Piston Metering Pump FEDOS E / DX

Transcription

1 MB / 1 General The FEDOS E / DX combines the properties of the FEDOS series working reliably for many years with the latest requirements in metering technology. Advantages of piston metering pumps: - little dependency on back pressure - linear flow variation as a function of stroke length Due to an improved flexibility and the further development of individual components, the FEDOS E / DX pumps can be integrated even more efficiently in metering processes. Heads and pistons are the same as for the previous pumps so that the continuity of spare parts keeping and service is ensured. The FEDOS is available for capacities from 0.17 to 31.5 l/h, with or without microprocessor control. Pressures are admissible between 25 and 100 bar, depending on the size and packing material. If no control is required for constant metering, the motor is connected directly to the terminal box. In this case, FEDOS E pumps are used. Three-phase and a.c. motors are available. To change the metering capacity, either the stroke length can be adjusted mechanically or the speed of the three-phase motor can be controlled by means of a separate frequency converter. The microprocessor-based FEDOS DX is used if the pump is to be integrated in controls or automatic control systems. The intelligence of the FEDOS DX is derived from the well-proved series of MEMDOS E/DX diaphragm metering pumps. It allows the adaption to a large number of different control signals and system monitoring equipment. It controls the chemical supply in two ways. The signals required for external activation of the pump can be simple voltage-free closing contacts from water meters or controllers or analog 0(4)...20 ma signals. Depending on the version, the FEDOS DX can be adjusted continuously between 0 and 142 strokes/min. for internal control. A single stroke follows each contact. In addition, the stroke frequency can be changed by pulse division or multiplication. Metering Head Metering heads are supplied in stainless steel for max. 100 bar. As a standard, type stainless steel heads with PTFE packings are used for up to 40 bar. In the case of higher pressures, Aramidreinforced packings are preferred. The correct choice of metering heads depends on the aggressivity of the chemical metered, its temperature and viscosity, and on the system pressure. Environmental factors (harsh operating conditions, radiant heat, etc.) must also be taken into consideration. Valves Suction and discharge valves can be supplied in the form of double-ball or spring-loaded single-ball valves. Spring-loaded valves are to be recommended if the chemical used has a viscosity exceeding 400mpas. Piston Metering Pump FEDOS E / DX JESCO DOSIERTECHNIK GmbH & Co. KG

2 MB / 2 Drive To operate the pump three-phase or a.c. motors can be used for FEDOS E pumps. The intelligent FEDOS DX pumps with control unit are always equipped with a single-phase a.c. motor. The gearbox is made of light but inherently stable and high-alloyed cast aluminum. It contains a single-stage worm wheel set running in an oil bath just as the roller bearings. Metering happens while the push rod is displaced by means of an eccentric. The suction stroke is caused by the resetting of the spring. To set the metering capacity by manual stroke adjustment, the spring-loaded piston rod is locked at the corresponding position. Thus an adjustment range from 0 to 100 % is possible. Abrasive media Piston packings can be supplied in the form of Teflon/silk packings and Aramid packings. The Teflon/silk packing supplied as a standard can be used with nearly all types of chemicals and up to 40 bar. Where abrasive media are concerned it may be advisable to use Aramid-Keflar packings if the chemical employed allows it. Aramid-Keflar is not resistant to concentrated acids ar alkalis. Technical data Control unit In general the following functions are possible with the control unit: - Indication of operating states and menu guidance on 3-digit LC display. - Operating panel with four pressure-sensitive keys and three LEDs. - Internal control of stroke frequency, continuously adjustable between strokes/min., depending on the gear reduction. - External control by a) voltage-free contacts (mechanical or semiconductors). b) analog and ma signal. - External pump stop by voltage-free opening contact. - Warning alarm relay with voltage-free changeover contact (signaling of (almost) low level, life zero error with ma, remote switchoff). - Pulse multiplication for contact control with factor 2 / 4 / 8 / 16 / 32 / Pulse division for contact control with divisor 2 / 4 / 8 / 16 / 32 / Chemical tank level control with alarm signal and main alarm (pump stops). FEDOS E/DX Power at maximum pressure [ bar] [ l/h] [ ml/stroke] P iston-ø [ mm] S troke frequency [ 1/min] S troke length [ mm] 9 S uction lift [ mbar] 800 P ower E (3~) [ W] P ower DX (1~) [ W] 120 W eight [ kg] Piston Metering Pump FEDOS E / DX Additional modules The precision and operational life of metering pumps can be increased considerably if the appropriate fittings are used. These are among others: - Pulsation dampeners for suction and discharge side. - ATE servomotors for electrical metering capacity adjustment. - Approximation initiators for indicating individual strokes, e.g. counters. - Application-oriented suction lines, also with level control for the medium to be metered. - Relief valves as safety valves to protect pump and system. JESCO DOSIERTECHNIK GmbH & Co. KG

3 MB / 3 Technical data of the control unit Mains voltage V AC, Hz Electrical connection Safety plug with 2.5 m cable Power consumption (without motor) 10 W Insulation class F Protective class IP 65 * Pulse for contact activation min. 30 ms Voltage at pulse input 5V DC (must be voltage-free for contact making) Multiplication / division of contacts 1 / 2 / 4 / 8 / 16 / 32 / 64 Load for 0(4)...20 ma input 150 Ohm Voltage at level connection 5V DC (level probe w/break contact for alarm/empty Alarm relay, voltage-free changeover contact 250V AC, 2.5 A or 30V DC, 2.5A Remote pump switchoff by voltage-free break contact (on site) Max. admissible ambient temperature 40 C Digital display 3-digit display for stroke frequency and level state LEDs for functional display, 3 off green = in operation, red = trouble, green = external control Pressure-sensitive keypad 4 keys for programming and operation Weight 0.8 kg * if ports protected by caps or with serial plug-in connectors. Operating panel 1a 1b 1c 8 1a Check display "in operation" 1b Check display "external control" 1c Check display "alarm" 7 2 Remote switchoff 6 3 Level connection 4 External control 5 5 Selection of operating mode Piston Metering Pump FEDOS E / DX 6 Setting of values 7 ON /OFF switch 8 Display JESCO DOSIERTECHNIK GmbH & Co. KG

4 MB / 4 Dimensions FEDOS E / DX L L Dimension L refer to table 5 on MB / d approx. ca approx. ca Piston Metering Pump FEDOS E / DX JESCO DOSIERTECHNIK GmbH & Co. KG

5 MB / 5 Performance curves The upper limit of the area represents pressureless operation, the lower limit represents maximum backpressure. The performance curves refer to water at 20 C and a suction lift of 0.5m. Output valid for 50 Hz; at 60 Hz higher by factor 1.2. Installation example Legend 1 Metering pump E / DX MB Suction line MB Electric agitator MB Tank MB Relief valve MB Diaphragm shutoff valve MB Injection nozzle MB Pulsation dampener MB Switchbox upon request Selection tables In order to be able to offer the user a variety of pumps, these have been divided into the main functional groups. They can thus be assembled according to the user's individual requirements: 1 Drive 2 Motor 3 Metering head 4 Valves 5 Connections Control unit The numbers on the pump drawing refer to the relevant selection tables. Piston Metering Pump FEDOS E / DX JESCO DOSIERTECHNIK GmbH & Co. KG

6 MB / 6 Pump type manual E DX Pump type Motor type Transformation Pump type Part No. E / DX Three-phase current 55:1 E / 230 V, Bg 63 30:1 E kw, 50 Hz, IP 55, ISO-F 15:1 E06 / :1 E / 230 V, Bg 63 10:1 E kw, 50 Hz, IP 55, ISO-F A.C. 55:1 E/DX V, Bg 63 30:1 E/DX kw, 50 Hz, IP 55, ISO-F 15:1 E/DX06/ :1 E/DX Motor FEDOS E / DX ø8 h approx. ca ø 90 Piston Metering Pump FEDOS E / DX ø75 ø60 j6 M5 4x at peripheral area JESCO DOSIERTECHNIK GmbH & Co. KG

7 MB / 7 Pump type * Asbestos-free fiber packing Piston diameter 4 Metering head with PTFE silk packing E / DX E / DX E / DX E / DX E / DX E / DX E / DX E / DX E / DX Housing material P acking material AF* Double-ball valves (DN3) Double-ball valves (DN6) Spring-loaded valves (DN6) 3 suction valve discharge valve suction valve discharge valve suction valve discharge valve Pict. DN di 5 da L St. steel B B D 6 - G 1/ D1 6 - G 1/ E E E E E E Piston Metering Pump FEDOS E / DX G5/8 ø 20 G5/8 ø 20 G5/8 ø 20 B B1 D D1 E E1 Hose clamp connection Threaded connection Ermeto connection JESCO DOSIERTECHNIK GmbH & Co. KG

8 MB / 8 Order example case 1 The requirement is for 17 l/h of aluminium sulphate to be metered against a pressure of 6 bar. Drive via 400 V three-phase current motor. The injection point is 45 meters away from the metering pump. Because of the long distance between the metering pump and the injection point, without a pulsation dampener, acceleration pressure peaks would occur which would affect not only the metering pump but also the flow rate and the metering process. The installation of a PDM 160 pulsation damper is therefore recommended (for details see data sheet MB ). Solution: The requirements stated can be met with the standard piston metering pump type FEDOS E17. Standard materials can be used for the packings. The pump consists of the following modules: Drive Three-phase current motor Metering head (stainless steel) Valves (stainless steel / AF) suction valve discharge valve Connections suction side discharge side Order example case 2 1 l/h of a coloring substance are to be added proportionally to a process line. An analog ma signal or 6000 contacts per hour are available as flow-proportional signal. The system pressure is 6 bar. No aggressive medium is used. The viscosity is, however, 500 mpa*s. Solution: As the viscosity exceeds 400 mpa*s, spring-loaded valves are required. Due to the type of control, a FEDOS DX 1 ( l/h) is chosen. As the pump is able to carry out 95 strokes/min., 5700 metering strokes are maximally possible per hour. This is insufficient compared to the incoming Therefore the pump is set to activation by the analog signal. It consists of the following modules: Drive A.C Metering head (stainless steel) Spring-loaded valves (stainless steel / AF) suction valve discharge valve Connections suction side discharge side Note: If only contact making can be used, the pump must be selected as follows: With the help of the pulse divsion function, divisor 2, the aforementioned pump would have to carry out max. 6000/2=3000 strokes. As a result the flow rate would be reduced to 1.42/5700x3000=0.75 l/h < 1 l/h. Now choose the next larger pump size. The FEDOS DX2 can carry out 142 strokes/min with a capacity of 2.13 l/h pulses/h correspond to 100 pulses/min, i.e.: the DX 2 would supply pulses/min. 2.13l/h x 142 = 1.5 l/h. To achieve 1 l/h, the stroke is reduced to approx. 66% by means of the stroke length adjustment. Piston Metering Pump FEDOS E / DX JESCO DOSIERTECHNIK GmbH & Co. KG

9 ET / 1 General view of modules ET / 2 ET /3-4 ET / 8 ET / 7 ET / 6 ET / 7 ET / 8 ET / 5 Piston Metering Pump FEDOS E / DX

10 ET / 2 Spare parts kit includes Motor Piston Packing rings Gaskets Valve balls Valve seats P ump type M etering head/ Part No. E / DX E / DX 1-2 E / DX 5 E / DX 8 E / DX 17 E / DX 30 seal materials / PTFE / AF / AF / AF / AF / AF Motor assembly Motor Worm Adapter Pump Gear shaft sleeve type Electrical data Part No. Ratio Pos. 1 Pos. 2 Pos. 3 Part No. Part No. Part No. E 01 Three-phase : E /230V, 50Hz, 0,05kW : E 06/1 Bg63, IP55, ISO-F : E : E /230V, 50Hz, 0,25kW : Bg63, IP55, ISO-F E / DX 01 A.C : E / DX V, 50Hz, 0,12kW : E / DX 06/1 Bg63, IP55, ISO-F : E / DX S : Piston Metering Pump FEDOS E / DX

11 ET / 3 Drive FEDOS E / DX ,39 35, , ,40,41, Piston Metering Pump FEDOS E / DX

12 ET / 4 Item Description * incl. sealing pos. 26 M aterial Part No. 1 Gearbox GKAlSi Housing cover E * GKAlSi Clamping flange GKAL Eccentric shaft 9mm stroke 9SMnPb28K Bearing flange AlCuMg Worm wheel 30: 2 Bronze Worm wheel Worm wheel Worm wheel 55:1 10:1 30:1 7 Spacer 8 Adjusting spring 9 Grooved ball bearing 10 Grooved ball bearing 11 Grooved ball bearing 12 Retaining ring 13 Adjusting eccentric 9mm stroke 14 Deflector plate 15 O-ring 16 Hex. head screw 2 17 Piston rod M Pressure spring 19 Adjusting knob 20 Knurled knob 21 Grooved ball bearuing 22 Threaded plug 23 Sleeve bearing bushing 24 Compact seal 25 Stripper 26 Gasket 27 Gasket 28 O-ring 29 O-ring 30 Scale 31 Oil gauge 32 Screw 2 33 Washe r 34 Screw 2 35 Screw 2 36 Cup spring 0 37 Hex. head screw 2 38 Washe r 2 39 Washe r 4 40 Washe r 4 41 Hex. head screw 4 E / DX01 E / DX03 Bronze Bronze Bronze SMnPb28K St St St St Spring steel IXEF Hypalo n Viton A Spring steel LURAN Plastic St Plastic MB1415DU AU Simritan NBR Klingeri t NBR NBR Plastic Plastic A Cu A A A A A A A E / DX06 E / DX1 E / DX2 E / DX5 E / DX8 E / DX17 E / DX30 Piston Metering Pump FEDOS E / DX

13 ET / 5 Control unit Item Description Material Qty Part No. 1 Electronic housing assembly GKAlSi12/PPO Gear cover GKAlSi Electronic unit Display unit Spacer bolt M3x5 Brass nickel-pl Spacer bolt M3x10 Plastic Oval flat-head screw A Spacer bolt M3x6 Plastic Coaxial Cinch socket Misc pin socket CSA/UL Plastic Mono jack socket Plastic Stereo jack socket Plastic Dummy plug Ms Approximation initiator Misc Screw A Union M16x1.5 (from ) PA black Cover seal DX NBR Mains cable Misc I 18 Insulating nozzle A Dummy plug PS black Display transparency FEDOS DX Foam rubber cord EPDM 0.4m Warning alarm cable Misc Screw A Oval-head screw A Toothed washer Spring st. tinned Motor connecting cable Misc Washer Copper Screw St. tinned Toothed washer A * incl. sealing pos. 16 Connecting cable for external control Part No Connecting cable for remote switchoff Part No , ,29 5 Piston Metering Pump FEDOS E / DX 20 10,12,19 8,18, ,17,18 11,12,19 15,18,26 15,22 24,25

14 ET / 6 Stainless steel metering head Item Qty Discriptio n Material E/DX01-06 E/DX1-2 E/DX5 E/DX8 E/DX17 E/DX30 Metering head assembly Piston housing Piston Support ring Gland Union nut P acking ring PTFE-silk pack Supporting disk PVDF Piston Metering Pump FEDOS E / DX

15 ET / 7 Valves Item Suction valve Description Double-ball valve Suction valve Discharge valve M aterial Part No. FEDOS E / DX FEDOS E / DX 1-30 Double-ball valve Suction valve Discharge valve Suction valve Spring-loaded valve Spring-loaded valve Discharge valve Double-ball valve DN6 DN6 DN3 Discharge valve Suction valve Discharge valve Suction valve Discharge valve Seal material: AF= asbestos free 1 Valve housing Ball guide Valve ball Ceramic Valve seat Gasket 6 Gasket 7 O-ring 8 Valve spring 9 O-ring 10 all guide 11 alve ball 12 Valve seat AF PTFE PTFE PTFE Hastello y PTFE B V Ceramic Piston Metering Pump FEDOS E / DX

16 ET / 8 Connections Connection B B1 D D1 E E1 Material Size Conn. assembly t ype Part No. Item Spare parts D escription Part No / Union nut Tubing conn Hose clamp / Hose liner Hose clamp G 1/ Union nut Cemented conn G 1/ Flange bushing Union nut Cutting ring Union nut Cutting ring Union nut Cutting ring Union nut Cutting ring Union nut Cutting ring Union nut Cutting ring Piston Metering Pump FEDOS E / DX

17 BW / 1 Keep the operating instructions of the metering pump and the accessories readily accessible. List of contents 1. Scope of delivery 2. Technical data 3. Installation 4. Electrical connection of pump 5. Safety instructions 6. Injection nozzle assembly 7. Startup 8. FEDOS DX control unit 9. Maintenance 10. Troubleshooting 2. Technical data 3. Installation For selection of a pump during construction of a plant as well as for installation and operation, the local rules must be observed. This applies to the selection of suitable pump materials, the handling of the chemicals and the electrical installation. At the same time the technical data of the metering pump according to the above tables must be considered, and the plant must be designed correspondingly (e.g. pressure loss in lines depending on nominal diameter and length). Both, the designer and the user are responsible to make sure that the whole plant including the metering pump is constructed so that neither plant equipment nor buildings are severely damaged in the case of chemical leakage due to the failure of wear parts (e.g. wear of packing) or burst tubing. In the case of a high potential of danger of the chemical plant, the installation must be carried out so that no consequential damages appear which are 1. Scope of delivery Be careful when unpacking the metering pump and order-related accessories in order not to miss small parts. Immediately compare the scope of delivery to the delivery note. If there are any discrepancies, try to find out the reason. For the transportation of the metering pumps, no special fittings are required. It is, however, advisable to choose a transportation method, which is appropriate for the weight of the metering pumps (e.g. wagon). During transportation without oil, the metering pump should be lying. Otherwise it must be tightened to the transportation device. FEDOS E/DX Power at maximum pressure [ bar] [ l/h] [ ml/stroke] P iston-ø [ mm] S troke frequency [ 1/min] S troke length [ mm] 9 S uction lift [ mbar] 800 P ower E (3~) [ W] P ower DX (1~) [ W] 120 W eight [ kg] unreasonably high even if the metering pump fails. We recommend installing leakage probes and containment tanks. Note: For constructional reasons piston pumps are not leakage-free. This must be taken into account when planning the plant. Metering pumps are produced according to highest quality standards and have a long service life. Nevertheless some parts are subject to wear (e.g piston, packing, valve seat, valve ball). To ensure a long operating life, visual checks are required regularly. Operating and maintenance personnel must be able to access the pump easily. Periodic maintenance protects the metering pump against shutdowns. To increase the metering accuracy and reliability, we recommend using additional fittings. These include backpressure valves, relief valves, leakage probes and chemical low level indicators, as shown in the following installation example. Piston Metering Pump FEDOS E / DX JESCO DOSIERTECHNIK GmbH & Co. KG

18 BW / 2 Always use appropriate tools for the installation of plastic connecting parts. In order to avoid damage, never apply excessive force. Plastic parts (especially PVC parts) can be screwed and unscrewed more easily if the thread is lubricated with vaseline or silicone grease before. Note: For this purpose, the compatibility with the chemical to be metered must be checked. Ambient temperatures exceeding 40 C are not permitted. Radiant heat of apparatus and heat exchangers must be kept in limits allowing the pump to sufficiently dissipate its own heat. Exposure to direct sunlight must be avoided. If the pump is installed outside, provide a roof to protect it against weather. Mount the pump so that the suction and discharge valve are in vertical position. To ensure that the pump stands firm, fasten it with screws on an appropriate foundation. The system piping must not exert any force on the connections and valves of the metering pump. To avoid incorrect metering after the process is finished, provide an electric and hydraulic interlocking system. Installation example Legend 1 Metering pump E/DX MB Suction line MB Electric agitator MB Tank MB Relief valve MB Diaphragm shutoff valve MB Injection nozzle MB Pulsation dampener MB Switchbox upon request Electrical connection of pump - The electrical connection of the pump must be made according to the local rules and may only be carried out by technical personnel. - Cable type und cable cross section of the supply lines must be selected according to the motor data. - The cable passage to the motor terminal box must be made professionally. We recommend gland screw connections with traction relief. - The required protection class must be ensured by professional installation of the electrical connections. Electrical connection data (other types upon request) Pump Voltage Power Current size [Volt] [Watt] [A] FEDOS 400/ /0.87 E ~ 50 Hz FEDOS 400/ /1.55 E ~ 50 Hz FEDOS E/DX ~ 50 Hz Wiring diagram of the drive motor Attention! To avoid early wear of the gear drive adhere to the correct rotation direction of the motor by all means: looking at the fan wheel, counterclockwise. - FEDOS E - FEDOS DX (standard allocation) - Special versions For other special versions please refer to the corresponding separate circuit diagrams. - The electrical connection of the FEDOS DX is shown and described in chapter 7, FEDOS DX control unit. Piston Metering Pump FEDOS E / DX JESCO DOSIERTECHNIK GmbH & Co. KG

19 BW / 3 5. Safety instructions - When working on metering equipment, observe the local safety rules (e.g. wear personal protective clothes). - Before working on the metering pump and plant, disconnect them from the main power supply and secure them against reconnection. Before the voltage supply is switched on again, the metering lines must be connected so that chemical left in the metering head cannot spurt out. - Caution: The piston area must remain open for control reasons and might be dangerous if accessed directly. Maintenance works in the piston area may therefore only be carried out with the pump switched off. - The metering head of the pump as well as connections and lines in the plant may be under pressure. Working on the metering plant requires special safety precautions and may only be carried out by instructed technical personnel. - Before startup, all screwed connections must be checked for correct tightness and, if necessary, must be tightened up using appropriate tools. - If connections at the metering head are unscrewed during operation for venting or other reasons, leaking chemical must be removed completely. This is the only way to avoid the danger of physical injury and corrosion at the metering pump. Leaking chemical may also affect the pump housing. - When changing the chemical, check whether the materials used for the metering pump and the other plant parts are chemically resistant. If there is the danger of a chemical reaction between different media, thorough cleaning first is mandatory. - To operate the pump mount the fan shell in order to ensure sufficient cooling of the motor. - The protective class of the control unit is only reached if ports are protected by caps or serial plugin connectors are used. Note: Under certain operating conditions, the drive motor of the DX version might warm up considerably. To avoid unintentional contact, provide an appropriate device, if necessary. 6. Injection nozzle assembly Injection nozzles are fitted with either spring-loaded ball valve or tube valve to prevent any return flow. Injection from bottom to top is recommended to allow air bubbles to escape and to be carried away so that precipitations are avoided. The experience with the chemical to be metered and its properties must be taken into account. 7. Startup Injection nozzle 1. Before starting the metering pumps all works mentioned in the "Installation" section must be carried out. At the same time the safety instrustions must be observed. 2. The FEDOS E metering pump is switched on by a control to be installed externally. The FEDOS DX has its own control. The electrical connection and the different possibilities of control are described in chapter 8, FEDOS DX control unit. 3. The manual capacity adjustment must be set to maximum stroke to improve priming. During first priming no backpressure should be applied. For this purpose we recommend to install a relief valve on the discharge side of the metering pump. 4. A previously installed priming aid must be filled with chemical first. If the pump is not priming, remove the discharge valve and fill water or chemical (if not dangerous!) into the metering head. Remount valve and start priming. 5. If a venting facility is available as separate unit, open it and wait until liquid flows out. Then close it again. In the case of effervescent liquids allow the liquid to flow out permanently (approx. 1 drop for strokes). 6. When correct operation is achieved, set to required output by means of the adjusting knob. For first approximation refer to the performance curves shown in MB Depending on the installation and the chemicals used, these values may differ and must be checked under operating conditions. Piston Metering Pump FEDOS E / DX JESCO DOSIERTECHNIK GmbH & Co. KG

20 BW / 4 7. The manufacturer of the metering equipment is not responsible for damages due to excessive or low flow rates resulting from faulty pump settings or incorrect and insufficient installation of peripheral fittings. 8. FEDOS DX control unit Operating panel The operating panel has two green LEDs for operation and external control, one red LED for alarm, one 3-digit multifunctional display and four keys for settings. The inputs for remote switchoff, low level indication and external control are located below the display. Remote switchoff External control Low level indication Switchon/-off The pump is switched on / off using the I/0 key. While disconnected the display shows OFF. By opening the contact for remote switchoff the pump is also turned off. The Extern LED is on. Operating modes To select the operating mode, press the Mode key. The display shows the designation of an operating mode which can be changed using keys and. Internal operation: int appears in the display, and after releasing the Mode key, the set stroke frequency is shown. The latter can be modified using keys and. The value is changed at an increasing speed with the key pressed. External control: The display shows the multiplier or the divisor After releasing the Mode key, the number of strokes still to be carried out is indicated in the case of multiplication operation. In the case of division operation, the number of received input pulses is shown. The Extern LED is on. 0/4..20mA control signal: It is possible to choose between a ma or ma standard signal (display 0.20 or 4.20 ). After releasing the Mode key, the stroke frequency corresponding to the current appears in the display. The Extern LED is on. If the current exceeds 20 ma (display OVL) or falls below 4mA in the range of ma (display E-I ), the Alarm LED lights up, the alarm relay is actuated and the pump stops. Alarm The pump allows to control the metering process. An alarm is indicated visually in the display and forwarded by the warning alarm relay. Low level alarm signaling: The Alarm LED blinks and the alarm relay is actuated. The display shows E-L. Low level main alarm: The Alarm LED is on and the alarm relay is actuated. The pump stops. The display shows E-L. Internal error: The pump carries out a self-check which switches off the pump, if no stroke has been carried out two seconds after startup of motor (e.g. in the case of excessively high backpressure) or if the stroke sensor does not work (display E-2). The alarm is reset by removing the mains plug. Factory setting These settings should only be made if the electronic unit is replaced. Max. number of strokes: Keep the keys Mode and I/0 pressed while applying voltage and set the maximum number of pump strokes using keys and. After releasing the Mode key, normal operation starts. Alarm relay: As a standard the relay is currentless in the case of error and OFF. If the keys Mode and are pressed while applying voltage (display RE0), the relay is currentless in the case of error and OFF, when pressing the keys Mode and, the relay pulls up in the case of error (display RE1). Piston Metering Pump FEDOS E / DX JESCO DOSIERTECHNIK GmbH & Co. KG

21 BW / 5 Circuit diagram Important note! When exchanging the electronic unit, only remove the plug connectors. DO NOT PULL THE CABLE! 1 6 L1 - Motor L - Mains L2 - Motor N - Motor brown black brown black black red blue white blue white green/yellow green/yellow L1 6 1 X1 L bl X3 X2 L2 bn X7 blue blue X4 N sw X5 brown brown black black N - Mains PE - Mains X6 N X8 A U 0 Stroke sensor S1 P1 X9 R0 Break contact R1 Make contact Rw Change over contact Alarm R0 RwR1 brown red blue white black black Cursive corresponds to CSA version Standard configuration: In operation mode R1 and Rw closed In case of failure R0 and Rw closed * blue if CSA version Boards are connected with the rear sides pointing to each other. External Wiring diagram for the input / plug to be connected. ext. OFF AL-H AL-V l/pulse GND GND GND red red blue red black* black black Remote switchoff Prealarm Main alarm + Input 0 Input 0 Level 0 Remote switchoff Level Piston Metering Pump FEDOS E / DX Remote switchoff: 3.5 mm mono jack 1 : Input (+) brown 2 : (0) ground white Low level indication: 3.5 mm stereo jack 1 : Low level main alarm red 2 : Low level prealarm white 3 : 0 (ground) black JESCO DOSIERTECHNIK GmbH & Co. KG

22 BW / 6 External control: Cinch plug 1 : Middle contact = input (+) brown 2 : Outer ring = 0 (ground) white 9. Maintenance Lubrication The piston metering pump FEDOS E/DX requires little maintenance. The gear of the pump is lubricated with gear oil of viscosity class ISO-VG 460 according to DIN (corresponds to SAE 80 according to DIN 51512). The enclosed first filling must be renewed after approximately 500 operating hours. Further oil changes should be carried out every 5,000 operating hours. The filling capacity is about 0.25 l. The actually required quantity of gear oil can be determined by checking the min.-max. markings of the oil gauge. Attention! DX version: To avoid damaging of the approximation initiator, the pump must be switched off before removing the oil gauge. Replacing the piston A defective piston or worn packing can be replaced as follows: 1. The chemical contained in the metering line is drained so that the metering line becomes pressureless. Please observe the aforementioned safety instructions for this purpose. 2. The head is removed using an appropriate tool: Unscrew the attachment screws of the metering head, loosen the gland stud. The metering head is then removed in axial direction from the holder. Slight rotations of the head make dismantling easier. External control: CSA version 3pin cable socket 1 : Input (+,brown) 2 : 0 (ground, blue) 3 : Not used Protective class of the control unit is only reached if ports are protected by caps or serial plug connectors are used. 3. The piston can now be unscrewed from the piston rod and replaced by a new one, if necessary. 4. To change the packing, the gland stud must be unscrewed. The defective packing is removed using a packing worm. Alternatively, a hook can be used to remove the old packing. 5. After cleaning the packing area, the new packing rings are mounted with staggered gaps, and the gland stud fastened sturdily. Attention: The packing material must fit the application and the chemical. 6. The metering head is now pushed in alignment with the piston and the holding flange and fixed with the attachment screws after it has reached it final position. Make sure that the valves are located vertically. 7. The gland stud is tightened carefully to start the bedding-in process of the new packing. For this purpose the pump is run dry first without connection to the medium. After some strokes the gland is tightened once more. 8. After connecting the metering lines the pumps is started as described in section 6, startup. Continue to prestress the gland stud until a minimum leakage occurs. If prestressing is too strong, the return movement of the piston might be restrained. In this case slightly loosen the gland stud again. Piston Metering Pump FEDOS E / DX JESCO DOSIERTECHNIK GmbH & Co. KG

23 BW / Troubleshooting TYPE OF FAULT POSSIBLE CAUSE RECOMMENDED ACTION Pump not delivering. Valves leaking. Clean and remove air from valves. (See also startup of pump.) Tighten screw connections. Valves incorrectly installed. Suction filter, foot valve or suction pipe leaking or blocked. No stroke movement. Reassemble valves. Ensure that the valve balls of suction and discharge valve are located above the valve seats. Clean and seal suction line. Return spring broken. Replace spring. Consider density of the chemical! Suction lift too high. Pump delivering too little Valves blocked or leaking. Clean and re-seal valves. or irregularly. Pump delivering too Pressure on suction side too Install backpressure valve in much. high (pump siphoning). discharge line. Strong leakage at Packing not tightened Tighten gland stud carefully. piston. strong enough. Piston has longitudinal grooves due to normal wear. Excessive wear due to abrasive medium. Replace piston and pakcing. See also section 9, maintenance. Replace PTFE packing by Aramid packing. Pump very noisy. Roller bearing defective. Replace roller bearing. No or little oil in gearbox. Refill oil, as described in section "maintenance". Motor hums and Wrong connection. Check electrical wiring. doesn't start. Capacitor defective, wrong Connect capacitor correctly or size or incorrectly connected. replace. Piston Metering Pump FEDOS E / DX Pressure too high. Check process. Indication of alarm states Low level alarm signaling, Check functions as described in by red LEDs at display. Low level main alarm, chapter 7 (FEDOS DX control unit). internal error. If the problem cannot be corrected on the basis of the above data, return the pump to the factory or contact our Techical Sales Service for further measures. Repairs will be carried out immediately. JESCO DOSIERTECHNIK GmbH & Co. KG

24 MB / 1 General Rekos pumps can be supplied as simplex piston metering pumps type KR and duplex piston metering pumps type ZKR. Advantages of piston metering pumps are: minor dependency on back pressure and linear flow variation as a function of the stroke length. The metering pumps are therefore very suitable for proportional metering where the stroke length is adjsuted by means of a remote control signal. Standard versions have the metering head on the lefthand side. Type KR...L (Symbol ) Upon request metering pumps are available with the metering head on the right-hand side. Type KR...R (Symbol ) For duplex metering pumps, the heads may be combined as listed in the below tables. Depending on the head size they are arranged in parallel (Symbol ) or diagonally (Symbol ) Type code ZKR.../... Metering head Metering heads are supplied in plastic for max. 10 bar and in stainless steel for up to 200 bar. The correct choice of the metering heads depends on the aggressivity of the chemical, its temperature and viscosity, and on the system pressure. Environmental factors (harsh operating conditions, radiant heat) must also be considered. Suction and discharge valves Suction and discharge valves can be supplied as double-ball valves, spring-loaded single-ball valves or disk valves, depending on the size. Spring-loaded valves are recommended if the viscosity of the chemical exceeds 400 mpas. Technical data Flushing attachment Metering heads are generally fitted with a flushing attachment. Flushing water should be applied if the chemical being used is very aggressive, to prevent damage by corrosion from leakage that is bound to occur. If the medium used is abrasive, the flushing water is intended to prevent the piston and packing from failing after only a short time of operation as a result of intensified leakage. The flushing water pressure should,in this case, be greater than that of the medium. Piston Metering Pump REKOS KR REKOS KR Max. pressure Plastic 10 5 [bar] SS Output at [l/h] max. pressure [ml/stroke] Piston ø [mm] Stroke frequency [1/min] 100 Suction lift [mbar] 120 Motor output [kw] 0.55 kw (0.75 kw with frequency converter) Metering Plastic head SS Simplex manual gear ATE/ATP Duplex manual gear ATE/ATP Weight [kg]

25 MB / 2 Abrasive media Piston packings can be supplied as PTFE net packings or Aramid-kevlar packings. PTFE packings with the edges reinforced with Aramid are also available. The standard PTFE packing can be used with practically all chemicals at a pressure of up to 40 bar. Higher pressures may increase leakage. As far as abrasive media are concerned, and in the case of pressures much higher than 40 bar, it may be advisable to use Aramid-kevlar packings, if the chemical allows it. Aramid-kevlar is not resistant to concentrated acids or alkalis. If these substances are to be metered at higher pressures, the user should revert to the edge-reinforced PTFE packing, despite the intensified leakage that will occur, and apply flushing. Piston-diaphragm system KMS Three sizes of piston-diaphragm metering heads are also available. Their use is recommended where, dispite higher pressures, it is important to avoid leakage due to a toxic, aggressive or abrasive chemical being used. Piston-diaphragm metering heads are separated from the transmission lubricant, and have their own hydraulic system (glycerine). Piston-diaphragm metering heads can also be retrofitted to piston metering pumps already installed (see MB ). Functional diagram Plunger disk Return spring for suction stroke Drive cam Eccentric serving as stroke limiter Drive cam moves freely until it reencounters plunger disk. Drive The drive is an oil-filled worm gear with a single-state down mechanism. The stroke is created by means of a drive cam moving back and forth a spring-loaded plunger to which the piston is fixed. The metering stroke is induced by the thrust of the drive cam, the suction stroke by the return spring. Length of stroke is determined by means of a plunger return stop, with a manually adjustable eccentric serving as a stroke limiter. The stroke length, which determines the flow rate, can be adjusted manually during operation in a range of between 0 and 100%. The standard version is equipped with a manual adjustment. Electrical (ATE) remote control adjustment equipment can be supplied on request. The drive motor is normally a three-phase motor. Controllable a.c. motors and explosion-proof motors can also be supplied. Through the combination of a controllable drive motor and a remotely controllable stroke length adjuster, the metering pump is provided with two independent means of adjustment control so that disturbance-variable feedforwarding is possible in automatic control systems. Optional components Stroke counting The metering pump can, on request, be equipped with an inductive scanning head for the eccentric shaft in order to count the number of strokes for batch processes. Metering head heating For fluids which are solid when cold the metering head can be fitted with warm water, steam or electrical heating. Thyristor controller For controlling the direct current drive. (See MB ) For other accessories - see "Installation example". Performance curves Flow rate % without back pressure with back pressure FDOH Piston Metering Pump REKOS KR

26 MB / 3 Simplex pumps Left-hand version KR 8 L... KR 725 L KR 8 R... KR 725 R Right-hand version Piston Metering Pump REKOS KR

27 MB / 4 Duplex pumps ZKR 8-75 / 8-75 ZKR / 8-75 ZKR / 8-75 ZKR / Installation example ZKR / ZKR / With duplex pumps that have differently sized metering heads, the larger metering head is always positioned on the left (L) (other versions on request). Dimensions Pump A B C D Type Plastic SS Plastic SS Plastic SS Plastic SS For dimension (L) see Table 5 Legend 1 Metering pump MB Suction line MB Electric agitator MB Tank MB Relief valve MB Diaphragm shutoff valve MB Injection nozzle MB Pulsation dampener MB Control unit Piston Metering Pump REKOS KR

28 MB / 5 Selection tables To offer the user a large variety of different versions, JESCO metering pumps have been divided into the main functional groups. They can thus be assembled according to the user's individual requirements. The user can combine the pump from the following components: 1 Drive 2 Motor 3 Head 4 Valves 5 Connections The numbers shown on the pump drawing refer to the relevant selection tables. Pump type Gear with capacity adjustmen t manua l KR...L KR...R ** For duplex pumps the metering heads can be of any combination. If they are of different sizes, the larger metering head is given the first in order. ca A TE Combination of heads ** or KMS I 40 3 or KMS I KMS III Piston Metering Pump REKOS KR 6. 21,5 ø 120 ø 100 ø 80 j 6 ø19 k M6 (4 x) 2 E- Motor Part Conn. Voltage Curr.consumption Output Speed Frequency Classes Type No. mode V A kw 1/min Hz ISO Cl. IP AF 80 / 4A D Y 230/400 2,6 / 1,55 0, F 55 AF 80 / 4B D Y 230/400 3,5 / 2,0 0, F 55 AF 80 / 4B D Y 230/400 3,5 / 2,0 0, F* 55 * Motor fitted with cold-conductor thermometer probe.

29 MB / 6 3 Pump- Piston Metering head material type KR d Plastic Piston material Ceramic Pump Standard valves type KR KR Double-ball KR 725 Spring-loaded with hastelloy spring Suction valve assembly Discharge valve assembly PVC PVC Seals of: Hypalon Viton AF Hypalon Viton Hypalon Viton AF Hypalon Viton Pump Spring-loaded valves with hastelloy spring type KR Suction valve complete Discharge valve complete PVC PVC Seals of: Hypalon Viton AF Hypalon Viton Hypalon Viton AF Hypalon Viton Piston Metering Pump REKOS KR

30 MB / 7 5 Pump Dimensions Part No. type Version DN Pict. D di da L Plastic SS 6 A G 3/ A G 3/ A G 3/ B G 3/ B1 d C G 3/ C G 3/ D G 3/4 G 1/ D 1 d 20 G 1/ E 1 d E 1 d E 1 d B G 11/ B G 11/ C G 11/ C G 11/ C G 11/ D G 1 1/4 G 3/ D G 1 1/4 G 1/ D G 1 1/4 G 3/ E G 1 1/ E G 1 1/ F G 1 1/ B C C D1 68 G 3/ D1 68 G D1 68 G 11/ E F KR 725 KR KR Order example Lime slurry is to be metered at a rate of 30 litres per hour against 20 bar. It is required that the metering pump is controlled via ph value so that an electrical stroke adjustment must be provided. The metering head is to be in the standard version, with left hand arrangement. Drive by 400 V 3 phase motor. According to the corrosion resistance list, asbestos-free fiber (AF) is to be selected as the sealing material. Determination of type of metering pump Lime slurry, because of its suspended constituents, can have an abrasive effect and thus cause damage to standard piston metering pumps. Standard diaphragm pumps are not suitable here due to the operating pressure of 20 bar. Therefore a piston diaphragm metering pump must be chosen in this case A Tubing connection C Cemented connection D 1 Threaded connection F Flange connection B Hose clamp connection C 1 Cemented connection E Stainless steel pipe connection B 1 Hose clamp connection D Threaded connection E 1 Screwed (Ermeto) connection F 1 Flange connection The electrically operated stroke length ajduster ATE is selected from table 1: According to MB , KMS size I is used for achieving the required flow rate. The appropriate drive system has Part No The motor required is the 3 phase motor listed in table 2 under Part No The metering head is to be ordered under the clear text as described in MB : KMS metering head size I for 40 l/h lime slurry at 20bar; stainless steel, Part No Valves are to be selected from Table 4. Suction valve: Part No Discharge valve: Part No The connections to be selected from Table 5 are type D with G 1/4. Part No. 2x Piston Metering Pump REKOS KR

31 MB / 8 General Metering pumps for use as a correcting element in control lines or automatic control systems are equipped with a servomotor: The stroke length can thus be adjusted by sensor contacts or controllers with a relay output. In the case of duplex pumps, each metering head may have a separate servomotor and can be adjusted independently. These pumps are described by the letters ATE used as a suffix after the type: e.g.: KR 50 L - ATE Mechanical manual adjustment of the pump with ATE drive is possible using a separate hand crank. Two models with different technical data are available (see pages 10 and 11). On request, "increased safety" and "air-tight" explosionproof servomotors can be offered. Dimensions approx. Pump type KR A B C D E For dimension L see table 5 (MB / 7) approx. Piston Piston Metering Metering Pump Pump REKOS REKOS KR-ATE Montagemaß Mounting dimension

32 MB / 9 Technical data - types AR 30W23 and AR 30W23S Type AR 30W.. AR 30W..S Design Reversible a.c. motor with self-locking reduction gear. Use For controllers with switching For controllers with continuous output (3-point control) output (2...10V or mA) Auxiliary voltage 230V~ ± 15% 24V ~ ± 20% Hz Hz Control V or mA Power consumption 2 W 7 W Regulating time/bevel 360s / 270 = % Position repeating signaling Potentiometer 0.5 W mV = % for remote display Ω = % Limit switch Internal limit switch for limiting Internal limit switch for limiting the angle of rotation. the angle of rotation. Signaling of final position via terminals 16 and 17 Protection class IP 55 (EN 60529) Ambient temperature C Option 2nd potentiometer Ω 0.5 W Limit switches (2 off) max. 250V 1A Wiring diagrams Type AR 30W23 F V~ and AR 30W23 F020 24V ~ Type AR 30W23S F020 24V~ PE Open N Close 230 V~ E A M Position repeating signaling 0...1kOhm Position repeating signaling 0...1kOhm HE HA Volt.-free contacts max. 250 V~ 1A Piston Piston Metering Metering Pump Pump REKOS REKOS KR-ATE V~ ma mV

33 MB / 10 Technical data - types WAN 1 and WAN 1-S Type WAN 1 WAN 1-S Design Reversible a.c. motor with self-locking reduction gear. Use For controllers with switching For controllers with continuous output (3-point control) output 0(4)...20mA Auxiliary voltage 230V~ ± 10% Hz 230V~ ± 10% Hz Other voltage on Control request. 0(4)...20mA Power consumption approx W Regulating time/bevel 360s / 270 = % Position repeating signaling Potentiometer 0.5 W 0(4)...20mA (only as an option) for remote display Ω = % Limit switch Internal limit switch for limiting the angle of rotation. Signaling of final positions via terminals 4 and 5 Protection class IP 54 according to DIN Ambient temperature max. 60 C Option 2nd potentiometer Ω 0.5 W Limit switches (2 off) max. 250V 1A Electrical wiring diagrams WAN 1 WAN 1-S PE Open N Close 230 V~ E A Position repeating signaling 1kOhm Position repeating signaling 1kOhm Control by 230V/ Hz supply voltage M Volt.-free contacts max. 250 V~ 1A Position repeating signaling 0(4)...20mA Piston Piston Metering Metering Pump Pump REKOS REKOS KR-ATE L N V~ CLOSE OPEN - + Final position repeating signaling Conductance 0(4)...20mA Control by 0(4)...20mA standard signal

34 General view of modules ET / 1 see MB / 5 see MB / 7 ET / 3-5 ET / 6-11 ET / 3-5 see MB / 7 ET / Piston Metering Pump REKOS KR Spare parts kits see ET / 2

35 Spare parts kits ET / 2 Include: Pump Head/ Part No. type seal-/ materials Piston KR 8 PVC / Hypalon Packing rings PVC / Viton Positioning rings* / AF Gaskets Valve balls KR 20 PVC / Hypalon Valve seats PVC / Viton / AF KR 30 PVC / Hypalon PVC / Viton / AF KR 40 PVC / Hypalon PVC / Viton / AF KR 75 PVC / Hypalon PVC / Viton / AF KR 125 PE / Hypalon PE / Viton / AF KR 180 PE / Hypalon PE / Viton / AF KR 295 PE / Hypalon PE / Viton / AF KR 420 PE / Hypalon PE / Viton / AF Piston KR 725 PE / Hypalon Packing rings PE / Viton O-rings / Hypalon Valve springs / Viton Valve seats Valve disks Piston Metering Pump REKOS KR * only in the case of stainless steel models KR 8... KR 75

36 Valves DN 6 for Rekos KR ET / 3 upvc version Item Description Material Part Double-ball valve Spring-loaded valve No. Suction valve Discharge valve Suction valve Discharge valve PVC PVC PVC PVC Seal material: H=Hypalon, V=Viton, AF=asbestos free H V AF H V AF H V AF H V AF Double-ball valves Valve housing PVC Ball guide PVC PVC Valve ball Ceramic Valve seat PVC Gasket Hypalon Viton AF Gasket Hypalon Viton Gasket Hypalon Viton Valve spring Hastelloy Stainless steel version Suction valve Discharge valve Discharge valve Suction valve Spring-loaded valves Suction valve Discharge valve Suction valve Discharge valve Piston Metering Pump REKOS KR

37 DN 10 Valves for Rekos ET / 4 Suction valve PP version Discharge valve Suction valve Stainless steel version Discharge valve Item Description Material Part Double-ball valve Spring-loaded valve No. Suction valve Discharge valve Suction valve Discharge valve PP PP PP PP Sealing Material: H=Hypalon, V=Viton, AF=asbestos free fibrous seal H V AF H V AF H V AF H V AF 1 Valve housing PP Ball guide PP PP Valve ball KER d Valve seat PP Gasket Hypalon Viton AF Gasket Hypalon Viton AF Gasket Hypalon Viton Valve spring Hastelloy Piston Metering Pump REKOS KR

38 Valves DN 25 for Rekos KR 725 ET / 5 Item Description Material Part No. Suction and discharge valve PP EPDM Viton EPDM Viton Valve assembly Valve guide PP Valve disk PVDF Flat valve seat PP Piston Metering Pump REKOS KR 4 O-ring Hypalon Viton Valve spring Hastelloy

39 Plastic head for KR ET / 6 Item Qty Description Material Piston material Ceramic Pump type KR 8 KR 20 KR 30 KR 40 KR Piston housing PVC Piston Ceramic Gland PVC Thrust collar PVC Flushing bush PVC Prop ring PVC Packing ring PTFE-silk packing Locking screw PVC Piston Metering Pump REKOS KR

40 Plastic head for ET / 7 Item Qty Description Material Piston material = Ceramic Pump type KR 125 KR 180 KR 295 KR Piston housing PE Piston Ceramic Gland PVC Thrust collar PVC Flushing bush PVC Prop ring PVC Packing ring PTFE-silk packing Spacer Al Seperator bolt **8 Hexagonal nut A **8 Washer A Locking screw PVC Cap PE Stuffing-box flange St ** with stuffing-box flange 12 off required Piston Metering Pump REKOS KR

41 Plastic head for KR 725 ET / ,11,14 13 Item Oty Description 1 1 Piston housing 2 1 Piston 3 1 Stuffing-box packing 4 1 Thrust collar 5 1 Flushing bush 6 1 Prop ring 7 5 Packing ring 8 1 Spacer 9 4 eperator bolt exagonal nut asher 12 2 Locking screw 13 2 Valve cap 14 4 Cap 15 1 tuffing-box flange Material S 1 H 2 W 2 S 5 Piston material Ceramic KR PE Ceramic PVC PVC PVC PVC PTFE-silk packing Al A A PVC PP PE Piston Metering Pump REKOS KR

42 Stainless steel for KR ET / 9 Item Qty Description Material Piston material Pump type KR 8 KR 20 KR 30 KR 40 KR Piston housing Piston Gland Thrust collar Flushing bush Prop ring Packing ring PTFE-silk packing Locking screw Gasket AF Supporting ring PVDF Piston Metering Pump REKOS KR

43 Stainless steel for KR ET / 10 Item Qty Description Material Piston material = Pump type KR 125 KR 180 KR 295 KR Piston housing Piston Gland Thrust collar Flushing bush Prop ring Packing ring PTFE-silk packing Locking screw Gasket Klingerit Disk A Socket screw A Piston Metering Pump REKOS KR

44 Stainless steel for KR 725 ET / 11 Item Qty Description Material Piston material KR Piston housing Piston Stuffing-bo x Thrust collar Flushing bush Prop ring Packing ring PTFE-silk packing Threaded plug Valve cap Separator bolt Washe r A Hexagonal nut A Gasket AF Stuffing-box flange Piston Metering Pump REKOS KR

45 Single drive ET / 12 Piston Metering Pump REKOS KR

46 Duplex drive ET / 13 Piston Metering Pump REKOS KR

47 Drive ET / 14 Item Description Material Part No. Single drive Duplex drive 1 Gear housing, single Cast iron Gear housing, duplex Cast iron Eccentric housing Al Oil gauge G 3/4 Plexi Bearing flange Al Bearing flange Al Driving shaft single St Driving shaft ZKR parallel St Driving shaft ZKR diagonal St Driving eccentric St Adjusting eccentric Plastic Adjusting eccentric Steel Adjusting knob Plastic Thumbscrew d 50 - M8 x 30 Plastic Scale Plastic Retaining ring 62 x 2 Spring steel Pinion shaft St Piston rod Return spring Spring steel Worm shaft 13.5 St Worm wheel 13.5 Bronze Ball bearing 30/62/16 St Ball bearing 10/35/11 St Retaining ring A 30 x 1.5 Spring steel Retaining ring A 15 x 1 Spring steel Housing base Al Plug G 1/4 Brass Seal 120/90/1 AF Seal 165/90/1 AF Seal 100/70/1 AF Seal 120/80/1 AF Disk 8.4 A Locking ring 18/35/8 Simrit Adjusting spring A 5 x 5 x 40 St Adjusting spring A 6 x 6 x 28 St Retaining ring A 25 x 1.2 Spring steel Retaining ring A 55 x 2 Spring steel Hex. head screw M8 x 20 A Cylinder head screw M6 x galv Cylinder head screw M8 x galv Cylinder head screw M6 x galv Clamping flange for KR Cast iron (1) (2) Screw flange for KMS I Cast iron (1) (1) Screw flange for KR Cast iron (1) (2) Screw flange for KMS II Cast iron (1) (2) Screw flange for KR 725 Cast iron (1) (2) Screw flange for KMS III Cast iron/st (1) (2) 39 Cylinder head screw M8 x 30 A Disk 8.4 A Adjusting spring A 8 x 7 x 36 St Deflector disk 60/17/1.5 Hypalon Ball bearing 25/62/17 St Needle bearing 55/85/28 St Buffer disk St O-ring 25 x 2.5 Perbunan Gasket 18/13/1.2 AF Plug 13.1 PE Spring ø20/8.2 x Supporting plate 15/21/1.5 Spring steel Cylinder head screw M8 x 20 A2 1) ) For screw flange the Part No. of the screw is Piston Metering Pump REKOS KR

48 ATE - Drive ET / 15 Item Description Material Part No. KR ZKR x Servomotor 220V~ misc Support Al Threaded rod M8/M Coupling d Clamping pin 5 x 26 St Locking plate 8.4 A Hex. head screw M8x35 A Cyl. head screw M6 x 20 A Washer 5.3 A Cyl. head screw M5 x 20 A Spring washer 20/8.2x1 A Setscrew M8 x 20 A Washer Brass Piston Metering Pump REKOS KR

49 Operating and maintenance instructions BW / 1 Contents 1. Technical data 2. Scope of delivery 3. Installation 4. Electrical connection of the pump 5. Safety instructions 6. Installation of the injection nozzle 7. Start-up 8. Maintenance 9. Troubleshooting 1. Technical data REKOS KR max. pressure Plastic [bar] Stainless steel Flow rate at [l/h] 2, max. pressure [ml/stroke] Piston dia. [mm] Stroke freq. 1/min 100 Suction head [mbar] 120 Motor rating [kw] 0.55 kw Metering Plastic head Stainless steel Single manual gear ATE/ATP Duplex manual gear ATE/ATP Weight [kg] The operating instructions for the metering pump and accessories must be kept within easy reach. 2. Scope of delivery The metering pump and any enclosed accessories must be unpacked with care so that small parts do not remain unnoticed in the packaging. The parts delivered must be checked immediately against the delivery note and any discrepancies investigated without delay. REKOS KR 3. Installation When planning, installing and operating a system, the metering pump must be selected with due regard to the local regulations. This applies to the choice of suitable pump materials, the handling of the chemicals and the electrical installation. The technical data of the pump listed above must also be taken into account and the system dimensioned accordingly (e.g. loss of pressure when dimensioning the line with regard to nominal width and length). The planning engineer and user are responsible for ensuring that the entire system with integrated metering pump is designed in such a way that leaking chemicals due to a failure of wear parts (e.g. worn packing) or ruptured tubing do not cause any permanent damage to system parts and buildings. If there is a large danger potential of the chemical plant the installation must be designed in such a way as to prevent unnecessarily high consequential damage even if the metering pump fails. We therefore recommend to install leakage monitors and containment tanks. Note: Due to their design piston pumps are not leakage-free. This must be taken into account when planning the process and the system. Metering pumps are designed according to the highest quality standards and have a long service life. Despite this, some parts are subject to wear caused by operation (e.g. piston, packing, valve seats, valve balls). Regular visual inspection is therefore necessary to ensure reliable longterm operation. The metering pump must be installed so that it is readily accessible to operating and maintenance personnel. It should be serviced regularly to avoid downtimes. Supplementary fittings are recommended to increase the metering accuracy and functional reliability. Such fittings include backpressure valves, relief valves, leakage monitors and low-level warning devices as shown in the following installation example. Suitable tools must always be used to work on plastic connecting parts. Undue force must never be applied as otherwise the parts may be damaged or destroyed. Plastic parts (particularly those made of PVC) can be screwed and unscrewed more easily if the thread has been lubricated with Vaseline or silicone grease. Note: The compatibility of the Vaseline or grease with the metered chemical must always be checked first. The ambient temperature of the pump must not exceed 40 C. Radiated heat from devices and heat exchangers must be shielded so that the metering pump can still dissipate its own heat. Direct sunlight must be avoided. A canopy roof must be provided to protect the pump against the weather when installed outdoors.

50 BW / 2 The metering pump must be installed with suction and discharge valves in an upright position. It must be bolted onto suitable ground to ensure stability. The system piping must not apply any forces to the connections and valves of the metering pump. The pump must be interlocked electrically and hydraulically to prevent accidental metering after the process has ended. Installation example Electrical connection data Pump Voltage Power Current size [Volt] [kw] [A]...KR / / Hz...KR / / Hz...KR / / Hz...KR / / Hz...KR / / Hz...KR / / Hz REKOS KR Wiring diagram of the drive motor - 3-phase supply Legend 1 REKOS KR MB Suction line MB Electric agitator MB Tank MB Relief valve MB Diaphragm shutoff valve MB Injection nozzle MB Pulsation dampener MB Backpressure valve MB circuit - Special version Other electrical versions can be found in the separate circuit diagrams. - Electric servomotor ATE The technical data and connection diagrams can be found on page BW / Safety instructions circuit 4. Electrical connection of the pump - The electrical connection of the metering pump must be in accordance with the local regulations and may only be carried out by qualified personnel. - The cable type and cross-section of the power supply cables must be selected according to the motor data. - The cable bushing to the motor terminal box must be made correctly. We recommend the use of compression glands with strain relief. - The required protection class must be ensured by correct installation of the electrical connections. The safety rules applicable on site must be observed when working on metering plants (e.g. use of personal protective equipment). Before starting any work on the metering pump and system, all mains lines must be disconnected and secured against reconnection. The metering lines must be connected before reconnecting the power supply in order to prevent any chemical still in the metering head from being expelled. Important: The piston area must remain open for checking, which may be dangerous if accessed directly. Maintenance work in the piston area may only be carried out if the pump is switched off.

51 BW / 3 The metering head of the pump and the system connections and lines may be under pressure. Working on the metering pump requires special safety precautions and may only be carried out by instructed, qualified personnel. Before startup, all screwed connections must be checked for correct tightness and, if necessary, must be tightened up using appropriate tools. If connections at the metering head are unscrewed during operation for venting or other reasons, leaking chemical must be removed correctly and completely. This is the only way to avoid the danger of physical injury and corrosion at the metering pump. Leaking chemical may also affect the pump housing. When changing the chemical, check whether the materials used for the metering pump and the other plant parts are chemically resistant. If there is the danger of a chemical reaction between different media, thorough cleaning first is mandatory. To operate the pump mount the fan shell in order to ensure sufficient cooling of the motor. 6. Installation of injection nozzle Injection nozzles are fitted with either spring-loaded ball valve or tube valve to prevent any return flow. Injection from bottom to top is recommended to allow air bubbles to escape and to be carried away so that precipitations are avoided. The experience with the chemical to be metered and its properties must be taken into account. 7. Startup 1. All the work described in the section Installation must be carried out before starting the metering pump. The safety instructions must also be observed. 2. The metering pump is switched on via a control system to be installed externally. 3. The manual or electrical capacity adjustment must be set to maximum stroke to improve priming. During first priming no backpressure should be applied. For this purpose we recommend to install a relief valve on the discharge side of the metering pump. 4. A previously installed priming aid must be filled with chemical first. If the pump is not priming, remove the discharge valve and fill water or chemical (if not dangerous!) into the metering head. Remount valve and start priming. 5. If a venting facility is available as separate unit, open it and wait until liquid flows out. Then close it again. In the case of effervescent liquids allow the liquid to flow out permanently (approx. 1 drop for strokes). 6. When correct operation is achieved, set to required output by means of the adjusting knob or remote adjustment. For first approximation refer to the values shown in the "Technical data" table. Depending on the installation and the chemicals used, these values may differ and must be checked under operating conditions. 7. The manufacturer of the metering equipment is not responsible for damages due to excessive or low flow rates resulting from faulty pump settings or incorrect and insufficient installation of peripheral fittings. REKOS KR Injection nozzle

52 BW / 4 8. Maintenance Lubrication The piston metering pump REKOS KR is designed for easy maintenance. The gear of the pump is lubricated with gear oil of viscosity class ISO-VG100 according to DIN (corresponds to SAE 80 as defined by DIN 51512). The initial filling provided should be replaced after approx. 500 hours of operation. The oil should then be changed every 5,000 hours of operation. The capacity equals 0.7 liters for the single gear and approx. 0.9 litres for the duplex gear. The amount of gear oil actually required can be read off from the oil gauge: the oil is filled up to the middle of the viewglass. 7. The gland stud is tightened carefully to start the bedding-in process of the new packing. For this purpose the pump is run dry first without connection to the medium. After some strokes the gland is retightened. 8. After connecting the metering lines the pumps is started as described in the 'Startup' section. Continue to prestress the gland stud until a minimum leakage occurs. If prestressing is too strong, the return movement of the piston might be restrained. In this case slightly loosen the gland stud again. REKOS KR Replacing the piston Proceed as follows to replace a defective metering piston or worn packing: 1. The chemical contained in the metering line must be drained to depressurize the metering line. Please observe the aforementioned safety instructions for this purpose. 2. The head is removed using an appropriate tool: Unscrew the attachment screws of the metering head, loosen the gland stud. The metering head is then removed in axial direction from the holder. Slight rotations of the head make dismantling easier. 3. The piston can now be unscrewed from the piston rod and replaced by a new one, if necessary. 4. To change the packing, the gland stud must be unscrewed. The defective packing is removed using a packing worm. Alternatively, a hook can be used to remove the old packing. 5. After cleaning the packing area, the new packing rings are fitted with offset joints and the gland studs fastened sturdily. Caution: The seal material must be compatible with the application and with the chemical. 6. The metering head is now pushed in alignment with the piston and the holding flange and fixed with the attachment screws after it has reached it final position. Make sure that the valves are positioned vertically.

53 BW / 5 9. Troubleshooting TYPE OF FAULT POSSIBLE CAUSE RECOMMENDED ACTION Metering not delivering. Valves leaking. Clean and remove air from valves (see also startup of pump). Tighten screw connections. Valves installed incorrectly. Reassemble valves. Ensure that the valve balls of suction and discharge valves are located above the valve seats. REKOS KR Suction filter, foot valve or suction line leaking or blocked. No stroke movement. Clean and seal suction line. Return spring broken. Replace spring Consider density of medium! Suction lift too high. Pump delivering too little Valves blocked or Clean and reseal valves. or irregularly. leaking. Pump delivering Pressure on suction side too Install backpressure valve too much. high (pump siphoning). in discharge line. Major leakage at Packing not tightened Tighten gland stud carefully. piston. sufficiently. Piston has longitucinal grooves due to normal wear. Replace piston and packing. See also section 8, maintenance. Excessive wear due to abrasive medium. Use aramid seal instead of PTFE seal. Pump very noisy. Defective rolling bearing. Replace roller bearing. No oil or too little oil in gearing. Refill oil, as described in section "maintenance". Motor hums but and does Wrong connection. Check electrical wiring. not start. Pressure too high. Check process. If the problem cannot be corrected on the basis of the above data, return the pump to the factory or contact our Techical Sales Service for further measures. Repairs will be carried out immediately.

54 Operating and maintenance instructions BW / 7 The operating instructions for the metering pump and accessories must be kept within easy reach. Contents 1. General 2. Technical data 3. Installation 4. Safety instructions 5. Wiring diagrams 6. Start-up 7. Manual adjustment 8. Maintenance 1. General The metering pump is installed in accordance with the applicable operating instructions. The following description refers exclusively to the ATE servomotor, types AR 30W.. and AR 30W..S. 2. Technical data Type AR 30W23 AR 30W23S Design Reversible AC motor with self-locking step-down gear. Electrical connections via two PG 16 glands to screw-type terminals 1.5 mm 2 ) Use For controllers with switching For controllers with constant output (3-point control) output (0(2)...10V or 0(4)...20mA) Auxiliary voltage 230V~ ± 15% 24V ~ ± 20% Hz Hz Control (24 V ~ ± 20% on request) 0(2)...10V or 0(4)...20 ma Internal impedance 30 kω at 0-10 V, 500 Ω at 0-20mA Power consumption approx. 5 VA approx. 6W (approx. 2 VA at standstill) Actuating time / bevel 360 s / 270 = % (330 s at 60 Hz) Position feedback Potentiometer 1 W mV- ^= % for remote display Ω = % V- ^= % Permissible load 2,5 kω at V- 100 kω mv- Limit switches Internal limit switches for Internal limit switches for limiting the angle of rotation. Limit position signalled via terminals 16 and 17 (Important: note potential) Protection class IP 55 according to EN (with cable gland) Ambient temperature C C Optional 2nd potentiometer Ω 1 W Limit switches (2 off) max. 250V~ 2A 3. Installation The ATE servomotor is connected to the pump and calibrated in the factory. When installing the servomotor, sufficient clearance of at least 150 mm must be provided for later maintenance works. The electrical connection of the ATE drive must correspond to the local regulations and may only be carried out by technical personnel. The two basic connection versions possible are shown in the following wiring diagrams. Cable type and cable cross-section must be selected according to the motor data. The cable passage to the motor terminal box must be made professionally. The use of gland screw connection with strain relief is recommended. The required protection class must be ensured by correct installation of the electrical connections. Please take into account that the ATE drive can only be actuated with the main motor running, i.e.: the ATE drive must be locked electrically, otherwise the adjusting eccentric wears out frequently or is destroyed. limiting the angle of rotation. REKOS KR - ATE (AR 30W23)

55 BW / 8 4. Safety instructions The following safety instructions refer to the ATE servomotor. Furthermore, the notes contained in the enclosed operating instructions of the metering pump also apply to this extended version. When working on the metering equipment, observe the local safety rules. Before working on the metering pump and the ATE servomotor, disconnect the main power supply and protect it against reconnection. Adjustment works in the interior of the ATE drive must be carried out carefully. Connections and internal limit switches might be "alive". Additional limit switches might be "alive" even with the auxiliary voltage switched off. After installation works at the ATE servomotor or before startup remount the cover. 5. Wiring diagrams Connecting terminals mm 2 6. Start-up Switch on the main drive motor of the metering pump. The installed electrical interlocking system prevents adjustment of the ATE drive until the main drive motor is running. Apply brief control pulses to the ATE servomotor to check the sense of rotation. If the sense of rotation is wrong, the supply lines (terminals 2 and 3 in the case of direct controls) are reversed. The ATE servomotor must be moved to the respective final positions in order to check the limit stop mechanism of the integrated limit switches. The angle of rotation provided by the manufacturer equals 270. If necessary, the angle of rotation and thus the maximum flow rate can be restricted by adjusting the upper switching cam to the required amount. 7. Manual adjustment of the ATE drive In the case of an electrical failure of the ATE servomotor, it can be adjusted manually by means of a hand crank. The crank can be ordered as accessory part No For manual adjustment proceed as follows: 1. Switch off power supply to the ATE servomotor. 2. Remove ATE cover. 3. Switch on main drive motor. 4. Insert the hand crank in the opening provided, as shown below, and turn it into the required direction. Important: The limit positions must not be crossed! 5. After manual adjustment is complete remount the cover. REKOS KR - ATE (AR 30W23) AR 30 W 23 F V ~ AR 30 W 23 F V ~ 24 V connecting terminals mm Adjustment of angle of rotation Insert and turn hand crank AR 30 W 23 S F 020 S5 y =0...10V-/0...20mA S4 yo=0...10v-/ mv 8. Maintenance The ATE servomotor has been lubricated for life before leaving the factory. Nevertheless, regular inspections are recommended if the drive is operated under extreme service conditions, such as high ambient temperatures or in continuous operation. Molybdenum bisulphite is used to relubricate the ATE gear. Suitable grades include Molykote BR2plus and OKS400.

56 Operating manual / maintenance instructions BW / 9 The operating instructions for the metering pump and accessories must be kept within easy reach. Contents 1. General 2. Technical data 3. Installation 4. Safety instructions 5. Wiring diagrams 6. Start-up 7. Maintenance 1. General The metering pump is installed in accordance with the applicable operating instructions. The following description refers exclusively to the ATE servomotor, types WAN 1 and WAN 1-S. 2. Technical data 3. Installation The ATE servomotor is connected to the pump and calibrated in the factory. When installing the servomotor, sufficient clearance of at least 150 mm must be provided for later maintenance works. The electrical connection of the ATE drive must correspond to the local regulations and may only be carried out by technical personnel. The two basic connection versions possible are shown in the following wiring diagrams. Cable type and cable cross-section must be selected according to the motor data. The cable passage to the motor terminal box must be made professionally. The use of gland screw connection with strain relief is recommended. The required protection class must be ensured by correct installation of the electrical connections. Please take into account that the ATE drive can only be actuated with the main motor running, i.e.: the ATE drive must be locked electrically, otherwise the adjusting eccentric wears out frequently or is destroyed. Type WAN 1 WAN 1-S Design Reversible AC motor with self-locking step-down gear. Use For controllers with switching For controllers with constant output (3-point control) output 0(4)...20mA Auxiliary voltage 230V~ ± 10% Hz 230V~ ± 10% Hz Other voltages on request Control 0(4)...20mA Power consumption approx W Actuating time / bevel 360 s / 270 = % Position feedback Potentiometer 0.5 W 0(4)...20mA (only as an option) for remote display Ω = % Limit switches Internal limit switches for limitation of the angle of rotation. Limit position signalled via terminals 4 and 5 Protection class IP 54 according to DIN Ambient temperature max. 60 C Optional 2nd potentiometer Ω 0.5 W Limit switches (2 off) max. 250V 1A REKOS REKOS KR - KR ATE - ATE (AR (WAN..) 30W23)

57 BW / Safety instructions The following safety instructions refer to the ATE servomotor. Furthermore, the notes contained in the enclosed operating instructions of the metering pump also apply to this extended version. When working on the metering equipment, observe the local safety rules. Before working on the metering pump and the ATE servomotor, disconnect the main power supply and protect it against reconnection. Adjustment works in the interior of the ATE drive must be carried out carefully. Connections and internal limit switches might be "alive". Additional limit switches might be "alive" even with the auxiliary voltage switched off. After installation works at the ATE servomotor or before startup remount the cover. 5. Wiring diagrams PE V/50Hz WAN 1 Open N Closed Control by 230V/ Hz supply voltage M Position repeating signaling 1 k Ω Position repeating signaling 1 k Ω OPTION Volt.-free contacts max 250V~ 1A Position repeating signaling 0/ ma 6. Start-up Switch on the main drive motor of the metering pump. The installed electrical interlocking system prevents adjustment of the ATE drive until the main drive motor is running. Apply brief control pulses to the ATE servomotor to check the sense of rotation. If the sense of rotation is wrong, the supply lines (terminals 2 and 3 in the case of direct controls) are reversed. The ATE servomotor must be moved to the respective final positions in order to check the limit stop mechanism of the integrated limit switches. The angle of rotation provided by the manufacturer equals 270. If necessary, the angle of rotation and thus the maximum flow rate can be restricted by adjusting the upper switching cam to the required amount. 7. Maintenance The ATE servomotor has been lubricated for life before leaving the factory. Nevertheless, regular inspections are recommended if the drive is operated under extreme service conditions, such as high ambient temperatures or in continuous operation. Molybdenum disulphite is used to relubricate the ATE gear. Suitable grades include Molykote BR2plus and OKS400. REKOS REKOS KR - KR ATE - ATE (AR 30W23) (WAN..) PE 230V~ WAN 1-S L N 4 5 Open Closed Final position repeating signaling Control by 0(4)...20mA standard signal Conductance 0/ ma

58 MB / 1 General KARDOS stands for a group of precision metering pumps which have been developed especially for applications with a high demand for accuracy, reliability and flexibility in a wide performance range. Versions The symmetrically designed gearbox allows the arrangement of two metering heads on the same level and the stacking of three heads above one another, thus enabling a maximally 6-head pump. Each metering head is 100% adjustable independently. Any speed adjustment to the main drive has a simultaneous effect on all metering - heads, but the relative volume ratios remain unchanged. Standard versions have the metering head on the left-hand side. Type N...L (Symbol ) Upon request, pumps with the metering head on the right-hand side are available. Type designation Type N... R (Symbol ) Duplex metering pumps are available with the metering heads opposite to each other. Type ZN... (Symbol ) Metering head The correct choice of the metering head depends on the aggessivity of the chemical, its temperature and viscosity, and on the system pressure. Environmental factors (rough operating conditions, radiant heat, etc.) must also be taken into consideration. Plastic metering heads can be used up to 10 bar ; stainless steel metering heads allow operating pressures of up to max. 400 bar. Metering head pistons are available in ceramic or stainless steel material (see selection table). Suction and discharge valves Suction and discharge valves can be supplied as double-ball or spring-loaded single-ball valves. Spring-loaded valves are to be recommended if the chemical used has a viscosity exceeding 400 mpas. Flushing attachment As a standard the metering heads are provided with a flushing lantern. Flushing water should be connected if the chemical is very aggressive, in order not to cause any corrosion damage due to unavoidable leakages. If the medium is abrasive, the flushing water will prevent premature failure of the piston and packing in the event of severe leakage. In this case, the pressure of the flushing water should be higher than that of the medium. Piston Metering Pump KARDOS N

59 MB / 2 Technical data KARDOS N Max. pressure plastic [bar] SS Flow rate at max. [l/h] pressure [ml/stroke] Piston- ø [mm] Stroke frequency [1/min] 100 Suction lift [mbar] 120 Motor power [kw] selectable Weight [kg] Metering head Simplex gear Duplex gear Abrasive media Piston packings are available as: 1. PTFE-braided packing and 2. Aramid-kevlar packing Functional diagram plastic SS manual ATE manual ATE The standard PTFE packing can be used for basically all chemicals up to a pressure of 100 bar. At higher pressures, leckage may become more severe. In the case of abrasive media or pressures much higher than 100 bar, it is advisable to use aramidkevlar packings if compatible with the chemical used. Aramid-kevlar is not resistant to concentrated acids ar alkalis. If these are to be metered against higher pressures, the PTFE packing must be used despite the more severe leakage, and, possibly, the flushing attachment must be connected. Stroke travel Stroke adjustment by handwheel or electrical servomotor Crank radius Gear rack for continuous adjustment of eccentricity and thus of stroke Connecting rod Worm gear Motor Drive The drive consists of an oil-filled worm gear with single-stage reduction. The heart of the KARDOS drive is the radially displaceable cam. It can be adjusted via the helical gear rack according to the desired flow rate. An advantage of this system is that, after stroke adjustment, there is no relative movement of the sliding parts. The cam acts like a rigid crank pin. The drive is normally a 3-phase motor, although variable DC motors and explosion-proof motors are available. The stroke length, which determines the flow rate, can be varied linearly during operation between 0 and 100%. The standard version is equipped with manual adjustment. Upon request, electrical remote adjustment (ATE) is available. By combining the variable drive motor and the remotely settable stroke length adjustment, two independent control points for the metering pump are available, and enable disturbance variable superimposition in automatic control systems. Performance curves Output % without back pressure with maximum back pressure Stroke or speed setting % Piston Metering Pump KARDOS N

60 MB / 3 Accessories Stroke counter Upon request, the metering pump can be fitted with an inductive scanner button to count the strokes. Proportional metering e.g. as a function of water meter contacts, where every contact initiates a positively adjustable pump running time of 1 to 30 seconds (see data sheets MB ). Dimension table for simplex and duplex pumps Simplex pump Metering head heating For fluids which are solid when cold the metering head can be fitted with a warm water, steam or electrical heating. Remote control Electrical, reversible sevomotor for remote adjustment of the stroke length via a manual key or via a 3-point step controller. See data sheet MB / 9 for details. Pump A B C D E Type Plastic SS Plastic SS Plastic SS Plastic SS Plastic SS N N N N N Piston Metering Pump KARDOS N

61 MB / 4 Douplex pump E Piston Metering Pump KARDOS N

62 MB / 5 1.Metering pump KARDOS N MB Pulsation dampener for suction line MB Pulsation dampener for discharge line MB Relief valve MB Backpressure valve MB lnjection nozzle MB Selection tables In order to offer the user a wide variety of pumps, the metering pumps have been divided into the most important functional groups. These can be combined individually as required. 1 4 Gear Valves 2 5 Motor Connections 3 Metering head 7. Electric agitator MB Polyethylene tank MB Shutoff valve MB Dirt trap MB Low level protection MB The accessories shown may be fitted as required. The numbers of the pump drawing refer to the corresponding selection tables. More than 2 metering heads or superimposed metering heads on request. Piston Metering Pump KARDOS N

63 MB / 6 1 Gear Left-hand version Right-hand version Output adjustment Pump type manual ATE manual ATE N N N N N Gear for multiple-head pumps upon request. Coupling Piston Metering Pump KARDOS N 2 Motor Voltage 380/220 V, frequency 50 Hz, Y circuit, ISO class B, lp 54 Motor type Motor Motor Current Power Speed Assbly Part consumpt. Dimensions [mm] PartNo No [A] [kw] [1/min] a g~ s e f b d I u t k~ RF0.55/ / RF0.75/ / RF1.1/ / RF1.5/ / RF2.2/ / M Other motor versions upon request. P = a x Q x (p+i) P [Watt] p [bar] pressure Determination of motor power (approximation values for single and duplex pumps). Q [l/h] a = 0.125

64 MB / 7 3 Metering head Packing material* PTFE silk packing Metering head material Plastic Piston material Ceramic Pump type Piston-ø ) * Other materials upon request. 1) Piston material SS Valves Seal material Viton Hypalon AF Valve material Plastic Plastic Valve type Pump type S D S D S D S D S D Double-ball N N valves N N Spring-loaded N N single-ball N N valves N N N N S = Suction valve D = Discharge valve AF = asbestos-free fiber packing Piston Metering Pump KARDOS N

65 N N N N MB / 8 5 Connections Pump Dimensions Part No. type material DN Abb. ø D di da L Plastic A G 3/ A G 3/ A G 3/ B G 3/ B1 ø C G 3/ C G 3/ D G 3/4 G 1/ D1 ø 20 G 1/ E1 ø E1 ø E1 ø B G 11/ B G 11/ C G 11/ C G 11/ C G 11/ D G 11/4 G 3/ D G 11/4 G 1/ B C C D1 68 G D1 68 G 1 1/ E F C D1 100 G 11/ F C F D1 100 G Pump selection It can be seen from MB / 1 that the KARDOS N 4200 metering pump is suitable for this application. Since an abrasive medium is involved, the packing material should be aramid and the metering head and piston should be made of stainless steel Hypalon seals are resistant to this medium and are therefore satisfactory. Order example A metering pump is required for injecting lime slurry. The l/h of lime slurry at 20 C have to be metered against 3bar. The output has to be manually adjustable. C C1 D Cemented connection Threaded connection D1 E1 F1 Threaded Stainless steel pipe Flange connection connection connection Order The metering pump consists of the following modules: A B B1 Tubing Hose clamp connection connection Gear: Part No Drive motor: Part No Metering head: Part No with aramid kevlar packing Suction valve: Part No Discharge valve: Part No Piston Metering Pump KARDOS N 5 Connections suction and discharge side, 2 off Part No

66 MB / 9 General Metering heads with a servomotor are used as correcting elements in automatic control systems or control lines. A reversible AC motor allows to adjust the stroke length for each metering head, in the case of multiple-head pumps separately for each head. Manual adjustment is possible by using the hand wheel. This type of pump is specified by adding "ATE" to the name, e.g. KARDOS N 65-ATE. Technical data of the servomotor Design: reversible AC motor with reduction gear Mains connection: 220 V, 50 Hz approx. 10 VA Protection class: IP 54 ISO Cl. B Ambient temperature: - 15 C C Regulating distance: 50 rotations Regulating time: 2 minutes Position indication: mounted handwheel with scale Remote display: integrated potentiometer with 1000 Ohm overall resistance Weight: extra weight 3 kg Other versions of power supply or possibilities of control upon request. Wiring diagram Caution! The ATE servomotor must not be in operation when the pump motor is not working. Therefore the main motor is to be locked electrically. E A Additional equipment: 1. other repeating signaling resistance than 1000 Ohm 2. higher protection class IP other power supply Piston Piston Metering Metering Pump Pump KARDOS KARDOS N - ATE N 230 V PE Open N Close Position repeating signaling 1 k Ω Position repeating signaling 1 k Ω Option Volt.-free contacts max. 250 V 1A Position repeating signaling 0(4) 20 ma

67 MB / 10 Dimensions KARDOS N - ATE L C L For dimension L refer to table 5 Pumpe type approx D B A Stainless steel metering head , Dimensions 150 approx Plastic metering head A B C D A B C D Piston Piston Metering Metering Pump Pump KARDOS KARDOS N - ATE N N N N N

68 Piston Metering Pump KARDOS N ET / 1 see MB / 5 see MB / 7 ET / ET / ET / ET / see MB / 7 For spare parts kit see ET / 2

69 ET / 2 Spare parts kits Piston Metering Pump KARDOS N include: Pump Metering head/ Part type packing No. material Piston N 16 PVC / Hypalon Packing rings PVC / Viton Gaskets / AF Valve balls N 36 PVC / Hypalon Valve seats PVC / Viton / AF N 56 PVC / Hypalon PVC / Viton / AF N 72 PVC / Hypalon PVC / Viton / AF N 130 PP / Hypalon PP / Viton / AF N 225 PP / Hypalon PP / Viton / AF N 320 PP / Hypylon PP / Viton / AF N 530 PP / Hypalon PP / Viton / AF Piston N 750 PP / Hypalon Packing rings PP / Viton O-rings / Hypalon Valve semi-balls / Viton Valve seats N 1300 PP / Hypalon Valve springs PP / Viton / Hypalon / Viton N 2500 PP / Hypalon PP / Viton / Hypalon / Viton Piston N 4200 PP / Hypalon Packing rings PP / Viton O-rings / Hypalon Gaskets / Viton Valve semi-balls Valve seats Valve springs AF=asbestos-free

70 ET / 3 DN 6 valves for KARDOS N N 72 PVC version Double-ball valve Stainless steel version Piston Metering Pump KARDOS N Suction valve Discharge valve Suction valve Discharge valve Spring-loaded valves Suction valve Discharge valve Suction valve Discharge valve Item Description Material Part No. Double-ball valve Spring-loaded valve Suction valve Discharge valve Suction valve Discharge valve PVC PVC PVC PVC Sealing material: H=Hypalon, V=Viton, AF=Asbestos free H V AF H V AF H V AF H V AF Valve housing PVC Ball guide PVC PVC *3 Valve ball Glas *4 Valve seat PVC *5 Gasket Hypalon Viton AF *6 Gasket Hypalon Viton Hypalon Viton *7 Gasket Hypalon Viton Hypalon Viton *8 Valve spring Hastelloy * recommended spare parts (included in spare parts kit ET / 2)

71 ET / 4 DN 10 valves for KARDOS N Piston Metering Pump KARDOS N Double-ball valve Spring-loaded valve Suction valve Discharge valve Suction valve Discharge valve Item Description Material Part No. Double-ball valve Spring-loaded valve Suction valve Discharge valve Suction valve Discharge valve PP PP PP PP Sealing material : H=Hypalon, V=Viton, AF=asbestos free H V AF H V AF H V AF H V AF Valve housing PP Ball guide PVC PP *3 Valve ball ceramics d *4 Valve seat PP *5 Gasket Hypalon Viton AF *6 Gasket Hypalon Viton AF *7 Gasket Hypalon Viton *8 Valve spring Hastelloy * recommended spare parts (included in spare parts kit ET / 2)

72 ET / 5 Spring-loaded valves KARDOS N Piston Metering Pump KARDOS N PP version stainless steel version Item Description Material Part No. Suction and discharge valve PP EPDM Viton EPDM Viton Valve assembly Valve guide PP Valve disk PVDF Flat valve seat PP O-ring EPDM Viton Valve spring Hastelloy

73 Piston Metering Pump KARDOS N ET / 6 Spring-loaded valves KARDOS N 2500 and N PP version stainless steel version Item Description 1 Valve guide 2 Valve disk 3 Flat valve seat 4 Gasket 5 O-ring 6 Valve spring M aterial Part No. EPDM Hypalon Suction and discharge valve PP Viton EPDM Hypalo n Valve assembly Viton PP PVDF PP Hypalo n Viton EPDM Viton Hastello y

74 ET / 7 Plastic metering head Piston Metering Pump KARDOS N KARDOS N Item Qty Description Pump type N 16 N 36 N 56 N 72 Material Part No Piston housing PVC Piston Ceramics Gland PVC Thrust ring PVC Flushing attachment PVC Supporting ring PVC Packing ring PTFE-silk packing Locking screw PVC KARDOS N Item Qty Description Pump type N 130 N 225 N 320 N 530 Material Part No Piston housing PP Piston Ceramics Gland PVC Thrust ring PVC Flushing attachment PVC Supporting ring PVC Packing ring PTFE-silk packing Spacer Al, painted Separator bolt Hexagonal nut A Washer A Locking screw PVC Cap PE

75 Piston Metering Pump KARDOS N ET / 8 Plastic metering head Item Qty Description 1 1 Piston housing 2 1 Piston 3 1 Compression gland packing 4 1 Thrust ring 5 1 Flushing attachmen t 6 1 Supporting ring 7 5 Packing ring 8 1 Spacer 9 4 eparator bolt exagonal nut asher 12 2 Locking screw 13 2 Valve cover 14 4 Cap 15 1 Compression gland flange S 1 H 2 W 4 Piston material Ceramics Pump type N 750 N 1300 M aterial Part No PP Ceramics/brass PVC PVC PVC PVC PTFE-silk packing Al A A PVC PP PE St

76 ET / 9 Plastic metering head Piston Metering Pump KARDOS N ,11, ,16,18 KARDOS N Item Qty Description Piston material Ceramics Pump type N 2500 N 4200 M aterial Part No Piston housing PP Piston Ceramics/ Compression gland PVC packing 4 1 Thrust ring PVC Flushing attachmen t PVC Supporting ring PVC Packing ring PTFE-silk packing Spacer St Separator bolt Hexagonal nut A Washe r A Separator bolt Locking screw PVC Valve cover GG/St Washe r A Hexagonal nut A Cap PE Cap PE Compression gland St flange

77 Piston Metering Pump KARDOS N ET / 10 Stainless steel metering head KARDOS N Item Qty Description Pump type N 16 N 36 N 56 N 72 Material Part No Piston housing Piston Gland Thrust ring Flushing attachment Supporting ring Packing ring PTFE-silk packing Locking screw Gasket AF Supporting disk PVDF KARDOS N Item Qty Description Pump type N 130 N 225 N 320 N 530 Material Part No Piston housing Piston Gland Thrust ring Flushing attachment Supporting ring Packing ring PTFE-silk packing Locking screw Gasket AF Cylinder head screw A Washer A Supporting disk PVDF

78 ET / 11 Stainless steel metering head Piston Metering Pump KARDOS N KARDOS N Item Qty Description 1 1 iston housing 2 1 iston 3 1 ompression gland packing 4 1 hrust ring 5 1 lushing attachmen t 6 1 upporting ring 7 5 Packing ring 8 2 ocking screw 9 2 alve cover 10 4 eparator bolt asher exagonal nut 13 2 Gasket 14 1 Compression gland flange P 1 P 1 C 1 Piston material Pump type N 750 N 1300 M aterial Part no T F S PTFE-silk packing L V S W A H A AF St

79 ET / 12 Stainless steel metering head Piston Metering Pump KARDOS N ,17 Item Qty Description 1 1 iston material 2 1 iston 3 1 ompression gland packing 4 1 hrust ring 5 1 lushing attachmen t 6 1 upporting ring 7 5 Packing ring 8 2 ocking screw 9 2 Valve cover 10 2 eparator bolt 11 4 eparator bolt asher exagonal nut 14 4 asher 15 4 exagonal nut 16 2 Gasket 17 4 Cap 18 1 Compression gland flange P 1 P 1 C 1 Piston material Pump type N 2500 N 4200 M aterial Part no T F S PTFE-silk packing L GG/St S S W A H A W A H A AF PE St

80 ET / 13 Single drive Piston Metering Pump KARDOS N Item 86 only for N

81 Piston Metering Pump KARDOS N ET / 14 Single drive

82 ET / 15 Drive Piston Metering Pump KARDOS N Item Description Material Part No. 1 Gear housing, single drive Cast iron Gear housing, double drive Cast iron Pump base Cast iron Crank case Cast iron Stroke adjustment housing Cast iron Adaptor flange Cast iron Pump head support for N Cast iron Pump head support for N Cast iron Pump head support for N Cast iron Pump head support for N 2500 Cast iron Pump head support for N 4200 Cast iron * Gear shaft St * Stroke adjustment assembly consisting of: Bronze items 7, 25, 36, 49, 70, 76, 77, 92 9 Connecting rod Bronze Bearing ring St Guide flange Cast iron Guide bush St Push rod St Siphon Rubber Union nut St nickel-plated Clamping flange St Bearing flange Cast iron Worm gear Bronze/St Worm shaft St * Guide shaft St Bearing flange Cast iron Bearing support plate St Locking plate St Shaft nut St Bush Brass Adjustment spindle with guide bush St Flange St Handwheel with position indicator Al/St ** Coupling for kw motor St Coupling for kw motor St Coupling for 2.2 kw motor St Bearing flange Cast iron Tapered ball bearing St Roller bearing St Grooved ball bearing St Grooved ball bearing St Tapered ball bearing St Grooved ball bearing St Adjusting spring St Adjusting spring St Adjusting spring St Hexagonal nut A Washer A * Items 7, 8 and 20 only available as a set ** Included in the motor assembly Part No.

83 ET / 16 Drive Piston Metering Pump KARDOS N Item Description Material Part No. 43 Hex head screw A Stud 8.8 galvanized Hexagon socket screw 8.8 galvanized ** Threaded pin 8.8 galvanized Hexagon socket screw 8.8 galvanized Countersunk screw 5.8 galvanized Hexagon socket screw 8.8 galvanized Hexagon socket screw 8.8 galvanized Threaded pin 8.8 galvanized Dowel pin St Locking screw Brass Hexagon socket screw 8.8 galvanized Nut St Hexagonal nut 8 galvanized Plug Ms galvanized Venting screw Plastic Oil gauge Plexiglass Gasket AF Retaining ring Spring steel Supporting disk Spring steel Retaining ring Spring steel Gasket AF Cutting ring St nickel-plated Supporting ring PVC Seal misc Retaining ring Spring steel Gasket AF Retaining ring Spring steel Spacer St Gasket AF Gasket AF Retaining ring Spring steel Retaining ring Spring steel O-ring Perbunan O-ring Perbunan Hexagonal nut 8 galvanized Washer St nickel-plated Plug Ms Gasket Brass Cylinder head screw A Gasket AF Transmission lubricant Washer Cu Washer Cu Hex head screw A Supporting disk St Gasket Cu ** Included in the motor assembly Part No.

84 ET / 17 ATE drive Item Description Material Part No. 1 Servomotor misc Assembly kit misc * Flange St Coupling misc Locking sleeve Spring steel Handwheel misc Locking sleeve Spring steel ATE servomotor assembly * Included in the main drive Piston Metering Pump KARDOS N Piston Metering Pump KARDOS N - ATE

85 Operating and maintenance instructions BW / 1 List of contents 1. Technical data 2. Scope of delivery 3. Installation 4. Electrical connection of pump 5. Safety instructions 6. Injection nozzle assembly 7. Startup 8. Maintenance 9. Troubleshooting 1.Technical data 3. Installation When planning, installing and operating a system, the metering pump must be selected with due regard to the local regulations. This applies to the choice of suitable pump materials, the handling of the chemicals and the electrical installation. The technical data of the pump listed above must also be taken into account and the system dimensioned accordingly (e.g. loss of pressure when dimensioning the line with regard to nominal width and length). The planning engineer and user are responsible for ensuring that the entire system with integrated metering pump is designed in such a way that leaking chemicals due to a failure of wear parts (e.g. worn packing) or ruptured tubing do not cause any permanent damage to system parts and buildings. If there is a large danger potential of the chemical plant the installation must be designed in such a way as to prevent unnecessarily high consequential damage even if the metering pump fails. We therefore recommend to install leakage monitors and containment tanks. Note: Due to their design piston pumps are not leakage-free. This must be taken into account when planning the process and the system. Metering pumps are designed according to the highest quality standards and have a long service life. Despite this, some parts are subject to wear outdoors. Keep the operating instructions of the metering pump and the accessories readily accessible. 2. Scope of delivery Be careful when unpacking the metering pump and order-related accessories in order not to miss small parts. Immediately compare the scope of delivery to the delivery note. If there are any discrepancies, try to find out the reason. KARDOS N max. pressure Plastic [bar] St. steel Flow rate at [l/h] max. pressure [ml/stroke] Piston - ø [mm] Stroke frequency [1/min] 100 Suction lift [mbar] 120 Motor power [kw] selectable Metering head Simplex gear Duplex gear Plastic St. steel manual manual ATE ATE Weight [kg] caused by operation (e.g. piston, packing, valve seats, valve balls). Regular visual inspection is therefore necessary to ensure reliable longterm operation. The metering pump must be installed so that it is readily accessible to operating and maintenance personnel. It should be serviced regularly to avoid downtimes. Supplementary fittings are recommended to increase the metering accuracy and functional reliability. Such fittings include backpressure valves, relief valves, leakage monitors and low-level controls as shown in the following installation example. Suitable tools must always be used to work on plastic connecting parts. Undue force must never be applied as otherwise the parts may be damaged or destroyed. Plastic parts (particularly those made of PVC) can be screwed and unscrewed more easily if the thread has been lubricated with Vaseline or silicone grease. Note: The compatibility of the Vaseline or grease with the metered chemical must always be checked first. The ambient temperature of the pump must not exceed 40 C. Radiated heat from devices and heat exchangers must be shielded so that the metering pump can still dissipate its own heat. Direct sunlight must be avoided. A canopy roof must be provided to protect the pump against the weather when installed KARDOS N

86 BW / 2 The metering pump must be installed with suction and discharge valves in an upright position. It must be bolted onto suitable ground to ensure stability. The system piping must not apply any forces to the connections and valves of the metering pump. The pump must be interlocked electrically and hydraulically to prevent accidental metering after the process has ended. Installation example Electrical connection data Pump Voltage Power Current size [Volt] [kw] [A]...N / / Hz...N / / Hz...N / / Hz...N / / Hz...N / / Hz...N / / Hz KARDOS N Wiring diagram of the drive motor - Three-phase supply Legend 1 KARDOS N MB Suction line MB Electric agitator MB Tank MB Relief valve MB Diaphragm shutoff valve MB Injection nozzle MB Pulsation dampener MB Backpressure valve MB Electrical connection of the pump - The electrical connection of the metering pump must be in accordance with the local regulations and may only be carried out by qualified personnel. - The cable type and cross-section of the power supply cables must be selected according to the motor data. - The cable bushing to the motor terminal box must be made correctly. We recommend the use of compression glands with strain relief. - The required protection class must be ensured by correct installation of the electrical connections. connection connection - Special version Other electrical versions can be found in the separate circuit diagrams. - Electric servomotor ATE The technical data and connection diagrams can be found on page BW / Safety instructions The safety rules applicable on site must be observed when working on metering plants (e.g. use of personal protective equipment). Before starting any work on the metering pump and system, all mains lines must be disconnected and secured against reconnection. The metering lines must be connected before reconnecting the power supply in order to prevent any chemical still in the metering head from being expelled. Important: The piston area must remain open for checking, which may be dangerous if accessed directly. Maintenance work in the piston area may only be carried out if the pump is switched off.

87 BW / 3 The metering head of the pump and the system connections and lines may be under pressure. Working on the metering pump requires special safety precautions and may only be carried out by instructed, qualified personnel. Before startup, all screwed connections must be checked for correct tightness and, if necessary, must be tightened up using appropriate tools. If connections at the metering head are unscrewed during operation for venting or other reasons, leaking chemical must be removed correctly and completely. This is the only way to avoid the danger of physical injury and corrosion at the metering pump. Leaking chemical may also affect the pump housing. When changing the chemical, check whether the materials used for the metering pump and the other plant parts are chemically resistant. If there is the danger of a chemical reaction between different media, thorough cleaning first is mandatory. To operate the pump mount the fan shell in order to ensure sufficient cooling of the motor. 6. Injection nozzle assembly Injection nozzles are fitted with either spring-loaded ball valve or tube valve to prevent any return flow. Injection from bottom to top is recommended to allow air bubbles to escape and to be carried away so that precipitations are avoided. The experience with the chemical to be metered and its properties must be taken into account. 7. Startup 1. All the work described in the section Installation must be carried out before starting the metering pump. The safety instructions must also be observed. 2. The metering pump is switched on via a control system to be installed externally. 3. The manual or electrical capacity adjustment must be set to maximum stroke to improve priming. During first priming no backpressure should be applied. For this purpose we recommend to install a relief valve on the discharge side of the metering pump. 4. A previously installed priming aid must be filled with chemical first. If the pump is not priming, remove the discharge valve and fill water or chemical (if not dangerous!) into the metering head. Remount valve and start priming. 5. If a venting facility is available as separate unit, open it and wait until liquid flows out. Then close it again. In the case of effervescent liquids allow the liquid to flow out permanently (approx. 1 drop for strokes). 6. When correct operation is achieved, set to required flow rate by means of the adjusting knob or remote adjustment. For first approximation refer to the values shown in the "Technical data" table. Depending on the installation and the chemicals used, these values may differ and must be checked under operating conditions. 7. The manufacturer of the metering equipment is not responsible for damages due to excessive or low flow rates resulting from faulty pump settings or incorrect and insufficient installation of peripheral fittings. KARDOS N Injection nozzle

88 BW / 4 8. Maintenance Lubrication The piston metering pump KARDOS N is designed for easy maintenance. The gear of the pump is lubrivcated with gear oil of viscosity class SAE 85W- 90 according to DIN The initial filling provided should be replaced after approx. 500 hours of operation. The oil should then be changed every 5,000 hours of operation. The capacity equals 4.5 litres for the single gear and approx. 5.5 litres for the duplex gear. The amount of gear oil actually required can be read off from the oil gauge: the oil is filled up to the middle of the view glass. Replacing the piston A defective piston or worn packing can be replaced as follows: 1. The chemical contained in the metering line must be drained to depressurize the metering line. Please observe the aforementioned safety instructions for this purpose. 2. The head is removed using an appropriate tool: Unscrew the attachment screws of the metering head, loosen the gland stud. The metering head is then removed in axial direction from the support. Slight rotations of the head make dismantling easier. 3. The piston can now be unscrewed from the piston rod and replaced by a new one, if necessary. 4. To change the packing, the gland stud must be unscrewed. The defective packing is removed using a packing worm. Alternatively, a hook can be used to remove the old packing. 5. After cleaning the packing area, the new packing rings are fitted with offset joints and the gland studs fastened sturdily. Caution: The packing material must be compatible with the application and with the chemical. 6. The metering head is now pushed in alignment with the piston and the supporting flange and fixed with the attachment screws after it has reached it final position. Make sure that the valves are positioned vertically. 7. The gland stud is tightened carefully to start the bedding-in process of the new packing. For this purpose the pump is run dry first without connection to the medium. After some strokes the gland is retightened. 8. After connecting the metering lines the pumps is started as described in the 'Startup' section. Continue to prestress the gland stud until a minimum leakage occurs. If prestressing is too strong, the return movement of the piston might be restrained. In this case slightly loosen the gland stud again. Correction of the stroke length indicator 1. Handwhell A is turned to the left until stop. 2. Then the handwheel is turned back to the right by one rotation. The pump now works at maximum flow rate. 3. Tightening bolt B at the periphery of the handwheel is unscrewed. 4. The indicator housing C can now be turned into the 100% position, the red and black indicator pointing both to 100%. 5. The indicator housing C is now fixed with the tightening bolt. 6. As a check test turn the stroke adjustment into the opposite direction thus verifying the zero stroke position. If there is any deviation, the indicator element C can also be adjusted to this position or fixed to an average position. KARDOS N

89 BW / 5 9. Troubleshooting TYPE OF FAULT POSSIBLE CAUSE RECOMMENDED ACTION Pump not delivering. Valves leaking. Clean and remove air from valves. (See also startup of pump.) Tighten screw connections. Valves incorrectly installed. Reassemble valves. Ensure that the valve balls of suction and discharge valve are located above the valve seats. KARDOS N Suction filter, foot valve or suction pipe leaking or blocked. No stroke movement. Clean and seal suction line. Return spring broken. Replace spring. Consider density of the chemical! Suction lift too high. Pump delivering too little Valves blocked or leaking. Clean and re-seal valves. or irregularly. Pump delivering too Pressure on suction side too Install backpressure valve in much. high (pump siphoning). discharge line. Strong leakage at Packing not tightened Tighten gland stud carefully. piston. strong enough. Piston has longitudinal grooves due to normal wear. Excessive wear due to abrasive medium. Replace piston and packing. See also section 8, maintenance. Replace PTFE packing by Aramid packing. Pump very noisy. Roller bearing defective. Replace roller bearing. No or little oil in gearbox. Refill oil, as described in section "maintenance". Motor hums and Wrong connection. Check electrical wiring. doesn't start. Pressure too high. Check process. If the problem cannot be corrected on the basis of the above data, return the pump to the factory or contact our Techical Sales Service for further measures. Repairs will be carried out immediately.

90 Operating and maintenance instructions BW / 7 The operating instructions for the metering pump and accessories must be kept within easy reach. Contents 1. General 2. Technical data 3. Installation 4. Safety instructions 5. Wiring diagrams 6. Start-up 7. Maintenance 1. General The metering pump is installed in accordance with the applicable operating instructions. The following description refers exclusively to the ATE servomotor, types WAN-G2-AA. 3. Installation The ATE servomotor is connected to the pump and calibrated in the factory. When installing the servomotor, sufficient clearance of at least 150 mm must be provided for later maintenance works. The electrical connection of the ATE drive must correspond to the local regulations and may only be carried out by technical personnel. The two basic connection versions possible are shown in the following wiring diagrams. Cable type and cable cross-section must be selected according to the motor data. The cable passage to the motor terminal box must be made professionally. The use of gland screw connections with strain relief is recommended. The required protection class must be ensured by correct installation of the electrical connections. Please take into account that the ATE drive can only be actuated with the main motor running, i.e.: the ATE drive must be locked electrically, otherwise the adjusting eccentric wears out frequently or is destroyed. KARDOS N - ATE 2. Technical data Type WAN-G2-AA WAN-G2-AA/PMR1 Design Reversible AC motor with self-locking step-down gear. Use For controllers with switching For controllers with output (3-point control) continuous output 0(4)...20mA Auxiliary voltage 230V~ ± 10% Hz 230V~ ± 10% Hz Other voltages upon request. Control 0(4)...20mA Power consumption approx W Actuating time / bevel 2minutes = 50 rotations = % Position feedback Potentiometer 0.5 W 0(4)...20mA (only as an option) for remote display Ω = % Limit switches Internal limit switches for limitation of the angle of rotation. Limit position signalled via terminals 4 and 5 Protection class IP 54 according to DIN Ambient temperature max. 60 C Option 2nd potentiometer Ω 0.5 W Limit switches (2 off) approx. 250V 1A

91 BW / 8 4. Safety instructions The following safety instructions refer to the ATE servomotor. Furthermore, the notes contained in the enclosed operating instructions of the metering pump also apply to this extended version. When working on the metering equipment, observe the local safety rules. Before working on the metering pump and the ATE servomotor, disconnect the main power supply and protect it against reconnection. Adjustment works in the interior of the ATE drive must be carried out carefully. Connections and internal limit switches might be "alive". Additional limit switches might be "alive" even with the auxiliary voltage switched off. After installation works at the ATE servomotor or before startup remount the cover. 5. Wiring diagrams PE 4 2 Open 230V/50Hz N Closed Position repeating signaling 1 k Ω Position repeating signaling 1 k Ω OPTION Volt.-free contacts max 250V~ 1A Position repeating signaling 0/ ma 6. Start-up Switch on the main drive motor of the metering pump. The installed electrical interlocking system prevents adjustment of the ATE drive until the main drive motor is running. Apply brief control pulses to the ATE servomotor to check the sense of rotation. If the sense of rotation is wrong, the supply lines (terminals 2 and 3 in the case of direct controls) are reversed. The ATE servomotor must be moved to the respective final positions in order to check the limit stop mechanism of the integrated limit switches. The angle of rotation provided by the manufacturer equals 270. If necessary, the angle of rotation and thus the maximum flow rate can be restricted by adjusting the upper switching cam to the required amount. 7. Maintenance The ATE servomotor has been lubricated for life before leaving the factory. Nevertheless, regular inspections are recommended if the drive is operated under extreme service conditions, such as high ambient temperatures or in continuous operation. Molybdenum disulphite is used to relubricate the ATE gear. Suitable grades include Molykote BR2plus and OKS400. KARDOS N - ATE WAN-G2-AA in the case of control via 230V/ Hz supply voltage M PE 230V~ L N 4 5 Open Closed Final position repeating signaling Conductance 0/ ma WAN-G2-AA in the case of control via 0(4)...20mA standard signal

92 MB / 1 General KARDOS stands for a group of precision metering pumps which have been developed especially for applications with a high demand for accuracy, reliability and flexibility in a wide performance range. Versions The symmetrically designed gearbox allows the arrangement of four metering heads on the same level and the stacking of three heads above one another, thus enabling a maximally 12-head pump. Each metering head is 100% adjustable independently. Any speed adjustment to the main drive has a simultaneous effect on all metering heads, but the relative volume ratios remain unchanged. KARDOS KN Standard versions have the metering head on the left-hand side. Type KN...L (Symbol ) Upon request, pumps with the metering head on the right-hand side are available. Type KN...R (Symbol ) Duplex metering pumps are available with head combinations as indicated in the tables. In the standard version the heads are arranged opposite to each other. Type ZKN... (Symbol ) Metering head The correct choice of the metering head depends on the aggessivity of the chemical, its temperature and viscosity, and on the system pressure. KMS piston-diaphragm system Piston-diaphragm heads are also available in three sizes. These are recommended if, despite higher pressures, leakage-free metering is required because the chemical is toxic, aggressive or abrasive. Piston-diaphragm heads are separated from the gear oil, and have their own hydraulic system (glycerine). Piston- diaphragm heads may also be retrofitted in existing installations (see data sheets MB ). Technical data KARDOS KN Max. pressure Plastic [bar] SS Flow rate at [l/h] 9, max. pressure [ml/stroke] Piston ø [mm] Stroke frequency [1/min] 110 Suction lift [mbar] 120 Motor power [kw] depending on power consumption Metering head Simplex gear Duplex gear Plastic manual manual SS ATE ATE Weight (kg)