Pulsafeeder larm User Manual

PULSAlarm

Leak Detection Vacuum and Pressure Options For PULSA Series Metering Pumps

Models 680, 880, 7120, 7440, 7660, and 8480

Installation, Operation & Maintenance Instruction

Bulletin #: IOM–PSVLD-03 Rv B

ENGINEERED PUMP OPERATIONS 2883 Brighton Henrietta Townline Road Rochester, New York, 14623 Telephone (585) 292-8000 Fax (585) 424-5619 www.pulsa.com E-mail:pulsa@idexcorp.com

Manufacturers of Quality Pumps,

Controls and Systems

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 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 that 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.

4-27-2007 Rev B – change material references to “PTFE”

Notice

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

Information in this document is subject to change without notice. No part of this publication may 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

Pulsa Series® and PULSAlarm® are registered trademarks of Pulsafeeder, Inc.

Table of Contents

1. S

YSTEM INFORMATION

1.1 Description and Theory of Operation...............................................................5

1.2 PULSAlarm Reagent Head..............................................................................6

1.3 PULSAlarm Leak Detection Diaphragm ..........................................................6

1.4 Diaphragm Construction..................................................................................7

2. E

LECTRICAL

3. S

ETUP FOR VACUUM SYSTEM

4. S

ETUP FOR PRESSURE

.............................................................................................................. 8

...............................................................................................5

..................................................................................... 9

..............................................................................................10

4.1 Pressure fill chamber.......................................................................................14

5. M

AINTENANCE

........................................................................................................... 16

5.1 Switch Setpoint Adjustment.............................................................................16

5.2 PULSAlarm Diaphragm Maintenance..............................................................17

5.2.1 PULSAlarm Diaphragm Removal.............................................................. 17

5.2.2 Inspection.................................................................................................. 18

5.2.3 PULSAlarm Diaphragm Reinstallation ...................................................... 18

5.3 Leak Detection system conversion ..................................................................19

6. S

ILICONE FLUID

MSDS.............................................................................................. 19

Conventions:

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

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

For information on overall pump operation and maintenance, refer to the Installation, Operation, and Maintenance manual specific to the model of pump in question. The information in this bulletin pertains only to the PULSAlarm leak detection system supplied as an option on Pulsafeeder PULSA Series pumps.

1. System Information

1.1 Description and Theory of Operation

The PULSAlarm leak detection system utilizes a two-layer PTFE diaphragm, coupled to a pressure or vacuum switch.

For the vacuum-based option, a vacuum is drawn between the two layers of the diaphragm assembly. During normal operation, vacuum is maintained. If there is a failure of either layer of the diaphragm, the vacuum is lost. When the vacuum reaches a set value, the sensing switch is trigger to signal an alarm. This system allows for simple setup, however the vacuum will leak down over time under normal conditions. The system will need to have this vacuum occasionally renewed during operation.

For the pressure-based option, the system is initially primed by filling the void within the detection assembly and between the diaphragm layers with a barrier fluid. The setup process then bleeds excess fluid from between the diaphragm layers until they are in close contact. The system operates as follows:

During normal pump operation, the two layers of the PTFE diaphragm bear directly against one another, and there is no pressure generated between the two layers. The sensing system monitors the space between the layers, which will remain at zero pressure as long as the diaphragm layers remain undamaged.

In the event of a failure of either layer of the diaphragm, liquid will enter the space between the two layers. This liquid will be either the hydraulic oil (if the rear layer fails) or the pumped fluid (if the front layer fails). As the pump operates, this liquid will generate pressure between the layers of the diaphragm that will then be transferred outwards by the barrier fluid. This fluid will create pressure against the pressure switch. This switch has a trip point of 5 psi (0.34 bar). When this pressure is reached the switch will operate. The pressure system requires a more complex setup procedure, however once operational it should require no further maintenance or operator interaction.

The output of the switch on either system (both normally closed and normally open connections are available) can then signal the failure of the diaphragm. It is recommended that the pump be stopped in the event a leak is detected. Immediate attention to the problem, followed by cleanup and appropriate maintenance, will avoid further damage to the pump.

The barrier fluid used with the pressure-based system should be chosen for compatibility with the process and environmental conditions. The fluid chosen should have as low a viscosity as possible to aid in priming the system. Water can be used, and ethylene or propylene glycol can be added for corrosion and temperature protection. Thin oils such as silicone oil or mineral oil can also be used. Liquids of higher viscosity will extend the time required to properly prime the system. Thinner liquids will allow for faster setup. Pulsafeeder supplies as standard a low viscosity silicone oil.

System identification (vacuum or pressure based) is noted on the switch cover nameplate, and also on your Pulsa Series pump Specification Data Sheet.

1.2 PULSAlarm Reagent Head

The PULSAlarm leak detection reagent head assembly consists of reagent head, leak detection diaphragm, suction and discharge check valves, bleed port, and optional switch and gauge. The reagent head, diaphragm, suction and discharge check valves are the only parts of the pump to contact the process liquid; consequently, maintenance is critical to pump performance

SEALED SYSTEM MUST BE MAINTAINED AT ALL TIMES DURING PUMP OPERATION, WHETHER LEAK DETECTION IS REQUIRED OR NOT. IF THE PROPER LEVEL OF VACUUM, BETWEEN 10 IN AND 26 IN. PRESSURE SYSTEM IS NOT PRESENT, DECREASED FLOW AND/OR DIAPHRAGM DAMAGE WILL OCCUR. PLEASE NOTE THAT THE FACTORY SETPOINT FOR ACTUATION OF THE VACUUM SWITCH IS 6 IN

(

PRESSURE

(250

Figure 1 – reagent head

MM TO

650MM) HG,

(152MM) HG (

VACUUM) OR 5 PSIG

OR A SEALED

1.3 PULSAlarm Leak Detection Diaphragm

Double, or sandwiched, PTFE diaphragms are sealed at their peripheries to an intermediate metal spacer ring. The space between the diaphragms is sealed so that the diaphragm functions as does a standard single diaphragm. For the vacuum system, the space between the diaphragms is evacuated of air to produce a vacuum. For the pressure system, the space between the diaphragms is filled with a small amount of fluid. This space is connected to an adjustable electrical switch (optional) that actuates in response to loss of vacuum or buildup of pressure resulting from rupture of either or both diaphragms. Switch operation can be used to perform any external function, typically to signal an alarm or turn off the pump. Refer to Figures 1 and 2.

During installation, ensure that adequate space is available at the front of the reagent head assembly to allow for service of both the pressure switch and the diaphragm assembly.

1.4 Diaphragm Construction

The adhesive rings aid in assembly and are not present for sealing purposes.

Capillary tube

Support ring

Process side PTFE layer

Hydraulic side PTFE layer

Figure 2 – diaphragm construction

Adhesive ring

2. Electrical

If equipped with an optional pressure switch, install electrical wiring and conduit in accordance with local electrical codes.

The switch is rated as follows:

Figure 3 – switch and housing

30 VDC or 125 VAC 1 Ampere Resistive.

The switch is the SPDT (single pole, double throw) type and can therefore be connected to either open or to close upon detection of diaphragm leak condition. Contacts or wires are identified as follows:

Normally Open (NO) wire color WHITE

Normally Closed (NC) wire color RED

Common (Com) wire color BLACK

HE ENCLOSURE IS LABELED WITH APPLICABLE SAFETY AGENCY RATINGS FOR HAZARDOUS AREA INSTALLATION. SINCE THE SWITCH IS OF THE MECHANICAL CONTACT TYPE, IT CAN NEVER QUALIFY AS NON-SPARKING (NON-INCENDIVE, OR FOR OCCASIONAL AND SHORT-TERM HAZARDOUS AREA USE. PROTECTION MUST BE PROVIDED BY THE ENCLOSURE.

“M”)

+ 16 hidden pages