Using Elcometer KARA 30/40/40A Correctly: Flow Rate, Basic Settings, Troubleshooting
For stable material supply in coating processes – including reference settings from the manual, professional workflow, and maintenance checklist.
The Elcometer KARA double diaphragm transfer pumps are designed for low-pressure material delivery – e.g., from containers to a target vessel or for the material supply of a spray gun. Typically, you benefit from a uniform material flow and a robust construction for water- and solvent-based media (abrasive media also possible depending on the variant).
- Fewer downtimes: clean start-up, venting/purging, and a clear shutdown/cleaning routine
- Better process stability: appropriate hose/filter selection and not "cranking up" pressure when the nozzle/passage is limited
- Longer service life: correct depressurization + consistent cleaning after use
Graphic: Part number overview (for quick identification in purchasing/service).
Product Overview: KARA 30 vs. KARA 40 vs. KARA 40A (Applications & Advantages)
| Model | Typical Use | Performance Guidelines | Wetted Parts (WET) – Key Difference |
|---|---|---|---|
| KARA 30 | Compact for transfer/supply with water- & solvent-based media | Max. Free Flow: 30 l/min; Max. Air: 6 bar; Fluid Working Pressure: 6 bar | Seats/Balls: Stainless Steel; Diaphragm: Polyethylene |
| KARA 40 | Higher throughput for longer lines/multiple extraction points (process dependent) | Max. Free Flow: 40 l/min; Max. Air: 7 bar; Fluid Working Pressure: 7 bar | Seats: Polypropylene; Balls: PTFE; Diaphragm: PTFE |
| KARA 40A | For abrasive media (e.g., ceramic-based/pigment-rich materials) – more wear-resistant design | Max. Free Flow: 40 l/min; Max. Air: 7 bar; Fluid Working Pressure: 7 bar | Seats/Balls: Stainless Steel; Diaphragm: PTFE |
Note: Performance values are technical specifications under test conditions (e.g., "water as test medium") and should be understood as guidelines in practice – viscosity, hose length/diameter, and filters influence actual throughput.
Go directly to the matching model
Choose based on throughput requirements and material type (standard vs. abrasive):
Recommended Basic Settings (Derived from manual – as guidelines)
The following values are practical guidelines from the processes described in the manual – in reality, viscosity, hose length/diameter, and filter condition strongly affect the result.
- Depressurization/Relief: Set the product pressure regulator so that the gauge shows approx. 0.5–1 bar (if present).
- Venting/Purging (Startup with Gun): After starting, let the product run through the return/flush line for approx. 30 seconds to remove air from the pump.
- Cleaning after Transfer: Typically set air pressure for flushing to 2–2.5 bar (guideline from cleaning procedure).
- Cleaning after Application (Spray Gun): Use a product pressure of around 1 bar as a guideline during the process until clean solvent/cleaner flow is achieved.
Important: "More pressure" does not automatically mean "more process stability." The manual warns that excessive product pressure increases wear and wastes material – check passage/nozzle/filter first.
Pro Workflow (5–7 steps): Stable Start to Clean Shutdown
- Start Safely & Cleanly: Check grounding/anti-static hoses, check connections for leaks, ensure suction strainer/filter is clean.
- Prepare Material: Mix and filter material according to manufacturer instructions; keep an eye on viscosity (manual recommends viscosity control).
- Transfer Operation: Securely mount the suction, place the outlet hose safely in the target container, then open the air supply and increase the air regulator step-by-step until the material is suctioned cleanly and desired speed is reached.
- Application with Gun (if used): Open return/venting, start the pump, vent for ~30 s, then close the venting valve and bring material pressure to target value.
- Fine Adjustment instead of Pressure Orgies: If flow is too low, check nozzle/passage/filter first or increase passage before increasing working pressure further.
- Short Stop: If material does not cure: leave suction in the material and perform depressurization.
- Job End: Turn air pressure down to 0 bar, relieve the gun (trigger), then clean according to the procedure with suitable solvent/water (depending on material) until it runs "clear."
Troubleshooting (4 typical problems + actions)
- Check diaphragm and replace if defective.
- Check diaphragm screw/seal, tighten or replace.
- Tighten suction hose/fittings (avoid false air).
- Check seals on diaphragm screw, replace if necessary.
- Check air supply/air pressure and open air regulator correctly.
- Clean or replace outlet hose/filter/suction filter (including anti-pulsation filter).
- Suction hose: secure, tight, and with matching diameter (viscosity dependent).
- Check and replace distributor/slide/O-rings (seal kit).
- Check distributor plate/insert, replace if necessary.
Maintenance (5 points that really pay off)
- Before Shift Start: Check product hoses & connections for condition/leaks.
- Before Working on the Device: Always perform depressurization first and disconnect from the compressed air network.
- Keep it Clean: Regularly clean suction filter/anti-pulsation filter – contamination = pulsation/blockage/loss of performance.
- Lubrication only if necessary: The manual usually does not require greasing – exception: O-rings during repairs; if air must be lubricated: max. "one drop per minute" (suitable oil).
- Original Parts: Original spare parts are recommended for fit & operational safety.
FAQ (Practical)
Conclusion
With the right KARA variant (30/40/40A), clean grounding/anti-static hoses, consistent depressurization, and a clear cleaning routine, you get a robust, process-stable material supply. Use the mentioned guidelines as a starting point – and optimize filters/cross-sections/nozzles first before increasing pressure.
