IWAKI WALCHEM EHC Series User manual

EHC & EHE FF Series
Electronic Metering Pump
Instruction Manual
Part of the Family of Products
Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA TEL [phone] FAX [phone]
WEBSITE: www.iwakiwalchem.com

Notice
© 2001 Iwaki Walchem Corporation
Five Boynton Road, Holliston, MA 01746 USA
tel [phone] fax [phone]
All Rights Reserved
Printed in USA
Proprietary Material
The information and descriptions contained herein are the property of Iwaki
Walchem Corporation. Such information and descriptions may not be copied or
reproduced by any means, or disseminated or distributed without the express
prior written permission of Iwaki Walchem Corporation.
This document is for information purposes only and is subject to change without
notice.
Statement of Limited Warranty
IWAKI WALCHEM Corporation warrants equipment of its manufacture and
bearing its identification to be free from defects in workmanship and material for
a period of two years from date of delivery from the factory or authorized
distributor under normal use and service and otherwise when such equipment is
used in accordance with instructions furnished by IWAKI WALCHEM
Corporation and for the purposes disclosed in writing at the time purchased, if
any. IWAKI WALCHEM Corporation’s liability under this warranty shall be
limited to replacement or repair, F.O.B. Holliston, MA U.S.A. of any defective
equipment or part which, having been returned to IWAKI WALCHEM
Corporation, transportation charges prepaid, has been inspected and
determined by IWAKI WALCHEM Corporation to be defective.
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EITHER
EXPRESS OR IMPLIED, AS TO DESCRIPTION, QUALITY, MERCHANT-
ABILITY, FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR ANY
OTHER MATTER.
P/N E00092.A
August, 2001

TABLE OF CONTENTS
Thank you for choosing a Iwaki Walchem EH-FF Series metering pump. This instruction
manual deals with the correct installation, operation, maintenance and troubleshooting
procedures for the EHC-FF and EHE-FF model metering pumps. Please read through it
carefully to ensure the optimum performance, safety and service of your pump.
1.0 INTRODUCTION................................................................................................1
1.1 Safety and Caution Notes ..............................................................................1
1.2 Principle of Operation.....................................................................................1
1.3 Model Code....................................................................................................2
1.4 Specifications.................................................................................................3
1.5 Dimensions.....................................................................................................3
2.0 INSTALLATION.................................................................................................5
2.1 Unpacking ......................................................................................................5
2.2 Location..........................................................................................................5
2.3 Installing Back Pressure/Anti-syphon Valve...................................................6
2.4 Electrical.........................................................................................................6
3.0 OPERATION......................................................................................................7
3.1 Priming...........................................................................................................7
3.2 Adjustment .....................................................................................................7
3.3 Calibration......................................................................................................8
3.4 External Control..............................................................................................9
3.5 STOP Function.............................................................................................17
3.5 STOP Function.............................................................................................18
3.6 AC Power Interruption (Y/E-Control Module)................................................18
4.0 MAINTENANCE...............................................................................................19
4.1 Diaphragm Replacement..............................................................................19
4.2 Valve Replacement ......................................................................................19
5.0 TROUBLESHOOTING.....................................................................................20
6.0 SERVICE POLICY...........................................................................................21

EHB & EHC Series Metering Pumps 1
1.0 INTRODUCTION
1.1 Safety and Caution Notes
WARNING Risk of electrical shock! This pump is supplied with a grounding
conductor and grounding-type attachment plug. To reduce the risk of electrical
shock, be certain that it is connected only to a properly grounded, grounding type
receptacle.
Connect the pump to a GROUNDED outlet providing proper voltage.
§ 115 VAC for models with electrical code 1 in the model number
§ 230 VAC for models with electrical code 2 in the model number
Disconnect the pump from electrical power source before performing any
maintenance.
Depressurize the discharge tubing before disconnecting the tubing or performing any
maintenance on the pump.
When working on or around a metering pump, always wear proper protective clothing
and equipment as recommended by the supplier of the liquid being pumped.
CAUTION! This pump has been tested by Underwriters Laboratories Inc. using
water only. The suitability of this pump for use with liquids other than water is the
responsibility of the user. For liquids other than water, select the best suited liquid
end material combination using a chemical compatibility chart.
Avoid areas where ambient temperature exceeds 122°F (50°C) or falls below 32°F
(0°C), or where the pump or tubing would be exposed to direct sunlight.
1.2 Principle of Operation
The EH series electronic metering pump consists of a pump unit, a drive unit, and a
control unit. The drive unit is an electromagnetic solenoid. When the solenoid coil is
energized by the control unit the armature shaft moves forward due to the magnetic
force of the solenoid. The shaft is attached to a PTFE faced diaphragm which is part
of the pump unit. The diaphragm is forced into the pump head cavity decreasing
volume and increasing pressure which forces liquid in the pump head out through the
discharge check valves. When the solenoid coil is de-energized, a spring returns the
armature to its starting position. This action pulls the diaphragm out of the head
cavity increasing volume and decreasing pressure. Atmospheric pressure then pushes
liquid from the supply tank through the suction check valves to refill the pump head.

2
1.3 Model Code
1 2 3 4 5 6
1 Pump Series
EHC Electronic metering pump with external pulse control or manual speed control (adjustable to
360 strokes per minute) and manually adjustable stroke length. (Typical turndown ratio 125:1.)
EHE Electronic metering pump with external pulse control or manual speed control (adjustable to
360 strokes per minute) and manually adjustable stroke length. (Typical turndown ratio 1800:1.)
2 Capacity/Pressure Rating
Output Capacity Output Per Stroke Connection Size
Max mL
Max Pressure I.D. X O.D.
Size mL/min GPH Min max PSI Mpa Tube mm
30 270 4.3 0.30 0.75 30 0.2 10 X 12
35 420 6.7 0.46 1.16 30 0.2 10 X 12
55 1250 19.9 0.69 3.47 30 0.2 10 X 12
3Liquid End
Pump Head Connections Valve Valve Seat Diaphragm Gasket
FF PTFE PFA PTFE PTFE EPDM/PTFE PTFE
4 Voltage/Wiring
11UP 115VAC, 50/60 Hz, single phase, with plug
23UP 230VAC, 50/60 Hz, single phase, with plug
5 Control Module
R - For use on all EHC models, features external pulse and stop capability.
Y - For use on all EHC models, features programmable 4-20mA control and external pulse capability
with pulse divide and multiply.
E - For use on EHE model, features programmable 4-20mA control and external pulse capability
with pulse divide and multiply.
6 Connections
Connection Size, I.D. X O.D. ,Tube
in (mm)
12 0.39 X 0.47 (10 X 12)
EHC 35 11UP R12
-
FF

3
1.4 Specifications
Operating Conditions
Ambient temperature 32°F to 122°F (0°C to 50°C)
Relative humidity 30% to 90% non-condensing
Liquid Temperature 32 – 140 °F (0 – 60 °C)
Adjustment Range
Recommended stroke length adjustment range 40% to 100%
Recommended frequency adjustment range 0 to 360 strokes per minute
1.5 Dimensions
EHC-30/35FF
W
F
C
R
STVZ
X
H
G
E
L
AB
0
.
39"
x
0
.
4
7
"
J
0.39" x 0.47"
Model A B C D E F G H J L W
EHC 30/
35
R FF 3.82 1.47 0.67 3.94 1.19/
1.23 0.20 6.61/ 6.69 7.46 (7.95)74.65/ 4.72 8.29/8.33
(8.62/8.66) 74.57
7With Y-Control Module
All dimensions in inches
Mounting Dimensions R S T V Z X

4
EHC all variations 3.94 0.28 0.63 0.39 1.81 0.24
EHE-55FF
0
.
39"
x
0
.
4
7
"
0.39" x 0.47"

5
2.0 INSTALLATION
2.1 Unpacking
Open the shipping carton and inspect contents for damage. If any items are missing
or damaged contact your local distributor to arrange for replacement.
2.2 Location
Choose a location for the pump that is clean, dry, close to an electrical outlet, and
allows convenient access to stroke length control, frequency control, and tubing
connections. Avoid areas where ambient temperature exceeds 122°F (50°C) or falls
below 32°F (0°C), or where the pump or tubing would be exposed to direct sunlight.
This pump is cord connected and not intended for permanent mounting to a building
structure. However, temporary mounting to stabilize the pump during operation may
be necessary as long as tools are not required for the installation or removal of the
pump.
Flooded suction (mounting the pump below the level of liquid in the supply tank) is
strongly recommended, especially when pumping liquids that readily generate gas
bubbles. Hydrogen peroxide is a common example of such a liquid. (See Figure 1.)
If flooded suction mounting is not possible, a shelf adjacent to (but not directly
above) the supply tank often works well. (See Figure 2.) The supply tank or cover
can also be used if it has provisions for mounting a pump. (See Figure 3.) In any
case, the total suction lift should not exceed 3.3 ft (1.m).
Figure1 Figure2
Shelf Mount Flooded Suction

6
2.3 Installing Back Pressure/Anti-syphon Valve
It is recommended for all EH-FF installations that a back pressure/anti-siphon valve
be used to ensure pump accuracy and repeatability.
The back pressure/anti-siphon valve acts to create back pressure when pumping into
atmosphere or low pressure applications. It also prevents siphoning through the pump
when the supply level is above the installed unit.
IMPORTANT: Always install the injection/back pressure valve at the end of the
discharge tubing to prevent over-pumping in atmospheric or low pressure situations.
2.4 Electrical
WARNING: Risk of electrical shock! This pump is supplied with a grounding
conductor and grounding-type attachment plug. To reduce the risk of electrical
shock, be certain that it is connected only to a properly grounded, grounding type
receptacle.
Connect the pump power cord to a GROUNDED outlet supplying proper voltage.
Avoid branch circuits that also supply power to heavy machinery or other equipment
that could generate electrical interference.

7
3.0 OPERATION
3.1 Priming
R-Module
Install the pump as described above. With the pump turned on, set stroke length at
100% and frequency at 100%. Liquid should move through the suction tubing and
into the pump head. When liquid enters the discharge tubing at the pump head set
frequency to 0% to stop the pump. Adjust frequency and stroke length as necessary.
Y/E-Module
Install the pump as described above. With the pump plugged in but not pumping, set
stroke length at 100% and frequency at 360 (use the or buttons as necessary to
adjust the frequency. Push the START/STOP button to start the pump. As soon as
liquid enters the discharge tubing at the pump head, push the START/STOP button
again to stop the pump. Adjust stroke length, controller configuration as necessary.
If the pump does not self prime, remove the check valve housing on the discharge and
suction sides to make sure the valve cartridges and gaskets are in correct positions
(see Section 4.2). Remove and shake cartridges to make sure ball is loose inside.
Wetting cartridges before re-installing will help in priming. Temporarily flooding
pump suction is recommended to ensure pump head is sufficiently wetted for
subsequent priming.
Note: Suction tubing arrangement and priming height may affect pump dispense
accuracy.
3.2 Adjustment
A. Pumps using the ‘R’ Control Module
The pump will operate best with the stroke length at 100%. If less than full output is
required, set the frequency to the approximate percentage of maximum desired.
Example: Model EHC35FF-11UPR12 has maximum output of 420 ml/min.
Desired output is 210 ml/min. 210 ÷ 420 = 0.5 or 50%, so set
frequency knob at 50.
For outputs less than 2% of maximum it will be necessary to also reduce the stroke
length. (Minimum recommended stroke length is 40%.)

8
B. Pumps using the ‘Y’ Control Module
The pump will operate best with the stroke length at 100%. If less than full output is
required, set the frequency to the desired strokes per minute using the UP and DOWN
arrow keys.
Example: Model EHC35FF-11UPY12 has maximum output of 420 ml/min.
Desired output is 210 ml/min. 210 ÷ 420 = 0.5 or 50%, so set frequency
to 0.5 x 360 = 180 spm by pushing the UP or DOWN arrow key.
For very low outputs it will be necessary to also reduce the stroke length.
(Minimum recommended stroke length is 40%.)
C. Pumps using the ‘E’ Control Module
The pump will operate best with the stroke length at 100%. If less than full output is
required, set the frequency to the desired percentage of maximum.
Example: Model EHE55FF-11UPE12 has maximum output of 1250 ml/min.
Desired output is 900 ml/min. 900 ÷ 1250 = 0.72 or 72%, so set frequency
to 0.72 x 360 = 263 spm by pushing the UP or DOWN arrow key.
For very low outputs it will be necessary to also reduce the stroke length.
(Minimum recommended stroke length is 40%.)
3.3 Calibration
If exact output calibration is required, first prime and adjust the pump as above. Then
connect a calibration column to the suction side of the pump. Turn the pump on for
one minute and read the amount of liquid pumped from the column. Adjust the
frequency up or down as necessary and check the output again. When the desired
output is reached, disconnect the calibration column and reconnect the suction tubing.
(See Figure 8.)
Figure 8 Calibration

9
3.4 External Control
A. Pumps using the ‘R’ Control Module
For pulse proportional external control of pump frequency, connect the control signal
leads to terminals 4 (positive) and 6 (common) inside the control module. The input
signal should not exceed 360 pulses per minute (See Figure 9). The external circuit
should be capable of switching 10 VDC at 2 mA with a pulse width of 10 ms to 100
ms (for R & E modules, 50 ms to 100 ms for Y modules).
In order for the pump to operate properly in External Mode, the frequency knob must
be set fully counter clockwise so it points to the “E”. (See Figure 10.)
Figure 9
Figure 10
23 456
GROUND POWER
SUPPLY
EXTERNAL
SIGNAL INPUT
TERMINALS
STOP
FUNCTION
TERMINAL
S
HotNeutral
+
(EXT)
+
(STOP)
Common
100%
STROKE RATE
90
70
50
30
10
E

10
B. Pumps using the ‘Y’ Control Module
The EH-Y Series is able to operate in both digital and analog external modes. An
external stop function is also available.
Display/Keypad Overview
Alpha/numeric display. Indicates
stroke frequency, external mode or
external settings.
Start/Stop key.
Manually starts or
stops the pump. This
key is used in setting
external modes and
values. EXT key. Push to set
pump for external input
operation. This key is also
used to select external
mode and settings.
WAIT indicator.
Visible when pump is
in standb
y
mode.
EXT indicator.
Visible when pump
is operating via
external input.
STOP indicator. Visible
when the pump is stopped
via external signal. The
pump stops pumping.
OVER indicator. Visible
when an input signal
exceeds the pump’s 360
spm capability.
SET indicator. Visible
when pump external mode
and/or setting are being
selected.
UP key. Increases
numeric values. Is used
with EXT key to select
external modes.
DOWN key. Decreases
numeric values. Is used
with EXT key to select
external settings.
ON light. Indicates AC
power to the pump and
goes on and off with
each stroke.
3 6 0
EH Controller
1
2
WAIT EXT STOP OVER SET
START/STOP
ON
EXT
423 5678
Power Ground
Stop Input
Digital Input
Analog Input
Sensor Power
DC 12V
2
0
m
A
m
a
x.
+
+
-
-
White
NEU
Black
HOT
Green

11
C. Pumps using the ‘E’ Control Module
The EHE Series is able to operate in both digital and analog external modes. An external
stop function is also available.
Display/Keypad Overview
2
1345678
+
+
-
-
POWER GROUND
GREEN
BLACK
HOT
WHITE
NEU Digital Input
Stop Input
Analog Input
Sensor Power
DC 12V
10 mA max.
External Signal
Cable
Power
cord
Alpha/numeric display. Indicates
stroke frequency, external mode or
external settings. UP key. Increases
numeric values. Is used
with EXT key to select
external modes.
DOWN key. Decreases
numeric values. Is used
with EXT key to select
external settings.
ON light. Indicates AC
power to the pump and
goes on and off with
each stroke.
SET indicator. Visible
when pump external mode
and/or setting are being
selected.
OVER indicator. Visible
when an input signal
exceeds the pump’s 360
spm capability.
STOP indicator. Visible
when the pump is stopped
via external signal. The
pump stops pumping.
EXT indicator. Visible when
pump is operating via
external inut.input
operation.
WAIT indicator. Visible
when pump is in standby
mode.
EXT key. Push to set
pump for external input
operation. This key is
also used to select
which external mode
and settings.
Start/Stop key.
Manually starts or stops
the pump. This key is
used in setting external
modes and values.
3 6 0

12
EH-Y/E Quick Reference Guide
S/S = Start/Stop key EXT = External key
From: Press: To:
WAIT S/S run in manual mode
decrease frequency (1to 360 spm)
increase frequency (1to 360 spm)
EXT run EXT
EXT + SET external mode
EXT + SET external values
Running in manual mode decrease frequency (1to 360 spm)
increase frequency (1to 360 spm)
S/S return to WAIT
Running in EXT mode S/S return to WAIT
SET external mode or Toggles between DIG (multiply or divide) and
ANA (milliamp input)
S/S accept data and return to WAIT
SET external values
DIG EXT select / (divide) or X(multiply)
increase value (1to 999)
decrease value (1to 999)
S/S accept data and return to WAIT
ANA EXT scrolls through the following selections:
Analog signal level (point 1)
Pump speed (point 1)
Analog signal level (point 2)
Pump speed (point 2)
increase value (A from 0.00 to 20.0 mA, P from 0
to 360 spm
decrease value (A and P)
S/S accept data and return to WAIT
STOP indicates stop function is asserted
OVER indicates one or more input pulses were received prior to completing
action required by previous input pulse. Up to 255 input pulses will be
stored in memory.

13
Digital Mode In digital mode, the pump accepts a pulse signal from a flowmeter or other
instrument. This pulse signal should be in the form of a "dry" contact (no voltage
closing contact). The pump can be set to divide pulses by a factor of 1 to 999; or in
multiply mode, 1 input pulse can produce 1 to 999 pump strokes.
Connecting a digital input device
Disconnect AC power to the pump. Remove the four screws from the terminal block
cover and remove the cover. Remove the cord nut and bushing from the terminal
block cover. Remove the terminal block from the connector. Slide the nut and
bushing over the external control cable and insert the cable through the terminal block
cover. Strip 1/4” insulation from conductors. See schematic below for connections
for Y-Module or E-Module control unit.
Y-Module E-Module
WAIT
Increase Decrease
Pump Speed RUN
MANUAL RUN EXTERNAL SET EXTERNAL MODE SET EXTERNAL VALUES
S/S S/S S/S S/S S/S
Incr Decr
Pump Speed DIG ANA
DIG: ANA:
toggles
between
X, /
to scroll thru
A1, P1, A2, P
2
Incr Decr
Numeric Value
4
23 5678
Power
Ground
Stop Input
Digital Input
(dry contacts)
Analog Input
Sensor Power
DC 12V
20 mA max.
+
+
-
-
White
NEU
Black
HOT
Green
4
23 5678
Power Ground
Digital Input
Stop Input
Analog Input
Sensor Power
DC 12V
10 mA max.
+
+
-
-
White
NEU Black
HOT Green

14
Sensor Power
Y-Module
The control circuit of the Y Module has the ability to provide 12 VDC at up to
20 mA to power a Hall effect sensor or similar device.
Connect the sensor power leads to terminal 4 (positive) and terminal 8 (negative) of
the terminal block.
E-Module
The control circuit of the EHE series has the ability to provide 12 VDC at up to 10
mA to power a Hall effect sensor or similar device.
Connect the sensor power leads to terminal 4 (positive) and terminal 8 (negative) of
the terminal block.
Settings
Start with pump in the WAIT state. If it is not currently in wait, press
START/STOP once.
1. Set it to digital mode
Press and EXT simultaneously.
The SET indicator is highlighted and DIG (digital) or ANA (analog) will be
displayed.
If DIG is displayed, press START/STOP to accept that mode.
You will be returned to the WAIT state.
If ANA is displayed, press to change to DIG and then press
START/STOP to enter that choice.
You will be returned to the WAIT state.
2. Set multiply or divide
To set values for digital operation, press EXT and
simultaneously. The display will show ‘/’ or ‘X’ and a number. Now pressing
the EXT button will alternate between X (multiply) and / (divide).
3. Set the value
or will increase or decrease the multiplier or divider. Pressing a
button once will change the value by one. Holding a button down will
continuously increment or decrement the value, slowly at first, then rapidly.
Press START/STOP to accept values and return to WAIT.

15
Press EXT to operate the pump in external mode. The pump will now
respond to the incoming pulse signal. The stroke length can be adjusted
manually to set the volume pumped per stroke.
Analog Mode In analog mode the pump will accept a milliamp signal and produce a pump speed
proportional to the signal level received. The pump’s response can be fine-tuned by
variable set points to meet system requirements.
Connecting an analog signal device
Disconnect AC power to the pump. Remove the four screws from the terminal block
cover and remove the cover. Remove the cord nut and bushing from the terminal
block cover. Remove the terminal block from the connector. Slide the nut and
bushing over the external control cable and insert the cable through the terminal block
cover.
Caution: An open loop signal voltage exceeding 25 VDC will permanently damage
the control unit!. If the signal voltage is greater than 25 VDC, power down the signal
source prior to connection.

16
Strip 1/4” insulation from conductors. See schematic below for connections for Y-
Module or E-Module control unit.
Y-Module E-Module
Settings
The pump’s response to a 4 to 20 milliampere signal can be adjusted to meet almost
any need. The adjustment is done by selecting two points. A signal level and a pump
speed are entered for each point. These two points determine a straight line and the
pump speed resulting from any given signal will be defined by that line. The factory
settings for point 1 are 4.0 mA, 0 spm and for point 2 are 20.0 mA, 360 spm. An ‘A’
in the leftmost position of the display indicates the data shown is Analog signal level.
A ‘P’ indicates Pump speed. The 1 on the right side of the display is highlighted when
viewing or changing data for point 1. The 2 is highlighted to indicate data for point 2.
Start with pump in the WAIT state. If it is not currently in wait, press
START/STOP once.
1. Set it to analog mode.
Press and EXT simultaneously.
The SET indicator is highlighted and DIG (digital) or ANA (analog) will be
displayed.
If ANA is displayed, press START/STOP to accept that mode.
You will be returned to the WAIT state.
If DIG is displayed, press to change to ANA and then press
START/STOP to enter that choice. You will be returned to the WAIT state.
4
23 5678
Power
Ground
Stop Input
Digital Input
(dry contacts)
Analog Input
Sensor Power
DC 12V
20 mA max.
+
+
-
-
White
NEU
Black
HOT
Green
4
23 5678
Power Ground
Digital Input
Stop Input
Analog Input
Sensor Powe
r
DC 12V
10 mA max.
+
+
-
-
White
NEU Black
HOT Green

17
2. Set the value
To set values for analog operation, press EXT and simultaneously. The
display will show A04.0 (or some value between 00.0 and 20.0 mA) with the
point 1 indicator highlighted. Press or to adjust the value to the
desired analog signal level for point 1.
Press EXT to display the pump speed for point 1. The display will show P0
(or some value between 0 and 360 spm) with the point 1 indicator highlighted.
Press or to adjust the value to the desired pump speed for point 1.
Press EXT again to display the analog signal level for point 2, which can be
adjusted as for point 1. Pressing EXT a third time will display the pump
speed for point 2m which can be adjusted as for point 1.
Continued pressing of EXT key will scroll through the above four parameters
for review or adjustment. When settings are as desired, press START/STOP
to accept the new values and return to WAIT.
Press EXT to operate the pump in external mode. The pump speed will now
be determined by the level of the milliamp signal as shown in the graph. The
stroke length can be adjusted manually to set the volume pumped per stroke.
04 8121620
A
1
A
2
90
180
270
360
P1
P2
INPUT SIGNAL
,
mA
P
U
M
PFRE
Q
UENCY,SPM