CHEMICAL DOSING PUMP OM5540#06.

Chemical dosing pump

1 General
The chemical dosing pump is a microprocessor controlled solenoid metering pump.
The pump offers highly accurate reproducible metering in the dosing of liquid
chemicals in pressurised pipe systems, and into open and closed containers. The
main components of the chemical dosing pump are the operating panel, power end,
and liquid end. Figure 1 illustrates the chemical dosing pump.
The working principle of the pump is that chemical feed occurs as a result of pulsed
deflections of the dosing diaphragm within the liquid end, which causes pressure
differentiation between the suction side, liquid end cavity, and discharge side. The
pressure differentiation causes the suction and discharge self-acting valves to open
and close, resulting in chemical feed. The dosing diaphragm is driven by an
electromagnet, which is stimulated and controlled by a microprocessor.
The pump capacity (feed rate) is determined by the stroke length and stroke rate.
The stroke length is set between 0% and 100% using the stroke length adjustment
knob. Optimum dosing reproducibility is achieved by setting the stroke length
between 30% and 100%. The stroke rate adjustable in 10% steps between 0% and
100% using the multifunction switch. However, in "external" operating mode the
stroke rate is controlled by electrical signals. The dosing precision reproducibility is
-5% to +10% at maximum stroke length and maximum operating pressure. At
constant conditions and minimum 30% stroke length it is 2%.

Illustration of the chemical dosing pump

Control unit Power end

Discharge
valve

L iq uid en d

Bleed
valve

Vent
hole

Suction
valve

Figure 1 chem_pump1a.cdr

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2 Safety
The following safety guidelines must always be observed during installation,
commissioning, operation, maintenance, and repair:
 Please note that the pump is not designed for:
 Use with gaseous chemicals or suspended solids.
 Use in explosion-hazardous locations.
 In emergency cases the pump should be switched off immediately. Disconnect
the power cable from the power supply.
 The pump must be accessible at all times for both operation and servicing.
Access must not be obstructed in any way.
 The pumps and peripherals must be serviced and repaired by qualified and
authorised persons only.
 Before working on a pump always disconnect the mains power.
 Before working on a pump always de-pressurise the discharge line, empty the
liquid end, and rinse out.
 Always read the chemical safety data.
 Always wear protective clothing when handling hazardous or unknown
chemicals.
 Never allow the metering pump to operate if the discharge line is blocked, as
this can result in a rupture of the discharge line.

3 Installation
The chemical dosing pump is normally pre-mounted on a chemical tank. However,
in case that the pump must be mounted elsewhere or replaced please observe the
following general installation notes:
 The chemical dosing pump must be located in an environment with ambient
temperature between -10C to +45C and a maximum permissible relative
humidity of 92% non-condensing.
 The pump must be mounted with the pump foot resting on a firm horizontal
base. Ensure that it is fastened into place firmly, and will not vibrate in
operation.
 The maximum permissible priming and operating pressures must not be
exceeded. For this type of pump the maximum priming lift is 2 mmWC and the
maximum operating pressure is 16 barg. In case that the operating pressure is
exceeded, e.g. due to the position of the chemical feed into the feed water
system, the discharge side must be provided with a relief valve. The surplus
chemicals should be led back to the chemical tank.
 Suction and discharge valves must be installed in a vertical position.

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 The tubing should be attached in such a way that it allows lateral detachment of
the pump and liquid end, if necessary. The tubing must be free from stress and
bends when fitted. Only original hoses with the correct dimensions should be
used.
 The suction tubing should be as short as possible and rising in order to prevent
air bubbles forming.
 The foot valve should be installed so that it hangs just above the bottom of the
chemical tank. For chemicals with impurities or sedimentation at the bottom, the
foot valve should be positioned well above this layer.
 The check valve, which connects the discharge line to the feed water system,
must be tightened properly.

3.1.1 Assembling of the tubing to plastic valves

When assembling the suction and discharge tubing to the plastic valves of the liquid
end carry out the following work procedures (see Figure 2):
Step A: Cut the hose ends straight across.

Step B: Push the union nut and clamping ring onto the hose.

Step C: Push the hose end over the nozzle to the stop (widen if necessary).

Step D: Ensure that the O-ring is sitting correctly onto the valve.

Step E: Clamp the connector hose by tightening the union nut while pressing in the
hose.

Step F: Retighten the hose connector by pulling the hose connected to the liquid end
briefly and then retighten the union nut.

Assembling of the tubing to plastic valves

H ose

U nion nut

C lam ping ring

N ozzle

O -ring

Valve

Figure 2 chemical_tub.cdr

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3.2 Electrical installation

The pump is connected to the mains power supply by using the mains lead. If the
pump is connected to the mains in parallel with inductive power consumers (e.g.
solenoid valves, motors) it must be electrically isolated. This prevents damage
caused by induction and voltage surges when switching off. Figure 3 illustrates the
power element of the pump.
If the pump is intended to operate with options for "external control" and/or "float
switch" the actual plugs must be connected to the actual terminals in the power end
of the pump. Figure 4 illustrates the optional plug configuration for the pump. Please
also see Figure 6 for the location of the terminal connections.

Illustration of the power element

O p e r a tio n a l
r e la y
c o n n e c to r
Fuse

S o le n o id
N
c o n n e c to r
L1
PE

S o le n o id M a in s
e a r th le a d c o n n e c to r
Figure 3 chem_circ1a.cdr

Illustration of the optional terminal connections

“External control” “Float sw itch”

term inal term inal
Pin 1 : Pause Pin 1 : Earth
Pin 2 : External Pin 2 : M inim um prior
Pin 3 : N ot configured w arning
Pin 4 : Earth Pin 3 : M inim um lim it
Pin 5 : Auxiliary frequency sw itch
Figure 4 chem_circ2a.cdr

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4 Commissioning

Step A: Check that the connections for the pump are completed properly.

Step B: Open the bleed valve by rotating the knob anticlockwise.

Step C: Switch on the pump and allow it to run at maximum stroke length and rate
until the liquid end is full and free from air bubbles (the feed chemical is
visible at the bleed valve). The stroke length should only be set while the
pump is running.

Note: The pump should prime at 100% stroke length as the suction lift is
dependent upon the lift volume when the liquid end is empty. If the
pump is required to prime at less than 100% stroke length, and fails to
do so, then select a correspondingly smaller suction lift.

Step D: Close the bleed valve (turn clockwise).

Step E: Switch off the pump.

Step F: The pump is ready to operate. Retighten screws in the liquid end after 24
hours operation time.

4.2 Determining the feed capacity

When the necessary chemical dosing feed is known, e.g. by means of feed and boiler
water analysis, the feed capacity of the pump can be set. Figure 5 shows the feed
rate setting diagram for the pump. The measurements for determining the feed rate
from the diagram were carried out using water as medium. In order to find the feed
capacity the correction factor must be found and subsequently the stroke rate and
stroke length should be set. For determination of the feed capacity carry out the
following procedures:
Step A: Mark the operating pressure for the chemical dosing pump in the lower
diagram. The operating pressure is equal to the pressure in the feed water
system at the point of dosing.

Step B: Trace a line from this value vertically up to the curve and then horizontally
left. Read off the correction factor.

Step C: Divide the required feed rate by the determined correction. Mark this value
(l/h) on the "l/h" axis in the upper diagram.

Step D: Trace a horizontally line from this value to the left. Trace a line from the
intersection with the straight line for the adjustable stroke frequencies
vertically downwards the "stroke length" axis.

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Step E: Set the pump to one of the stroke frequencies determined in this way, and
the corresponding stroke length.

Feed rate setting diagram

Feed rate Stroke rate
[l/h] Pump at medium op erating pressure [% ]
1.6

1.4 100% (180 strokes/m in.)

90% (162 strokes/m in.)

1.2
80% (144 strokes/m in.)

1.0 70% (126 strokes/m in.)

60% (108 strokes/m in.)

0.8

50% (90 strokes/m in.)

0.6
40% (72 strokes/m in.)

0.4 30% (54 strokes/m in.)

20% (36 strokes/m in.)

0.2
10% (18 strokes/m in.)

0.0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Stroke len gth

Correction facto r
1.5

1.0

0.5

0.0
1 2 4 6 8 11 13 16
O perating pressure
Figure 5 feedgraph.cdr

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5 Operation
The operation panel of the chemical dosing pump is equipped with operation
knobs/switches, connection terminals, and indicators, which support the operation
and setting of the pump. Figure 6 illustrates the operation panel of the chemical
dosing pump.
The pump can be operated through manual control or external control. If the pump is
intended only to operate in manual mode it will not be provided with the optional
terminal connection "external control" (see Figure 4). When the pump is intended to
operate via "external control" and/or "float switch" the actual terminal connections
must be provided.
The "Float switch" option provides information on the liquid level in the feed
chemical tank, which is transmitted to the pump. This option requires the installation
of a two-stage float switch and connection to the "float switch" terminal. The pump
can, furthermore, be equipped with fault indicating relays for warning of low levels.
The following instruction for pump operation is described as a complete instruction.
If the chemical dosing pump includes parts or features, which are not provided for
the actual dosing unit, the specified instructions should be disregarded.

Illustration of the operating panel for the chemical dosing pump

Stroke length adjusting knob

Fault indicator (red)

Warning indicator (yellow)

M ultifunction sw itch 50
O perating indicator (green)
40 60
30 70
20
80
10
90
EX TER N 1 00
STOP
TES T

External operating term inal

M ains pow er supply

Float sw itch connector

Figure 6 chem_pump2a.cdr

5.1 Basic information for the pump

5.1.1 Stroke length adjustment knob

The stroke length is continuously adjustable between 0% and 100% via the stroke
length adjustment knob. Reproducibility is only technically practicable in the
adjustment range 30% to 100%.
5.1.2 Multifunction switch
The multifunction switch is used to select the operating mode and to set the stroking
rate. The following operating modes are selected using the multifunction switch:

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 Stop.
 External.
 Manual (to set stroking rate in 10% steps).
 Test (priming suction function).
Stop
 The "Stop" function allows the pump to be deactivated without disconnecting
from the power supply.
External
 The "External" operating mode allows adjustment of individual strokes via the
external operating mode terminal by means of contact or semi-conductor
devices.
 The "Auxiliary frequency" operating mode enables activation of optionally
selectable and programmable stroking rate, controlled via the external operating
mode terminal. This stroking rate overrides "Manual" and "External" operating
modes. In the standard version the "Auxiliary frequency" function is
programmed to 100% stroking rate.
 The "Pause" function can be used to operate a remote pump stop function via the
external operating terminal.
Manual
 In the "Manual" operating mode the stroking rate is manually adjustable in 10%
steps via the multifunction switch.
Test
 The "Test" function checks the priming function of the pump. The switch setting
"Test" on the multifunction switch is self-acting.

5.1.3 LED indicators

The operating and error status are shown via three LEDs on the operating panel:
 Green LED indicator, operating display: this LED illuminates briefly when a
discharge stroke is activated.
 Yellow LED indicator, warning indicator: if provided with float switch, the LED
lights up when the liquid level drops below the first triggering level.
 Red LED indicator, fault indicator: if provided with float switch, the LED lights
up when the liquid level reaches the fault indicating level. It also flashes to
indicate undefined operating status.

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6 Maintenance
To ensure a safe and reliable function of the chemical dosing pump maintenance
work must be performed with regular intervals. The normal maintenance interval is
three months. This is based on approximately 30% operation time. But in case of
heavier use (e.g. continuous operation) the intervals should be shortened. Carry out
the following maintenance work:
 Check for the correct feed rate by running the pump for a short period (press
both arrow keys together).
 Check the chemical seepage at the vent hole.
 Check that the discharge tubing is connected firmly the liquid end.
 Check that the discharge and suction valves are firmly fixed.
 Check that the liquid end is generally watertight, especially at the vent hole.
 Check the diaphragm for damage.
 Check that the liquid end screws are fastened tightly. The screw fastening torque
should be 2.5 to 3.0 Nm.
 Check that the bleed valve is firmly fixed in place.
 Check that the bleed function is working correctly.
 Check the electrical connections for wear.

7 Repair
Repair work should only be carried out by qualified personnel. Suitable precautions
must always be taken when using hazardous chemicals. Furthermore, is must be
ensured that the pump and suction/discharge lines are de-pressurised. Figure 7
illustrates the discharge valve, suction valve, and exchanging of the diaphragm.

Illustration of discharge valve, suction valve, and exchanging of diaphragm

Screws Liquid end Top plate Pum p housing

Diaphragm Safety diaphragm

Discharge valve Suction valve

Figure 7 chemical_rep.cdr

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7.1.1 Cleaning the discharge valve

Step A: Loosen the discharge line from the valve.

Step B: Unscrew the discharge valve from the liquid end and rinse thoroughly.

Step C: Remove the O-ring from the liquid end with a small screwdriver.

Step D: Insert an Allen key or similar into the smaller hole of the pressure connector
and push out the valve inserts.

Step E: Remove the valve seats with a small screwdriver and allow the valve balls
to drop out.

Step F: Clean all parts.

Step G: Drop the valve balls into the valve seats and push them on the valve inserts.

Step H: Press the valve seats into the pressure connector with their smaller hole in
the direction of the flow (see the direction of the arrows on the fluting of the
pressure connector).

Step I: Insert the O-ring into the liquid end.

Step J: Screw the valve in as far as it will go.

Step K: Secure the discharge line onto the valve.

Step L: Reset the pump after replacing a valve.

7.1.2 Cleaning the suction valve

Dismantling, cleaning, and reassembling of the suction valve is practically the same
as for the discharge valve. Take care, however, that:
 Both valve inserts are actually identical.
 An additional spacer is found under the valve inserts.
 In the liquid end a shaped seal is used instead of an O-ring.
 The flow direction of the suction connection is reversed as for the pressure
connector.

7.1.3 Change diaphragm

Step A: When the pump is running set the stroke length to 0% (the drive axis is then
set). Switch off the pump.

Step B: Unscrew the connectors from the discharge and suction side.

Step C: Pull out the fine bleed (knob) and lift off the cover from the liquid end
using a screwdriver.

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Step D: Empty the liquid end (turn the unit upside down and let the feed chemical
run out, rinse with a suitable material).

Step E: Remove the screws.

Step F: Loosen (only loosen) the liquid end and the top plate from the pump
housing.

Step G: Hold the housing in one hand and with the other, clamp the diaphragm
between the liquid end and the top plate. Release the diaphragm from the
drive spindle with a light anticlockwise turn of the liquid end and top plate.

Step H: Unscrew the diaphragm completely from the drive spindle.

Step I: Remove the top plate from the housing. Please note the position.

Step J: Check the condition of the safety diaphragm and replace if necessary.

Step K: Push the safety diaphragm only as far onto the drive axis until it just lies
flat on the pump housing.

Step L: Screw the new diaphragm carefully up to the stop on the drive axis - this
must be exact to ensure correct metering.

Step M: Screw the diaphragm tight once more.

Step N: Position the top plate on the pump housing. The top plate must be
positioned correctly. Do not distort the top plate on the pump housing,
otherwise the safety diaphragm will not fit.

Step O: Lay the diaphragm onto the top plate.

Step P: Hold the top plate and screw the diaphragm in a clockwise direction until it
is firmly in position (the resistance of the return spring can be felt). Do not
over-tighten the diaphragm.

Note: The top plate must remain in position to prevent the safety diaphragm
from distorting.

Step Q: Place the liquid end with the screws on the diaphragm and the top plate.
The priming connector must point downwards once the pump is fully
assembled.

Step R: Screw on the screws lightly and tighten. The torque should be 2.5 to 3.0
Nm.

Step S: Ensure that the liquid end cover engages in the liquid end and push the bleed
vent (knob) into the liquid end.

Step T: Check the screw torque after 24 hours operation time.

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8 Trouble shooting
The trouble shooting list is based on a proper set-up of the chemical dosing pump
during commissioning and/or service. The list can be seen in Table 1.
Please note that the trouble shooting list is general for chemical dosing pumps and
has not been made for any particular plant, but is based on several years of
experience. Therefore, the cause of the specific problem may not be mentioned and
vice versa. You are always welcome, however, to contact our service department for
advice or service assistance.

Fault finding chart

Fault
Pump does not prime despite full
stroke and bleed function.
Fluid is leaking from the back
plate.
Green LED indicator (operating
display) is not lit.
Yellow LED display is lit.
Red LED display is flashing.
Red LED display is lit.
Possible cause
Crystalline deposits on the ball seat because valves
have dried out.
The liquid end is not sealed against the pump
diaphragm.
Incorrect or no mains voltage.
Fuse defective.
Liquid level in the chemical storage tank has reached
"liquid level low, stage 1", (if provided).
Pump operating mode is undefined.
Fluid level in the chemical storage tank has reached
"liquid level low, stage 2", (if provided).
Remedy
Remove suction sleeve from chemical
supply and rinse out liquid end throughly.
If still unsuccessful, dismantle valves and
clean.
Tighten screws in the liquid end.
If unsuccessful, replace the diaphragm.
Use the recommended mains voltage as
given in the voltage specification on the
name plate.
Contact Aalborg Industries.
Fill the chemical storage tank.
Select the required operating mode.
Fill the chemical storage tank.

Table 1

9 Decommissioning
When dismantling a pump, clean thoroughly, paying particular attention to the liquid
end in order to remove all traces of chemicals and dirt. When disposing of a pump it
must be broken down into separate material types. All parts must be sent for
recycling or for correct disposal according to currently legal waste disposal
requirements.

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