Pulsafeeder GLM DM7 User Manual

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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)

6.3.3 Oil Changes

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

Normal service: Clean/dry atmosphere, an ambient operating temperature of 00 C to 400 C

F to 104

(32

F) and up to 2,000 annual operating hours.

Severe Service: Humid atmosphere, an ambient operating temperature below 00 C (320 F) or

above 40

C (1040 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.

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. Ensuree that any other fluid used for priming is compatible with the product that will be pumped.





Figure 6, process

flow

6.5 Calibration

Figure 7, 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

BEFORE 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 AND THE ENVIRONMENT BY CLEANING AND CHEMICALLY NEUTRALIZING AS APPROPRIATE

WEAR 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 GLM maintenance program. It is recommended that KOPkits and PULSALube EP Gear Oil be kept available at all times.

IF THE DIAPHRAGM HAS FAILED, PROCESS FLUID MAY HAVE CONTAMINATED THE PUMP

ECCENTRIC HOUSING DIAPHRAGM WOULD PASS THROUGH THE BOTTOM DRAIN HOLE CARE

KOPkit will contain all replacement parts normally used in a preventative

, RENDER THE PUMP SAFE TO PERSONNEL

(ALTHOUGH NORMALLY, ANY PROCESS FLUID BEHIND A FAILED

). HANDLE WITH APPROPRIATE

Figure 8, wet end

components

GLM® DM7 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.

7.1 Diaphragm Removal & Reinstallation

1. Adjust the stroke setting to 0% and disconnect the power source to the drive motor.

2. Relieve all pressure from the piping system.

Take all precautions described under the WARNINGS on page 14, Section 7 to prevent

environmental damage and exposure of personnel to hazardous materials.

3. Close the inlet and outlet shutoff valves.

4. Place a pan underneath the pump head adaptor to catch any liquid leakage.

5. Note the orientation of the existing check valve components. Loosen the union nuts holding the check valves and piping to the reagent head. Remove the check valve assemblies, drain and rinse them, and set them aside in a safe place. Unscrew the union nuts completely from the regent head.

Figure 9, wet end

components

6. Remove all but one top reagent head bolt. Product will leak out between the pump head adaptor and reagent head as the bolts are loosened.

7. Remove the final bolt and rinse or clean the reagent head with an appropriate material.

8. Insert a screwdriver or similar tool through the oil fill hole and into the hole provided in the pushrod, this will keep the pushrod from turning as the diaphragm is removed. Note that depending to access the hole.

on pushrod

position, you may have to rotate the motor coupling or the diaphragm

Figure 10, securing

pushrod

9. Remove the diaphragm by turning it counter-clockwise.

10. Inspect the diaphragm. The diaphragm must be replaced if it is cracked, separated, or obviously damaged.

11. Install the diaphragm. a) Ensure that the critical sealing areas of diaphragm, reagent head, and pump head are

clean and free of debris.

b) Lubricate the elastomer side of the diaphragm liberally, where it is in contact against

the pump head and deflection plate. Use a silicone grease or silicone-based o-ring lubricant.

c) Coat the threads and the end of the pushrod with an anti-seize paste or lubricant.

12. Thread the diaphragm (clockwise) fully onto the shaft. When reinstalling a used diaphragm it is not necessary to maintain the previous orientation

relative to the reagent head or pump head hole pattern.

13. Remove the screwdriver from the oil fill hole and replace the cap.

14. Install the reagent head bolts and tighten in an alternating pattern to ensure an even seating

force. Torque to the values recommended in Section 6.1.

15. Reassemble the piping connections and check valves to the reagent head, using care to orient all check valve parts properly (refer to figures 9 and 12).

16. Re-prime the pump following the procedure outlined in Section 6.3.

7.2 Diaphragm Shaft Seal

While the diaphragm is removed, inspect the shaft seal located in the pump head. If there is evidence of damage or wear and/or oil leakage, the seal should be replaced.

1. Remove the three retainer screws and the seal retainer.

2. Pry the old seal out of the retainer.

3. Ensure the surfaces of the retainer are clean and clean of debris, scratches, or burrs.

4. Insert the new seal into the retainer by hand, do not use tools to prevent damage to the seal.

5. Inspect the piston shaft and remove any scratches, burrs, or surface corrosion or damage.

6. Lubricate the shaft with a small amount of pump oil.

7. Slide the seal and retainer back into position and secure with the three screws.

Figure 11, piston shaft seal replacement

7.3 Check Valves

Most fluid metering problems are related to check valves. Problems usually stem from solids accumulation between valve and seat, corrosion of seating surfaces, erosion, or physical damage due to wear or the presence of foreign objects.

The valve incorporates a ball, guide, and seat. Flow in the unchecked direction lifts the ball off the seat, allowing liquid to pass through the guide. Reverse flow forces the ball down, sealing it against the sharp edge of the seat. The guide permits the ball to rotate but restricts vertical and lateral movement in order to minimize “slip” or reverse flow. Ball rotation prolongs life by distributing wear over the entire surface of the ball. Since ball return is by gravity, the valve must be in the vertical position in order to function properly. Parts are sealed by “O”-rings.

GLM® DM7 xpumps utilize a multi-part check valve assembly, secured to the reagent head with a union nut clamping arrangement (plastic construction) or a tie-bar arrangement (metal construction).

Figure 12, check valves

DM7

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

1. Disconnect the power source to the drive motor.

2. Relieve all pressure from the piping system, and take all precautions necessary to prevent contamination to the environment and personnel exposure to hazardous materials.

3. Close the inlet and outlet shutoff valves.

4. Loosen the union nuts that hold the check valves in place. It is not necessary to completely remove the nut.

5. Push the check valve assembly out of the front by inserting your finger or a tool into the clearance hole at the back of the holder. Note carefully the position of the component parts, to assist in re- assembly. Be aware that product may leak out as the check valve parts are removed.

6. Replace both valve assemblies onto the pump, taking care to ensure they are oriented correctly, with the balls above the seats, and the seats oriented with the o-ring seat facing up and the chamfered edge down.

The check assemblies must be pushed into the holder until they stop against the back surface. Replace parts with new as required. Sealing o-rings should generally be replaced even if the check components are re-used.

Figure 13, union-nut type check

valve

Inserting the check valve assembly into the pump in the wrong directiom, or having the check seat upside down, will prevent proper seals at the o-rings, decrease pump performance, and can cause damage to the diaphragm. Each union nut should be tightened only until the o-ring seal makes good contact.

7. Carefully make sure that the check asse mblies are i n proper position , and tighten the union nuts .

8. Retighten any unio ns, flanges, or other proces s connections t hat may hav e been loosened p reviously.

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

1. Disconnect the power source to the drive motor.

2. Relieve all pressure from the piping system.

3. Take all precautions necessary to prevent contamination to the environment and personnel exposure to hazardous materials.

4. Close the inlet and outlet shutoff valves.

5. Loosen the suction valve tie-bar bolts (4) and spring the suction piping slightly away from the head, allowing liquid to drain. It may be necessary to loosen a union or flange.

6. Remove the suction check valve assembly by sliding it towards you, holding it together as a unit. Note carefully the position of the component parts, to assist in re-assembly.

7. Loosen the discharge valve tie-bar bolts (4) and spring the discharge piping slightly away from the head, allowing liquid to drain. It may be necessary to loosen a union or flange.

8. Remove the discharge check valve assem bly by slidi ng it towards y ou, holding it together as a uni t. Note carefully the position of the component parts, to assist in re-assembly.

9. Disassemble both valves and check components for wear or damage. The seats should have a sharp edge and be free from dents or nicks. Hold a ball firmly against the seat in front of a bright light and inspect for fit, observation of light between the ball and seat is cause for replacement.

10. Reassemble both valves using new parts as required. Sealing o-rings should always be

replaced.

11. Replace both valve assemblies onto the pump, taking care to ensure they are oriented correctly, with the balls above the seats, and the seats oriented with the sharp edge up and the chamfered edge down.

Inserting the check valve assembly into the pump in the wrong direction, or having the check seat upside down, will prevent proper seals at the o-rings, decrease pump performance, and can cause damage to the diaphragm.

12. Carefully make sure that the check assemblies are in proper position, and tighten the four tie-bar bolts, using a star pattern, to a torque of 6 Ft-lbs (8 N-m).

13. Retighten any unions, flanges, or other process connections that may have been loosened

previously.

Figure 14, Check valves, metal construction

7.6 Motor Removal & Reinstallation

1. Disconnect the power source to the drive motor.

2. Disconnect the motor wiring from the motor.

3. Remove the four bolts retaining the motor to the motor adaptor.

Lift the motor upwards away from the

4. Apply an anti-seize paste or lubricant to all bolts, setscrews, and keys before reassembling..

5. Reinstall the motor in the reverse from removal.

6. Insert and tighten the four bolts removed in step 3.

7. Reconnect the motor wiring to the motor.

8. Connect power to the drive motor.

Motor rotation must be wired for CW rotation, as viewed from the top of the motor, as noted

pump.

by the arrow on the top of the pump housing.

Figure 15, motor

mounting

8. Replacement Parts

8.1 KOPkit Program

GLM® DM7 KOPkits contain all replacement parts normally used in a preventative maintenance program. (PULSAlube oil is also available separately for preventative maintenance programs. Refer to Section 6 – Equipment Startup). There is a specific KOPkit for every GLM All GLM

pumps have the KOPkit number identified on the pump nameplate and Pulsafeeder

order documents. KOPkits can also be selected from the technical data sheet shipped with the pump or by a Pulsafeeder representative. A list of the GLM found on the next page. The kit is identified by the model number of the pump, the wetted end material, and the process connection thread type. For models with tie-bar type check valves, the appropriate components (check valve balls, seats, and o-rings) are supplied instead of the cartridges pictured.

pump model. Each KOPkit is vacuum-packed for extended storage.

KOPkit numbers can also be

Figure 16, KOPkit parts

8.2 Ordering KOPkits or Parts

When ordering replacement parts always specify:

•

Pump model and serial number (from pump nameplate), e.g., Model No. (DM7) with Serial No. F406365-3.

•

Part number and description from the GLM® parts list. Include the three-character suffix. (Note: GLM NP170001-THY or

part numbers begin either with the letters NP, or the letter W, e.g.,

W210221-001.)

8.3 KOPkit numbers by model:

Pump Model

Wetted Material

Connection Type

KOPkit number

Position

Sample

Specifies

Options

1 – 4

Size/Flow

DM GLM

for DM7)

O-rings - Ceramic Ball Valves

DM7 DM7

NOTES: (1) DM1 through 6 models are covered in a separate publication (2) Polypropylene KOPkits are identical as only balls and insert o-rings are supplied

Polypropylene NPT / ISO / FLG

31 6

KD7P

NPT KD7A

9. Model Number Identification

5 Y Motor

Frame and Size

6 P Wetted

Materials

7 P Connection P 1.5” FNPT with 1.5” ANSI/DIN flange ring as standard

3 3PH 220/380V (and 460V) MOTOR IEC Frame, TEFC [50/60 Hz]

Y NO MOTOR - IEC frame (IEC71 for DMC1-6, IEC90 standard

A 316L SS Liquid End - PTFE Diaphragm and PTFE O-rings – 316SS Ball Valves

F PVDF/Viton - PVDF Liquid End - PTFE Diaphragm and Viton® O-rings - Ceramic Ball Valves

P PP/Viton - PP Liquid End - PTFE Diaphragm and Viton®

10. Troubleshooting

DIFFICULTY PROBABLE CAUSE REMEDY

Faulty power source Check power source Blown fuse, circuit breaker overload Replace - eliminate

Pump does not start

Broken wire Locate and repair Wired improperly Check diagram

Process piping blockage Open valves, clear other obstructions

No delivery

Low delivery

Motor not running

Check power source. Check wiring

diagram (see above) Supply tank empty Fill tank Lines clogged Clean and flush Closed line valves Open valves Ball check valves held open with solids Clean - inspect, flush with clear fluid Vapor lock, cavitation Increase suction pressure Prime lost Re-prime, check for leak

Strainer clogged

Remove and clean. Replace screen if

necessary Stroke adjustment set at zero Increase stroke lenth setting

Check voltages, frequency, wiring and Motor speed too low

terminal connections. Check

nameplate vs. Specificatio n s Check valves worn or dirty Clean, replace if damaged Calibration system error Evaluate and correct

Lower viscosity by increasi ng produc t Product viscosity too high

temperature or dilution. Increase

pump and/or piiping size Product cavitating Increase suction pressure

Delivery gradually drops

Check valve leakage Clean, replace if damaged Leak in suction line Locate and correct Strainer fouled Clean or replace screen Product change Check viscosity and other variables Supply tank vent plugged Unplug vent

DIFFICULTY PROBABLE CAUSE REMEDY

Leak in suction line Locate and correct Product cavitating Increase suction pressure Entrained air or gas in product Consult factory for suggested venting

Delivery erratic

Motor speed erratic Check voltage and frequency Fouled check valves Clean, replace if necessary

Increase discharge pressure to obtain a Inadequate backpressure

minimum pressure difference of 5 psi from

suction to discharge

Delivery higher than rated

Noisy gearing, knocking

Piping noisy

Motor overheats

Suction pressure higher than discharge pressure

Back pressure valve set too low Increase setting Vack pressure valve leaks Repair, clean or replace

Discharge pressure too high Reduce pressure

Water hammer Install pulsation dampener

Low oil level

Pipe size too small

Pip runs too long Install pulsation dampener in line

Pulsation sampener inoperative or flooded

No surge chamber or dampener used Install pulsation dampener

Pump overloaded

High or low voltage Check power source

Loose wire Trace and correct

Incorrect motor wiring Verify and correct

Oil level low Check and add as cecessary

Install backpressure valve or consult

factory for piping recommendations

Examine sight glass on side of pump, add or

replace oil as required.

Increase size of piping - install pulsation

dampener

Refill with air or insert gas. Inspect and replace

diaphragm and recharge

Check operating conditions against pump

design. Verify discharge pressure

11. Piping Accessories

Pressure Relief Valves

Pressure relief valves are designed to protect chemical feed systems from damage that may be caused by defective equipment or a blockage in the discharge line. These valves function to limit the pressure downstream of the pump. Field adjust the pressure relief valve to operate when the discharge pressure exceeds operating pressure by 10-15%. Pressure relief valve should always be adjusted to a setting below the maximum rated pressure of the pump. No potentially restrictive components, such as a valve, the PRV.

Diaphragm Backpressure Valve A diaphragm backpressure valve creates constant back pressure. A PTFE or PTFE-faced

diaphragm offers maximum chemical protection and service life, and seals spring and bonnet from product.

Be sure to install with fluid flow in direction of arrow on valve body.

Pulsation Dampener A pulsation dampener is a pneumatically charged diaphragm-type chamber that intermittently

stores hydraulic energy. Used on the inlet, it can improve NPSHA (Net Positive Suction Head available) characteristics of the suction piping system. On the discharge line it will reduce discharge pressure and pulsating flow variations.

should be

installed between the pump discharge and