LCM_IOM revD - Depco Pump Company
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1. o re FULOJAFEEDEAR A Unit of IDEX Corporation gt NeCAtea U ia Series M cd Installation Operation amp Maintenance Instruction Bulletin IOM PN LCM 0403 D ENGINEERED PUMP OPERATIONS HM YAPULSAFEEUER 2883 Brighton Henrietta Townline Road A Unit of IDEX Corporation Rochester New York 14623 Telephone 585 292 8000 Fax 585 424 5619 Manufacturers of Quality Pumps www pulsa com Controls and Systems Pulsafeeder Factory Service Policy Should you experience a problem with your Pulsafeeder pump first consult the troubleshooting guide in your operation and maintenance manual If the problem is not covered or cannot be solved please contact your local Pulsafeeder Sales Representative or our Technical Services Department for further assistance Trained technicians are available to diagnose your problem and arrange a solution Solutions may include purchase of replacement parts or returning the unit to the factory for inspection and repair All returns require a Return Authorization number to be issued by Pulsafeeder Parts purchased to correct a warranty issue may be credited after an examination of original parts by Pulsafeeder Warranty parts returned as defective which test good will be sent back freight collect No credit will be issued on any replacement electronic parts Any modifications or out of warranty repairs will be subject to bench fees and costs associated with2. a CONSULT FACTORY 25 NPT FEM DISCHARGE PORT T 7 51 25 LEM SUCTION PORT ALL OIMENSIONS ARE INCHES DIMENSIONAL DwG SMALL MECHANICAL PUMP SECT 1ON PAGL EFFECTIVE SUPERSEDES AJ ADD HISSING OMS Rer REVISION UPOATE gare LI2 Small Mechanical Pump Dimensional Diagram 18 4X 0 26 THRU FOUNDATION MOUNTING HOLES CONSULT FACTORY 50 NPT FEM DISCHARGE PORT ALL _OIMENSIONS ARE IN INCHES i A o CEK Corpora DIMENSIONAL DWG MED MECHANICAL PUMP ew S6C FR EXTERNAL 220 MISSING Dr 12 05 00 DwN BY e eo Dare DATE 03 19 00 21762 001 LI4 Medium Mechanical Pump Dimensional Diagram 19 12 Parts Diagrams and Parts Lists LI2 MECHANICAL PUMP ISOMETRIC 00280 000 DATE 02720701 NPT MAT L BSPT MAT L MOTOR FR ITEM DESCRIPTION OTY PART NUMDER 316 CWC 316 56E 63 1 SUPPORT PLATE NF 140054 HB5 2 DIAPHRAGM NP 1 0U39 AT 3 REAGENT HEAD MP 160054 316 BDLT WP990426 304 5 FLT WASHER NP99 1017 304 O RING 1 1801300 7 DISCHARGE assy L3200TE4 PYE 314 7 DISCHARGE ASSY L32BOTC4 PVC 318 8 SUCTION ASSY L31Q0TC4 316 8 SUCTION VLV ASSY L31BOTCA4 PVC 316 RETURN SPRING
3. NP420633 000 37 GEAR BOX GASKETrwor sic NP460046 000 an SET 774004 022 ag NEEDLE BEARING NP400046 000 45 KEY WORM GEAR rwer sawn Ww 75087 904 41 ECCENTRIC SPACER 470031 000 4z GASKET NP460047 000 23 SCREW 990008 5 44 DIL SEAL NP450029 000 45 PIPE PLUG ENDT SHOWN w772565 5TL 7 1 1 4 2 2 1 1 1 1 1 10 BASE 1 NP88001 3 000 11 BOLT 4 INP990414 108 12 STHADDLE ASSEMBLY 1 410066 000 13 BEARING 1_ 7 000 14 1 MPa70ni3 nnn 15 HEAR ING 1 NP400041 000 16 THHUST WASHER 2 NPa70U33 000 17 WORM 11 1 1 206961 000 20 1 1 0568655 000 40 1 1 wn47022 000 18 SCREW 1 770270 5 18 BASKET 1 460043 000 20 SIDE COVER 1 NP250060 STL 24 HDI T 4 NP990414 18R 22 GEAR 11 1 w206446 017 20 1 W206248 020 40 1 W206446 040 THRUST WASHER 7 MPz70025 000 24 ECCENTRIC SHAFT 1 419094 000 25 BEARING 2 400039 000 26 STRK AD ASSEMBLY 4 NP26001 1 000 27 KNOB 1 NP260001 EPE 28 KNOB COVER 4 Ne25006 1 900 29 SCREW W77100 070 30 LABEL 1 550084 000 31 WASHER 1 271000 5 12 MDTOR ARSY TAC 1 490022 0 MDTOR ADAPT ASSY 63 1 NPA4SDC24 DUD 33 WUHM SHAF ASSI 11 1 NPU60U31 20 1 1 A20 20 40 1 1 MP060031 A40 C40 34 GEARBOX 4 MP 40025 STL 3
4. Gear Ratio Maximum Flow Piston Diameter Maximum Pressure KOPKit All the above information can be obtained from the pump nameplate Refer to the Pump Specification Data Sheet for additional information Date Serviced By Maintenance Performed 25 IIMPULSAFEEDER e A Unit of IDEX Corporation ale Engineered Pump Operations 2883 Brighton Henrietta Townline Road Rochester NY 14623 Telephone 585 292 8000 Fax 585 424 5619 http www pulsa com pulsa idexcorp com 26 VIKING PUMP WARREN RUPP PULSAFEEDER LIQUID CONTROLS 05 2004 Bulletin IOM PN LCM 0403 Rev D
5. 39 30 Metal 4 M6 1 0 3 39 30 Model LI4 Torque Bolts and size N m In Lbs Plastic 4 M8 1 25 6 77 60 Metal 4 M8 1 25 6 77 60 6 2 Output Adjustment All PULSAtron Series M pumps have a hand wheel for manual stroke adjustment The hand wheel can be adjusted at any point from 0 to 100 stroke setting Turn the lock screw counterclockwise to release the stroke lock us LOCK SCREW Adjust the hand wheel to the desired output a The stroke barrel indicates stroke length in 20 90 e STROKE BARREL increments HAND WHEEL b The hand wheel indicates stroke length in 196 increments To set the pump to 75 stroke length starting from the factory default setting of 096 turn the hand wheel counter clockwise until he 6046 indicator is visible on the stroke barrel Continue the counter clockwise rotation until the hand wheel indicator is at 15 Refer to the drawing on the right side of the page Turn the lock screw clockwise to lock the stroke adjustment into position Figure 2 Adjustments can be made while the pump is at rest or operating although adjustments are easier to make while the pump is in operation 6 3 Priming the Reagent Head me meom When handling process liquids follow all applicable personal and facility safety guidelines Ensure that the pump is ready for operation and that all process connections are secure Open the suction and discharge line shutoff valv
6. PROCESS FLUID MAY HAVE CONTAMINATED THE PUMP ECCENTRIC HOUSING ALTHOUGH NORMALLY ANY PROCESS FLUID BEHIND A FAILED DIAPHRAGM WOULD PASS THROUGH THE BOTTOM DRAIN HOLE HANDLE WITH APPROPRIATE CARE WARNING Item Description Qty 1 Discharge Check Valve Assembly 1 Diaphragm 1 i Suction Check Valve Assembly 1 Flat Washer 4 4 2 Hex Head Bolt O Ring ofn ala PI Figure 5 PULSAtron Series M diaphragms do not have a specific cycle life however the accumulation of foreign material or debris sufficient to deform the diaphragm can eventually cause failure Failure can also occur as a result of system over pressure or chemical attack Periodic diaphragm inspection and replacement are recommended 7 2 1 1 2 Diaphragm Removal amp Reinstallation Adjust the stroke setting to 5096 and disconnect the power source to the drive motor Relieve all pressure from the piping system Take all precautions described under the WARNING on the previous page to prevent environmental damage and exposure of personnel to hazardous materials 10 1 12 14 Close the inlet and outlet shutoff valves Place a pan underneath the pump head adaptor to catch any liquid leakage Disconnect piping to the reagent head and drain any process liquid following material safety precautions described Remove all but one top reagent head bolt Product will leak out between the pump head adap
7. replacement parts Safety Considerations 1 Read and understand all related instructions and documentation before attempting to install or maintain this equipment 2 Observe all special instructions notes and cautions 3 Act with care and exercise good common sense and judgment during all installation adjustment and maintenance procedures 4 Ensure that all safety and work procedures and standards that are applicable to your company and facility are followed during the installation maintenance and operation of this equipment Copyright 2004 Pulsafeeder Inc All rights reserved Information in this document is subject to change without notice No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or any means electronic or mechanical including photocopying and recording for any purpose other than the purchaser s personal use without the written permission of Pulsafeeder Inc ii Table of Contents 1 INTRODUCTION 2 PRINCIPLES OF OPERATION 2 1 Overall Operation 2 2 Reagent Head Assembly 2 3 Control Assembly 2 4 Gear Ratio Assembly 3 EQUIPMENT INSPECTION 4 STORAGE 4 1 1 Short Term 4 1 2 Long Term 5 INSTALLATION 5 1 Location 5 2 Piping System 5 3 Suction Pressure Requirements 5 4 Discharge Pressure Requirements 6 EQUIPMENT STARTUP 6 1 Fastener Inspect 6 2 Output Adjustment 6 3 Priming the Reagent He
8. 5 TAG shown 17 550086 000 36 TAG SCREW tor 4 2710 0 188 1 1 1 1 1 4 1 1 46 WASHER 771011 8 DENOTES RECOMMENDED SPARE PARTS ADDED SPT CORRECTED 7 8 P N 05 05 52 REF REVISION UPDATE DATE ALL TONS ARE IN INCHES LIZ MECHANICAL PUMP ISOMETRIC BILL OF MATERIAL Dwi BY DATE 02 20 91 AN0028 1 000 21 LI4 MECHANICAL PUMP ISOMETRIC DATE 02 21 01 00282 000 MAT L BSPT MAT L MOTOR FR PART NUMBER PVC 316 PVC 316 56C 71 NP140055 8RS TEM DESCRIPTION 2 1 SUPPORT PLATE 2 DI AFHRAGM NP170031 THT 3 REAGENT HEAD 160055 315 amp BOLT 980436 304 5 FLT WASHER NPS 1019 304 7 VALVE CONN KIT DISCH NP32BVC8 PVE 7 VALVE CONN KIT DISCH NP32BRAAG 316 7 VALVE CONN KIT DISCH NP32PVvC amp PVE 7 e VALVE CONN DISCH 2 316 B VALVE CONN KIT SUCT NP318VC PVC 8 VALVE LONN KIT SUCT MP31B A8 316 VALYE CONN KIT SUCT NP31PVC8 VENG amp VALVE CONN KIT SUCT NPS 1 8 315 RETURN SPRING NP430044 000 10 BASE NP580013 20 0 11 BOLT NP990415 198 12 STRADDLE ASSEMBLY NP4 10067 0900 13 BEARING 400038 200 14 E
9. 6 000 to both sides of the thrust washer and install onto the eccentric shaft On the LI4 models the washer fits into a shallow counter bore 2 Assemble Worm Gear Item 8 and key Item 10 to the eccentric shaft Do not tighten the set screw yet 3 Thread a M6 1 0 screw into the threaded hole in the end of the eccentric shaft Tighten the Worm Gear set screw while simultaneously pulling on the screw in the end of the shaft in order to eliminate any endplay in the eccentric shaft 4 Rotate the Worm Gear It should turn easily with no perceptible endplay 5 Remove the screw that was inserted in the shaft in step 3 Assemble and install the worm shaft assembly a If you have a LI2 model Apply PULSAlube grease NP980006 000 to the two lips of the worm shaft seal Apply PULSAlube grease NP980006 000 to the small end of the worm shaft Carefully insert the worm shaft into the pump housing Assemble the lower thrust bearing with a washer on each side into the shallow counter bore in the bottom of the housing cavity Fit the shaft into the bearing in the housing b If you have a LI4 model Apply PULSAlube grease NP980006 000 to the small end of the worm shaft Insert the worm shaft into the pump housing fitting the end of the shaft into the bearing in the housing Apply PULSAlube grease NP980006 000 to the two lips of the seal Assemble the adapter to the pump housing while carefully slipping the seal over the worm shaft 7 Fill the g
10. All metering pumps must be calibrated to accurately specify stroke length settings for required flow rates A typical calibration chart is shown above Although output is linear with respect to stroke length setting an increase in discharge pressure decreases output uniformly describing a series of parallel lines one for each pressure only two are shown The theoretical output flow rate at atmospheric discharge pressure is based on the displacement of the diaphragm stroke length and the stroking rate of the pump With increasing discharge pressure there is a corresponding decrease in output flow Pumps are rated for a certain flow at a rated pressure check nameplate Whenever possible calibration should be performed under actual process conditions i e the same or a similar process liquid at system operating pressure To construct a calibration chart measure the flow rate several times at three or more stroke settings i e 25 50 75 and 100 plot these values on linear graph paper and draw a best fit line through the points For stable conditions this line should predict settings to attain required outputs 7T Maintenance A WARNING BEFORE PERFORMING ANY MAINTENANCE REQUIRING REAGENT HEAD OR VALVE WET END DISASSEMBLY BE SURE TO RELIEVE PRESSURE FROM THE PIPING SYSTEM AND WHERE HAZARDOUS PROCESS MATERIALS ARE INVOLVED RENDER THE PUMP SAFE TO PERSONNEL AND THE ENVIRONMENT BY CLEANING AND CHEMICALLY NEUTRALIZING AS APPRO
11. CCENTRIC NPO OO 14 900 15 BEARING NP400042 000 16 17 WORM 19 5 W208764 O10 13 1 W208764 015 30 1 wW208762 030 18 SCREW 770010 57 19 GASKET 0050 000 20 CAVER MP250062 STL 21 BOLT MP9904 14 188 22 GEAR 19 1 W208765 010 15 1 208795 015 30 1 208785 030 23 THRUST WASHER NP470030 000 24 ECCENTRIC SHAFT 23 BEARING 26 STRE ADJ ASSEMBLY MP4 10055 000 NP400040 200 NP260011 900 27 KNOB NP260001 GPC 28 KNOB COVER MP250061 200 29 SCREW w77 1001 010 30 LABEL NP550084 000 31 WASHER W7 1006 STL 32 MOTOR ADAPT ASSY 55C MOTOR ADAPT ASSY 71 NP499023 900 NP 90025 200 35 WORM SHAFT ASST 10 1 MPU6UU32 A10 B10 13 1 NP060032 A15 B15 30 1 NP 60032 A30 B3 0 34 GEARBOX NPO10021 STL 35 TAG ANOT 550086 200 36 MAME TAG SCREW suowon wW771900 188 Sr GEAR 5 shown 4 580044 200 36 SET SCREW 2 771004 022 40 KEY WORM GEAR shouni 1 W7735098 005 41 RETAINING RING 1 NP899032 STL 42 GASKET 7 MP4 0047 2300 A3 SCREW 2 NP990008 STA 44 211 SEAL NP450029 000 ALL DIMENSIONS ARE IM INCHES FINDEN DENOTES RECOMMENDED SPARE PARTS RILL DP MATERIAL Apc RATE ERE moine 23 24 13 Maintenance Log Pump Model Serial
12. Head Bolt Side Cover Gasket Worm Gear Socket Head Screw Key E des s 14 Worm Shaft Assembly Shown Figure 8 Remove the four socket head screws Item 1 that attach the motor adaptor Item 2 to the pump housing and remove the adaptor Loosen and remove the Hex Head Bolts Item 5 and remove the pump side cover Item 6 and gasket Item 7 pump housing On LI2 Modes be careful not to lose the lower Remove the Worm Shaft Assembly Item 4 by carefully pulling it straight up out of the X LI2 Worm Shaft Assembl thrust bearing and washers Item 11 amp 12 X Loosen the set screw Item 9 on the worm item Description gear Item 8 and remove it along with its shaft 4 Worm Shaft Assembly 1 key Item 10 31 Thrust Washer 2 12 Thrust Bearing 1 If you have the LI2 model go to step 8 If you have the model go to step 9 Remove the Thrust Washers and Bearing Item 11 amp 12 from the housing If the Thrust Washers show signs of excessive wear or scoring replace them during re assembly Figure 9 Clean grease from the gear cavity Examine the Worm Shaft Grease Seal Item 3 in the pump housing on an LI2 model or in the motor adaptor on LI4 models If the Grease Seal shows excessive wear or damage replace it during re assembly 12 7 6 Gearset Replacement 1 Apply PULSAlube grease NP98000
13. If this requirement is not met the pump will not provide reliable accurate flow In suction lift conditions the use of a foot valve is recommended at the lowest point of the pickup tube or pipe Pumps under suction lift conditions may require some liquid priming before they will operate reliably Discharge Pressure Requirements All PULSAtron Series M Metering Pumps are designed for continuous service at the rated discharge pressure If system suction pressure exceeds discharge pressure a condition sometimes described as pumping downhill flow would be generated siphoning in addition to that caused by the pump This results in a reduction in accuracy and loss of control over the metering process To prevent this condition commonly referred to as flow through the discharge pressure must exceed suction pressure by at least 0 35 Bar or 5 psi This can be achieved where necessary by the installation of a backpressure valve in the discharge line 6 Equipment Startup 6 1 Fastener Inspection All pump fasteners should be checked prior to pump operation This would include reagent head mounting bolts motor mounting bolts and the hardware that secures the pump to its foundation Most hardware can be checked simply to ensure it is not loose However utilize the following values when checking reagent head bolt torque Head Bolts Model LI2 Torque Bolts and size N m In Lbs Plastic 4 M6 1 0 3
14. NP170001 THY or W210221 001 14 9 Troubleshooting Difficulty Probable Cause Remedy Pump does not start Faulty power source Check power source Blown fuse circuit breaker Replace eliminate overload Broken wire Locate and repair Wired improperly Check diagram Pipe line blockage Open valves No delivery Motor not running Check power source Check wiring diagram Supply tank empty Fill tank Lines clogged Clean and flush Closed line valves Open valves Ball check valves held open with solids Clean inspect Vapor lock cavitation Increase suction pressure Prime lost Re prime check for leak Strainer clogged Remove and clean Replace screen if necessary Stroke Adjustment set at zero Increase strike length setting Low delivery Motor speed too low Check voltages frequency wiring and Terminal connections Check nameplate vs Specifications Check valves worn or dirty Clean replace if damaged Calibration system error Evaluate and correct Product viscosity too high Lower viscosity by increasing product temperature Increase pump and or piping size Product cavitating Increase suction pressure Cool product as necessary Delivery gradually Check valve leakage Clean replace if damaged drops Leak in suction line Locate and correct Strainer fouled Clean or replace screen Product change Check viscosity
15. PRIATE WEAR PROTECTIVE CLOTHING AND EQUIPMENT AS AP PROPRIATE Accurate records from the early stages of pump operation will indicate the type and levels of required maintenance A preventative maintenance program based on such records will minimize operational problems It is not possible to forecast the lives of wetted parts such as diaphragms and check valves Since corrosion rates and operational conditions affect functional material life each metering pump must be considered according to its particular service conditions 7 1 PULSAtron Series M KOPkits contain all replacement parts normally used in a preventative maintenance program It is recommended that KOPkits and PULSAlube grease be kept available at all times Lubrication PULSAtron Series M pumps are supplied completely lubricated from the factory For optimum pump performance gear grease should be redistributed every 500 hours Disconnect the power source to the drive motor and relieve all pressure from the piping system Remove the side cover from the pump Refer to Figure 4 Redistribute grease onto gear and worm teeth On LI2 pumps force grease into the hole in the end of the gear shaft using a screwdriver or putty knife Replace the side gasket and cover lt Side Cover Gasket Primary Lubrication Points Figure 4 7 7 2 Wet End Removal Inspection amp Reinstallation IF THE DIAPHRAGM HAS FAILED
16. Supply tank vent plugged Unplug vent Delivery erratic Leakinsucionlin Locatandcomect SCS Product cavitating Increase suction pressure Entrained air or gas in product Consult factory for suggested venting Motor speed erratic Check voltage and frequency Fouled check valves Clean replace if necessary Delivery higher than Suction pressure higher than discharge Install back pressure valve or consult rated pressure factory for piping recommendations Discharge piping too small Increase pipe size install Pulsation dampener at pump in discharge line Back pressure valve set too low Increase setting Back pressure valve leaks Repair clean or replace 15 Difficulty Probable Cause Remedy Noisy gearing Discharge pressure too high Reduce pressure knocking Water hammer Install Pulsation dampener Stroke length at partial setting Nondestructive knocking is characteristic of lost motion pumps Low grease level Add or replace grease Piping noisy Pipe size too small Increase size of piping install Pulsation dampener Pipe runs too long Install Pulsation dampener in line Surge chambers flooded Replace with air or inert gas If a Pulsation dampener is installed replace diaphragm and recharge No surge chambers used Install Pulsation dampeners Motor overheats Pump overloaded Check operating conditions against pump design High or low voltage Check powe
17. ad 6 4 Calibration 7 MAINTENANCE 7 1 Lubrication m 7 2 Wet End Removal Inspection amp Reinstallation 7 2 1 Diaphragm Removal amp Reinstallation 7 8 Check Valves 7 3 1 General Description 7 3 2 Check Valve Removal amp R 7 4 Motor Removal amp Reinstallation 7 5 Gearset Removal 7 6 Gearset Replacement 8 REPLACEMENT PARTS 8 1 KOPkit Program 8 2 Ordering KOPkits or Parts 9 TROUBLESHOOTING 10 PIPING ACCESSORIES 11 DIMENSIONAL DRAWINGS 12 PARTS DIAGRAMS AND PARTS LISTS 13 MAINTENANCELOG iii iv 1 Introduction PULSAtron Series M metering pumps are positive displacement reciprocating pumps Each pump consists of a power end and a process end separated by a mechanically operated diaphragm Individual pumps will vary in appearance due to various liquid ends and accessories however the basic principles of operation remain the same 2 Principles Of Operation 2 1 Overall Operation x x Sucton Stoke Dacharge Sore Figure 1 A diaphragm reciprocates at a preset stroke length displacing an exact volume of process fluid Diaphragm retraction causes the product to enter through the suction check valve Diaphragm advance causes the discharge of an equal amount of the product through the discharge check valve 2 2 Reagent Head Assembly The typical reagent head assembly consists of reagent head diaphragm and suction and discharge cartrid
18. alves for isolation while not in use Piping weight must not be supported by valve housings or other portions of the reagent head as the resulting stresses can cause leaks If appropriate provide for thermal expansion and contraction so that no excess force or moments are applied to the pump When making process connections ensure that the check valve assemblies do not rotate as the threaded connections are secured It is critical especially with plastic construction that the check valves not be too tight into the reagent head In piping assembly use a sealing compound chemically compatible with the process material Users of sealing tape are cautioned to ensure that the entering pipe thread ends are not taped and that tape is removed from previously used threads to the maximum practical extent prior to re use Both new and existing piping should be cleaned preferably by flushing with a clean liquid compatible with process material and blown out with air prior to connection to the pump Suction Pressure Requirements Although PULSAtron Series M metering pumps have some suction lift capability a flooded suction i e suction pressure higher than atmospheric pressure is preferable whenever possible The pump should be located as close as possible to the suction side reservoir or fluid supply source For fluid with a vapor pressure of 5 psia or less at operating temperature the wet suction lift capability is approximately ten 10 feet
19. ear cavity completely with PULSAlube grease NP980006 000 and reassemble the pump side cover and gasket 8 Reassemble the motor to the pump Verify that motor rotation is clockwise when viewed from the top 9 Reinstall the pump in the system and restart the pump refer to Section 6 Startup 13 8 Replacement Parts 8 1 Program PULSAtron Series M KOPkits contain all replacement parts normally used in a preventative maintenance program PULSAlube grease is also available separately for preventative maintenance programs Refer to Section 6 Equipment Startup There is a specific KOPkit for every PULSAtron Series M pump model Each KOPkit is vacuum packed for extended storage All PULSAtron Series M pumps have the KOPkit number identified on the pump nameplate and Pulsafeeder order documents KOPkits can also be selected from the technical data sheet shipped with the pump or by a Pulsafeeder representative Kit Contains 1 Diaphragm Assembly 1 Suction Valve Cartridge 1 Discharge Valve Cartridge Figure 10 8 2 Ordering KOPkits or Parts When ordering replacement parts always specify e Pump model and serial number stamped on pump nameplate e g Model No LI2 with Serial No 9876303 1 or F406365 3 e Part number and description from the PULSAtron Series M parts list Include the three character suffix Note PULSAtron Series M part numbers begin either with the letters NP or the letter W e g
20. eck with the factory if concerned with the suitability of the operating environment The pump must be rigidly bolted to a solid and flat foundation to minimize vibration which can loosen connections When the pump is bolted down care must be taken to avoid distorting the base and affecting alignments The pump must be level within 5 This will assure that the check valves can operate properly 5 2 Piping System 5 3 5 4 All piping systems should include A separate system relief valve to protect piping and process equipment including the pump from excess process pressures An external relief valve is required Shutoff valves and unions or flanges on suction and discharge piping This permits check valve inspection without draining long runs of piping Shutoff valves should be of the same size as connecting pipe Ball valves are preferred since they offer minimum flow restriction An inlet strainer if appropriate for the product being pumped Pump check valves are susceptible to dirt and other solid contaminants and any accumulation can cause malfunction The strainer should be located between the suction shutoff valve and the pump suction valve It must be sized to accommodate the flow rate and the anticipated level of contamination A 100 mesh screen size is generally recommended Vacuum pressure gauges in the suction and discharge lines in order to check system operation Gauges should be fitted with protective shutoff v
21. es If the piping system design and the storage tank are such that the product flows due to gravity through the pump reduce the discharge pressure and the system will self prime when the pump is started In the event the discharge line contains a significant amount of pressurized air or other gas it may be necessary to lower the discharge pressure to enable the pump to self prime Tf the installation involves a suction lift it may be necessary to prime the reagent head and suction line Operate the pump as in step 4 above many times the pump will be capable of self priming If it does not begin to pump remove the discharge valve assembly Carefully fill the reagent head through the discharge valve port with process or compatible liquid and then reinstall the check valve Start the pump at the zero stroke length setting and slowly increase the setting to 100 to prime the pump If this does not work it will be necessary to fill the suction line Filling of the suction line will necessitate the use of a foot valve or similar device at the end of the suction line so that liquid can be maintained above the reservoir level Remove the suction valve assembly fill the line replace the suction valve then remove the discharge valve assembly and fill the reagent head as described in Step 3 above The pump will now self prime when started up per step 4 above 6 4 Calibration Stroke Length Indicator Capacity Figure 3
22. ge check valves This assembly is the only part of the pump to contact the process liquid consequently maintenance is critical to pump performance 2 3 Control Assembly PULSAtron Series M pumps incorporate a lost motion style of stroke length adjustment to limit diaphragm travel during the suction portion of each stroke The stroke length setting is indicated by a 0 100 scale located on the stroke adjustment assembly Stroke length is changed by loosening the locking screw and turning the hand knob This turns a mechanism which limits rearward travel of the diaphragm 2 4 Gear Ratio Assembly PULSAtron Series M pumps are driven by an electric motor mounted on the motor adaptor input flange The motor drives a set of worm gears that convert rotational speed into torque They in turn power the eccentric shaft assembly that converts rotary motion into reciprocating motion 4 1 1 4 1 2 5 5 1 Equipment Inspection Check all equipment for completeness against the order and for any evidence of shipping damage Shortages or damage must be reported immediately to the carrier and your authorized representative or distributor of PULSAtron Series M pumps Storage Short Term Storage of PULSAtron Series M pumps for up to 12 months is considered short term The recommended short term storage procedures are a Store the pump indoors at room temperature in a dry environment b If required by the operating environment take preca
23. r source Loose wire Trace and correct 16 10 Piping Accessories Pressure Relief Valves Pulsafeeder diaphragm relief valves are designed to protect chemical feed systems from over pressure damage that may be caused by defective equipment in the line or a blockage in the discharge line Field adjust the pressure relief valve to operate when the discharge pressure exceeds operating pressure by 10 1596 Diaphragm Back Pressure Valve The Pulsafeeder diaphragm back pressure valve creates constant back pressure A TFE diaphragm offering maximum chemical protection and service life seals spring and bonnet from product This diaphragm seals directly on a replaceable seat Be sure to install with fluid flow in direction of arrow on valve body If arrow is missing from plastic valve body install with flow exiting out center hole of valve body ADJUSTMENT SCREW LOCKNUT INLET H N OUTLET FLOW Pulsation Dampener The Pulsation dampener is a pneumatically charged diaphragm type chamber that intermittently stores hydraulic energy Used on the inlet it can improve NPSHA Net Positive Suction Head available characteristics of the suction piping system On the discharge line it will reduce discharge pressure and pulsating flow variations PULSAtrol Drain Discharge Back Pressure Valve Suction DISCHARGE INSTALLATION 17 11 Dimensional Drawings 4X 0 26 THRU FOUNDATION MOUNTING HOLES
24. re to ensure that they are in the correct ports 3 Lettering on the side of each valve should be right side up when assembled to pump It is not 7 necessary to coat the threads of the cartridge vale with a pipe sealant NOTE 10 Reinstall both suction and discharge piping 7 4 Motor Removal amp Reinstallation l Disconnect the power source to the drive motor Disconnect the motor wiring from the motor 3 Remove the four bolts retaining the motor to the motor adaptor The motor shaft fits into a bore on the pump input shaft Motor aos 4 Slide the motor shaft out of the pump input shaft Be careful not to lift the pump input shaft up out of the pump p Motor Shaft gt 5 Apply a lubricant such as Loctite Silver Grade Anti seize paste to the motor shaft and key before reassembling 6 Reinstall the motor by sliding the motor shaft into the pump input shaft Motor Bolts 4 Insert and tighten the four bolts removed in step 3 Reconnect the motor wiring to the motor Connect power to the drive motor Motor rotation must be wired for CW rotation as viewed from the top of the motor Figure 7 NOTE 11 7 5 Gearset Removal 1 2 3 10 Disconnect power source and wiring from the motor Set stroke adjustment to zero Remove motor from the pump refer to Section 7 4 Hem Description Socket Head Screw Motor Adaptor Grease Seal Worm Shaft Assembly Hex
25. tor and reagent head as the bolts are loosened Tilt the head and pour out any liquids retained by the check valves into a suitable container continuing to follow safety precautions as appropriate Remove the final bolt and rinse or clean the reagent head with an appropriate material Remove the dia phragm by turning it counter clockwise Inspect the diaphragm The diaphragm must be replaced if it is cracked separated or obviously damaged Install the diaphragm a Ensure that the critical sealing areas of diaphragm reagent head and pump head are clean and free of debris b Lubricate the elastomer side of the diaphragm liberally where it is in contact against the pump head and deflection plate with a lubricant compatible to the fluid being pumped silicone grease is preferred Thread the diaphragm clockwise fully onto the shaft When reinstalling a used diaphragm it is not necessary to maintain the previous orientation relative to the reagent head or pump head hole pattern Install the reagent head bolts and tighten in an alternating pattern to ensure an even seating force Torque to the values recommended in Section 6 1 Re prime the pump following the procedure outlined in Section 6 3 7 3 Check Valves 7 3 1 General Description Most fluid metering problems are related to check valves Problems usually stem from solids accumulation between valve and seat corrosion of seating surfaces erosion or physical damage d
26. ue to wear or the presence of foreign objects The valve incorporates a ball guide and seat Flow in the unchecked direction lifts the ball off the seat allowing liquid to pass through the guide Reverse flow forces the ball down sealing it against the sharp edge of the seat The guide permits the ball to rotate but restricts vertical and lateral movement in order to minimize slip or reverse flow Ball rotation prolongs life by distributing wear over the entire surface of the ball Since ball return is by gravity the valve must be in the vertical position in order to function properly Parts are sealed by O rings Figure 6 10 7 9 2 Check Valve Removal amp Reinstallation 3 Valving is of the cartridge design and is intended to be replaced as an assembly NOTE l Disconnect the power source to the drive motor Relieve all pressure from the piping system u Take all precautions necessary to prevent contamination to the environment and personnel exposure to hazardous materials Close the inlet and outlet shutoff valves Disconnect the suction line at the installed union on the suction port Loosen and remove the suction valve cartridge slowly to drain any liquid from the reagent head Disconnect the discharge line at the installed union on the discharge port Loosen and remove the discharge valve cartridge slowly to drain any trapped liquid w p Reinstall both new valve assemblies taking ca
27. utions to prevent entry of water or humid air into the eccentric enclosure c Prior to startup perform a complete inspection and then start up in accordance with instructions in this manual Long Term Every twelve months in addition to the above short term procedures power up the motor and operate the pump for a minimum of one hour It is not necessary to have liquid in the reagent head during this operation but the suction and discharge ports must be open to atmosphere After twelve months of storage Pulsafeeder s warranty cannot cover such items which are subject to deterioration with age such as seals gaskets and diaphragms If the pump has been in storage longer than 12 months it is recommended that such items be inspected and replaced as necessary prior to startup Materials and labor to replace this class of item under this circumstance are the purchaser s responsibility For a continuance of the initial warranty after extended storage equipment inspection and any required refurbishing must be done by a Pulsafeeder representative Installation Location When selecting an installation site or designing a chemical feed package system consideration should be given to access for routine maintenance PULSAtron Series M pumps are designed to operate indoors and outdoors but it is desirable to provide a hood or covering for outdoor service External heating is required if ambient temperatures below 0 C 32 F are anticipated Ch
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