Pulsafeeder PULSAtron HV User Manual

Electronic Metering Pumps

Series C, C+, A+, E, E-DC, E+ & HV

Installation Operation Maintenance Instruction

READ ALL WARNINGS CAREFULLY

BEFORE INSTALLING

TABLE OF CONTENTS

1.0 SAFETY INSTRUCTIONS ................................................................................................................. 3

1.1 General Safety Considerations ........................................................................................... 3

1.2 Safety Operating Procedures .............................................................................................. 3

2.0 UNPACKING THE PUMP ................................................................................................................... 4

3.0 INTRODUCTION ................................................................................................................................. 4

3.1 Principle of Operation.......................................................................................................... 5

3.2 Materials of Construction .................................................................................................... 5

4.0 INSTALLATION .................................................................................................................................. 5

4.1 Mounting ............................................................................................................................. 5

4.2 Piping .................................................................................................................................. 6

4.3 Wiring .................................................................................................................................. 7

4.4 Well Pump System Installation ........................................................................................... 7

5.0 START UP AND OPERATION ........................................................................................................... 7

5.1 Power .................................................................................................................................. 7

5.2 Priming ................................................................................................................................ 8

5.3 Capacity Control .................................................................................................................. 8

5.3.1 Stroke Frequency Adjustment ............................................................................................. 8

5.3.2 Stroke Length Adjustment ................................................................................................... 8

5.3.3 Controlling Procedure ......................................................................................................... 8

5.4 Control Panel Symbols ....................................................................................................... 9

5.5 Operation By External Input Signals ................................................................................. 10

5.5.1 Stop Functions .................................................................................................................. 10

5.5.2 External Pacing Function .................................................................................................. 10

5.5.3 4-20mA DC Input Function ............................................................................................... 11

6.0 MAINTENANCE ................................................................................................................................ 11

6.1 Routine Maintenance ........................................................................................................ 11

6.2 Disassembly and Assembly Diaphragm Removal ............................................................ 12

6.3 Diaphragm Replacement .................................................................................................. 12

6.4 Valve Replacement ........................................................................................................... 12

7.0 TROUBLESHOOTING ..................................................................................................................... 13

8.0 POLICIES AND PROCEDURES ...................................................................................................... 15

8.1 Manufacturer's Product Warranty ..................................................................................... 15

8.2 Returns .............................................................................................................................. 15

8.3 Credits ............................................................................................................................... 15

1.0 SAFETY INSTRUCTIONS

When using chemical feed pumps, basic safety precautions should always be followed to reduce risk of fire, electric shock, and personal injury. Failure to follow these instructions could result in death or serious injury.

READ ALL INSTRUCTIONS

1.1 General Safety Considerations

Always wear protective clothing including gloves and safety goggles when working on or near chemical metering pumps. Inspect tubing regularly when replenishing chemical solution for cracking or deterioration and replace as necessary.

(Always wear protective clothing and safety glasses when inspecting tubing.) When pump is exposed to direct sunlight use U.V. resistant tubing. Follow directions and warnings provided with the chemicals from the chemical manufacturer. User is responsible for

determining chemical compatibility with chemical feed pump. Secure chemicals and metering pumps, making them inaccessible to children and pets. Make sure the voltage on the chemical metering pump matches the voltage at the installation site. Do not cut plug or the ground lug off of the electrical cord – consult a licensed electrician for proper installation. Pump is NOT to be used to handle flammable liquids.

1.2 Safety Operating Procedures

Each Electronic Metering Pump has been tested to meet prescribed specifications and safety standards. Proper care in handling, installation and operation will help in ensuring a trouble free installation. Please read all these cautionary notes prior to installation and start-up of your metering pump.

Important: Pump must be installed and used with supplied back pressure/injection valve. Failure to do so could result in excessive pump output.

Handle the pump with care. Dropping or heavy impact causes not only external damage to the pump, but also to electrical parts inside.

Install the pump in a place where the ambient temperature does not exceed 104ºF (40ºC). The pump is water resistant and dust proof by construction and can be use outdoors, however do not operate the pump submerged. To avoid high internal pump temperatures, do not operate in direct sunlight.

Solenoid housing, head and pump housing may be hot to touch 160ºF (70ºC). Install the pump in a place convenient for its future maintenance and inspection, and then secure it to prevent vibration. Protective caps must be removed prior to installing tubing onto valve assemblies. Use tubing of specified size. Connect

the tubing to the suction side securely to prevent the entrance of outside air. Make sure that there is no liquid leakage on the discharge side.

Be careful to check that the voltage of the installation matches voltage indicated on the pump data label. Most pump models are equipped with a three-prong plug. Always be sure the pump is grounded. To disconnect, do not pull wire but grip the plug with fingers and pull out. Do not use the receptacle in common with heavy electrical equipment, which generates surge voltage. It can cause failure of the electronic circuit inside the pump.

Tampering with electrical devices can be potentially hazardous. Always place chemicals and pump installation well out of the reach of children.

Never repair or move the metering pump while operating. Always disconnect electrical power. For safety, always wear

protective clothing (protective gloves and safety glasses) when working on or near chemical metering pumps.

An air bleed valve is available for most models with tubing connections. Air purges should be performed when the pump-

Figure 1

chamber contains no fluid at the time of start-up. As a safety measure, connect the return tubing to the air bleed valve and bypass fluid back to storage tank or a suitable drain.

For accurate volume output, the pump must be calibrated under typical operating conditions. Chemicals used may be dangerous and should be used carefully and according to warnings on the label. Follow the

directions given with each type of chemical. Do not assume chemicals are the same because they look alike. Always store chemicals in a safe location away from children and others. We cannot be responsible for the misuse of chemicals being fed by the pump. Always have the material safety data sheet (MSDS) available for any fluid being pumped.

All pumps are pretested with water before shipment. Remove head and dry thoroughly if you are pumping a material that will react with water, (i.e. sulfuric acid, polymers). Valve seats, ball checks, gaskets, and diaphragm should also be dried. Before placing pump into service, extreme care should be taken to follow this procedure.

Valve cartridges are stamped to indicate fluid flow direction. Always install so that markings read from top to bottom, with the arrow pointing in the direction of flow.

When metering hazardous material DO NOT use plastic tubing, strictly use proper rigid pipe. Consult supplier for special adapters or valve assemblies.

Pump is NOT to be used to handle or meter flammable liquids or materials. Standard white discharge tubing is not recommended for installations exposed to direct sunlight. Consult supplier for

special black tubing. Factory will not be held responsible for improper installation of pump, or plumbing. All cautions are to be read thoroughly

prior to hookup and plumbing. For all installations a professional plumber should be consulted. Always adhere to local plumbing codes and requirements.

When using pump with pressurized systems, make sure the pressure of the system does not exceed the maximum pressure rating on the pump data label. Be sure to depressurize system prior to hook up or disconnecting a metering pump.

Electronic power modules are equipped with automatic reset thermal overload devices and may reset unexpectedly.

2.0 UNPACKING THE PUMP

Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damages should be reported immediately to the carrier and to the seller of the equipment.

The carton should Contain:

 Metering Pump  Clear Flexible Suction Tubing*  Stiff White Discharge Tubing*  Foot valve/Strainer Assembly  Backpressure Injection Valve Assembly  Manual  Bleed Valve Assembly*  Strainer Weight*

*Items may or may not be included depending on model. Make sure that all items have been removed from the shipping carton before it is discarded.

3.0 INTRODUCTION

These installation, operation and maintenance instructions cover your electronic metering pump. Refer to the pump data label to determine the actual model.

3.1 Principle Of Operation

Diaphragm metering pumps are used to dispense chemicals or fluids. This is achieved by an electromagnetic drive mechanism (solenoid), which is connected to a diaphragm. When the solenoid is pulsed by the control circuit it displaces the diaphragm, which, through the use of check valves, moves the fluid out the discharge under pressure. When the solenoid is de-energized it returns the diaphragm and pulls more fluid into the pump head and the cycle repeats.

The pump stroke rate is controlled by an internal circuit and is changed by turning the rate knob. The mechanical stroke length is controlled by the stroke length knob. Some models do not allow stroke rate control and do not have the stroke rate knob.

3.2 Materials Of Construction

The wetted materials (those parts that contact the solution being pumped) available for construction are FPP (glass filled polypropylene), PVC, CSPE, Viton, PTFE or FTF, 316 Stainless Steel, PVDF, Ceramic and Alloy C. These materials are very resistant to most chemicals. However, there are some chemicals, such as strong acids or organic solvents, which cause deterioration of some elastomer and plastic parts, such as the diaphragm, valve seats, or head.

Consult a Chemical Resistance Guide or Supplier for information on chemical compatibility. Various manufacturers of plastics, elastomers and pumping equipment publish guidelines that aid in the selection of

wetted materials for pumping commercially available chemicals and chemical compounds. Two factors must always be considered when using an elastomer or plastic part to pump chemicals. They are:

The temperature of service: Higher temperatures increase the effect of chemicals on wetted materials. The increase varies with the material and the chemical being used. A material quite stable at room temperature might be affected at higher temperatures.

Material choice: Materials with similar properties may differ greatly from one another in performance when exposed to certain chemicals.

4.0 INSTALLATION

The metering pump should be located in an area that allows convenient connections to both the chemical storage tank and the point of injection. The pump is water resistant and dust proof by construction and can be used outdoors, however, do not operate submerged. Avoid continuous temperatures in excess of 104˚F (40˚C). To do otherwise could result in damage to the pump.

4.1 Mounting

Typical mounting arrangements are shown in Figures 3, 4, and 5.

Important: Injection point must be higher than the top of the solution supply tank to prohibit gravity feeding, unless suitable backpressure is always present at the injection point. Installation of an anti-siphon valve will prohibit gravity feeding.

For wall or shelf mounting refer to Figure 3. Connect suction tubing to suction valve of chemical pump. Suction valve is the lower valve. Tubing should be long enough so that the foot valve/strainer assembly hangs about 1-2 inches (2-5 cm) above the bottom of chemical tank. To keep chemical from being contaminated, the tank should have a cover.

Flooded suction mounting (installing the pump at the base of the chemical storage tank, Figure 4) is the most trouble free type of installation and is recommended for very low output requirements. Since the suction tubing is filled with chemical, priming is accomplished quickly and the chance of losing prime is reduced.

To mount pump, drill four holes of .25” (6 mm) diameter in the shelf as shown in the dimension drawing (figure 2). Attach pump securely using four #10 (M5) bolts and nuts.

The pump can be mounted on top of a solution tank as shown in Figure 5. Install chemical pump on the cover. Insert suction tubing through the center hole and cut tubing so foot valve/strainer hangs about 1 or 2 inches (2-5 cm) above the bottom of the tank. Mount the chemical pump rigidly by drilling four .25” (6 mm) holes and using four (4) #10 (M5) screws and nuts.

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