249 1000249 1000249 1000250 1000250 1000250 1000250 1000250 1000250 1000250 1000250 1000250 Material Code Complete Liquid End Spare Parts Kit Spare Valves Only (adapter sets not included) Suction Discharge Diaphragm
0220
BT5A 1605 PPE PPB PCE NPE PCB NPB PVT TTT SST PPE PPB PCE NPE PCB NPB PVT TTT SST PPE PPB PCE NPE PCB NPB PVT TTT SST PPE PPB PCE NPE PCB NPB PVT TTT SST PPE PPB PCE NPE PCB NPB TTT SST 1002060 1002068 1002368 1002196 1002361 1002204 1018072 1002348 1002560 1002061 1002069 1002369 1002197 1002362 1002205 1018073 1002349 1002561 1002062 1002070 1002370 1002198 1002363 1002206 1018084 1002350 1002562 1002063 1002071 1002371 1002199 1002364 1002207 1018085 1002351 1002563 1002064 1002072 1002609 1002200 1002608 1002208 1002352 1002564 beta10 1001647 1001655 1001716 1001716 1001724 1001724 1019066 1001740 1002552 1001648 1001656 1001717 1001717 1001725 1001725 1019067 1001741 1002553 1001649 1001657 1001718 1001718 1001726 1001726 1019069 1001742 1002554 1001650 1001658 1001719 1001719 1001727 1001727 1019070 1001754 1002555 1001651 1001659 1001720 1001720 1001728 1001728 1001755 1002556 792644 792646 792119 792119 792026 792026 1002267 809407 809424 1001437 1001436 1001435 1001435 1001434 1001434 1002267 809445 809497 1001437 1001436 1001435 1001435 1001434 1001434 1002267 809445 809497 1001437 1001436 1001435 1001435 1001434 1001434 1002267 809445 1002547 1001437 1001436 1001435 1001435 1001434 1001434 809445 1002547 740350 740351 740349 740349 740348 740348 1002267 809406 809423 1001441 1001440 1001439 1001439 1001438 1001438 1002267 809444 809496 1001441 1001440 1001439 1001439 1001438 1001438 1002267 809444 809496 1001441 1001440 1001439 1001439 1001438 1001438 1002267 809444 1002548 1001441 1001440 1001439 1001439 1001438 1001438 809444 1002548 1000247 1000247 1000247 1000247 1000247 1000247 1000247 1000247 1000247 1000248 1000248 1000248 1000248 1000248 1000248 1000248 1000248 1000248 1000249 1000249 1000249 1000249 1000249 1000249 1000249 1000249 1000249 1000250 1000250 1000250 1000250 1000250 1000250 1000250 1000250 1000250 1000251 1000251 1000251 1000251 1000251 1000251 1000251 1000251
Suction Valve 1/2"
1008
0713
30 30 35 46 46 55 77
5.0 7.5 11.5 16.5 21.5 26.0 33.5
0420
46 46 55 77 91
16.5 21.5 26.0 33.5 46.0
0232
Spare parts kit and Diaphragm

Complete liquid ends include pump head, valves, mounting screws, diaphragm and back plate. Spare parts kits include: PP & NP Liquid Ends 1 Diaphragm 1 Suction Valve 1 Discharge Valve 1 Adapter Set Liquid End Version BT4A 1601 PPE PPB NPE NPB PPE PPB NPE NPB PPE PPB NPE NPB PPE PPB NPE NPB PPE PPB NPE NPB PPE PPB NPE NPB 1002393 1002392 1002248 1002242 1002395 1002394 1002249 1002243 1002399 1002398 1002250 1002244 1002397 1002396 1002251 1002245 1002401 1002400 1002252 1002246 1002403 1002402 1002253 1002247 1001756 1001762 1001660 1001666 1001757 1001763 1001661 1001667 1001758 1001764 1001662 1001668 1001759 1001765 1001663 1001669 1001760 1001766 1001664 1001670 1001761 1001767 1001665 1001671 792644 792646 792119 792026 792644 792646 792119 792026 792644 792646 792119 792026 1001437 1001436 1001435 1001434 1001437 1001436 1001435 1001434 1001437 1001436 1001435 1001434 1001067 1001066 1001065 1001064 1001067 1001066 1001065 1001064 1001067 1001066 1001065 1001064 1001071 1001070 1001069 1001068 1001071 1001070 1001069 1001068 1001071 1001070 1001069 1001068 1001063 1001062 1001061 1001060 1001063 1001062 1001061 1001060 1001063 1001062 1001061 1001060 1001063 1001062 1001061 1001060 1001063 1001062 1001061 1001060 1001063 1001062 1001061 1001060 1000245 1000245 1000245 1000245 1000246 1000246 1000246 1000246 1000247 1000247 1000247 1000247 1000248 1000248 1000248 1000248 1000249 1000249 1000249 1000249 1000250 1000250 1000250 1000250 2 Valve Balls 1 Set Seals 1 Vent Valve, Complete
Material Code
Complete Liquid Spare Parts End Kit
Spare Valves Only (adapter sets not included) Suction Discharge Vent
Diaphragm
1602
1005
(sdb) Vent Valve
0708
0413
0220
BT5A 1605 PPE PPB NPE NPB PPE PPB NPE NPB PPE PPB NPE NPB PPE PPB NPE NPB 1002399 1002398 1002250 1002244 1002397 1002396 1002251 1002245 1002401 1002400 1002252 1002246 1002403 1002402 1002253 1002247 1001758 1001764 1001662 1001668 1001759 1001765 1001663 1001669 1001760 1001766 1001664 1001670 1001761 1001767 1001665 1001671 792644 792646 792119 792026 1001437 1001436 1001435 1001434 1001437 1001436 1001435 1001434 1001437 1001436 1001435 1001434 1001067 1001066 1001065 1001064 1001071 1001070 1001069 1001068 1001071 1001070 1001069 1001068 1001071 1001070 1001069 1001068 1001063 1001062 1001061 1001060 1001063.5 1001062.7 1001061.9 1001060.1 1001063.5 1001062.7 1001061.9 1001060.1 1001063.5 1001062.7 1001061.9 1001060.1 1000247 1000247 1000247 1000247 1000248 1000248 1000248 1000248 1000249 1000249 1000249 1000249 1000250 1000250 1000250 1000250
30 30 35 46 46 55 77
5.0 7.5 11.5 16.5 21.5 26.0 33.5
1008
0713 46 46 55 77 91 16.5 21.5 26.0 33.5 46.0
0420
beta11
ProMinent
ProMinent beta auto-degassing Materials
ProMinent
beta/4a 1602-2 NPE0 Liquid End Complete EXPLODED VIEW

a1 a2 a3 a4 A
Description
1602-2 NPE0 liquid end complete 1 2 3 4 A B C *
Qty. Part No.

1 1 1 1 4 1 1 1 1002075 1000262 1000246 1000286 1000268 817060 740349 792119
b1 b2 b3 b4 b5 b6 b3 b4 b7 4 * B
backplate B1602 70 x 16.5-2 ................. diaphragm 35.0 x 11.5 ............................ dosing head 70 x 16.5-2 NP0 ................. screw M5 x 55 & washer ........................ connector set 1/4" PCE .......................... discharge valve beta 1/4" PCE ............... suction valve beta 1/4" PCE ................... indicates location of spring if needed A a1 a2 a3 a4 B b1 b2 b3 b4 b5 b6 b7 C c1 c2 c3 c4 c5 c6 connector set 1/4" PCE union nut M20 x 1.5 PVC ............ clamp ring 1/4" ferule ................... tube nozzle 3/16" PVC ................ O-ring 9 x 2.5 EPDM/P ................ dis. valve beta 1/4" PCE dis. valve body beta 1/4" PVC ..... valve insert 4.7-1 PVC ................. valve ball 4.7mm Ceramic ........... ball seat 3 x 9.5 EPDM/P ............. O-ring 9 x 2.5 EPDM/P ................ valve insert (dis.) 4.7-1 PVC ........ O-ring 14 x 2 EPDM/P ................. suction valve beta 1/4" PCE sealing gasket 18 x 2.5 EPDM/P . valve insert 4.7-1 PVC ................. valve ball 4.7mm Ceramic ........... ball seat 3 x 9.5 EPDM/P ............. distance sleeve (suction) PVC ..... suction valve body beta 1/4" PVC
1 2 2 2 2 1 1 1 2 2 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 3 1 1 2 4
817060 800518 800712 800520 1001263 740349 791880 791090 404201 1001233 1001263 791879 1001264 792119 1001232 791090 404201 1001233 791089 800569 1001715 817060 740349 792119 1000246 1001263 1001264 1001232 404201 1001233
3 c2 c3 c4 c2 c3 c4 c5
c1
* Spare Parts Set 1602-2 PCE A B C 2 b5 b7 c1 c3 c4 connector set 1/4" PCE ............... discharge valve beta 1/4" PCE .... suction valve beta 1/4" PCE ........ diaphragm 35.0 x 11.5 ................. O-ring 9 x 2.5 EPDM/P ................ O-ring 14 x 2 EPDM/P ................. sealing gasket 18 x 2.5 EPDM/P . valve ball 4.7mm Ceramic ........... ball seat 3 x 9.5 EPDM/P ............
c6 a4 a3 a2 a1
#BT4ANPE0-11/98
beta12
beta/5a 1008-2 PCE2 Liquid End Complete EXPLODED VIEW

a1
Description
a2 1008-2 PCE2 liquid end complete a3 a4 A 1 2 3 4 5 6 7 8 A B C *
Qty. Part No.

1 1 1 1 1 1 1 4 1 1 1 1 1002369 1000264 1000248 1001262 1001984 1001696 809490 1000268 800832 740160 1001439 1001435
b1 b2 b3 b4 b5 b6 b7 b3 b4 b5 b8 b9 b10 6 7 8
backplate B1008 90 x 29-2 .................... diaphragm 46.0 x 21.5 ........................... O-ring 7.65 x 1.78 EPDM/P .................... upper part nozzle PVC ........................... dosing head 90 x 29-2 PC2 .................... bleed valve complete EPDM .................. screw M5 x 55 & washer ........................ bleed valve knob PP ............................... connector set 1/2" PCE .......................... discharge valve beta 1/2" PCE ............... suction valve beta 1/2" PCE ................... indicates location of spring if needed A a1 a2 a3 a4 B b1 b2 b3 b4 b5 b6 b7 b8 b9 b10 C c1 c2 c3 c4 c5 c6 c7 c8 c9 c10 connector set 1/2" PCE union nut M20 x 1.5 PVC ............ clamp ring 1/2" ferule ................... tube nozzle 3/8" PVC .................. O-ring 9 x 2.5 EPDM/P ................ dis. valve beta 1/2" PCE dis. valve body beta 1/2" PVC ..... valve insert 9.2-2 (top) PVC ........ valve ball 9.2mm Ceramic ........... ball seat disc PVC ....................... O-ring 7.65 x 1.78 EPDM/P ......... O-ring 9 x 2.5 EPDM/P ................ valve insert 9.2-2 (lower) PVC ..... valve lid 9.2-2 PVC ...................... O-ring 14 x 2 EPDM/P ................. sealing gasket 14 x 1.5 EPDM/P . suction valve beta 1/2" PCE O-ring 14 x 2 EPDM/P ................. valve insert 9.2-2 (top) PVC ........ valve ball 9.2mm Ceramic ........... ball seat disc PVC ....................... O-ring 7.65 x 1.78 EPDM/P ......... O-ring 9 x 2.5 EPDM/P ................ valve insert 9.2-2 (lower) PVC ..... valve lid 9.2-2 PVC ...................... sealing gasket 14 x 1.5 EPDM/P . suction valve body beta 1/2" PVC
1 2 2 2 2 1 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 3 2 6 4 2 2
740160 800518 800715 800523 1001263 1001439 1000500 1000490 404281 140554 1001262 1001263 1000492 1000494 1001264 1001231 1001435 1001264 1000490 404281 140554 1001262 1001263 1000492 1000494 1001231 1000498 1001717 740160 1001439 1001435 1000248 1001265 404281 1001262 1001263 1001264 1001231
c1 c2 c3 c4 c5 c6 c7 c3 c4 c5 c8 c9 c10 C
3 4
Spare Parts Set 1008-2 PCE A B C 2 6 b3 b5 b6 b9 b10 connector set 1/2" PCE ............... discharge valve beta 1/2" PCE .... suction valve beta 1/2" PCE ........ diaphragm 46.0 x 21.5 ................. O-ring (bleed valve) EPDM/P ...... valve ball 9.2mm Ceramic ........... O-ring 7.65 x 1.78 EPDM/P ......... O-ring 9 x 2.5 EPDM/P ................ O-ring 14 x 2 EPDM/P ................. sealing gasket 14 x 1.5 EPDM/P .
a4 a3 a2 a1
#BT5APCE2-1/99
beta13
ProMinent
ProMinent
beta/4a 1005-2 NPB9 Liquid End Complete EXPLODED VIEW

Description a1 a2 a3 a4 A
1005-2 NPB9 liquid end complete 1 2 3 4 5 A B C D E * backplate B1005 90 x 23-2 ............................. diaphragm 46.0 x 16.5 .................................... dosing head 90 x 23-2 NP9 ............................ screw M5 x 50 ................................................ washer ............................................................ connect. set 1/4" sing. PCB ............................ vent valve sdb beta 1/4" PCB ......................... suction valve beta 1/4" PCB ........................... discharge valve beta sdb 1/4" PCB ................ connect. set 1/2" sing. PCB ............................ indicates location of spring if needed A a1 a2 a3 a4 connector set 1/4" sing. PCB union nut M20 x 1.5 PVC .................... clamp ring 1/4" ferule .......................... tube nozzle 3/16" PVC ....................... O-ring 9 x 2.5 FPM-B .......................... vent valve sdb beta 1/4" PCB vent body sdb beta 1/4" PVC ............. valve insert 4.7-1 PVC ........................ valve ball 4.7mm Ceramic .................. ball seat 3 x 9.5 FPM-B ...................... distance sleeve sdb PVC ................... ball seat disc 8.95 x 2.1 Ceramic ....... valve insert sdb PVDF ........................ sealing gasket 18 x 2.5 FPM-B .......... suction valve beta 1/4" PCB sealing gasket 18 x 2.5 FPM-B ........... valve insert 4.7-1 PVC ........................ valve ball 4.7mm Ceramic .................. ball seat 3 x 9.5 FPM-B ...................... distance sleeve (suction) PVC ............ suct. valve body beta 1/4" PVC .......... dis. valve beta sdb 1/4" PCB O-ring 14 x 2 FPM-B ........................... valve lid sdb 4.7-1 PVC ...................... ball seat 3 x 9.5 FPM-B ...................... valve ball 4.7mm Ceramic .................. spring cone Hast. ................................ valve insert sdb (dis.) 4.7-1 PVC ........ dis. body sdb beta 1/4" PVC ...............
Qty.
1 1 1 1 4 4 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1
Part No.
1002244 1000263 1000247 1001089 468075 462228 817065 1001060 792026 1001064 817067 817065 800518 800712 800520 791421 1001060 1001038 791090 404201 792759 1001042 1001589 791839 791051 792026 791051 791090 404201 792759 791089 800569 1001064 791628 1001047 792759 404201 791052 1001040 1001036
b1 b2 b3 b4 b5 b6 b7 b3 b6 b8 B
D d1 d2 d3 d4 d5 d6 d7
B b1 b2 b3 b4 b5 b6 b7 b8 C c1 c2 c3 c4 c5 c6 D d1 d2 d3 d4 d5 d6 d7 E e1 e2 e3 e4 **
3 c2 c3 c4 c2 c3 c4
c1 4
C c5
c6 e4 e3 e2 e1
connect. set 1/2" sing. PCB **2 817067 union nut M20 x 1.5 PVC .................... 1 800518 clamp ring 1/2" ferule .......................... 1 800715 tube nozzle 3/8" PVC ......................... 1 800523 O-ring 9 x 2.5 FPM-B .......................... 1 791421 sdb sp. parts kits ship with single connector sets. Quantities reflect # of components in each set. 1 1 1 1 1 2 1 4 2 1 4 1001668 817065 1001060 792026 1001064 817067 1000247 792759 791051 791628 404201
Spare Parts Set 1005-2 sdb PCB A B C D E 2 b4 b8 d1 d4 connect. set 1/4" sing. PCB ................ vent valve sdb beta 1/4" PCB ............. suction valve beta 1/4" PCB ............... dis. valve beta sdb 1/4" PCB .............. connect. set 1/2" sing. PCB ................ diaphragm 46.0 x 16.5 ........................ ball seat 3 x 9.5 FPM-B ...................... sealing gasket 18 x 2.5 FPM-B .......... O-ring 14 x 2 FPM-B ........................... valve ball 4.7mm Ceramic ..................
#BT4ANPB9-12/98
beta14
SECTION _______- CHEMICAL METERING PUMPS 1.1 APPLICATION A. Quantity: _________ B. Chemical Service: _______________________ C: Tag. Nos.: ____________________________ D: Capacity (US gallons per hour)_______________________ E. Backpressure (psig): _______________________ 1.2 DESCRIPTION A. The chemical metering pump(s) shall be a microprocessor-controlled, simplex, solenoiddriven, reciprocating, mechanically-actuated diaphragm type. The housing shall be rated NEMA 4X. B. The manufacturer shall provide a two year warranty on the pump drive and one year warranty on the pump liquid end, including diaphragm and O-rings. The pump shall be fully tested to meet rated flow and pressure by the manufacturer. C. The power supply shall be ____ VAC, ____ Hz, single phase. The microprocessor is to automatically compensate for supply voltage variations within 15% of the rated voltage such that frequency of the pump remains constant. D. The liquid end shall be physically separated from the drive unit by back plate with weep hole creating an air gap. An elastomer shaft wiper seal shall prevent contamination of the solenoid if the primary diaphragm fails. The diaphragm shall be nylon-reinforced EPDM with PTFE-faced fluid contact surface. 1.3 LIQUID END ((SELECT ONE)) - The liquid end shall be glass-filled polypropylene, with built coarse valve and needle valve for air bleed, manually adjusted for continuous degassing of process fluid and self-priming against pressure. The suction and discharge valve shall be of the double ball check design. - The liquid end shall be Plexiglas (acrylic) with built coarse valve and needle valve for air bleed, manually adjusted for continuous degassing of process fluid and self-priming against pressure. The suction and discharge valve shall be PVC, with double ball check design - The liquid end shall be of the self-degassing type, with integral automatic air relief valve for self priming under maximum rated discharge line pressure. The liquid end shall be con structed of (PVC). The suction valve shall be of the double ball check design and discharge valve shall be double ball design, perpendicular to the suction valve. - The Liquid end shall be constructed of virgin PVDF, suitable for pumping high viscosity fluids up to 3000 cPs. The suction and sischarge valve shall be PVDF with PTFE faced Viton gasket seals and spring-loaded ceramic valve balls. - The liquid end shall be constructed of carbon-filled PTFE. The suction and discharge valve shall be of the double ball check design. - The liquid end shall be constructed of 316 stainless steel. The suction and discharge valve shall be of the double ball check design. 1.4 CONTROL A. Stroke length control shall be manually adjusted between 100% and 0% with a stroke adjust ing knob on the pump control face.
beta/a-1 beta15
ProMinent
((THIS IS A MASTER, EDIT FOR SPECIFIC APPLICATION)) PROMINENT FLUID CONTROLS, INC. beta 4 and beta 5 (for flow rates up to 8.4 gph)
ProMinent
B. Stroke frequency control shall be manually adjusted in 10% increments by a multifunction switch. The metering pump shall be capable of receiving a pulse input via optional external control cable such that 1 pulse gives 1 pump stroke. The metering pump shall be capable of remote ON-OFF operation using the PAUSE function via a voltage-free contact relay through an optional control cable. 1.5 STATUS / LOW LEVEL INDICATION ((OPTIONAL)) A. Low Level Control - A 2-stage Float Switch shall be supplied to stop the pump prior to losing prime and annunciate low level on the pump via a LCD light. B. Relay Output - An SPDT relay shall be installed on the pump for: ((SELECT ONE OR BOTH OF THE FOLLOWING)) - Fault Indication - ((OPTIONAL)) the metering pump shall have an integral relay to allow remote annunciation of a fault condition (i.e. low supply solution early warning/lack of supply solution shut down, flow monitor, system faults, and fuse/power supply failure). - Pacing Relay - ((OPTIONAL)) the metering pump shall have an integral relay to issue a contact closure with every pump stroke to pace a second PROMINENT metering pump. - If both of the above options are chosen, two SPST relay contacts shall be provided through a -conductor cable. 1.6 ACCEPTABLE MANUFACTURER: A. ProMinent Fluid Controls, model _______________________________ B. Or pre-approved equal. 1.7 ACCESSORIES ((ALL ARE OPTIONAL AND MAY BE INCLUDED AS SEPARATE ITEMS OR AS COMPONENTS OF A PUMP STAND)) A. Steel)) support stand suitable for wall, floor or top-of-tank mounting, and including the following accessories pre-piped and factory tested: B. A foot valve and strainer shall be provided with each pump. C. An injection check valve shall be provided with each pump. D. A universal control cable with 4 pole round plastic connector and 5-wire cable with loose ends shall be provided with each pump. E. A two-stage float switch compatible with the chemical metering pump shall be provided for monitoring tank level. F. A diaphragm failure detector shall be provided to ((open/close)) a contact in the event of diaphragm failure. G. An adjustable-pressure, diaphragm-type back pressure/antisiphon valve shall be provided with each metering pump. H. An in-line, adjustable-pressure, diaphragm-type pressure relief valve shall be provided with each metering pump. I. A pump-mounted, multi-function, fixed-spring pressure diaphragm-type valve for backpressure/antisiphon protection, pressure relief, priming and discharge line drain shall be provided with each metering pump. J. An air-charged, bladder-type pulsation dampener shall be provided with each metering pump. K. A clear PVC calibration column with FNPT fittings top and bottom shall be provided with each pump. L. Fifteen feet of tubing compatible with the fluid pumped shall be provided with each pump. END OF SECTION
beta16 beta/a-2

CONTROLAUTOMATICO

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INSTITUTO POLITCNICO NACIONAL ESCUELASUPERIORDEINGENIERIAMECANICAYELECTRICA

CONTROL AUTOMTICO DE FLUJOS QUMICOS PARA EL ACONDICIONAMIENTO DEL SECADOR YANKEE

IVAN HERNNDEZ GARCA JOS LUIS HERNNDEZ PEREA

M. EN C. PEDRO F. HUERTA GONZLEZ ING. JESS HERNNDEZ MUOZ

MXICO, D.F. 2010

CAPITULO IV Anlisis Costo Beneficio.......................................................................................61

Fuentes de Consulta...................................................................................................................66 Anexos.........................................................................................................................................66

INGENIERA EN CONTROL Y AUTOMATIZACIN

INGENIERA EN CONTROL Y AUTOMATIZACIN

INGENIERA EN CONTROL Y AUTOMATIZACIN

INGENIERA EN CONTROL Y AUTOMATIZACIN

INGENIERA EN CONTROL Y AUTOMATIZACIN

INGENIERA EN CONTROL Y AUTOMATIZACIN

INGENIERA EN CONTROL Y AUTOMATIZACIN

Figura 1.1 Diagrama General sobre el proceso de papel

INGENIERA EN CONTROL Y AUTOMATIZACIN

INGENIERA EN CONTROL Y AUTOMATIZACIN

Figura 1.3 Ubicacin del secado por evaporacin Sistema Yankee

INGENIERA EN CONTROL Y AUTOMATIZACIN

Figura 1.4 Ubicacin de Cuchillas para el proceso de crepado

INGENIERA EN CONTROL Y AUTOMATIZACIN

Figura 1.5 Imagen del Acondicionamiento la superficie del secador Yankee

INGENIERA EN CONTROL Y AUTOMATIZACIN

INGENIERA EN CONTROL Y AUTOMATIZACIN

Sistema de alimentacin en lnea

Regulador de Intercambiador de presin n presion

FIGURA 1.6 Sistema de alimentacin en lnea

Sistema de Alimentacin en lnea Ventajas Desventajas

Sistema cerrado limpio. Poca o nula contaminacin

No hay contaminacin de polvo. Fcil mantenimiento.

Equipo utilizado ampliamente papeles calidad media

INGENIERA EN CONTROL Y AUTOMATIZACIN

Sistema de preparacin con tanque

Flotador para control de Nivel de agua. Linea de

3 bar or 40 PSI pressure

FIGURA 1.7 Sistema de alimentacin por tanque

Sistema de Alimentacin con tanque Ventajas Desventajas

Presin constante. Flujo constante. Recubrimiento uniforme. Presin uniforme de regadera.

Se ensucia con facilidad. Puede formar microorganismos.

Tendencia alto costo de mantenimiento.

INGENIERA EN CONTROL Y AUTOMATIZACIN

FIGURA 1.8 Funcin de la cuchilla de crepado

La funcin de la cuchilla de crepado es separar al papel de la superficie del yankee.

INGENIERA EN CONTROL Y AUTOMATIZACIN

FIGURA 1.9 Separacin de la hoja de la superficie del secador

FIGURA 1.10 Acercamiento de la separacin de la hoja del secador

INGENIERA EN CONTROL Y AUTOMATIZACIN

FIGURA 1.11 Geometra de Crepado

INGENIERA EN CONTROL Y AUTOMATIZACIN

FIGURA 1.12 ngulo al de crepado

INGENIERA EN CONTROL Y AUTOMATIZACIN

FIGURA 1.13 Estado de la cuchilla a mayor presin.

INGENIERA EN CONTROL Y AUTOMATIZACIN

FIGURA 1.14 Consecuencias de una mala penetracin de la cuchilla en las fibras

FIGURA 1.16 Capas formadas por el release

INGENIERA EN CONTROL Y AUTOMATIZACIN

1.3 Sistema Yankee Spray. 1.3.1 Diseo de regadera Yankee Spray.

FIGURA 1.17 Sistema Yankee-Spray

FIGURA 1.18 Regaderas para el acondicionamiento del secador (SYS)

INGENIERA EN CONTROL Y AUTOMATIZACIN

1.3.1.1 Seleccin de espreas para regadera yankee spray Geometra de la boquilla

FIGURA 1.18 Esquema de boquilla para regaderas

FIGURA 1.19 Vista lateral de regadera y boquilla

INGENIERA EN CONTROL Y AUTOMATIZACIN