Walchem EW-F series User manual

EW-F & EK Series
Electronic Metering Pump
Instruction Manual
W A L C H E M
IWAKI America Inc.
EW-F & EK Series Metering Pumps
Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA
TEL: [phone] FAX: [phone] WEB: www.walchem.com

Notice
© 2014 WALCHEM, Iwaki America Inc. (hereinafter “Walchem”)
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 WALCHEM. Such
information and descriptions may not be copied or reproduced by any means, or disseminated or
distributed without the express prior written permission of WALCHEM.
This document is for information purposes only and is subject to change without notice.
Statement of Limited Warranty
WALCHEM 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 WALCHEM and for the purposes disclosed in
writing at the time purchased, if any. WALCHEM’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 WALCHEM, transportation charges prepaid, has been inspected and
determined by WALCHEM 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 E00118.P
Sept 2014

TABLE OF CONTENTS
Thank you for choosing a Walchem E-Class metering pump. This instruction manual deals with the
correct installation, operation, maintenance and troubleshooting procedures for the EW and EK 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
1.3Model Code ............................................................................................................... 2
1.4 Specifications ............................................................................................................ 3
1.5 Dimensions ................................................................................................................ 4
2.0 INSTALLATION............................................................................................................7
2.1 Unpacking ................................................................................................................. 7
2.2 Location ..................................................................................................................... 7
2.3 Supply Tubing............................................................................................................ 8
2.4 Discharge Tubing ...................................................................................................... 9
2.5 Installing Injection/BackPressure Valve ................................................................... 10
2.6 Electrical .................................................................................................................. 10
3.0 OPERATION...............................................................................................................11
3.1 Pump Operation & Programming ............................................................................. 11
3.2 External Inputs & Outputs ........................................................................................ 13
3.3 Adjustment .............................................................................................................. 16
3.4 MultiFunction Valve Operation ................................................................................. 17
3.5 Auto Air Vent Valve Operation ................................................................................. 18
3.6 Priming .................................................................................................................... 18
3.7 Calibration ............................................................................................................... 19
3.8 AC Power Interruption ............................................................................................. 19
4.0 MAINTENANCE..........................................................................................................20
4.1 Diaphragm Replacement ......................................................................................... 20
4.2 Valve Replacement ................................................................................................. 20
4.3 Tubing ..................................................................................................................... 20
5.0 EXPLODED VIEW & PARTS GUIDE..........................................................................21
6.0 TROUBLESHOOTING................................................................................................32
7.0 SERVICE POLICY ......................................................................................................32

1
1.0 INTRODUCTION
1.1 Safety and Caution Notes
Always wear protective clothing, eye protection and gloves before working on or near a
metering pump. Follow all recommendations of the supplier of the solution being pumped.
Refer to the MSDS from the solution supplier for additional precautions.
Walchem E-Class metering pumps should be installed where ambient temperatures do not
exceed 122°F (50°C) or do not fall below 32°F (0°C). Pumps should always be shielded from
direct exposure to the elements. Black UV resistant tubing should be used if the tubing is
exposed to strong UV radiation (sunlight/lamps). The EK Series is specifically designed to
withstand the elements and can be mounted directly outdoors within the temperature
specfications. To protect and maintain the IP rating of the pump, the clear covers that protect
the electronic controls MUST be left in a secured/tightened condition at all times other than
during adjustment of the pump.
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 with ratings conforming to the
data on the pump data plate. Prior to performing any maintenance on a pump, disconnect the
pump from the electrical power source.
Plumbing Precautions
All tubing must be securely attached to the fittings prior to starting the pump (see Section 2.3).
Only use Walchem tubing with your pump. Tubing should be shielded to prevent possible
injury in case of rupture or damage. UV resistant tubing should be used if the tubing is exposed
to UV light. Always adhere to local plumbing codes and requirements. Be sure that the
installation does not constitute a cross connection. Walchem is not responsible for improper
installations. Prior to performing any maintenance on a pump, depressurize the discharge
tubing.
If you are pumping downhill or into little or no system pressure, a back pressure/anti-syphon
device must be installed to prevent over-pumping. Contact your Walchem distributor for
additional information.
Solution Compatibility
CAUTION! This pump has been evaluated for use with water only. The suitability of this
pump for use with liquids other than water, such as acid and alkaline, is the responsibility of the
user. For liquids other than water, select the best-suited liquid end material combination using a
chemical compatibility chart.
1.2 Principle of Operation
The E-Class electronic metering pumps consist 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
EW B16 F 1 -VC A
1 2 3 4 5 6
1 Pump Series
EW IP 65 electronic metering pump with external pulse control or manual
speed control (adjustable to 360 strokes per minute) and manually
adjustable stroke length. (Turndown ratio 1800:1.)
EK IP 67 aggressive environment rated electronic metering pump with
external pulse control or manual speed control (adjustable to 360
strokes per minute) and manually adjustable stroke length. (Turndown
ratio 1800:1.)
2 Capacity/Pressure Rating (See Section 1.4 for detailed chart.)
3 Control Module
F For use on all EW models, features digitally adjustable speed and
external pulse input control, stop & pre-stop inputs
RFor use on all EK models, features external pulse input control and stop
input.
4 Voltage
1115 VAC, 50/60 Hz
2230 VAC, 50/60 Hz
5 Liquid End (See Section 1.4 for detailed chart.)
6 Options
AAuto Air Vent Valve is supplied in place of the manual air vent valve.
Available for B11, B16, C16 and C21 sizes with -VC liquid ends only.
MMultifunction Valve is supplied in place of the manual air vent valve.
Available for the EW and EK 11-21 sized pumps with VC, VE, VF, PC,
and PE liquid ends. Not available with the AAVV feature.
HHigh Pressure pump configuration available with EW–PC and –PE
liquid ends only. High Pressure pump maximum speed is 240 SPM.

3
1.4 Specifications
Electrical 50/60 Hz, single phase
EWB/EKB 115 VAC±10% 0.8 Amp max. 20 watt avg.
230 VAC±10% 0.4 Amp max. 20 watt avg.
EWC/EKC 115 VAC±10% 1.2 Amp max. 22 watt avg.
230 VAC±10% 0.6 Amp max. 22 watt avg.
Operating Conditions
Ambient temperature 32°F to 122°F (0°C to 50°C)
Relative humidity To 85% (EW) / 95% (EK) non-condensing
Liquid temperature 32° to 104°F (0 to 40°C) for PVC based liquid ends
32° to 140°F (0 to 60°C) for PP, PVDF, SS based liquid ends
Below 32°F (0°C), pump is limited to 70% of max. pressure. Liquid cannot freeze.
Capacity/Pressure Rating
Size
Maximum
Output Capacity
Output
per Stroke (mL)
Maximum
Pressure
1
Connection
Size (in)
Tubing O.D
(Gal/hr)
(mL/min)
Min.
Max.
PSI
MPa
B11
0.6
38
0.03
0.11
150
1.0
3/8
B16
1.0
65
0.04
0.18
105
0.7
3/8
B21
1.8
115
0.07
0.32
60
0.4
3/8
B31
3.3
210
0.12
0.58
30
0.2
1/2
C16
1.3
80
0.05
0.22
150
1.0
3/8
C16-H
0.6
40
0.03
0.17
250
1.7
⅜ (suc) x ¼ NPT (dis)
C21
2.3
145
0.08
0.40
105
0.7
3/8
C31
4.3
270
0.15
0.75
50
0.35
1/2
C362
6.7
420
0.24
1.17
30
0.2
1/2
1 Auto Air vent valve reduces maximum pressure approx. 35 PSI (0.2 MPa)
2Output of the EW/EKC36-TC/FC/SH is 6.3 GPH (400 ml/min)
Adjustment Range
Stroke length adjustment range 20% to 100%
Frequency adjustment range 0 to 360 strokes per minute
Materials of Construction
Liquid End
Code
Pump Head
& Fittings
Diaphragm
Valve
Balls
Valve
Seat
Valve
Seals
Gasket
Tubing
PC
GFRPP
PTFE
(bonded to
EPDM)
CE
FKM
FKM
PTFE
PE
PE
GFRPP
CE
EPDM
EPDM
VC
PVC
CE
FKM
FKM
VE
PVC
CE
EPDM
EPDM
VF
PVC
PTFE
EPDM
EPDM
TC
PVDF
CE
FKM
FKM
FC
PVDF
CE
PCTFE
PTFE
SH
SS
HC
HC
PTFE
¼” NPTF
CE Alumina ceramic PE Polyethylene
EPDM Ethylene propylene diene monomer PTFE Polytetrafluoroethylene
FKM Fluoroelastomer PVC Polyvinylchloride (translucent)
GFRPP Glass fiber reinforced polypropylene PVDF Polyvinylidenefluoride
HC Hastelloy C276 SS 316 stainless steel
PCTFE Polychlorotrifluoroethylene

4
1.5 Dimensions
EW-11,16 and 21 Models with thermoplastic liquid end materials
EW-31 and 36
Models with thermoplastic liquid ends
Notes:
1. All dimensions in inches.
(10.14”)(3.02”)
1.50”
(10.45”)
(2.65”) 4.92”
(0.96”)
4.17”
3.15”
0.59”
0.79”
0.59”
1.57”
4.57”
3.94”
0.24”
ø3/8” X ø1/2”
TUBING (ID x OD)
TUBING (ID x OD)
TUBING (ID x OD)
ø3/8” X ø1/2”
ø3/8” X ø1/2”
(7.17”)
(8.43”)
3.94”
(0.70”)
0.39”
Notes:
1. Addition of a Multifunction valve increases overall
length by 0.37”. Addition of an Auto Air Vent Valve
increases overall length by 1.59”
2. Addition of a Multifunction Valve increases discharge
height by 0.22”. No change for the Auto Air Vent Valve.
3. Addition of a Multifunction Valve increases overall
liquid end height by 1.16”. No change for the Auto Air
Vent Valve.
4. All dimensions in inches.
4.92”
4.57”
3.94”
0.24”
3.15”
4.17”
0.59”
0.79”
0.59”
1.57”
ø1/4” x ø3/8”
ø1/4” x ø3/8”
TUBING (ID X OD)
TUBING (ID X OD)
TUBING (ID X OD)
ø1/4” x ø3/8”
(1.46”)
(10.02”)
(3.02”)
(10.45”)
(2.65”) (0.89”)
0.39”
(1.42”)
3.94”
(6.30”)
(7.64”)
(See Note 1)
(See Note 1)
(See Note 2)
(See Note 3)

5
EW-SH Models (EWB11,21/C21 shown below. See notes for changes in dimensions with other sizes)
EW-HP Models
(3.02”) (10.77”)
(2.20”)
(10.45”)
(2.65”) 4.92” (0.89”)
TUBING (ID x OD)
ø1/4” x ø3/8”
TUBING (ID x OD)
ø1/4” x ø3/8”
THREAD
1/4” NPT
(7.64”)
(6.30”)
3.94”
(1.42”)
0.39”
4.57”
3.94”
0.24”
1.57”
0.59”
0.59”
0.79”
3.15”
4.17”
Notes:
1. All dimensions in inches.
2. (0.91”) for EWC31 and 36 sizes.
3. (1.34”) for EWC31 and (1.24”) for EWC36.
4. (6.57”) for EWC31 and (6.67”) for EWC36.
5. (8.34”) for EWC31 and (8.48”) for EWC36.
Notes:
1. All dimensions in inches.
(9.15”)
(3.02”)
(0.59”)
(10.45”)
4.92”
(2.65”) (0.85”)
ø4
OD
NPT 1/4”
0.39”
(1.73”)
3.94”
(6.10”)
(7.91”)
NPT 1/4”
4.17”
3.15”
1.57”
0.59” 0.79”
0.59”
4.57”
3.94”
0.24”
(See Note 2) (See Note 3)
(See Note 4)
(See Note 5)

6
EK-11,16 ands 21 Models with thermoplastic liquid end materials
EK-31 and 36 Models with thermoplastic liquid ends
Notes:
1. Addition of a Multifunction valve increases overall
length by 0.37”. Addition of an Auto Air Vent Valve increases overall length
by 1.59”
2. Addition of a Multifunction Valve increases discharge height by 0.22”. No
change for the Auto Air Vent Valve.
3. Addition of a Multifunction Valve increases overall liquid end height by 1.16”.
No change for the Auto Air Vent Valve.
4. All dimensions in inches.
Notes:
1. All dimensions in inches.
(SEE NOTE 1)
(SEE NOTE 1)
(SEE NOTE 3)
(SEE NOTE 2)
10.14"
1.46"
9.61"
8.27"
5.91"
3.39"
0.51"
0.91"
5.71"
7.78"
4.80"
3.94"
0.24"
3.15"
4.33"
0.31"
1.77"
ø1/4" x ø3/8"
ø1/4" x ø3/8"
ø1/4" x ø3/8"
IN
OUT AIR
10.33"
1.50"
ø3/8" x ø1/2"
ø3/8" x ø1/2"
ø3/8" x ø1/2"
5.71" 1.06"
7.78"
0.51"
2.68"
5.91"
9.14"
10.40"
4.80"
3.94"
1.77"
0.67"0.79" 0.67"0.79"
0.31"
0.24"
3.15"
4.33"

7
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.
Pumps are pre-primed with water at the factory. If the application is not compatible with water,
drain and dry before use. Be sure to remove caps from fittings before attaching tubing.
CAUTION: Head bolts may have loosened during storage or shipment. Be sure to check and
tighten to 19 lb-in torque, if necessary.
2.2 Location
Choose a location for the pump which is clean, dry, vibration-free, 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). Pumps should always be shielded from direct exposure to the elements. Black UV
resistant tubing should be used if the tubing is exposed to strong UV radiation (sunlight/lamps).
The EK Series is specifically designed to withstand the elements and can be mounted directly
outdoors within the temperature specifications.
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. Sodium
hypochlorite and hydrogen peroxide are common examples of such liquids. (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 5 ft (1.5m).
Figure 3
Tank Mount
Figure 2
Shelf Mount
Figure 1
Flooded Suction
Recommended for
liquids that out-gas

8
2.3 Supply Tubing
The supply tubing run should be as short as possible. For flooded suction mounting, install a
shut-off valve with an appropriate tubing connector at the tank outlet. Cut a length of tubing
from the coil supplied and install between the shut-off valve and the pump inlet fitting. For
suction lift applications, slide on the ceramic weight, then install a foot valve on one end of
suction tubing. Cut the tubing to a length such that the foot valve hangs vertically about 1 in
(25mm) above the bottom of the tank. Avoid any loops in the tubing run that could form a
vapor trap. Running the tubing through a length of pipe will help to keep tubing straight. Total
vertical suction lift should be no more than 5ft. (1.5m). Reference Figure 4.
Attach tubing as shown in Figure 5. First slide the coupling nut, small end first, onto the tubing.
Push the tubing over the valve housing tip all the way to the valve housing shoulder. (Tip: if the
tubing is stiff from cold, dip the tubing end in hot tap water for a few minutes so it will slide on
and flare out more easily. Push the coupling nut onto the threads. Apply some pressure on the
coupling nut and tubing while tightening the nut, making sure the tubing has not backed off of
the shoulder of the valve housing.
WARNING:All fittings and coupling nuts should be tightened by hand only. If necessary, a
small tool may be used to make it snug. DO NOT use excessive force or large wrenches.
The coupling nut should not bottom out completely against the fitting. If this happens during
connection, either the tubing has slid down the shoulder while tightening, or the tubing has been
pinched. Remove the coupling nut, re-cut the tubing and re-connect.
Figure 4
Connecting Tubing
Foot
PVC Pipe Tubing
(user
Air Gap
Return
Point of
Injection
Injection
Valve
Coupling
Coupling Nut
(Air Vent
Coupling

9
WARNING: If there is any leakage around the coupling nut and it appears to have been
installed correctly, DO NOT TIGHTEN the coupling further! Release pressure in the line,
disconnect tubing, re-cut and re-connect. Tightening of misinstalled tubing may cause the
tubing to pop off under pressure.
2.4 Discharge Tubing
Cut a length of tubing long enough to go from the pump to the application (injection) point.
Additional tubing can be ordered from your distributor. Avoid sharp turns or bends and hot
surfaces. Routing tubing through rigid pipe such as PVC pipe is recommended for long runs
and/or as protective shielding against corrosive chemicals. If applicable, install the injection
valve in 1/2” NPT thread at the injection point (see section 2.5) and connect the discharge tubing
to the injection valve.
Attach tubing as described in section 2.3 and as shown in Figures 5 and 6. Note: Some models
have an air vent valve with two outlet connections. The connection marked ‘OUT’ is the
discharge side to the application point. (Fig 6).
Attach a second length of tubing to the air vent side marked (‘AIR’) and route back to the
chemical solution tank or drum. On the larger pumps (31 & 36 sizes), the air vent valve
connections are not marked, however, the discharge side is the vertical (UP) connection and the
air vent connection is on the side of the valve.
Valve
Housing
Shoulder
Coupling Nut
Tubing
Figure 6
Air Vent Valve Tubing
Figure 5
Attaching the Tubing
"AIR"
"OUT"
Drains back to tank
Discharges to injection point

10
2.5 Installing Injection/BackPressure Valve
A fitting or tee with 3/8” or 1/2” NPTF threads and with sufficient depth will accept the
injection valve assembly. If required, trim off an amount of the extension tip until it fits into the
fitting or tee. (Fig. 7.)
The position of the injection/back pressure valve can be at any orientation as long as the spring
is retained in the valve. DO NOT REMOVE THE SPRING. Be sure to check and replace the
spring as needed. Attach the tubing following the same instructions in section 2.3, connecting
the supply tubing.
CAUTION:Some chemicals may have reactions as they are injected into the main flow. For
example, sulfuric acid may react with water causing excess heat. If the chemical is heavier than
water, mount the injection valve as close as possible to vertical coming into the bottom of the
pipe. This will keep the injection nozzle facing up and keep the heavier chemistry from draining
into the pipe and causing adverse reactions within the injection valve and pipe.
In addition to preventing backflow from pressurized lines, the injection valve acts somewhat as a
back pressure valve when pumping into open atmosphere type applications. However, the back
pressure by the injection valve is very low and can vary. The output of the metering pumps is
rated at maximum back pressure and will increase as back pressure decreases dependent on the
specific installation. Additionally, the valve does NOT act as an anti-siphon valve. If siphoning
is a possibility, or if pumping downhill into open atmosphere (open tank), a Walchem
MultiFunction valve or a separate back pressure/anti-siphon valve must be installed.
Note: Siphoning can also occur at the tip of the injection valve because of the high flow rate in
the main pipe flowing past the small injection nozzle (venturi effect). In this case, an anti-
siphon device must be installed to avoid over feeding or siphoning of chemistry.
2.6 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.
CAUTION! The electronics within the pump can be damaged by excessive surges in voltage.
Do not install the pump near high-power electrical equipment that generate high surge voltages.
Avoid branch circuits that also supply power to heavy or other equipment that could generate
electrical interference. If necessary, install a surge suppression device (such as a varistor with a
resistance greater than 2000A) or a noise reducing transformer at the pump’s power connection.
Figure 7
Injection Valve
Trim back as needed
to fit tee or fitting
Injection/Back Pressure Valve

11
3.0 OPERATION
3.1 Pump Operation & Programming
The EW an EK pumps have a digital display, two LED indicators and three pushbutton keys to
change the pump speed and programming.
A. Operation Overview
360
Power ON
EXT
360
T-5
Set mode
++
UP stroke rate
DOWN stroke rate
EXT operation display
Operating at
max spm while
both keys are
pressed. MANUAL operation display
UP stroke rate
DOWN stroke rate
Setting display
MOVES
to next
menu
SCROLL
thu choices
DISPLAY
Operating condition and
programming is displayed
UP Key
Increases numeric values.
Used with Start/Stop key to
change the programs.
DOWN Key
Decreases numeric values.
Used with Start/Stop key to
set the pump to operate in
EXT mode.
3 6 0
ON
STOP
STOP/START Key
Manually stops and starts the
pump. Used with Up/Down
keys for programming and
mode selection.
ON LED
Indicates AC power to the
pump and goes off and on
with each pump stroke.
STOP LED
ORANGE when Pre-Stop signal
is input (EW only). RED when
a START/STOP signal is input

12
B. Programming
Pressing the stop/start and up keys simultaneously will enter the program mode. The up and
down keys scroll through the menus and choices and the stop/start key will exit back to the wait
mode.
On-Time Menu
The first item displayed will be the factory set choice of the External Input On-Time menu (T-
5). There are three choices in this menu: T-5, T-20, and T-50 that can be scrolled through by
repeatedly pressing the up key. These settings are time in milliseconds and correlate to the
required minimum closure time of the external input signal for the pump to recognize it as a true
signal. Selecting the smaller T-5 (5 msec) will allow shorter duration pulses to be recognized
(typical for Hall Effect input), while the T-50 (50 msec) setting will help to reduce erroneous
pulses from noise (as from a reed switch).
Stop Input NO/NC Selection
Pressing the down key will move from the Eternal Input On-Time menu to the Stop menu and
the initial factory setting is M-OF (input is normally open and contact closure will stop the
pump). Pressing the up key will toggle between M-OF and M-ON. Setting the pump to M-ON
means that the pump will be stopped continuously and a contact closure into the stop/start input
will now start the pump and the pump will run as long as the contact is made.
Pressing the down key will again move back to the On-Time menu and pressing the stop/start
key will go back to the wait mode.
3 6 0
Initial
Power Up
WAIT MODE
Increases Stroke Rate
Decreases Stroke Rate
Stop/Start
MANUAL RUN MODE
Increases Stroke Rate
Decreases Stroke Rate
Goes back to WAIT Mode
Stop/Start
EXTERNAL MODE
Holding the UP and DOWN
together in EXT mode will
override external and manually run
the pump at 360 SPM (priming).
Down
+
Goes back to WAIT Mode
Stop/Start
PROGRAM MODE
Scrolls through the choices in the
Menu selection
Up
Goes back to WAIT Mode
Enters choice and moves to next
Menu selection
3 5 2
EXT
T- 5
+

13
Figure 9
C. Pump Operation
Manual and On/Off Control
The pumps can be operated manually by pressing the stop/start key from the wait mode. Once
pressed, the pump will begin to operate at the stroke rate shown on the display. From here, the
up and down keys can be used to change the stroke rate, and the stroke length knob can be
adjusted down to further reduce the pump output.
Once adjusted/calibrated to the desired flow rate, the pump can be left in manual mode for
on/off control via power (connecting/disconnecting AC power from an external source) or for
on/off control via the stop/start input. Pressing the stop/start key will go back to the wait mode.
External Control
Pressing the stop/start key and the down key simultaneously from the wait mode will set the
pump to operate in external mode. In this mode, the pump will operate at a speed correlating to
the frequency of digital inputs that it receives (see section 3.2 for wiring inputs). If used, the
stop/start input will override the digital input signals.
If at any time in external mode the up and down keys are held down simultaneously, the pump
will manually run at 360 SPM as long as the two keys are held down. This feature is useful for
priming or the elimination of air trapped in the pump or tubing.
Pressing the stop/start key will disable external control and go back to the wait mode.
3.2 External Inputs & Outputs
The EW and EK pumps are capable of being controlled by an external pulse proportional input
as well as being controlled by an external stop/start signal. Additionally, the EW pumps have
two contact closure relay outputs – one output is ynchronous with the pump frequency and the
other is tied to the external stop/start signal.
A. EW Pumps and the ‘F’ control module
Two circular mini-DIN female connectors are used to make these connections. Figure 9 shows
the mating connections on the back of the pump. Connector 1 is a 5-PIN standard-key connector
(P/N E90495) and Connector 2 is a 4-PIN reverse-key connector (P/N E90494).
CONNECTOR 1:
PIN FUNCTION
1 Voltage In (24VDC max)
2 External Digital Input
3 Out 2 (Synchronous with stroke)
4 Out 1 (Stop output)
5* Common
CONNECTOR 2:
PIN FUNCTION
1 Stop/Start Input
2 Pre-Stop Input
3 Not Used
4 Common
1
3
4
2
1
5
3
4
2
Connector 1
Connector 2
*Note: The center pin is marked as ‘5’ for
easy identification purposes throughout the
manual. Actual marking on the part may
be any capital letter (mold cavity ID) or the
number ‘5’.

14
External Control
The external pulse input should not exceed 360 pulses per minute (6Hz)
and the pump will output one stroke for every input pulse. The control
signal can be a contact closure type switch (reed) with a max load of 1mA
or a solid state device. If a solid state device is used, the external circuit
should be capable of switching 5VDC at 1.2mA with an active duty cycle
pulse width of 5ms to 100ms (actual closure time).
To connect the pulse input from an external device, wire PINs 2 and 5
from the contact closure. If using a solid state switching device, wire the
connector ensuring that PIN 2 is positive (+) and PIN 5 is Common (-).
Stop/Start and Pre-Stop Control
The EW pumps have two stop inputs. The Pre-Stop is an external input
that changes the green STOP LED to orange to signal a “LOW” condition.
This input does not control the pump. An external Stop/Start signal,
however, not only turns the STOP LED to red, but also controls the pump.
In this mode, AC power is applied continuously, but the pump operation is
stopped (or started – see section on programming) by completing the
circuit between PIN 1 and PIN 4 in Connector 2. Both the Pre-Stop and
Stop/Start signals can be a contact closure type switch (reed) with a max
load of 1mA or a solid state device. If a solid state device is used, the
external circuit should be capable of switching 5VDC at 1.2mA with an
active duty cycle pulse width of 5ms to 100ms (actual closure time).
To connect the Pre-Stop input from an external device, wire PINs 2 and 4 from the contact
closure. If using a solid state switching device, wire the connector ensuring that PIN 2 is
positive (+) and PIN 4 is Common (-).
To connect the Stop/Start input from an external device, wire PINs 1 and 4 from the contact
closure. If using a solid state switching device, wire the connector ensuring that PIN 1 is
positive (+) and PIN 4 is Common (-).
Output Relays
The EW pumps have two output relays (non-isolated PNP
transistors with a 330Ωresistance) in Connector 1. Output 1 is
tied to the Stop/Start input and will activate when a Stop/Start
input connection is made. Output 2 activates synchronously
with the pump stroke rate.
Contact Closure Type Outputs
The EW circuit can make either the Stop/Start (Out 1) or the
synchronous pulse (Out 2) function as contact closures, but
ONLY ONE output can be used at a time. To use the
synchronous pulse out, connect the positive side to PIN 1 and
the negative side to PINS 3&5 (jumped together). To use the
start/stop output, connect the positive side to PIN 1 and the
negative side to PINS 4&5 (jumped together).
1
5
3
4
2
1
3
4
2
STOP Input
Pre-STOP
Input
Stop/
Start
Input
Contact
Closure Input
1
5
3
4
2
Sync
Pulse
Input
OR
EW
Connector 1

15
Voltage Input Type Outputs (Non-Contact Closure)
PIN 1 will take a voltage in from an external source (max
24VDC). When this external voltage is present, then both
relays will independently switch the input voltage. Both
outputs can be used simultaneously. The figure to the left
shows a schematic with the output relays configured to
switch the powered input. This setup can only be used with
voltage input type circuits (not contact closure types) such as
those commonly found in a PLC.
B. EK Pumps and the ‘R’ control module
One custom watertight connector is used for the digital input and stop/start connections on the
EK pumps. There are no outputs on the EK pumps. The Connector Holder is keyed to fit into
the pump only one direction. There is a set of painted alignment marks on the connector and
connector holder that identify the correct orientation of the connector. Be sure to double check
that the connector is installed properly into the connector assembly before installation onto the
pump.
Digital Control
The external pulse input should not exceed 360 pulses per minute (6Hz)
and the pump will output one stroke for every input pulse. The control
signal can be a contact closure type switch (reed) with a max load of 1mA
or a solid state device. If a solid state device is used, the external circuit
should be capable of switching 5VDC at 1.2mA with an active duty cycle
pulse width of 5ms to 100ms (actual closure time).
To connect the pulse input from an external device, wire Terminal 4 and
Terminal 6 from the contact closure. If using a solid state switching
device, wire the connector ensuring that Terminal 4 is positive (+) and
Terminal 6 is Common (-).
Connector
Lock Nut
Connector
Holder
Gasket &
Adapter
Cord Nut
4
5
6
+
+
Connector
PIN FUNCTION
4 External Digital Input
5 Stop/Start Input
6 Common
Orientation
Marks
+
4
5
6
Connector
Digital
Input
Stop/
Start
Input
Voltage type
Input
1
5
3
4
2
Sync
Pulse
Input
Power
OUT
PLC
EW
Connector 1

16
Stop/Start Control
An external Stop/Start signal will turn the STOP LED to red and also
control the pump. In this mode, AC power is applied continuously, but
the pump operation is stopped (or started – see section on
programming) by completing the circuit between Terminal 5 and
Terminal 6. The Stop/Start signal can be a contact closure type switch
(reed) with a max load of 1mA or a solid state device. If a solid state
device is used, the external circuit should be capable of switching
5VDC at 1.2mA with an active duty cycle pulse width of 5ms to 100ms
(actual closure time).
To connect the Stop/Start input from an external device, wire Terminals 5
and 6 from the contact closure. If using a solid state switching device, wire
the connections ensuring that Terminal 5 is positive (+) and Terminal 6 is Common (-).
3.3 Adjustment
A. EW Pumps using the ‘F’ Control Module
The pump will operate best keeping the stroke length at 100%. If less than full output is
required, set the frequency to the approximate percentage of maximum desired.
Example: Model EWB21F1-VC has maximum output of 1.8 GPH.
Desired output is 1.2 GPH. 1.2 ÷ 1.8 = 0.667 or 67%
Using the UP and DOWN arrows, set the frequency of the pump to
0.67 x 360 = 241 SPM.
For outputs less than 2% of maximum it will be necessary to also reduce the stroke
length. (Minimum recommended stroke length is 20%.) It is good practice to change
the frequency first, however, if low flows are required, a balanced turndown of speed
and stroke length will yield the best results.
B. EK Pumps using the ‘R’ Control Module
The pump will operate best keeping the stroke length at 100%. If less than full output is
required, set the frequency to the approximate percentage of maximum desired.
Example: Model EKC21R1-VC has maximum output of 4.3 GPH.
Desired output is 3.0 GPH. 3.0 ÷ 4.3 = 0.7 or 70%
Using the UP and DOWN arrows, set the frequency of the pump to
0. 7 x 360 = 252 SPM.
For outputs less than 2% of maximum it will be necessary to also reduce the stroke
length. (Minimum recommended stroke length is 20%.) It is good practice to change
the frequency first, however, if low flows are required, a balanced turndown of speed
and stroke length will yield the best results.
+
4
5
6
Connector
Stop/Start
Input

17
3.4 MultiFunction Valve Operation
The MultiFunction Valve is optional on select E-Class pumps and replaces the standard Manual
Air Vent Valve when ordered. It integrates the air venting/bleeding functions with a back
pressure and anti-siphon valve.
Air Vent / Bleed Function
1. Open the air vent by turning the air vent adjustment
knob counter-clockwise one to one and a half
turns.
2. Operate the pump until all of the air is purged and
only liquid is discharged from the air vent drain.
3. Turn the air vent adjustment knob clockwise until it
bottoms out and will not turn further.
Back Pressure / Anti-Siphon Valve
1. A spring-loaded diaphragm automatically adds
30PSI of back pressure to the discharge side of the
pump when the air vent adjustment knob is closed.
2. If back pressure is not observed, the pressure
release knob may be in the release position (the
knob is resting in its ‘up’ location). If this is the
case, turn the knob clockwise until it ‘clicks’ down
(approximately ¼ turn).
3. The diaphragm prevents siphoning of chemical
through the pump.
Pressure Release
1. Stop the pump operation.
2. Turn the pressure release knob clockwise until it ‘clicks’ into the release or ‘up’ location
(approximately ¼ turn). If the knob is turned too far, it will ‘click’ again return to the back
pressure or ‘down’ position. If this happens, keep turning the knob clockwise until it ‘clicks’ one
time in the release (‘up’) position. Note: To avoid damage, do not turn the knob counter-
clockwise.
3. Turn the air vent adjustment knob counter-clockwise one or one and a half turns to release the
pressure in the discharge tubing/piping through the air vent drain. The air vent drain should
always be plumbed back to the supply tank or to safe disposal. Do not submerge the air vent
drain tubing under chemical in the supply tank.
CAUTION:Confirm that liquid is discharged from the air vent drain. If the liquid is not
discharged, the pressure may not be released. If this is the case, repeat the Pressure Release
procedure.
Air Vent
Drain
Pressure
release
knob
Liquid
Discharge
Port
Air Vent
Adjustment
Knob
Lock
Nut