Walchem EZ Series Instruction Manual

EZ Series

Electronic Metering Pump

Instruction Manual

Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA

W A L C H E M

EZ Series Metering Pumps

IWAKI America Inc.

TEL: [phone] FAX: [phone] WEB: www.walchem.com

Notice

© 2014 WALCHEM, Iwaki America Inc. (hereinafter “Walchem”)
Five Boynton Road, Holliston, MA 01746 USA
tel [phone] fax [phone]
All Rights Reserved
Printed in USA

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 Warranty

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 E00159.H
Nov 2014

TABLE OF CONTENTS

Thank you for choosing a Walchem EZ Series metering pump. This instruction manual deals
with the correct installation, operation, maintenance and troubleshooting procedures for the EZ
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 ............................................................................................................ 5

2.1 Unpacking ................................................................................................................. 5

2.2 Location ..................................................................................................................... 5

2.3 Supply Tubing............................................................................................................ 6

2.4 Discharge Tubing ...................................................................................................... 7

2.5 Installing Injection/BackPressure Valve ..................................................................... 7

2.6 Interlocking Pump ...................................................................................................... 8

2.7 Electrical .................................................................................................................... 8

3.0 OPERATION ................................................................................................................. 9

3.1 Priming ...................................................................................................................... 9

3.2 Adjustment and Control ............................................................................................. 9

3.3 Calibration ............................................................................................................... 13

3.4 STOP Function ........................................................................................................ 13

3.5 AC Power Interruption ............................................................................................. 13

3.6 Auto Air Vent Valve Operation ................................................................................. 14

3.7 MultiFunction Valve Operation ................................................................................. 15

4.0 MAINTENANCE .......................................................................................................... 16

4.1 Diaphragm Replacement ......................................................................................... 16

4.2 Valve Replacement ................................................................................................. 16

4.3 Tubing ..................................................................................................................... 16

5.0 EXPLO

6.0 TROUBLESHOOTING ................................................................................................ 27

7.0 SERVICE POLICY ...................................................................................................... 27

DED VIEW & PARTS GUIDE .......................................................................... 17

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 EZ Series 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).

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.

In flooded suction, pumping downhill, or pumping into little or no system pressure installations,
a back pressure/anti-syphon device must be installed to prevent over-pumping or siphoning.
Contact your Walchem distributor for additional information.

Solution Compatibility

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

pump for use with liquids other than water (such as acids or alkalines) is the responsibility of the
user. For liquids other than water, select the best-suited liquid end material combination using a
chemical compatibility chart.

1.2 Principle of Operation

The EZ series 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

1 2 3 4 5 6

EZ B16 D 1 - VC A

1 Pump Series

EZ Electronic metering pump with manual speed control (adjustable to 360 strokes

per minute)

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

3 Control Module

D For use on all EZ models, features digitally adjustable speed and fixed
stroke length

T Timer module allows daily, weekly, or 2 week operation with digitally

adjustable speed and external stop control. Available on 115V EZB models.

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

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

for the EZ series pumps with VC, VE, VF, PC and PE liquid ends. Not available
with the AAVV feature.

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

Available for the EZ Series in B11, B16, C16 and C21 sizes with –VC liquid
ends only.

3

1.4 Specifications

Size

Maximum

Output Capacity

Maximum
Pressure1

Tubing O.D

(Gal/hr)

(mL/min)

PSI

MPa

B11

0.6

38

0.11

150

1.0

3/8

B16

1.0

65

0.18

105

0.7

3/8

B21

1.5

95

0.26

60

0.4

3/8

B31

3.2

200

0.56

30

0.2

1/2

C16

1.3

80

0.22

150

1.0

3/8

C21

2.0

130

0.36

105

0.7

3/8

C31

4.3

270

0.75

50

0.35

1/2

C36

6.3

400

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

FKM

PE

GFRPP

CE

EPDM

EPDM

VC

PVC

CE

FKM

FKM

VE

PVC

CE

EPDM

EPDM

VF

PVC

PTFE

EPDM

EPDM

TC

PVDF

CE

FKM

FKM

FC

PVDF

CE

PCTFE

PTFE

Electrical 50/60 Hz, single phase

EZB 115 VAC±10% 0.9 Amp max. 16 watt avg.

230 VAC±10% 0.4 Amp max. 16 watt avg.

EZC 115 VAC±10% 1.4 Amp max. 24 watt avg.

230 VAC±10% 0.6 Amp max. 24 watt avg.

Operating Conditions

Ambient temperature 32°F to 122°F (0°C to 50°C)
Relative humidity 30% to 90% 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

Capacity/Pressure Rating

Max Output per

Stroke (mL)

Connection

Size (in)

1

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

Adjustment Range

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
PCTFE Polychlorotrifluoroethylene

PE

4

1.5 Dimensions

P & Q

-VC

-TC

-VE

-VF

1.46

[1.83]2

7.44

[7.81]2

-VC

-TC

-VE

-VF

1.46

[1.83]2

8.15

[8.52]2

-VC

-TC

-VE

-VF

C

B

P

X

Z

R

S T
V

L

E

A

Q F

J

W

H

G

D

EZ Models with thermoplastic liquid end materials

EZB Model Shown for reference

All dimensions in inches

Model A B C D E F G H J L

11
16
21

EZB

31

-PC

-FC 3.21 0.87 0.08 3.54 0.51 0.20 6.09 6.83 1.00 6.50 3/8” O.D. 3.94

D1

-VC

D2

-PC

-TC

-FC 3.21 1.02 0.08 3.54 0.63 0.20 6.85 6.85 0.24 6.77 1/2” O.D 3.94

-PE

3.21 0.87 0.08 3.54

-VE

-PE

3.21 1.02 0.08 3.54 0.87 0.20 6.75 8.00 0.32 7.01 1/2” O.D. 3.94

-VF

(3.03)

TUBING

1

0.20

5.91

[6.11]

2

7.24

[8.39]2

1.02

(9.53)1

3/8” O.D. 3.94

W

16
21

EZC

31
36

1

Mounting Dimensions R S T X V Z

EZB all variations 3.46 0.28 0.63 0.24 0.39 1.26

EZC all variations 3.94 0.59 1.18 0.28 0.59 1.18

-PC

-FC 4.13 0.94 --- 3.94 0.51 0.31 6.48 7.44 1.39 7.20 3/8” O.D. 4.57

D1
D2

-PC

-FC 4.13 1.10 --- 3.94 0.63 0.31 7.44 7.44 0.63 7.48 1/2” O.D. 4.57

-PE

-PE

Dimension with automatic air vent valve option

4.13 0.94 --- 3.94

4.13 1.10 --- 3.94 0.87 0.31 7.11 8.37 0.71 7.72 1/2” O.D. 4.57

(3.03)

1

0.31

6.30

[6.50]

7.64

2

[8.79]2

2

With Multifunction valve

1.42

(10.24)1

3/8” O.D. 4.57

5

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.

Do not handle or move the pumps using the Control Module only. The pump should be
supported by the base or drive unit during handling

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).

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.)

Figure 1 Figure 2 Figure 3

Flooded Suction Shelf Mount Tank Mount

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).

6

Foot Valve

PVC Pipe Tubing Straightener
(user supplied)

Air Gap

Return Line

Point of
Injection

Injection
Valve

Coupling Nut

Coupling Nut
(Air Vent Valve)

Coupling Nut

Valve
Housing
Shoulder

Coupling Nut

Tubing

Figure 5

Figure 4 Tubing Connections

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. Ensure
that siphoning through the pump will not occur when the pump is not in operation. If possible,
install a back pressure/anti-siphon valve in the discharge line of the pump. 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 the 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.

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.

7

2.4 Discharge Tubing

"AIR"

"OUT"

Drains back to tank

Discharges to injection point

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.

Figure 6 Air Vent Valve Tubing

2.5 Installing Injection/BackPressure Valve

A fitting or tee with 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 your 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.