Walchem LKN Operating Manual

LK Series

Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA

Metering Pump

Instruction Manual

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

Notice

© 2016 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 one year 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 180173.N
April 2016

TABLE OF CONTENTS

Thank you for choosing a Walchem LK Series Metering Pump. This instruction manual
deals with the correct installation, operation, maintenance and troubleshooting procedures
for the LK metering pumps. Please read through it carefully to ensure the optimum
performance, safety and service of your pump.

IMPORTANT INSTRUCTIONS .................................................................................. 1

1 Operating Principle ........................................................................................... 3

2 Model Identification Guide ............................................................................... 4

3 Specifications and Outer Dimensions ............................................................ 4

4 Names of Parts .................................................................................................. 7

5 Description on Main Unit and Label .............................................................. 15

6 Handling Instructions ..................................................................................... 17

7 Installation ....................................................................................................... 18

8 Piping ............................................................................................................... 19

9 Wiring .............................................................................................................. 21

10 Operating Instructions ................................................................................... 21

11 Troubleshooting .............................................................................................. 24

12 Maintenance and Inspection .......................................................................... 25

13 Spare Parts ...................................................................................................... 27

14 Disassembly and Assembly ........................................................................... 27

1

Warning

Non-observance or misapplication of the contents of the
"Warning" section could lead to a serious accident, including
death or injury.

Caution

Non-observance or misapplication of the contents of the
"Caution" section could lead to serious physical injury to the
user or serious damage to the product.

IMPORTANT INSTRUCTIONS

Important notes and statements about the safe operation and prevention of physical injury and/or
property damage are included throughout this instruction manual.

Always Observe These Safety Instructions!

Safety Instructions to Prevent Personal Injury

In this manual, the following symbols and signs are used to clearly indicate safety instructions:

Warning

(Always read and observe the following instructions to prevent personal injury.)

 Damaged or deteriorated tools are very dangerous. Use only qualified and suitable tools.
 Use protective gear. When disassembling, assembling, and conducting maintenance or when

handling a dangerous type of liquid or a liquid of unknown property, be sure to wear safety gloves, a
helmet, and protective shoes. In addition, when handling wet-end parts, always wear protective
goggles, masks, etc.

 Prevent death or injury from a falling pump. Make sure the rope or chain used for lifting the

pump is not accidentally cut or disconnected during installation. Make sure the rope or the chain
used to lift the pump has sufficient strength for the pump load. Do not to stand underneath a lifted or
suspended pump.

 Always turn off the power supply prior to servicing the pump. Make special provisions so

that the power supply cannot be turned on while someone is working on the pump. In a noisy or
poor visibility environment, display a sign near the power supply switch to notify others that
someone is "WORKING" on the pump. Power mistakenly applied during maintenance may lead to
personal injury.

 Check and make sure that there is no one near the pump when switching on the power

supply. The pump is not equipped with an ON/OFF switch. Connecting the power cable or power

plug supplies the power to the pump and starts the operation.

 Run the pump at the specified power supply voltage on the nameplate only. Fire or electric

shock may result if the supply voltage is incorrect. 

 If pump operation is stopped due to a power failure or closure of discharge line, turn off

the power switch at once. After normal conditions are established, reapply power.

2

 Do not use the pump for anything that it is not designed to do. User’s failure to observe this

instruction exempts Walchem from any responsibility for personal injury or damage to the
equipment or facility caused by the pump’s misuse.

 When handling liquid with toxic or strong vapors, ventilate the working area well. In addition,

the operator must wear protective gear (such as a safety mask, safety goggles, and protective gloves).

 Do not allow toxic substances such as lubricants, solvents, or similar substances to flow

into the local sewage system or river systems. Do not drain hazardous liquids such as chemical

solutions discharged out of the pump directly onto the ground. Instead, drain such liquids into an
appropriate container. Observe the laws and regulations related to the application, handling, and
processing of hazardous substances.

Caution

(Always read and observe the following instructions to prevent personal injury.)

 Wear gloves when working with rope or chain. Working with bare hands may result in

serious injury, since fingers are likely to be caught between the pump and the rope or chain
when the rope or chain is under tension.

 The pump is not designed to be used under water. Install the pump in a clean, dry

environment where the pump cannot become submerged. It is recommended that the pump
be shielded from direct exposure to the elements.

 Install a safety valve on the discharge line. Installation of a pressure relief valve is highly

recommended. Check local codes and regulations.

 Do not close off the discharge or suction lines while the pump is operating. The pump or

piping may become damaged.

3

DIAPHRAGM

SHAFT

SPRING

CONTROL

SHAFT

DIAL

SLIDER

WORM WHEEL

SHAFT

MOTOR

1 Operating Principle

The rotation of the motor is reduced by means of the worm and wheel. The rotary motion is
converted to a reciprocating motion by the spring-back mechanism (including the worm wheel
shaft, slider, spring, etc.). The reciprocating motion is transmitted to the diaphragm directly
connected with the shaft, changing the volume inside the pump chamber. The variation in volume
inside the pump chamber and the functioning of the valves in the pump head produce the pump
operation. To adjust stroke length, the adjusting dial fixed on the control shaft is rotated to change
the return of the slider.

4

Material symbol

VC

VH

VS

TC

S6

Part

Pump head

PVC

PVC

PVC

PVDF

316 SS

Valve ball

CE

HC

HC/304 SS

CE

HC

Valve seat

Type 32

FKM

EPDM

304 SS

FKM

316 SS

Type 45 to 57

PVC

PVC

304 SS

PVDF

316 SS

O ring

FKM

EPDM

EPDM

FKM

-

Valve gasket

PTFE

Diaphragm

PTFE + EPDM

Model

Capacity

Maximum Pressure

PSI (MPa)

Stroke speed

(spm)

Connection

NPT

Viscosity

cps

50Hz

(l/h)

60Hz

(GPH)

PVC/PVDF

SS

50Hz

60Hz

PVC/PVDF

SS

LKN32

30

9.5

150 (1)

225 (1.5)

96

116

½”

½”

VC: 300

TC: 300

VH: 500

VS: 1000
S6: 1000

LKN45

50

15.9

150 (1)

225 (1.5)

48

58

½”

½”

LKN47

100

31.8

120 (0.8)

120 (0.8)

96

116

½” *

½”

LKN55

168

53.4

75 (0.5)

75 (0.5)

48

58

1”

1”

LKN57

360

114.3

45 (0.3)

45 (0.3)

96

116

1”

1”

2 Model Identification Guide

LK N 32 A – VC

1 2 3 4 5

1 LK Series motor-driven metering pump
2 N – NEMA 42C motor mounting flange
3 Capacity/Pressure Rating. Refer to specifications and outer dimensions below.
4 Motor Code:

 A = 115/230V, 60Hz, 1 ph, 1/3 HP, 1725 RPM, TEFC Frame 42C
 B = 230/460V, 60Hz, 3 ph, 1/3 HP, 1725 RPM, TEFC Frame 42C
 C = 190/380V//230/460V, 50/60Hz, 3 ph, 1/3 HP, 1450/1725 RPM, TEFC, Frame 42C
 D = 90VDC, 1 ph, 1/3 HP, 1750 RPM, TENV, Frame 42C Variable Speed Motor, 115V Control
 E = 180VDC, 1 ph, 1/3 HP, 1750 RPM, TENV, Frame 42C Variable Speed Motor, 230V Control

 F = 230/460V, 60Hz, 3 ph, 1/3 HP, 1725 RPM, Explosion Proof Motor: Class 1, Div 1, Group C & D
 G = 230/460, 60 Hz, 3 ph, 1/3 HP, 1725 RPM, Inverter Duty Motor, TENV, 42C

5 Liquid End Code. Refer to the table below.

CE: Alumina ceramic HC: Hastelloy C267

3 Specifications and Outer Dimensions

* LKN47-VS has 1” NPT connections

5

Model

L A C E F J K

LKN32, VC, VH, VS

10.91
(277)

12.05
(306)

3.82
(97)

4.06

(103)

4.61

(117)

½” NPT

4 x ø0.35”

(ø9)

LKN45, 47, VC, VH, VS

11.06
(281)

12.01
(305)

3.90
(99)

4.06

(103)

4.69

(119)

LKN47VS

11.06
(281)

10.83
(275)

3.90
(99)

3.46
(88)

4.69

(119)

1” NPT

LKN55, 57, VC, VH, VS

11.77
(299)

12.48
(317)

4.53

(115)

4.17

(106)

5.31

(135)

F

3.35”

(85mm)

0.79”

(20mm)

4.92”

(125mm)

c

L

6.50"

(165mm)

E

K

3.94"

(100mm)

4.72"

(120mm)

j

2.00"

(51mm)

A

Outer dimensions
 LKN32, 45, 47, 55, 57, VC, VH, VS

Dimensions in inches (mm)

6

Model

L A C E F J K

LKN32, S6

10.91
(277)

7.80

(198)

3.82
(97)

1.93
(49)

4.61

(117)

½” NPT

4 x ø0.35”

(ø9)

LKN45, 47, S6

11.14
(283)

11.69

(297)

3.98

(101)

3.86
(98)

4.76

(121)

LKN55, 57, S6

11.61
(295)

14.53

(369)

4.37

(111)

5.31

(135)

5.16

(131)

1” NPT

F

3.35"

(85mm)

4.92"

(125mm)

L

A

6.50"

(165mm)

E

K

j

3.94"

(100mm)

4.72"

(120mm)

2.00"

(51mm)

0.79"

(20mm)

F

Outer Dimensions
 LKN32, 45, 47, 55, 57, S6

Dimensions in inches (mm)

7

4.72"

(120mm)

3.94"

(100mm)

E

6.50"

(165mm)

F

c

3.35"

(85mm)

4.92"

(125mm)

L

0.79"

(20mm)

A

2.00"

(51mm)

Model

L A C E F J K

LKN32, TC

10.91
(277)

12.05

(306)

3.82
(97)

4.06

(103)

4.61

(117)

½” NPT

4 x ø0.35”

(ø9)

LKN45, 47, TC

11.06
(281)

12.95

(329)

3.90
(99)

4.89

(114)

4.69

(119)

LKN55, 57, TC

11.77
(299)

12.48

(317)

4.53

(115)

4.17

(106)

5.31

(135)

1” NPT

Outer Dimensions

 LKN32, 45, 47, 55, 57, TC

Dimensions in inches (mm)

8

No.

Part

Qty

VC

VH

VS

Part No.

Material

Part No.

Material

Part No.

Material

1

Pump head

1

L0770

PVC

L0770

PVC

L1227

PVC

*2

Ball 2 L0063

Alumina
Ceramic

L0062

Hastelloy

C

L0062

Hastelloy

C

*3

Valve guide

2

L0064

PVC

L0064

PVC

L0488

PVC

*4

Valve seat

2

L0066

FKM

L0065

EPDM

L0489

SS304

*5

Valve Gasket

2

L0068

PTFE

L0068

PTFE

L0068

PTFE

6

Adapter

2

L0072

PVC

L0072

PVC

L0072

PVC

*7

O-ring

2

L0074

FKM

L0073

EPDM

L0073

EPDM

*8

O-ring

2

L0016

FKM

L0015

EPDM

L0015

EPDM

No.

Part

Qty

Part No.

Material

20

Hex head bolt

6

L0246

SS

21

Split washer

6

EH2012

SS

22

Plate washer

6

EH2011

SS

29

Reinforcing plate

1

L0771

Steel

*30

Diaphragm

1

L0080

PTFE + EPDM

*31

Retainer

1

L0081

SS304

50

Nut 2 L0022

PVC

51

Fitting 2 L1590

PVC

4 Exploded View and Parts List

 LKN32 VC, VH, VS

 L0506 (PVC) is used on the suction side.

* Parts included in the spare parts kit.

9

No.

Part

Qty

VC

VH

VS

Part No.

Material

Part No.

Material

Part No.

Material

1

Pump head

1

L1500

PVC

L1500

PVC

L1500

PVC

*2

Ball 2 L0093

Alumina
Ceramic

L0092

Hastelloy C

L0092

Hastelloy C

*3

Valve guide

2

L0094

PVC

L0094

PVC

L0094

PVC

*4

Valve seat

2

L0095

PVC

L0095

PVC

L0096

SS304

*5

Valve Gasket

2

L0097

PTFE

L0097

PTFE

L0097

PTFE

*7

O-ring 2 L0103

FKM

L0102

EPDM

L0102

EPDM

No.

Part

Qty

Part No.

Material

Notes

20

Hex head bolt

8

L1166

SS

22

Plate washer

8

L1610

SS

29

Reinforcing plate

1

L1224

FC200

*30

Diaphragm

1

L0109

PTFE + EPDM

*31

Retainer 1 L0110

SS304

50

Nut 2 L1596

PVC

51

Fitting, ½” NPT

2

L1593

PVC

For LKN45/47-VC/VH and LKN45-VS

51

Fitting, 1” NPT

2

L1595

PVC

For LKN47-Vs only

22

50

50

 LKN45, 47 VC, VH, VS

* Parts included in the spare parts kit.

10

No.

Part

Qty

VC

VH

VS

Part No.

Material

Part No.

Material

Part No.

Material

1

Pump head

1

L1513

PVC

L1513

PVC

L1513

PVC

*2

Ball 2 L0151

Alumina
Ceramic

L0150

Hastelloy C

L0150

Hastelloy C

*3

Valve guide

2

L0152

PVC

L0152

PVC

L0152

PVC

*4

Valve seat

2

L0153

PVC

L0153

PVC

L0154

SS304

*5

Valve Gasket

2

L0155

PTFE

L0155

PTFE

L0155

PTFE

*7

O-ring 2 L0161

FKM

L0160

EPDM

L0160

EPDM

No.

Part

Qty

Part No.

Material

20

Hex head bolt

8

L1168

SS

22

Plate washer

8

L1610

SS

29

Reinforcing plate

1

L1600

FC200

*30

Diaphragm

1

L0167

PTFE + EPDM

*31

Retainer

1

L0168

SS304

50

Nut 2 L1596

PVC

51

Fitting 2 L1595

PVC

50

50

22

 LKN55, 57 VC, VH, VS

* Parts included in the spare parts kit.

11

No.

Part

Qty

Part No.

Material

1

Pump head

1

L1204

SS316

*2

Ball 2 L0062

Hastelloy C

*3

Valve guide

2

L1205

SS316

*4

Valve seat

2

L1206

SS316

*5

Valve gasket A

4

L0244

PTFE

*6

Valve gasket B

2

L0245

PTFE

20

Hex head bolt

6

L0246

SS

21

Split washer

6

EH2012

SS

22

Plate washer

6

EH2011

SS

*30

Diaphragm

1

L0080

PTFE + EPDM

*31

Retainer plate

1

L0081

SS304

70

Fitting 2 L1592

SS316

 LKN32 S6

* Parts included in the spare parts kit.

12

No.

Part

Qty

Part No. for

LKN45, 47

Part No. for

LKN55, 57

Material

1

Pump head

1

L1209

L1212

SS316

*2

Ball 2 L0092

L0265

Hastelloy C

*3

Valve guide

2

L0826

L1213

SS316

*4

Valve seat

2

L0827

L1214

SS316

*5

Valve Gasket

6

L0257

L0269

PTFE

20

Bolt w/split washer

8

L1167

L1167

SS

22

Plate washer

8

L1610

L1610

SS

*30

Diaphragm

1

L0109

L0167

PTFE + EPDM

*31

Retainer plate

1

L0110

L0168

SS304

71

Fitting 2 L1594

L1599

SS316

80

Stud bolt 8 L1509

L1518

SS

81

Hex nut 8 L0762

L1523

SS

82

Split washer

8

L1512

L0189

SS

71

71

22

 LKN45, 47, 55, 57 S6

* Parts included in the spare parts kit.

13

No.

Part

Qty

Part No.

Material

1

Pump head

1

L1226

PVDF

*2

Ball 2 L0063

Ceramic

*3

Valve guide

2

L0332

PVDF

*4

Valve seat 2 L0066

PVDF

*5

Valve Gasket

2

L0068

PTFE

*6

Adapter 2 L0335

PVDF

*7

O-ring 2 L0074

FKM

*8

O-ring 2 L0016

FKM

20

Bolt 6 L0246

SS

21

Split washer

6

EH2012

SS

22

Plate washer

6

EH2011

SS

29

Reinforcing plate

1

L0771

SS41

*30

Diaphragm

1

L0080

PTFE + EPDM

*31

Retainer plate

1

L0081

SS304

50

Nut 2 L1611

PVDF

51

Fitting 2 L1591

PVDF

 LKN32 TC

* Parts included in the spare parts kit.

14

No.

Part

Qty

Part No.

Material

1

Pump head

1

L1505

PVDF

*2

Ball 2 L0093

Ceramic

*3

Valve guide

2

L0347

PVDF

*4

Valve seat 2 L0348

PVDF

*5

Valve Gasket

2

L0097

PTFE

6

Adapter 2 L0350

PVDF

*7

O-ring 2 L0103

FKM

*8

O-ring 2 L0016

FKM

9

Nut 2 L1539

PVDF

20

Bolt w/split washer

8

L1166

SS304

22

Plate washer

8

L1610

SS

29

Reinforcing plate

1

L1224

SS41

*30

Diaphragm

1

L0109

PTFE + EPDM

*31

Retainer plate

1

L0110

SS304

50

Nut 2 L1611

PVDF

51

Fitting 2 L1591

PVDF

 LKN45, 47 TC

* Parts included in the spare parts kit.

15

No.

Part

Qty

Part No.

Material

1

Pump head

1

L1521

PVDF

*2

Ball 2 L0151

Ceramic

*3

Valve guide

2

L0363

PVDF

*4

Valve seat 2 L0364

PVDF

*5

Valve Gasket

2

L0155

PTFE

*7

O-ring 2 L0161

FKM

20

Bolt w/split washer

8

L1168

SS304

22

Plate washer

8

L1610

SS

29

Reinforcing plate

1

L1600

FC200

*30

Diaphragm

1

L0167

PTFE + EPDM

*31

Retainer plate

1

L0168

SS304

50

Nut 2 L1598

PVDF

51

Fitting 2 L1597

PVDF

 LKN55, 57 TC

* Parts included in the spare parts kit.

16

Caution: Do not use any solvent when wiping the nameplate, labels or the pump
main unit.

Discharge

Pump

(Liquid end)

Suction Port

Specification Nameplate

Model number and
specifications are indicated
on the nameplate. Operate
the pump within the limits of
the specifications.

Stroke Length
Knob/Indicator

The stroke length can be
adjusted through a range
of 100% to 0% by rotating
the dial.

Motor

Reducing

mechanism

5 Description on Main Unit and Label

17

6 Handling Instructions

Warning

Do not operate the pump with dangerous or hazardous mediums (such as explosive, combustible,
flammable, or toxic substances).

Caution

Read the following information prior to installation of the pump:

 Protective gear:

When operating the pump or working near it, always wear protective clothing, face guard, goggles,
and gloves. Further precautionary measures must be taken depending upon the type of liquid used.

 Pump repair:

Do not try to disassemble or repair the pump beyond the range specified in this instruction manual
Contact the local distributor for further help.

1. Handle the pump carefully.
Impacts caused by dropping the pump on the floor or striking it may result in damage or faulty
performance.

2. Do not operate the pump under the following condition:

 where the temperature falls below 0°C
 where corrosive gas or explosive gas may be present
 exposed to splashing water
 where the ambient temperature is 40°C or above
 where the humidity is excessively high (Permissible humidity: 35~85%RH)
 places filled with or likely to be filled with explosive or corrosive atmosphere
 danger due to dust, fire, earthquake and/or any externally imposed shock

3. Keep the pump away from fire.
To prevent fire and explosions, do not place dangerous or flammable substances near the pump.

4. Damaged pump or motor
Do not operate a damaged pump due to the possibility of electric shock.

5. Pump modification
Never attempt to modify the pump. This may cause a serious accident or damage.

6. No disassembly or repair
Users should not disassemble and repair the pump beyond the level given in the "Disassembly
and Assembly" section of this manual.

Caution

The pump must be repaired by trained and qualified operators only. If in need of repair,
stop operation and contact your supplier for service.

18

7. Do not close the discharge or suction lines while in operation.
Pump operation with valves closed increases the load onto the pump itself and will eventually
damage the pump or piping.

8. Do not adjust the stroke length while the pump is not operating.
Rotating the stroke adjustment dial while not in operation applies load onto the dial and will
eventually damage the pump.

9. Allowable pressure limit
Set the discharge pressure at or below the allowable pressure limit level indicated in the
“Specifications” section.

10. Temperature/humidity fluctuation

Temperature fluctuation may not affect the performance of the pump itself. However, the
liquid may change in terms of its viscosity, pressure, or corrosion resistance. Pay special
attention to changes in liquid characteristics as a result of temperature fluctuation.

Liquid temperature range:

Material symbol VC, VH, VS: 0~50°C
Material symbol S6, TC: 0~80°C
Ambient temperature range: 0~40°C
Humidity range: 35~85%RH

7 Installation

1. Installation position

 Install the pump as close to the suction tank and as low as possible. Flooded

suction is the ideal installation.

 The suction lift ability depends upon the liquid properties, temperature, and length

of the suction piping. For details of the setup, consult your distributor.

2. Indoor and outdoor use

The pump can be operated either indoors or outdoors. However, safety measures should be
taken so as not to expose the motor and power distribution unit to flooding and it is always
recommended that the pump be shielded from direct exposure to the elements (rain, snow,
direct sun, etc.).

3. Installation site

Select an installation site that is flat and free of vibrations caused by nearby machines.
Sufficient space for maintenance should be provided.

 Lifting

Lift the pump horizontally so that the gear oil will not leak out of the pump drive unit.


 

19

P

PG

Back Pressure Valve

Discharge Valve

Air Vent Valve

(flushing valve)

Expansion

joint

Expansion

joint

Drain Valve

(flushing valve)

Suction

Valve

Pressure Relief
Safety Valve

Pulsation
Dampener or
Air Chamber

Shut off
Valve

 Foundation preparation (before pump installation)

1. The area for anchoring the pump should be greater than the area of the pump base. If the

anchoring area is too small, the base may be destroyed due to the concentrated load on it.

2. If pump operation is to be subject to vibration (resonation with the piping, for example),

provide an expansion joint between the pump and the piping. Otherwise, the piping, gauge, etc.,
may be damaged.

3. Installation advice

• Use anchor bolts to fasten the pump base firmly.

• Install the pump horizontally.

• Sufficient space is required to allow cool air from the motor fan to circulate.

• Allow ample space around the pump for easy and efficient maintenance work.

8 Piping

 Load of piping for LK-N

 General precautions

When plumbing the pump, support the piping and use an expansion joint so as not to apply a load
onto the pump discharge/suction ports.

1. All piping should be supported independently so that unnecessary weight and vibration are not

transmitted directly to the pump. Expansion joint is recommended to avoid damaging the pump
head especially.

2. The best piping arrangement for minimum pressure loss is achieved with straight runs and full

bore piping containing as few bends and fittings as possible.

20

3. When handling a high or low temperature liquid, provide an expansion joint in the pipeline to

allow for stress caused by thermal expansion and contraction.

4. When handling a slurry liquid, provide a drain plug at the bottom of the piping and do not make

a “trap” in the piping system.

5. When handling a viscous, toxic or a liquid that easily crystallizes, install piping for cleaning.

6. Use adequate piping materials that can resist pressure and corrosion.

7. Clean the inside of pipes before installation. Remove the caps fitted on the pump inlet and

outlet before installing piping. The caps are provided for preventing contamination by foreign
matter.

8. A pressure relief safety valve and a pulsation dampener should be installed on the discharge

line near the pump.

CAUTION! Operation without a pressure relief safety valve installed could result in catastrophic
failure and a dangerous condition if the discharge line is closed for any reason during operation

 Suction piping

1. Flooded suction is always recommended.

2. The diameter of the suction pipe should never be smaller than the size of the pump inlet.

3. The suction piping should be as short as possible. Excessive length may lead to flow

restriction, cavitation and damage to the pump.

4. Air ingress from the joints in the piping system may cause pumping damage or inconsistent

flow. Make sure the joints are well sealed.

 Discharge piping

1. Install a pressure relief safety valve as close to the pump discharge as possible. Its setting

pressure should not exceed the pressure permissible for the pump and pipes.

2. Maintain pipe diameter (match pump discharge size) through discharge point including all

valves and injectors. At a minimum, match size through pressure relief valve to ensure safety
and protect the pump.

3. Firmly connect and seal all the joints using proper pipe support (this includes flexible tubing

as pulsation and tubing flex can stress pump head connection).

4. Install a pressure gauge on the discharge piping to verify actual pressure in discharge. The

pressure gauge must be installed before any pipe reductions to measure an accurate pressure to
the pump..

5. Install a pulsation dampener (air chamber or accumulator) in the discharge piping to prevent

any fluctuation of pressure. Install the pulsation dampener in a position close to the pump
discharge port. A pulsation dampener will significantly increase the life of the pump.

21

Model

Liquid

temp °C

Max. surface temp. at

40°C ambient temp °C

LKN32, 45,47,55,57 VC, VH, VS

50

45

LKN32, 45,47,55,57, S6

80

75

9 Wiring

 Electrical connections

WARNING

The electrical connection should be carried out by an authorized electrician in accordance with
local regulations. Please make sure that the electrical data on the nameplate of the motor
corresponds to the electrical supply on which it will be used. Motors must be connected to a
motor protection switch.

1. Use an electromagnetic switch that conforms to the specifications (voltage, capacity, etc.) of the

pump motor.

2. If using the pump outdoors, waterproof the wiring to protect the switches from rainwater.

3. Electromagnetic switches and push buttons should be installed at a reasonable distance from the

pump.

10 Operating Instructions

1. Never operate the pump with the suction and discharge side valve closed. Otherwise, the inside

of the pump or the piping will be damaged.

2. In the event of a service power failure, turn off the power switch immediately and close the

discharge valve.

3. Maximum pump surface temperature (not motor)

The max. pump surface temperature of each model is shown in the table. Arrange protective
measures in accordance with the temperature levels.

4. Sound generated by pump

The level of sound generated by LKN type of pump is 85 (dB). Arrange a muffling device to
reduce the sound level if necessary. The procedure for sound measurement conforms to the EN
31201 (ISO11201).

22

Oil Cap

Oil Gauge

Hex socket head bolt

Stroke length dial

 Preparation for start-up

The following inspections should be made before the initial operation after installation and
operation after a long period of inactivity.

1. Thoroughly clean the inside of the tank and pipe. Then, supply liquid.

2. Tighten the pump connections and the installation bolts on the base.

3. Check every part of the pump for defects, loosened bolts, oil leakage, etc.

4 Check the oil gauge to see if the drive unit is filled with the specified amount of oil.

5. Run the motor instantaneously to check for correct direction of motor rotation. The motor

should run in the direction indicated with the arrow on the pump. If the direction is reversed,
rewire the motor power wires in accordance with the wiring schematic on the motor nameplate.

 Operation

1. Open the valves of the suction and discharge pipes.

Caution

DO NOT OPERATE THE PUMP WITH THE VALVES CLOSED.

2. Provide power to the motor.

3. Loosen the hex socket head bolt of the stroke length dial. Set the stroke length to 0% by

turning the stroke length dial clockwise

Caution

DO NOT TURN THE DIAL WHILE THE PUMP IS NOT OPERATING.

23

LKN3

0 ½ 1 1½ 2

Revolution

0 1 ½ 3 4½ 6

Revolution

LKN4

0 2 4 6 8 10

Revolution

LKN5

4 Continue to run the pump for 30 minutes or longer to let it warm up. Check that no

abnormality is found. This procedure is necessary only during the first operation, but when the
ambient temperature is extremely low, continue no-load running until the oil temperature rises
sufficiently because the motor may sometimes be overloaded a little due to an increase in the
viscosity of oil in the drive unit.

5. Open an air vent valve to purge the discharge line of air.

6. Increase the stroke length up to 100% and continue to run the pump for 30 minutes or longer

again.

7. Close the air vent valve gradually, watching the pressure gauge. The liquid will come into the

discharge line and be discharged from the end of the pipe. Should the discharge pressure
exceed the permissible pressure for the pump before the air vent valve is completely closed,
check the piping system.

8. Check that the motor amperage does not exceed the rated value and that no abnormality is

found.

 Metering and Calibration

1. Operate the pump using the actual liquid and installation conditions.

2. Setting the stroke length at 100%, determine the discharge capacity per minute several times. If

no noticeable variation is found after repeated measuring, the pump is working normally.

3. Measure the discharge capacity at two or three points of the stroke length. When a set point is

changed, measure the discharge capacity after running one minute or longer.

4. Plot a pump calibration curve using the results of the above procedures.

[Note] Our in-plant test data is based on pumping water at normal ambient temperature with a
short piping system. Therefore, there will be a difference between the test data and the practical
performance data.

5. The relationship between the amount of stroke length dial revolution and stroke length is shown

in the following graphs.

24

Item

Problem

Ref. No. for

Cause/Countermeasure

A

Discharge capacity is low.

1, 2, 4, 5, 6, 7, 8, 9, 11, 12

B

Discharge capacity is excessive.

3, 7, 9

C

Discharge capacity is unstable.

1, 2, 3, 4, 5, 7, 8, 11, 12

D

No liquid is discharged.

1, 2, 4, 7, 8, 11, 12

E

Discharge pressure does not increase.

1, 2, 4, 8, 10, 11, 12

F

Pump will not prime.

1, 2, 4, 5, 6, 7, 8, 12

G

Liquid leaks.

5, 6 H Motor does not run.

15, 16, 17, 18, 19

I

Motor draws excessive amperage.

13, 15, 16, 17, 19

J

Excessive vibration and loud noise.

8, 12, 13, 15, 19

K

Oil leaks.

14 L Gearbox temperature is excessive.

7, 13, 19

Ref.

Cause

Countermeasure

1

Foreign matter is clogging valve ball, valve seat
and/or valve guide.

Disassemble and clean.
2 Valve seat and/or valve ball is worn.

Replace.

3

Differential pressure is inadequate.

Install a back-pressure valve in discharge line. (5
PSI is required as min. differential pressure.)

4

Air leaks into suction line.

Inspect suction pipes and connections. Re­tighten.

5

Defective valve gasket or O-ring

Replace.

6

Damage to diaphragm

Replace. Check the discharge pressure for
foreign matter or crystallization in the pump
chamber if it fails prematurely.

7

Pumping condition (liquid, temperature,
pressure, piping, etc.) changes.

Renew pump performance data of the altered
pumping condition after confirming that the
pump is good.

8

Suction pipe or strainer is clogged.

Disassemble and clean.

9

Stroke length dial has moved.

Readjust and tighten lock bolt securely after
confirming that no liquid is discharged at stroke
length of 0%.

 Starting after the pump is stopped or out of use

1. When the pump is stopped for a short period of time (within a week), it can be re-started at

its prescribed pressure and capacity.

2. When the pump has been out of use for a long period of time, operate the pump at zero

pressure for a few minutes to lubricate it thoroughly. Do not start the pump at a prescribed
pressure immediately.

 Pulsation dampener

It is always recommended to install a pulsation dampener, i.e. diaphragm type accumulator, air
chamber, etc. Because a metering pump is a reciprocating device, it produces pressure pulsations
that the system sees in the form of acceleration, inertia, shock, noise, and reduced service life.
When the piping is long, it is especially important to use a pulsation dampener for accurate
metering.

11 Troubleshooting

25

10

Dust is clogging mouth of pressure gauge or
pressure gauge is defective.

Clean or replace.

11

Leak from safety valve

Readjust pressure setting or replace if it is
defective.

12

Cavitation occurs due to insufficient NPSHr.

Examine suction conditions.

13

Lubricating oil of the drive unit is not correct.

Check that the correct oil has been used. Check
the oil quantity and level. Replenish or replace if
necessary.

14

Defective oil seal or O-ring

Replace.

15

Defective motor

Replace.

16

Wrong wiring or defective contact

Check wiring. Replace switch, etc. if necessary.

Ref.

Cause

Countermeasure

17

Voltage drop

Inspect cause and take countermeasures
accordingly.

18

Blown fuse.

Inspect cause and take countermeasures
accordingly.

19

Overload (excessive discharge pressure)

Check discharge line and take countermeasures
to lower the pressure.

12 Maintenance and Inspection

 Daily inspection

1. Check whether the pump operates smoothly and without any abnormal noise or vibration.

2. Check the level of the liquid in the solution supply tank.

3. Check the pump and piping for leakages.

4. Check the drive unit for oil loss and leakage.

5. Compare the discharge pressure and electric current measured during operation with the values

indicated on the motor nameplate for verification of normal pump load.

 Note that the values indicated on the pressure gauge vary in proportion to the specific

gravity of the liquid. The valve to the pressure gauge must be opened only when
measurement is carried out. It must be closed upon the completion of each
measurement. If the valve remains open during pump operation, the meter mechanism
in the gauge may be affected or damaged by noise or vibration.

6. If a spare pump is available, activate it from time to time to keep it ready for use any time.

Check to be sure there are no leaks from the pump before operating it. If leakage is detected,
never try to operate the pump.

7. Check to be sure the discharge pressure, discharge flow rate, and motor power supply voltage

do not fluctuate during pump operation. If considerable fluctuation is observed, refer to the
Troubleshooting section for corrective measures.

26

Model

Oil Qty

Recommended Oil

LKN

7.44oz

(220 mL)

Esso (Exxon) GP80W-90, Shell Spirax/EP80,
Mobil Pegasus Gear Oil 80
(Automobile Gear Oil SAE-80, API Grade GL-4),
Castrol Hypoy Gear Oil

Drain plug

 Periodic inspection

To ensure efficient and smooth operation of the pump, periodically inspect the pump and
installation. When inspecting, overhauling, or if repair is necessary, stop the pump operation and
contact the supplier as necessary.

The overhauling and repair work for Walchem pumps must be performed by qualified personnel
who have been trained and certified by the pump supplier. User’s failure to observe this instruction
exempts Walchem from the responsibility for personal injury or damage to the equipment or facility
that result from its misuse.

1. Valve Unit

Check the valve balls, valve seats and valve guides every 6 months. If flaws or worn parts are
found, replace them.

2. Diaphragm

Check the diaphragm every 6 months if the usage is fairly light. The life of the diaphragm
depends on the characteristics, pressure, temperature, etc. of the liquid being pumped. If any
deformation or crack is found, the diaphragm should be replaced with a new one.

3. Oil

Change the oil in the drive unit once a year. If emulsification of the oil is found during
inspection, immediately change the oil. Remove the drain plug and drain the drive unit. Flush
the inside with oil to clean it. Then, add new oil up to the specified level of the oil gauge.
Ensure any replacement oil is SAE (80W-90) and must exceed API Service GL-4.

Contact your Walchem distributor if the oil listed above is unavailable. Use of incorrect oil may
shorten the life-term of the gear unit.

27

Recommended Spare Parts

Estimated Service Life

Valve, Valve guide, Valve seat

12 months (life is dependent on the
characteristics of liquid being pumped)

O-ring and Gasket

12 months (o-rings and gaskets shall be
replaced at each disassembly)

Diaphragm

4,000 hrs (life is dependent on the discharge
pressure, liquid, temperature, etc.)

Drive unit

3 years

13 Spare Parts

If downtime is critical, it is recommended to always maintain a stand-by pump and a spare parts kit
if the pump is being used continuously.

Note: The above service life figures are only estimates and not a guarantee. Actual application will
determine pump life.

14 Disassembly and Assembly

Refer to exploded view of the model corresponding to your pump. The views are shown in Section
4 – Exploded View and Parts List.

Caution

• Before disassembling/assembling the pump, to turn off the main power supply. Display a
“WORKING” sign near the power switch to let other personnel know the situation.
Accidental power ON initiated by an other person may result in an accident. The operator
must take special precautions to prevent this situation.

• Prior to disassembly or assembly, close the suction valve and discharge valve fully.

• The piping and the pump often retain liquid. When working around a dangerous liquid,
wear appropriate protection (goggles, rubber gloves, etc.) when disconnecting the pipes
and decontaminating the pump.




28

Spanner

Hex head bolt (20)

 Disassembly

1. Disassemble only after thoroughly decontaminating the pump by flushing and cleaning the
piping and the inside of the pump.

Warning

Wear protection (goggles, rubber gloves, etc.).
Certain liquids are dangerous and may hurt your eyes and skin.

2. Remove the discharge and suction piping.

Caution

Close the suction valve and discharge valve fully,
prior to removing the discharge and suction piping.

 Valve

1. Remove the suction and discharge fitting by
loosening the nut (50).
Remove the adapter (6) if any, and take out the
valve (2), valve guide (3), valve seat (4), valve
gasket (5) and O-ring (7). If the pump head is
made of stainless steel, the valve assembly can
be taken out by loosening the setting flange (54)
or the nuts (81).

2. Check the valve and valve seat. If they are damaged
or worn, replace with a new ones. It is highly
recommended to replace the gasket and O-ring
every time the liquid end is disassembled.

 Diaphragm

1. Loosen the hex head or socket head cap bolts (20).

2. Remove the pump head (1).

3. Connect power supply and run the motor
temporarily (without the liquid end).
Set stroke length to 100%. Turn off when the
diaphragm comes to the top dead center (when
the diaphragm is most extended).
Disconnect power supply.

Caution

Do not touch any moving parts during operation.

4. Remove the diaphragm from the pump shaft by turning the diaphragm counterclockwise with
hand. If it is worn or deformed part in any way, replace it with a new one

29

Bottom dead center

Top dead center

Stroke
Length, 100%

Diaphragm

insert

bolt

Pump shaft

Retainer (31)

Bracket

Diaphragm (30)

.

5. Attach the new diaphragm firmly to the pump shaft by turning it clockwise by hand (hand
tighten only, no tools). Confirm that the retainer (31) is sitting correctly around the diaphragm
insert bolt and rests against the end of the pump shaft. If the position of the pump shaft moves
during reassembly of the diaphragm, set it at top dead center, following the above procedure #3.

 Assembly

The pump should be assembled by carrying out the steps of disassembly in reverse. Pay special
attention to the following points:

 Valve

1. Replacement of o-ring and gasket
Replace the o-ring or gasket, with a new one. Additionally, ensure that the o-ring or gasket
is not twisted or pinched between parts.
* The sealing section should be free of dust or scratches before installation.

2. Assemble the valve assembly by reversing the procedure, taking special care with the
direction and position of the valve guide, valve seat and valve gasket.

Caution

If the direction or position of the valve guide, valve ball, or valve seat is incorrect, the pump
will not pump and/or may be damaged.

30

LKN 32

LKN 45, 47

LKN 55, 57

VC, VH, VS, TC

27 in-lbs (3.0 Nm)

106 in-lbs (12.0 Nm)

106 in-lbs (12.0 Nm)

S6

44 in-lbs (5.0 Nm)

106 in-lbs (12.0 Nm)

106 in-lbs (12.0 Nm)

Spanner

Spanner

3. When installing the LKN32 fiiting/nut (VC, VH, or VS type), use a spanner wrench to hold the
adapter (6) then fasten the nut (50) by hand.



Diaphragm

1. Connect power supply and temporarily run the motor, moving the diaphragm to the bottom

dead center where the diaphragm is fully drawn back. Turn off motor.

Caution

Only attach the head when the diaphragm is at bottom dead center. Premature
diaphragm failure may occur if this step is not observed.

Do not touch any moving parts during operation.

2. Fit the pump head (1) to the bracket of the drive unit with the hex head or socket head cap

bolts (20). Tighten all the bolts securely and uniformly.

Tighening torque for bolts (20)

FIVE BOYNTON ROAD

HOPPING BROOK PARK

HOLLISTON, MA 01746 USA

TEL: [phone]

FAX: [phone]

Web: www.walchem.com