Jesco MAGDOS LB Guide

MAGDOS LB
Solenoid-driven diaphragm dosing pump
Operation &
Maintenance Instructions
Read these operation and maintenance instructions before start up!
To be held for future reference.
EN 02
Dosing
Conveying
Control
Liquids
Gases
Systems

List of Contents
1. Safety .........................................................................................................................................................................3
1.1 General............................................................................................................................................................. 3
1.2 Warnings used in this Operation & Maintenance Manual...................................................................................... 3
1.3 Qualification and training of personnel ................................................................................................................ 3
1.4 Important safety instructions .............................................................................................................................. 3
1.5 Hazards due to non-compliance with the safety instructions................................................................................. 4
1.6 Safe operation................................................................................................................................................... 4
1.7 Safety instructions for the owner/operator........................................................................................................... 4
1.8 Safety instructions for installation, maintenance and inspection............................................................................ 4
1.9 Unauthorized modification and production of spare parts...................................................................................... 4
1.10 Impermissible modes of operation .................................................................................................................... 5
1.11 Dosing of Chemicals........................................................................................................................................ 5
1.12 Scope of delivery............................................................................................................................................. 6
2. Compliant use ............................................................................................................................................................7
3. Function .....................................................................................................................................................................7
4. Dimensions ................................................................................................................................................................7
5. Technical data............................................................................................................................................................8
6. Performance curves...................................................................................................................................................9
7. Installation ...............................................................................................................................................................10
7.1 General notes of instruction.............................................................................................................................. 10
7.2 Installation location.......................................................................................................................................... 10
7.3 Arrangement of the dosing pump...................................................................................................................... 10
7.4 Electrical connection ....................................................................................................................................... 11
7.5 Hydraulic connections...................................................................................................................................... 11
7.6 Injection nozzle installation............................................................................................................................... 12
7.7 Installation example/ Example for accessories ................................................................................................... 12
8. Operation..................................................................................................................................................................13
8.1 Setting of flow rate .......................................................................................................................................... 13
9. Start up.....................................................................................................................................................................14
10. Shutdown ...............................................................................................................................................................15
10.1 Disposal of old equipment.............................................................................................................................. 15
11. Maintenance ..........................................................................................................................................................16
11.1 Replacing the diaphragm ............................................................................................................................... 16
11.2 Valves........................................................................................................................................................... 17
12. Calibration of the stroke frequency adjustment...................................................................................................18
12.1 Calibration procedure..................................................................................................................................... 18
12.2 Deleting the calibration .................................................................................................................................. 18
13. Spare part list ........................................................................................................................................................19
14. Troubleshooting .....................................................................................................................................................20
15. Unit revision ...........................................................................................................................................................21
16. Index.......................................................................................................................................................................22
17. Drill template .........................................................................................................................................................23
Declaration of conformity............................................................................................................................................25
Declaration of harmlessness ......................................................................................................................................26
Warranty Application...................................................................................................................................................27
2 | Operation & Maintenance Instructions | List of Contents

1. Safety
1.1 General
This Operating & Maintenance Manual contains basic information to be noted during installation, operation
and maintenance. It is therefore essential that the Manual be read by the contractor before installing and
commissioning the pump/system, as well as by the relevant operating personnel /owner of the unit. It must
remain accessible at the dosing pump/system for reference at all times.
In addition to the general safety instructions under this main heading Safety, the special safety precautions
outlined in other sections must also be observed.
1.2 Warnings used in this Operation & Maintenance Manual
This Operation & Maintenance Manual contains vital information which may endanger people, the environ-
ment and the dosing pump/system if they are disregarded. These statements are identified by the following
symbols:
DANGER!
Refers to an imminent danger.
Non-compliance can lead to death or extremely serious injury.
WARNING!
Refers to a potentially hazardous situation. Non-compliance can lead to death or extremely serious injury.
CAUTION!
Refers to a potentially hazardous situation. Non-compliance can lead to minor injury or property damage.
IMPORTANT! or NOTICE!
Appears in conjunction with safety instructions which may endanger the machine and its operation if
disregarded.
IMPORTANT!
Draws attention to supplementary information to make the work easier and ensure troublefree operation.
Markings which are affixed directly to the pump, such as
• Cable markings
• Markings for process fluid connections
must be observed without fail and must remain fully legible at all times.
1.3 Qualification and training of personnel
The personnel employed for installation, operation, inspection, and maintenance, must be suitably qualified
for this work. The areas of responsibility, competence and supervision of the personnel must be pre-
cisely defined by the owner. Personnel who do not have the required know-how must be duly trained and
instructed. If necessary, this can also be undertaken by the manufacturer/supplier on behalf of the owner.
In addition, the owner of the system must ensure that the relevant personnel are fully familiar with and have
understood the contents of this Operation & Maintenance Manual.
1.4 Important safety instructions
When installing and using this electrical equipment, basic safety precautions should always be followed,
including the following:
NOTICE!
Read and follow all instructions!
Save these instructions!
Safety | Operation & Maintenance Instructions | 3

WARNING!
To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at
all times.
WARNING!
Risk of Electric Shock. Connect only to a grounding type receptacle protected by a ground-fault circuit-in-
terrupter (GFCI). Contact a qualified electrician if you cannot verify that the receptacle is protected by a GFCI.
Do not bury cord. Locate cord to minimize abuse from lawn mowers, hedge trimmers, and other equipment.
WARNING!
To reduce the risk of electric shock, replace damaged cord immediately.
WARNING!
To reduce the risk of electric shock, do not use extension cord to connect unit to electric supply; provide a
properly located outlet.
1.5 Hazards due to non-compliance with the safety instructions
Failure to comply with the safety instructions may endanger not only people, but also the environment and
the unit. Non-compliance with the safety instructions can lead to the loss of all entitlement to damages.
The following hazards in particular may arise:
• Failure of major unit functions.
• Failure of specified methods for maintenance and repair.
• Danger to people due to electrical, mechanical and chemical effects.
• Danger to the environment due to leakage of hazardous substances.
1.6 Safe operation
The safety instructions contained in this Operation & Maintenance Manual must be observed. The owner is
responsible for ensuring compliance with local safety regulations.
Disturbances susceptible of impairing safety are to be eliminated immediately!
1.7 Safety instructions for the owner/operator
• Leakages (e.g. when a membrane breaks) of dangerous materials to be conveyed (e.g. aggressive, poi-
sonous) must be purged in such a way that they do not become a risk to people and the environment.
Statutory regulations must be observed.
• Danger due to electric current must be excluded (for further details, refer to the German VDE1) stand-
ards as well as local rules and regulations as well as chapter 1.4).
1) Association of German Electrotechnical Engineers
1.8 Safety instructions for installation, maintenance and inspection
The owner must ensure that all maintenance, inspection and installation work is undertaken by authorized
and duly qualified skilled personnel who have also studied this Operation & Maintenance Manual.
The dosing pump must always have come to a complete stop before starting any work on the pump. The
procedure specified in the Operation & Maintenance Manual for shutting down the dosing pump/system
must be observed without fail.
Dosing pumps or systems in contact with potentially harmful media must be decontaminated.
All safety mechanisms and guards must be refitted and reactivated as soon as the work is complete.
The instructions outlined in chapter 7.2 “Installation location” and 9. “Start up” must be observed before
starting the pump/system.
1.9 Unauthorized modification and production of spare parts
The device may only be modified or converted in consultation with the manufacturer. Genuine spare parts
and accessories authorized by the manufacturer ensure greater safety. The use of other parts can void the
liability for the subsequent consequences.
4 | Operation & Maintenance Instructions |

1.10 Impermissible modes of operation
Other usage and modifications in opposition to chapter 2 "Appropriate and intendet use" will lead to the
immediate cancellation of the warranty and any other manufacturer’s liability.
1.11 Dosing of Chemicals
CAUTION!
When working on dosing systems, the accident prevention regulations applicable on site must be observed
and the specified personal protective equipment worn.
The following standard protective clothing is recommended, depending on the hazard associated with the
metered medium:
Protective clothing Protective gloves Goggles
All people responsible for installation and maintenance of pumps, piping, hoses and accessories should
wear this protective equipment.
Before working on the dosing pump and plant, disconnect it from the mains supply and protect it against
reconnection.
CAUTION!
Any chemical still present in the dosing head may spray out when the power supply is reconnected. This
may lead to caustic or other burns to the face and hands. Dosing lines must always be connected before
starting the pump again.
The chemical resistance of the pump’s materials of construction must be verified before dosing aggressive
media!
The dosing head of the dosing pump as well as connections and lines of the system may be under pressure.
Working on the dosing plant requires special safety precautions and may only be carried out by instructed
technical personnel:
CAUTION!
Chemical could spray out. This may lead to caustic or other burns. Always relieve the pressure before start-
ing work on the dosing pump.
Before working on the dosing head, valves and connections, flush the dosing pump with a harmless medium
(mainly water) to avoid unintentional contact with the metered medium.
WARNING!
Never look into the open end of a clogged line or valve. Chemical may emerge unexpectedly and cause
caustic or other burns to face and hands.
Before start up, all connections must be inspected for correct tightness and, if necessary, must be tightened
up using appropriate tools.
CAUTION!
If connections at the dosing head are loosened during operation for venting or other reasons, leaking
chemical must be removed professionally. This is the only way to avoid the danger of physical injury and
corrosion at the dosing pump. Leaking chemical may also damage the diaphragm at its mounting points.
| Operation & Maintenance Instructions | 5

NOTICE!
When changing the chemical, check whether the pump’s and the system’s materials are chemically
resistant. If there is the danger of a chemical reaction between different media, a thorough cleaning
first is mandatory.
DANGER!
Fire hazard. Pressure surge: parts may burst and cause fatal injury. The equipment may not be used
in a highly combustible area under any circumstances.
CAUTION!
Hot metal parts may burn your hands. Always disconnect the mains power supply before opening the
magnetic drive and let the dosing pump cool down for at least one hour.
CAUTION!
Malfunctions may arise in circuits, magnetic strips or mobile phones if brought into the direct vicinity
of the stroking solenoid.
1.12 Scope of delivery
IMPORTANT!
Please unpack the dosing pump and ordered accessories carefully in order not to miss small parts.
Immediately compare the scope of delivery to the delivery note. If there are any discrepancies, contact
your local distributor.
6 | Operation & Maintenance Instructions |

2. Compliant use
The product is especially designed for the following purpose: conveyance and dosing of chemicals.
The operational safety of the delivered unit can only be guaranteed when it is used in conformity with its
intended use. Other usage and modifications will determine the immediate cancellation of the warranty and
any other manufacturer’s liability. The operating conditions described in chapter 5 "Technical Data" must be
observed!
3. Function
Dosing pumps are used to add chemicals specifically in various processes. Metering capacities range from
0.5 to 15 litres per hour. The exact metered capacities can be derived in the chapter "performance curves".
4. Dimensions
100
70
O6,5
80O
153
76
187~
116
43
59
120
180~
L L
MAGDOS Tubing connection with union nut G5/8 Dim. L
LB 05 ... 2 4/6 31
LB 4 ... 15 6/9, 1/4“-3/8“ 34
6/12 15
Fig. 4.1: all dimensions in mm.
Bestimmungsgemäßer Gebrauch | Operation & Maintenance Instructions | 7

5. Technical data
MAGDOS LB 05 LB 1 LB 2 LB 4 LB 6 LB 10 LB 15
Diaphragm ø 24 mm 33 mm 39 mm
max. back pressure 16 bar 16 bar 16 bar 16 bar 8 bar 6 bar 3 bar
Flow rate
at max. pressure *
0.36 l/hr 0.75 l/hr 1.9 l/hr 3.4 l/hr 6.2 l/hr 9.0 l/hr 13 l/hr
Average back pressure 8 bar 8 bar 8 bar 8 bar 4 bar 3 bar 1 bar
Flow rate
at medium pressure *
0.54 l/hr 1.1 l/hr 2.3 l/hr 3.8 l/hr 6.8 l/hr 10 l/hr 15 l/hr
Max. stroke frequency 120 min-1 250 min-1 160 min-1 180 min-1 250 min-1
Suction lift for non-ef-
fervescent media
5 mWS 5 mWS 3 mWS 3 mWS 2 mWS 2 mWS 2 mWS
Max. inlet pressure 800 mbar
Power supply 110-240 V AC, 50/60 Hz
Power supply cable 1.8 m with mains plug
Power consumption 18 W
Max. power
consumption during
dosing stroke
approx. 4 A
Protection class IP 65
Insulation class F
Weight approx. 3 kg
Max. ambient
temperature
45 °C (with PVC parts 40 °C)
Max. media
temperature
50 °C (with PVC parts 35 °C)
* The exact metered capacities can be derived from the performance curves.
8 | Operation & Maintenance Instructions | Technical data

6. Performance curves
The performance curves refer to water at 20 ℃ (68 °F). The performance of the dosing pump depends on
the viscosity of the process fluid and hydraulic installation conditions. Dosing pumps must therefore be
gauged in litres during application.
0
1
2
3
4
5
6
0 2 4 6 8 10 12 14 16
[l/h]
[bar]
LB 4
LB 2
LB 1
LB 05
0
2
4
6
8
10
12
14
16
0 2 4 6 8
LB 6
LB 10
LB 15
[l/h]
[bar]
Performance curves | Operation & Maintenance Instructions | 9

7. Installation
7.1 General notes of instruction
For the selection of a dosing pump when designing a system as well as for the installation and operation,
local rules and regulations must be observed. This applies to the selection of appropriate materials of con-
struction, the handling of the chemicals and the electrical installation. At the same time the technical data of
the dosing pump (chapter 5.) must be taken into consideration. The system must be designed accordingly/
properly (e.g. pressure loss in lines depending on nominal diameter and length).
The designer and the user are responsible to make sure that the whole plant including the dosing pump
is constructed so that neither plant equipment nor buildings are damaged in the case of chemical leakage
due to the failure of wear parts (e.g. diaphragm rupture) or burst tubing. If the chemical plant represents
a potential source of danger, the installation must be carried out in a way that no unreasonably high
consequential damages occur, even if the dosing pump fails. Therefore we recommend the installation of
containment tanks.
The drain outputs of the dosing head must be visible in order for a diaphragm failure to be detected. The
flow of the drainage outputs must be on a free downwards gradient if possible.
To increase the dosing accuracy and to ensure the functional reliability, we recommend the use of additional
accessories. This includes back pressure valves and relief valves.
Always use appropriate tools for the installation of plastic connecting parts. To avoid damage, never apply
excessive force.
IMPORTANT!
Plastic parts (especially PVC parts) can be tightened and loosened more easily if the thread is lubricated
with slip additive (e.g. silicone grease or PTFE spray).
NOTICE!
The slip additive must be compatible with the chemical to be metered.
7.2 Installation location
The installation location of the dosing pump must be easily accessible for the operating and service staff.
When installing the dosing pump below the level storage level of the process fluid, care must be taken to
ensure that chemical leakages due to a broken diaphragm cannot cause any damage (collecting pan). It is
also possible to mount the pump with a container adapter on the chemical supply tank.
Please note the ambient temperature of the dosing pump (refer to the technical data table). Radiant heat of
apparatus and heat exchangers must be shielded so that the dosing pump can still dissipate its own heat
sufficiently. Exposure to direct sunlight must be avoided. If the dosing pump is installed outside, provide a
roof to protect it against weather.
7.3 Arrangement of the dosing pump
The dosing pump can be mounted to the floor but also mounted directly on the wall without additional ele-
ments. The dosing head must be turned accordingly (for installation and tightening torque see chapter 11,
Maintenance), in order to ensure the flow direction of the medium through the dosing head.
Fig. 7.1: Floor or wall mounting of the dosing pump
10 | Operation & Maintenance Instructions | Installation

7.4 Electrical connection
DANGER!
Fire hazard. Pressure surge: parts may burst and cause fatal injury. The equipment may not be used in a
highly combustible area under any circumstances.
The electrical connection of the dosing pump must be made according to the local rules and regulations and
may only be carried out by technical personnel.
NOTICE!
The metering pump has to be plugged into a grounded power outlet.
NOTICE!
The metering pump is double-insulated and grounded. To avoid incorrect metering after the process is
finished, the dosing pump must be locked electrically and hydraulically.
7.5 Hydraulic connections
The MAGDOS LB is delivered with loose hose connections. The tubings to the pump may not be under pres-
sure und must be equipped with a tension safeguard. Cut the tubing neatly and in an exact right angle to
the appropriate length. Chose the tubing connection according to the character of the tubing (material, inner
diameter, wall thickness) in order to considerate the maximum pressure load.
e
c
d
b
a
Fig. 7.2: Example 4/6 tubing connection Example 6/12 tubing connection
To mount the union nuts a/band the clamping ring c, pull them onto the tubee . Then push the tube
as far as it will go on the connection d. Tighten the union nut b. Place the connection dwith the gasket
to the dosing head and tighten it with the union nuta.
When connecting the tubing connections observe the flow direction and the horizontal positioning of the
dosing head. The dosing head is marked with an arrow g . The suction line hmust always point to the
bottom. Consequently the arrow gand the pressure linefalways point to the top. This is irrespective from
the positioning of the dosing head to the drive (see fig. 7.1).
f
g
h
Fig. 7.3: Dosing head flow direction
Installation | Operation & Maintenance Instructions | 11

7.6 Injection nozzle installation
Injection nozzles are used to mix the metered process fluid into a main stream and simultaneously fulfill a
non-return function. The injection nozzle is usually installed in the main line from above. Installation from
below is only recommended in the case of media with a tendency to crystallize. Thus entrapped air is able
to leave.
In the case of media with a tendency to contaminate the injection nozzle, it is advisable to use an injection
nozzle which can be dismantled for maintenance and shut off.
Injection fitting mounted from above
Injection nozzle mounted from below
(for media with a tendency to crystallize)
Fig. 7.4: Injection nozzle installation
7.7 Installation example/ Example for accessories
Excerpt of the comprehensive metering technology acessory program of the manufacturer.
Mounting of the MAGDOS LB on a container with a container adapter.
aMAGDOS LB
bChemical tank
cSuction line
dPriming aid
e Electric agitator
fPulsation dampener
gInjection nozzle with non-return and shutoff valve
hback-pressure valve
⑨Pressure relief valve (safety valve)
jContainer adapter
Mul- tifunction valve PENTABLOC (without figure)
Fig. 7.5: Example of installation of a dosing pump with accessories
2
1
3
4
5
6
789
1
12 | Operation & Maintenance Instructions | Installation

8. Operation
a
b
Fig. 8.1: Control panel MAGDOS LB with astroke frequency adjustment with dial, bpower cable
The dosing pump has no on/off-switch and is operated externally via the power supply. To stop the dosing
pump, the power supply must be interrupted, or the metering capacity must be adjusted by turning the
stroke frequency dial to the right to "0 %".
8.1 Setting of flow rate
In dependence to the model variant, the dosing pump has a fixed stroke length and a fixed dosing quantity
per stroke. The dosing quantity is controlled continously variable via the stroke frequency in the metering
capacity of 0 to 100% (see stroke frequency adjustment a). The stroke frequency adjustment is ap-
proximately linear in proportion to the conveyed dosing quantity. For the maximum dosing quantity (100%
metering capacity) in dependence of the back pressure refer to the flow rate characteristics. The maximum
and the medium capacity are also indicated on the type plate of the dosing pump.
The actual metering capacity in the respective surroundings may differ from the theoretical capacity. The
stroke frequency adjustment may be adapted by a calibration process to the surrounding (see chapter 12).
Operation | Operation & Maintenance Instructions | 13

9. Start up
CAUTION!
Personal protective equipment as specified by the applicable accident prevention regulations must be worn
during all work on the dosing pump/system!
Protective clothing Protective gloves Goggles
The start-up may only take place after the installation was completed (see chapter 7). All lines must be
connected pressure-resistant.
WARNING!
Chemical could spray out. This may lead to caustic or other burns. Ensure that the discharge line is pres-
sureless before disconnecting it.
1. For the first start-up, set the pump to 100% stroke frequency and allow the pump to prime. Priming aid
is recommended. (Refer to installation examples, Chapter 7.7)
2. Open the vent screw in the dosing head while the dosing pump is switched on until fluid comes out.
Then close it again. In the case of effervescent media, allow the liquid to escape permanently (approx.
1 drop for 1...3 strokes). The escaping chemical must be returned to the supply tank with the aid of a
hose connector.
3. When correct operation is achieved, set desired flow rate. For a rough estimation, please refer to the
performance ratings on the type plate of the dosing pump. Intermediate values must be acquired.
NOTICE!
Depending on the installation, the chemicals used and the temperature of the process fluid, these values
may differ and must be checked under operating conditions.
The manufacturer of the dosing equipment is not responsible for damages due to excessive or low flow
rates resulting from faulty dosing pump settings or insufficient and incorrect installation of peripheral acces-
sories.
a
Abb. 9.1: a Vent screw, automatc dosing head vent valve
14 | Operation & Maintenance Instructions | Start up

10. Shutdown
Before starting any maintenance and before prolonged downtime, drain the chemical from the dosing pump
and rinse it thoroughly with a neutral medium.
CAUTION!
Excess chemical must be disposed of in accordance with local rules and regulations. Note the applicable
accident prevention regulations and wear personal protective equipment.
Protective clothing Protective gloves Goggles
CAUTION!
The dosing pump must be disconnected from the power supply and secured to prevent unauthorized
restarting.
CAUTION!
The pressure must be relieved before disconnecting the discharge line from the pump discharge valve so
that chemical cannot be sprayed out.
10.1 Disposal of old equipment
If the equipment is to be disposed of, it has to be thouroughly rinsed. Excess chemicals must be disposed
of in accordance with local rules and regulations. The equipment is manufactured allowing for the ROHS
guideline and the old electrical equipment law. The manufacturer takes care of the disposal if the equipment
is sent back free of charge. It is not part of domestic waste.
Shutdown | Operation & Maintenance Instructions | 15

11. Maintenance
Dosing pumps are produced according to the highest quality standards and have a long service life. Nev-
ertheless some parts are subject to wear caused by operation (e.g. diaphragm, valve seats, valve balls). To
ensure a long operating life, visual inspections are recommended regularly. Periodic maintenance protects
the dosing pump and system from unexpected downtime. The manufacturer recommends an annual main-
tenance if local valid regulations do not stipulate more frequent maintenance.
NOTICE!
Before working on the dosing head, valves and connections, flush the dosing pump with a harmless medium
(mainly water) to avoid unintentional contact with the metered medium.
NOTICE!
After replacing the diaphragm or other spare parts it might become necessary to gauged in litres, readjust
or calibrate (stroke frequency) the dosing pump.
11.1 Replacing the diaphragm
CAUTION!
Chemical could spray out. This may lead to caustic or other burns. The dosing pump head must always be
depressurized and rinsed thoroughly with water or a suitable medium before starting any work on the dosing
pump.
ab
Replacing the diaphragm
IMPORTANT!
Do not continue before having disconnected the power supply of the pump.
Remove the dosing head aby loosening the four dosing head screws with a suitable tool
(Allen wrench SW 3).
Bend the diaphragm edge bslightly up, grip it with pliers and unscrew it anticlockwise.
IMPORTANT!
The diaphragm section of the dosing pump must be cleaned to remove any chemical before fitting a new
diaphragm, otherwise the diaphragm may be attacked from the rear.
Apply some grease (for example Molykote Longterm W2) to the thread of the new diaphragm. The new
diaphragm is turned clockwise manually until it sits close in the diaphragm rod.
Fit the dosing head at the front. Insert all four dosing head screws and tighten them lightly. After this tighten
the screws alternately, e.g. top left – bottom right – top right – bottom left. A tightening torque of 180 Ncm
is required for the dosing head screws.
16 | Operation & Maintenance Instructions | Maintenance

IMPORTANT!
The diaphragm will not provide a tight seal if the tightening torque is too low. The dosing head may be dam-
aged if the tightening torque is too high.
The dosing pump is started as described in the section Start-up (Chapter 9) after connecting the dosing
lines. If the diaphragm is frequently worn down, refer to the section "Troubleshooting" (Chapter 14) for a
description of possible causes.
11.2 Valves
Check the double-ball valves of the dosing pumps regularly for impurities. A valve is replaced by replacing
the complete dosing head.
CAUTION!
Chemical could spray out. This may lead to caustic or other burns. The dosing pump must always be
depressurized and rinsed with water or a suitable medium before starting any work on the dosing pump.
NOTICE!
Debris in the check valves will reduce the dosing accuracy.
Maintenance | Operation & Maintenance Instructions | 17

12. Calibration of the stroke frequency adjustment
The maximum performance of the pump was calibrated by the manufacturer under standard conditions.
In operation the performance may differ according to the surroundings and the medium. The operator may
therefore adapt the performance of the pump to the actual flow rate.
12.1 Calibration procedure
1. After installation and start-up of the pump, take the suction line out of the dosing container and put it
into a priming aid containing the same medium.
2. In order to ventilate the dosing pump and the line, operate the dosing pump until no bubbles are left in
the lines. Then switch off the dosing pump.
3. Fill up the priming aid again and mark the fluid level.
4. Turn the stroke frequency dial to the right (< 0%).
5. Adjust the required flow rate as follows:
5.1 Switch on the dosing pump and after 1 s turn the dial within 5 s right to the left (> 100%).
5.2 Within 5 s turn it to the right (< 0%).
5.3 Within 5 s adjust it to the required flow rate (Target %).
(If one of the steps takes longer than 5 s, no calibration takes place and the dosing pump starts). The
required flow rate can be calculated via the maximum performance of the dosing pump. Example:
15 l/h = max. performance of the dosing pump, 9 l/h = required performace--> 9/15 = 60%.
6. The dosing pump will start operating for 60 s and will then stop automatically. Then switch off the dos-
ing pump.
7. Fill up the quantity that was conveyed from the priming aid with a measuring glass to the marked fluid
level.
8. The quantity in ml or cm³ filled up from the measuring glass corresponds with the dosing quantity. The
actual flow rate of the maximum performance in % can now be calculated. This means: actual flow rate
[%] = quantity taken out * 6 / max. performance of the dosing pump.
(Example: 15 l/h = max. performance of the dosing pump, 180 ml = quantity taken out in 60 s -->
actual flow rate = 180 * 6 / 15 = 72 %)
7. Put the suction line back into the container.
8. Turn the stroke frequency dial to the right (< 0%).
9. Switch on the dosing pump and after 1 s turn the dial within 5 s right to the left (> 100%).
10. Within 5 s turn it to the right (< 0%).
11. Adjust it within 5 s to the calculated, actual flow rate (ACTUAL %).
12. The pump will calibrate automatically to the new value.
12.2 Deleting the calibration
- Turn the stroke frequency dial to the right (< 0%) while the dosing pump is switched off.
- Switch on, after 1 second turn the stroke frequency dial within 5 s to the left (> 100%). Within 5 s turn
it to the right (< 0%) and then turn it to the left (> 100%).
After switching on/off the dosing pump once, it is back in delivery status.
max. 5 s. max. 5 s. max. 5 s.
< 0 % > 100 % < 0 % Target %
min. 1 s. min. 1 s. min. 1. s.
< 0 % > 100 % ACTUAL %
max. 5 s. max. 5 s.
min. 1 s. min. 1 s.
18 | Operation & Maintenance Instructions | Calibration of the stroke frequency adjustment

13. Spare part list
Diaphragm with dosing head screws
Material Part-no. for pump dimension
LB 05 LB 1 LB 2 LB 4 LB 6 LB 10 LB 15
d 24 mm d 33 mm d 39 mm
PTFE-coated 39121 39122 39123
Dosing head including vlaves and dosing head screws
Material Valves Gas-
kets
Part-no. for pump dimension
LB 05 LB 1 LB 2 LB 4 LB 6 LB 10 LB 15
Ball Seat d 24 mm d 33 mm d 39 mm
PVC Glass PVDF FPM 38981 38982 38983
PTFE PVDF 39081 39082 39083
Stainless steel 39087 39088 39089
Glass PVDF EPDM 39042 39043 39044
PTFE PVDF 39096 39097 39098
Stainless steel 39102 39103 39104
PP Glass PVDF FPM 38978 38979 38980
PTFE PVDF 39084 39085 39086
SS SS 39090 39091 39092
Glass PVDF EPDM 39045 39046 39047
PTFE PVDF 39099 39100 39101
Stainless steel 39105 39106 39107
PVDF Glass PVDF FPM - - -
PTFE PVDF 38984 38985 38986
Stainless steel 39093 39094 39095
Glass PVDF EPDM - - -
PTFE PVDF 39048 39049 39050
Stainless steel 39108 39109 39110
Spare part list | Operation & Maintenance Instructions | 19

14. Troubleshooting
Problem Possible cause Recommended Action
Dosing pump not
delivering or output
too low.
Check valves leaking or
blocked.
Clean check valves and bleed dosing head.
See also "start up".
Suction valve or suction line
leaking or blocked.
Clean or seal suction line.
Suction lift too high. - Install dosing pump at lower position.
- Install pulsation dampener on suction side.
- Install priming aid.
Viscositiy too high - Enlarge suction and discharge line/diameter.
- Use special dosing head
>> Contact manufacturer
No stroke move-
ment observed
Stroke length set to zero. Correctly adjust pump stroke frequency.
Diaphragm return spring
broken.
inform Lutz-Jesco service.
Fuse blown. Check power supply voltage, contact service.
Power supply interrupted Switch on power supply voltage.
Solenoid defective. inform Lutz-Jesco service.
Frequent dia-
phragm failures
Diaphragm was not properly
tightened to the diaphragm
rod.
Screw in new diaphragm.
System back pressure too high.
(measured at discharge con-
nection of dosing pump)
Inspect system. Clean blocked injection nozzle.
Reduce pressure spikes resulting from extremely
long tubes by installing pulsation dampeners.
Check function of safety valves.
Media sediment in dosing
head.
Flush dosing head.
Dosing Pump
delivering too
much.
(Pump siphoning)
Pressure on suction side too
high.
Install back pressure valve or suction controller.
If the problem cannot be solved with the support of the above instructions, contact our After-Sales Service
for further assistance or return dosing pump to manufacturer. Repairs will be carried out immediately.
20 | Operation & Maintenance Instructions | Troubleshooting