KNIGHT OP-4FM Flush Manifold Laundry Pump Instruction Manual

: June 1, 2024
: KNIGHT

Table of Contents

KNIGHT OP-4FM Flush Manifold Laundry Pump
Product Information
Product Usage Instructions
FAQ
INTRODUCTION
PRE-INSTALLATION
MOUNTING THE MANIFOLD TO THE DISPENSER
MAINTENANCE
TROUBLESHOOTING
WARRANTY
CONTACT
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KNIGHT OP-4FM Flush Manifold Laundry Pump

Product Information

Specifications

Model: OP-4FM/6FM
Operation: Chemical dispensing with water flush
Pressure Range: 20 to 40 PSI dynamic pressure
Recommended Water Temperature: Warm or cool
Distance Range from Dispenser to Washer: Up to 100 feet

Product Usage Instructions

Pre-Installation Steps

Before mounting the manifold to the dispenser, perform a site survey including:

Location of dispenser about washer
Proximity to water source
Pressure and temperature of water source
Backflow prevention requirements
Discharge tubing path from manifold to washer
Assessment of plumbing hardware needed

Mounting the Manifold to the Dispenser

Attach mounting brackets to the pump case.
Install check valve fittings for each pump injecting into the manifold.
Connect each pump’s squeeze tube to a port on the manifold.
Mount the flush solenoid on the dispenser.
Connect flush solenoid wires to the terminals on the circuit board.
Connect the output side of the flush solenoid to the manifold input fitting using the provided tubing.

Connecting Solenoid to Water Source

Refer to the provided diagram for two options:

Option 1: Use ball valves and tee for plumbing into the water source, allowing independent shut-off.

FAQ

Q: What is the recommended distance between the dispenser and washer?
A: The dispenser should be no more than 100 feet from the washer for optimal operation.
Q: What is the ideal water pressure range for the system?
A: The system should operate at a dynamic pressure of 20 to 40 PSI for best results.

INTRODUCTION

The OP (On-Premise) Flush Manifold offers an increased level of safety for operators as well as protection against corrosion to the washer and protection against chemical burns to the fabric.
When the highly corrosive laundry chemicals are dispensed by the peristaltic pumps into the flush manifold, the unique flush mode of the control opens the built-in water solenoid to provide a diluted flush to the washer through a single injection line.
Concentrated chemicals can now be dispensed with less chemical shock to the fabrics being washed.
The built-in check valve prevents back-siphoning as well as cross-contamination of the chemicals.

THEORY OF OPERATION
After liquid chemicals are dispensed into the Flush Manifold assembly, water is injected into the manifold to “push” diluted chemistry to the washer. The delivery tube is flushed clean in a post-flush operation and is ready for the next chemical. The flush mode of the OP and OP-Plus dispensers flush chemicals “with” water as they are dispensed to the manifold and washer. Consult your dispenser programming manual for setting the flush mode.

PRE-INSTALLATION

Before mounting the manifold to the dispenser, a site survey should be performed to avoid installation problems and to identify any items that will be needed to complete the task. You may also wish to read through the rest of this manual to get familiar with the installation steps. Your site survey should include the following:

Location of a dispenser concerning the washer — The dispenser can be located at the washer or remotely located with the chemical supplies. The dispenser should be no more than 100’ from the washer.
Determine proximity to water source — the water source should be as close to the dispenser as possible.
Pressure and temperature of the water source — the system should operate at 20 to 40 PSI dynamic pressure. Warm or cool water temperatures are recommended for best results.
Backflow prevention — local codes may require vacuum breakers or other safeguards for backflow prevention.
Discharge tubing path from manifold to washer.
Assessment of plumbing hardware required to connect the system — this will help identify what hardware is required, based on how you choose to plumb the system.

MOUNTING THE MANIFOLD TO THE DISPENSER

The diagrams on page 3 can be used as a reference for the following installation steps.

Attach the two mounting brackets to the bottom of the pump case using provided screws. For retrofitting to an older style case, a single bracket (available from Knight) is used instead of the two-end brackets.
One check-valve fitting is required for each pump that will be injected into the manifold. Plugs are provided with some manifolds to block off unused ports. Use a wrap of plumbing tape over the threads to help avoid leakage.
Connect each pump’s squeeze tube directly to a port on the manifold (pull down on the output side of the tube to create slack). Cinch a cable tie around each connection to prevent leakage.
Remove the label from the left side of the dispenser and mount the flush solenoid using screws and nuts provided. For 6 -pump applications, the solenoid mounts through the bottom of the pump case.
Connect the flush solenoid wires to the terminals marked “FLUSH PUMP” on the circuit board in the OP or OPPlus dispenser — refer to the wiring diagram in the dispenser’s instruction manual for more information.
Connect the output side of the flush solenoid to the input fitting on the manifold using the 1/4″ tubing provided.

CONNECTING SOLENOID TO WATER SOURCE
Refer to the diagram above for an illustration of the following two options.

OPTION 1: Ball valves and a “tee” can be used to plumb into the water source. This permits shutting off the entire water source, or just the water to the manifold independently.
OPTION 2: Using a “Y” valve allows a single hose to feed both the solenoid and the water inlet to the washer.

KNIGHT-OP-4FM-Flush-Manifold-Laundry-Pump-FIG-1

ROUTING MANIFOLD DISCHARGE TO WASHER
For best results, keep the distance between the manifold and the washer as short as possible. Avoid long vertical climbs that may require increased water pressure and/or lengthy flush time. 1/2″ ID tubing will be required, and the connection to the barbed output fitting on the manifold should be secured with either a cable tie or a hose clamp. If using the optional “Flow Switch”, ensure that it is connected within a few inches from the outlet of the manifold. The switch includes barbed fittings to accommodate the 1/2″ ID line. See the wiring diagram included in the dispenser’s instruction manual for connecting the wires from the switch to the circuit board. Be sure to remove any jumper wires or shunt jumpers from the circuit board if using the flow switch.

MAINTENANCE

Routine inspection and maintenance of the flush manifold will ensure that it continues to provide trouble-free operation.
Each time you visit the installation, check all hose and tubing connections for leaks or obstructions. In areas that have hard water, deposits can build up inside the flush solenoid, checkvalves, and manifold.
Also, check the flush line for obstructions or wear.
Check that chemicals are flushing completely to the washer.
Check valves are like pump squeeze tubes in that they do wear over time.
Checkvalves should be inspected on each service call to determine proper checking action and positive flow.
The checkvalve has an internal PTFE ball and Viton seal — it is the user’s responsibility to evaluate the proper compatibility of laundry products to these checkvalves.
Knight is not responsible for any damage resulting from product use or misuse.
The customer should determine a reasonable change-out interval for checkvalves to ensure proper performance and prevent chemical cross-contamination or damage to lines.

KNIGHT-OP-4FM-Flush-Manifold-Laundry-Pump-FIG-2

TROUBLESHOOTING

Flush water flowing constantly

Turn off power to the dispenser — if the flush stops, the problem is related to the pump circuit board.
If the flush does not stop with the power off, then the problem is mechanical — may be debris or blockage inside the solenoid assembly, or may be a problem with the diaphragm inside the solenoid.

Flush water does not flow

Check to see if a “flush error” has happened — refer to the dispenser’s instruction manual for details.
Check dispenser programming to ensure that a flush pump volume is called for on each formula used.
Check the solenoid coil to verify that it is receiving voltage from the dispenser.
Check incoming water source for adequate pressure.
Check for obstructions or debris inside the solenoid (around the diaphragm) and in the manifold output line.

Flush errors keep happening

Check “Proof of Flow Switch” (if used) for correct operation — this can be done with a continuity tester or multimeter by verifying that the switch makes contact across its 2 wires when water flows through.
Check for a “jumper” wire (or shunt jumper) if the flow switch is not used. The jumper connects the necessary terminals on the circuit board — refer to the wiring diagram included in the dispenser’s instruction manual.

Pumps do not dispense chemicals into the manifold

Check the pump’s checkvalve fitting on the manifold — if it appears clogged, soak it in warm water to clean, or replace checkvalve.
Check for correct pump operation per troubleshooting tips in dispenser’s instruction manual.
Check the water pressure to manifold — pressure must be less than 40 PSI (dynamic).

DISCLAIMER
Knight LLC does not accept responsibility for the mishandling, misuse, or non- performance of the described items when used for purposes other than those specified in the instructions. For hazardous materials information consult label, MSDS, or Knight LLC. Knight products are not for use in potentially explosive environments. Any use of our equipment in such an environment is at the risk of the user, Knight does not accept any liability in such circumstances.

WARRANTY

All Knight controls and pump systems are warranted against defects in material and workmanship for ONE year. All electronic control boards have a TWO-year warranty. Warranty applies only to the replacement or repair of such parts when returned to the factory with a Knight Return Authorization (KRA) number, freight prepaid, and found to be defective upon factory-authorized inspection. Bearings and pump seals or rubber and synthetic rubber parts such as “O” rings, diaphragms, squeeze tubing, and gaskets are considered expendable and are not covered under warranty. The warranty does not cover liability resulting from the performance of this equipment nor the labour to replace this equipment. Product abuse or misuse voids warranty.

FOOTNOTE
The information and specifications included in this publication were in effect at the time of approval for printing. Knight, LLC reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatsoever.