Pulsafeeder HypoPump2 User Manual

PULSAR®

Bulletin #: PS-IOM-HYPO2-0111-B

Installation, Operation &

Maintenance Instruction ADDENDUM

HYPOPUMP2®

AUTO DE-GAS METERING PUMP

FACTORY SERVICE POLICY

If you are experiencing a problem with your Pulsafeeder pump, first review the IOM, and consult the troubleshooting guide. If the problem is not covered or cannot be solved, please contact your local PULSA Series Sales Representative or our Technical Service Department at (585) 292-8000 for further assistance.

Trained individuals are available to diagnose your problem and arrange a solution. Solutions may include purchasing a replacement unit or returning the pump or components to the factory for inspection and repair. All returns require a Return Material Authorization (R.M.A.) number to be issued by Pulsafeeder.

Certain components may be purchased for replacement. Parts purchased to correct a warranty issue may be credited after examination of the original parts by Pulsafeeder personnel. Parts returned for warranty consideration that test satisfactorily, will be sent back to the originator freight collect.

Any field modifications will void the Pulsafeeder warranty. Out-of-warranty repairs will be subject to Pulsafeeder's stand ard bench fees and tes ting cos ts assoc iat ed wi th repla ce ment components.

Notice

Information and specifications in this document are subject to change without notice.

Revision Histor y:

Rev A (01-01-11)

- Original Release Date

Rev B (04-7-14)

- Updated label graphics

- Updated electrical drawings

- Updated maintenance and retrofit information (section 9)

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.

Trademarks

PULSAR® is a registered trademark of Pulsafeeder, Inc. PULSAR HypoPump PULSAR Shadow

is a registered trademark of Pulsafeeder, Inc.

iii

Table of Contents

1. Conventions ...................................................................................................................................... iv

2. General Safety................................................................................................................................... 1

2.1 Explosive Atmosphere Safety ................................................................................................ 1

2.2 Electrical Safety ....................................................................................................................... 1

2.3 Hydraulic Safety ...................................................................................................................... 1

3. Equipment Inspection ...................................................................................................................... 2

4. Storage………………………………………………………………………………………………..………2

4.1 Short Term (0 - 12 months) ..................................................................................................... 2

4.2 Long Term (12 months or more) ............................................................................................ 2

5. Retrofit………………………………………………………………………………………,………………2

6. Overall System Diagram .................................................................................................................. 3

7. Installation ......................................................................................................................................... 4

7.1 Location .................................................................................................................................... 4

7.2 Installation Notes ..................................................................................................................... 4

7.3 Electrical Wiring ...................................................................................................................... 4

8. Description and Operation .............................................................................................................. 6

8.1 Principle of Operation ............................................................................................................. 6

8.2 General Description ................................................................................................................ 6

8.3 Operation of Manual Override Button .................................................................................. 6

9. Maintenance ...................................................................................................................................... 7

9.1 Maintenance Notes .................................................................................................................. 7

9.2 Auto De-gas Valve Seal Kit Replacement ............................................................................. 7

9.3 Auto De-gas Valve Body and Discharge Valve Assembly Removal………………………11

10. Troubleshooting Guide………………………………………………………………………………..…11

11. Hypo Valve Replacement Instruc tions .......................................................................................... 12

USER NOTE: This addendum serves as additional information for Pulsafeeder PULSAR® and PULSAR Shadow® metering pumps equipped with the Auto De-gas Valve for purging trapped gasses from the reagent head. You must also reference the latest revision of the complete PULSAR® or PULSAR Shadow® pump IOM for critical safety and operational information.

1. Conventions

Tips have been included within this bulletin to help the operator run the equipment

For the remainder of this bulletin, the following Conventions are in effect.

WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE EQUIPMENT AND THE PERSONNEL OPERATING IT ATTENTION TO ANY WARNING

Notes are general information meant to make operating the equipment easier.

in the most efficient manner possible. These “Tips” are drawn from the knowledge and experience of our staff engineers, and input from the field.

. PAY CLOSE

The HYPOPUMP2

Auto De-gas Pump, designed for purging entrained gas from the pump reagent

head, is referred to in this manual as the “ADV”.

2. General Safety

The Auto De-gas Valve (ADV) was designed as a gas handling/priming aid for operation solely with Pulsafeeder PULSAR considered un-safe and voids all certification markings and warranties.

and PULSAR Shadow® metering pumps. Use for any other application is

2.1 Explosive Atmosphere Safety

Explosion Hazard -- Do not perform installation or maintenance of any kind on this device while circuit is live and/or the area is known to be hazardous. This unit is not intended for use in explosive or hazardous locations.

2.2 Electrical Safety

Improper application and use of the ADV can be hazardous. You are solely responsible for its use. The ADV electrical installation must conform to all relevant electrical codes. Installation and electrical

maintenance must be performed by a qualified electrician. Before installing or servicing this device, all power must be disconnected from the source at the main distribution panel.

The ADV emits electro-magnetic energy. Its use is restricted to industrial applications. You are responsible for shielding this device if necessary.

It is recommended that the ADV be powered from a Ground Fault Circuit Interrupter (GFCI) protected electrical ci rcuit.

2.3 Hydraulic Safety

Thoroughly review and adhere to the contents of the latest version of the PULSAR® or PULSAR Shadow metering pump.

Installation, Operation, Maintenance (IOM) manual for hydraulic installation of your

3. Equipment Inspection

When you receive your order, check all equipment for:

• Completeness against the shipping document / purchase order

• Evidence of shipping damage.

Shortages or damage should be reported immediately to the carrier and your PULSAFEEDER representative.

4. Storage

The ADV can be successfully stored for extended periods. The key to this success is temperature and humidity control.

Be certain to follow the additional storage instructions provided in the IOM for the PULSAR Shadow attached to the pump.

4.1 Short Term (0 - 12 months)

pumps, and also those included in the IOM for any controllers (DLC, DLCM, ECA) that are

or PULSAR

The ADV should be stored in a temperature and humidity controlled environment. It is preferable to keep the temperature constant in the range of -18 to 60° Celsius (0 to 140° Fahrenheit). The relative humidity should be 0 to 90% non-condensing.

If the ADV is installed on the pump, it should not be removed during this period – provided the above conditions can be applied to the pump as well. If the ADV was shipped in its own carton, it should be stored in that carton.

4.2 Long Term (12 months or more)

Storage of the ADV for periods of longer than twelve months is not recommended. If extended storage is unavoidable the ADV should be stored in accordance with those conditions stipulated for Short Term Storage. In addition, a porous bag of 85g (3 oz) silica gel or similar desiccant should be placed inside the ADV enclosure. The cover should be re-installed to seal the desiccant within the enclosure. The conduit connection must be tightly capped.

5. Retrofit

Retrofit kits including the HypoPump2® reagent head assembly, the ADV, and other necessary parts and hardware, are available. These allow the conversion of an existing Pulsafeeder PULSAR PULSAR Shadow

Converting from the HypoPump

the Hypo Valve Replacement Instructions within this IOM.

metering pumps to a HypoPump2®. This conversion can be performed in the field.

to the HypoPu mp®2 does not have any port-to-port changes. See

and

6. Overall System Diagram

Figure 1

The ADV consists of a pressure balanced valve which opens periodically to allow fluid from the discharge line to bypass the discharge check valve and flow back into the pump head. The valve is actuated by a solenoid controlled by a solid-state tim er. The ADV Valve Assembly incorporates a dual sealing design to insure the valve function even if the Primary Bellows seal fails. The Leak Detection Port (1/8” NPTF) allows visual indication of a Bellows failure while allowing the ADV to keep functioning. At the discretion of the user, this port may be used to pipe any leakage to a safe vessel or a leak detection device.

7. Installation

7.1 Location

Review the Safety section prior to installing the pump with ADV. It contains information required to properly install and operate the ADV in an industrial environment.

Review the PULSAR your metering pump. It details system related issues that are important to proper operation of the pump and also the ADV. The ADV should be mounted in an area where the operator has access to the front of the unit. Avoid locations where the ADV would be subjected to extreme cold or heat. Note the warning statement on the next page. The installation of this device must comply with national, s ta te an d lo ca l codes.

Allow 6 inches minimum clearance from the front of the ADV enclosu re to allow for removal and re-installation of the ADV as a unit.

AVOID LOCATIONS WHERE THE ADV WOULD BE SUBJECTED TO EXTREME COLD OR HEAT OR

DIRECT SUNLIGHT ITS WARRANTY

MINIMUM OPERATING TEMPERATURE 0 MAXIMUM (PVC CONSTRUCTION) 49 MAXIMUM (PVDF CONSTRUCTION) 65

. FAILURE TO OBSERVE THIS WARNING COULD DAMAGE THE ADV AND VOID

or PULSAR Shadow® Installation Operation Maintenance manual provided with

CELSIUS / 32° FAHRENHEIT

CELSIUS / 120° FAHRENHEIT

CELSIUS / 150° FAHRENHEIT

7.2 Installation Notes

1. Do not make any electrical connections without adequate grounding.

2. Conduit connections can carry fluids and vapors into the ADV causing damage and voiding the

warranty. Care should be taken when installing conduit to protect against fluid/vapor entry. If necessary, provide sealed entries or conduit drains near the point of entry.

3. It is recommended that the ADV be powered from a Ground Fault Circuit Interrupter (GFCI) protected

electrical ci rcuit.

7.3 Electrical Wiring

The ADV is available in two voltages, and is rated as follows:

115 VAC, 50/60 Hz, 0.2 A

230 VAC, 50/60 Hz, 0.1 A

The ADV voltage is indicated on the enclosure label.

Wiring Diagram

Install wiring to the unit using a minimum of 18 inches of flexible conduit or cable attached to the auto valve assembly in order to facilitate removal of the valve assembly from the reagent head for cleaning or maintenance.

Wiring must conform to all applicable codes. Prior to pump startup; always check to ensure that the ADV

voltage and frequency matches that of the power supply. It is recommended that the ADV be powered

from a Ground Fault Circuit Interrupter (GFCI) protected electrical circuit.

1. Remove the enclosure front cover. Note: The plastic screw hole plugs can be pried out using a flat

bladed tool.

2. Bring AC power and ground wires into valve assembly enclosure through the 7/8” diameter hole in the

side of the enclosure. Use #20 AWG 105 degree C insulation wire size minimum. Connect per the wiring diagram. The wiring diagram is also reproduced on a label affixed to the back of the enclosure cover.

3. Apply power to the valve assembly with or without the pump running. Verify that the solenoid

mounted on the pump reagent head clicks every 30 seconds.

4. Reattach cover and replace plastic hole plugs over screws.

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