Nova-Tech DC7 User Manual

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Installation, Operation, & Maintenance Instruction

Model DC7

Bulletin #: IOM-DC7-0407- C

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 A (4-07)

- First Release

Rev B (8-07)

- Updated lubricating oil specification and part numbers

- Add instruction to fill with oil prior to storage

- Minor text revisions

Rev C (1-09)

- Added Duplex Dimensional and BOM

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

......................................................................................................................................4

..................................................................................................................4

2.1 Reagent Head Assembly.........................................................................................................5

2.2 Control Assembly....................................................................................................................5

2.3 Gear Ratio Assembly ..............................................................................................................5

3. E

QUIPMENT INSPECTION

4. S

TORAGE

5. I

NSTALLATION

5.1 Location....................................................................................................................................6

5.2 Piping System..........................................................................................................................7

5.3 Suction Pressure Requirements............................................................................................7

5.4 Discharge Pressure Requirements........................................................................................8

6. E

QUIPMENT STARTUP

6.1 Fastener Inspection.................................................................................................................9

6.2 Output Adjustment..................................................................................................................9

6.3 Oil Fill and Maintenance .........................................................................................................10

6.4 Priming the Reagent Head......................................................................................................11

6.5 Calibration................................................................................................................................13

7. M

AINTENANCE

7.1 Diaphragm Removal & Reinstallation ...................................................................................16

7.2 Diaphragm Shaft Seal .............................................................................................................18

7.3 Check Valves............................................................................................................................19

7.4 Check Valve Removal & Reinstallation, Plastic Union-Nut type ........................................20

7.5 Check Valve Removal and Reinstallation, Metal Tie-Bar type............................................21

7.6 Motor Removal & Reinstallation ............................................................................................23

8. R

EPLACEMENT PARTS

………………………………………………………………………………………………..…...6

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

......................................................................................................................................14

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

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

..........................................................................................................................24

8.1 KOPkit Program.......................................................................................................................24

8.2 Ordering KOPkits or Parts......................................................................................................24

8.3 KOPkit numbers by model: ....................................................................................................25

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

..............................................................................................................................27

...........................................................................................................................29

........................................................................................................................30

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

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

.....................................................................................................32

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 Teflon 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 full motion style of stroke length adjustment. 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 changes the amplitude of the stroke length. As the stroke adjustment knob is turned towards 100%, it displaces the cam eccentrically to the rotating drive shaft. This in turn causes the pushrod and diaphragm to travel over a longer distance. 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. The gear assembly and eccentric shaft run submerged in a lubricating oil bath.

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) The lubricating oil should be added to the gearbox prior to storage c) If required by the operating environment, take precautions to prevent entry of water or

humid air into the eccentric enclosure.

d) 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. Lubricating oil should also be changed 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 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.

pumps are designed to operate indoors and outdoors, but it is desirable to provide a

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. 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.

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.

For long suction lines, and also for pumps that have a high stroking rate, the largest possible suction line diameter should be used to provide best suction conditions. In some cases, the proper line size may exceed the suction connection size on the pump. Consult your local Pulsafeeder Representative for assistance and further information on proper suction system design.

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

DC7

Plastic (8) M10 * 1.5 8.5 75

Metal (8) M10 * 1.5 8.5 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.

Reagent Head Bolt Torque

# Bolts and size N-m In. - Lbs

Figure 4, stroke adjustment knob and scale

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 0.25% increments. For example, to set the pump to 75% stroke length, (starting from the factory default setting

of 0%) turn the hand wheel clockwise until the 60% indicator on the stroke barrel is aligned with the edge of the knob at the “0” position on the knob scale.

Continue the clockwise rotation until the hand wheel indicator passes zero again (this is 70%) and comes to 5, this is 75%. 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.

6.3 Oil Fill and Maintenance

6.3.1 Oil Capacities

It is recommended that adequate supplies of PulsaLube oil be on hand for periodic changes and emergency requirements. The approximate amounts of oil required to fill the OMNI DC7 pump to specified levels are:

Pump Capacity Gearbox, Model DC7

PulsaLube EP Gear Oil 2,500 ml (2.6 Qt)

Pulsafeeder Part No. Description Container Size

NP980010-001 PulsaLube EP Gear Oil 500 ml NP980010-002 PulsaLube EP Gear Oil 1 liter NP980010-003 PulsaLube EP Gear Oil 2.5 liter NP980010-004 PulsaLube EP Gear Oil 18 liter

6.3.2 Gearbox Oil Fill

Fill the gearbox with oil by removing the threaded oil fill cap on the top of the pump. Fill with the proper oil (PulsaLube EP Gear Oil) to the upper edge of the sight glass on the side of the pump. Replace the cover or controller. Replace the oil fill cap. See figure 5. Note that during operation, the oil should be visible at the middle of the sight glass.

Figure 5, oil filler cap and sight glass

6.3.3 Oil Changes

The recommended oil change intervals are dependent upon the operating environment and level of pump usage, classified as follows:

C (32

C (320 F to 1040

F) or above 400

Normal service: Clean/dry atmosphere, an ambient operating temperature of 00 C to 40 F) and up to 2,000 annual operating hours.

Severe Service: Humid atmosphere, an ambient operating temperature below 0 C (104

F), and over 2,000 annual operating hours.

The recommended eccentric oil change interval is two (2) years for normal service and one (1) year for severe service. The procedure is as follows:

1. Disconnect the power source to the drive motor

2. Relieve all pressure from the piping system.

3. Remove the fill plug from the top of the pump gearbox.

4. Drain the oil by removing the drain plug on the bottom of the gearbox, opposite the stroke adjustment knob.

5. Replace the drain plug.

6. Fill the eccentric box with PulsaLube oil as described under Gearbox Oil Fill

7. Replace the fill plug and double check that the drain plug is secure.

6.4 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.

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