Pulsafeeder 680 User Manual

Installation Operation Maintenance Instruction

Bulletin #: IOM-680

IOM-680 Rev B.

Table of Contents

1. INTRODUCTION ..................................................................................................................................... 1

1.1 How Things Work .................................................................................................................... 1

1.2

Hydraulically Balance Flat Diaphragm Design ..................................................................... 1

1.3

Pump Head Assemblies .......................................................................................................... 2

1.4

Make-up Hydraulic Bypass and Bleeder Valves within the Hydraulic System ................. 2

1.5

Hydraulic Bypass Valve .......................................................................................................... 4

1.6

Pressure Relief Valve .............................................................................................................. 4

1.7

Bleeder Valve ........................................................................................................................... 4

Reagent Head Assemblies ..................................................................................................... 4

1.8

INSTALLATION ...................................................................................................................................... 5

2.1

Check the Shipment ................................................................................................................ 5

2.2

Locating the 680 Pumps ......................................................................................................... 5

2.3

Flooded Suction Desirable ..................................................................................................... 5

2.4

Discharge Pressure ................................................................................................................. 5

2.5

Piping ........................................................................................................................................ 5

2.6

Strainers ................................................................................................................................... 6

Flush Piping System ............................................................................................................... 6

2.7

2.8

Metal Reagent Head Models ................................................................................................... 7

2.9

Plastic Reagent Head .............................................................................................................. 7

START-UP INSPECTION ......................................................................................................................... 7

3.1

Filling Gear and Oil Reservoirs .............................................................................................. 7

3.2

Final Inspection ....................................................................................................................... 7

Start-up ..................................................................................................................................... 8

3.3

3.4

Priming Process Head ............................................................................................................ 8

To Adjust Flow Rate ................................................................................................................ 9

3.5

4. OPERATION AND MAINTENANCE ............................................................................................................ 9

Diaphragm Inspection ............................................................................................................. 10

4.1

4.2

Repriming Hydraulic ............................................................................................................... 11

Piston and Diaphragm Alignment .......................................................................................... 11

4.3

4.4

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

4.5

Hydraulic Make-up Valve ........................................................................................................ 12

4.6

Adjustable Valves .................................................................................................................... 13

Hydrualic Bypass Valve .......................................................................................................... 13

4.7

4.8

Automatic Bleed Valve ............................................................................................................ 14

4.9

Manual Bleed Valve ................................................................................................................. 15

4.10

Lubricating Instructions ......................................................................................................... 15

4.11

Oil Capacity .............................................................................................................................. 16

STORAGE INSTRUCTIONS ....................................................................................................................... 16

5.1

Short Term ............................................................................................................................... 16

5.2

Long Term ................................................................................................................................ 16

5.3

Maintenance and KOPkits ...................................................................................................... 17

5.4

Ordering Parts ......................................................................................................................... 17

5.5

Additional Services ................................................................................................................. 17

TROUBLESHOOTING .............................................................................................................................. 18

PULSATROL ....................................................................................................................................... 20

7.1

Installation ................................................................................................................................ 20

Operation .................................................................................................................................. 21

7.2

DIAPHRAGM BACK PRESSURE VALVES .................................................................................................. 22

Revision History:

Rev A Release Date Sept 1997, first revision Rev B Release Date January 2006

iii

1. Introduction

1.1 How it Works

A standard foot mounted motor drives a worm shaft at constant speed. Through worm gear reduction and eccentric, a reciprocating power stroke is transferred to a plunger. The length of the plunger stroke determines pump capacity and can be adjusted manually to provide pumping range from

0-100% of rating. However, this plunger does not pump chemicals, but an exceptionally stable oil*, having excellent lubrication qualities. This makes a perfect pumping medium.

1.2 Hydraulically Balanced Flat Diaphragm Design (Figure 2)

Using this oil, the plunger hydraulically moves a diaphragm alternately forward and backward. A displacement from this diaphragm movement in turn, takes in the liquid (chemical) being pumped through a suction check valve on the suction stroke of the plunger and discharges a like amount of liquid (chemical) through a discharge check valve on a forward or discharge stroke. The plunger operating in a sized cylinder and at exact stroke length gives exact displacement and accurate pumping rate. The diaphragm isolates the chemical being pumped within the reagent head and check valves. No other parts need to be of special chemically stable material. This isolation of prompt eliminates the possibility of contamination. The plunger handles only oil and no stuffing box is required.

*A special property petroleum oil tradenamed “PULSAlube” is generally used as hydraulic fluid. Continual reference to “Oil” as hydraulic medium implies its general use rather than its use of necessity. Check with your representative or the factory if substitute oils must be used.

(Figure 2)

1.3 Pump Head Assemblies

The hydraulic pump head assembly contains the plunger cylinder and various hydraulic components to protect and maintain a precise hydraulic balance between the plunger and the diaphragm. Figure No. 3 and Figure No. 4 shows various styles of pump head assemblies.

1.4 Make-Up, Hydraulic Bypass and Bleeder Valves within the Hydraulic System

Figures No. 3 and Figure No. 4 show the locations of valves according to piston diameter and diaphragm style selected.

Make-Up Valve

Any leakage past the plunger or bleeder, however slight, is replaced by the make-up valve which permits flow of replacement oil from the oil reservoir. This is an automatic function. The oil loss allows the diaphragm to get out of phase with plunger thus creating a vacuum ahead of the plunger during the suction stroke. The make-up valves are factory set.

1.5 Hydraulic Bypass Valve

Any excess hydraulic pressure buildup within the pump compression chamber or chemical end due to accidental valve closure or line stoppage is relieved through the hydraulic bypass valve. It blows off oil under excess pressure ahead of the plunger back into the oil reservoir thus terminating the pumping action and protecting the pump mechanism. Hydraulic bypass valves are factory set at full design pressure unless specified differently by purchaser.

1.6 Pressure Relief Valve

A separate process relief valve should be installed in the process piping to protect piping and sensitive process equipment.

1.7 Bleeder Valve

The function of this valve is to release any air or oil vapors from ahead of the piston and maintain a solid hydraulic medium to transmit infinite movements of the piston to the diaphragm. In large piston models where adequate oil movement exists, the bleed valve functions automatically weeping a minute quantity of oil plus any air or vapor out of the hydraulic system. In small piston models where oil movement and hydraulic instabilities are minimal a manual bleed valve is used.

Additional detail on the function of these valves will be given as applicable in the Operation, Maintenance and Trouble Shooting Sections.

1.8 Reagent Head Assemblies

Flat diaphragm reagent head assemblies are available in several basic configurations. They are:

Figure No. 5 ¼” through 1 ½” piston metal reagent head and plastic diaphragm Figure No. 6 ¼” through Figure No. 7 ½” through 1 ½”, plastic reagent head and plastic diaphragm

5/8” metal reagent head and metal diaphragm

2. Installation Tips

2.1 Check the Shipment

A standard Pulsafeeder shipment includes the pump, PULSAlube oil, wrenches, instruction and parts list packet as well as replacement parts if ordered. Unpack carefully, check packing list and make sure all parts are received. Check voltage of electric motor against the service to be used.

2.2 Locating the 680 Pumps

PULSAFEEDER pumps are designed to operate under indoor atmospheric conditions. It is desirable to provide a hood or covering for outdoor service. Alternate oil or external heating is required if ambient

temperatures will be below 40

◦

below 40

1. Check level of pump. Shim where necessary.

2. Securely bolt to foundation. Do not

3. Check motor alignment, reagent head, and valve bolt tightness before operation. Follow bolt torque

NOTE: Most 680 models will operate without bolting down. However, it is important to have a solid

and level foundation so that a minimum of vibration is evident. Continual vibration can loosen gaskets and pipe connections.

F (4.4 ◦C).

readings carefully.

◦

F (4.4 ◦C). Check with factory if fluid temperatures entering the pump will be

distort base.

2.3 Flooded Suction Desirable

Installation will be simpler to operate if the liquid will flow to the pump by gravity. Wherever possible, the pump should be located below the level of storage vessel.

2.4 Discharge Pressure

All 680 models are designed for continuous service at the rated discharge pressure. To prevent liquid flow through, it is necessary that discharge pressure be at least 5 psi above suction pressure. When pumping downhill, a back pressure valve should be placed in the discharge line.

2.5 Piping

Pipe size and length are critical to proper operation of any metering pump. A restricted discharge or starved suction condition spells immediate failure to any metering pump installation. A separate brochure entitled “Designing a Successful Metering Pump Installation” is provided to assist engineers responsible for piping system design. Copies are available upon request (Technical Sheet 304). Inlet piping must be at least equal in size to pump inlet connection.

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