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Series EXPSection No. 6.4
EXP Solar and AC-Powered Chemical Injection Pump for Class I, Division 2 Hazardous Locations with DigiMax ADC ControlApplicationThe WellMark EXP Class I, Div. 2 Solar-Electric Chemical InjectionPump provides an environmentally-clean method for injection ofchemical into a line under pressure. It is a positive-displacementdesign, powered by an electric motor, thereby eliminating the gasemissions inherent with pneumatic-style pumps. Applicationsinclude injection of methanol, corrosion inhibitors, friction reducersor scale inhibitors into wellheads or pipelines. A unique TemperatureSensor allows the operator to set a temperature threshold to disal-low pumping until the temperature falls to a specified level.
with Auto Mode, Voltage Monitor, Temperature Sensor,Manual Pump Override, Fuse Protected
Mounts . . . . . . . . . . . . . . . . Mast with Quad Legs (Standard)Skid Mount (Optional)
Principle of OperationAny chemical injection pump utilizing a photovoltaic power system must manage numerous variables in an attempt to maintain ade-quate power for the task at hand. Among those variables are:• Available Sunlight• Size and Capability of the Solar Panel• Size of the Battery or Batteries• Power Draw of the Motor• Size/Displacement of the Plunger• Required Discharge Pressure of the Pump
All of these variables must be considered when sizing a photo-voltaic pump system.
Unit Positioning and Panel Tilt AdjustmentRegional information about available sunlight can be found athttp://www.nrel.gov/gis/solar.html. Further evaluation of the spe-cific site may be necessary to maximize clear presentation of thesolar panel to the sun. Any adjacent items that may casts shadowson the panel throughout the day will negatively affect the overallperformance of the package. Maximum exposure will help to assurethat the battery maintains enough power to drive the pump through-out the night. To get the most from position-fixed (or seasonallyadjusted) photovoltaic solar panels, you need to point them in thedirection that captures the most sun. Solar panels should alwaysface true south in the Northern Hemisphere and north in theSouthern Hemisphere, tilted from the horizontal at a degree equal toyour latitude plus 15 degrees in winter, or minus 15 degrees insummer. An additional 3- 5% can be gained by evaluating this morecarefully and fine-tuning adjustments accordingly.
Solar-Powered ModelShown with skid mount, double battery and single solar panel.
Pump OverrideRuns pump continuously, overriding the program until the button ispressed again or until the pump runs for 2 minutes.
Temperature SensorThe Control Timer is equipped with a Temperature Sensor feature.When actvivated this feature turns the pump off until the temperaturedrops to a set temperature threshold or lower, regardless of programsettings. This allows the user to minimize the waste of methanol byonly pumping during conditions approaching freezing temperatures.
Pump SelectionA wide ratio between OFF time and RUN time (OFF:RUN) will usual-ly result in maximized efficiency of the battery/solar charging system.For example: 30 seconds OFF time versus 5 seconds RUN timewould result in a ratio of 6:1. Ratios lower than 2:1 may result inprogressive loss of battery charge, depending upon available sun-light and differential pumping pressure.As reviewed against the “Pump Displacement & Timer Settings”charts, (refer to Installation, Operation & Maintenance Instructions forSolar and AC-Powered Chemical Injection Pumps) the pumps' requiredrate should optimally fall within the middle of the pumps' capacityrange. This gives room for adjustment if the service criteria changes.
OperationThe WellMark Solar and AC-Powered Chemical Injection Pumps feature a control timer that allows a broad range of operating con-ditions. The pump head can be adjusted for one of three differentdisplacement settings. Control of fluid volume can be achieved byutilizing an infinite number of combinations of RUN and OFF timesalong with three different displacement settings. Suggested set-tings for common volumes are listed on included charts.
DigiMax ADC Control/TimerProgram FunctionsAuto ModeAfter a one-time setup, this feature allows the operator to simplyenter the number of quarts desired per day - No need to consult RUNTIME and OFF TIME charts. The DigiMax ADC is programmed to behassle-free. Of course, Manual Mode is available allowing the userto manually set the control if desired.In Auto Mode Digital Display continuously indicates settings:• Plunger Size and Pin Setting• Battery Voltage• Temp. Settings (ON/OFF, Temp. Threshold Setting and Current)• Pump Rate (Quarts per Day)
In Manual Mode Digital Display continuously indicates settings:• RUN Time• OFF Time• Cycle Cvount• Battery Voltage• Temp. Settings (ON/OFF, Temp. Threshold Setting and Current)
Pin position (1, 2 or 3) determines displacement (see charts).Factory preset is Position 3.
1**• Ext. Cable - Pump to Bat. Box2**• Ext. Cable - Panel to Bat. BoxG • Explosion Proof "Locking" Plug
(AC Only)P* • Ext. Post - Inches Over Std.S • Coated Plungers
3 • Digimax - DC5 • Digimax - AC
2nd Pump Head
Plunger Options
Controller
Options
Mount
Power
Panel
Motor Options
Determining the Model NumberExample given: Standard Model EXP-102052223-S Pump with 1/4” Plunger, No 2nd Head, Teflon®-Buna-N/Buna-N Packing and Seals, 1/6hp 12 VDC64 RPM Motor, 80 Watt Solar Panel, 110Amp Hour Battery, Mast with Quad Legs, DigiMax DC Timer Controller with Coated Plungers.
EXP Solar and AC-Powered Chemical Injection Pump for Class I, Division 2 Hazardous Locations with DigiMax ADC ControlSolar-Powered Pump Unit Component Parts
50
4
44
5857
53
55
46
33
45
44
56
52
35
2
25
36
24
23
22
21
20
28
24
23
25
27
1617
1839
19
5138 7
1032
11
112
41
6
34
8
40
29
512
33
43
42
1011
1314
15
69
70
71
72 73 7
3
37
9
3031
48 4947
26
74
AC-Powered Pump Unit Component Parts
4
51
2
35
44
25
36
24
23
22
21
20
28
24
23
25
27
1617
1839
19
333
1011
12
7
37
34
8
40
29
5 612
1110
1314
15
1
41
38
66
9
3031
48 4947
42
26
32
52
43
51
68
4557
56
58
55
54
46
50
55
5253
Series EXPSection No. 6.4
EXP Solar and AC-Powered Chemical Injection Pump for Class I, Division 2 Hazavrdous Locations with DigiMax ADC Control
EXP Solar and AC-Powered Chemical Injection Pump for Class I, Division 2 Hazardous Locations with DigiMax ADC ControlSolar and AC-Powered Pump Unit Component PartsItem Description Qty. Part No.
Solar-Powered AC-Powered1 HOUSING 1 05013-9999 05013-99982 SPEED REDUCER 1 06000-9515 06000-95433 SOCKET HEAD SCREW 4 05000-5640 05000-63224 MOTOR 1 06000-9495 06000-95355 ELECTRIC WHEEL ASSEMBLY 1 05013-7059 06500-75426 SET SCREW 1 or 2 05000-62647 LOCK WASHER 4or 8 107098 BEARING 1 06000-95639 RECIPROCATING BLOCK 1 05013-781010 BUSHING 2 05013-701211 O-RING, BUNA 2 1101712 GUIDE NUT 2 05013-702013 GUIDE 1 05013-698614 JAM NUT 1 05013-696815 CAP 1 05013-7119