Dosing system Manual
Table of Contents
Manual Overview
Instructions for use of dosing device
I. Overview
This dosing device is a continuous preparation and dosing system integrating reagent dissolution, metering, and intelligent control. It is suitable for the preparation and dosing of powdered reagents (such as PAM) and liquid reagents (such as residual chlorine removers, flocculants, and scale inhibitors). The equipment features a compact structure, convenient maintenance, precise dosing, and easy transportation. Its intelligent control system automatically monitors and adjusts parameters such as liquid level, concentration, and pH value, making it widely applicable in water treatment and related fields.
Its core working principle is as follows: Dry powder reagents are premixed and moistened with clean water in a premixer after being added via a quantitative dosing system. Then, they are diluted and mixed to the set concentration in a preparation tank, and finally fully matured in a maturation tank before being stored in a storage tank. The system controls the dispensing process in real time through liquid level monitoring. Dispensing stops when the liquid level in the storage tank reaches a high level and automatically restarts when it drops to a low level, ensuring continuous and stable dosing. Liquid reagents are precisely added to designated points according to process requirements via a metering pump.
II. Structural Composition
(a) Core system components
- Pharmaceutical preparation system: includes an integrated three-tank combination tank (preparation tank, maturation tank, storage tank), dry powder impregnation device, dissolving tank, maturation tank, and finished drug tank, responsible for the dilution, mixing, maturation and storage of pharmaceuticals.
- Dosing system: Includes a dry powder metering dispenser, an insertion sinusoidal metering pump (optional), and a metering water inlet system to achieve precise dosing of dry powder and liquid reagents.
- Mixing system: Equipped with a stirrer (standard) and an optional stirrer to ensure that the reagent is fully diluted and mixed evenly.
- Water supply and piping system: Composed of pressure stabilizing valve, water inlet device, flow meter, electric valve, safety valve, pulsation damper, back pressure valve, etc., to ensure stable water supply and pipeline safety.
- Control and monitoring system: may include intelligent control box, level monitor, pH meter, conductivity meter, corrosion online monitor, etc., to realize automatic control of equipment and monitoring of operating parameters.
- Auxiliary systems include a dehumidification and drying system (moisture-proof device), heater, filter, drain valve, etc., to ensure the operating environment and service life of the equipment.
Fully automatic dosing device
(b) Description of Key Components
- Liquid level monitoring gauge: includes monitoring points for extremely high, high, low, and extremely low levels, enabling precise control of material preparation and shutdown protection.
- Intelligent control box: Enables manual/automatic mode switching, operating parameter setting, and fault alarm.
- Metering pump: positive displacement type, adjustable stroke to ensure dosing accuracy; includes one working and one standby configuration to deal with sudden failures.
III. Specifications
Model
JYH-300
JYH-500
JYH-1000
JYH-1500
JYH-2000
JYH-3000
JYH-4000
JYH-5000
Semi-automatic dosing device
IV. Installation and Debugging
(a) Installation Precautions
- After the equipment arrives, first check whether there is any damage or loose bolts during transportation, and verify that the number of accessories is complete.
- Confirm that the rated voltage, number of phases, and current of equipment such as the medicine mixer and metering pump are consistent with the on-site power supply requirements.
- Verify that the installation location of the dosing tank, the orientation of the pipe inlets, and the dimensions of the civil foundation match the actual dimensions of the equipment to ensure that the installation is flat and stable.
- Accurately connect the inlet and outlet pipes, vent pipes, and valves, and tighten all threaded joints to prevent fluid leakage; properly position the upper and lower operating platforms.
- When connecting the power supply, open the junction box of the electrical control cabinet and connect the compliant three-phase four-wire power supply wire to the corresponding terminal block, ensuring that the wiring is correct and secure.
- Close the drain valve and check the status of each valve to ensure that the pipeline is unobstructed.
(b) Debugging Steps
- Manual mode adjustment: Turn the manual/automatic switch knob to manual and perform the following checks and settings:
Check whether the rotation direction of the impeller mixer and the dry powder feeding screw is correct.
Verify that the power supply frequency and voltage are consistent with the specifications on the motor nameplate, check whether the oil level in the reducer has reached the center line of the sight glass, and add lubricating oil as needed.
Adjusting the dry powder dosage: Start the dry powder conveyor (set the speed controller or frequency converter speed), use a device to receive the output dry powder for 1 minute and weigh it, calculate and adjust to the required dosage (example: when the drug concentration is 0.1% and the influent flow rate is the corresponding value, the dry powder dosage must meet the corresponding standard).
Adjust the inlet water flow rate: Start the inlet solenoid valve, adjust the inlet manual valve, and observe the flow meter until the desired flow rate is displayed. - Automatic mode test: Turn the knob to automatic, press the automatic operation button, and monitor the system response:
When the liquid level reaches a high level, the inlet solenoid valve and dry powder conveyor should automatically close; when the liquid level drops to a medium level, they should automatically start; when the liquid level reaches an extremely low level, the system should alarm and stop.
Check whether the monitoring equipment such as pH meter and conductivity meter are working properly. When the pH value or conductivity of the drug solution exceeds the set range, the dosing pump should stop automatically. - Component function test: Test components such as safety valves, back pressure valves, and pulsation dampers to ensure that pressure regulation is normal and there is no leakage or abnormal vibration.
V. Operating Procedures
(a) Preparations before powering on
- Check that all parts of the equipment are intact, and that the pipes and valves are securely connected without any looseness or leakage; clean any residual impurities from the solution tank to ensure cleanliness.
- Depending on the type of agent to be added, pour the agent (dry powder or liquid) into the corresponding powder dispenser or solution tank as required, ensuring that the agent is sufficient and free of lumps.
- Check if the water pressure meets the requirements. If the water pressure of the water press is lower than the set value, it needs to be dealt with in time (some models have a water pressure alarm function).
- After confirming that the power and water supply are normal, open the electrical control cabinet and check that the electrical components are free from moisture or water ingress.
Semi-automatic dosing device
(b) Operation
Dosing of dry powder agents (applicable to powdered agents such as PAM):
- Set the dry powder dosage and water flow rate according to the parameters determined during debugging. Start the mixer for 3 seconds, then start the water inlet solenoid valve and the dry powder conveyor.
- Observe the mixing of the reagents in the maturation tank to ensure that there is no dry powder clumping and that the solution is uniform.
Liquid chemical dosing (chlorine remover, flocculant, scale inhibitor, etc.):
- Measure the required concentration of reagent and water, add the reagent to the solution tank, open the water supply valve to fill the water to the specified level, and then close the water supply valve.
- Open the valves of the dosing system, adjust the dosing rate of the metering pump, start the metering pump to add the reagent to the dosing point, and fine-tune the dosing rate according to the process requirements to ensure that the treatment needs are met.
Automatic monitoring:
- When the system is running automatically, the liquid level must be above the middle level for it to start normally. The data from instruments such as the liquid level monitor, flow meter, and pressure gauge should be observed in real time.
- Regularly check the remaining amount of the medicine and replenish it in time (the system will not automatically stop when the dry powder is insufficient).
(c) Shutdown Procedure
- Normal shutdown: When the liquid level in the storage tank reaches the high level or the dosing task is completed, the system will automatically shut off the water inlet solenoid valve and the dry powder conveyor, and shut off the mixer after 30 minutes; the automatic operation button can also be manually turned off.
- Emergency shutdown: In case of equipment failure, leakage or other emergencies, immediately disconnect the main power supply, close the main water inlet valve, troubleshoot the problem and then restart.
- Post-shutdown procedures:
- Empty any remaining powder from the dry powder box to prevent clumping and clogging of the conveyor screw.
- Empty the remaining liquid from the medicine tank and dosing pipeline, and rinse the medicine tank, pipeline and metering pump with clean water (the dosing screw pump needs to be rinsed with clean water for 3 minutes before stopping).
- Turn off the main water valve, disconnect all power, clean equipment containers, meters and instruments, and keep the equipment in good working order.
VI. Standard Procedures for Chemical Dosing
(a) Residual chlorine removal agent
- Dosing location: Before the pre-treated influent.
- Dosing parameters: Adjust the flow rate of the dosing machine to a suitable range; set the dosage of the drug per corresponding volume of pure water according to the requirements of the equipment model.
- Concentration adjustment: When the residual chlorine concentration in the raw water exceeds the normal value, the amount of dechlorination in the dosing tank should be adjusted proportionally to the excess concentration.
(b) Flocculants
- Dosage location: before the pre-filter and raw water pump.
- Dosing parameters: Adjust the flow rate of the dosing machine to a suitable range; when using tap water with turbidity that meets the conventional standards as the water source, prepare the dosage according to the equipment model.
- Concentration adjustment: If the raw water is groundwater, surface water, or concentrated water reuse, the flocculant dosage in the dosing tank should be adjusted according to the proportion of turbidity exceeding the conventional standard.
(c) Scale inhibitors
- Dosing location: before the multistage pump or high-pressure pump.
- Dosing parameters: Adjust the flow rate of the dosing machine to the appropriate range; when the hardness of the raw water is within the normal range (calculated as calcium carbonate), prepare the dosage according to the equipment model.
- Concentration adjustment: When the hardness of the raw water exceeds the upper limit of the normal range, the concentration of the scale inhibitor should be adjusted according to the excess ratio (not exceeding the upper limit of the specified multiple).
Fully automatic dosing device
VII. Common Faults and Solutions
Fault phenomenon
Possible reasons
Solution
No water inlet
Damaged inlet solenoid valve; blocked pipeline
Replace the solenoid valve; unclog the pipeline.
The feed screw is not feeding material.
The feed motor is damaged; there is sludge or clumps of medicine inside the screw.
Repair or replace the feed motor; remove the screw to clean away sludge or clumps.
The mixer is not mixing.
Damaged mixing motor
Repair or replace the mixer
The liquid level probe is not working.
The level probe is damaged; chemicals are adhering to the probe surface.
Repair or replace the level probe; wipe away impurities from the probe surface.
Dosing pump does not add medicine
Damaged or clogged dosing pump; damaged motor; pump running dry or in reverse.
Repair/replace the dosing pump and motor; clean blockages inside the pump; ensure valves before and after the pump are open, pre-inject the medium, and correct the rotation direction.
Metering pump malfunction
Inverter malfunction; unstable pressure
Start the backup metering pump and reset the frequency converter according to the instruction manual; check the pressure settings of the back pressure valve and safety valve, and install a pulse damper to improve pulsation.
Inaccurate level gauge readings
Material sticks to surface when damp
Wipe the level gauge every shift to remove any adhering material.
There is still flow even after the inlet valve/discharge valve is closed.
Valve damage
Inspect and replace damaged valves promptly.
Feeding pipe is blocked
Drug adhesion and blockage; heater damage
Disassemble the piping and clear any blockages (it is recommended to check this after each corresponding running time); replace the damaged heater.
VIII. Maintenance and Care
(a) Routine maintenance (daily/per shift)
- Inspect the equipment's operating status, check instrument data, pipeline leaks, and motors for abnormal noise or overheating.
- Wipe the surface of the level gauge to remove any adhering material; check the remaining amount of reagent in the hopper and replenish it as needed.
- Observe whether the feeding pipeline is unobstructed. If there is no downward suction or backflow at the top end cover of the hopper, it needs to be cleared in time.
(b) Regular maintenance
- Weekly: Clean the solenoid valve (after disconnecting the power and water supply, unscrew the bolts, remove the valve cap, clean the upper chamber, throttling orifice and small hole, and reassemble correctly); check the tightness of each mechanical component.
- Monthly: Disassemble and clean the flow meter (close the shut-off faucet, disassemble the meter head and main unit, check the cleanliness of the turbine ring, assemble in the correct flow direction, and take care to protect the cable); clean the diaphragm in the center of the pressure level gauge head.
- Quarterly: Thoroughly rinse the dosing tank, premixer, maturation tank, etc., to remove pesticide residues and condensates; inspect mechanical parts that come into contact with the pesticides, and replace them promptly if there is corrosion or wear.
- Annually: Conduct a full equipment inspection and replace severely worn parts; perform maintenance according to the reducer manufacturer's instructions.
(c) Special Maintenance
- Screw pump for chemical dosing: When starting up, the screw pump bushing must be lubricated with tap water at the same time. After it is running normally, turn it off. Before stopping, rinse with clean water for 3 minutes and then clean and maintain it.
- Electrical system: Do not wash the control cabinet with water. Keep the cabinet door tightly closed to prevent water from damaging electrical components. Regularly check the tightness of the wiring terminals and clean the dust inside the cabinet.
- Moisture-proof device: Regularly check the dehumidification and drying effect to ensure that the inside of the equipment is free from moisture and condensation.
IX. Safety Precautions
- Equipment operation and maintenance must be performed by trained professionals who are familiar with the equipment structure, electrical principles, and operating procedures.
- When performing maintenance, the main power supply must be disconnected and the main water inlet valve must be closed. It is strictly forbidden to operate under power or pressure.
- The agent is corrosive, and protective equipment (gloves, mask, etc.) must be worn during handling to avoid direct contact with skin and respiratory tract; if contact occurs, immediately rinse with plenty of water.
- Metering pumps must not be run dry or in reverse. Before starting the pump, be sure to confirm that the valves before and after the pump are open and that the medium has been injected in advance.
- The pressure setting of the safety valve must not exceed the upper limit of the rated working pressure of the metering pump. Overpressure operation is the main cause of damage to the metering pump.
- Adhering to the principle of "safety first, prevention foremost", we will strictly abide by all safety rules and regulations, strengthen safety production education, and raise awareness of safety precautions.
- After the work is completed, the equipment must be thoroughly cleaned, any residual chemicals drained, and all power and water supplies disconnected to ensure the equipment is in a safe condition.
Note: This manual integrates the operating requirements of PAM fully automatic dosing devices and general automatic dosing devices. Specific parameters and operations need to be adjusted according to the actual equipment model and the type of reagent to be added.
This section provides comprehensive documentation for all products in the Dosing system category. Please select a specific product below to view its detailed manual.
Available Products
SS316-300-Automatic Dosing Device
SS316-5000-Automatic Dosing Device
SS316-4000-Automatic Dosing Device
SS316-3000-Polymer Dosing Unit
SS316-2000-automatic dosing device
SS316-1500-Polymer Dosing Unit
SS316-1000-Polymer Dosing Unit
SS316-500-Polymer Dosing Unit
SS304-4000-Polymer Dosing Unit
SS304-1500-Polymer Dosing Unit
SS304-2000-automatic dosing device
SS304-5000-Automatic Dosing Device
SS304-300-Semi-Automatic Dosing Device
SS304-1000-Polymer Dosing Unit
SS304-300-Polymer Dosing Unit
SS304-3000-Polymer Dosing Unit
SS304-500-Polymer Dosing Unit
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