Pulsafeeder GLM DM1-6 User Manual

PULSA GLM®

Bulletin #: IOM-GLM-1303-A

Installation, Operation &

Maintenance Instruction

Models: GLM M1 – 6

MECHANICAL DI AP HRAGM

METERING PUMP

Pulsafeeder Factory Service Poli cy

Pulsafeeder’s Factory Service Policy is maintained on its website. Please source this document at this URL:

http://www.pulsa.com/downloads/pdf/Pulsafeeder%20EPO%20Limited%20Warranty%20Statement.pdf

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.

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.

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Table of Contents

1. EQUIPMENT INSPECTION ....................................................................................................................... 1

2. INSTALLATION ...................................................................................................................................... 1

2.1 Location ................................................................................................................................... 1

2.2 Motor ........................................................................................................................................ 1

2.3 Piping System ......................................................................................................................... 2

2.4 Suction Pressure Requirements ........................................................................................... 3

2.5 Discharge Pressure Requirements ....................................................................................... 4

3. EQUIPMENT STARTUP .......................................................................................................................... 5

3.1 Fastener Inspection ................................................................................................................ 5

3.2 Output Adjustment ................................................................................................................. 5

3.3 Priming the Reagent Head ..................................................................................................... 6

3.4 Calibration ............................................................................................................................... 7

4. MAINTENANCE ..................................................................................................................................... 7

4.1 Lubrication .............................................................................................................................. 8

4.2 Wet End Removal, Inspection, & Reinstallation .................................................................. 9

4.3 Check Valves ........................................................................................................................... 11

4.4 Motor Removal & Reinstallation ........................................................................................... 13

4.5 Pump Head Removal .............................................................................................................. 14

5. REPLACEMENT PARTS ......................................................................................................................... 15

5.1 KOPkit Program ...................................................................................................................... 15

5.2 Ordering KOPkits or Parts ..................................................................................................... 15

5.3 KOPkit numbers by model:.................................................................................................... 16

6. TROUBLESHOOTING ............................................................................................................................. 17

7. PIPING ACCESSORIES .......................................................................................................................... 19

8. DIMENSIONAL DRAWING ....................................................................................................................... 20

9. PARTS DIAGRAM S AN D ITEM NUMBERS ................................................................................................. 22-23

1. Equipment Inspection

Figure 1: Foot Valve Kit

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 PULSA GLM

Included Items:

• PULSA GLM® Metering Pump with Motor Adaptor

Optional Items:

• Motor (pre-installed at the factory)

• Foot Valve Kit (provided on PULSA GLM® models M1 and M2 only).

pumps.

2. Installation

2.1 Location

When selecting an installation site or designing a chemical feed system, plan for operation and routine maintenance. Provide 1M (3.25FT) of space around the pump for this purpose.

PULSA GLM sunlight, and precipitation (i.e., under shelter). The ambient temperature must be between 0° C (32° F) and 40° C (104° F). If necessary add environmental controls.

pumps are designed to operate in an environment where the pump is protected from direct

The pump must be rigidly bolted to a solid and flat foundation to minimize vibration and prevent loosening of the connections. The pump must be level within 5° to assure proper ch eck valve operation.

2.2 Motor

The PULSA GLM® is typically shipped with the motor pre-installed. It must be wired in accordance with local and national requirements by a qualified electrician. Please refer to the motor nameplate for further manufacture specific information.

If the PULSA GLM® was purchased less motor, please refer to section 5.4 Motor Installation for further instructions.

2.3 Piping System

Figure 3: Discharge P&ID

Figure 2: Suction P&ID

Attention to piping detail will assure an easy startup and long life of your GLM

Suction Piping

Isolation Valve and Unions: Isolation valves allow

the system to be isolated from the process fluid to facilitate safe servicing. They also aid in the operation of Calibration columns. Valves should include good visible indications of open/closed condition. Unions assist with installation and maintenance. Valves that integrate union fittings are ideal.

Strainer: Successful installations always include a strainer on the suction side of the pump to exclude material that can cause the check valves to malfunction or the diaphragm to rupture. Select the material, size and mesh to be compatible with the fluid type, intended flow rate and service interval. A 100 mesh screen is generally recommended.

Calibration Column (Optional): Used to calibrate pump performance. Include an isolation valve and vent line back to the supply tank to facilitate safe operation.

Pressure Gage (Optional): A pressure gage should be included on the suction side of the pump when the suction pressure of the system is unknown or variable. The gage is also a good indicator of Strainer maintenance status.

Discharge Piping

. Please follow these guidelines:

Discharge Pressure Gage: Install a pressure gage no less than 2 pipe diameters from the threaded fitting on the discharge valve. A discharge pressure gage is critical to confirming proper operation of the pump and setting the pressure relief and back pressure valves.

IMPORTANT: DO NOT Install an elbow directly into the discharge valve threaded fitting as it will create excessive back pressure that can lead to premature diaphragm failure.

Pressure Relief Valve: Install a Pressure Relief Valve as close

to the pump as possible. Using the leg of a T fitting for this purpose is acceptable (with the normal discharge taking the straight path and the relief flow taking the leg). The relief pressure must be set at or below the rated pressure indicated on the pumps nameplate.

NOTE: Failure to install and properly set a Pressure Relief Valve can lead to damage of the Pumps drive mechanism that will not be covered under warranty.

Back Pressure Valve: Install a Back Pressure Valve to

generate a consistent Back Pressure to the pump for accurate operation and to prevent siphoning.

Pulsation Dampener: Reciprocating diaphragm metering pumps only discharge fluid for ½ of a pump cycle. A Pulsation Dampener will smooth the associated flow/pressure variation to

the down stream process.

Piping System Recommendations

1. When making the threaded joint to the valve cap assembly, use a sealing compound chemically compatible with the process material (for example Loctite® 8551 [Loctite is a registered Trade Mark of Henkel Corporation] for water service). Do not use sealing tape. The valve cap should be tightened by hand and then tightened 1 additional turn (i.e., 360 degrees) with the aid of an adjustable wrench.

2. 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.

Note - Debris from manufacturing the pip ing system (e.g., PVC shavings, TFE Tape, dirt, etc.) can be unknowingly assembled inside the pipe. When fluid is introduced this material can be transferred to the pump and prevent proper check valve operation. T h is is a common startup

issue.

3. Piping weight must not be supported by valve housings or other portions of the reagent head, as the resulting stresses can cause leaks. Valve loads must not exceed 13.5 N-M (10 FT-LBF) moment or 22N (5 LBF) in any direction. When temperature variations are expected provide for thermal expansion and contraction of piping components so that force and/or moments are controlled within the allowable range.

4. When making process connections, ensure that pipe joint cement and thread sealants do not run into the check valve assemblies as this will inhibit valve operation. This is a common startup issue.

2.4 Suction Pressure Requirements

Although PULSA GLM® 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 0.35 Bar (5 psia) or less (at operating temperature) the wet suction lift capability is approximately 3 meters (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 operating under suction lift conditions may require some liquid priming before they will operate reliably.

2.5 Discharge Pressure Requirements

All PULSA GLM® metering pumps are designed for continuous service at the rated discharge pressure. If the system suction pressure exceeds the discharge pressure (a condition sometimes described as “pumping downhill”), flow will be generated in addition to that generated 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 the 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 pumps rating are to be avoided as they will cause damage to the pump components.

Figure 4: PULSA GLM P&ID

3. Equipment Startup

Figure 5: Reagent Head Bolt tightening

Figure 6: Stroke Adjustment Knob

3.1 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.

The motor and reagent head mounting bolts should be torqued to 4.5 N-M (40 IN-LBF). Bolts should be tightened in a star pattern across the head to assure uniform clamping of the diaphragm (see recommended tightening sequence in above diagram).

3.2 Output Adjustm ent

All PULSA GLM® pumps have a knob for manual stroke length adjustment. The knob can be adjusted to any value between 0 to 100%. The stroke length setting is directly proportional the flow rate of the pump.

1. Push the knob in towards the gearbox to release the locking mechanism.

Note - Making adjustments without releasing the lock may damage the locking mechanism.

2. Adjust the knob to the desired output. a) Read the setting directly from the knob marking where it aligns with

the stroke barrel.

b) The knob is labeled in 10% increments with 1% graduation marks.

The knob will lock in 0.5% increments.

Note – Do not adjust the knob beyond the indicated range.

For example, to set the pump to 75% stroke length (starting from the factory default setting of 0%) push the knob in (to unlock) and turn it approximately ¾ turn clockwise until he 75% indicator is aligned with the line on the stroke adjustment barrel.

3. Release the knob to re-engage the locking mechanism.

Note – Stroke adjustments should be made while pump is operating.

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