Walchem EW-F series, EK series Instruction Manual

EW-F & EK Series

Electronic Metering Pump

Instruction Manual

W A L C H E M

EW-F & EK Series Metering Pumps

Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA

IWAKI America Inc.

TEL: 508-429-1110 FAX: 508-429-7433 WEB: www.walchem.com

Notice

Proprietary Material

The information and descriptions contained herein are the property of WALCHEM. Such information and descriptions may not be copied or reproduced by any means, or disseminated or distributed without the express prior written permission of WALCHEM.

This document is for information purposes only and is subject to change without notice.

Statement of Limited Warr a nty

WALCHEM warrants equipment of its manufacture and bearing its identification to be free from defects in workmanship and material for a period of two years from date of delivery from the factory or authorized distributor under normal use and service and otherwise when such equipment is used in accordance with instructions furnished by WALCHEM and for the purposes disclosed in writing at the time purchased, if any. WALCHEM’s liability under this warranty shall be limited to replacement or repair, F.O.B. Holliston, MA U.S.A. of any defective equipment or part which, having been returned to WALCHEM, transportation charges prepaid, has been inspected and determined by WALCHEM to be defective.

THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EITHER EXPRESS OR IMPLIED, AS TO DESCRIPTION, QUALITY, MERCHANT-ABILITY, FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR ANY OTHER MATTER.

P/N E00118.P

Sept 2014

TABLE OF CONTENTS

Thank you for choosing a Walchem E-Class metering pump. This instruction manual deals with the correct installation, operation, maintenance and troubleshooting procedures for the EW and EK model metering pumps. Please read through it carefully to ensure the optimum performance, safety and service of your pump.

1.0 INTRODUCTION ........................................................................................................... 1

1.1 Safety and Caution Notes .......................................................................................... 1

1.2 Principle of Operation ................................................................................................ 1

1.3 Model Code ............................................................................................................... 2

1.4 Specifications ............................................................................................................ 3

1.5 Dimensions ................................................................................................................ 4

2.0 INSTALLATION ............................................................................................................ 7

2.1 Unpacking ................................................................................................................. 7

2.2 Location ..................................................................................................................... 7

2.3 Supply Tubing............................................................................................................ 8

2.4 Discharge Tubing ...................................................................................................... 9

2.5 Installing Injection/BackPressure Valve ................................................................... 10

2.6 Electrical .................................................................................................................. 10

3.0 OPERATION ............................................................................................................... 11

3.1 Pump Operation & Programming ............................................................................. 11

3.2 External Inputs & Outputs ........................................................................................ 13

3.3 Adjustment .............................................................................................................. 16

3.4 MultiFunction Valve Operation ................................................................................. 17

3.5 Auto Air Vent Valve Operation ................................................................................. 18

3.6 Priming .................................................................................................................... 18

3.7 Calibration ............................................................................................................... 19

3.8 AC Power Interruption ............................................................................................. 19

4.0 MAINTENANCE .......................................................................................................... 20

4.1 Diaphragm Replacement ......................................................................................... 20

4.2 Valve Replacement ................................................................................................. 20

4.3 Tubing ..................................................................................................................... 20

5.0 EXPLODED VIEW & PARTS GUIDE .......................................................................... 21

6.0 TROUBLESHOOTING ................................................................................................ 32

7.0 SERVICE POLICY ...................................................................................................... 32

1.0 INTRODUCTION

1.1 Safety and Caution Notes

Always wear protective clothing, eye protection and gloves before working on or near a metering pump. Follow all recommendations of the supplier of the solution being pumped. Refer to the MSDS from the solution supplier for additional precautions.

Walchem E-Class metering pumps should be installed where ambient temperatures do not exceed 122°F (50°C) or do not fall below 32°F (0°C). Pumps should always be shielded from direct exposure to the elements. Black UV resistant tubing should be used if the tubing is exposed to strong UV radiation (sunlight/lamps). The EK Series is specifically designed to withstand the elements and can be mounted directly outdoors within the temperature specfications. To protect and maintain the IP rating of the pump, the clear covers that protect the electronic controls MUST be left in a secured/tightened condition at all times other than during adjustment of the pump.

WARNING Risk of electrical shock! This pump is supplied with a grounding conductor and grounding-type attachment plug. To reduce the risk of electrical shock, be certain that it is connected only to a properly grounded, grounding type receptacle with ratings conforming to the data on the pump data plate. Prior to performing any maintenance on a pump, disconnect the pump from the electrical power source.

Plumbing Precautions

All tubing must be securely attached to the fittings prior to starting the pump (see Section 2.3). Only use Walchem tubing with your pump. Tubing should be shielded to prevent possible injury in case of rupture or damage. UV resistant tubing should be used if the tubing is exposed to UV light. Always adhere to local plumbing codes and requirements. Be sure that the installation does not constitute a cross connection. Walchem is not responsible for improper installations. Prior to performing any maintenance on a pump, depressurize the discharge tubing.

If you are pumping downhill or into little or no system pressure, a back pressure/anti-syphon device must be installed to prevent over-pumping. Contact your Walchem distributor for additional information.

Solution Compatibility

CAUTION! This pump has been evaluated for use wit h water only. The suitability of this

pump for use with liquids other than water, such as acid and alkaline, is the responsibility of the user. For liquids other than water, select the best-suited liquid end material combination using a chemical com p atib il ity chart.

1.2 Principle of Operation

The E-Class electronic metering pumps consist of a pump unit, a drive unit, and a control unit. The drive unit is an electromagnetic solenoid. When the solenoid coil is energized by the control unit the armature shaft moves forward due to the magnetic force of the solenoid. The shaft is attached to a PTFE faced diaphragm which is part of the pump unit. The diaphragm is forced into the pump head cavity decreasing volume and increasing pressure which forces liquid in the pump head out through the discharge check valves. When the solenoid coil is deenergized, a spring returns the armature to its starting position. This action pulls the diaphragm out of the head cavity increasing volume and decreasing pressure. Atmospheric pressure then pushes liquid from the supply tank through the suction check valves to refill the pump head.

1.3 Model Code

EW B16 F 1 - VC A

1 2 3 4 5 6

1 Pump Series

EW IP 65 electronic metering pump with external pulse control or manual

speed control (adjustable to 360 strokes per minute) and manually adjustable stroke length. (Turndown ratio 1800:1.)

EK IP 67 aggressive environment rated electronic metering pump with

external pulse control or manual speed control (adjustable to 360 strokes per minute) and manually adjustable stroke length. (Turndown ratio 1800:1.)

Capacity/Pressure Rating (See Section 1.4 for detailed chart.)

3 Control Module

For use on all EW models, features digitally adjustable speed and

external pulse input control, stop & pre-stop inputs R For use on all EK models, features external pulse input control and stop

input.

4 Voltage

1 115 VAC, 50/60 Hz 2 230 VAC, 50/60 Hz

5 Liquid End (See Section 1.4 for detailed chart.)

6 Options

A Auto Air Vent Valve is supplied in place of the manual air vent valve.

Available for B11, B16, C16 and C21 sizes with -VC liquid ends only.

M Multifunction Valve is supplied in place of the manual air vent valve.

Available for the EW and EK 11-21 sized pumps with VC, VE, VF, PC, and PE liquid ends. Not available with the AAVV feature.

H High Pressure pump configuration available with EW–PC and –PE

liquid ends only. High Pressure pump maximum speed is 240 SPM.

Size

Maximum

Output Capacity

Output

per Stroke (mL)

Maximum Pressure1

Tubing O.D

(Gal/hr)

(mL/min)

Min.

Max.

PSI

MPa

B11

0.6

0.03

0.11

150

1.0

3/8

B16

1.0

0.04

0.18

105

0.7

3/8

B21

1.8

115

0.07

0.32

0.4

3/8

B31

3.3

210

0.12

0.58

0.2

1/2

C16

1.3

0.05

0.22

150

1.0

3/8

C16-H

0.6

0.03

0.17

250

1.7

⅜ (suc) x ¼ NPT (dis)

C21

2.3

145

0.08

0.40

105

0.7

3/8

C31

4.3

270

0.15

0.75

0.35

1/2

C362

6.7

420

0.24

1.17

0.2

1/2

Liquid End

Code

Pump Head

& Fittings

Diaphragm

Valve

Balls

Valve

Seat

Valve Seals

Gasket

Tubing

GFRPP

FKM

GFRPP

EPDM

PVC

FKM

PVC

EPDM

PVC

PTFE

EPDM

PVDF

FKM

PVDF

PCTFE

PTFE

¼” NPTF

1.4 Specifications

Electrical 50/60 Hz, single phase

EWB/EKB 115 VAC±10% 0.8 Amp max. 20 watt avg.

230 VAC±10% 0.4 Amp max. 20 watt avg.

EWC/EKC 115 VAC±10% 1.2 Amp max. 22 watt avg.

230 VAC±10% 0.6 Amp max. 22 watt avg.

Operating Conditions

Ambient temperature 32°F to 122°F (0°C to 50°C) Relative humidity To 85% (EW) / 95% (EK) non-condensing Liquid temperature 32° to 104°F (0 to 40°C) for PVC based liquid ends

32° to 140°F (0 to 60°C) for PP, PVDF, SS based liquid ends

Below 32°F (0°C), pump is limited to 70% of max. pressure. Liquid cannot freeze.

Capacity/Pressure Rating

Connection

Size (in)

Auto Air vent valve reduces maximum pressure approx. 35 PSI (0.2 MPa)

Output of the EW/EKC36-TC/FC/SH is 6.3 GPH (400 ml/min)

Adjustment Range

Stroke length adjustment range 20% to 100%

Frequency adjustment range 0 to 360 strokes per minute

Materials of Construction

PTFE

(bonded to

EPDM)

PTFE

CE Alumina ceramic PE Polyethylene

EPDM Ethylene propylene diene monomer PTFE Polytetrafluoroethylene FKM Fluoroelastomer PVC Polyvinylchloride ( translucent) GFRPP Glass fiber reinforced polypropylene PVDF Polyvinylidenefluoride HC Hastelloy C276 SS 316 stainless steel PCTFE Polychlorotrifluoroethylene

EW-31 and 36 Models with thermoplastic liquid ends

Notes:

(10.14”)(3.02”)

1.50”

(10.45”)

(2.65”)

4.92”

(0.96”)

4.17”

3.15”

0.59”

0.79”

0.59”

1.57”

4.57”

3.94”

0.24”

ø3/8” X ø1/2”

TUBING (ID x OD)

ø3/8” X ø1/2”

(7.17”)

(8.43”)

3.94”

(0.70”)

0.39”

Notes:

4.92”

4.57”

3.94”

0.24”

3.15”

4.17”

0.59”

0.79”

0.59”

1.5

7”

ø1/4” x ø3/8”

TUBING (ID X OD)

ø1/4” x ø3/8”

(1.46”)

(10.02”)

(3.02”)

(10.45”)

(2.65”)

(0.89”)

0.39”

(1.42”)

3.94”

(6.30”)

(7.64”)

(See Note 1)

(See Note 2)

(See Note 3)

1.5 Dimensions

EW-11,16 and 21 Models with thermoplastic liquid end materials

1. Addition of a Multifunct ion valve increases overal l length by 0.37”. Addition of an Auto Air Vent Valve increases overall length by 1.59”

2. Addition of a Multifunction Valve increases discharge height by 0.22”. No change for the Auto Air Vent Valve.

3. Addition of a Multifunction Valve increases overall liquid end height by 1.16”. No change for the Auto Air Vent Valve.

4. All dimensions in inches.

1. All dimensions in inches.

(3.02”) (10.77”)

(2.20”)

(10.45”)

(2.65”)

4.92”

(0.89”)

TUBING (ID x OD) ø1/4” x ø3/8”

THREAD 1/4” NPT

(7.64”)

(6.30”)

3.94”

(1.42”)

0.39”

4.57”

3.94”

0.24”

1.57”

0.59”

0.79”

3.15”

4.17”

Notes:

(9.15”)

(3.02”)

(0.59”)

(10.45”)

4.92”

(2.65”)

(0.85”)

ø4

NPT 1/4”

0.39” (1.73”)

3.94” (6.10”)

(7.91”)

NPT 1/4”

4.17”

3.15”

1.57”

0.59”

0.79”

0.59”

4.57”

3.94”

0.24”

(See Note 2)

(See Note 3)

(See Note 4)

(See Note 5)

EW-SH Models (EWB11,21/C21 shown below. See notes for changes in dimensions with other sizes)

1. All dimensions in inches.

2. (0.91”) for EWC31 and 36 sizes.

3. (1.34”) for EWC31 and (1. 24”) for EWC36.

4. (6.57”) for EWC31 and (6. 67”) for EWC36.

5. (8.34”) for EWC31 and (8. 48”) for EWC36.

EW-HP Models

1. All dimensions in inches.

Notes:

(SEE NOTE 1)

(SEE NOTE 3)

(SEE NOTE 2)

10.14"

1.46"

9.61"

8.27"

5.91"

3.39"

0.51"

0.91"

5.71"

7.78"

4.80"

3.94"

0.24"

3.15"

4.33"

0.31"

1.77"

ø1/4" x ø3/8"

OUT

AIR

10.33"

1.50"

ø3/8"

x ø1/2"

ø3/8" x ø1/2"

5.71"

1.06"

7.78"

0.51"

2.68"

5.91"

9.14"

10.40"

4.80"

3.94"

1.77"

0.67"

0.79"

0.67"

0.79"

0.31"

0.24"

3.15"

4.33"

EK-11,16 ands 21 Models with the r moplastic liqui d en d ma ter ials

EK-31 and 36

Models with thermoplastic liquid ends

1. Addition of a Multifunct ion valve increases overal l length by 0.37”. Addition of an Auto Air Vent Valve increases overall length by 1.59”

2. Addition of a Multifunct ion Valve increases discharge height by 0.22”. No change for the Auto Air Ven t Valve.

3. Addition of a Multifunction Valve increases overall liquid end height by 1.16”. No change for the Auto Air Vent Valve.

4. All dimensions in inches.

1. All dimensions in inches.

Figure 3

Figure 2

Figure 1

2.0 INSTALLATION

2.1 Unpacking

Open the shipping carton and inspect contents for damage. If any items are missing or damaged contact your local distributor.

Pumps are pre-primed with water at the factory. If the application is not compatible with water, drain and dry before use. Be sure to remove caps from fittings before attaching tubing.

CAUTION: Head bolts may have loosened during storage or shipment. Be sure to check and tighten to 19 lb-in torque, if necessary.

2.2 Location

Choose a location for the pump which is clean, dry, vibration-free, close to an electrical outlet, and allows convenient access to stroke length control, frequency control, and tubing connections. Avoid areas where ambient temperature exceeds 122°F (50°C) or falls below 32°F (0°C). Pumps should always be shielded from direct exposure to the elements. Black UV resistant tubing should be used if the tubing is exposed to strong UV radiation (sunlight/lamps).

The EK Series is specifically designed to withstand the elements and can be mounted directly outdoors with in th e temperature spe c if ications.

This pump is cord connected and not intended for permanent mounting to a building structure. However, temporary mounting to stabilize the pump during operation may be necessary as long as tools are not required for the installation or removal of the pump.

Flooded suction (mounting the pump below the level of liquid in the supply tank) is strongly recommended, especially when pumping liquids that readily generate gas bubbles. Sodium hypochlorite and hydrogen peroxide are common examples of such liquids. (See Figure 1.)

If flooded suction mounting is not possible, a shelf adjacent to (but not directly above) the supply tank often works well. (See Figure 2.) The supply tank or cover can also be used if it has provisions for mounting a pump. (See Figure 3.) In any case, the total suction lift should not exceed 5 ft (1.5m).

Flooded Suction

Recommended for

liquids that out-gas

Shelf Mount

Tank Mount

Figure 4

Foot

PVC Pipe Tubing

(user

Air Gap

Return

Point of

Injection

Valve

Coupling

Coupling Nut

(Air Vent

Coupling

2.3 Supply Tubing

The supply tubing run should be as short as possible. For flooded suction mounting, install a shut-off valve with an appropriate tubing connector at the tank outlet. Cut a length of tubing from the coil supplied and install between the shut-off valve and the pump inlet fitting. For suction lift applications, slide on the ceramic weight, then install a foot valve on one end of suction tubing. Cut the tubing to a length such that the foot valve hangs vertically about 1 in (25mm) above the bottom of the tank. Avoid any loops in the tubing run that could form a vapor trap. Running the tubing through a length of pipe will help to keep tubing straight. Total vertical suction lift should be no more than 5ft. (1.5m). Reference Figure 4.

Attach tubing as shown in Figure 5. First slide the coupling nut, small end first, onto the tubing. Push the tubing over the valve housing tip all the way to the valve housing shoulder. (Tip: if th e tubing is stiff from cold, dip the tubing end in hot tap water for a few minutes so it will slide on and flare out more easily. Push the coupling nut onto the threads. Apply some pressure on the coupling nut and tubing while tightening the nut, making sure the tubing has not backed off of the shoulder of the valve housing.

WARNING: All fittings and coupling nuts should be tightened by hand only. If necessary, a small tool may be used to make it snug. DO NOT use excessive force or large wrenches.

The coupling nut should not bottom out completely against the fitting. If this happens during connection, either the tubing has slid down the shoulder while tightening, or the tubing has been pinched. Remove the coupling nut, re-cut the tubing and re-connect.

Connecting Tubing

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Walchem EW-F series, EK series Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual