Pulsafeeder Pro 900 User Manual
BULLETIN No.: PulsaPro 900-IOM-2009 Rev. J
PulsaPro Control Addendum
INSTALLATION
OPERATION
MAINTENANCE
INSTRUCTIONS
Manufacturers of Quality Pumps,
Controls and Systems
Pulsafeeder, Inc.
2883 Brighton Henrietta Town Line Road
Rochester, New York, 14623
Email: pulsa@idexcorp.com
Telephone: ++1 (585) 292-8000
Fax: ++1 (585) 424-5619
pulsafeeder.com
PulsaPro Series Guarantee
Should you experience a problem with your Pulsafeeder pump, first consult the troubleshooting
guide in your operation and maintenance manual. If the problem cannot be solved, please contact
your local Pulsafeeder Sales Representative, 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.
In addition, Pulsafeeder guarantees its
years from the date of shipment. All other material and workmanship are fully covered for a
period of one year. Any parts found to be defective within the above time span will be replaced
free of charge, F.O.B. our factory.
Equipment or accessories manufactured by others but purchased through Pulsafeeder, such as
electric motors, are guaranteed only to the extent of the original manufacturer.
Damages incurred from misuse, abuse, and/or improper protection during storage will be cause to
void this guarantee. Erosion, corrosion, or improper application of the equipment or related
piping by the buyer or any third party is also excluded.
The above guarantee is in lieu of any other guarantee, either expressed or implied. We make no
warranty of fitness or merchantability. No agent of ours is authorized to make any warranty other
than the above.
PulsaPro
Series drive assemblies for a period of five
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.
Copyright ©2009 Pulsafeeder, Inc. All rights reserved.
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.
ii
Table of Contents
1. INTRODUCTION ..................................................................................................................................... 1
1.1 General Description ................................................................................................................ 1
2. PRINCIPLES OF OPERATION ................................................................................................................... 1
2.1 Overall Operation .................................................................................................................... 1
2.2 Component Location ............................................................................................................... 2
2.2.1 Reagent Head Assembly ................................................................................................. 3
2.2.2 Pump Head/Piston Assembly ......................................................................................... 4
2.2.3 Control Assembly ............................................................................................................ 6
2.2.4 Gear Reducer Assembly ................................................................................................. 7
3. EQUIPMENT INSPECTION ....................................................................................................................... 8
4. STORAGE INSTRUCTIONS ...................................................................................................................... 8
4.1 Short Term ............................................................................................................................... 8
4.2 Long Term ................................................................................................................................ 8
5. INSTALLATION ...................................................................................................................................... 9
5.1 Location .................................................................................................................................... 9
5.2 Mounting .................................................................................................................................. 9
5.3 Piping System .......................................................................................................................... 10
5.3.1 Suction Pressure Requirements .................................................................................... 11
5.3.2 Discharge Pressure Requirements ................................................................................ 11
6. EQUIPMENT STARTUP ........................................................................................................................... 12
6.1 Lubrication ............................................................................................................................... 12
6.1.1 Oil Capacities ................................................................................................................... 12
6.1.2 Oil Fill ................................................................................................................................ 14
6.1.3 Oil Changes ...................................................................................................................... 16
6.2 Startup ...................................................................................................................................... 17
6.2.1 Output Adjustment .......................................................................................................... 17
6.2.2 Priming the Pump Head .................................................................................................. 18
6.2.3 Priming the Reagent Head .............................................................................................. 18
6.2.4 Motor Rotation ................................................................................................................. 19
6.2.5 Calibration ........................................................................................................................ 20
7. MAINTENANCE ...................................................................................................................................... 21
7.1 Wet End Removal, Inspection, and Reinstallation ............................................................... 22
7.2 Re-Priming the Pump Head .................................................................................................... 24
7.2.1 Re-Filling the Hydraulic System ..................................................................................... 25
7.2.2 Re-Priming the Hydraulic System .................................................................................. 25
7.3 Check Valves ........................................................................................................................... 26
7.3.1 Check Valve Removal ..................................................................................................... 27
7.3.2 Ball Valve – Inspection and Repair ................................................................................ 27
7.3.3 Disk Valve – Inspection and Repair ............................................................................... 27
7.3.4 Check Valve Reinstallation ............................................................................................. 28
7.4 Hydraulic Performance Valve (HPV) ...................................................................................... 29
7.4.1 HPV Removal and Replacement .................................................................................... 30
7.5 Hydraulic Bypass Valve (HBV) ............................................................................................... 31
7.5.1 PTP (Push To Purge) Valve ............................................................................................ 32
7.5.2 PTP Removal, Cleaning, and Reinstallation ................................................................. 33
7.5.3 Piston Seal ....................................................................................................................... 34
7.5.4 Piston Removal ................................................................................................................ 35
7.5.5 Piston Seal Reinstallation ............................................................................................... 35
7.6 Oil Seals ................................................................................................................................... 37
7.6.1 General Description......................................................................................................... 37
7.6.2 Motor Adaptor Oil Seal Removal and Replacement ..................................................... 38
7.7 Stroke Control Assembly ....................................................................................................... 40
7.7.1 Stroke Control Assembly Maintenance ......................................................................... 40
7.8 Motor Removal and Reinstallation ........................................................................................ 41
8. REPLACEMENT PARTS .......................................................................................................................... 42
8.1 PulsaPro Series KOPkit Program .......................................................................................... 42
iii
8.2 Ordering KOPkits or Parts ...................................................................................................... 42
9. PULSALARM LEAK DETECTION PUMP HEAD ASSEMBLY ....................................................................... 43
9.1 PULSAlarm Leak Detection Diaphragm ................................................................................ 44
9.2 Leak Detection – Setup for Pressure ..................................................................................... 44
9.3 Pressure System Set-up and Priming ................................................................................... 45
9.4 PULSAlarm Leak Detection Diaphragm Maintenance ......................................................... 47
9.4.1 Leak Detection Diaphragm Removal ............................................................................. 48
9.4.2 Inspection ......................................................................................................................... 48
9.4.3 Leak Detection Diaphragm Reinstallation .................................................................... 48
10. TROUBLESHOOTING CHART................................................................................................................... 49
APPENDIX I – PIPING CALCULATIONS ........................................................................................................... 51
Suction Head Requirements .............................................................................................................. 51
System Back Pressure ........................................................................................................................ 53
Nomenclature ....................................................................................................................................... 53
APPENDIX II – OIL SPECIFICATIONS .............................................................................................................. 54
PULSAlube Universal 1HG ................................................................................................................. 54
APPENDIX III – BOLT TORQUE RECOMMENDATIONS/NOZZLE LOADS ............................................................. 55
Reagent Head and Tie-Bar .................................................................................................................. 55
Pump Head Bolts ................................................................................................................................. 55
Nozzle Loads ........................................................................................................................................ 56
APPENDIX IV DIMENSIONAL DRAWINGS ........................................................................................................ 57
APPENDIX V EC DECLARATION OF CONFORMANCE ...................................................................................... 62
P
ULSA PRO CONTROL ADDENDUM ............................................................................................................... 63
Conventions
For the remainder of this bulletin, the following Conventions are in effect.
A 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.
Tips have been included within this bulletin to help the operator run the
equipment in the most efficient manner possible. These “Tips” are drawn from
the knowledge and experience of our staff engineers, and input from the field.
iv
. PAY CLOSE
1. Introduction
1.1 General Description
Diaphragm Metering pumps are positive displacement reciprocating pumps that combine the
high efficiency of the plunger pump with a sealed diaphragm that prevents product leakage.
Each pump consists of a power end and a process end separated by a hydraulically operated
diaphragm. Individual pumps will vary in appearance due to various liquid ends, accessories,
and multiplexing - however, the basic principles of operation remain the same.
2. Principles of Operation
2.1 Overall Operation
Figure 1
A piston reciprocates within an accurately sized cylinder at a preset stroke length, displacing
an exact volume of hydraulic fluid. The hydraulic fluid acts against a sealed diaphragm,
which pumps the chemicals.
The piston and associated mechanisms are enclosed by a chamber called the Pump Head or
intermediate housing. This also acts as a hydraulic oil reservoir.
The diaphragm separates the hydraulic oil from the product pumped. The diaphragm moves
in exact response to the piston displacement. The diaphragm does no work, and acts only as a
separator.
The displacement of the oil is translated into an equal displacement of the chemical being
pumped. Therefore, piston retraction causes the product to enter through the suction check
valve. Piston advance causes the discharge of an equal amount of the product through the
discharge check valve.
1
2.2 Component Location
Figure 2
2
2.2.1 Reagent Head Assembly
The term Reagent Head Assembly refers to the pump components that come into direct
contact with the process fluid (or Reagent). The typical Reagent Head Assembly consists of
the following components:
a) Reagent Head
b) Diaphragm
c) Suction Check Valve
d) Discharge Check Valve
High flow pump models use disk valves.
DISK VALVE DESIGN BALL VALVE DESIGN
Figure 3
3
2.2.2 Pump Head/Piston Assembly
The pump head/piston assembly is installed on the intermediate housing. This assembly contains
the hydraulic system which consists of the pump head, cylinder, piston assembly, and four
hydraulic valves:
a) Push-To-Purge (PTP)
b) Hydraulic Performance Valve (HPV)
c) Hydraulic Makeup Valve (HMV)
d) Hydraulic Bypass Valve (HBV)
PTP
HBV
Figure 4
HMV
Detail A
HPV
Detail A
4
2.2.2.1 Push to Purge (PTP)
The Push to Purge (PTP) valve is located at the top of the Pump Head. It
automatically removes air entrained in the hydraulic system. Pressing down on the
button at the top of the PTP overrides its automatic operation. This allows a small
amount of hydraulic fluid to bleed from the pump head to the reservoir every stroke.
Activating the PTP in this manner helps determine if the pump head is properly
primed and diaphragm integrity is maintained.
2.2.2.2 Hydraulic Performance Valve (HPV)
The Hydraulic Performance Valve (HPV) automatically maintains the hydraulic oil
that “connects” the piston to the diaphragm. During normal operation small amounts
of hydraulic fluid is lost past the piston seal and PTP. This causes the diaphragm to
move progressively closer to the button on the HPV valve (see Figure 4, Detail A).
Over time, the diaphragm will come into contact with this button. When this occurs, it
will push the HPV valve open allowing lost hydraulic fluid to be replenished.
2.2.2.3 Hydraulic Makeup Valve (HMV)
The Hydraulic Makeup Valve (HMV) works in conjunction with the HPV to assure
hydraulic oil flows in one direction (into the diaphragm/piston chamber) at the correct
pressure.
2.2.2.4 Hydraulic Bypass Valve (HBV)
The Hydraulic Bypass Valve (HBV) protects the pump from over-pressurizing by
relieving any excess pressure. It is typically set at 110% of the Pump’s discharge
pressure.
5
2.2.3 Control Assembly
The output of the
with each pump stroke. The Piston is attached to a rotating cam with a connecting rod. The
Control Assembly allows the throw of the cam to be adjusted (see Figure 5). The assembly
consists of the following parts:
e) Hand wheel
f) Threaded Shaft
g) Inner Stroke Adjust Shaft
h) Large and Small Plunger
i) Inner Cam
2.2.3.1 Operation
The output of the pump is varied by turning the Hand Wheel. The Hand Wheel turns a
threaded shaft. Depending on the direction of rotation, this either pulls the inner stroke
adjustment shaft towards the hand wheel or pushes it away. The inner stroke shaft includes
two opposite faces that are machined on an angle. A Large and Small Plunger ride on these
opposite faces. An Inner Cam rides over the plungers. As the position of the Inner Stroke
Adjustment Shaft changes, the Plungers shift from one side to the other causing the throw of
the cam to change.
PulsaPro 900
can be controlled by changing how far the piston moves
Figure 5
The stroke length setting is denoted by a 0 – 100% scale with 2.5% increments. The scale is
located on the top part of the stroke control housing under a clear sealed cover.
6
2.2.4 Gear Reducer Assembly
PulsaPro 900
adaptor that completely encloses a coupling. The motor drives a worm gear reduction that
turns an eccentric shaft assembly – converting the rotary motion into reciprocating motion.
pumps are driven by a standard C-face electric motor mounted to an
Figure 6
A single drive assembly can drive up to four Pump/Reagent Head assemblies. This is
referred to as multiplexing.
Figure 7
Whenever pumps are multiplexed the eccentric shafts are positioned to place a uniform load
on the drive. Before full disassembly always note the relative positions of the eccentric shafts
to each other so they can be reassembled back in the same orientation.
7
3. Equipment Inspection
Check all equipment for completeness against the order and for any evidence of shipping
damage. Shortages or damage should be reported immediately to the carrier and your
PulsaPro
Representative.
4. Storage Instructions
4.1 Short Term
Storage of
recommended short-term storage procedures are:
a) Store the pump indoors at room temperature in a dry environment.
b) Prior to startup, inspect the pump head, and gearbox. Replenish oil as required to
c) Prior to startup, perform a complete inspection and then start up in accordance with the
PulsaPro
maintain operating levels. If water or condensation is present, change oil as described in
the Equipment Startup section.
instructions in this manual.
4.2 Long Term
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 and gaskets. If the pump has been in storage longer than 12
months it is recommended that all seals and gaskets be inspected and replaced as necessary
prior to startup. Materials and labor to replace this class of item under this circumstance are the
purchaser’s responsibility. For a continuance of the 5 year warranty after extended storage,
equipment inspection and any required refurbishing must be done by a Pulsafeeder
Representative.
Series pumps for up to 12 months is considered short-term. The
8
5. Installation
5.1 Location
When selecting an installation site or designing a skid package, consideration should be given to
access for routine maintenance.
PulsaPro 900
covering to protect the pump from direct weather and sunlight is required. External heating
and/or the use of synthetic lubricants for the gearbox is recommended if ambient temperatures
below 20°C (0°F) or above 40°C (104°F) are anticipated. Check with the factory if you are
concerned with the suitability of the operating environment.
pumps are designed to operate indoors and outdoors. At a minimum, a
5.2 Mounting
The pump must be rigidly bolted to a solid and flat foundation to minimize vibration, which can
loosen connections. Bolt each base with a minimum of 1” diameter studs with flat and lock
washers in 4 locations per base (note: the quad configurations include 2 bases). The pump must
be level within 2°. This will assure that the oil is maintained at the proper level and that the
check valves can operate properly.
mm
[inch]
Figure 7
9
5.3 Piping System
DISCHARGE
RETURN TO TANK
FROM SUPPLY TANK
Figure 8A
All piping systems should include:
1. Shutoff valves and unions (or flanges) on suction and discharge piping.
a) This permits check valve inspection without draining long runs of piping.
b) Shutoff valves should be of the same size as connecting pipe.
c) Ball valves are preferred since they offer minimum flow restriction.
2. An inlet strainer, if the process fluid is not a slurry.
a) Pump check valves are susceptible to dirt and other solid contaminants unless designed
for that service, and any accumulation can cause malfunction.
b) The strainer should be located between the suction shutoff valve and the pump suction
valve.
c) It must be sized to accommodate the flow rate and the anticipated level of contamination.
d) 100 mesh screen is recommended.
3. Vacuum/pressure gauges in the suction and discharge lines in order to check system operation.
a) Gauges should be fitted with protective shutoff valves for isolation while not in use.
10
4. A separate system relief valve to protect piping and process equipment, including the pump,
from excess process pressures.
a) The hydraulic bypass valve (HBV) in the pump is not intended to protect the system.
Piping weight must not be supported by valve housings or other portions of the reagent head, as
the resulting stresses can cause leaks. If appropriate, provide for thermal expansion and
contraction so that no excess force or movement is applied to the pump.
In piping assembly, use a sealing compound chemically compatible with the process material.
Users of sealing tape are cautioned to ensure that the entering pipe thread ends are not taped,
and that tape is removed from previously-used threads prior to re-use. 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.
5.3.1 Suction Pressure Requirements
Although metering pumps have suction lift capability, all pump installations should be designed
to minimize lift for optimal performance. A flooded suction (i.e., suction fluid level higher than
the centerline of the pump) is preferable whenever possible. The pump should be located as
close as possible to the suction side reservoir or other source.
If suction lift is required, the minimum net positive suction pressure required (NPSH
psia (0.21 bar) above the Vapor Pressure of the Process Fluid. If this requirement is not met
the Process Fluid may cavitate inside the pump, degrading metering accuracy.
Likewise, if the suction pressure is low enough, it is possible to cavitate the hydraulic fluid used
to move the diaphragm in the pump. Therefore, suction pressure must also be maintained at a
minimum absolute value of 5 psia (0.34 bar) to ensure proper hydraulic system and pump
operation.
The suction pressure must not exceed 165 psia (11.38 bar) for pumps with TFE diaphragms.
Please consult the factory for higher suction applications.
Higher pressures may be possible with optional alternate diaphragm materials or
modified dish plates.
Refer to Appendix I for a complete explanation of Suction Pressure Requirements including
methods to calculate values for your system.
5.3.2 Discharge Pressure Requirements
All Pulsafeeder Metering Pumps are designed for continuous service at the rated discharge
pressure. If system suction pressure were to exceed system discharge pressure (a condition
sometimes described as “pumping downhill” or “flow-through”), excess flow would be
generated, resulting in a reduction in accuracy and loss of control over the metering process. To
prevent this condition, the discharge pressure must exceed the suction pressure by at least 25
psia (1.7 bar). This can be achieved where necessary by installing a backpressure valve in the
discharge line.
DISCHARGE PRESSURE MUST NEVER EXCEED THE HYDRAULIC BYPASS VALVE (HBV)
SETTING ON THE NAMEPLATE
PERFORMANCE
, DAMAGE THE PUMP AND VOID THE WARRANTY.
. EXCESSIVE DISCHARGE PRESSURE COULD IMPAIR
) is 3
R
Refer to Appendix I for a complete explanation of Discharge Pressure Requirements including
methods to calculate values for your system.
11
6. Equipment Startup
6.1 Lubrication
PULSAPRO 900 PUMPS USE PULSALUBE UNIVERSAL 1HG OIL AS STANDARD FOR THE
PUMP HEAD AND GEARBOX
PERFORMANCE
, DAMAGE THE PUMP AND VOID THE WARRANTY.
6.1.1 Oil Capacities
. USE OF ALTERNATIVE LUBRICANTS COULD IMPAIR
The approximate amounts of oil required to fill the
Pulsalube Universal 1HG is standard oil supplied with all pumps unless
specified. Temperatures +40 – 280 °F
Total - Pump Head and Gear Box 25
PULSAlube Universal 1HG is available as follows:
• 1 quart (0.94 liters) Part #: 1HG-1QT
• 1 gallon (3.79 liters) Part #: 1HG-1GL
• 5 gallons (18.9 liters) Part #: 1HG-5GL
• 55 gallons (208.2 liters) Part #: 1HG-55GL
It is recommended that adequate supplies of Pulsalube Universal 1HG be on hand for
periodic changes and emergency requirements.
PulsaPro 900
94.6
to the specified level is:
Gallons
Liters
Pulsafeeder also offers oil options for extreme operating conditions.
Pulsalube Ultra 6HGS is Non-standard oil and is for special applications
Temperatures -40 – 400 °F
Total - Pump Head and Gear Box 25
94.6
PULSAlube Ultra 6HGS is available as follows:
• 1 gallon (3.79 liters) Part #: 6HGS-1GL
• 5 gallons (18.9 liters) Part #: 6HGS-5GL
• 55 gallons (208.2 liters) Part #: 6HGS-55G
12
Gallons
Liters
13
6.1.2 Oil Fill
The pump is shipped from the factory filled to the proper level with PULSAlube Universal
or Ultra. The oil is held within two main reservoirs – the Gear Box (located on the motor
end of the pump) and the Pump Head (located on the process fluid end of the pump). The
two reservoirs are connected to allow lubricant to flow between them to assure a constant oil
level across the entire pump.
Two sight glasses provide a visual confirmation of oil level. One is located in the Pump
Head next to the HBV valve. The second is located in the Gearbox below the motor on the
centerline. The construction and operating conditions of the pump can cause the oil level to
go up or down during operation – this is normal. The level should be set to the center of the
sight glass. During operation the level can increase or decrease from this position, but should
always be visible within the window. For reliable measurements shut the pump off, set the
Stroke Adjustment to 0% stroke and wait approximately 5 minutes before reading the sight
glass levels.
The oil fill is located on the top of the gearbox opposite the motor (see Figure 9A). To fill,
remove the cover and add PULSAlube Universal or Ultra. Because this one fill location
supplies two reservoirs, it is necessary to wait several minutes for the level to stabilize across
the entire pump.
DO NOT OVERFILL! OVERFILLING CAN CAUSE MALFUCTION AND MAY RESULT IN
DAMAGE NOT COVERED BY WARRANTY
During normal operation, the worm gear running behind the sight glass in the gearbox
will cause oil to cover the glass completely. This is normal and does not reflect the true
measure of oil level. Turn the pump off and set the Stroke Adjustment to 0% to check
the oil level properly.
.
Oil Fill
Rear Sight
Glass
Figure 9A: Gearbox Oil Level
Rear
REAR SIGHT GLASS
Sight
Glass
Proper Oil
Level with
Pump Off
14
FRONT SIGHT
GLASS
Proper Oil
Level with
pump off
Maximum
Oil Level
Minimum
Oil Level
Figure 9B: Pump Head Oil Level – Maximum/Minimum Definition
15
6.1.3 Oil Changes
6.1.3.1 Service Level Definition
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 0°C to 40°C (32°F to
104°F), and up to 2,000 annual operating hours.
Severe Service
Humid atmosphere, an ambient operating temperature below 0°C (32°F) or above
40°C (104°F), and over 2,000 annual operating hours.
6.1.3.2 Oil Change:
The recommended oil change interval is 2 years for normal service and 1 year for severe
service. The first oil change should be done after six (6) months of continuous operation
(approximately 1,000 hours). The procedure is as follows:
1. Disconnect the power source to the drive motor (e.g., lockout/tagout the motor
disconnect).
2. Relieve all pressure from the piping system.
3. Set the Stroke Adjustment to 0% Stroke.
4. Remove the oil fill cap.
5. Drain the oil by opening the Oil Drain Valve at back of the Gearbox underneath the base.
6. Close the Oil Drain Valve.
7. Fill the Pump with 20 Gallons (75 Liters) of PULSAlube Universal or Ultra.
8. Wait for 10 minutes for the oil to level across the pump.
9. Slowly add more PULSAlube Universal or Ultra until the oil level centers on the
gearbox sight glass and the pump head sight glass.
Rear Sight Glass
10. Replace the Oil Fill Cap.
11. Set the Stroke Adjustment to the proper setting.
12. Remove Motor Starter Lockout/Tagout.
Proper Oil
Level with
pump off
GEAR BOX PUMP HEAD
16
6.2 Startup
6.2.1 Output Adjustment
When starting up the pump for the first time, it is best to set the stroke adjustment to
0% output and then slowly increase the setting to 100%. This allows you to react to
any leaks that may be present in the piping system before they become severe.
PulsaPro 900
The
rear of the stroke adjust housing (refer to Figure 10). The hand wheel can be adjusted at any
point from 0 to 100%. It includes a stroke lock mechanism. Before making an adjustment
pull out the stroke lock handle and rotate it ¼ turn to hold it in the disengaged position. With
the stroke lock disengaged, crank the hand wheel in either direction to adjust the stroke length
to the desired setting – do not go below the 0% or above the 100% marks. After you have
completed your stroke length setting, re-engage the stroke lock by turning the stroke lock
handle ¼ turn.
Please be sure the stroke lock is then engaged during pump operation to prevent drift.
uses a hand wheel for manual stroke adjustment. It is mounted on the
Stroke
Adjustment
Stroke
Lock
Figure 10
17
6.2.2 Priming the Pump Head
All pumps are shipped with a fully primed hydraulic system. However, during shipping,
handling and storage some air may accumulate in the hydraulic system resulting in reduced
performance. Generally this air will be automatically purged after a short run-in period. If
necessary, rapid purging may be accomplished by:
1. Fully depressing and holding the button on top of the PTP valve while the pump is
operating at any stroke length setting above 30%.
2. With the PTP button depressed, oil should begin to flow out of the small diagnostic port.
3. Hold the valve down for several seconds after the oil is clear of bubbles to ensure a good
prime.
If the pump fails to prime refer to Section 7.2.1, Re-Priming the Pump Head.
PTP
DIAGNOSTIC
PORT
DIAGNOSTIC WINDOW
6.2.3 Priming the Reagent Head
To prime the Reagent Head with the process fluid:
1. Open the suction and discharge line shutoff valves.
2. If the piping system design and the storage tank are such that the product flows due to
gravity through the pump, no priming is required.
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.
3. If the installation involves a suction lift, it may be necessary to prime the reagent head
and suction line. Try priming the reagent head first.
a) Remove the discharge valve by unscrewing the four tie bar bolts and removing the
valve as a unit.
b) Fill the head through the discharge valve port with process (or compatible) liquid
c) Reinstall the valve and retighten the tie bar bolts.
4. Start the pump at the 100% stroke length setting to prime the pump. If this does not
work, it will be necessary to fill the suction line.
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.
a) Remove the suction valve assembly.
b) Fill the line
c) Replace the valve.
d) Remove the discharge valve assembly and fill the reagent head as described in Step 3
above.
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