Flomotion Systems 4001V Series User manual

4001V
Peristaltic Chemical Feed Pump

4001V Peristaltic Pump O&M Manual
Installation and Operation Manual
4001V Series
Peristaltic Chemical Feed Pump
January 1, 2018
Flomotion Systems, Inc.
3 . Main St
Middleport, Y 14105
Toll Free: [phone] (U.S. & Canada)
Fax: [phone]
[email protected]
www.flomotionsystems.com
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TABLE OF CONTENTS
1.0 - SYSTE OVERVIEW................................................................................................................................................... 4
1.1 SAFETY................................................................................................................................................................................................ 4
1.2 WARRA TY.......................................................................................................................................................................................... 4
1.3 RECEIVI G........................................................................................................................................................................................... 5
1.4 CUSTOMER MODIFICATIO ..................................................................................................................................................................... 5
1.5 I FORMATIO FOR RETUR I G PUMPS ................................................................................................................................................... 5
2.0 INSTALLATION.............................................................................................................................................................. 6
2.1 I SPECTIO .......................................................................................................................................................................................... 6
2.2 TEMPERATURE CO SIDERATIO S............................................................................................................................................................. 6
2.3 SET-UP................................................................................................................................................................................................ 6
2.4 PIPI G................................................................................................................................................................................................. 6
2.5 ELECTRICAL CO ECTIO S..................................................................................................................................................................... 6
3.0 – 4001V/VE SERIES PU P AND PU PHEAD.............................................................................................................. 7
3.1 PUMP ASSEMBLY & TUBI G I STALLATIO ............................................................................................................................................... 7
3.2 PUMP MOU TI G A D COLLET I STALLATIO PROCEDURE........................................................................................................................ 8
3.3 HOSE A D ROLLER I STALLATIO ........................................................................................................................................................... 8
3.4 TUBI G CO ECTIO S .......................................................................................................................................................................... 9
4.0 – 4001V OTOR & GEARBOX.................................................................................................................................... 10
4.1 MOTOR SPECIFICATIO S...................................................................................................................................................................... 10
4.2 4001VE MOTOR WIRI G.................................................................................................................................................................... 10
4.3 OPERATIO A D WIRI G...................................................................................................................................................................... 11
4.3 4001V CO TROLLER WIRI G.............................................................................................................................................................. 12
4.4 GEARBOX SPECIFICATIO S................................................................................................................................................................... 13
5.0 - ISCELLANEOUS DIAGRA S................................................................................................................................. 14
5.1 ROLLER ASSEMBLY............................................................................................................................................................................. 14
5.2 PUMP ASSEMBLY................................................................................................................................................................................ 15
5.3 TUBI G RUPTURE DETECTOR SYSTEM OVERVIEW.................................................................................................................................. 16
5.3.1 ALARM CAUSES............................................................................................................................................................................... 16
5.3.2 What to do in an alarm condition.............................................................................................................................................16
5.3.3 Resetting the alarm.................................................................................................................................................................. 16
5.3.4 Resuming Service.................................................................................................................................................................... 16
5.3.5 Interfacing................................................................................................................................................................................ 17
5.3.6 Calibration................................................................................................................................................................................ 17
6.0 - PRODUCT USE AND DECONTA INATION DECLARATION..................................................................................18
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1.0 - System Overview
The 4001V Series Chemical Feed Pump consists of a controller, motor, gearbox and peristaltic pump.
4001 Pump & otor 4001V K4 SERIES Controller
1.1 Safety
In the interests of safety, this pump and the tubing selected should only be used by competent, suitably trained
personnel after they have read and understood this manual, and considered any hazard involved. Any person
who is involved in the installation or maintenance of this equipment should be fully competent to carry out the
work.
Maintenance and repair should be performed by qualified personnel only. Make sure that no voltage is
applied while work is being carried out on the pump or motor. The motor must be secured against
accidental start up.
1.2 Warranty
Flomotion Systems, Inc. warrants the 4001 Series pumps to be free of defects in material and workmanship for
a period of eighteen months from the date of sale to the user, or two years from the date of shipment, which
ever occurs first. A control, or any component contained therein, which under normal use becomes defective
within the stated warranty time period, shall be returned to Flomotion Systems, Inc., freight prepaid, for
examination (contact Flomotion Systems, Inc. for authorization prior to returning any product). Flomotion
Systems, Inc. reserves the right to make the final determination as to the validity of a warranty claim, and sole
obligation is to repair or replace only components, which have been rendered defective due to faulty material
or workmanship. o warranty claim will be accepted for components which have been damaged due to
mishandling, improper installation, unauthorized repair and/or alteration of the product, operation in excess of
design specifications or other misuse, or improper maintenance. Flomotion Systems, Inc. makes no warranty
that its products are compatible with any other equipment, or to any specific application, to which they may be
applied and shall not be held liable for any other consequential damage or injury arising from the use of its
products. This warranty is in lieu of all other warranties, expressed or implied. o other person, firm or
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corporation is authorized to assume, for Flomotion Systems, Inc., any other liability in connection with the
demonstration or sale of its products.
1.3 Receiving
Inspect all cartons for damage, which may have occurred during shipping. Carefully unpack equipment and
inspect thoroughly for damage or shortage. Report any damage to carrier and/or shortages to supplier. All
major components and connections should be examined for damage and tightness, with special attention given
to PC boards, plugs, knobs and switches.
1.4 Customer odification
Flomotion Systems, Inc., its sales representatives and distributors, welcome the opportunity to assist our
customers in applying our products. Many customizing options are available to aid in this function. Flomotion
Systems, Inc. cannot assume responsibility for any modifications not authorized by its engineering department.
1.5 Information for Returning Pumps
Equipment that has been contaminated with, or exposed to, body fluids, toxic chemicals or any other
substance hazardous to health must be decontaminated before it is returned to Flomotion Systems or its
distributor.
A certificate included at the rear of these operating instructions, or signed statement, must be attached to the
outside of the shipping container.
This certificate is required even if the pump is unused. If the pump has been used, the fluids that have been in
contact with the pump and the cleaning procedure must be specified along with a statement that the equipment
has been decontaminated.
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2.0 Installation
2.1 Inspection
Check for any damage that may have occurred during shipment. In addition, all components should be
compared to the order upon receipt of the shipment.
Report any damage or missing components immediately.
2.2 Temperature considerations
Make sure that the pump is located in an area where the ambient temperatures during operation are not lower
than 0°F, or higher than +120°F. If ambient temperatures are out of this range please contact the factory for
suitability of the specific equipment.
2.3 Set-up
ormal pump installations are for indoor use in an unclassified electrical area. Make sure that the floor surface
is level and sufficiently rigid to support the pump. Make sure that there is enough room around the pump to
perform maintenance. The hose is serviced thru the front cover! In addition, make sure that the room is
adequately ventilated, so that the heat developed by the pump and drive can be dissipated. Open clearance
should also be kept between the fan cover of the motor and wall to enable proper cooling.
2.4 Piping
All piping to and from the pump must be independently supported. Undue stress on
the pump suction and discharge can cause equipment failure. Locate the supports as
close to the pump as possible.
Keep suction line to the pump as short and direct as possible.
Try to limit sharp bends in the piping.
The piping ID should be equal to or greater than the bore size of the pump.
Increase the piping size when the fluid has a high velocity or inertia due to high specific
gravity. This will help keep dynamic friction and impulse losses to a minimum.
A pulsation dampener mounted in the discharge and/or an inlet pulse accumulator may
be necessary if long piping lengths are unavoidable.
Back pressure valves are not required in peristaltic pump applications. However, a pressure relief valve is
recommended to be installed in the discharge piping. This will prevent the possibility of exceeding the
maximum working pressure of the pump. Check valves installed in the process piping may increase pulsation
and negatively impact hose life.
Install isolation valves and a pipe-drain in the suction and discharge lines to allow fluid isolation and drainage
from the pump during maintenance. Flush connections are recommended when pumping slurries in which the
solids settle out of suspension when the pump is off. Accumulations of solids in the piping during shutdown
can cause plugging.
2.5 Electrical connections
For variable speed operation the pump may be supplied with an AC or DC variable speed controller. Follow all
vendor precautions and installation information for both the motor and drive. In addition, your pump may be
equipped with an optional Hose Rupture Monitor. Refer to the instructions of this device if required.
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3.0 – 4001V/VE Series Pump and Pumphead
The 4001 H/HE Series pumphead has two spring-loaded working rollers, which automatically compensate for
minor variations in tubing wall thickness, giving extended tube life.
I PORTANT: The 4001 Series is equipped with a pump cover for safety and protection against
chemical spills. The cover must be installed whenever the pump is in use.
3.1 Pump Assembly & Tubing Installation
! I PORTANT: Disconnect pump controller from power supply BEFORE changing tubing!
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3.2 Pump ounting and Collet Installation Procedure
1. To install the pump housing on the gearbox, slide it over the central pilot on the gearbox adaptor plate.
See drawing in Section 5.2
2. ext install and torque the mounting screws to 5 T.M (45 lbf-in).
3. ext install the collet on the gearbox shaft. There is a slot in the shaft where a key is inserted. Orient
the collet to allow the key to slide into the slot on the collet and push the collet completely onto the
gearbox shaft. When the collet bottoms out it is in the correct position.
3.3 Hose and Roller Installation
! I PORTANT: Disconnect pump controller from power supply BEFORE changing tubing!
1. Remove housing cover from pumphead. Loosen and remove the center roller assembly screw.
2. Remove the roller assembly from the gearmotor shaft.
3. Loosen the hose clamps that secure the hose on the inlet and outlet fittings. Carefully remove the old
Hose from the pump casing.
4. Place two hose clamps on new hose insert.
5. IMPORTA T Install new pump insert making sure no twists occur when working hose onto connectors.
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Slide a hose clamp over the
end of the hose.
Slide the hose onto the barbed fitting then tighten
the hose clamp over the barbed area. Repeat for
the second clamp.
Important: Assure that the hose is not twisted
when attaching the second clamp.

4001V Peristaltic Pump O&M Manual
6. ote: Flomotion tubing segments are pre-cut to the correct length for installation.
7. Tighten hose clamps securely.
8. Re-install the roller assembly into the pumphead and torque roller assembly screw to 30 T-M (265 lbf-
in) as shown on drawing at right.
9. Spread small amount of non-petroleum silicone grease on inner surface of hose (where rollers contact
hose).
10. Reinstall pumphead housing cover.
3.4 Tubing Connections
Tubing or pipe connections are made at the inlet and outlet of the pump using standard 1” PT fittings.
See the drawing below.
Estimated Pumping Capacity
Tubing I.D. 1/2” 3/4” 1”
ml/rev* 99 171 296
Pressure rating PSI 60 30 30
Max Suction Lift (ft) 20 15 10
GPH @ 3-60 RPM* 4.7 - 109 8.1 - 189 14.1 - 329
*Actual flow rates may vary.
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4.0 – 4001V Motor & Gearbox
4.1 otor Specifications
Motor Type: Permanent Split Capacitor or 3-Phase Inverter Duty
Rotation: Reversible.
Insulation: Class B minimum
Finish: Powder-coat gloss black.
(Thermostat wires not used)
4.2 4001VE otor Wiring
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4.3 Operation and Wiring
For complete details about the pump controller please refer to the included K4 SERIES (KBDA) Drive
Controller Operating Instructions booklet.
Shown here are program settings specific to the operation with the 4001 Series Peristaltic Pump.
4.4 Programming
The K4 SERIES programming differs from the factory defaults shown in the Operating Instruction booklet in
relation to the following parameters:
0.04 = 0000 GFCI operation disabled
1.00 = 0001 Remote Start/Stop input enabled
1.05 = 0003 Auto restart after power failure or fault
2.01 = 0001 Update speed change w/o having to press E TER
2.02 = 0002 Local/Remote select input enabled
3.02 = 0060 60Hz Full Scale
4.00 = 0000 Display in Hz
5.00 = 0000 Run Relay output enabled
7.03 = 0010 Remote Start/Stop output enabled
7.04 = 0000 External Local/Remote select input OFF (0013 = O )
7.06 = 0008 External Fault Input enabled
8.00 = 0001 Fault Relay output enabled
8.01 = 0009 Remote Status Output
9.07 = 0020 4-20mA Input enabled
8.09 = 0002 Enable fault when the 4-20mA output is disconnected*
6.05 = 1010 reset to Flomotion Defaults
*8.09 = 0000 to avoid fault when 4-20mA Output is disconnected when not using 4-20mA output
Refer to section 4.3 for wiring and program for the above signals and functions.
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4001V Peristaltic Pump O&M Manual
4.3 4001V Controller Wiring
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4.4 Gearbox Specifications
Housing: Precision machined die cast aluminum.
Lubrication: Lifetime oil bath, sealed and gasketed.
Shafts: Stainless steel.
Mounting: Face (any angle) or optional footplate.
Gearing: AGMA class 9 heat treated steel. 1st stage helical metal, balance spur metal.
Bearings: eedle with thrust ball.
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5.0 - Miscellaneous Diagrams
5.1 Roller Assembly
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5.2 Pump Assembly
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5.3 Tubing Rupture Detector System Overview
5.3.1 Alarm Causes
A rupture alarm is triggered by the presence of a conductive fluid in the pump. When the fluid bridges the two
stainless steel electrodes on the LIQUID SE SOR the alarm is triggered.
5.3.2 What to do in an alarm condition
To clear the alarm, first stop the pump and disconnect power from the pump controller. Remove the pump
cover and remove the ruptured pump tubing. Clean the inside of the pump with a soft rag. Remove any liquid
or tubing debris from the inside of the pump and the area around the LIQUID SE SOR. Inspect rollers and
clean if necessary.
5.3.3 esetting the alarm
Press the pushbutton (LEAK I DICATOR & RESET SWITCH) on the Tubing Rupture Detector to reset the
alarm.
5.3.4 esuming Service
Install a fresh tubing insert and the pump is ready to resume service.
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5.3.5 Interfacing
A dual 8 Amp DC DPDT relay is provided to signal or control an external device during an alarm condition.
Connect one set of the Tubing Rupture Detector O relay contacts to pins 7 & 8 of the K4 SERIES pump
controller.
Program the K4 SERIES Pump Controller step 7.06 to 0008 for external leak fault to stop the drive in case of a
tubing rupture.
DUAL PU P SYSTE S
You may optionally connect the second set of relay contacts to pins 16 & 4 of the backup pump K4 SERIES
Pump Controller to make that pump take over when the first pump stops.
5.3.6 Calibration
Turn the P1 sensitivity adjusting screw counter clockwise several turns. Apply a wet rag to the LIQUID
SE SOR electrodes. Adjust the sensitivity clockwise slowly until the alarm trips.
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6.0 - Product use and decontamination declaration
Please declare the substances which have been in contact with the product(s) you are returning to Flomotion Systems, Inc.
Failure to do so will cause delays in servicing the product. Therefore, please complete this form to ensure that we have the
information before receipt of the product(s) being returned. A COPY MUST BE ATTACHED TO THE OUTSIDE OF THE
PACKAGI G CO TAI I G THE PRODUCT(S). You are responsible for cleaning and decontaminating the product(s) before
returning them.
Please complete a separate Decontamination Certificate for each pump returned.
RA No: ____________________ Serial Number: ___________________________________________
Company: ________________________________________________________________________________________
Address: ______________________________________________________ City, State, Zip: _______________________
Tel: _____________________________
Has the Product been used? YES / O
If yes, please complete all the following Sections.
Description of substances pumped:
Chemical names:
(1)______________________________________ (3)________________________________________
(2)______________________________________ (4)________________________________________
I hereby confirm that the only substances(s) that the equipment specified has pumped or come into contact with are those
named, that the information given is correct, and the carrier has been informed if the consignment is of a hazardous nature.
Signed ______________________________________________________ Date: _________________________________
ame _______________________________________________________ Position: ______________________________
Precautions to be taken in handling these substances: To assist servicing, please describe any fault condition(s) you have
witnessed
(1)______________________________________________________________________________________________
(2)______________________________________________________________________________________________
(3)______________________________________________________________________________________________
(4)______________________________________________________________________________________________
Action to be taken in the event of human contact:
(1)______________________________________________________________________________________________
(2)______________________________________________________________________________________________
(3)______________________________________________________________________________________________
(4)______________________________________________________________________________________________
Cleaning fluid to be used if residue of chemical is found:
(1)______________________________________________________________________________________________
(2)______________________________________________________________________________________________
(3)______________________________________________________________________________________________
(4)______________________________________________________________________________________________
Flomotion Systems, Inc. Buffalo, Y 14228, Tel: [phone] or 716-691-3941, Fax: [phone]
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Notes
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