FLUX Pumps for the Industry sector

Task:
In one division of a gearbox manufacturer, various gearboxes are to be filled with lubricant greases of classes 1 to 4 in quantities of 0.1 to .3 gal at room temperature. The grease is removed from 55 gal drums and the transfer path is up to 6 feet. The grease drips in certain cases.

Customer's requirement:
- Filling accuracy:  +/- 10 g   
- Delivery pressure:  up to 4 bar  
- Flow rate: 20 l/min
- The transfer system must be able to fill for 2 hours per unit and do so several times a day.

Solution:
Drum emptying system VISCOFLUX lite
Eccentric worm-drive pump F 550 S
Spur gear drive motor
For the application designed accessories on request

Application description:
The VISCOFLUX lite drum emptying system for pumping high-viscosity media offers the precise solution in this case.

The drum emptying system consists of an F 550 S eccentric worm-drive pump with a gear motor, a pump eccentric crossbeam and a follower plate. The plate is positioned on the lubricant grease and sealed air-tight against the drum wall by the process seal. The pump eccentric crossbeam is placed on the drum. Then the eccentric worm-drive pump can be guided through the opening of the crossbeam and the guide of the follower plate down to the bottom of the drum. During pumping – i.e. removal – a negative pressure arises, resulting in the follower plate sinking.

The follower plate seals so flexibly that there is almost no medium residue left on the drum wall; ultimately there will be residual quantities of less than 1% in the drum. After emptying, the follower plate is released from the bottom of the drum by compressed air. At the end of the filling hose, there is a FLUX FAE filling unit, which prevents dripping of the medium thanks to a check valve.

Task:
Filling of canisters, plus 55 gal drums. Since the IBCs are vertically stacked on the shelves, they are not accessible from the top. Therefore filling is only possible via the bottom outlet.

Solution:
Drum pump F 430 TR
Commutator motor F 457
Flow meter FMO
Evaluation electronic FLUXTRONIC^®
Switched-mode amplifier
For the application designed accessories on request

Application description:
Whenever containers are not top accessible – and in the case of conventional drum pumps that go into the liquid but cannot be used – our dry well installation drum pumps (TR version) are the perfect solution.

These drum pumps can be mounted vertically on the IBC using a console, or can be mounted horizontally on a pump trolley.

If our flow meter FMO with evaluation electronic FLUXTRONIC^® and a switched-mode amplifier are also used, the desired fill quantity can be predefined and filling can then be done at the push of a button. The filling starts by pressing the button on the outlet unit and switches off automatically after the filling process.

For an example, see our drum and container pump brochure, page 38.

Task:
Greases (class 2) require filling into canisters of various sizes. As little of the greases should be left in the ISO lidded drum containers as possible. The filling should be automated, in other words done using a pre-configured volume.

Solution:
Drum emptying system VISCOFLUX lite
Eccentric worm-drive pump F 550 S
Three-phase motor
Flow meter FMO
Evaluation electronic FLUXTRONIC^®
Switched-mode amplifier
For the application designed accessories on request

Application description:
Our VISCOFLUX lite drum emptying system will be placed directly on the surface of the grease in the open drum. Next, our F 550 S eccentric worm-drive pump will be attached via a crossbeam. Filling can begin immediately after the motor is put on. The follower plate skims the grease cleanly from the drum wall. In this way, after emptying completely, residue of less than 1% remains in the drum.

The required volume can be predefined with the additional use of our FLUXTRONIC^® evaluation electronic plus FMO flow meter and switched-mode amplifier. This volume can then be filled automatically at the push of a button. Our VISCOFLUX lite drum-emptying system is ideal for quickly and easily decanting high-viscosity media and high-quality or air-sensitive substances, with no pulsations.

Overall, the filling is extremely economical: there is no need to warm the medium, only tiny amount of residue remains in the drum and all system components can be cleaned quickly.

Task:
Various boot polishes require filling into drums from different mixing vessels in a way that is quicker and more cost effective than manual removal.

Solution:
Drum pump F 430 S with mechanical seal
Commutator motor F 460-1
For the application designed accessories on request

Application description:
Our drum pumps are perfect for filling low-viscosity media, e.g. boot polishes, and other applications as a quick and simple alternative to manual filling – especially the FLUX drum pump F 430 S in stainless steel with mechanical seal.

The mechanical seal on the shaft prevents the medium from being dispersed. This means that the drum pump can be used for different polishes or media one after the other with a minimal amount of cleaning.

To remove the medium, the drum pump – at immersion depths of up to 118 in – is simply placed in the mixing vessel and the polish is pumped via a hose into a drum or other container.

Task:
Calcium hydroxide requires decanting from IBCs and dispensing into various wastewater tanks. A flow rate of approx. 15 gpm is required by the customer. Due to the abrasive nature of calcium hydroxide, the wear on a previously used centrifugal pump was too much for the pump to handle. The air-operated diaphragm pump RFM 25 stands up to abrasive media very well and is well-suited to handle calcium hydroxide.

Solution:
Air-operated diaphragm pump RFM 25 with flap valves
Suction tube with IBC cover
Pressure reducer
For the application designed accessories on request

Application description:
Wastewater from production is collected in a tank and then requires neutralizing with calcium hydroxide.

The calcium hydroxide is now supplied by our RFM 25 air-operated diaphragm pump. Our air-operated diaphragm pumps are self-priming and safe in dry operation.

In this case, the RFM 25 was equipped with flap valves. This is an advantage for abrasive media, such as calcium hydroxide. With its solid construction, our RFM series air-operated diaphragm pump is made from highly resilient materials and has extremely low shear forces, meaning that the wear has been significantly reduced.

Task:
Various silicone oils with a viscosity of up to 12,500 cPs require filling into sealed containers from 55 gal drums. In doing so, a height of 32 feet must be overcome.

Customer's requirements:
- Flow rate: min. 5 gpm
- Mobile use required

Solution:
Eccentric worm-drive pump F 550 GS 
Commutator motor F 458-1 
Overflow valve
Hose and hose sleeve
For the application designed accessories on request

Application description:
The F 550 GS model FLUX eccentric worm-drive pumps are outstanding for high-viscosity media such as silicone oil with a viscosity of up to 30,000 cPs. Their specific gearboxes make them suitable for a lightweight AC motor, making mobile use and simple operation possible.

Simply insert the eccentric worm-drive pump into the drum and filling can begin.

With positive displacement pumps, counter-pressures of up to 8 bars are possible making the 32 foot delivery head and pump capacity of min. 5 gpm required here easily achievable.

An overflow valve can be fitted to the eccentric worm-drive pump. This makes it possible to push the end of the hose off while the pump is running without critical pressures occurring in the pump/hose system.

Task:
Various cooling lubricants require filling into smaller containers from an IBC at a flow rate of approx. 21 gpm. The liquid needs to be mixed continually.

Solution:
Drum pump F 426 for mixing and/or pumping
Commutator motor F 457-1 EL 
Hose and pump nozzles
For the application designed accessories on request

Application description:
FLUX drum pumps are ideal for low-viscosity media such as cooling lubricants. Our F 426 drum pump is the perfect solution for cases like this where the medium needs to be mixed and/or pumped.

The F 426 drum pump is recommended for the mixing and/or pumping of diverse media. It enables media prone to rapid separation to be kept in motion even during the pumping process.

The transition between "Mix" and "Pump" is performed seamlessly by activating a control lever which can even be changed during operation. This makes it possible to switch easily between the filling and mixing process.

With the F 426 drum pump, the cooling lubricants are filled into smaller containers from the IBC and are then mixed for a certain period of time to ensure that the medium is kept moving.

Task:
For component testing by a large automotive group, various vehicles require refueling for test purposes.

Solution:
Drum pump F/FP 425 Ex for 99.98% drum emptying
Commutator motor F 460 Ex 
Flow meter FMC 100 
Chemical hose
Pump nozzle
For the application designed accessories on request

Application description:
To test the suitability of individual components, various vehicles will be refueled from 55 gal standard drums with different special fuels and country-specific special fuels. Consumption and emission measurements are taken at the same time.

Our 400 series drum pumps are perfect for low-viscosity and highly flammable media such as fuels. Our F/FP 425 stainless steel drum pump is tailor made for areas subject to explosion hazards. The FLUX F/FP 425F 425 drum pump ensures 99.98% drum emptying. The non-return device on the pump prevents the medium from flowing back into the emptied drum. This means that for a 55 gal drum, residues of less than 0.01 gal are ensured and, thanks to optimal product use, so are reduced drum cleaning and waste disposal costs.

The filling process is performed with maximum precision and the greatest possible safety with the FMC 100 flow meter, constructed based on the disk type displacement principle and equipped with FLUXTRONIC^® evaluation electronics. An additional switched-mode amplifier ensures that predefined quantities of the various fuels can be filled in a semi-automated manner.

Operators set the desired flow rate and can fill the vehicle with the medium in question at the push of a button. Once the specified fill quantity is reached, the drum pump turns off automatically. This process can be repeated continuously.

Task:
Different small quantities of transmission oils require filling into gearboxes directly in predefined quantities.

Solution:
Drum pump F 430 S with mechanical seal
Commutator motor F 457 
Flow meter FMO 102 
FLUXTRONIC^® evaluation electronics
FSV 100 switched-mode amplifier
For the application designed accessories on request

Application description:
Prior to introducing our drum pumps, the transmission oil was filled in the gearboxes by hand using oil cans but this often lacked speed.

Our F 430 S drum pumps with mechanical seal are now used. These are ideal for low-viscosity media. The mechanical seal prevents the medium from being dispersed. This means that the drum pump can be used for vastly different media one after another.

Each workstation has been equipped with a semi-automatic filling system specially designed for the application in question. This consists of drum pump, motor, flow meter, FLUXTRONIC^® evaluation electronics, switched-mode amplifier and solenoid valve. Each employee can now fill the predefined quantity automatically at the push of a button via the external evaluation electronics. After the filling process, the drum pump turns off automatically and the process can be repeated. This prevents over and underfilling.