Flomotion Systems V21 User manual

Installation and Operation Manual
V21
Peristaltic Chemical Feed Pump
October 2021
Flomotion Systems, Inc.
3 N. Main St, Middleport, N 14105
Toll Free: [phone] (U.S. & Canada)
Tel: [phone]
Fax: [phone]
[email protected]
www.flomotionsystems.com

TABLE OF CONTENTS
Table of Contents
1.0 - System Overview.......................................................................................................................................................... 3
1.1 SAFETY...............................................................................................................................................................................................3
1.2 RECEIVING..........................................................................................................................................................................................3
1.3 CUSTOMER MODIFICATION...................................................................................................................................................................3
1.4 INFORMATION FOR RETURNING PUMPS ................................................................................................................................................3
1.5 WARRANTY.........................................................................................................................................................................................4
2.0 – V21 Series Pump and Pumphead................................................................................................................................ 5
2.1 TUBING, SPINDLE AND COVER INSTALLATION.......................................................................................................................................6
2.2 MOUNTING PUMP ON GEARBOX, INSTALLATION OF COLLET.................................................................................................................7
2.3 PUMP MOUNTING AND COLLET INSTALLATION PROCEDURE..................................................................................................................
2.4 TUBE AND ROLLER INSTALLATION.......................................................................................................................................................9
2.5 TUBING & CONNECTIONS...................................................................................................................................................................15
3.0 – V21 Series Gearbox................................................................................................................................................... 16
3.1 RUN-IN PERIOD.................................................................................................................................................................................16
3.2 V21 SERIES MOTOR WIRING.............................................................................................................................................................16
4.0 – K4 Pump Controller.................................................................................................................................................... 17
4.1 OPERATION AND WIRING...................................................................................................................................................................17
4.2 PROGRAMMING .................................................................................................................................................................................17
4.3 MAKING PROGRAMMING CHANGES....................................................................................................................................................19
4.4 CALIBRATION PROCEDURE FOR MAXIMUM PUMP OUTPUT IN GPH.....................................................................................................19
4.5 DRAW DOWN PROCEDURE: ...............................................................................................................................................................19
4.6 PROGRAMMING GUIDE:......................................................................................................................................................................19
5.0 - Tubing Rupture Detector............................................................................................................................................. 21
5.1 ALARM CAUSES.................................................................................................................................................................................21
5.2 WHAT TO DO IN AN ALARM CONDITION...............................................................................................................................................21
5.3 RESUMING SERVICE...........................................................................................................................................................................21
5.4 RESETTING THE ALARM......................................................................................................................................................................21
6.0 Troubleshooting Guide.................................................................................................................................................. 22
7.0 Recommended Spare Parts.......................................................................................................................................... 23
pg. 2

1.0 - System Overview
The V21 Chemical Feed Pump consists of a controller, motor, gearbox and peristaltic pump.
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 Receivin
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.
1.3 Customer Modification
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.
1.4 Information for Returnin 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.
Please contact Flomotion Systems for a Return Authorization number and instructions for returnin
the pump.
pg. 3

1.5 Warranty
Flomotion Systems, Inc. warrants all Flomotion Systems pumps against any defects that are due to faulty material or
workmanship for a period of two years from date of shipment.In the event that a defect is discovered during the warranty
period, Flomotion Systems, Inc. agrees that, at its option, it will repair or replace the defective product. Any product
repaired or replaced under this warranty will be warranted only for the remainder of the original product warranty period.
This warranty does not apply to consumable components of a product such as, but not limited to, hose, tubing, rollers, and
fuses.
Contact Flomotion Systems, Inc. or your distributor to initiate warranty support. Products may not be returned without
authorization from Flomotion Systems, Inc. All returns shall be freight prepaid.
Limitations
This warranty does not cover:
Damage caused by acts of God, natural disaster, labor unrest, acts of war (declared or undeclared), terrorism,
civil strife, acts of any governmental jurisdiction or any other cause beyond the seller's control
Damage caused by misuse, neglect, accident or improper application or installation
Damage caused by any repair or attempted repair not authorized by Flomotion Systems, Inc.
Any product not used in accordance with the instructions furnished by Flomotion Systems, Inc.
Any product not paid in full in agreed upon terms.
Modifications performed on this product by person(s) not authorized by Flomotion Systems, Inc.
Freight charges to return merchandise to Flomotion Systems, Inc.
Freight charges on expedited or express shipment of warranted parts or product
Travel fees associated with on-site warranty repair
This warranty contains the sole express warranty made by Flomotion Systems, Inc. in connection with its products. All
implied warranties, including with limitation, the warranties of merchantability and fitness for a particular purpose, are
expressly disclaimed.
Some states within the United States do not allow the disclaimer of implied warranties and if this is true in your state the
above limitation may not apply to you. This warranty gives you specific rights, and you may also have other rights that
vary from state to state.
This warranty constitutes the final, complete, and exclusive statement of warranty terms and no person is authorized to
make any other warranties or representations on behalf of Flomotion Systems, Inc.
pg. 4

2.0 – V21 Series Pump and Pumphead
The V21 Series pumphead has two spring-loaded working rollers, which automatically compensate for minor
variations in tubing wall thickness, giving extended tube life.
IMPORTANT: The V21 Series is equipped with a pump cover for safety and protection a ainst chemical
spills. The cover must be installed whenever the pump is in use.
pg. 5
ROLLER ASSEMBL
COLLET SCREW
4MM HEX WRENCH
7 NT.M 60 IN.OZ

2.1 Tubin , Spindle and Cover Installation
! IMPORTANT: Disconnect pump controller from power supply BEFORE chan in tubin !
Item No. Qty Part No. Description
1 1 PHSS-R Pump Housing, Rear
2 1 RA-01 Roller Assembly
3 1 PHC01 Cover
4 1 100324 Collet Screw
5 1 PHG01 Cover Gasket
6 4 100307C Cover Screw
7 1 n/a Tube
8 1 Varies with tubing selection* Tube Seal
9 1 Shaft Seal 10x28x7 Shaft Seal
*Tube Seal PN TS16 TS32 TS48 TS64 TS80 TS96
pg. 6

2.2 Mountin Pump on Gearbox, Installation of Collet
Item No. Qty Part No. Description
1 1 PHSS-R Pump Housing with Tube Seal
2 1 100306 Collet
3 2 100330 Pump Mounting Screws
4 1 NA Tubing
pg. 7
1
2
34

2.3 Pump Mountin and Collet Installation Procedure
1. To install the pump housing on the gearbox, slide it over the central pilot on the gearbox adapter plate.
Next install and torque the mounting screws to 5 NT.M (45 in. oz).
2. Next install the collet on the gearbox shaft. There is a slot in the collet that the flat drive tang on the
gearbox shaft must slide into. Orient the collet to allow the drive tang to slide into the slot and push the
collet completely onto the gearbox shaft. When the collet bottoms out it is in the correct position.
pg. 8
Tubing is shown bent forward out of the pump housing to illustrate the correct tubing
and roller assembly position, prior to sliding the tubing and roller assembly into the
housing and over the collet.

2.4 Tube and Roller Installation
! IMPO TANT: Disconnect pump controller from power supply BEFO E changing tubing!
! IMPO TANT Make sure pump suction and discharge lines are completely drained and
isolated. Note that the tubing hose seal size must match the selected tubing size.
Disassembly
1. Remove four (4) 4mm pump cover screws.
2. Loosen Tube Seal Clamp Screw with 5mm hex
wrench.
3. Remove 5mm collet screw.
pg. 9

4. Remove the roller assembly.
5. Remove worn pump tubing from pumphead.
6. Remove and inspect collet for wear. Note that the
collet may remain in the roller assembly when the
roller assembly is removed from the pump shaft.
pg. 10

7. Clean inside of pump housing with damp rag or an
appropriate cleaning solution to remove any chemical
or tubing residue.
eassembly
1. Reinstall the collet onto the pump shaft.
! IMPORTANT: There is a slot in the collet that the
flat drive tan on the earbox shaft must slide into.
Orient the collet to allow the drive tan to slide into
the slot and push the collet completely onto the
earbox shaft. When the collet bottoms out it is in
the correct position.
2. Mark an 11” section of tubing, which will be the portion, contained within the pump. Leave sufficient
excess on the suction and discharge sides of the pump for the desired connections. If you leave the
excess intake tubing in a coil near the pump it will make it easy to feed a new section of tubing
through the rollers when the section in the pump becomes worn.
pg. 11
Mark an 11”
section of pump tubing.

3. Install tubing into the pumphead.
Note: during tubing installation the loop of tubing
may develop a twist. Examine the tubing for this
condition and if needed turn one end of the tubing
where it exits the tubing clamp to eliminate the
twist. Correctly adjusted the tubing loop will be flat
and parallel to the front face of the pump housing.
4. Loop tubing around roller assembly between
guides as shown. Remove slack in tubing while
rotating roller assembly and sliding onto collet.
pg. 12

5. Align marks on tubing with outside edge of the
tubing Clamp.
6. Reinstall collet screw firmly.
! IMPORTANT Ti hten tubin seal clamp screw.
Be sure to ti hten firmly to prevent “tubin
walk.” Tubin walk can occur when the tubin
seal is the wron size or is not sufficiently ti ht
to keep the rollers from pullin the tubin
throu h the pump as it rotates.
pg. 13
Mark an 11 inch
length of tubing
and locate the
marks at the
outside edge of
the tubing seal
(see arrows)
Tubing seal size
varies with the
selected tubing size.
See tables on
following pages for
details
Align the tubing marks
with the outside edge
of the Hose Seal.

7. Inspect pump cover gasket. Replace if damaged.
Reinstall pump cover gasket and cover.
pg. 14
Align the tubing marks
with the outside edge
of the Hose Seal.

2.5 Tubin & Connections
Tubing connectors are available for many configurations. See the drawing below for details.
V21 SERIES ESTIMATED PUMPING CAPACITY* *Actual flow rates may vary
Tubin Size 1.6mm bore
(1/16”)
3.2mm bore
(1/8”)
4.8mm bore
(3/16”)
6.4mm bore
(1/4”)
8mm bore
(5/16”)
9.6mm bore
(3/8”)
Max Pressure (psi) 100 100 80 60 30 30
ml/rev 0.4 1.7 4.1 6.5 10.8 13.6
Flow Range (GPH) 0.01 - 1.5
(0.6 - 96 ml/m) 0.03 - 6.5
(1.9 - 408 ml/m) 0.09 - 15.6 (5.7 - 984 ml/m) 0.2 - 24.7
(12.6 - 1560 ml/m) 0.2 - 41.1 (12.6 - 2,592 ml/m) 0.3 - 51.7 (18.9 - 3,262 ml/m)
Continuous Duty
Up To: 0.6
(40 ml/m) 2.7
(170 ml/m) 6.5 (410 ml/m) 10.3
(650 ml/m) 17.1 (1,080 ml/m) 21.6
(1,360 ml/m)
Medium Duty
Up To: 1.1
(70 ml/m) 4.7
(297 ml/m) 11.4 (719 ml/m) 18.0
(1,136 ml/m) 30.0 (1,893 ml/m) 37.7 (2,378 ml/m)
Light Duty
Up To: 1.5
(96 ml/m) 6.5
(408 ml/m) 15.6 (984 ml/m) 24.7
(1,560 ml/m) 41.1 (2,592 ml/m) 51.7
(3,262 ml/m)
Hose Barb - PVC
Color / PN
Black
HBC16P
Gray
HBC32P
White
HBC48P
Black
HBC64P
Gray
HBC80P
White
HBC96P
Hose Barb - PTFE
Color / PN
White
HBC16T
White
HBC32T
White
HBC48T
White
HBC64T
White
HBC80T
White
HBC96T
Tube Seal PN TS16 TS32 TS48 TS64 TS80 TS96
Pump Tubin
FLOPRENE FLO16N FLO32N FLO48N FLO64N FLO80N FLO96N
Pump Tubin
VITON VIT16 VIT32 VIT48 VIT64 VIT80 VIT96
*Recommended Use for Optimal Performance
Continuous Duty Cycle: 24/7/365 100rpm max. Run time- No limit continuous max speed.
Medium Duty Cycle: 12/7/365 175rpm max. Run time- 6 hour continuous max speed/twice per day.
Light Duty Cycle: 1/7/365 240rpm max Run time- 1 hour continuous max speed/once per day.
Note: Above outputs based on water at no back pressure. Actual flow rates may vary.
pg. 15

3.0 – V21 Series Gearbox
3.1 Run-in Period
The maximum efficiency of worm reducers is obtained after a “Run-In” period. The length of time required will
depend on the load applied and may be two to four hours at rated load and will be considerably longer at
lighter loads. During Run-In a slightly higher than normal current and temperatures along with lower efficiency
and output torque can be expected. The gear box is sealed and does not require additional lubrication.
3.2 V21 Series Motor Wirin
Motor Type: Permanent Split Capacitor or 3-Phase Inverter Duty
Rotation: Reversible.
Insulation: Class B minimum
Finish: Powder-coat gloss black.
pg. 16

4.0 – K4 Pump Controller
CAUTION!
The K4 VFD Controller has been tested and configured using 120VAC line power and may not be
configured for your line voltage.
CHECK THE POSITION OF THE LINE VOLTAGE SELECT JUMPER ON THE MAIN BOARD
PRIOR TO APPLYING POWER! Failure to do so may cause permanent damage to the VFD.
4.1 Operation and Wirin
For complete details about the motor drive controller please refer to the included K4 SERIES Operating
Instructions booklet.
IMPORTANT: Make sure the Mains volta e jumper is in the correct location for the supplied
volta e. See the K4 drive operatin instructions booklet for details.
Shown here are program settings specific to the operation with the V21 Peristaltic Pump.
4.2 Pro rammin
K4 Default Program Settings
0.04 = 0000 GFCI disabled, enable if power pump through GFCI mains circuit (some additional noise from the drive is
normal).
1.00 = 0001 Remote Start/Stop contacts enable (CHANGE TO 0000 to use 4-20 with manual start/stop)
1.05 = 0003 Power fail auto restart
2.00 = 0003 Freq Control Analog 2 (4-20mA)
2.01 = 0001 Speed change w/o pressing enter
2.02 = 0002 Enable external Local/Remote switching
3.00 = 0005 Stored Set Frequency (5hz)
3.02 = 0100 Upper Frequency Limit
4.00 = 0000 Display in user defined units (Hz)
5.00 = 0000 Enable Run Relay N.O.
7.03 = 0010 Remote Start/Stop - N.O. Start
7.04 = 0000 External Local/Remote Select OFF (13 for remote auto select)
7.06 = 0008 External Fault input select
8.00 = 0001 NC Fault Relay
8.01 = 0009 Enable Status Output
9.07 = 0020 4-20mA Input
8.09* = 0002 When speed feedback 4-20ma output is connected
NOTES:
*8.09 = 0000 to avoid fault when 4-20mA Output is disconnected when not using 4-20mA output
Keypad speed can only be changed in local mode
For manual speed with remote start/stop set 2.00 to 0000
For remote (4-20ma) speed with manual (keypad) start/stop set 1.00 to 0000
Large hose pumps - Boost Value 3.11 default 7, up to 12 or higher
6.05 = 1010 reset to Flomotion Defaults
pg. 17

4.3 Makin Pro rammin Chan es
1. Press the Stop key to make sure the pump is stopped. Display will read Stop.
2. Press the Program key.
3. Using the arrow keys, enter the parameter number you would like to change and then press Enter.
4. Using the Arrow keys, enter the desired settings.
5. Press the Program key when all changes have been made.
6. Press the Run key for pump operation.
4.4 Calibration Procedure for Maximum Pump Output in GPH
A 30-second graduated calibration cylinder should be used to perform a draw-down of actual chemical and
including typical system injection pressure to establish the maximum pump output during normal operating
conditions.
Using the pump to fill the cylinder, make sure the K4 Drive/VFD is set to the highest possible speed using the
‘up’ arrow on the keypad. Since there is a short ramp-up time for the pump to reach maximum speed, it is
recommended to over-fill the calibration cylinder for higher accuracy. After filling the calibration column, make
sure the appropriate valves are open to allow the pump to draw from the calibration column only.
4.5 Draw Down Procedure:
At the same time start the pump and the stop watch. If you slightly over-filled the calibration cylinder, start the
pump and then start the watch when the chemical reaches the "0" point on the calibration cylinder.
Once the stopwatch reaches 30 seconds stop the pump.
Review the graduated markings on the calibration cylinder to find out how much liquid was pumped in 30
seconds.
4.6 Pro rammin Guide:
On the K4 Drive/VFD you will go into the program settings section below.
Change Function Codes:
4.00 = 0002
4.01 = Gallons per Hour x 10
4.02 = 0001
This will set your max value on the K4 Drive/VFD display to be your max GPH pumping capacity.
The full K4 SE IES Drive Operating & Programming manual may be downloaded
from our web site at www.flomotionsystems.com/support
pg. 18

4.7 Controller Wirin Examples
pg. 19

5.0 - Tubing Rupture Detector
Rupture Detector System Overview
5.1 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 in the LIQUID SENSOR in the pump the alarm is triggered.
5.2 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 SENSOR. Inspect rollers and
clean if necessary.
5.3 Resumin Service
Install a fresh tubing insert and the pump is ready to resume service.
5.4 Resettin the alarm
Press the pushbutton (Red LED leak indicator and reset switch) on the front of the Tubing Rupture Detector to
reset the alarm.
! IMPORTANT: Resettin the Tubin Rupture Detector will cause the pump to resume turnin !
! ALWAYS reinstall the pump cover BEFORE resettin the tubin rupture detector !
The full Tubing upture Detector manual is online at
www.FlomotionSystems.com/support
pg. 20