Hydrotech MP Series PULSAtron User Manual

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 & metering pumps, making them inaccessible to children & 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 rotatiing 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.

2

TABLE OF CONTENTS

Page

SAFETY INSTRUCTIONS................................................................................................................................. 2

INTRODUCTION ............................................................................................................................................... 3

UNPACKING THE PUMP..................................................................................................................................5

PRECAUTIONS FOR OPERATION...................................................................................................................5

INSTALLATION, PIPING AND WIRING............................................................................................................7

DESCRIPTION OF CONTROLS AND OPERATION........................................................................................13

CONTROL OPTIONS ...................................................................................................................................... 14

RELAY SETTINGS ......................................................................................................................................... 15

ALARMS......................................................................................................................................................... 16

CONTROL REFERENCE SUMMARY ............................................................................................................. 17

START-UP AND OPERATION ........................................................................................................................ 20

MAINTENANCE .............................................................................................................................................. 23

TROUBLESHOOTING ..................................................................................................................................... 25

EXPLODED VIEW DRAWINGS .................................................................................................................... 27

PUMP SPECIFICATIONS .............................................................................................................................. 30

REPAIR SERVICE ......................................................................................................................................... 31

INTRODUCTION

These installation, operation and maintenance instructions cover your electronic metering pump. Refer to the pump
nameplate to determine the actual model.

MM 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 deenergized it returns the diaphragm and pulls more fluid into the
pumphead 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.

3

MM 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, Teflon, 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.

MM MANUFACTURER’S PRODUCT WARRANTY

The manufacturer warrants its equipment of its manufacture to be free of defects in material or workmanship.
Liability under this policy extends for eighteen (18) months from the date of purchase or one ( 1 ) year from
date of installation or whichever comes first. The electronic components will be covered under this policy for
a period which extends for twenty four (24) months from the date of purchase. The manufacturer’s liability
is limited to repair or replacement of any device or part which is returned, prepaid, to the factory and which
is proven defective upon examination. This warranty does not include installation or repair cost and in no event
shall the manufacturer’s liability exceed its selling price of such 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
unauthorized repair. Replaceable elastomeric parts are expendable and are not covered by any warranty either
expressed or implied. The manufacturer is not responsible for consequential or other damages, injuries or
expense incurred through use of its products.

The above warranty is in lieu of any other warranty, either expressed or implied. The manufacturer makes
no warranty of fitness or merchantability. No agent of ours is authorized to make 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

MM EUROPEAN TECHNICAL FILE LOCATION

P.O. Box 91
Washington
NE37 1YH
United Kingdom

4

MM 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*

- Footvalve/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 40°C (104°F). 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.

5

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.
Consult supplier for special black tubing.

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.

6

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 40°C (104°F). 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 footvalve/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.

2. 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 .25" (6.3 mm) diameter in the shelf as shown in the dimension drawing (Figure
F). Attach pump securely using four #10 bolts and nuts.

7

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.

4. 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 .25"
(6.3 mm) holes and using four #10 screws and nuts.

5. 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.

8

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 overtightened. 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 footvalve/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 footvalve/strainer should be cleaned regularly, to ensure continuous
troublefree 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.

9

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

10

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 - Pulse Overflow

- Signal Loss - Pulse Rate High

- Full Count

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 button. To
resume operation as before, press the button.

To display the present stroking rate as a percentage of the
maximum rate of the pump at any time, press the button.
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.

11

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 flowmeter, which is of too high a frequency to cause the desired feed by directly stroking the pump.

12

EXTERNAL PULSE CONTROL - MULTIPLICATION

The pump operates as described previsously 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.

13

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.

14

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.

CONTROL REFERENCE SUMMARY

CONTROL OPTIONS

Fixed Rate

External Pulse

Straight

Division

Multiplication

External Current

Fixed Rate 100%Fixed Rate 100%

Straight PulseStraight Pulse

Pulse Storage option

Pulses Pulses :

Pulse Storage option

Pulse Storage option

Pulse-Store 9999Pulse-Store 9999

999999

:

999999 Store 999 Store 999

x999/999x999/999

x999 Store 9999x999 Store 9999

4-20 mA

20-4 mA

Ratio option

Ratio option

4-20mA Signal4-20mA Signal

4-20 Ratio 100%4-20 Ratio 100%

20-4mA Signal20-4mA Signal

20-4 Ratio 100%20-4 Ratio 100%

15

Count Strokes

Count 9999/9999Count 9999/9999

Timed Interval

OUTPUT RELAY OPTIONS

Relay Off

Stop Function

Current Signal Loss

Full Count

External Pulse Overflow

Repeat Strokes

Circuit Failure

999m Every 999h999m Every 999h

Relay OffRelay Off

Relay-StopRelay-Stop

Relay-No SignalRelay-No Signal

Relay-Full CountRelay-Full Count

Relay-OverflowRelay-Overflow

Relay-RepeatRelay-Repeat

Relay-FailureRelay-Failure

ALARMS (full flashing display)

Circuit Failure

Signal Loss

Full Count

Pulse Overflow

Pulse Rate High

Circuit FailureCircuit Failure

Signal LossSignal Loss

Full CountFull Count

Pulse OverflowPulse Overflow

Pulse Rate HighPulse Rate High

START UP AND OPERATION

16

17

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 pumphead (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. 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.

2. Adjust the stroke length knob to the 100% setting mark (for more information see “Stroke Length Adjustment”
on the following page).

3. 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 pumphead before the pump will pump against pressure.

A) While pump is running, turn adjustment screw counter-

clockwise.

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.

Air Bleed Operation:

C) Close air bleed valve by turning adjustment screw

clockwise.

4. Chemical should reach the pumphead 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.

5. If the pump continues to refuse to prime, refer to Troubleshooting Section of these instructions.

18

6. Turn the power on once more and adjust the pump flow to the desired rate (see “Controlling Procedure” below).

7. Always check the calibration of the pump after start-up. It’s best to calibrate the pump under your typical use
conditions.

STROKE LENGTH ADJUSTMENT

M Stroke length can be controlled within 0 to 100% of the

diaphragm displacement. (It should be controlled within 20
to 100% for practical use.)

M 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) Set the stroke length to 100%. Measure the output capacity.
B) 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.

Example Selected Model = LMD4
Set Stroke Length = 100%
Set Stroke Rate = 100%
Output Capacity = 21 GPD*

(Rated Pressure)

Desired Flow = 17 GPD
Adjust Stroke Rate to 81%
Output Capacity = 17 x 100 = 81% (approx.)*

21

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.

OPERATION BY EXTERNAL INPUT SIGNALS:

19

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 multicontact control relay or similar means.

M 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 multicontact control relay or similar means.

M 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.

M 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 accomodated 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).

MAINTENANCE

20

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%):

The signal cord is provided with the pump and has the following polarity:

White = Positive (+)
Black = Common

Signal input impedance is 187 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.

21

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 Current Power
mimimum = 12 VAC, 50/60 HZ minimum = 10 mAmps minimum = .12 watts (at 12 VAC)
maximum = 250 VAC, 50/60 HZ maximum = .5 Amps 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.

22

: 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 160°F (70°C)]

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 short-term 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 pumphead 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 pumphead screws and then remove the pumphead

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). Don’t 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 Teflon 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.

DIAPHRAGM REPLACEMENT

23

Refer to drawings in the back of the manual.

1. When replacing the diaphragm, it’s 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 pump’s wet end. All your supplier
needs to know is the “KOPkit No.” on your pump’s
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 unit’s 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 pumphead

onto the adaptor with valve flow arrows pointing up and install and tighten pumphead screws. Tighten screws
until pumphead 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 pumphead.

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 pumphead is SAN material.

5. Reconnect tubing or piping and reinstall the pump.

6. Check for leaks around newly installed fittings.

24

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE REMEDY

1. Pump setting too low 1. Adjust to higher setting (pump must be operating during
the stroke length adjustment).

LOSS OF 2. Scale at injection point 2. Clean injection parts with 8% muriatic acid or undiluted
CHEMICAL vinegar. Also, see Maintenance Section).
RESIDUAL

3. Solution container allowed 3. Refill the tank with solution and prime. (See Start-Up

to run dry and Operation Section).

1. Pump setting too high 1. Lower pump setting (pump must be operating to adjust
stroke length knob).

TOO MUCH 2. Chemical in solution tank 2. Dilute chemical solution. NOTE: For chemical that
CHEMICAL too rich reacts with water, it may be necessary to purchase a

more dilute grade of chemical direct from chemical
supplier.

3. Siphoning of chemical into 3. Test for suction or vacuum at the injection point. If

well or main line suction exists, install an anti-siphon valve.

1. Worn tube ends 1. Cut off end of tubing (about 1") and then replace as

LEAKAGE before.
AT TUBING
CONNECTIONS 2. Chemical attack 2. Consult your seller for alternate material.

1. Leak in suction side of pump 1. Examine suction tubing. If worn at the end, cut

2. Valve seats not sealing 2. Clean valve seats if dirty or replace with alternate

approximately an inch off and replace.

material if deterioration is noted.

3. Low setting on pump 3. When pumping against pressure, the dial should be set
above 20% capacity for a reliable feed rate.

FAILURE 4. Low solution level 4. Solution must be above foot valve.
TO PUMP

5. Diaphragm ruptured 5. Replace diaphragm as shown in the “Maintenance

6. Pumphead cracked or broken 6. Replace pump head as shown in “Maintenance Section.”

7. Pumphead contains air or 7. Bleed pump head, see “Air Bleed Operation.”

chlorine gas

8. Breakdown or disconnection 8. Connect wiring properly. Check fuse or circuit breaker.

of wiring

9. Voltage drop 9. Take measures after investigation of cause.

10. Malfunction of electronic 10. Contact supplier.

control board

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.

Make sure fittings are hand tight only. Using pliers
and wrench can crack pump head. Also, chemical
incompatibility can cause cracking and subsequent
leakage.

25

PROBLEM PROBABLE CAUSE REMEDY

1. Dirty check valve 1. Remove and replace or clean off any scale or sediment.

PUMP 2. Ball checks not seating or 2. Check seat and ball checks for chips, clean gently. If
LOSES not sealing properly deformity or deterioration is noted, replace part with
PRIME proper material. Resulting crystals can hold check

3. Solution container allowed 3. Refill the tank with solution and prime. (See Start-Up
to run dry and Operation Section).

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).

4. Chemical Outgassing 4. Bleed gas, use flooded suction, maintain chemical at room

1. Loose fittings 1. Tighten hand tight. Replace gasket if hand tight does

temperature (approx. 20KF / -6KC).

not stop leakage

LEAKAGE

AT FITTING 2. Broken or twisted gasket 2. Check gaskets and replace if broken or damaged.

3. Chemical attack 3. Consult your pump supplier for alternate material.

1. Too much pressure at 1. Turn off all pressure valves, loosen outlet tubing
discharge connection at discharge point. Remove discharge valve

2. Check valves not sealing 2. Disassemble, loosen, clean and check for deterioration

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.

PUMP WILL swelling. Reassemble and wet the valve assembly,
NOT PRIME then prime. See Start-Up and Operating Section.

3. Output dials not set at 3. Always prime pump with output dial set at maximum
maximum rated capacity.

4. Suction lift height too much 4. Decrease suction lift or pull vacuum on pump discharge

5. Pump equipped with spring 5. Loosen discharge valve to aid in priming, take necessary
loaded high viscosity valves safety precautions. Or apply vacuum to pump discharge.

until pump is primed.

26

272829

Specifications

Pressure, MAX, PSI/BAR
@ GPD/GPH/LPD

Capacity, MAX, GPD/GPH/LPD
@ PSI/BAR

Reproducibility, % MAX Capacity 2
Viscosity, MAX, CPS (1) 1000
Suction Lift @ 1 CPS, MAX, FT/M

@ 3000 CPS
Controls 6-Station Membrane Switch

Status Display

LED Indicator Lights,
Panel Mount

Stroke Frequency, MAX, SPM 125
External Stroke Frequency Control,

(Automatic)
Stroke Frequency Turn Down Ratio 100:1
Stroke Length Turn Down Ratio 10:1

300/20
3/.13/11

500/20.8/1890
20/1.4

10/3.1 (once primed)

3.5/1.1

16-Position LCD Dot Matrix
Backlight

Power On - Green
Pulsing - Green Flashing
Stop - Red

4-20 mADC, 20-4 mADC
External Pacing

Output Relay (Signal Level Option) 24 VDC, 10 mA
Output Relay (Power Option) 250 VAC, 50/60 HZ, .5A

Power Input

Current Draw @ 115 VAC, AMPS 1
Average Input Power @MAX SPM, Watts 130

Circuit Board Protection Circuit Breaker (Panel Mount)

Temperature, MAX, F/ C

- Environmental (Shaded) 104/40

Connections - Tubing (Suction & Discharge)
.
.
. - Piping (Suction & Discharge)

115 VAC/50-60HZ/1ph
230 VAC/50-60HZ/1ph

.25" ID X .38" OD
.38" ID X .50" OD
.50" ID X .75" OD
.25" FNPT
.50" FNPT

30

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 pumphead 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.

31

Keep-On-Pumping kits that can save you time and money!

The manufacturer has
built a reputation for
superior reliability by
supplying carefully­designed, high-quality
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, you’ve 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
troubleshooter’s 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.

i

L9404500-000
F/9

PRINTED IN U.S.A.