Related Manuals for ALLDOS KM 255
Summary of Contents for ALLDOS KM 255
- Page 1 Piston Diaphragm Dosing Pump KM 255 Operation Manual Please read the Operating and Servicing Manual completely and retain for future refe- rence! 15.720045-V1.0...
-
Page 2: Imprint
KM 255 en Imprint Piston Diaphragm Dosing Pump KM 255 Operation Manual Version 1.0 Issued by ALLDOS Eichler GmbH Reetzstraße 85 • 76327 Pfinztal (Söllingen) Postfach 1160 • 76317 Pfinztal Germany Tel. ++49 (0) 72 40 61-0 / Fax. ++49 (0) 72 40 61-177 Mail: alldos.de@alldos.com... -
Page 3: Table Of Contents
KM 255 en Content Imprint..................... 2 General ................... 6 1.1 Introduction ..................6 1.2 Information About the Product ............6 1.2.1 Pump Types ..................6 1.2.2 Pump Performance ................6 1.2.3 Accuracy ..................7 1.2.4 Admission Pressure and Counterpressure / Suction Height ..7 1.2.5 Sound Pressure Level ..............7 1.2.6 Degree of Protection ..............7... - Page 4 KM 255 en 4.5 Versions ..................17 4.5.1 Dosing heads: Materials and Additional Features .......17 4.5.2 Valves: Materials and Additional Features ........18 4.6 Materials ..................19 4.7 Data of contact manometer for MBS (optional) ......19 4.8 Installation Location ...............19 4.8.1 Space Required for Operation and Maintenance ......19 4.8.2 Permissible Ambient Influences ..........19...
- Page 5 KM 255 en Operating the Pump ..............33 8.1 Switching On/Off ................33 8.1.1 Switching On the Pump ...............33 8.1.2 Switching Off the Pump ...............33 8.2 Setting the dosing capacity ............33 8.2.1 Setting the dosing flow and locking the stroke adjustment button ..................33...
-
Page 6: General
Information About the Product 1.2.1 Pump Types The KM 255 piston diaphragm dosing pump is available for a variety of power ranges in various sizes: Pump types and designation see type plate The following is indicated on the type plate of the pump: •... -
Page 7: Accuracy
KM 255 en General 1.2.3 Accuracy Dosing flow smaller ± 1 % fluctuation Linearity ±1 % of the full-scale value (for water with a fully deaerated deviation dosing head) 1.2.4 Admission Pressure and Counterpressure / Suction Height Maximum admission pressure at the suction side [bar]... -
Page 8: Mains Voltage
KM 255 en 1.2.7 Mains Voltage Power supply for AC voltage Nominal voltage Deviation from the nominal value 230 / 400 V ± 10 % 240 / 415 V ± 10 % 115 V ± 10 % max. permissible mains impedance (0.084 + j 0.084) Ohm (testing according to DIN EN 61000-3-11) -
Page 9: Application Of The Device
Application of the Device 1.3.1 Appropriate, Acceptable and Correct Usage The KM 255 pump, described here is suitable for dosing liquid media strictly in accor- dance with the instructions in this manual. Note Pumps in explosion protected version are identified accordingly on the pump type... -
Page 10: Safety
KM 255 en Safety This operation manual contains general instructions that must be observed during instal- lation, operation and maintenance of the pump. This operation manual must therefore be read by the installation engineer and the relevant qualified personnel/operators prior to installation and start-up, and must be available at the installation location of the pump at all times. -
Page 11: Safety Instructions For The Operator / User
Observe the points described in the initial start-up section prior to subsequent start-up. Warning Electrical connections should only be connected by qualified personnel! The pump housing must only be opened by personnel authorised by ALLDOS! Observe the manufacturer's safety instructions when handling chemicals. When working on the dosing head, connections or lines:... -
Page 12: Safety Of The System In The Event Of A Failure In The Dosing System
Safety of the System in the Event of a Failure in the Dosing System KM 255 dosing pumps are designed according to the latest discoveries and are carefully manufactured and tested. However, a failure may occur in the dosing system. Systems in which dosing pumps are installed must be designed in such a way that the safety of the entire system is still ensured following a failure of the dosing pump. -
Page 13: Transport And Intermediate Storage
Risk of malfunction or damage to the pump! Do not throw or drop the pump. 3.1.1 Delivery The piston diaphragm dosing pump KM 255 is supplied in different packaging depending on the overall delivery. For transport and intermediate storage, use the correct packaging to protect the pump against damage. -
Page 14: Product Description And Accessories
Product Description and Accessories General Description The KM 255 are oscillatory positive-displacement pumps with hydraulic diaphragm con- trol. The operation procedure of the dosing pump is shown in the sectional drawing. The rotational movement of the drive motor (1p) is converted via the worm gearing (2p) and eccentric (3p) into the oscillatory suction and stroke movement of the piston (6p). -
Page 15: Combined Overpressure And Degassing Valve
KM 255 en Product Description and Accessories 1p Motor 2p Worm gearing 3p Eccentric 4p Recuperating spring (not with drive size 3) 5p Sliding plug 6p Piston M combined overpressure and degassing valve 9p Diaphragm protection valve (AMS) Q Dosing diaphragm... -
Page 16: Dimensional Drawing
KM 255 en diaphragm gap (the manometer indicates “0” when the pump is running and when it is stopped). If one of these diaphragms breaks, the dosing or hydraulic medium penetrates into the intermediate gap and, when the ball is removed, into the valve. The system pressure is therefore impinged on the valve and the contact manometer is activated. -
Page 17: Stroke Volume
KM 255 en Product Description and Accessories Stroke volume Stroke volume [cm Type 10bar 16 bar 25 bar KM 255 — — Versions 4.5.1 Dosing heads: Materials and Additional Features For all dosing heads: • Diaphragm material: PTFE • with no manual deaeration Dosing Index No. -
Page 18: Valves: Materials And Additional Features
KM 255 en 4.5.2 Valves: Materials and Additional Features For KM 255, p 10 bar: • Nominal width DN 20 • Screwed connection 1 1/4“ Index No. Valve Body Gasket Valve Ball Seat Description R000 Viton Glass PTFE R001 Viton... -
Page 19: Materials
KM 255 en Product Description and Accessories Note Further information on resistance with regard to the medium, medium temperature and operating pressure is available on request. Materials Pump Housing Material Pump Pump housing Al 226 Data of contact manometer for MBS (optional) The contact manometer have a reed switch with electrically isolated contact output, maxi- mum switching power 10 W for DC current or 10 VA for AC current. -
Page 20: Installation
KM 255 en Installation Mounting Mount the pump on a console or pump foundation using 4 screws. Note Make sure that the flow runs in the opposite direction to gravity. General Information on Installation Warning Observe the specifications for the installation location and range of application described in the “General”... -
Page 21: Installation Examples And Tips
KM 255 en Installation 5.2.2 Installation Examples and Tips Picture of optimal installation max. 1m 1i Dosing tank 2i Electric agitator 3i Extraction device 4i Suction pulsation damper 5i Dosing pump 6i Overflow valve 7i Pressure retention valve 8i Pulsation damper... - Page 22 KM 255 en Pressure retention valve p ≥ 2 bar With open outflow of the dosing medium or low counter- pressure: A positive pressure difference of at least 2 bar has to exist bet- ween the counterpressure at the injection point and the pres- sure of the dosing medium at the suction valve of the dosing pump.
- Page 23 KM 255 en Installation For suction-side installation • Depending on the pump type and line length, it may be necessary to use a suction pulsation damper (4i). Observe the “Approximate values when using pulsation dampers” auf Seite 20 and if necessary request a system-specific calculation from our calculation program.
-
Page 24: Tube/Pipe Lines
KM 255 en Tube/Pipe Lines 5.3.1 General Warning The resistance of the parts that come into contact with the media depends on the media, media temperature and operating pressure. Ensure the parts that come into contact with the media are chemically resistant to the dosing medium in operating... -
Page 25: Connecting A Liquid-Heated Dosing Head (Optional)
KM 255 en Installation When connecting DN 32 pipe lines • Depending on the pipe material, mount it to the welding neck flange and weld it (stainless steel) or insert into the headed bush and weld (PP, PVDF). 5.3.3 Connecting a liquid-heated dosing head (optional) As an option, liquid-heated dosing heads are available in stainless steel version. -
Page 26: Electrical Connections
Observe the local safety regulations! The pump housing must only be opened by personnel authorised by ALLDOS! Protect the cable connections and plugs against corrosion and humidity. Only remove the protective caps from the sockets that are being used. -
Page 27: Connecting The Power Supply Cable
KM 255 en Electrical Connections S Contact manometer 5s Union nut 6s Contact output T Ball check U Connection piece 2u Deaeration screw 3u O-rings 4u Connection for earthing cable 5u Union nut *2) or locking unit Connecting the Power Supply Cable... -
Page 28: Start-Up/Shutdown
Check fixing screws on the dosing head are tightened with the specified torque and tighten, if necessary. Tighten the dosing head screws crosswise using a torque wrench: Torque: 50 - 54 Nm for KM 255 7.2.2 Oil filling Note The pump is checked at the factory, and the oil is drained for shipping purposes. -
Page 29: Start-Up/Subsequent Start-Up
Following initial start-up and after each time the diaphragm is changed, tighten the fixing screws on the dosing head: After approximately 6 - 10 working hours or two days, tighten the dosing head screws crosswise using a torque wrench. Torque: 50 - 54 Nm for KM 255 V1.0... -
Page 30: Setting The Pressure Relief Valve
KM 255 en Setting the pressure relief valve If the written agreement does not specify a system-specific opening pressure, then the pressure relief valve is set to a slightly greater opening pressure than the bleed pressure for the pump. It can however be set by the customer to a smaller opening pressure. -
Page 31: Adjusting The Zero Point
KM 255 en Start-up/Shutdown from this value, adjusting the zero point will ensure that the values are more precise. Counterpressure for zero point setting of the pump at the factory Bleed pressure of Counterpressure for zero point setting the pump [bar] of the pump at the factory [bar] 7.4.2... -
Page 32: Shutdown
KM 255 en Shutdown Warning When working on the dosing head, connections or lines: Risk of injuries! Wear the necessary protective clothing (goggles, gloves)! Do not allow any chemicals to leak from the pump. Collect and dispose of all che-... -
Page 33: Operating The Pump
KM 255 en Operating the Pump Operating the Pump Switching On/Off Caution Before switching on the pump, check that it is installed correctly. See the “Installa- tion” and “Start-Up” sections. 8.1.1 Switching On the Pump • Switch on the mains voltage 8.1.2... - Page 34 KM 255 en controller. 15.720045-V1.0...
-
Page 35: Maintenance
KM 255 en Maintenance Maintenance General Notes Warning When dosing dangerous media, observe the corresponding safety precautions! When working on the dosing head, connections or lines: Wear the necessary pro- tective clothing (goggles, gloves)! Do not open the pump! Repairs must only be carried out by authorised and qualified personnel! -
Page 36: Checking The Oil Level
KM 255 en Clean the valves. • At least every 12 months or after 4000 operating hours, or • if the pump isn’t performing, or • in the event of an error. Clean the valves and replace if necessary (for stainless steel valves: inner parts of valve) Change diaphragms and gear oil. - Page 37 KM 255 en Maintenance DN 20 valve stainless steel/ plastic, optional spring-loaded DN 32 valve suction side/ pressure side Caution The O-rings must be correctly placed in the specified groove. Observe flow direction (arrow)! Tighten plastic valves by hand only. Risk of damage!
-
Page 38: Changing The Diaphragm And Gear Oil For Dosing Head With Single Diaphragm (No Mbs)
Before removing the dosing head, valves and media lines, empty any remaining medium in the dosing head into a driptray by carefully unscrewing the suction valve. Caution Only use original ALLDOS gear oil! ALLDOS gear oil Pump Type Order No. -
Page 39: Fitting The Dosing Head
Following initial start-up and after each time the diaphragm is changed, tighten the fixing screws on the dosing head: After approximately 6 - 10 working hours or two days, tighten the dosing head screws crosswise using a torque wrench. Torque: 50 - 54 Nm for KM 255 V1.0... -
Page 40: Replacing The Diaphragm For Dosing Head With Double Diaphragm
KM 255 en Replacing the diaphragm for dosing head with double diaphragm 9.7.1 Removing the dosing head 1. Close dosing lines on suction and pressure side and loosen suction and pressure valve connections. 2. Loosen the 6 dosing head screws (1q with 2q) and remove the dosing head (2). -
Page 41: Fitting The Dosing Head
KM 255 en Maintenance Contact manometer (installation position) Q1 Diaphragm on dosing head side Q2 Diaphragm on oil side/pump side 3q Intermediate disk 4q Sealing rings 5q Covering rings 6q Clamping sleeves Caution The paraffin oil between the diaphragms (Q) is connected via the clamping sleeves (6q) to the contact manometer (S) in order to fill and activate the diaphragm brea- kage signal. -
Page 42: Filling Gear Oil
After approximately 6 - 10 working hours or two days, tighten the dosing head screws crosswise using a torque wrench. Torque: 50 - 54 Nm for KM 255 9.7.7 Cleaning the ball check valve Note Only clean the ball check after a diaphragm breakage! 15.720045-V1.0... - Page 43 KM 255 en Maintenance Contact manometer 5s Union nut 6s Contact output Ball check Connection piece 2u Deaeration screw 3u O-rings 4u Connection for earthing cable 5u Union nut *2) or locking unit Removing the ball check and contact manometer 1.
-
Page 44: 10 Possible Errors
KM 255 en 10 Possible Errors Caution Actions that are taken to overcome faults on the pump and which are not described in the operation manual, must only be carried out by the service centre! Fault Diagnosis Cause Remedy No motor sound or vibrations, Connect at power supply, Motor is not running. - Page 45 KM 255 en Possible Errors Fault Diagnosis Cause Remedy Suction valve: during the pressure stroke the dosing liquid flows back into the suction line. Suction/pressure valves dirty Pressure valve: during the suction Clean or exchange valves. or leaky. stroke, the dosing liquid flows back into the dosing head;...
-
Page 46: 11 Spare Parts
KM 255 en 11 Spare Parts Manufacturer recommendation We recommend that you keep some spare parts in stock to ensure that worn parts can be replaced quickly when necessary. Two spare parts are required for double pumps. Permissible -10 °C to +50 °C... - Page 47 KM 255 en Spare Parts Nominal width/Valve material Order Pump Pres- Version number type sure Balls Seat Gasket Diaphragm breakage 553-388-1 10,00 bar DN20 / DN32 Glass PTFE / PP Viton safety device Diaphragm breakage 553-389-1 10,00 bar DN20 / DN32 PTFE...
-
Page 48: 12 Dosing Curves
KM 255 en 12 Dosing Curves The dosing curves refer to: • The dosing medium water, • Zero point of pump Q for specified pressure - see diagram. Q Dosing flow Zeropoint of the pump Stroke length 255-194 (50Hz) Q... - Page 49 KM 255 en Dosing Curves 255-403 (50Hz) Q = 3bar 255-403 (60Hz) Q = 3bar Q [l/h] Q [l/h] 3bar 3bar 10bar 10bar 90 100 90 100 h [%] h [%] 255-550 (50Hz) Q = 3bar Q [l/h] 10bar 3bar...
-
Page 50: Ec Declaration Of Conformity (Translation)
EC machinery directive 98/37/EC, EC directive for EMC 89/336/EEC The design of the product range Piston Diaphragm Dosing Pumps KM 255 has been developed, constructed and manufactured in compliance with EC directives 98/37/EC and 89/336/EEC at the sole responsibility of ALLDOS Eichler GmbH Reetzstr. - Page 51 KM 255 en V1.0...
- Page 52 KM 255 en 15.720045-V1.0...
Need help?
Do you have a question about the KM 255 and is the answer not in the manual?
Questions and answers