Flomotion Systems 2001H Series, 2001H K4 Series Installation And Operation Manual

2001H Series

Peristaltic Chemical Feed Pump

2001H Series Peristaltic Pump O&M Manual

Pg. 2

Installation and Operation Manual

2001H Series

Peristaltic Chemical Feed Pump

May 2017

Flomotion Systems, Inc.

165 Creekside Drive, Suite 112

Buffalo, NY 14228-2103

[e-mail]

Toll Free: [phone]

Tel: [phone]

Fax: [phone]

Flomotion Systems, Inc. 2001H Series

2001H Series Peristaltic Pump O&M Manual

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TABLE OF CONTENTS

Table of Contents

1.0 - SYSTEM OVERVIEW.....................................................................................................................................................................4

1.1 SAFETY...............................................................................................................................................................................................4

1.2 WARRANTY.........................................................................................................................................................................................4

1.3 RECEIVING..........................................................................................................................................................................................5

1.4 CUSTOMER MODIFICATION...................................................................................................................................................................5

1.5 INFORMATION FOR RETURNING PUMPS ................................................................................................................................................5

2.0 – 2001H SERIES PUMP AND PUMPHEAD....................................................................................................................................6

2.1 TUBING, SPINDLE AND COVER INSTALLATION.......................................................................................................................................7

2.2 MOUNTING PUMP ON GEARBOX, INSTALLATION OF COLLET.................................................................................................................8

2.3 PUMP MOUNTING AND COLLET INSTALLATION PROCEDURE..................................................................................................................9

2.4 TUBE AND ROLLER INSTALLATION.....................................................................................................................................................10

2.5 TUBING & CONNECTIONS...................................................................................................................................................................16

Tubing and Accessory Part Numbers...............................................................................................................................................17

3.0 – 2001H MOTOR & GEARBOX.....................................................................................................................................................18

3.1 MOTOR SPECIFICATIONS....................................................................................................................................................................18

3.3 GEARHEAD SPECIFICATIONS...............................................................................................................................................................18

4.0 – K4 SERIES PUMP CONTROLLER............................................................................................................................................19

4.1 OPERATION AND WIRING...................................................................................................................................................................19

4.2 PROGRAMMING .................................................................................................................................................................................19

4.3 INTERFACING TO THE 2001H K4 SERIES PUMP CONTROLLER..........................................................................................................20

5.0 - 2001 SERIES TUBING RUPTURE DETECTOR.......................................................................................................................21

RUPTURE DETECTOR SYSTEM OVERVIEW.................................................................................................................................................21

5.1 ALARM CAUSES.................................................................................................................................................................................21

5.2 WHAT TO DO IN AN ALARM CONDITION...............................................................................................................................................21

5.3 RESETTING THE ALARM......................................................................................................................................................................21

5.4 RESUMING SERVICE...........................................................................................................................................................................21

Flomotion Systems, Inc. 2001H Series

2001H Series Peristaltic Pump O&M Manual

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1.0 - System Overview

The 2001H Series Chemical Feed Pump consists of a controller, motor, gearbox and peristaltic pump.

Model 2001H

with wall mount controller.

1.1 Safety

In the interests of safety, this pump and the tubing selected should only be used by competent, suitably trained
personnel after they have read and understood this manual, and considered any hazard involved. Any person
who is involved in the installation or maintenance of this equipment should be fully competent to carry out the
work.

with pump-mounted controller

Model 2001H

Maintenance and repair should be performed by qualified personnel only. Make sure that no
voltage is applied while work is being carried out on the pump or motor. The motor must be
secured against accidental start up.

1.2 Warranty

Flomotion Systems, Inc. warrants the 2001 Series pumps to be free of defects in material and workmanship for
a period of eighteen months from the date of sale to the user, or two years from the date of shipment, which
ever occurs first. An MC Series control, or any component contained therein, which under normal use becomes
defective within the stated warranty time period, shall be returned to Flomotion Systems, Inc., freight prepaid,
for examination (contact Flomotion Systems, Inc. for authorization prior to returning any product). Flomotion
Systems, Inc. reserves the right to make the final determination as to the validity of a warranty claim, and sole
obligation is to repair or replace only components, which have been rendered defective due to faulty material
or workmanship. No warranty claim will be accepted for components which have been damaged due to
mishandling, improper installation, unauthorized repair and/or alteration of the product, operation in excess of
design specifications or other misuse, or improper maintenance. Flomotion Systems, Inc. makes no warranty
that its products are compatible with any other equipment, or to any specific application, to which they may be
applied and shall not be held liable for any other consequential damage or injury arising from the use of its
products. This warranty is in lieu of all other warranties, expressed or implied. No other person, firm or
corporation is authorized to assume, for Flomotion Systems, Inc., any other liability in connection with the
demonstration or sale of its products.

Flomotion Systems, Inc. 2001H Series

2001H Series Peristaltic Pump O&M Manual

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1.3 Receiving

Inspect all cartons for damage, which may have occurred during shipping. Carefully unpack equipment and
inspect thoroughly for damage or shortage. Report any damage to carrier and/or shortages to supplier. All
major components and connections should be examined for damage and tightness, with special attention given
to PC boards, plugs, knobs and switches.

1.4 Customer Modification

Flomotion Systems, Inc., its sales representatives and distributors, welcome the opportunity to assist our
customers in applying our products. Many customizing options are available to aid in this function. Flomotion
Systems, Inc. cannot assume responsibility for any modifications not authorized by its engineering department.

1.5 Information for Returning Pumps

Equipment that has been contaminated with, or exposed to, body fluids, toxic chemicals or any other
substance hazardous to health must be decontaminated before it is returned to Flomotion Systems or its
distributor.

A certificate included at the rear of these operating instructions, or signed statement, must be attached to the
outside of the shipping container.

This certificate is required even if the pump is unused. If the pump has been used, the fluids that have been in
contact with the pump and the cleaning procedure must be specified along with a statement that the equipment
has been decontaminated.

Flomotion Systems, Inc. 2001H Series

2001H Series Peristaltic Pump O&M Manual

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2.0 – 2001H Series Pump and Pumphead

The 2001H Series pumphead has two spring-loaded working rollers, which automatically compensate for minor
variations in tubing wall thickness, giving extended tube life.

ROLLER ASSEMBLY
COLLET SCREW
5MM HEX WRENCH
7 NT.M 60 IN.OZ

IMPORTANT: The 2001 Series is equipped with a pump cover for safety and protection against
chemical spills. The cover must be installed whenever the pump is in use.

Flomotion Systems, Inc. 2001H Series

2.1 Tubing, Spindle and Cover Installation

Pg. 7

! IMPORTANT: Disconnect pump controller from power supply BEFORE changing tubing!

Item No. Qty Part No. Description

1 1 n/a Pump Body
2 1 100511 Roller Assembly
3 1 100304B Cover
4 1 100324 Collet Screw
5 1 100305C Cover Gasket
6 4 100307C Cover Screw
7 1 varies Tubing
8 1 Varies with tubing selection* Tube Seal

2001H Series Peristaltic Pump O&M Manual

*Tube Seal PN

100329 100330 100331 100332 100333 100334

8

Tubing is shown bent forward out of the pump
housing to illustrate the correct tubing and roller
assembly position, prior to sliding the tubing and
spindle into the housing and over the collet.

Flomotion Systems, Inc. 2001H Series

2.2 Mounting Pump on Gearbox, Installation of Collet

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2001H Series Peristaltic Pump O&M Manual

Item No. Qty Part No. Description

1 1 na Pump Housing with Tube Seal & Tube

Seal Cover
2 1 100306 Collet
3 2 100312 Pump Mounting Screws
4 1 na Tubing

Flomotion Systems, Inc. 2001H Series

2001H Series Peristaltic Pump O&M Manual

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2.3 Pump Mounting and Collet Installation Procedure

1. To install the pump housing on the gearbox, slide it over the central pilot on the gearbox adaptor plate.
Next install and torque the mounting screws to 5 NT.M (45 in. oz).

2. Next install the collet on the gearbox shaft. There is a slot in the collet that the flat drive tang on the
gearbox shaft must slide into. Orient the collet to allow the drive tang to slide into the slot and push the
collet completely onto the gearbox shaft. When the collet bottoms out it is in the correct position.

Flomotion Systems, Inc. 2001H Series

2001H Series Peristaltic Pump O&M Manual

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2.4 Tube and Roller Installation

! IMPORTANT: Disconnect pump controller from power supply BEFORE changing tubing!

! IMPORTANT Make sure pump suction and discharge lines are completely drained and
isolated. Note that the tubing hose seal size must match the selected tubing size.

Disassembly

1. Remove four (4) 4mm pump cover screws.

2. Loosen Tube Seal Clamp Screw with 5mm hex

wrench.

3. Remove 5mm collet screw.

Flomotion Systems, Inc. 2001H Series

4. Remove the roller assembly.

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5. Remove worn pump tubing from pumphead.

2001H Series Peristaltic Pump O&M Manual

6. Remove and inspect collet for wear. Note that the
collet may remain in the roller assembly when the
roller assembly is removed from the pump shaft.

Flomotion Systems, Inc. 2001H Series

7. Clean inside of pump housing with damp rag or an

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appropriate cleaning solution to remove any chemical
or tubing residue.

Reassembly

1. Reinstall the collet onto the pump shaft.

There is a slot in the collet that the flat drive tang on the
gearbox shaft must slide into. Orient the collet to allow the
drive tang to slide into the slot and push the collet
completely onto the gearbox shaft. When the collet
bottoms out it is in the correct position.

2001H Series Peristaltic Pump O&M Manual

2. Mark an 11” section of tubing, which will be the portion, contained within the pump. Leave sufficient
excess on the suction and discharge sides of the pump for the desired connections. If you leave the
excess intake tubing in a coil near the pump it will make it easy to feed a new section of tubing through
the rollers when the section in the pump becomes worn.

Mark an 11”

section of pump tubing.

Flomotion Systems, Inc. 2001H Series

3. Install tubing into the pumphead.

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Note: during tubing installation the loop of tubing may
develop a twist. Examine the tubing for this condition
and if needed turn one end of the tubing where it
exits the tubing clamp to eliminate the twist. Correctly
adjusted the tubing loop will be flat and parallel to the
front face of the pump housing.

2001H Series Peristaltic Pump O&M Manual

4. Loop tubing around roller assembly between guides
as shown. Remove slack in tubing while rotating
roller assembly and sliding onto collet.

Flomotion Systems, Inc. 2001H Series

5. Align marks on tubing with outside edge of the tubing

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Clamp.

6. Reinstall collet screw firmly.

2001H Series Peristaltic Pump O&M Manual

Mark an 11 inch
length of tubing
and locate the
marks at the
outside edge of
the tubing seal
(see arrows)

Tubing seal size
varies with the
selected tubing size.
See tables on
following pages for
details

7. Tighten tubing seal clamp screw. Be sure to tighten
firmly to prevent “tubing walk.” Tubing walk can occur
when the tubing seal is the wrong size or is not
sufficiently tight to keep the rollers from pulling the
tubing through the pump as it rotates.

Align the tubing marks
with the outside edge
of the Hose Seal.

Flomotion Systems, Inc. 2001H Series

8. Inspect pump cover gasket. Replace if damaged.

Pg. 15

Reinstall pump cover gasket and cover.

2001H Series Peristaltic Pump O&M Manual

Flomotion Systems, Inc. 2001H Series

2001H Series Peristaltic Pump O&M Manual

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2.5 Tubing & Connections

Tubing adapters are available for many configurations. See the drawing below for details.

Hose Barb
Color

Hose Seal
PN

Violet Green White Black Gray Blue

100329 100330 100331 100332 100333 100334

Flomotion Systems, Inc. 2001H Series

Tubing and Accessory Part Numbers

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FLOPRENE TUBING - 50 Ft Length (Santoprene)
FLO.016.024 1.6mm (1/16”) bore 100 PSI max
FLO.032.024 3.2mm (1/8”) bore 100 PSI max
FLO.048.024 4.8mm (3/16”) bore 70 PSI max

CONNECTORS / ADAPTORS
1/2” NPTM x pump tubing (bore as required)
3/8” PE tubing x pump tubing (bore as required)
Two-piece Color Coded tubing Barb & Collar Set.

PUMPHEAD tubing SEALS
100329 tubing Seal 1.6mm (1/16”) bore
100330 tubing Seal 3.2mm (1/8”) bore
100331 tubing Seal 4.8mm (3/16” bore

2001H Series Peristaltic Pump O&M Manual

FLO.064.024 6.4mm (1/4”) bore 50 PSI max
FLO.080.024 8.0mm (5/16”) bore 30 PSI max
FLO.096.024 9.6mm (3/8”) bore 30 PSI max

100332 tubing Seal 6.4mm (1/4”) bore
100333 tubing Seal 8.0mm (5/16”) bore
100334 tubing Seal 9.6mm 3/8”) bore

Flomotion Systems, Inc. 2001H Series

3.0 – 2001H Motor & Gearbox

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3.1 Motor Specifications

 Motor Type: Permanent Split Capacitor or 3-Phase Inverter Duty
 Rotation: Reversible.
 Insulation: Class B minimum
 Finish: Powder-coat gloss black.

Thermostat signal wires are not used in the 2001H

2001H Series Peristaltic Pump O&M Manual

3.2 2001H Power & Motor Wiring

3.3 Gearhead Specifications

 Housing: Precision machined die cast aluminum.
 Lubrication: Lifetime oil bath, sealed and gasketed.
 Shafts: Hardened steel.
 Mounting: Face (any angle) or optional footplate.
 Gearing: AGMA class 9 heat treated steel. 1st stage helical metal, balance spur metal.
 Bearings: Needle with thrust ball.

Flomotion Systems, Inc. 2001H Series

2001H Series Peristaltic Pump O&M Manual

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4.0 – K4 SERIES Pump Controller

4.1 Operation and Wiring

For complete details about the pump controller please refer to the included K4 SERIES (KBDA) Drive
Controller Operating Instructions booklet.

Shown here are program settings specific to the operation with the 2001H Series Peristaltic Pump.

4.2 Programming

The K4 SERIES programming differs from the factory defaults shown in the Operating Instruction booklet in
relation to the following parameters:

0.04 = 0000 GFCI operation disabled

1.00 = 0001 Remote Start/Stop input enabled

1.05 = 0003 Auto restart after power failure or fault

2.01 = 0001 Update speed change w/o having to press ENTER

2.02 = 0002 Local/Remote select input enabled

3.02 = 0100 100Hz Full Scale

4.00 = 0000 Display in Hz

5.00 = 0000 Run Relay output enabled

7.03 = 0010 Remote Start/Stop output enabled

7.04 = 0000 External Local/Remote select input OFF (0013 = ON)

7.06 = 0008 External Fault Input enabled

8.00 = 0001 Fault Relay output enabled

8.01 = 0009 Remote Status Output

9.07 = 0020 4-20mA Input enabled

8.09 = 0002 Enable fault when the 4-20mA output is disconnected*

6.05 = 1010 reset to Flomotion Defaults
*8.09 = 0000 to avoid fault when 4-20mA Output is disconnected when not using 4-20mA output

Refer to section 4.3 for wiring and program for the above signals and functions.

Flomotion Systems, Inc. 2001H Series

4.3 Interfacing to the 2001H K4 SERIES Pump Controller

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2001H Series Peristaltic Pump O&M Manual

Flomotion Systems, Inc. 2001H Series

2001H Series Peristaltic Pump O&M Manual

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5.0 - 2001 Series Tubing Rupture Detector

Rupture Detector System Overview

5.1 Alarm Causes

A rupture alarm is triggered by the presence of a conductive fluid in the pump. When the fluid bridges the two
stainless steel electrodes on the LIQUID SENSOR the alarm is triggered.

5.2 What to do in an alarm condition

To clear the alarm, first stop the pump and disconnect power from the pump controller. Remove the pump
cover and remove the ruptured pump tubing. Clean the inside of the pump with a soft rag. Remove any liquid
or tubing debris from the inside of the pump and the area around the LIQUID SENSOR. Inspect rollers and
clean if necessary.

5.3 Resetting the alarm

Press the yellow pushbutton (LEAK INDICATOR & RESET SWITCH) on the top of the Tubing Rupture
Detector to reset the alarm.

! IMPORTANT: Resetting the Tubing Rupture Detector will cause the pump to resume turning !
! ALWAYS reinstall the pump cover BEFORE resetting the tubing rupture detector !

5.4 Resuming Service

Install a fresh tubing insert and the pump is ready to resume service.

Flomotion Systems, Inc. 2001H Series

Notes

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2001H Series Peristaltic Pump O&M Manual

Flomotion Systems, Inc. 2001H Series