Pulsafeeder GLM DM7 User Manual

PULSA GLM®

Bulletin #: IOM-GLM-DM7-001

Installation, Operation &

Maintenance Instruction

Models: GLM7

MECHANICAL DI AP HRAGM

METERING PUMP

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.

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.

Table of Contents

1. INTRODUCTION ................................................................................................................................................ 4

2. PRINCIPLES OF OPERATION .......................................................................................................................... 4

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

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

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

3. EQUIPMENT INSPECTION ................................................................................................................................ 6

4. STORAGE .......................................................................................................................................................... 6

5. INSTALLATION ................................................................................................................................................. 6

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

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

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

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

6. EQUIPMENT STARTUP ..................................................................................................................................... 9

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. MAINTENANCE ............................................................................................................................................... 14

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. REPLACEMENT PARTS ................................................................................................................................. 24

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

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

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

9. MODEL NUMBER IDENTIFICATION ............................................................................................................... 25

10. TROUBLESHOOTING ..................................................................................................................................... 26

11. PIPING ACCESSORIES ................................................................................................................................... 28

12. DIMENSIONAL DRAWIN G .............................................................................................................................. 29

13. PARTS DIAGRAMS AND PARTS LISTS ........................................................................................................ 31

1. Introduction

The GLM® DM7 m etering 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 GLM® DM7 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

GLM® DM7 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. lubricating oil bath.

The gear assembly and eccentric shaft run submerged in a

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 GLM

4. Storage

4.1.1 Short Term

Storage of your GLM® DM7 pump for up to 12 months is considered short-term.

4.1.2 Long 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.

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 be inspected and be changed prior to

in storage

longer than 12 months it is recommended that these items

replaced as

startup. Materials

necessary prior to startup. Lubricating oil should also

this circumstance are the purchaser’s responsibility. Consult your local Pulsafeeder representative for assistance in obtaining parts and service for your pump.

DM7 pumps.

and labor to replace this class of item under

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.

GLM

DM7 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 operate properly.

the check

valves can

5.2 Piping System

1. All systems should include a pressure relief valve on the discha rge side, to p rotect pipi ng and process equipment, including the pump, from excess process pressures. An external relief valve is required! There should be no devices capable of restrictin g flow (such as a valve) located between the pump and the relie f device.

2. Shutoff valves and unions (or flanges) on suction and discharge piping ar e recommended. This permits check valve inspec tion without d raining long runs of pipin g, making periodi c maintenance and inspectio n easier.

Shutoff valves should be of the same si ze as conn ecting pipe. Bal l valves are preferred since they offer minim um flow restric tion.

3. Suction systems should include an inlet strainer, if app ropriate for the product bein g pumped. Pump check valves are susceptible to di rt and other solid contamina nts, 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 accommo date the flow rate and the anticipated level of contamination. A 100 mesh screen siz e is generally recommended.

4. Vacuum/pressure gauges in the suction and dischar ge lines are hel pful in orde r to check system operation. Gauges should be fitted with pro tective shuto ff valves for isola tion while no t in use.

5. Piping weight must not be supported by v alve housin gs or other po rtions of the reagent head, as the resulting stresses can ca use leaks. If appropriate, pr ovide for the rmal expansion and contraction so that no ex cess force o r moments are applied to the pump.

6. In piping assembly, use a sealing c ompound chemical ly compatible w ith the proce ss material. Users of sealing tape are cautioned to en sure that the entering pipe t hread ends a re not taped, and that tape is removed from previously-used threads to the maximum practical e xtent prior to re-use . Both new and existing pipi ng should be cleaned, pr eferably by flushing w ith liquid (compatible with proc ess material) a nd blown out w ith air, prior to connection to the pu mp. Debris from the piping sy stem that prev ents proper che ck valve opera tion is a common startup issue.

a clean

5.3 Suction Pressure Requirements

Although GLM® DM7 metering pumps have s ome suction li ft capability, a flooded s uction (i.e., suction pressure higher tha n atmospheric p ressure) is preferable w henever possible. The pump should be located as clo se as possible to the suction side reservoir or fluid supply source.

For fluid with a vapor pressure of 5 psia or les s (at oper ating temperature) the wet suc tion lift capability is approximately ten (10) feet. If this require ment is not met, the pump will not provide reliable, accurate flow. In suction lift con ditions, the use of a foot valve is recommended at the low est point of the pickup tube or pipe. Pu mps under suc tion lift conditions may require som e liquid primin g before they will operate reliably.

For long suction lines, and also for pumps that hav e a high s troking rate, the largest pos sible suction line diameter should be used to provide best suction condition s. In some cases, the proper line size may ex ceed the suction connection siz e on the pump . Consult you r local Pulsafeeder Representative for assistance and further informatio n on proper s uction syste m design.

5.4 Discharge Pressure Requirements

All GLM® DM7 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 in the discharge line. Conditions where the actual discharge pump’s rating are to be avoided as they will cause damage to the pump components.

a backpressure

pressure exceeds

valve

the

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 tha t 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

DM7

6.2 Output Adjustment

All GLM® DM7 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.

Material

Plastic (8) M10 * 1.5 Metal

(8) M10 * 1.5

Reagent Head Bolt Torque

# Bolts and size N-m In. - Lbs

8.5

75 75

Figure 4, stroke adjustment knob and scale

2. Adjust the hand wheel to the d esired ou tput.

a. The stroke barrel indicates s troke len gth in 20 % incr ements.

b. The hand wheel indicates stro ke len gth in 0 .25% inc rements. 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

Pulsafeeder Part No.

Description

Container Size

NP980010-001

PULSALube EP Gear Oil

500 ml

NP980010-002

PULSALube EP Gear Oil

liter

NP980010-003

PULSALube EP Gear Oil

2.5

liter

NP980010-004

PULSALube EP Gear Oil

liter

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 GLM

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.

DM7 pump to specified levels are:

Pump Capacity

PULSALube EP Gear Oil

Figure 5, oil filler cap and sight glass

Gearbox, Model DM7

2,500 ml (2.6 Qt)

+ 23 hidden pages