HST CHEMICAL METERING PUMPS

Operating Manual

HST-2 HST-5 HST-25 2246816 2246808 2246813

HST-8 HST-60 2246805 Special order

i

Table of Contents 1� Please Observe the Following ....................................................................................................... 1�

1.1� Emphasized Sections ............................................................................................................ 1�

1.2� For Your Safety ....................................................................................................................... 1�

1.3� Unpacking and Inspection ..................................................................................................... 2�

1.4� Items supplied ......................................................................................................................... 2�

1.5� Features ................................................................................................................................... 2�

2� Description ...................................................................................................................................... 3�

2.1� Functional Descriptions ....................................................................................................... 3�

2.1.1� HST-2 Chemical Metering Pump; 2246816 ...................................................................... 3�

2.1.2� HST-5, HST-8, & HST-25 Chemical Metering Pump; (2246808, 2246805, 2246813) 5�

2.1.3� HST-60 Chemical Metering Pump; (Special Order) ........................................................ 6�

2.2� PUMP CONTROLS - Diagrams ........................................................................................... 7�

2.2.1� HST-2 Chemical Metering Pump; 2246816 ...................................................................... 7�

2.2.2� HST-5, HST-8, & HST-25 Chemical Metering Pump; (2246808, 2246805, 2246813) 8�

2.2.3� Description of Symbols on Pump Controls ....................................................................... 8�

2.2.4� HST-60 Chemical Metering Pump; (Special Order) ........................................................ 9�

3� Technical Data ............................................................................................................................ 10�

3.1� Utilities ................................................................................................................................. 10�

3.2� Physical Characteristics .................................................................................................... 10�

4� Installation ................................................................................................................................... 11�

4.1� Installation Instructions ..................................................................................................... 11�

4.2� Electrical Connection ......................................................................................................... 11�

4.3� HST-2 Start up .................................................................................................................... 11�

4.4� HST-5, HST-8, & HST-25 Start up .................................................................................. 21�

ii

4.5� HST-60 Start up .................................................................................................................. 22�

5� Operation ...................................................................................................................................... 23�

5.1� HST-2 Setting the Mechanical Stroke Adjustment ...................................................... 23�

5.2� HST-5, HST-8, & HST-25 Setting the Metering Capacity (Mechanical) .................. 27�

5.3� Setting the Metering Capacity (Mechanical) ................................................................ 28�

6� Troubleshooting .......................................................................................................................... 29�

6.1� Faults Which You Can Correct ......................................................................................... 29�

6.2� Faults Which Must Be Corrected by Integrated Equipment Solutions ..................... 30�

6.3� HST-2 Display Metering Warning Messages ................................................................ 30�

6.4� HST-2 Display Alarm Messages ...................................................................................... 31�

7� Care and Maintenance ............................................................................................................... 32�

7.1� Preventive Maintenance ................................................................................................... 32�

7.2� HST-2 Diaphragm and Pump Head Replacement ........................................................ 33�

7.3� HST-5, HST-8, & HST-25 Diaphragm and Pump Head Replacement ...................... 33�

7.4� HST-60 Diaphragm and Pump Head Replacement ...................................................... 34�

7.5� HST60 Gear Oil Change .................................................................................................... 37�

7.6� HST-60 Pump - Wearing and Replacement Parts ........................................................ 38�

8� Accessories and Spare Parts .................................................................................................... 39�

8.1� Accessory Items .................................................................................................................. 39�

8.2� Spare Parts .......................................................................................................................... 39�

8.2.1� 2246816 E-AP HST 2 Pump .............................................................................................. 39�

8.2.2� 2246808 E-AP HST-5 & 2246805 E-AP HST-8 Pumps ................................................ 40�

8.2.3� 2246813 E-AP HST 25 Pump ........................................................................................... 41�

8.2.4� HST-60 Pump ...................................................................................................................... 42�

9� Diagrams ...................................................................................................................................... 43�

9.1� HST-2 Dimensions in millimeters .................................................................................... 43�

9.2� Dimensions in Inches HST5 and HST8, HST25 ............................................................ 44�

iii

9.3� Dimensions in Inches HST60 ........................................................................................... 45�

10� Warranty ....................................................................................................................................... 46�

iv

1

1 Please Observe the Following

1.1 Emphasized Sections

Warning!

Refers to safety regulations and requires safety measures that protect the operator or other persons from injury or danger to life.

Caution!

Emphasizes what must be done or avoided so that the unit or other property is not damaged.

Notice:

A notice gives recommendations for better handling of the unit during operation or adjustment as well as for service activities.

1.2 For Your Safety

For safe and successful operation of the unit, read these instructions completely. If the instructions are not observed, the manufacturer can assume no responsibility.

Do not expose the connecting cable to heat, oil, or sharp edges.

Make sure the Unit stands stable and secure.

Use only original equipment replacement parts.

Always disconnect the power supply before servicing the unit.

Observe general safety regulations for the handling of chemicals such as Bonderite products. Observe the manufacturer’s instructions as stated in the Safety Data Sheet.

While under warranty, the unit may be repaired only by an authorized Henkel service representative.

2

1.3 Unpacking and Inspection

Carefully unpack the HST Metering Pump and examine the items contained in the carton. Inspect the unit for any damage that might have occurred in transit. If such damage has occurred, notify the carrier immediately. Claims for damage must be made by the consignee to the carrier and should be reported to the manufacturer.

1.4 Items supplied

1.4.1 8906395 Equipment Manual

1.4.2 Power Cord

1.4.3 HST Metering Pump

1.5 Features

1.5.1 Manual stroke adjustment for control of delivery rate.

1.5.2 Pulse (frequency) adjustment for fine control of delivery rate with HST 2.

1.5.3 Manual or automatic operation

1.5.4 Dual check valve assemblies to ensure better priming, and consistent delivery rates.

1.5.5 Indicator lights; Power On, Stroke indicator, Fault.

3

2 Description

Henkel Corporation HST pumps are versatile, high quality, chemical metering pumps. Designed and manufactured by Henkel specifically for our chemical processes, the HST Pumps deliver accurate feeds from less than 1 GPH up to 60 GPH. Henkel Corporation offers five models: HST-2, HST-5, HST-8, HST-25, and HST-60. All pumps are compatible with most Henkel Corporation Chemicals and are built to the high quality and reliability standards that are a trademark of Henkel Corporation.

The HST metering pumps are electronic motor-driven diaphragm positive-displacement pumps.

2.1 Functional Descriptions

2.1.1 HST-2 Chemical Metering Pump; 2246816

Electronic motor-driven diaphragm positive-displacement pump with the addition of:

Digital display to configure and adjust pump’s settings. Features like pump control and alarm settings.

Power Supply: The mains power supply enters through a four-terminal frontal plug connector. This already has a plug screwed into it with a cable.

Note: To ensure the main power connection is properly sealed, the gasket (contained in the delivery scope and already built-in in the as-delivered condition) must be inserted and the fixing screw tightened into the middle of the plug.

4

Power cord connection for HST-2

Pin Conductor Color

(cable connection)Assignment

L1 Black 115 VAC (or if applicable 230VAC)

N White or Blue Neutral

PE Green or Yellow Ground

* - Not assigned

Note: Pump’s software version displayed as follow (when pressing ▲ and ▼ together):

The current software version (1) is displayed in the top right of the main menu screen. Lowercase letters after the software number (2) describe internal software modifications that do not affect the operation of the device. The volume can be adjusted only during operation via adjustment controls, limiting the movement of the diaphragm.

The pump heads are fitted with a pressure relief valve.

HST-2 Pump Structure

25

4

3

11

2

3

4

5

2.1.2 HST-5, HST-8, & HST-25 Chemical Metering Pump; (2246808, 2246805, 2246813)

The eccentric screw drive (1) moves the diaphragm (5) moving the solution through the discharge valve (2). The suction valve (3) is closed.

The diaphragm is returned using a return spring (6), causing the product to be drawn into the pump head via the suction valve (3). The discharge valve (2) is closed.

The volume of product can only be regulated via the stroke adjustment (4) in 2% increments and only during operation.

HST-5, HST-8, & HST-25 Pump Structure

2

56 1

3

4

1

4

2

5 6

3

6

2.1.3 HST-60 Chemical Metering Pump; (Special Order)

The eccentric screw drive (1) moves the diaphragm (5) moving the solution through the discharge valve (2). The suction valve (3) is closed. The diaphragm is returned using a return spring (6), causing the product to be drawn into the pump head via the suction valve (3). The discharge valve (2) is closed. The volume of product can only be regulated via the stroke adjustment (4) increments and only during operation.

HST-60 Pump Structure

3

4

12 5 6

7

2.2 PUMP CONTROLS - Diagrams

2.2.1 HST-2 Chemical Metering Pump; 2246816

Pos. Description

1 Control knob for setting the stroke length2 Menu/Exit, up arrow key3 Menu/Exit, down arrow key4 Start/Stop key (Enter function)5 Test key 6 Graphical display (LCD, back lit)

I Input for low-level warning and empty report (Short circuit plug used, factory setting)

II Input for pulse- / standard signal and metering lock (Not Utilized. Plug cover on)III Empty report, fault report and stroke signal (Not Utilized. Plug cover on) IV Mains power supply (115VAC or 230VAC)

The discharge flow can be regulated during operation via the stroke setting (Pos.1). This way, the resetting motion of the diaphragm is limited.

Electronic functions The pump is operated using four keys (Pos. 2, 3, 4 and 5). See Key functions below. The operating indicator is shown on a graphical display (Pos. Pos. 6).

Operation mode The pump may be used in three different operation modes:

INTERNAL Manual metering function (factory setting) EXTERNAL pulse control (N/A) EXTERNAL standard signal control (mA) (N/A)

The Configuration menu item can also be used to set batch metering (a specific quantity is metered on each start pulse) (N/A).

8

2.2.2 HST-5, HST-8, & HST-25 Chemical Metering Pump; (2246808, 2246805, 2246813)

2.2.3 Description of Symbols on Pump Controls

Fault Indicator Light (red) this light indicates that a pump fault has occurred. Operating indicator (green) this light indicates that the pump has power, and the motor is operating. Metering indicator (yellow) this light indicates that the motor is operating and is driving the diaphragm.

FAULTLIGHT(RED)

POWERONLIGHT(GREEN)

POWERSWITCH

9

2.2.4 HST-60 Chemical Metering Pump; (Special Order)

10

3 Technical Data

3.1 Utilities

3.2 Physical Characteristics

Model HST

Part No. Input

Power (W)

Max Input Current (A)

Fuse Rating 115 V

(A)HST-2 2246816 115 VAC 60 Hz 19.8 0.21 0.315HST-5 2246808

115VAC/60Hz 90

1.8 (starting max. 5.9)

4 HST-8 2246805 HST-25 2246813 115VAC/60Hz

HST-60 Special Order

115VAC/60Hz 300 7.6

(starting max 25.1) 12.5

Model HST

Part No.

Delivery Rate GPH

PSIG H x W x D

Inches [mm]

Weight lbs. [kg]

Tube OD

HST-2 2246816 0 to 2 29 4.78 x 5.34 x 8.40 [121 x 136 x 213]

5.3 [2.4]

3/8”

HST-5 2246808 1 to 5116

14.56 x 5.39 x 11.83 [370 x 137 x 300]

16.3 [7.4]

½” HST-8 2246805 1 to 8

HST-25 2246813 3 to 25 58 14.56 x 5.55 x 12.93

[370 x 141 x 328]

20 [8.6]

HST-60 Special Order

3 to 60 87 54.0 [24.5]

-

11

3.3 Physical Characteristics

4 Installation

Before using the equipment for the first time check it carefully for signs of external damage. If any shipping damage is found DO NOT USE THE EQUIPMENT – return it to your supplier immediately.

4.1 Installation Instructions

The following instructions are for installation and set-up of the equipment.

Long suction lines should be avoided (max. 9 feet if possible)

4.2 Electrical Connection

An AC cord is pre-wired. The motor windings are thermally protected and will shut down the pump if an overload should occur.

4.3 HST-2 Start up

1. Mount pump in a vertical position.

2. Connect suction and discharge tubing using the correct size and material compatible with the product to be pumped - Contact Henkel representative for suggestions.

Cut off tube cleanly. Push tubing nut (10) and tubing ferule (11) over

tube and push onto connecting nipple (12) as far as stop collar.

Place O-ring (13) into valve groove and tighten tubing nut (10).

Install the vent line (14).

3. Startup

On start-up, vent the system. Caution is required when handling chemical metering media. Metering media may escape which may cause skin irritation, depending on their properties. Therefore, before venting, always observe the product datasheet of the metering medium to prevent any type of injury.

To ensure an optimal suction performance, the stroke length should be set to 100% and the maximum stroke frequency.

10

11

10

11

12

13

1412

13

5

12

If pump has no suction or insufficient suction, the correct connection must be checked.

It is only possible to modify the stroke length setting when the pump is running.

Switching ON the pump: Press START/STOP key (min. 2 sec.).

Switching OFF the pump: Press START/STOP key (min. 5 sec.).

Venting the metering pump

Open the vent screw approximately 1 turn

Hold a suitable collection vessel under the vent connection

Press the Test key until the metering medium escapes from the venting outlet. Hold down the Test key for a further 60 seconds to fill the pump head fully with the product.

Reclose the vent screw.

Press the Test Key again until the metering medium is visible through the metering pipe, until it reaches approximately 2 cm in front of the inoculation valve.

Close the clear cover which protects the function keys, and seal it if necessary.

If no metering medium enters the metering pipe, repeat the venting.

Key functions:

MENU/EXIT function entry and exiting of the menu levels (keep keys pressed down together for 2 sec.)

Modify set values upwards

Modify set values downwards

Start the pump / Stop the pump / Confirmation key (ENTER) for set values

Test function (endurance test)

13

Key Functions Display Description

Pump’s operation mode: the top right indicator in the display makes a full rotation with each stroke.

(Level check feature is not utilized but it MUST be bypassed in order to operate the pump as an On/Off switching device as described in the note below “Configuring the electronic HST-2 pump as conventional On/Off pump”. If this feature it is utilized for Level Check, Level report is active (flashing display = low level advance warning, display is permanently visible = empty report),. Installing the suction pipe with low-level advance warning and empty report or configuration / Low-level contact

(N/A) Metering lock active, see metering lock Configuration / Metering lock

Fault report, see Alarm messages

Intern Operation mode internal, see “Operation mode / internal”MUL (N/A) Operation mode pulse multiplication, see “Operation mode / pulse” DIV (N/A) Operation mode pulse division, see “Operation mode / pulse”

x..xx mA (N/A) Operation mode current x – xx mA, see “Operation mode / current”Charge (N/A) Operation mode batch see “Configuration / Batch”xxx /min Display strokes / min at Operation mode internal

xx % Display % at Operation mode internalx.xx l/h Display l/h at Operation mode internal see “Display / setting operation mode internal”n = x (N/A) Display at operation mode pulse, see “Display / setting operation mode pulse”xx.x mA (N/A) Display at operation mode current, see “Display / operation mode current”

f = xx.x % Display of the current metering frequency in %OFF Pump is in operating state OFF (must be switched on), see “Display at operating display”E60+ (N/A) Dongle box is connected

E60++ (N/A) Dongle box is connectedMicroFlow (N/A) MicroFlow connected

Alarm (N/A) Alarm operation mode

Delivered Settings

In the as-delivered settings of the HST-2 pump is as follows:

Operation mode: Internal

Stroke frequency: 146 strokes/min (max. at 60 Hz)

Status: pump in the "OFF" operating state

To change the preconfigured factory settings, observe the corresponding menu items in "Configuration"

14

Delivered Operating Display

On delivery, the following basic factory settings appear on the display when the main voltage is switch on.

Operating mode: internal

Metering frequency/- quantity: strokes / min

(146 strokes/min at 60 Hz)

Operating state: OFF (at V 4.1, „Standby “at V4.0) (to start pump press START / STOP key)

With each stroke of the pump, the indicator in the upper right of the display rotates 1 turn.

Quick Setup: HST-2 pump configured as On/Off pump

Out off-the-box pump may need the following configuration to operate it as a conventional (On/Off) pump upon (Connecting/Disconnecting) the 120VAC power.

This feature will not be enabled without the connector plug (jumper plug) plugged in to the 3-pin connector for the low level & alarm shown below:

If this plug is NOT provided with the pump, make sure pin 1, 3, & 4 of the 3-pin connector are shorted together.

Follow the steps below to enable the “Auto Start” feature:

1. From the default screen, simultaneously press the up & down arrow buttons

2. From the main menu screen, press once the down arrow button to highlight the configuration, then press the Start/Stop (Enter) button to edit configuration.

15

3. At the configuration screen, scroll down using the down arrow button to highlight the autostart setting.

4. Press the Start/Stop (Enter) button at the while autostart is highlighted to edit.

5. Change the dash “-“ to a check mark “” using either the up or the down arrow button.

6. When is checked, it means autostart is enabled.

7. Simultaneously press the up & down arrow buttons together twice to exit and save.

Set the Operation Mode Internal to Percent:

1. From the default screen, simultaneously press the up & down arrow buttons

2. From the main menu screen, when operation mode is highlighted, press the Start/Stop (Enter) button to edit operation mode.

3. At the operation mode screen, when internal is highlighted, press the Start/Stop (Enter) button to edit internal settings.

4. At the operation mode, internal screen, highlight the gallons using the up/down arrow buttons, then press the Start/Stop (Enter) button to select.

8. Simultaneously press the up & down arrow buttons together three times to exit and save.

NOTE 1: After correct configuration, the following buttons will have the following functions:

The Start/Stop button acts as an ON/Off toggle switch.

16

The Up or Down button as the frequency adjusting knob (Note: to change press button for 2 sec. then it start changing)

The mechanical knob remains as the stroke adjusting knob.

NOTE 2: Operation mode MUST be set as follow:

Operation Mode: Internal

Operation Mode Internal: Percent (recommended)

NOTE 3: The internal mode can be set as either (Strokes/min.), (Percent), or (Gallons).

Range Strokes/min. Percent Gallons

Minimum 0/min. 0% 0 G/h

Maximum 146/min. 100% 2.16 G/h

Configuration

The following settings are defined in the configuration:

Default Configuration

language: English unit: Gallon code: not active (-) auto start: active () metering lock: not active (-) low level contact: open () alarm output: off () pulse memory: not active (-) oval gear meter: not active (-) metering controller: not active (-) meter monitor: not active (-) microflow: not active (-) batch: not active (-) degas: not active (-)

17

Scrolling the display

The display possesses a "scroll function", i.e. some menu items are only shown on the display when the end of the menu is reached on the display. Using the symbols ▲ (1) or ▼ (2) on the display, you can see which direction you can scroll in.

1 = (▲) scroll the display upwards

2 = (▼) scroll the display downwards

Configuration / Language (Keep “English”)

This is used to select the menu language.

Configuration / Unit (Keep “Gallons”)

If ‘litre’ is selected for the ‘internal’ operation mode, this can be used to change the display from litres/h to gallons/day (1 gallon = 3,785 litres).

Configuration / Code (Keep Inactive or Unchecked “ - “)

18

With this setting, a four-digit number combination can be assigned to secure the setting against unauthorized adjustment.

If ‘code’ has been activated, the four-digit code must be entered before configured values can be amended or the main menu can be accessed.

Configuration / AutoStart (Keep Active or Checked “ “)

This function determines whether the pump is set to ‘OFF’ (‘Standby‘ in V 4.0) when the mains connection is re-established following a power cut or if the pump should immediately recommence functioning in the configured operation mode.

- AutoStart is inactive. When the mains voltage is connected, the pump always enters the "OFF" operating state.

19

(Default setting)

AutoStart is active. When the mains voltage is connected, the pump starts functioning in the configured operation state.

Configuration / Metering lock (Keep Inactive or Unchecked “- “)

Configuration / Low-level contact (Setting Does Not Matter)

This function specifies whether an open or a closed contact at the level input

= contact open: level not OK (empty)

contact closed: level OK (full) (Default setting)

= contact closed: level not OK (empty)

contact open: level OK (full)

Configuration / Alarm output (Setting Does Not Matter)

20

This option permits the inversion of the alarm output (alarm output relay has pulled in or not pulled in when the alarm was triggered).

= When an alarm is triggered, the relay is pulled in for the alarm output. (Default setting)

= When an alarm is triggered, the relay is not pulled in for the alarm output.

In addition to the function mode of the relay, it is also possible to select whether the alarm output relay contact is closed (closing function on, default setting) when the relay is pulled in or open (opening function).

Configuration / pulse memory (Setting Does Not Matter)

If the incoming pulse rate is higher than the maximum pulse rate that the pump can process (max. pump frequency e.g. 122 strokes/min at 50 Hz), the pulses that cannot be processed can be stored.

The stored pulses are processed once no further external pulses are received. This means that the pump continues to function even though there is no external running condition. In the worst case, this can lead to metering taking place into a closed system and resulting in impermissibly high pressure in the system. This must be prevented through appropriate safety measures. The memory content is erased by activating the metering lock or switching off the pump.

21

Display in the operating display with an active pulse memory

Display in operation Meaning Pos Description

Pulse multiplication (Example: 10 external pulses become 20 strokes)

1 Pulse memory active2 Number of pulses received3 Set factor

Pulse division (Example: 10 external pulses become 20 strokes)

4.4 HST-5, HST-8, & HST-25 Start up

1. Mount pump in vertical position.

2. Connect suction and metering line:

Cut off tube cleanly.

Push tube nut (11) and tube Farrell (12) over tube and push onto connecting nipple (13) as far as stop collar.

Place O-ring (14) into valve groove and tighten tubing nut.

3. Set stroke setting and stroke frequency setting (if applicable) to 100% (see Para 4.6).

The metering pump head may contain residual water from factory testing.

After 24 hours of operation, the metering head screws should be diagonally tightened to 2-3 ft lbs.

11

12

13

14

22

4.5 HST-60 Start up

1. Mount pump in vertical position. 2. Connect suction and metering line:

a. Cut off tube (7) cleanly. b. Place O-ring (15) into groove of suction/pressure valve. c. Tighten up hose nipple (11 welded with insertion part) with union nut (10). d. Push hose clamp (9); 2 pieces recommend; over tube. e. Push tube over hose nipple (11) and tighten up hose clamps (9).

(Arrangement of hose clamps per shown figure below)

The metering pump head may contain residual water from factory testing.

After 24 hours of operation, the metering head screws should be diagonally tightened to 2-3 ft-lbs.

23

5 Operation

5.1 HST-2 Setting the Mechanical Stroke Adjustment

The metering pump is set at the factory to deliver rated volume. If re-adjustment is required follow the procedure below. Switch metering pump on.

1. Place knob on 100% and turn clockwise until adjusting screw is noticeably tensioned. Because of the eccentric drive, it is only possible to turn the knob with the pump running.

If no resistance is reached, repeat the above step until “0” output is reached.

2. Pull knob off and place indicator back to the zero position on the scales. Adjust for the % setting and confirm output in step 4, section 7.1 on page 15.

3. To determine the metering output accurately the pump should be measured in gallons.

The following operating data is recorded and displayed under this menu item:

Operating hours Litre / Gallons Amount of pulses

Operating data / Operating hours The pump running time (number of strokes • 480 ms) since it was first commissioned or last reset is displayed.

24

Selecting / Displaying / Deleting

Operating data / Litre or Gallon The metered quantity in litres since the pump was first commissioned or last reset is displayed. On operating the pump without an oval gear meter, this value is calculated (ml/stroke • number of metered strokes). If an oval gear meter is connected, the measured quantity is displayed (determined from the number of oval gear meter pulses).

Selecting / Displaying / Deleting

Operating data / Amount of pulses (N/A) The number of pulses received via the pumpʼs pulse input since it was first commissioned or last reset is displayed.

Selecting / Displaying / Deleting

HST-2 Menu description

Main menu The main menu can be accessed while the pump is operating.

It is started by simultaneously pressing the and keys.

25

Simultaneously press the and keys again to return to the operating display.

Overview

Operation mode

Configuration

Calibration

Operating data

Operation mode

Internal Pulse current

Operation mode / internal

26

The “internal” operation mode can be used to operate the metering pump without external signals. The following display options can be selected:

Strokes/min the configured metering speed (and thus the metering rate) is displayed in strokes/min. (Default setting)

Percent The configured metering speed (and thus the metering rate) is displayed as a percentage.

liter / Gallon The configured metering rate is displayed in litres/h, gallons/day, or gallons/h.

27

Display in the operating display/ Setting The metering rate can be configured / adjusted in the operating display during operations. NOTE: If the newly set value is not confirmed within 10 seconds by pressing the START/STOP key, the system reverts to the primarily value.

Strokes/min Percent (%)

liter /min Gallons

5.2 HST-5, HST-8, & HST-25 Setting the Metering Capacity (Mechanical)

The metering capacity can only be adjusted during operation using the stroke adjustment knob (4). The locking screw (15) should be loosened beforehand by about one turn.

Re-tighten locking screw after adjusting metering volume.

4

15

28

5.3 Setting the Metering Capacity (Mechanical)

The metering capacity can only be adjusted during operation using the stroke adjustment knob (4) in the figure below:

By turning the knob clockwise, metering capacity is reduced.

By turning the knob anticlockwise, metering capacity is increased.

The current set value is displayed through the position of the stroke adjustment knob (4) about the scale.

29

6 Troubleshooting

6.1 Faults Which You Can Correct

Before carrying out repair and maintenance work, always flush the metering head, relieve the pressure line with the pressure relief valve and wear protective clothing (protective glasses, protective gloves and apron).

Opening covers or removing parts may expose live (electrical) connections.

Before carrying out a calibration, service, or overhaul and when replacing parts, the pump must be disconnected from all power sources.

FAULT POSSIBLE CAUSE REPAIR

Metering pump does not work, green LED not lit

- Wrong voltage - Check power supply

Metering pump does not work, red LED is lit

- High Head Pressure - Check for output obstruction

- Cycle power on/off

Pump has no suction - Deposits, jamming, valves

dried out

- Wash out metering head through suction line, remove valves if required

and clean or replace

Metering head is not sealed, material exiting from leakage connection

- Metering head loose - Diagonally tighten metering head

attachment screw

- Diaphragm ruptured - Replace diaphragm

Metering pump not running although switch

is ON

- Air in pump head - Vent metering head

- Metering volume setting too low

- Increase stroke volume setting.

Metering pump doesn't operate

- Motor turned off by winding protector

- Motor turns on automatically after cooling

- Motor overload caused by too high back-pressure

- Check Discharge line

FOR 2246816 E-AP HST 2 Pump

Low-Level indicator appears on the display despite a full container.

Suction Pipe or Strapping Plug is Loose or not Plugged in

Tighten the plug. Clean the contacts, check whether the Strapping Plug is Plugged in.

Suction Pipe Cable is Faulty Replace The Empty report device.

30

6.2 Faults Which Must Be Corrected by Integrated Equipment Solutions

Before proceeding with any repair or maintenance operation disconnect the tool from the main electricity supply.

6.3 HST-2 Display Metering Warning Messages

If external signals are no longer being processed and the output signals (empty, fault) are switched off, the following error messages can be shown on the display of the metering pump:

Display Meaning Effect Cause Remedy

reserve report (flashing)

pump continues running

low-level advance warning active

Refill the metering medium

empty report pump is stopped empty report active Refill the metering medium

metering lock (only possible if this is configured)

pump is stopped no external enable of the pump

Activate external enable or deactivate the metering lock in the configuration menu.

Indicator in operation mode 4..20mA flashes standard signal monitoring responds

pump is stopped

standard signal is under 3mA or cable to standard signal connection is broken

check the standard signal or cable

--.- standard signal is above 23.0 mA

pump runs in continuous operation

standard signal exceeds the display range

reduce the standard signal

FAULT POSSIBLE CAUSE REPAIR

Metering pump does not work, no green LED display

- Power cable defective Replace power cable

31

6.4 HST-2 Display Alarm Messages

Display Meaning Effect Cause Remedy

Motor is running uncontrolled in continuous operation

over dosage power electronic failure replace PC-Board

Motor is not running despite of rotating dosing symbol.

no metering

backpressure too high reduce pressurevalve closed at pressure side

open valve

Motor overheated/damaged

cool of the motor, or. change

power electronic failure replace PC-board

motor in continuous operation without request

continuous metering

optical sensor polluted send in pump

PC-board faultPlug connection from gear to PC-Board interrupted

control optical sensor connection

error in evaluating the metering monitoring or oval gear meter

pump meters too little or too much

tube fault check the tubes

diaphragm fault check the diaphragm

backpressure too high or too low

check the backpressure

alarm

failure 1

permanent stroke

!

alarm

failure 2

no stroke

!

alarm

failure 3

motor control

!

alarm

failure 4

oval gear meter

!

32

7 Care and Maintenance

7.1 Preventive Maintenance

The following preventive maintenance instructions are set up at a quarterly maintenance interval; shorter intervals should be used if load is greater (e.g. constantly running).

It is recommended that the following be checked: (see diagram on following page)

1. Suction and discharge lines for leak-free connection.

2. Suction (3) and discharge valves (2) for debris/contamination and sealing function.

3. Check drain hole (A) on intermediate pump section for evidence of possible diaphragm break. If solution is present at the drain hole, the diaphragm is leaking into the pump gearbox and should be replaced immediately.

4. Check metering head screws:

a.) Metering head screws (15) (firm seating, 2-3 lb-ft).

b.) Metering head screws (16) (firm seating, 2-3 lb-ft).

The lifetime of the diaphragm varies depending on:

Back pressure, operating temperature and chemical pump.

Frequent checking of the diaphragm is recommended at extreme temperatures and when metering aggressive materials.

For safety reasons, the diaphragm should be replaced every 6 months to one year depending on the chemical used.

HST-2 HST-5, HST-8, & HST-25

16

16

2

15

1

2

3

1

A

33

HST-60

7.2 HST-2 Diaphragm and Pump Head Replacement

Remove cover (20) from metering head, loosen attachment screws (15) and remove pump head (16), unscrew diaphragm (17), including connecting piece (18) and back-up ring. Replace intermediate diaphragm (19) from ram. Re-install parts. When fitting the diaphragm, do not over tighten (by hand, without tools, lightly tighten). The leak connection of the connecting fitting must point downwards. The metering head must be evenly tightened diagonally.

Check metering head screw tightening torque after 24 hours and tighten as necessary. Tightening torque is 2-3 lb.-ft.

7.3 HST-5, HST-8, & HST-25 Diaphragm and Pump Head Replacement

Loosen attachment screws (16) pry out stopper (17) with screwdriver, ensuring that the piston rod does not twist (18), (Diaphragm and transition piece may need to be twisted to get the piston rod wrench surface into the right position), twist out diaphragm (15), intermediate piece (19) and support disk (20). Ensure that the mounting holes are aligned when tightening the diaphragm and the intermediate piece, (lightly tighten manually without tools). Turn the diaphragm and intermediate piece as one unit until the housing holes are aligned, and the leakage hole (A) points downwards. The metering head should be diagonally tightened evenly to about 3 lb.-ft.

19

18

16

1520

16

16

19

15

17

20

18

A

34

Check metering head screw torque after 24 hours. Torque should be 2-3 lb-Ft.

7.4 HST-60 Diaphragm and Pump Head Replacement

It is recommended to check the following:

Suction and pressure line for leak-free connection

Suction (3) and pressure valve (2) for soiling and sealing function the figure below:

Check exit hole (A) on intermediate ring (fractures in diaphragm)

Tight position of metering head screws (16) 8-9 lb-ft.

Oil-level on oil-level gauge glass (minimum level see figure below)

Replacement of suction and pressure valve, metering head, diaphragm,

motor and gear oil.

Before carrying out work on valves or metering head, the metering head must be emptied. All indications given in the product specification sheet of the metering medium must be observed.

Suction and pressure valve replacement (figure below):

35

Pump Head Disassembly

Loosen valve anti-clockwise with an appropriate tool and unscrew valve.

Carefully remove O-ring (18), which might have been left in the metering head, if necessary.

16: metering head screw 17: pressing plate 18: metering head 19: conveying diaphragm 20: intermediate ring 21: protective diaphragm

Pump Head Installation

Insert new O-ring (with pressure valve pos. 15; with suction valve pos. 15a in previous figure) into the O-ring groove of the valve.

Screw-in valve into metering head; take account of direction arrow (points upwards).

For metering head (18) replacement. If you plan to reuse valves, they should be initially dismantled as described in below.

Valve Disassembly

Loosen metering head screws (16) crosswise in three steps.

Loosen each screw by ½ a turn, and then loosen them in two steps according to the same order by 1 turn each.

Unscrew them completely; hold pressing plate (17) and metering head (18).

Remove pressing plate (17) and metering head (18).

36

Valve Installation

Place new metering head and pressing plate, and fix them with metering head screws.

Tighten metering head screws crosswise. Drive in each screw by proceeding in steps of 1 turns; final tightening torque: 8-9 lb-ft.

Install valves in accordance with the description previously mentioned

Check metering head screw-tightening torque after 24 hours. Torque should be 8-9 lb-ft.

Diaphragm Disassembly

Before replacing the diaphragm, set stroke length adjustment to less than 50 %.

Dismantle metering head as described before.

Take the intermediate ring (20) in such a way that the thumb presses the conveying diaphragm (19) against the intermediate ring, and unscrew the diaphragm with the intermediate ring clockwise. In case of stiffness, insert two metering head screws, approx. 0.59“ to 0.78“ into the intermediate ring in order to facilitate handling.

Remove diaphragm, intermediate ring and protective diaphragm (21).

Diaphragm Installation

Put on a new protective diaphragm and hold the intermediate ring against it.

Screw-on the new conveying diaphragm clockwise and tighten it up manually. When doing this, hold the intermediate ring in such a way that the thumb presses the conveying diaphragm against the intermediate ring.

Turn the intermediate ring clockwise until the outlet hole points downwards.

Install metering head as described before.

37

Check metering head screw-tightening torque after 24 hours. Torque should be 8-9 lb.-ft.

7.5 HST60 Gear Oil Change

Follow the local safety regulations and instruction given in the product specification sheet of the gear oil. Wear appropriate protective clothing.

Before changing the oil, the pump must be put into operation in order to achieve a minimum temperature of approx. 86 F.

Gear Oil Draining

Manually unscrew gear vent screw (22).

Put a suitable collecting basin (min. volume 0,9 l) underneath the locking nut (23).

Loosen locking nut with a proper tool and unscrew it carefully.

Let the running out oil drain off into the collecting basin.

Screw-in locking nut with new O-ring and tighten it up.

Gear Oil Filling

Fill new gear oil into the aperture for the gear vent screw (pos. by using an appropriate funnel (filling volume approx. 0.8 l).

Check oil level on oil-level gauge glass (24), min. and max. oil level, and rectify if necessary.

Only use gear oil of type L-CKT 320 that meets the ISO 6743 requirements. Dispose correctly of waste oil.

38

7.6 HST-60 Pump - Wearing and Replacement Parts

Position Description Position Description 1 Suction/pressure valve, 21 Protective cap 2 O-ring 22 Motor 230 or 115 V / 50/60 Hz 0,3 kW with start-up

electronics 3 Hexagon socket screw 23 Terminal box cover with start-up electronics4 Pressing plate 24 Connection cable 5 Metering head 25 Cable connection 6 Conveying diaphragm 26 Sealing plug (for transport only)7 Intermediate ring 27 Gear vent screw 8 Protective diaphragm 28 O-ring 9 Supporting disc 29 Spring element

10 Hexagon socket screw 30 Adjustment knob-coupling11 Receiver disc for protective diaphragm 31 Adjustment knob 12 Intermediate plate 32 Countersunk screw 13 Flange plate 33 Countersunk screw 14 Sealing cord 34 Thrust piece fixing 15 O-ring 35 Oval head screw 16 Locking nut 36 Front panel for version 17 Oval head screw 37 Protective cap for flip switch18 Mounting plate 38 Glow lamp 230 or 115V 19 O-ring 39 Flip switch Lever type slip-on sleeve for flip switch20 Oil-level gauge glass 40 Gear oil (filling volume 0,85 l) Specification

-pursuant to DIN 51 502:CLP PG 320 -pursuant to ISO 6743: L-CKT 320

39

8 Accessories and Spare Parts

8.1 Accessory Items

2252168 – Tubing, ½” OD for liquid acid or alkaline products, 50 feet length. 2252169 – Tubing, 3/8” OD for liquid acid or alkaline products, 50 feet length. 2251334 - Foot Valve, ½” NPT for liquid acid or alkaline products. 2251333 - Foot Valve Extension Kit for liquid acid, or alkaline products. 8906353 HST-1 & 2 Pumps Multi-Function Valve Adapter 8906354 HST-1 & 2 Pumps Multi-Function Valve 8906355 HST-5 & 8 Pumps Multi-Function Valve Adapter 8906356 HST-5 & 8 Pumps Multi-Function Valve 8906357 HST-25 Pump Multi-Function Valve

8.2 Spare Parts

8.2.1 2246816 E-AP HST 2 Pump

Item Matʼl No. Description1 8906361 HST-2 Pump Cover Plate PK-PP

2 8906359 HST-2 Pump Hex Screws (4) 8906360 HST-2 Pump Washers (4)

3 8906367 HST-2 Pump Head PVDF 4 2246826 E-AP HST 2 Diaphragm, Pump 5 8906366 HST-2 Pump Diaphragm Support Disk 6 8906368 HST-2 Pump Intermediate Plate 7 8906361 HST-2 Pump Bellows 8 2246825 E-AP HST 2 Coupling-Ferrule 9 2246824 E-AP HST 2 SCTN VLV 0.375 in - Suction Valve, 3/8” tube10 2246827 E-AP HST 2 DSCHRG VLV 0.375 in - Discharge Valve, 3/8”

tube- 8906358 HST-2 Pump Vent-Bore Plug (2)

2 3 4 5 6 71

9 8

810

40

8.2.2 2246808 E-AP HST-5 & 2246805 E-AP HST-8 Pumps

Item Matʼl No. Description1 2246810 E-AP HST 5-8 Discharge VLV Complete, 0.500 Tube2 2246809 E-AP HST 5-8 Suction VLV Complete, 0.500 Tube3 2246822 E-AP HST 5-8 Coupling-Ferrule ‒ Coupling nut with SS Ferrule4 8906369 HST-5 & 8 Pump M6x90 SS Hex Screws (4) 5 8906370 HST-5 & 8 Pump SS Pressure Plate

6 8906373 HST-5 Pump Head PVDF 8906376 HST-8 Pump Head PVDF

7 2246806 E-AP HST-5 Diaphragm, Pump 2246803 E-AP HST-8 Diaphragm, Pump

8 8906371 HST-5 Pump Diaphragm Support Disk 8906374 HST-8 Pump Diaphragm Support Disk

9 8906372 HST-5 Pump Intermediate Plate 8906375 HST-8 Pump Intermediate Plate

1

2

3

3

4

6

5 7

8

9

41

8.2.3 2246813 E-AP HST 25 Pump

Item Matʼl No. Description1 2246814 E-AP HST 25-60 SCTN-DSCHRG VLV for Pumps, 1.25 PVDF2 2246817 E-AP HST 25 COUPLING-FERRULE, Coupling Nut with SS Ferrule3 8906378 HST-25 Pump Head M6x75 SS Hex Screws (6)4 8906382 HST-25 Pump SS Pressure Plate 5 8906383 HST-25 Pump Head PVDF 6 2246811 E-AP HST 25 Diaphragm Pump 7 8906379 HST-25 Pump Diaphragm Support Disk 8 8906380 HST-25 Pump Intermediate Ring 9 8906377 HST-25 Pump M6x40 SS Hex Screws (4) 10 8906381 HST-25 Pump Intermediate Plate

1

2

1

2

3

4

5 6

7

8 9

10

42

8.2.4 HST-60 Pump

Item Matʼl No. Description

1 2246814 E-AP HST 25-60 SCTN-DSCHRG VLV for Pumps, 1.25 PVDF2 8906384 HST-60 Pump Head M6x100 SS Hex Screws (6)3 8906390 HST-60 Pump SS Pressure Plate 4 8906391 HST-60 Pump Head, PVDF 5 8906385 HST-60 Pump Diaphragm 6 8906387 HST-60 Pump Intermediate Ring, PVDF 7 8906389 HST-60 Pump Protective Diaphragm 8 8906386 HST-60 Pump Diaphragm Support Disk 9 - HST-60 Hexagon Socket Screw M8 x 20 VA (6)10 8906392 HST-60 Pump Protective Diaphragm Receiver Disk11 8906388 HST-60 Intermediate Plate 12 - HST-60 Flange Plate

2 3 1

1 4

5 7

6

9

8

11

10

43

9 Diagrams DIMENSIONS, CONNECTIONS

9.1 HST-2 Dimensions in millimeters

44

9.2 Dimensions in Inches HST5 and HST8, HST25

Capacity Dimensions in inches

GPH A C L H1 H2 D

HST 5 2.32 3.78 11.85 7.87 5.4 .625

HST 8 2.48 3.78 11.93 7.87 5.4 .625

HST 25 2.93 5.50 13.00 8.80 7.3 1.25

4.724

4.134

.2677

.551

5.413

B (80/120 I/H)

6.259A 2.224

D

C

H2

H1 1

4.6

26

L

45

9.3 Dimensions in Inches HST60

Capacity Dimensions in inches

GPH A C C1 L L1 H1 H2 D

210 5.256 6.693 6.85 15.433 15.748 11.023 8.85 1¼"

46

10 Warranty Henkel expressly warrants that all products referred to in this Instruction Manual for (IDH # Bonderite® process controller) (hereafter called “Products”) shall be free from defects in materials and workmanship. Liability for Henkel shall be limited, as its option, to replacing those Products which are shown to be defective in either materials or workmanship or to credit the purchaser the amount of the purchase price thereof (plus freight and insurance charges paid therefor by the user). The purchaserʼs sole and exclusive remedy for breach of warranty shall be such replacement or credit.

A claim of defect in materials or workmanship in any Products shall be allowed only when it is submitted in writing within one month after discovery of the defect or after the time the defect should reasonably have been discovered and in any event, within (12) months after the delivery of the Products to the purchaser. This warranty does not apply to perishable items, such as (indicate items: fuses, filters, lights, etc.). No such claim shall be allowed in respect of products which have been neglected or improperly stored, transported, handled, installed, connected, operated, used or maintained. In the event of unauthorized modification of the Products including, where products, parts or attachments for use in connection with the Products are available from Henkel, the use of products, parts or attachments which are not manufactured by Henkel, no claim shall be allowed.

No Products shall be returned to Henkel for any reason without prior written approval from Henkel. Products shall be returned freight prepaid, in accordance with instructions from Henkel.

NO WARRANTY IS EXTENDED TO ANY EQUIPMENT WHICH HAS BEEN ALTERED, MISUSED, NEGLECTED, OR DAMAGED BY ACCIDENT.

EXCEPT FOR THE EXPRESS WARRANTY CONTAINED IN THIS SECTION, HENKEL MAKES NO WARRANTY OF ANY KIND WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO THE PRODUCTS.

ALL WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND OTHER WARRANTIES OF WHATEVER KIND (INCLUDING AGAINST PATENT OR TRADEMARK INFRINGEMENT) ARE HEREBY DISCLAIMED BY HENKEL AND WAIVED BY THE PURCHASER.

THIS SECTION SETS FORTH EXCLUSIVELY ALL OF LIABILITY FOR HENKEL TO THE PURCHASER IN CONTRACT, IN TORT OR OTHERWISE IN THE EVENT OF DEFECTIVE PRODUCTS.

WITHOUT LIMITATION OF THE FOREGOING, TO THE FULLEST EXTENT POSSIBLE UNDER APPLICABLE LAWS, HENKEL EXPRESSLY DISCLAIMS ANY LIABILITY WHATSOEVER FOR ANY DAMAGES INCURRED DIRECTLY OR INDIRECTLY IN CONNECTION WITH THE SALE OR USE OF, OR OTHERWISE IN CONNECTION WITH, THE PRODUCTS, INCLUDING, WITHOUT LIMITATION, LOSS OF PROFITS AND SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER CAUSED BY NEGLIGENCE FROM HENKEL OR OTHERWISE.

47

Henkel Corporation One Henkel Way Rocky Hill, CT 06067-3910 USA

Henkel Canada Corporation 2515 Meadowpine Boulevard Mississauga, Ontario L5N 6C3 Canada

Henkel Corporation Automotive/ Metals H.Q. 32100 Stephenson Hwy, Madison Heights 48071 USA

Henkel Capital, S.A. de C.V. Calzada de la Viga s/n Fracc. Los Laureles Loc. Tulpetlac, C.P. 55090 Ecatepac de Morelos, MEXICO

Henkel Singapore Pte Ltd 401, Commonwealth Drive #03-01/02 Haw Par Technocentre SINGAPORE 149598

Henkel (China) Company Ltd. No. 928 Zhang Heng Road, Zhangjiang, Hi-Tech Park, Pudong, Shanghai, China 201203

Henkel Loctite Korea 8F, Mapo Tower, 418, Mapo-dong, Mapo-gu, Seoul, 121-734, KOREA

Henkel Japan Ltd. 27-7 Shin Isogo-cho, Isogo-ku Yokohama, 235-0017 JAPAN

Henkel AG & Co. KGaA Standort München Gutenbergstraße 3 85748 Garching b. München Deutchland

www.equipment.loctite.com

® and ™ designate trademarks of Henkel Corporation or its affiliates. ® = registered in the U.S. and elsewhere. © Henkel Corporation. All rights reserved. Data in this operation manual is subject to change without notice. Manual P/N: 8906395, Rev , Date: 10/04/2017