Honeywell DC3, DC2, DC4, DC6, DC5 User Manual

Installation, Operation, & Maintenance Instruction

Models DC2, 3, 4, 5, and 6

Bulletin #: IOM-OM-1104- E

Manufacturers of Quality Pumps, Controls, and Systems

STANDARD PUMP OPERATIONS 27101 Airport Road Punta Gorda, FL 33982 (941) 575-3800 Fax (941) 575-4085 www.pulsatron.com

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 Distributor, 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 with 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.

Revision History:

Rev B (3-1-05)

- Update diagram fig. 10

- Revise text step 11b page 11 diaphragm removal and replacement

Update all parts diagrams and lists, Section 12

Rev C (9-1-06)

- Update for Kynar (PVDF) heads

- Add model string ID page

- Update KOPkit list with PVDF kits

- Update parts lists with PVDF parts

Rev E (2-2007)

- Update all for introduction of model DC6, SPO address only

- Update materials references to “PTFE”

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.

1. I

NTRODUCTION

2. P

RINCIPLES OF OPERATION

Table of Contents

.....................................................................................................................................1

..................................................................................................................1

2.1 Reagent Head Assembly ........................................................................................................2

2.2 Control Assembly ....................................................................................................................2

2.3 Gear Ratio Assembly ..............................................................................................................2

3. E

QUIPMENT INSPECTION

4. S

TORAGE

5. I

NSTALLATION

5.1 Location....................................................................................................................................3

5.2 Piping System ..........................................................................................................................4

5.3 Suction Pressure Requirements............................................................................................5

5.4 Discharge Pressure Requirements........................................................................................5

6. E

QUIPMENT STARTUP

6.1 Fastener Inspection.................................................................................................................6

……………………………………………………………………………………………………...3

......................................................................................................................................3

.......................................................................................................................3

...........................................................................................................................6

6.2 Output Adjustment ..................................................................................................................6

6.3 Priming the Reagent Head......................................................................................................7

6.4 Calibration ................................................................................................................................8

7. M

AINTENANCE

7.1 Lubrication ...............................................................................................................................9

7.2 Wet End Removal, Inspection, & Reinstallation...................................................................10

7.3 Check Valves ...........................................................................................................................12

7.4 Motor Removal & Reinstallation ............................................................................................16

7.5 Gearset Removal .....................................................................................................................16

7.6 Gearset Replacement..............................................................................................................18

8. R

EPLACEMENT PARTS

8.1 KOPkit Program .......................................................................................................................19

8.2 Ordering KOPkits or Parts......................................................................................................19

......................................................................................................................................9

..........................................................................................................................19

iii

8.3 KOPkit numbers by model: ....................................................................................................20

9. M

ODEL NUMBER IDENTIFICATION

10. W

ET END MATERIALS REFERENCE

11. T

ROUBLESHOOTING

12. P

IPING ACCESSORIES

13. D

IMENSIONAL DRAWING

14. P

ARTS DIAGRAMS AND PARTS LISTS

..............................................................................................................................23

...........................................................................................................................25

........................................................................................................................26

...........................................................................................................21

........................................................................................................22

.....................................................................................................28

14.1 Parts diagram, DC2 and 3 .......................................................................................................28

14.2 Bill of Materials, DC2 ...............................................................................................................29

14.3 Bill of Materials, DC3 ...............................................................................................................31

14.4 Parts Diagram, DC4, 5, and 6..................................................................................................34

14.5 Bill of Materials, DC4 ...............................................................................................................35

14.6 Bill of Materials, DC5 ...............................................................................................................37

14.7 Bill of Materials, DC6 ...............................................................................................................39

1. Introduction

The OMNI® metering pump is positive displacement, mechanically operated reciprocating diaphragm pump. Each pump consists of a power end and a process end separated by a PTFE faced 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

Figure 1, reagent head operation

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.

2.1 Reagent Head Assembly

The typical reagent head assembly consists of reagent head, diaphragm, and suction and discharge cartridge check valves. This assembly is the only part of the pump to contact the process liquid; consequently, maintenance is critical to pump performance.

2.2 Control Assembly

The OMNI® pump incorporates 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. Refer to Section 6.2 for further information.

For automatic flow rate control, users can consider the Pulsafeeder MPC speed based control system, please contact your local Pulsafeeder dealer or representative for more information.

2.3 Gear Ratio Assembly

OMNI® 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.

Figure 2, isometric view

3. 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 OMNI® pumps.

4. Storage

4.1.1 Short Term

Storage of your OMNI® pump 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 precautions 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.

4.1.2 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 items that 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 these 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. Consult your local Pulsafeeder representative for assistance in obtaining parts and service for your pump.

5. Installation

5.1 Location

When selecting an installation site or designing a chemical feed system, consideration should be given to access for routine maintenance.

OMNI® 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, especially if pumps are not in continuous duty. Check 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

1. All systems should include a pressure relief valve on the discharge side, to protect piping and process

equipment, including the pump, from excess process pressures. An external relief valve is required! There should be no devices capable of restricting flow (such as a valve) located between the pump and the relief device.

2. Shutoff valves and unions (or flanges) on suction and discharge piping are recommended. This

permits check valve inspection without draining long runs of piping, making periodic maintenance and inspection easier.

Shutoff valves should be of the same size as connecting pipe. Ball valves are preferred since they offer minimum flow restriction.

3. Suction systems should include 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.

4. Vacuum/pressure gauges in the suction and discharge lines are helpful in order to check system

operation. Gauges should be fitted with protective shutoff valves for isolation while not in use.

5. 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.

6. 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. The threaded connection between the check valve assembly and the regent head uses on o-ring seal and does not require sealing tape or any other sealant.

7. 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. Debris from the piping system that prevents proper check valve operation is a common startup issue.

8. Note that for pumps which utilize cartridge-type check valve assemblies, no thread tape or sealant is

required on the threads which secure the cartridge assembly to the pump reagent head. This area is sealed with o-rings integral to the cartridge. Sealant on these threads can actually degrade sealing capability.

5.3 Suction Pressure Requirements

Although OMNI® 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. 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.

5.4 Discharge Pressure Requirements

All OMNI® 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 flow-through condition, the discharge pressure must exceed suction pressure by at least 0.35 Bar (5 psi). This can be achieved where necessary by the installation of a backpressure valve in the discharge line. Conditions where the actual discharge pressure exceeds the pump’s rating are to be avoided as they will cause damage to the pump components.

Figure 3, sample system configuration

6. Equipment Startup

6.1 Fastener Inspection

All pump fasteners should be checked prior to pump operation, and occasionally during use. 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:

Model Material

DC2

DC3 and 4

DC5

DC6

Plastic (4) M6 * 1.0 3.39 30

Plastic (4) M8 * 1.25 6.77 60

Plastic (6) M8 * 1.25 8.46 75

6.2 Output Adjustment

All OMNI® pumps have a hand wheel for manual stroke adjustment. The hand wheel can be adjusted to any point from 0 to 100%. This value represents the stroke length setting and therefore the flow rate of the pump relative to its maximum output.

1. Turn the red lock screw counterclockwise to release the

stroke lock. Making adjustments without releasing the lock may damage the mechanism.

2. Adjust the hand wheel to the desired output. a) The stroke barrel indicates stroke length in 20%

increments.

b) The hand wheel indicates stroke length in 1%

increments.

For example, to set the pump to 75% stroke length, (starting from the factory default setting of 0%) turn the hand wheel counter clockwise until he 60% indicator is visible on the stroke barrel.

Continue the counter clockwise rotation until the hand wheel indicator is at 15. Refer to Figure 4.

3. Turn the lock screw clockwise to lock the stroke adjustment into position.

Adjustments can be made while the pump is at rest or

operating, although adjustments are easier to make

while the pump is in operation.

Reagent Head Bolt Torque

# Bolts and size N-m In. - Lbs

Metal (4) M6 * 1.0 3.39 30

Metal (4) M8 * 1.25 6.77 60

Metal (6) M8 * 1.25 8.46 75

Figure 4, stroke adjustment

6.3 Priming the Reagent Head

1. When handling process liquids, follow all applicable personal and facility safety guidelines.

2. Ensure that the pump is ready for operation and that all process connections are secure.

3. Open the suction and discharge line shutoff valves.

4. 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.

5. If 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.

6. 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.

7. 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. Use appropriate precautions if handling process fluid. Ensure that any other fluid used for priming is compatible with the product that will be pumped.

Figure 5, process flow

6.4 Calibration

Figure 6, sample flow calibration curve

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.

All users are encouraged to test the flow rate of their pump once installed in their system, to ensure best accuracy and reliable operation.

7. Maintenance

EFORE 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 APPROPRIATE.

EAR PROTECTIVE CLOTHING AND EQUIPMENT AS APPROPRIATE

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.

The OMNI® KOPkit will 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.

7.1 Lubrication

OMNI® pumps are supplied completely lubricated from the factory. For optimum pump performance under normal conditions, gear grease should be redistributed every 1500 hours. For severe service in extreme temperatures or very dirty environments, this interval may be shorter.

1. Disconnect the power source to the drive motor, and relieve all pressure from the piping system.

2. Remove the side cover from the pump. Refer to Figure 7.

3. Redistribute grease onto gear and worm teeth. On DC2 and 3 pumps, force grease into the hole in the

end of the gear shaft using a screwdriver or putty knife. Primary lubrication points are called out in Figure 7, below.

4. Replace the side gasket and cover.

Figure 7, gearset lubrication points

7.2 Wet End Removal, Inspection, & Reinstallation

F THE DIAPHRAGM HAS FAILED, 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

Figure 8, wet end components

OMNI® 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. Each user should perform regular inspections to determine the replacement interval that is appropriate to their system conditions.

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