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Summary of Contents for Grundfos ALLDOS KM 251
- Page 1 Piston Diaphragm Dosing Pump KM 251 Operation Manual Please read the Operating and Servicing Manual completely and retain for future refe- rence! 15.720148-V1.0...
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Page 2: Imprint
KM 251 en Imprint Piston Diaphragm Dosing Pump KM 251 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 Internet: www.alldos.com ©... -
Page 3: Table Of Contents
KM 251 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 ..............8 1.2.6 Degree of Protection ..............8 1.2.7 Mains Voltage ................8 1.2.8 Ambient and Operating Conditions ..........8... - Page 4 KM 251 en 4.5 Versions ..................18 4.5.1 Etron Profi Electronics (optional) ..........18 4.5.2 Dosing heads: Materials and Additional Features .......18 4.5.3 Valves: Materials and Additional Features ........19 4.6 Materials ..................20 4.7 Electronic Etron Profi data (optional) ..........20 4.8 Data of contact manometer for MBS (optional) ......21 4.9 Installation Location ...............21 4.9.1 Space Required for Operation and Maintenance ......21 4.9.2 Permissible Ambient Influences ..........21...
- Page 5 KM 251 en 7.6 Shutdown ..................35 7.6.1 Switching Off/Uninstalling ............35 7.6.2 Cleaning ..................35 7.6.3 Storage ..................36 7.6.4 Disposal ..................36 Operating the Pump ..............37 8.1 Switching On/Off ................37 8.1.1 Switching On the Pump ...............37 8.1.2 Switching Off the Pump ...............37 8.2 Operating the Pump with Etron Profi Electronics (optional) ..37 8.3 Setting the dosing capacity ............37 8.3.1 Setting the dosing flow and locking the stroke adjustment...
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Page 6: General
KM 251 en General Introduction This operation manual contains all the information required for starting up and handling the described KM 251 pump. If you require further information or if any problems arise, which are not discussed in detail in this operation manual, contact ALLDOS directly for the information needed. ALLDOS Eichler GmbH Reetzstr. -
Page 7: Accuracy
KM 251 en General Type 50 Hz 60 Hz 100 Hz stroke stroke stroke p max p max p max value value value [l/h] [bar] [l/h] [bar] [l/h] [bar] Singlepump Doublepump [n/min] [n/min] [n/min] 251-11 251-11/2 251-17 251-17/2 — — —... -
Page 8: Sound Pressure Level
KM 251 en Maximum suction height * [m] for media with a viscosity similar to water Type Suction height Singlepump Doublepump max. [m WS] 251-2,4 251-2,4/2 251-5 251-5/2 251-13 251-13/2 251-19 251-19/2 251-24 251-24/2 251-2,3 251-2,3/2 251-4,9 251-4,9/2 251-12 251-12/2 251-18 251-18/2 251-23... -
Page 9: Dosing Medium
KM 251 en General Caution Risk of malfunction or damage to the device! The installation site must be under cover! Pumps with electronics are only suitable for indoor use! Do not install outdoors! 1.2.9 Dosing Medium Note In the event of questions regarding the material resistance and suitability of the KM 251 for specific dosing media, please contact the manufacturer. -
Page 10: Application Of The Device
KM 251 en Application of the Device 1.3.1 Appropriate, Acceptable and Correct Usage The KM 251 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 plate and motor type plate, and an EC Declaration of conformity is provided in accordance with guidelines 94/9/EC, which replaces the EC Declaration of conform- ity which is printed in this instruction manual. -
Page 11: Safety
KM 251 en Safety 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 12: Safety Instructions For The Operator / User
KM 251 en Safety Instructions for the Operator / User Hazardous hot or cold parts on the pump must be protected to prevent accidental contact. Leakages of dangerous substances (e.g. hot, toxic) must be disposed of in a way that is not harmful to humans or the environment. -
Page 13: Safety Of The System In The Event Of A Failure In The Dosing System
KM 251 en Safety Warning To operate a pump which has been identified as an explosion protected pump for the dosing of combustible liquids or for operation in potentially explosive opera- ting sites in accordance with guideline 94/9/EC, refer to the enclosed instruction manual “Operating an explosion protected pump”... -
Page 14: Transport And Intermediate Storage
KM 251 en Transport and Intermediate Storage Transport Caution 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 251 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 15: Product Description And Accessories
KM 251 en Product Description and Accessories Product Description and Accessories General Description The KM 251 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 16: Combined Overpressure And Degassing Valve
KM 251 en 1p Motor 2p Worm gearing 3p Eccentric 5p Sliding plug 6p Piston M combined overpressure and degassing valve Degassing valve 9p Diaphragm protection valve (AMS) Q Dosing diaphragm Dosing head 3a Suction valve 3b Pressure valve Stroke adjustment button Aeration screw with oil-level gauge 4.1.1 Combined overpressure and degassing valve... -
Page 17: Dimensional Drawing
KM 251 en Product Description and Accessories 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 18: Weight
KM 251 en Weight Weight [kg] Type Dosing Head Material Single / Double pump PVC, PP, PVDF KM 251 1.4571, 2.4610 Stroke volume Stroke volume [cm Type 10bar 16 bar 25 bar KM 251 Versions 4.5.1 Etron Profi Electronics (optional) Index No. -
Page 19: Valves: Materials And Additional Features
KM 251 en Product Description and Accessories Index No. Dosing Heating flange For pump types Head 10 bar D052 electric heating 16 bar D052 liquid heating D060 — with double diaphragm system for diaphragm D061 — breakage signal D062 — D063 PVDF —... -
Page 20: Materials
KM 251 en Index No. Valve Body Gasket Valve Ball Seat Description R055 Viton Stainless steel Stainless steel for abrasive media R056 Hastelloy C PTFE Hastelloy C Hastelloy C R070 Viton Stainless steel PTFE Warning Risk of malfunction or damage to the device! The resistance of the parts that come into contact with the media depends on the media, media temperature and operating pressure. -
Page 21: Data Of Contact Manometer For Mbs (Optional)
KM 251 en Product Description and Accessories Inputs and Outputs Outputs Current 0 - 20 mA Maximum load, 350 ohms maximum ohmic load Error signal 50V DC / 75V AC, 0.5 A Stroke signal Contact time/stroke 200 ms maximum ohmic load Pre-empty signal 50V DC / 75V AC, 0.5 A Data of contact manometer for MBS (optional) -
Page 22: Installation
KM 251 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 23: Installation Examples And Tips
KM 251 en Installation Stroke Nominal width of Maximum suction line Type value suction line length [m] 251-2,4 DN 8 251-5 DN 8 251-13 DN 8 251-19 DN 8 251-24 DN 8 251-2,3 DN 8 251-4,9 DN 8 251-12 DN 8 251-18 DN 8 251-23... - Page 24 KM 251 en Tank installation: • For non-degassing media with viscosity similar to water, the pump can be mounted onto the tank (observe the admissible suction height). Preferable for flooded suction. For dosing media which tend to sedimentation: • Install a suction line with filter (13i) in a way ensuring that the suction valve remains several centimetres a bove the botton of the tank.
- Page 25 KM 251 en Installation To install the suction line: • Keep the suction line as short as pos- sible, avoid a tangled suction line • If necessary, use swept bends instead of elbows. • Always lay the suction line rising to the suction valve of the dosing pump.
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Page 26: Tube/Pipe Lines
KM 251 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 conditions! Only use the specified line types! All lines must be free from strain! If necessary, use swept bends instead of elbows, avoid loops and buckles in the tubes! Ensure... -
Page 27: Connecting A Liquid-Heated Dosing Head (Optional)
KM 251 en Installation 5.3.3 Connecting a liquid-heated dosing head (optional) As an option, liquid-heated dosing heads are available in stainless steel version. 2f Dosing head, liquid heated 2f1 Hose nipple, DN10 connection Demands placed on heating liquid: • The heating liquid must not attack stainless steel. •... -
Page 28: Electrical Connections
KM 251 en Electrical Connections Warning Electrical connections should only be connected by qualified personnel! Before connecting the power supply cable and the relay contacts: Disconnect the mains voltage! 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. -
Page 29: Diaphragm Control (Optional)
KM 251 en Electrical Connections 2e1 Sensor 2e2 Heating 2e3 Power supply To connect the temperature controller to the mains supply, please refer to the instructions for the electric temperature controller. Diaphragm control (optional) Warning Pumps in explosion protected version with diaphragm breakage signal are fitted with a contact manometer in explosion protected version. -
Page 30: Version With Mains Plug
KM 251 en Warning The specified degree of protection can only be ensured, if the mains cable is con- nected to the same degree of protection. Caution Observe direction of rotation! To protect the motor, install a motor protecting switch or motor contactor, and set the bimetal relay to the nominal current of the motor for the present voltage and fre- quency. -
Page 31: Start-Up/Shutdown
KM 251 en Start-up/Shutdown Start-up/Shutdown Safety Information Warning When dosing dangerous media, observe the corresponding safety precautions! When working on the dosing head, connections or lines: wear the necessary protective clothing (goggles, gloves)! 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. -
Page 32: Start-Up/Subsequent Start-Up
KM 251 en 1. Unscrew the pressure valve (3b). 2. Add the dosing medium to the dosing head (2). 3. Screw the pressure valve (3b) back in. Caution Observe arrow for the pressure valve (for flow direction)! 7.2.4 Start-Up/Subsequent Start-Up 1q Dosing head screws Dosing head 3b Pressure valve... -
Page 33: After Start-Up
KM 251 en Start-up/Shutdown Caution Check the oil level at least every 2 weeks and add oil if necessary. Only use original ALLDOS gear oil! Pump Type Order No. Description KM 251 single / double 555-300 1.3 l white oil (Paraffin 55 DAB7) 7.2.5 After start-up Caution... -
Page 34: Zero Point Adjustments
KM 251 en Set the pressure relief valve as follows: 1. Close the shut-off valve after the manometer. 2. Remove the cover (1m) of the pressure relief valve. 3. Start up pump. 4. Using the screwdriver, slowly turn the adjusting screw (2m) of the pressure relief valve anticlock- wise, until the desired opening pressure is obtai- ned. -
Page 35: Operating The Pump
KM 251 en Start-up/Shutdown measuring beaker. 2. Set dosing flow to 15%. 3. Remove cover (1l) from stroke adjustment button (L). 4. Use a screwdriver to loosen the locking screw (21) by approximately 2 rotations. 5. Switch on the pump. 6. -
Page 36: Storage
KM 251 en 7.6.3 Storage When you store the pump: After cleaning (see above) • Carefully dry all parts and reinstall the dosing head and valves • Change the valves and diaphragm. See “Maintenance” section. 7.6.4 Disposal When you dispose of the pump: After cleaning (see above) •... -
Page 37: Operating The Pump
KM 251 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 Switching Off the Pump •... -
Page 38: Electronic Stroke Preset Counter (Optional)
KM 251 en Electronic stroke preset counter (optional) To operate the stroke preset counter, please refer to the instructions for the stroke preset counter. Electrically heated dosing head (optional) To operate the temperature controller, please refer to the instructions for the temperature controller. -
Page 39: Maintenance
KM 251 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! Switch off the pump and disconnect it from the mains before carrying out mainte- nance work and repairs! Before removing the dosing head, valves and media lines, empty any remaining... -
Page 40: Checking The Oil Level
KM 251 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 41 KM 251 en Maintenance DN 8 valve, stainless steel/plastic, optional spring-loaded DN 20 valve, plastic 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! V1.0...
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Page 42: Changing The Diaphragm And Gear Oil For Dosing Head With Single Diaphragm (No Mbs)
KM 251 en Changing the diaphragm and gear oil for dosing head with single diaphragm (no MBS) Warning When working on the dosing head, connections or lines: Wear the necessary protective clothing (goggles, gloves)! The dosing diaphragm should be replaced with each gear oil change. 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. -
Page 43: Fitting The Dosing Head
KM 251 en Maintenance 1q Dosing head screw 2q Intermediate disk Dosing head Diaphragm 9.6.4 Fitting the dosing head • Fit the dosing head and tighten the dosing head screws (1q with 2q) crosswise using a torque wrench. Note Refer to the “Start-up” section for subsequent start-up! 9.6.5 Filling gear oil Caution... -
Page 44: Replacing The Diaphragm For Dosing Head With Double Diaphragm
KM 251 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). 9.7.2 Replace the double diaphragm. -
Page 45: Fitting The Dosing Head
KM 251 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 46: Filling Gear Oil
KM 251 en 6. Only close the deaeration screw (2u) when the separating agent stops flowing. (after approx. 5 - 10 min) Note Once filled with separating agent and after a few operating hours, especially if the pressure of the manometer is increasing, deaerate again. Filling quantity of paraffin oil for dosing pumps with a double diaphragm (per dosing head) Pump Type Filling quantity in ml... - Page 47 KM 251 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.
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Page 48: 10 Possible Errors
KM 251 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 49 KM 251 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;...
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Page 50: 11 Spare Parts
KM 251 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 storage temperature Permissible Relative: 80%, maximum... - Page 51 KM 251 en Spare Parts Nominal width/Valve material Order Pump Pressure Version number type Housing 1) Balls Seat Gasket 553-259 16,00 bar DN 8 1.4401 Stainless steel Viton 553-1318 DN 8 1.4401 EPDM EPDM Diaphragm breakage 553-251-1 25,00 bar DN 4/8 Stainless steel PTFE Viton safety device...
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Page 52: 12 Dosing Curves
KM 251 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 251-5 (50Hz) Q = 3bar 251-5 (60Hz) Q = 3bar... - Page 53 KM 251 en Dosing Curves 251-24 (50Hz) Q = 3bar Q [l/h] 3bar 10bar 10 20 30 40 50 60 70 80 90 100 h [%] 251-4,9 (50Hz) Q = 10bar 251-4,9 (60Hz) Q = 10bar Q [l/h] Q [l/h] 3bar 10bar 10bar...
- Page 54 KM 251 en 251-23 (50Hz) Q = 10bar 251-23 (60Hz) Q = 10bar Q [l/h] Q [l/h] 16bar 10bar 16bar 10bar 3bar 3bar 10 20 30 40 50 60 70 80 90 100 10 20 30 40 50 60 70 80 90 100 h [%] h [%] 251-4,5 (50Hz) Q...
- Page 55 KM 251 en Dosing Curves 251-21 (50Hz) Q = 20bar Q [l/h] 20bar 25bar 10bar 10 20 30 40 50 60 70 80 90 100 h [%] V1.0...
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Page 56: Ec Declaration Of Conformity (Translation)
KM 251 en EC Declaration of Conformity (Translation) in the context of EC machinery directive 98/37/EC, EC directive for EMC 89/336/EEC The design of the product range Piston Diaphragm Dosing Pumps KM 251 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.
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