Advanced Main StationMP - MA - Dual Pressure Series

Service Manual ........................................................3 - 15EN

Content EN

1. Description ................................................................................................................................3 1.1 Layout Advanced MP .........................................................................................................4 1.2 Operating Diagrams Advanced MP ....................................................................................5 1.3 Layout Advanced MA .........................................................................................................6 1.4 Operating Diagrams Advanced MA ....................................................................................7

2. Maintenance .............................................................................................................................8 2.1 Layout Advanced MP .........................................................................................................8 2.2 Operating Diagrams Advanced MP ....................................................................................8

3. New system ..............................................................................................................................8

4. Daily Operation .........................................................................................................................8 4.1 Start ....................................................................................................................................8 4.2 Stop ....................................................................................................................................9 4.3 Rinsing the injector .............................................................................................................9

5. Service ......................................................................................................................................9 5.1 Components .......................................................................................................................9 5.1.1 Pump / motor .............................................................................................................9 5.1.2 Control system ..........................................................................................................9 5.1.3 Flowtrigger ................................................................................................................9 5.1.3.1 Adjusments .............................................................................................................9 5.1.4 Non-return valve / intake side ...................................................................................9

6. Trouble Shooting .....................................................................................................................10 6.1 The unit does not start .....................................................................................................10 6.2 The "Δ" - lamp on the control panel is on .........................................................................10 6.3 Too low or unstable pressure ........................................................................................... 11 6.4 Unsatisfactory foam quality .............................................................................................. 11 6.5 No foam ............................................................................................................................ 11

7. Recommended Spare Parts....................................................................................................12 7.1 Connection of Controller board and mounting of sensor ..............................................................13

8. Specifications ..........................................................................................................................14

9. Electric diagram ......................................................................................................................15

3

Fig. 2 0627120 Fig. 3 0627115

Fig. 1 0627084

1

3

2

1. DescriptionThe main station in the Chameleon range is a completely functioning hygiene and pumping station that supplies pressurised water to both its integrated hygiene point and to connected satellite hygiene sta-tions. Therefore the main station must be supplied with: water in suf-ficient quantity, power, compressed air, detergent(s) and disinfectant.

The station is then ready for hygi-ene duties.

The Advanced main station in-corporates a unique pneumati-cally controlled valve that ensures injectors are flushed with water between hygiene functions Depen-dent on the model the system can work automatically or pneumati-cally via the selector.

The main station is fitted with a frequency controlled pump which ensures a constant working pres-sure independent of usage pattern.

Using Hygiene Chemicals:The Advanced main station has been prepared to use of the Ecolab's European palette of foam detergents and disinfectants.

Warning:Do not change the settings made or recommended by the supplier of hygiene chemicals.

A typical installation of the Advan-ced series is shown in fig. 1· Main station (1)· Mixing system (2)· Satellite (3)

The supply of detergents are either supplied from the User Pack System, which can be delivered as attachments fig. 2 or from separate standard cans fig 3. The supply can also be established through piping systems.

Important: Do not use the water from the system for applications other than cleaning.

4

Fig. 4 0627140

Fig. 5 0627125

1.1 Layout Advanced MPMain StationMP321-MP322-MP332-MP333-MP421-MP422-MP432-MP433 (Fig. 4).

1. Water inlet 2. Manifold inlet 3. Trigger sensor, flow sensor 4. Pump 5. Manifold outlet 6. Outlet pipe 7. Intake union 8. Converter box 9. Injector block10. Air filter11. Dosing valve12. Quick coupling with check tap13. Inlet air14. External Injector15. Display16. Air regulator, foam17. Change-over switch foam/rinse/des18. Navigation buttons19. Operation panel • O Pushbutton.Stop • I Pushbutton.Start • Δ Lamp. Alight by error

5

C1C2

FST 1JP4FS 1

JP5

PE1CP1

PE2 TE1

W

2

4

6

13

8

C5

C4CR1

E1

C3CR2

E2

OV1

OR1

PR2

HV1

EJ2 EJ1

HC1

B

D

JP3

JP7

A

F

Connection with OV1 at port nr. 1

Fig. 6 0627146b

1.2 Opereting Diagrams ac-cording to ISO14617

Main Station MPB. Ball valve.F. Filter.*FS. Flow sensor.FST. Flowsensor and -trigger.C. Check valve.PE. Pressure sensor.TE. Temperature sensor.CP. Centrifugal pump.CR. Chemistry regulator.EJ. Ejector.HV. Hydraulic valve.HC. Hose connection.OR. OR element.OV. Operator valve.PR. Pressure regulator.A. Air supply.D. Outlet.E. Inlet, Ecolab detergent.W. Water inlet.SN : Socket no. controller

board.

* Has been suspended per. 1.10.2007

6

Fig. 7 0627121

Fig. 8 0627141

1.3 Layout Advanced MAMain StationMA321-MA322-MA332-MA333-MA421-MA422-MA432-MA433 (Fig. 7).

1. Water inlet 2. Manifold inlet 3. Trigger sensor, flow sensor 4. Pump 5. Manifold outlet 6. Outlet pipe 7. Intake union 8. Converter box 9. Injector blok10. Air filter11. Sensor for Block12. Dosing valve13. Quick coupling with check tap14. Inlet air15. External Injector16. Display17. Air regulator, foam18. Change-over switch foam/rinse/disinfectant19. Navigation buttons20. Operation panel • O Pushbutton.Stop • I Pushbutton.Start • Δ Lamp. Alight by error

7

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6

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Connection with OV1 at port nr. 1

Fig. 9 0627147b

1.4 Operating Diagrams ac-cording to ISO14617

Main Station MA

B. Ball valve.F. Filter.*FS. Flow sensor.FST. Flowsensor and -trigger.C. Check valve.PE. Pressure sensor.TE. Temperature sensor.CP. Centrifugal pump.SV. Solenoid valve.CR. Chemistry regulator.EJ. Ejector.HV. Hydraulic valve.HC. Hose connection.OR. OR element.OV. Operator valve.PR. Pressure regulator.A. Air supply.D. Outlet.E. Inlet, Ecolab detergent.W. Water inlet. SN : Socket no. controller

board.

* Has been suspended per. 1.10.2007

8

Fig. 14 0627151

Fig. 13 0627123

Fig. 10 0627117

Fig. 12 0627131

Fig. 11 0627106

2. MaintenanceThe main station is maintenance-free. However, filters must be cleaned at suitable intervals (approx. 1-3 months) depending on the content of impurities in the water.

2.1 Filter (Fig. 10)1. Press “0” on the control panel

to stop the main station.2. Interrupt the master switch.

(Fig.11)3. Close the water inlet .4. Open a tap to release the sys-

tem of pressure.5. Remove the filter and place it

in a descaling solution until the scale is dissolved.

6. Rinse the cleaned filter thor-oughly and remount.

3. New systemNote: Before use, the pump must always be bled and filled with water.

In order to ensure a problem-free start up of a new system the pipe system must be flushed and bled.

Bleeding the pipe system1. Turn on the water supply to

rinse and bleed the entire sys-tem. If satellites are installed open the tap furthest away until no air or dirt comes out. Then rinse and bleed the next tap and continue until the tap closest to you has been rinsed and bled.

2. Mount satellites, if any.

Bleeding the pump3. Loosen the relief plug (A, Fig

12) 1-2 revolutions until water and air begin to flow out.

Note. Never loose the relief plug while the pump is run-ning as this may damage the packing.

4. Tighten the relief plug again5. Start the pump so that all re-

maining air pockets are forced up to the top of the pump.

6. Stop the pump7. Loosen the relief plug 1-2

revolutions again and bleed the system until only water flows out.

8. Tighten the relief plug once more

The main station is now ready for operation. Press “I” on the control panel. (see fig. 14)

2.2 Long stopsIf long productions stops are planned (more than 6 months) and the pump is emptied of water, it is recommended that the pump be secured as follows:

1. Remove the coupling safety guard.

2. Spray a couple of drops of sili-cone oil onto the axle between the top section and the cou-pling.

Carefully follow the instructions given in the manual provided by the pump supplier.

4. Daily operation

4.1 StartMainstation

1. Check that water- and air sup-plies for the system are open.

2. Press “I” on the control panel to start.(see fig.14)

9

level: 1.3 l/minStart flow

EGA +

-OK

4.2 StopMainstation1. Press “0” on the control panel

to stop.2. Turn off the water supply.3. Close the air supply(A, Fig 13)

Note. It is important to shut off the water and air when the machine is left after use because:

• If the air supply is open when the main station and satellites are not in use, air may seep into the water pipe. If this is the case the system may have to bled again.

• The water separator, which is a part of the air regulator, is only to be emptied when the air is shut off.

It may be necessary to bleed the pipes and the main station again after it has been closed for a longer period of time (holidays, and the like)

4.3 Rinsing the chemistry sup-ply

IMPORTANT: The chemist sup-ply must always be rinsed thor-oughly after use.Remains of detergents or disin-fectants can clog the injector so it needs to be rinsed or replaced. The following procedure will clean the chemistry supply for detergents and/or remains of disinfectants.

1. Remove User Pack, if any.2. Hold the rinsing bottle with

clean water tightly against the suction opening (with User Pack) or against the hose (without User Pack). Alterna-tively, you can place a User Pack with clean water in the holder or – without User Pack – place the hose in a bucket of clean water.

3. Activate the hose handle until clean water comes out of the nozzle (approx. 30 seconds).

Note. This procedure should be followed both on the detergent and the disinfectant side (if this is installed).

5. ServiceService may only be carried out by authorized and qualified personnel.Warning: The system must only be serviced when there is no voltage or pressure on the system.

1. Turn off the main switch at the control box

2. Open a water outlet to depres-surise the system.

5.1 Components5.1.1 Pump/motor Pump/motor are maintenance free, see section 2.2.

5.1.2 Control systemMaintenance freeIf defective: Call service technician.

5.1.3 Flow triggerMaintenance-free. If defective, replace the flow switch.Attention! For operation of thedisplay menus see the softwaremanual.

5.1.3.1 AdjustmentsScroll to Start Flow:

Set the value to 1.3 L/min press OK to store the value.Test if the unit can start up in foammode or by the use of a Ø 2.0 mmnozzle.

If not, set the value lower. Contin-ue to reduce the start flow until firm start has been achie

5.1.4 Non-return valve/intake side

Maintenance-free.If defective, replace the non-return valve.

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6. Troubleshooting6.1 The unit does not startSteps 1 - 5

1 Is there voltage to the unit?

Reconnect voltage to the unit.

2 Is the water tempera-ture over 70°C?

Lower the water tem-perature.

Wait until the tempe-rature drops belows 60°C..

3Is the water supply switched on to the

unit?

Check the water sup-ply. Is the ball valve

open?

4Is the ‘Δ’ lamp on the control panel turned

off?Go to section 6.2

5 Call a service techni-cian

6.2 The "Δ"- lamp on the control panel is onSteps 1 - 4

1 Check the display for error messages. Go to Software manual.

Press "0" and then "I" on the control

panel to restart the system.

2 Is there suffucient water supply?

Check the water supply and clean the filter if it

is clogged.

3 Is the water temper-ature over 70°C?

Lower the water tem-perature.

Wait until the temperature drops below

60°C.

4 Call a service techni-cian.

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6.3 Too low or unstable pressureSteps 1 - 4

1 Is there sufficient water supply?

Check that the inlet pressure is between

2 - 8 bar.

2 Is the filter clogged? Clean the filter.

3Is the pump leaking or does the pump make

jarring sounds?Call a service technician.

4 Call a service technician

6.4 Unsatisfactory foam qualitySteps 1 - 4

1 Is the foam nozzle fitted?

Fit a 50/200 foam nozzle.

2 Is the air supply OK? Adjust on the air regu-lator.

3 Is the detergent/disin-tectant supply?

Adjust the supply on the dosage valve.

4 Call a service techni-cian

6.5 No foamSteps 1 - 7

1 Is the switch in foam position?

Turn the switch to foam posi-tion.

2 Is a foam nozzle fitted? Fit a 50/200 foam nozzle.

3 Is the dosage valve open? Open the dosage valve.

4 Is the air supply connected? Open the shut-off valve for air.

5Is the filter in the hose from the detergent/disinfectant contai-

ner clogged?Clean or replace the filter.

6 Is there detergent/disinfectant in the container?

Fill detergent/disinfectant in the container.

7 Call a service technician

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7. Recommended spare parts

Main stationsNr. Description Amount

0603338 Non-return valve pairs, water-inlet 1

**0631075 Flow sensor (15 - 300) (1)

0631077 Pressure/temperature sensor (Pump top) 1

0646050 Non return valve, chemistry 1

0664136 Non-return valve, air 1

0603339 Non-return valve, water 1

*0631076 Flow sensor, satellite 1

*0631060 Dry-running sensor 1

0670001 EPM 1

Shaft seal 1

* Does not concern all systems.

**Has been suspended per 01.10.2007

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8. Specifications

Technical Data Main station.

Water Unidad MP3-MA3 MP4-MA4 MP1.DP-MA1.DPMax.Outlet pressure. bar 25* 25* 40

Comsumption during rinsing. L/minConsumption during foaming. L/minMin. supply pressure. bar 2 2 2Max. supply pressure. bar Min. water supply. L/min 100 135 135Pressure @ 90 [L/min] bar 19,5 26,1Pressure @ 120 [L/min] bar 19,6 17,7Pressure @ 240 [L/min] barFlow @ 40 [bar] L/min 42,8Max. water temp. °C 70 70 70Pipe dimension inlet Ø inch 1.1/4“ 1.1/4“ 1.1/4“Pipe dimension outlet Ø inch 1.1/4“ 1.1/4“ 1.1/4“Compressed air

Min/max air pressure. bar 5-10 5-10 5-10Compressed air consumption. NL/min 200 200 200Pipe dimension inlet Ø mm 6 6 6Electricity

Supply voltage. V 3/PE 400/480 V±10%

3/PE 400/480 V±10%

3/PE 400/480 V±10%

Frequency. Hz 50/60 Hz48 -0%..62 +0%

50/60 Hz48 -0%..62 +0%

50/60 Hz48 -0%..62 +0%

Motor load (kW) kW 4 5.5 5.5Installation to EN 60204-1

Nominal current. A 10.6 14.2 14.2Fuse. A 16 20 20L1, L2, L3, PE mm2 2.5 2.5 2.5General

Sound level ISO 11202 dB Belowe 70 Belowe 70 Belowe 70Dimensions H x B x D mm 1074 x 560 x 385 1074 x 560 x 385 1074 x 560 x 385Weight. kg 115 100 100

* Pump pressure 20 +inlet pressure max. 25 bar

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© 2005 All rights reserved Ecolab GmbH & Co. OHGP.O. Box 13 04 06 D-40554 Düsseldorfwww.ecolab.comTel.: +49 211 98 93 203 - Fax: +49 211 98 93 223 Printed in Denmark