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

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.

2

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.)

2

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

3 Control Module

F

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.

3

Size

Maximum

Output Capacity

Output

per Stroke (mL)

Maximum Pressure1

Tubing O.D

(Gal/hr)

(mL/min)

Min.

Max.

PSI

MPa

B11

0.6

38

0.03

0.11

150

1.0

3/8

B16

1.0

65

0.04

0.18

105

0.7

3/8

B21

1.8

115

0.07

0.32

60

0.4

3/8

B31

3.3

210

0.12

0.58

30

0.2

1/2

C16

1.3

80

0.05

0.22

150

1.0

3/8

C16-H

0.6

40

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

50

0.35

1/2

C362

6.7

420

0.24

1.17

30

0.2

1/2

Liquid End

Code

Pump Head

& Fittings

Diaphragm

Valve

Balls

Valve

Seat

Valve Seals

Gasket

Tubing

PC

GFRPP

CE

FKM

PE

GFRPP

CE

EPDM

VC

PVC

CE

FKM

VE

PVC

CE

EPDM

VF

PVC

PTFE

EPDM

TC

PVDF

CE

FKM

FC

PVDF

CE

PCTFE

PTFE

SH

SS

HC

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)

1

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

2

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

PE

4

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.

5

(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

OD

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.

6

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"

IN

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.

7

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

8

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

9

Valve Housing Shoulder

Coupling Nut

Tubing

Figure 6

Figure 5

"AIR"

"OUT"

Drains back to tank

Discharges to injection point

WARNING: If there is any leakage around the coupling nut and it appears to have been

installed correctly, DO NOT TIGHTEN the coupling further! Release pressure in the line, disconnect tubing, re-cut and re-connect. Tightening of misinstalled tubing may cause the tubing to pop off under pressure.

2.4 Discharge Tubing

Cut a length of tubing long enough to go from the pump to the application (injection) point. Additional tubing can be ordered from your distributor. Avoid sharp turns or bends and hot surfaces. Routing tubing through rigid pipe such as PVC pipe is recommended for long runs and/or as protective shielding against corrosive chemicals. If applicable, install the injection valve in 1/2” NPT thread at the injection point (see section 2.5) and connect the discharge tubing to the injection valve.

Attach tubing as described in section 2.3 and as shown in Figures 5 and 6. Note: Some models have an air vent valve with two outlet connections. The connection marked ‘OUT’ is the discharge side to the application point. (Fig 6). Attach a second length of tubing to the air vent side marked (‘AIR’) and route back to the chemical solution tank or drum. On the larger pumps (31 & 36 sizes), the air vent valve connections are not marked, however, the discharge side is the vertical (UP) connection and the air vent connection is on the side of the valve.

Attaching the Tubing

Air Vent Valve Tubing

10

Figure 7

Trim back as needed to fit tee or fitting

Injection/Back Pressure Valve

2.5 Installing Injection/BackPressure Valve

A fitting or tee with 3/8” or 1/2” NPTF threads and with sufficient depth will accept the injection valve assembly. If required, trim off an amount of the extension tip until it fits into the fitting or tee. (Fig. 7.)

The position of the injection/back pressure valve can be at any orientation as long as the spring is retained in the valve. DO NOT REMOVE THE SPRING. Be sure to check and replace the spring as needed. Attach the tubing following the same instructions in section 2.3, connecting the supply tubing.

CAUTION: Some chemicals may have reactions as they are injected into the main flow. For example, sulfuric acid may react with water causing excess heat. If the chemical is heavier than water, mount the injection valve as close as possible to vertical coming into the bottom of the pipe. This will keep the injection nozzle facing up and keep the heavier chemistry from draining into the pipe and causing adverse reactions within the injection valve and pipe.

In addition to preventing backflow from pressurized lines, the injection valve acts somewhat as a back pressure valve when pumping into open atmosphere type applications. However, the back pressure by the injection valve is very low and can vary. The output of the metering pumps is rated at maximum back pressure and will increase as back pressure decreases dependent on the specific installation. Additionally, the valve does NOT act as an anti-siphon valve. If siphoning is a possibility, or if pumping downhill into open atmosphere (open tank), a Walchem MultiFunction valve or a separate back pressure/anti-siphon valve must be installed.

Note: Siphoning can also occur at the tip of the injection valve because of the high flow rate in the main pipe flowing past the small injection nozzle (venturi effect). In this case, an antisiphon device must be installed to avoid over feeding or siphoning of chemistry.

2.6 Electrical

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.

CAUTION! The electronics within the pump can be damaged by excessive surges in voltage. Do not install the pump near high-power electrical equipment that generate high surge voltages. Avoid branch circuits that also supply power to heavy or other equipment that could generate electrical interference. If necessary, install a surge suppression device (such as a varistor with a resistance greater than 2000A) or a noise reducing transformer at the pump’s power connection.

Injection Valve

11

360

Power ON

EXT

360

T-5

Set mode

+

UP stroke rate

DOWN stroke rate

EXT operation display

Operating at max spm while both keys are pressed.

MANUAL operation display

UP stroke rate

DOWN stroke rate

Setting display

MOVES to next menu

SCROLL thu choices

DISPLAY

UP Key

DOWN Key

3 6 0

ON

STOP

STOP/START Key

ON LED

STOP LED

3.0 OPERATION

3.1 Pump Operation & Programming

The EW an EK pumps have a digital display, two LED indicators and three pushbutton keys to change the pump speed and programming.

Manually stops and starts the

pump. Used with Up/Down

keys for programming and

mode selection.

Indicates AC power to the

pump and goes off and on

with each pump stroke.

A. Operation Overview

Operating condition and programming is displayed

ORANGE when Pre-Stop signal is input (EW only). RED when a START/STOP signal is input

Increases numeric values. Used with Start/Stop key to change the programs.

Decreases numeric values. Used with Start/Stop key to set the pump to operate in EXT mode.

12

3 6 0

Initial

Power U p

WAIT MODE

Increases Stroke Rate

Decreases Stroke Rate

Stop/Start

MANUAL RUN MODE

Increases Stroke Rate

Decreases Stroke Rate

Goes back to WAIT Mode

Stop/Start

EXTERNAL MODE

Holding the UP and DOWN

Down

+

Goes back to WAIT Mode

Stop/Start

PROGRAM MODE

Scrolls through the choices in the

Up

Goes back to WAIT Mode

Enters choic e and moves to next

3 5 2

EXT

+

B. Programming

Pressing the stop/start and up keys simultaneously will enter the program mode. The up and down keys scroll through the menus and choices and the stop/start key will exit back to the wait mode.

On-Time Menu

The first item displayed will be the factory set choice of the External Input On-Time menu (T-

5). There are three choices in this menu: T-5, T-20, and T-50 that can be scrolled through by repeatedly pressing the up key. These settings are time in milliseconds and correlate to the required minimum closure time of the external input signal for the pump to recognize it as a true signal. Selecting the smaller T-5 (5 msec) will allow shorter duration pulses to be recognized (typical for Hall Effect input), while the T-50 (50 msec) setting will help to reduce erroneous pulses from noise (as from a reed switch).

Stop Input NO/NC Selection

Pressing the down key will move from the Eternal Input On-Time menu to the Stop menu and the initial factory setting is M-OF (input is normally open and contact closure will stop the pump). Pressing the up key will toggle between M-OF and M-ON. Setting the pump to M-ON means that the pump will be stopped continuously and a contact closure into the stop/start input will now start the pump and the pump will run as long as the contact is made.

Pressing the down key will again move back to the On-Time menu and pressing the stop/start key will go back to the wait mode.

together in EXT mode will override external and manually run the pump at 360 SPM (priming).

Menu selection

T- 5

Menu selection

13

Figure 9

CONNECTOR 1: CONNECTOR 2:

1 3 4

2

1

5 3 4

2

Connector 1

Connector 2

*Note: The center pin i s marked as ‘5’ for

number ‘5’.

C. Pump Operation

Manual and On/Off Control

The pumps can be operated manually by pressing the stop/start key from the wait mode. Once pressed, the pump will begin to operate at the stroke rate shown on the display. From here, the up and down keys can be used to change the stroke rate, and the stroke length knob can be adjusted down to further reduce the pump output.

Once adjusted/calibrated to the desired flow rate, the pump can be left in manual mode for on/off control via power (connecting/disconnecting AC power from an external source) or for on/off control via the stop/start input. Pressing the stop/start key will go back to the wait mode.

External Control

Pressing the stop/start key and the down key simultaneously from the wait mode will set the pump to operate in external mode. In this mode, the pump will operate at a speed correlating to the frequency of digital inputs that it receives (see section 3.2 for wiring inputs). If used, the stop/start input will override the digital input signals.

If at any time in external mode the up and down keys are held down simultaneously, the pump will manually run at 360 SPM as long as the two keys are held down. This feature is useful for priming or the elimination of air trapped in the pump or tubing.

Pressing the stop/start key will disable external control and go back to the wait mode.

3.2 External Inputs & Outputs

The EW and EK pumps are capable of being controlled by an external pulse proportional input as well as being controlled by an external stop/start signal. Additionally, the EW pumps have two contact closure relay outputs – one output is ynchronous with the pump frequency and the other is tied to the external stop/start signal.

A. EW Pumps and the ‘F’ control module

Two circular mini-DIN female connecto rs are used to m ak e these connect ions. Figu re 9 shows the mating connections on the back of the pump. Connector 1 is a 5-PIN standard-key connector (P/N E90495) and Connector 2 is a 4-PIN reverse-key connector (P/N E90494).

PIN FUNCTION 1 Voltage In (24VDC max) 2 External Digital Input 3 Out 2 (Synchronous wit h stroke) 4 Out 1 (Stop output) 5* Common

PIN FUNCTION 1 Stop/Start Input 2 Pre-St o p Input 3 Not Used 4 Common

easy identification purposes t hroughout the manual. Actual marking on the part may be any capital letter ( mold cavity ID) or the

14

1

53 2

1 3 4

2

STOP I nput

Pre-STOP

Stop/

Contact

1

53 2

Sync

OR

EW

External Control

The external pulse input should not exceed 360 pulses per minute (6Hz) and the pump will output one stroke for every input pulse. The control signal can be a contact closure type switch (reed) with a max load of 1mA or a solid state device. If a solid state device is used, the external circuit should be capable of switching 5VDC at 1.2mA with an active duty cycle pulse width of 5ms to 100ms (actual closure time).

To connect the pulse input from an external device, wire PINs 2 and 5 from the contact closure. If using a solid state switching device, wire the connector ensuring that PIN 2 is positive (+) and PIN 5 is Common (-).

Stop/Start and Pre-Stop Control

The EW pumps have two stop inputs. The Pre-Stop is an external input

Input

that changes the green STOP LED to orange to signal a “LOW” condition. This input does not control the pump. An external Stop/Start signal, however, not only turns the STOP LED to red, but also controls the pump. In this mode, AC power is applied continuously, but the pump operation is stopped (or started – see section on programming) by completing the circuit between PIN 1 and PIN 4 in Connector 2. Both the Pre-Stop and Stop/Start signals can be a contact closure type switch (reed) with a max load of 1mA or a solid state device. If a solid state device is used, the external circuit should be capable of switching 5VDC at 1.2mA with an active duty cycle pulse width of 5ms to 100ms (actual closure time).

To connect the Pre-Stop input from an external device, wire PINs 2 and 4 from the contact closure. If using a solid state switching device, wire the connector ensuring that PIN 2 is positive (+) and PIN 4 is Common (-).

To connect the Stop/Start input from an external device, wire PINs 1 and 4 from the contact closure. If using a solid state switching device, wire the connector ensuring that PIN 1 is positive (+) and PIN 4 is Common (-).

Output Relays

The EW pumps have two output relays (non-isolated PNP transistors with a 330Ω resistance) in Connector 1. Output 1 is tied to the Stop/Start input and will activate when a Stop/Start input connection is made. Output 2 activates synchronously with the pump stroke rate.

Contact Closure Type Outputs

The EW circuit can make either the Stop/Start (Out 1) or the synchronous pulse (Out 2) function as contact closures, but ONLY ONE output can be used at a time. To use the synchronous pulse out, connect the positive side to PIN 1 and the negative side to PINS 3&5 (jumped together). To use the start/stop output, connect the positive side to PIN 1 and the negative side to PINS 4&5 (jumped together).

Closu r e Input

Connector 1

Pulse Input

Start

Input

15

Connector

Lock Nut

Connector

Gasket &

Cord Nut

4

5 6 +

+

Connector

PIN FUNCTION

Orientation

+

4

5

6

Connector

Digital

Stop/

Volta ge type

1

53 2

Sync

Power

PLC

EW

Voltage Input Type Outputs (Non-Contact Closure)

PIN 1 will take a voltage in from an external source (max 24VDC). When this external voltage is present, then both relays will independently switch the input voltage. Both outputs can be used simultaneously. The figure to the left shows a schematic with the output relays configured to switch the powered input. This setup can only be used with voltage input type circuits (not contact closure types) such as those commonly found in a PLC.

B. EK Pumps and the ‘R’ control module

One custom watertight connector is used for the digital input and stop/start connections on the EK pumps. There are no outputs on the EK pumps. The Connector Holder is keyed to fit into the pump only one direction. There is a set of painted alignment marks on the connector and connector holder that identify the correct orientation of the connector. Be sure to double check that the connector is installed properly into the connector assembly before installation onto the pump.

Input

Connector 1

OUT

Pulse

Input

Start

Input

Marks

4 External Digital Input 5 Stop/Start Input 6 Common

Holder

Adapter

Digital Control

The external pulse input should not exceed 360 pulses per minute (6Hz) and the pump will output one stroke for every input pulse. The control signal can be a contact closure type switch (reed) with a max load of 1mA or a solid state device. If a solid state device is used, the external circuit should be capable of switching 5VDC at 1.2mA with an active duty cycle pulse width of 5ms to 100ms (actual closure time).

To connect the pulse input from an external device, wire Terminal 4 and

Input

Terminal 6 from the contact closure. If using a solid state switching device, wire the connector ensuring that Terminal 4 is positive (+) and Terminal 6 is Common (-).

16

+

4

5

6

Connector

Stop/Start

Stop/Start Control

An external Stop/Start signal will turn the STOP LED to red and also control the pump. In this mode, AC power is applied continuously, but the pump operation is stopped (or started – see section on programming) by completing the circuit between Terminal 5 and Terminal 6. The Stop/Start signal can be a contact closure type switch (reed) with a max load of 1mA or a solid state device. If a solid state device is used, the external circuit should be capable of switching 5VDC at 1.2mA with an active duty cycle pulse width of 5ms to 100ms (actual closu re time).

To connect the Stop/Start input from an external device, wire Terminals 5 and 6 from the contact closure. If using a solid state switching device, wire the connections ensuring that Terminal 5 is positive (+) and Terminal 6 is Common (-).

3.3 Adjustment

A. EW Pumps using the ‘F’ Control Module

The pump will operate best keeping the stroke length at 100%. If less than full output is required, set the frequency to the approximate percentage of maximum desired. Example: Model EWB21F1-VC has maximum output of 1.8 GPH. Desired output is 1.2 GPH. 1.2 ÷ 1.8 = 0.667 or 67% Using the UP and DOWN arrows, set the frequency of the pump to

0.67 x 360 = 241 SPM.

For outputs less than 2% of maximum it will be necessary to also reduce the stroke length. (Minimum recommended stroke length is 20%.) It is good practice to change the frequency first, however, if low flows are required, a balanced turndown of speed and stroke length will yield the best results.

B. EK Pumps using the ‘R’ Control Module

The pump will operate best keeping the stroke length at 100%. If less than full output is required, set the frequency to the approximate percentage of maximum desired. Example: Model EKC21R1-VC has maximum output of 4.3 GPH. Desired output is 3.0 GPH. 3.0 ÷ 4.3 = 0.7 or 70% Using the UP and DOWN arrows, set the frequency of the pump to

0. 7 x 360 = 252 SPM.

For outputs less than 2% of maximum it will be necessary to also reduce the stroke length. (Minimum recommended stroke length is 20%.) It is good practice to change the frequency first, however, if low flows are required, a balanced turndown of speed and stroke length will yield the best results.

Input

17

Air Ven t

Drain

Pressure

release

knob

Liquid

Discharge

Port

Air Ven t

Adjustment

Knob

Lock

Nut

3.4 MultiFunction Valve Operation

The MultiFunction Valve is optional on select E-Class pumps and replaces the standard Manu al Air Vent Valve when ordered. It integrates the air venting/bleeding functions with a back pressure and anti-siphon valve.

Air Vent / Bleed Function

1. Open the air vent by turning the air vent adjustment knob counter-clockwise one to one and a half turns.

2. Operate the pump until all of the air is purged and only liquid is discharged from the air vent drain.

3. Turn the air vent adjustment knob clockwise until it bottoms out and will not turn further.

Back Pressure / Anti-Siphon Valve

1. A spring-loaded diaphragm automatically adds 30PSI of back pressure to the discharge side of the pump when the air vent adjustment knob is closed.

2. If back pressure is not observed, the pressure release knob may be in the release position (the knob is resting in its ‘up’ location). If this is the case, turn the knob clockwise until it ‘clicks’ down (approximately ¼ turn).

3. The diaphragm prevents siphoning of chemical through the pump.

Pressure Release

1. Stop the pump operation.

2. Turn the pressure release knob clockwise until it ‘clicks’ into the release or ‘up’ location

(approximately ¼ turn). If the knob is turned too far, it will ‘click’ again return to the back pressure or ‘down’ position. If this happens, keep turning the knob clockwise until it ‘clicks’ one time in the release (‘up’) position. Note: To avoid damage, do not turn the knob counterclockwise.

3. Turn the air vent adjustment knob counter-clockwise one or one and a half turns to release the

pressure in the discharge tubing/piping through the air vent drain. The air vent drain should always be plumbed back to the supply tank or to safe disposal. Do not submerge the air vent drain tubing under chemical in the supply tank.

CAUTION: Confirm that liquid is discharged from the air vent drain. If the liquid is not discharged, the pressure may not be released. If this is the case, repeat the Pressure Release procedure.

18

AAVV – Cross Sectional

Discharge to Process

Sleeve

Val v e

Suction

Gas Vent

Top Check Ball

and Seats

Access Knob

3.5 Auto Air Vent Valve Operation

The Auto Air Vent Valve is an option on select EW and EK pumps and replaces the standard Manual Air Vent Valve when ordered. It is used primarily in applications where gassing is a problem and pumps can lose prime.

Unlike the Manual Air Vent Valve, the Auto Air Vent Valve constantly bleeds a controlled amount of volume out of the “Air” vent. Therefore, the “Air” vent should always be plumbed back to the source tank. During priming, the access knob does not have to be loosened as with a manual air vent valve as pressure is relieved through the vent. The Top Valve Guide assembly uses a bottom seat to ensure that air is not introduced into the discharge media and utilizes a precisely machined top seat that allows air to be quickly purged but limits the amount of liquid returned to the tank. A sleeve valve is used to maintain backpressure within the pump head, which helps speed the purging of air.

3.6 Priming

Install the pump as described in Section 2.0. With the pump turned on, set stroke length at 100% and frequency to 360 SPM. If the pump is equipped with an air vent valve, open the knob 1/2 turn. Liquid should move up through the suction tubing and into the pump head. When liquid starts running through the vent side tubing, close the air vent knob and continue with output adjustment described below. If the pump has no air vent valve, disconnect the discharge tubing from the injection valve. When liquid enters the discharge tubing at the pump head, stop the pump. Then reconnect the discharge tubing to the injection valve.

If the pump does not self prime, remove the check valve housing on discharge & suction sides to make sure valve cartridges and gaskets are in correct positions (see section 4.2 for correct orientation).

Note: Pumps with FC liquid ends may need assistance if dry priming due to the hard valve seat material.

View

19

Figure 8 Calibration

3.7 Calibration

3.8 AC Power Interruption

If AC power is interrupted, the pump will power up as shown below:

State preceding power OFF

If exact output calibration is required, first prime and adjust the pump as above. Then connect a calibration column to the suction side of the pump. Turn the pump on for one minute and read the amount of liquid pumped from the column. Adjust the frequency up or down as necessary and check the output again. When the desired output is reached, disconnect the calibration column and reconnect the suction tubing. (See Figure 8.) Calibration must be performed with actual application equivalent back pressure for accurate results. Published flow rates are based on maximum pressures. Lower pressures may result in slightly higher flow rates.

State following power ON

WAIT WAIT Run Manual Run external

Run Manual Run external

20

CAUTION: Before working on the pump, disconnect the power cord, depressurize the

Always wear protective gear when working around chemicals.

CAUTION: There are many small

must be installed correctly for

FLOW

VALVE CARTRIDGE ORIENTATION

Valve Seat

Valve Guide

Valve Ball

4.0 MAINTENANCE

discharge tubing and drain or flush any residual liquid from the pump head and valves.

4.1 Diaphragm Replacement

Disconnect AC power to the pump and disconnect the suction tubing, discharge tubing, and air vent tubing. Remove the four head bolts with a 4mm or 5mm hex wrench. Turn the stroke length knob fully counter-clockwise. Unscrew the diaphragm and remove its retainer (small disk behind the diaphragm).

CAUTION: There may be small brass spacers between the retainer and the armature shaft.

These spacers need to be reused when replacing the diaphragm.

Install the new retainer and diaphragm on the shaft. Turn the diaphragm clockwise until it bottoms on the shaft. Use caution when handling the diaphragm – the PTFE surface can be damaged by tools, nails, or any sharp objects. Replace the pump head and tighten the head bolts to a torque of 19 lb-in (2.16 N-m).

4.2 Valve Replacement

Remove the suction and discharge tubing making sure discharge side has been depressurized. Remove the suction fitting, two valve cartridges, o-ring and gasket(s). Install the new o-ring, gasket(s) and valve cartridges. Be sure both valve seats are in the same orientation. Refer to Figure below. Tighten the suction fitting. Similarly remove and replace the discharge valve cartridges, o-ring and gasket(s). For a more detailed drawing, refer to the Section 6.0.

parts in the liquid end. These parts

proper operation of the pump.

4.3 Tubing

Check ends of tubing for splits, cracks, or thin spots. Examine the full length of tubing for damage due to chafing, abrasion, stress cracks, excessive temperature or exposure to ultraviolet light (direct sunlight or mercury vapor lamps). If any signs of deterioration exist, replace the entire length of tubing. It is a good idea to replace discharge tubing on a regular preventive maintenance schedule every 12 months.

21

C Entire Head Assembly

Manual Air

Auto Air Vent

4

23

26

25

14

11

13

12

11

13

12

19

17

1

17

14 11 13

12

11

13

12

3 4

ZZ

30

31

12

32

10

27

5

6

35

4

28

33 29

4

34

13

4

10

23

26

25

21

22

10

8

9

D

E

Part Numbers for these assem blies are on Page 30.

5.0 EXPLODED VIEW & PARTS GUIDE

PVC/GFRPP Liquid End Exploded View #1

For EW and EK pump model sizes 11, 16, and 21

Valve (Optional)

Vent Valve (Standard)

D Valve Cartr idge E Air Ve nt Valve

22

Item Part No Description Qty Size Liquid End Material

1 EH2015 Head, Pump, EW/EKB11, PVC 1 11 VC, VE, VF, VCA

EH2017 Head, Pump, EW/EKB11, GFRPP 1 11 PC, PE

EH1950 Head, Pump, EW/EK/EZ16, PVC 1 16 VC, VE, VF, VCA

EH1957 Head, Pump, EW/EK/EZ16, GFRPP 1 16 PC, PE

EH1951 Head, Pump, EW/EK/EZ21, PVC 1 21 VC, VE, VF, VCA

EH1958 Head, Pump, EW/EK/EZ21, GFRPP 1 21 PC, PE

3 EH0400 Housing, Valve, 3/8 PVC 1 11, 16, 21 VC, VE, VF, VCA

EH0418 Housing, Valve, 3/8 GFRPP 1 11, 16, 21 PC, PE

4 EH0401 Nut, Coupling, 3/8 PVC 3 11, 16, 21 VC, VE, VF, VCA

EH0419 Nut, Coupling, 3/8 GFRPP 3 11, 16, 21 PC, PE

5 EH0294 Fitting, Air Vent, PVC 1 11, 16, 21 VC, VE, VF, VCA

EH0315 Fitting, Air Vent, GFRPP 1 11, 16, 21 PC, PE

6 EH0295 Nut, Lock, Air Vent, P VC 1 11, 16, 21 VC, VE, VF, VCA

EH0316 Nut, Lock, Air Vent, GFRPP 1 11, 16, 21 PC, PE

*

8 EH1971 Diaphragm, EW/EK/EZ11 1 11 all

EH1972 Diaphragm, EW/EK/EZ16 1 16 all

EH1973 Diaphragm, EW/EK/EZ21 1 21 all

*

9 EH0059 Retainer, EW/EK/EZ11 1 11 all

EH0083 Retainer, EW/EK/EZ16 1 16 all

EH0067 Retainer, EW/EK/EZ21 1 21 all

10 EH0402 B ody, Manual Air Vent, PVC 1 11, 16, 21 VC, VE, VF

EH0420 Body, Manual Air Vent, GFRPP 1 11, 16, 21 PC, PE

EH0861 Body, Auto Air Vent, PVC 1 11, 16, 21 VCA

EH1406 Body, Multifunct ion Valve, PVC 1 11, 16, 21 VCM, VEM, VFM

EH1407 Body, Multifunct ion Valve, GFRPP 1 11, 16, 21 PCM, PEM

*

11 EH0060 Guide, Valve, 0.188 PVC 4 11 VC, VE, VF, VCA

EH0318 Guide, Valve, 0.188 GFRPP 4 11 PC, PE

EH0068 Guide, Valve, 0.250 PVC 4 16, 21 VC, VE, VF, VCA

EH1534 Guide, Valve, 0.250 GFRPP 4 16, 21 PC, PE

*

12 EH0061 Seat, Valve, 0.188 FKM 4 (5) 11 VC, PC (VCA)

EH0048 Seat, Valve, 0.188 EPDM 4 11 VE, PE, VF

EH0069 Seat, Valve, 0.250 FKM 4 16, 21 VC, PC

EH0071 Seat, Valve, 0.250 EPDM 4 16, 21 VE, PE, VF

*

13 EH0025 B all, Valve, 0.188 CE 4 (5) 11 VC, VE, PC, PE, (VCA)

EH0084 Ball, Valve, 0.250 CE 4 16, 21 VC, VE, PC, PE

E00063 Ball, Valve 0.188 PTFE 4 11 VF

E00064 Ball ,Valve 0.250 PTFE 4 16, 21 VF

*

14 EH0026 Gas ket, Valve, 0.188 & 0.250 PTFE 2 11, 16, 21 VC, VE, VF, VCA

EH0580 Gasket, Valve, 0.188 & 0.250 PTFE 2 11, 16, 21 PC, PE

*

17 EH0027 O-R ing, S14 FKM 2 11, 16, 21 VC, PC, VCA

EH0050 O-Ring, S14 EPDM 2 11, 16, 21 VE, PE, VF

19 EH1986 Bolt, M4 x 35 w/PW & SW, 316SS 4 11, 16, 21 all

21 E90374 Multifunction Valve Top Asm 1 11, 16, 21 all xxM ends

22 EH1410 Screw, M4 x 35 w/PW & SW, 316SS 4 11, 16, 21 all xxM ends

23 EH0299 Knob, Manual Air Vent Valve, PVC 1 11, 16, 21 VC , VE, VF

EH0321 Knob, Manual Air Vent Valve, GFRPP 1 11, 16, 21 PC, PE

*

25 EH0300 O-R ing, P4 FKM 1 11, 16, 21 VC, PC, VCA

EH0301 O-Ring, P4 EPDM 1 11, 16, 21 VE, PE, VF

*

26 EH0302 O-Ring, P10A FKM 1 11, 16, 21 VC, PC, VCA

EH0303 O-Ring, P10A EPDM 1 11, 16, 21 VE, PE, VF

*

27 EH0304 O-R ing, P7 FKM 1 11, 16, 21 VC, PC, VCA

EH0305 O-Ring, P7 EPDM 1 11, 16, 21 VE, PE, VF

28 EH0864 Fitting, Adapter, AAVV, PVC 1 11, 16, 21 VCA

29 EH0867 Fitting, AAVV, PVC 1 11, 16, 21 VCA

30 EH0774 Knob, AAVV, PVC 1 11, 16, 21 VCA

31 EH0862 Guide, Valve, AAVV, Titanium 1 11, 16, 21 VCA

E00080 Guide, Valve, AAVV, HC276 1 11, 16, 21 VCA-H

32 EH0775 Spacer, AAVV, PVC 1 11, 16, 21 VCA

*

33 EH0865 Tube, Valve, AAVV, FKM 1 11, 16, 21 VCA

*

34 EH0776 O-Ring, S12, FKM 1 11, 16, 21 VCA

35 EH0866 Gasket, AAVV, FKM 1 11, 16, 21 VCA

ZZ --------- Bra ss Spacers Drive specific/Reuse when replacing diaphra g m

*

Included in spare parts kit

Components

PVC/GFRPP Liquid End Exploded View #1

23

C Entire Head Assembly

14 11 13 12

11 13

12

17

19

1

17 14 11 13

12

11 13 12

3

4

ZZ

6

5

27

23

16

15

10

4

18

8

9

E

D

Part Numbers for these assem blies are on Page 30.

PVC/GFRPP Liquid End Exploded View #2

For EW and EK pump model sizes 31 and 36

D Valve Cartr idge E Air Ve nt Valve

24

Item Part No Description Qty Size Liquid End Material

1 EH1961 Head, Pump, EW/EK31, GFRPP 1 31 PC, PE

EH1960 Head, Pump, EW/EK31, PVC 1 31 VC, VE, VF

EH1962 Head, Pump, EW/EK36, GFRPP 1 36 PC, PE

EH1953 Head, Pump, EW/EK36, PVC 1 36 VC, VE, VF

3 EH0405 Housing, Valve, 1/2 PVC 1 31, 36 VC, VE, VF

EH0421 Housing, Valve, 1/2 GFRPP 1 31, 36 PC, PE

4 EH0406 Nut Coupling, 1/2 PVC 3 31, 36 VC, VE, VF

EH0422 Nut, Coupling, 1/2 GFRPP 3 31, 36 PC, PE

5 EH1078 Fitting, Air Vent, PVC 1 31, 36 VC, VE, VF

EH1088 Fitting, Air Vent, GFRPP 1 31, 36 PC, PE

6 EH1077 Nut, Lock, Air Vent, PVC 1 31, 36 VC, VE, VF

EH1087 Nut, Lock, Air Vent, GFRPP 1 31, 36 PC, PE

*

8 EH1974 Diaphragm, EW/EK/EZ31 1 31 all

EH1975 Diaphragm, EW/EK/EZ36 1 36 all

*

9 EH0087 R etainer, EW/EK/EZ31 1 31 all

EH0158 Retainer, EW/EK/EZ36 1 36 all

10 EH1101 Body, Manual Air Vent, PVC 1 31, 36 VC, VE, VF

EH1099 Body, Manual Air Vent, GFRPP 1 31, 36 PC, PE

*

11 EH0118 Guide, Valve, 0.375 PVC 4 31, 36 VC, VE, VF

EH0332 Guide, Valve, 0.375 GFRPP 4 31, 36 PC, PE

*

12 EH0119 Seat, Valve, 0.375 FKM 4 30. 35 VC, PC

EH0125 Seat, Valve, 0.375 EPDM 4 31, 36 VE, PE, VF

*

13 EH0120 Ball, Valve, 0.375 CE 4 31, 36 VC, VE, PC, PE

E00062 Ball, Valve, 0.375 PTFE 4 31, 36 VF

*

14 EH0121 Gasket, Valve, 0.375 PTFE 2 31, 36 VC, VE, PC, PE, VF

*

15 EH1080 O-Ring, P-3, FKM 1 31, 36 VC , PC

EH1083 O-Ring, P-3, EPDM 1 31, 36 VE, PE, VF

*

16 EH0029 O-Ring, P-6, FKM 1 31, 36 VC , PC

EH0052 O-Ring, P-6, EPDM 1 31, 36 VE, PE, VF

*

17 EH0122 O-Ring, P16 FKM 2 31, 36 VC, PC

EH0127 O-Ring, P16 EPDM 2 31, 36 VE, PE, VF

*

18 EH0027 O-Ring, S-14 FKM 1 31, 36 VC, PC

EH0050 O-Ring, S-14 EPDM 1 31, 36 VE, PE, VF

19 EH1986 Bolt, M4 x 35 w/PW & SW, 316SS 4 31 all

EH1988 Bolt, M5 x 35 w/PW & SW, 316S S 4 36 all

23 EH1079 Knob, Manual Air Vent, PVC 1 31, 36 VC, VE, VF

EH1089 Knob, Manual Air Vent, GFRPP 1 31, 36 PC, PE

*

27 EH1082 O-Ring, P-11 FKM 1 31, 36 VC, PC

EH1084 O-R ing, P-11, EPDM 1 31, 36 VE, PE , VF

ZZ --------- Brass Spacer s Drive specific/Reuse when replacing diaph ragm

*

Included in sp are parts kit

Components

PVC/GFRPP Liquid End Exploded View #2

25

C Entire Head Assembly

TC Only

FC Only

14

11

13

12

11

13

12

17

19

1

17

14

11

13

12

11

14 (FC only)

13

12

3

4

ZZ

4

23

26

25

10

27

5

6

3

4

6

5

27

23

16

15

10

4

18

8

9

D

PVDF Liquid End Exploded View #3

For all PVDF EW and EK Pump Models

31 and 36

11, 16, and 21

All sizes

D Valve Cartr idge E Air Ve nt Valve

Part numbers for these assemblies are on Page 30

26

Item Part No Description Qty Size Liquid End Material

1 EH2019 Head , Pump, EW/EKB11, PVDF 1 11 FC, TC

EH1970 Head, Pump, EW/EK16, PVDF 1 16 FC, TC

EH1965 Head, Pump, EW/EK21, PVDF 1 21 FC, TC

EH1966 Head, Pump, EW/EK31, PVDF 1 31 FC, TC

EH1967 Head, Pump, EW/EK36, PVDF 1 36 FC, TC

3 EH0425 Housing, Valve, 3/8 PVDF 2 / 1 11, 16, 21 FC, TC

EH0427 Housing, Valve, 1/2 PVDF 2 / 1 31, 36 FC, TC

4 EH0836 Nut, Coupling, 3/8 PVDF 2 / 3 11, 16, 21 FC, TC

EH0837 Nut, Coupling, 1/2 PVDF 2 / 3 31, 36 FC, TC

5 EH1051 Fitting, Air Vent, PVDF 1 11, 16, 21 TC

EH1093 Fitting, Air Vent, PVDF 1 31, 36 TC

6 EH1047 Nut, Lock, Air Vent, PVDF 1 11, 16, 21 TC

EH1092 Nut, Lock, Air Vent, PVDF 1 31, 36 TC

*

8 EH1971 Diaphragm, EW/EK/EZ11 1 11 all

EH1972 Diaphragm, EW/EK/EZ16 1 16 all

EH1973 Diaphragm, EW/EK/EZ21 1 21 all

EH1974 Diaphragm, EW/EK/EZ31 1 31 all

EH1975 Diaphragm, EW/EK/EZ36 1 36 all

*

9 EH0059 Retainer, EW/EK/EZ11 1 11 all

EH0083 Retainer, EW/EK/EZ16 1 16 all

EH0067 Retainer, EW/EK/EZ21 1 21 all

EH0087 Retainer, EW/EK/EZ31 1 31 all

EH0158 Retainer, EW/EK/EZ36 1 36 all

10 EH1052 Body, Manual Air Vent, PVDF 1 11, 16, 21 TC

EH1100 Body, Manual Air Vent, P VDF 1 31, 36 TC

*

11 EH0340 Guide, Valve, 0.188 PVDF 4 11 FC

EH1046 Guide, Valve, 0.188 PVDF 4 11 TC

EH1549 Guide, Valve, 0.250 PVDF 4 16, 21 FC, TC

EH0352 Guide, Valve, 0.375 PVDF 4 31, 36 FC

EH2368 Guide, Valve, 0.375 PVDF (EW/E W N) 4 31, 36 TC

*

12 EH1627 Seat, Valve, 0.188 PCTFE 4 11 TC

EH0592 Seat, Valve, 0.250 PCTFE 4 16, 21 FC

EH0593 Seat, Valve, 0.375 PCTFE 4 31, 36 FC

EH0061 Seat, Valve, 0.188 FKM 4 11 TC

EH0069 Seat, Valve, 0.250 FKM 4 16, 21 TC

EH0119 Seat, Valve, 0.375 FKM 4 31, 36 TC

*

13 EH0025 Ball, Valve, 0.188 CE 4 11 FC, T C

EH0084 Ball, Valve, 0.250 CE 4 16, 21 FC, TC

EH0120 Ball, Valve, 0.375 CE 4 31, 36 FC, TC

*

14 EH0342 Gasket, Valve, 0.188 & 0.250 PTFE 6 11, 16, 21 FC

EH1553 Gasket, Valve, 0.188 & 0.250 PTFE 2 11, 16, 21 TC

EH0354 Gasket, Valve, 0.375, PTFE 6 31, 36 FC

EH0121 Gasket, V alve, 0.375 , PTFE 2 31, 36 TC

*

15 EH1080 O-Ring, P-3, FKM 1 31, 36 TC

*

16 EH0029 O-Ring, P-6, FKM 1 31, 36 TC

*

17 EH0027 O-Ring, S-14, FKM 2 11, 16, 21 TC

EH0122 O-Ring, P-16, FKM 2 31, 36 TC

EH0591 Gasket, V-Housing, 0.188/ 0.250 PTFE 2 11, 16, 21 FC

EH0355 Gasket, V-Housing, 0.375 PT FE 2 31, 36 FC

*

18 EH0027 O-Ring, S-14, FKM 1 31, 36 TC

19 EH1986 Bolt, M4 x 35 w/PW & SW, 316SS 4 11, 16, 21, 31 FC, T C

EH1988 Bolt, M5 x 35 w/PW & SW, 316SS 4 36 FC, TC

23 EH1049 Knob, Air Vent Valve 1 11, 16, 21 FC, TC

EH1094 Knob, Air Vent, 1/2, PVDF 1 31, 36 FC, TC

*

25 EH0300 O-Ring, P-4, FKM 1 11, 16, 21 TC

*

26 EH0302 O-Ring, P-10A, FKM 1 11, 16, 21 TC

*

27 EH0304 O-Ring, P-7, FKM 1 11, 16, 21 TC

EH1082 O-Ring, P-11, FKM 1 31, 36 TC

ZZ ----------- Brass spacers Drive specific/Re-use when replacing diaphragm

*

Included in sp are parts kit

Components

PVDF Liquid End Exploded View #3

27

Item Part No Description Qty

1 EH2021 Head, Pump, EW/EKB11, 316 SS 1

EH2022 Head, Pump, EW/EK21, 316 SS 1

EH2023 Head, Pump, EW/EK31, 316 SS 1

EH2024 Head, Pump, EW/EKC36, 316 SS 1

3 EH0429 Housing, Valve, 0.188 & 0.250, 316 SS 1

EH0433 Housing, Valve, 0.375, 316 SS 1

*

8 EH1971 Diaphragm, EW/EK11, PTFE/EPDM 1

EH1973 Diaphragm, EW/EK21, PTFE/EPDM 1

EH1974 Diaphragm, EW/EK31, PTFE/EPDM 1

EH1975 Diaphragm, EW/EK36, PTFE/EPDM 1

*

9 EH0059 Retainer, Diaphragm, EW/EK11 1

EH0067 Retainer, Diaphragm, EW/EK21 1

EH0087 Retainer, Diaphragm, EW/EK31 1

EH0158 Retainer, Diaphragm, EW/EK36 1

11 EH0360 Guide, Valve, EW/EKB11, 316 SS 4

EH1551 Guide, Valve, EW/EK211, 316 SS 4

EH1552 Guide, Valve, EW/EKB31/36, 316 SS 4

12 EH1554 Seat, Valve, EW/EK11, 316 SS 4

EH1555 Seat, Valve, EW/EK21, 316 SS 4

EH1556 Seat, Valve, EW/EK31/36, 316 SS 4

13 EH0049 Ball, Valve, 0.188, HC 4

EH0072 Ball, Valve, 0.250, HC 4

EH0126 Ball, Valve, 0.375, HC 4

*

14 EH0362 Gasket, Valve Guide, EW/EK11/21 PTFE 2

EH0380 Gasket, Valve Guide, EW/EK31/36, PTFE 2

19 EH2089 Bolt, M4 x 45 316 SS, Hex Socket 4

EH0290 Bolt, M5 x 45 316 SS, Hex Socket 4

20 EH2000 Washer, Split, M4, 316 SS 4

EH2012 Washer, Split, M5, 316 SS 4

21 EH1999 Washer, Flat, M4, 316 SS 4

EH2011 Washer, Flat, M5, 316 SS 4

*

28 EH0365 Gasket, Guide/MAVV, EW/EK11/21, PTFE 9

EH0382 Gasket, Guide/MAVV, EW/EK31/36, PTFE 9

37 EH1014 Knob, MAVV, EW/EK-SH, 316 SS 1

38 EH1015 Nut, Loc, EW/EK-SH, 316 SS 1

*

39 EH1016 Seal, Ring, EW/EK-SH, 316 SS 1

*

40 EH1017 Seat, MAVV, EW/EK-SH, 316 SS 1

*

41 EH1018 Seat Ring, MAVV, EW/EK-SH, 316 SS 1

51 EH1557 Body, MAVV, EW/EK11, 316 SS 1

EH1558 Body, MAVV, EW/EK31/36, 316 SS 1

53 EH1508 Fitting, MAVV, EW/EK11, 316 SS 1

EH1510 Fitting, MAVV, EW/EK31/36, 316 SS 1

54 EH1559 Nut, Lock, MAVV, EW/EW-SH, 316 SS 1

55 EH1517 Connector, Air Vent, EW/EW-SH, ECTFE 1

*

Included in sp are parts kit

28 8 ZZ

20

21

Stainless Steel Liquid End Exploded View #4

For all EW and EK Pump Models

Components

C

28

Part No. Description Size Liquid End Mater ia l

E90494 Connector Assy, Stop Input, 4-pin-R EW/EW-Y all

E90495 Connector Assy, Ana/Dig Input, 5-pin EW/EW-Y all

E90496 Connector Assy, PosiFlow Input, 5-pin-R EW/EW-Y all

E90497 Connector Assy, Outputs, 4-pin-SQ EW/EW-Y all

E90665 Connector Assy, EK pump, Input EK all

E90001 Valv e, Injection 3/8 11, 16, 21 VC

E90002 Valv e, Injection 3/8 11, 16, 21 VE, VF

E90003 Valve , I nje ctio n, 3/8 11, 16, 21 PC

E90004 Valve , I nje ctio n, 3/8 11, 16, 21 PE

E90007 Valve , I nje ctio n, 1/2 31, 36 VC

E90008 Valve , I nje ctio n, 1/2 31, 36 VE, VF

E90011 Valve , I nje ctio n, 1/2 31, 36 PC

E90012 Valve, Injection, 1/2 31, 36 PE

E90238 Valve , I nje ctio n, 3/8 11, 16, 21 TC

E90020 Valve , I nj/Bac k Pre s s, 3/ 8 11, 16, 21 FC

E90022 Valve , I nj/Bac k Pre s s, 1/ 2 31, 36 TC, FC

E90013 Valve, Foot, 3/8 11, 16, 21 VC

E90015 Valve, Foot, 3/8 11, 16, 21 PC

E90016 Valve, Foot, 1/2 31, 36 VC

E90018 Valve, Foot, 1/2 31, 36 PC

E90034 Valve, Foot, 3/8 11, 16, 21 PE

E90035 Valve, Foot, 3/8 11, 16, 21 VE

E90036 Valve, Foot, 1/2 31, 36 PE

E90037 Valve, Foot, 1/2 31, 36 VE

E90193 Valve, Foot, 1/2 31, 36 VF

E90234 Valve, Foot, 3/8 11, 16, 21 VF

E90239 Valve, Foot, 1/2 31, 36 TC

E90240 Valve, Foot, 3/8 11, 16, 21 TC

E90241 Valve, Foot, 3/8 11, 16, 21 FC

E90275 Valve, Foot, 1/2 31, 36 FC

E00001-00 Tubing,1/2 OD LLDPE per foot 31, 36 all

E00001 Tubing,1/2 OD LLDPE, 20 FT 31, 36 all

E00001-50 Tubing,1/2 OD LLDPE, 50 FT 31, 36 all

E00001-100 Tubing,1/2 OD LLDPE, 100 FT 31, 36 all

E00001-250 Tubing,1/2 OD LLDPE, 250 FT 31, 36 all

E00001-500 Tubing,1/2 OD LLDPE, 500 FT 31, 36 all

E00002-00 Tubing, 3/8 OD LLDPE per foot 11, 16, 21 all

E00002 Tubing, 3/8 OD LLDPE, 20 FT 11, 16, 21 all

E00002-50 Tubing, 3/8 OD LLDPE, 50 FT 11, 16, 21 all

E00002-100 Tubing, 3/8 OD LLDPE, 100 FT 11, 16, 21 all

E00002-250 Tubing, 3/8 OD LLDPE, 250 FT 11, 16, 21 all

E00002-500 Tubing, 3/8 OD LLDPE, 500 FT 11, 16, 21 all

E00071 Weight, Ceramic all all

Accessories (Not Shown)

29

C

E

(Not shown

A

B

(Not shown in this view) (Inside)

D

in this view)

A Drive Unit B Control Module C Head Assembly D Valve Cartridge E Air Vent Assembly

30

A

B

(Spare Parts Kit)

PC

PE

VC

VE

VF

TC

FC

Valve Cartridge

31, 36

Valve Assembly

11, 16,

21

Valve Assembly

21

*

The P/N in the block is the head assembly part number and the spare parts kit is shown underneath in



For EK pump models, change the “W” to “K” and the “F” to “R”. The EK drive and control units are only

number or part number to a “Y” to determine the correct Control Module part number.

D C E

Pump

Model



Drive



Unit

EWB11F1- WB11-1 EW BF1

EWB11F2- WB11-2 EW BF2

EWB16F1- WB16-1 EW BF1

EWB16F2- WB16-2 EW BF2

EWB21F1- WB21-1 EW BF1

EWB21F2- WB21-2 EW BF2

EWB31F1- WB31-1 EWB30F1

EWB31F2- WB31-2 EW BF2

EWC16F1- WC16-1 EWCF1

EWC16F2- WC16-2 EWCF2

EWC21F1- WC21-1 EWCF1

EWC21F2- WC21-2 EWCF2

EWC31F1- WC31-1 EWCF1

EWC31F2- WC31-2 EWCF2

Control

Module



(X11PC-PK)

(X16PC-PK)

(X21PC-PK)

(X31PC-PK)

(X16PC-PK)

(X21PC-PK)

(X31PC-PK)

X11PC

X16PC

X21PC

X31PC

X16PC

X21PC

X31PC

X11PE

(X11PE-PK)

X16PE

(X16PE-PK)

X21PE

(X21PE-PK)

X31PE

(X31PE-PK)

X16PE

(X16PE-PK)

X21PE

(X21PE-PK)

X31PE

(X31PE-PK)

X11VC

(X11VC-PK)

X16VC

(X16VC-PK)

X21VC

(X21VC-PK)

X31VC

(X31VC-PK)

X16VC

(X16VC-PK)

X21VC

(X21VC-PK)

X31VC

(X31VC-PK)

Head Assembly *

X11VE

(X11VE-PK)

X16VE

(X16VE-PK)

X21VE

(X21VE-PK)

X31VE

(X31VE-PK)

X16VE

(X16VE-PK)

X21VE

(X21VE-PK)

X31VE

(X31VE-PK)

(X11VF-PK)

(X16VF-PK)

(X21VF-PK)

(X31VF-PK)

(X16VF-PK)

(X21VF-PK)

(X31VF-PK)

X11VF

X16VF

X21VF

X31VF

X16VF

X21VF

X31VF

X11TC

(X11TC-PK)

X16TC

(X16TC-PK)

X21TC

(X21TC-PK)

X31TC

(X31TC-PK)

X16TC

(X16TC-PK)

X21TC

(X21TC-PK)

X31TC

(X31TC-PK)

X11FC

(X11FC-PK)

X16FC

(X16FC-PK)

X21FC

(X21FC-PK)

X31FC

(X31FC-PK)

X16FC

(X16FC-PK)

X21FC

(X21FC-PK)

X31FC

(X31FC-PK)

EWC36F1- WC36-1 EWCF1

EWC36F2- WC36-2 EWCF2

11

Manual Air Vent

Automatic Air

Vent Valve

MultiFunction

16, 21

31, 36

11, 16,

21

11, 16,

Notes:

parentheses. For head assemblies with a Multifunction Valve, add an “M” to the end of the part number. Parts kits for pumps with Multifunction valves are the same as pumps without the “M” option. For head

assemblies or parts kits with the Auto Air Vent Valve, add “A” after the “VC” code in the number.

sold as an assembly only. Use the Drive Unit number but change the “W” to “K” and add an “R” before the voltage code (i.e. KB11-R1). For EW pumps using a “Y” Control Module, change the “F” in the model

X36PC

(X36PC-PK)

X36PE

(X36PE-PK)

X36VC

(X36VC-PK)

X36VE

(X36VE-PK)

X36VF

(X36VF-PK)

X36TC

(X36TC-PK)

E90041 E90042 E90038 E90039 E90302 E90305 ---

E90048 E90049 E90045 E90046 E90303 --- ---

E90055 E90056 E90052 E90053 E90304 --- ---

E90026 E90027 E90024 E90025 E90025 E90308 ---

E90248 E90249 E90246 E90247 E90247 E90250 ---

--- --- E90023 --- --- --- ---

E90364 E90365 E90362 E90363 E90363 --- ---

X36FC

(X36FC-PK)

31

Item Part No. Description Series

1 EH1580 Screw, M5 x 55, SS PFH, Black EW

2 EH1581 Screw, M5 x 47, SS PFH, Black EW

3 EH1653 Hinge Pin, Spr ing, EW-F/Y Cover EW

4 EH1646 Cover, Controller, Clear, EW-F/Y EW

5 EH1648 Thumb Bolt, Captive, EW-F/Y, Cover EW

6 EH1647 Gasket, Cover, EW-F/Y Controller, EPDM EW

7 EH2427 Gasket, Controller-Drive. EW, EPDM EW

8 EH1649 Knob, Stroke length, EW-F/Y EW

9 EH1650 Label, EW-F/Y Stroke length knob EW

10 EH1583 Cap, Mini din conne ctor, EPD M EW

11 EH1573 Gasket, Pump Head, EW/EK 11-21 EW, EK

EH1574 Gasket, Pump Head, EW/EK 31 EW, EK

EH1575 Gasket, Pump Head, EW/EK 36 EW, EK

12 EH1690 Spacer, Bracket, EW/EK/EZ-11 EW, EK

EH1431 Spacer, Bracket, EW/EK/EZ-16 EW, EK

EH1700 Spacer, Bracket, EW/EK/EZ-21 EW, EK

13 EH1410 Screw, M4 x 10, SS PFH, Black EK

14 EH1375 Knob, Stroke length, EK-B EK-B

EH1584 Knob, Stroke length, EK-C EK-C

15 EH1376 Screw, SL Knob, EK-B, M4 x 95 EK-B

EH1586 Screw, SL Knob, EK-C, M4 x 75 EK-C

16 EH0141 Cap, Stroke length Adjustment Knob EK

17 EH1372 Gasket, Cover, EK Controller, EPDM EK

18 E90633 Cover Asm, EK Control Unit, (no bolts, w/gasket) EK

E90634 Cover Asm, EK Cont rol Unit, (w/bolts & gasket) EK

19 EH1374 Thumb Bolt, C aptive, EK Cover EK

20 EH1567 Gasket, Locknut, EK Input EK

21 EH1565 Nut, Lock, Input connector, EK EK

A Drive Unit

Drive and Control Module

Exploded View

B Control Module Part numbers for these assemblies are on Page 30

32

Problem

Possible Cause

Corrective Action

Pump does not start

Faulty wiring

Correct wiring

Improper voltage

Connect to proper voltage source

Electronic control unit is damaged

Replace control unit (Contact distributor or factory)

Pump does not prime

Air in suction tubing

Reroute suction tubing to eliminate air trap

Valve gasket is not installed

Install valve gasket

Valve set assembly directi on is wrong.

Reassemble valve set

Pump is air locked

Open air vent valve

Suction or dischar ge valve i s clogged with foreign matter

Disassemble, inspect, clean Ball stuck to valve seat

Disassemble, inspect, clean

Output fluctuates

Suction or dischar ge valve i s clogged with foreign matter

Disassemble, inspect, clean Air is trapped in pump

Open air vent valve

Overfeeding

Install injection valve or back pressure valve

Diaphragm is damaged

Replace diaphragm

Liquid leaks

Fitting or coupling nut is loose

Re-install (see section 2.3/2.4)

Pump head is loose

Tighten pump head bolts Torque: 19 lb-in (2.16 N-m)

Diaphragm is damaged

Replace diaphragm

O-ring or valve gasket missing

Install o-ring or valve gasket

CAUTION: Before working on the pump, disconnect the power cord, depressurize the discharge

6.0 TROUBLESHOOTING

tubing and drain or flush any residual liquid from the pump head and valves, using proper chemical handling techniques.

7.0 SERVICE POLICY

The EW and EK Series electronic metering pumps have a 2-year limited warranty. Contact your Walchem distributor for service.

Walchem EW-F series, EK series Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual