Pulsafeeder Shadow User Manual

Bulletin #: PR – IOM – 0802 - D

Installation

Hydraulic Diaphragm Metering P ump

Operation Maintenance Instruction



PULSAR

Should you experience a problem with your PULSAR 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 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.

Factory Service Policy

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.

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 ..................................................................................................................................... 1

1.1 General Description ................................................................................................................ 1

2. PRINCIPLES OF OPERATION .................................................................................................................. 1

2.1 Overall Operation .................................................................................................................... 1

2.2 Component Location and Operation .................................................................................... 2

2.2.1 Reagent Head Assembly ................................................................................................ 2

2.2.2 PULSAlarm Leak Detection ............................................................................................ 3

2.2.3 Pump Head/Piston assembly ......................................................................................... 3

2.2.4 Control Assembly ............................................................................................................ 4

3. EQUIPMENT INSPECTION ....................................................................................................................... 6

3.1 Storage Instructions ............................................................................................................... 6

3.1.1 Short Term ....................................................................................................................... 6

3.1.2 Long Term ........................................................................................................................ 6

4. INSTALLATION ...................................................................................................................................... 6

4.1 Location ................................................................................................................................... 6

4.2 Piping System ......................................................................................................................... 7

4.3 Suction Pressure Requirements ........................................................................................... 8

4.4 Discharge Pressure Requirements ....................................................................................... 8

4.5 Automatic Control (DLC, DLCM or MPC) .............................................................................. 8

4.6 PULSAlarm Leak Detection Electrical Connections............................................................ 9

5. EQUIPMENT SETUP ............................................................................................................................... 10

5.1 Lubrication ............................................................................................................................... 10

5.1.1 Oil Capacities ................................................................................................................... 10

5.1.2 Gear Oil Fill ...................................................................................................................... 10

5.1.3 Hydraulic Oil Fill .............................................................................................................. 11

5.2 PULSAlarm Leak Detection .................................................................................................... 11

Drive Motor Installation ...................................................................................................................... 12

5.2.1 Motor Rotation ................................................................................................................. 12

5.2.2 Motor Installation ............................................................................................................. 12

5.2.3 Electrical ........................................................................................................................... 12

6. STARTUP PROCEDURE ......................................................................................................................... 13

6.1 Output Adjustment ................................................................................................................. 13

6.2 Suction System ....................................................................................................................... 14

6.3 Priming the Pumphead (Hydraulic System) ......................................................................... 14

6.4 Priming the Reagent Head (Product System) ...................................................................... 14

6.5 Calibration ............................................................................................................................... 15

6.6 Checking the Diagnostic Window ......................................................................................... 16

7. MAINTENANCE ..................................................................................................................................... 17

7.1 Oil Changes ............................................................................................................................. 17

7.1.1 Gear Oil Change: ............................................................................................................. 17

7.1.2 Hydraulic Oil Change: ..................................................................................................... 18

7.2 Wet End Removal, Inspection, and Rei n stallation .............................................................. 18

PULSAlarm Leak Detection System.............................................................................................. 18

7.2.1 Standard Diaphragm Replacement ................................................................................ 19

7.2.2 Re-Priming the Pumphead ............................................................................................. 20

7.3 Check Valves ........................................................................................................................... 20

7.3.1 General Description ........................................................................................................ 20

7.3.2 Removal, Inspection, and Reinstallation ...................................................................... 20

7.4 Hydraulic Performance Valve (HPV) ..................................................................................... 21

7.4.1 General Description ........................................................................................................ 21

7.4.2 Check Valve Screen - Removal and Cleaning .............................................................. 21

7.4.3 HPV Removal and Replacement - A & B Pumphead Style .......................................... 22

7.4.4 HPV Removal and Replacement - C & D Pumphead Style .......................................... 23

7.5 Hydraulic Bypass Valve (HBV) .............................................................................................. 24

7.6 PTP (Push to Purge / Automatic Bleed Valve) ..................................................................... 25

7.6.1 General Description ........................................................................................................ 25

7.6.2 Removal, Cleaning, & Reinstallation ............................................................................. 25

7.7 Piston Seal ............................................................................................................................... 26

7.7.1 General Description ........................................................................................................ 26

7.7.2 Removal ............................................................................................................................ 26

7.7.3 Reinstallation ................................................................................................................... 26

7.8 Oil Seals ................................................................................................................................... 27

7.8.1 General Description ........................................................................................................ 27

7.8.2 Removal and Replacement ............................................................................................. 27

7.9 Cover Assembly ...................................................................................................................... 28

7.9.1 Removal & Reinstallation ............................................................................................... 28

8. PUMP MOTOR ...................................................................................................................................... 29

8.1 Removal & Reinstallation ....................................................................................................... 29

9. REPLACEMENT PARTS .......................................................................................................................... 29

9.1 PULSAR KOPkit Program ...................................................................................................... 29

9.2 Ordering KOPkits or Parts ..................................................................................................... 29

10. TROUBLESHOOTING CHART .................................................................................................................. 30

10.1 Diagnosis of Diaphragm Failure ............................................................................................ 32

11. APPENDIX I PULSALARM LEAK DETECTION SYSTEM .......................................................................... 33

11.1 PULSAlarm Leak Detection Reagent Head Assembly ........................................................ 33

11.2 PULSAlarm Leak Detection Diaphragm ................................................................................ 33

11.3 Leak Detection Option – Setup for Vacuum ......................................................................... 34

11.4 Leak Detection Option – Setup for Pressure ....................................................................... 34

11.5 Pressure System Set-up and Priming ................................................................................... 35

11.6 Leak Detection System Maintenance .................................................................................... 37

11.6.1 Vacuum Setpoint Adjustment ........................................................................................ 37

11.7 PULSAlarm Leak Detection Diaphragm Maintena nce ......................................................... 38

11.7.1 Leak Detection Diaphragm Removal ............................................................................. 38

11.7.2 Inspection ......................................................................................................................... 39

11.7.3 Leak Detection Diaphragm Reinstallation .................................................................... 39

11.8 Leak Detection system conversion ....................................................................................... 39

12. APPENDIX II PIPING CALCULATIONS.................................................................................................... 40

Suction Head Requirements .............................................................................................................. 40

System Back Pressure ....................................................................................................................... 42

Nomenclature ...................................................................................................................................... 42

13. APPENDIX III OIL SPECIFICATIONS ...................................................................................................... 43

PULSAlube # 7H .................................................................................................................................. 43

PULSAlube # 8G .................................................................................................................................. 43

14. APPENDIX IV BOLT TORQUE RECOMMENDATIONS ............................................................................... 44

15. APPENDIX V PULSAFEEDER ACCESSORIES ......................................................................................... 44

Pulsatrol Installation, Operation, & Removal Instructions ............................................................. 44

Installation ....................................................................................................................................... 45

PULSAtrol Removal ........................................................................................................................ 46

Back Pressure Valve ........................................................................................................................... 46

Pressure Relief Valve ......................................................................................................................... 46

iii

Conventions:

The following conventions are used in this document.

A WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE EQUIPMENT

AND THE PERSONNEL OPERATING IT

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

Revision Histor y:

Rev D: Release 12-2006

• Added information on use of diagnostic window

• Added diaphragm failure information to troubleshooting section

• Revised oil level recommendations

• Added suction condition cautions

• General text and formatting corrections

. PAY CLOSE ATTENTION TO ANY WARNING.

1. Introduction

1.1 General Description

PULSAR metering pumps are positive displacement reciprocating pumps. They combine the high efficiency of the plunger pump with diaphragm sealing to prevent 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 fluid. This piston does not pump chemicals: it pumps hydraulic oil. The piston and associated mechanisms are enclosed in the eccentric box that also serves as a hydraulic oil reservoir. A diaphragm separates the oil from the product pumped. The diaphragm moves in exact response to piston displacement. The diaphragm does no work, and acts only as a separator. Consequently, oil displacement is translated into equal product displacement. 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.

2.2 Component Location and Operation

2.2.1 Reagent Head Assembly

The typical reagent head assembly consists of reagent head, diaphragm, and suction and discharge check valves. This assembly is the only part of the pump to contact the process liquid; consequently, maintenance is critical to pump performance.

Figure 2

Figure 3

Figure 4

PULSAlarm Leak Detection

The PULSAlarm leak detection reagent head assembly consists of reagent head, leak detection diaphragm, suction and discharge check valves, vacuum bleed port, and optional pressure switch and gauge. If your pump is equipped with this option, refer to Appendix I on page 33 for further information.

A 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. (250mm to 650mm) Hg, or a sealed 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 (152mm) Hg (vacuum) or 5 psig (pressure).

2.2.2 Pump Head/Piston assembly

HYDRAULIC PERFORMANCE

VALVE (HPV)

The pump head/piston assembly is installed on the eccentric box. This assembly contains the hydraulic system consisting of the pump head, cylinder, piston assembly, and three hydraulic valves:

PTP (Push-To-Purge) HPV (Hydraulic Performance Valve) HBV (Hydraulic Bypass Valve).

The PTP valve is situated at the top of the pump head and automatically removes gases from the hydraulic system during normal operation. Momentary manual actuation of the external valve button overrides automatic operation to validate priming or to determine diaphragm integrity.

The HPV automatically maintains the required hydraulic oil volume by replacing any oil lost past the piston or through the PTP valve.

The HBV protects the pump from over-pressurizing by relieving any excess pressure in the pump’s hydraulic system.

2.2.3 Control Assembly

Figure 5

PULSAR pumps incorporate a lost motion style of stroke length adjustment to limit piston travel during the suction portion of each stroke. The stroke length setting is denoted by a (0 - 100) scale located on the top of the unit.

Stroke is changed by depressing and turning the hand knob. This turns a screw which locates a slider cam to position the follower pin as to limit the rearward travel of the piston. If the control cover is removed and replaced, the bolts should be tightened to 20-24 In-lb (225 – 270 N-cm).

PULSAR pumps may also be equipped with the Pulsafeeder DLC or DLCM electronic stroke length controllers. These allow for local and/or remote automatic control over stroke length (DLC) or stroke length and motor speed (DLCM). Pumps equipped with the DLC or DLCM controllers are provided with separate instructions for the controller. Refer to the appropriate Installation, Operation and Maintenance Manual (IOM-PS-DLC-1101 or IOM-PS-DLCM-1101).

Some PULSAR pumps may also be equipped with the MPC control which allows for pump flow control over a wide range via a specially designed variable speed drive. The MPC Installation, Operation and Maintenance manual IOM-MPC-0104 covers information specific to this type of control and should be consulted prior to operating the pump or the controller.

2.2.5 Gear Ratio Assembly

Figure 6

PULSAR pumps are driven by a standard C-face electric motor mounted on the motor adaptor input flange. The motor drives a set of worm gears which convert rotational speed into torque. They in turn power the eccentric shaft assembly that converts rotary motion to reciprocating motion. The motor adaptor is available in a variety of configurations to accommodate different motor frame specifications.

Figure 7

More than one pump can be driven through a single drive assembly. This is referred to as multiplexing. The pumps are mounted on a common gear reducer assembly on the driver pump and the pump without a gear reducer is called the driven pump. Each pump is mounted on its respective standard simplex base.

Whenever pumps are multiplexed, the eccentric shafts are positioned to place a uniform load on the driver. Before full disassembly always note the relative positions of the eccentric shafts to each other so they can be reassembled in the same orientation.

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 Pulsafeed er rep rese ntat iv e.

3.1 Storage Instructions

3.1.1 Short Term

Storage of PULSAR pumps for up to 12 months is considered short-term. The recommended shortterm storage procedures are:

a) Store the pump indoors at room temperature in a dry environment. b) Within two months after date of shipment, fill the eccentric box to its normal operating level with

PULSAlube 7H (purple) hydraulic oil. If required by the operating environment, take steps to prevent entry of water or humid air into the eccentric enclosure.

c) Prior to start up, inspect housing, and gearbox. Replenish hydraulic and gearbox oils as required

to maintain operating levels. If water or condensation is present, change oil as described under Equipment Startup.

d) Start up in accordance with instructions in this manual.

3.1.2 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. If the pump is equipped with a PULSAlarm vacuum leak detection system, ensure that a vacuum is drawn before operating the pump. See Appendix I on page 33 for more information.

After twelve months of storage, Pulsafeeder’s warranty cannot cover such items which 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 such items 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 warranty after extended storage, equipment inspection and any required refurbishing must be done by a Pulsafeeder representative.

4. Installation

4.1 Location

When selecting an installation site or designing a skid package, consideration should be given to access for routine maintenance.

PULSAR pumps are designed to operate indoors and outdoors, but it is desirable to provide a hood or covering for outdoor service. External heating may be required if ambient temperatures below -18° C (0° F) are anticipated. Check with the factory regarding 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 2°. This will assure that the hydraulic and g ear oils are maintained at the proper levels and that the check valves can operate properly.

4.2 Piping System

All piping systems should include:

1. Shutoff valves and unions (or flanges) on

suction and discharge piping. This permits check valve inspection without draining long runs of piping. Shutoff valves should be of the same size as connecting pipe. Ball valves are preferred since they offer minimum flow restriction.

2. An inlet strainer, if the product is not a

slurry. Pump check valves are susceptible to dirt and other solid contaminants unless designed for that service, and any accumulation can cause a malfunction. The strainer should be located between the suction shutoff valve and the pump suction valve. It must be sized to accommodate the flow rate and the anticipated level of contamination. 100-mesh screen is recommended.

3. Vacuum/pressure gauges in the suction

and discharge lines in order to check system operation. Gauges should be fitted with protective shutoff valves for isolation while not in use.

4. A separate system relief valve to protect

piping and process equipment, including the pump, from excess process pressures.

Figure 8

The hydraulic bypass valve (HBV) in the pump is not intended to protect the system!

Piping weight must not be supported by the 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 moments are 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 pipe thread ends are not taped. 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. Flow issues at pump startup are often related to the check valves being fouled with piping and process debris.

4.3 Suction Pressure Requirements

Although PULSAR metering pumps have suction lift capability, all pump installations should have minimum lift for optimum performance. A flooded suction (i.e., suction pressure higher than atmospheric pressure) is preferable whenever possible. The pump should be located as close as possible to the suction side reservoir or other source. Piping should be sized to allow for best possible NPSH conditions.

It is not recommended to install a PULSAlarm equipped pump in a suction lift system.

If suction lift is required, the net positive suction pressure required (NPSHr) is 0.21 bar (or 3 psia). If this requirement is not met the process liquid may cavitate inside the pump, degrading metering accuracy. To maintain prime on a suction installation, a foot valve is required. In addition, suction pressure must be maintained at a minimum absolute value of 0.35 bar (or 5 psia) to ensure proper hydraulic system and proper pump operation.

The maximum inlet pressure is limited to 30 psig with the standard composite diaphragm. Higher suction pressures may be accommodated with optional diaphragm configurations.

It is critical that PULSAR pumps have free flowing and unobstructed suction conditions at all times. Closed valves, clogged strainers, obstructed piping, etc, are to be avoided. Suction restrictions can place stress on the diaphragm that may result in premature failure.

Refer to Appendix II for procedures for the calculation of suction pressure.

4.4 Discharge Pressure Requirements

All PULSAR 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”), flow would be generated in addition to that caused by the pump, resulting in a reduction in accuracy and loss of control over the metering process. To prevent this condition, commonly referred to as “flow-through”, discharge pressure must exceed suction pressure by at least

0.35 Bar (or 5 psi). This can be achieved where necessary by the installation of a backpressure valve in the discharge line.

Discharge systems should be protected from excessive pressures by utilizing a pressure relief or pressure limiting valve in the piping system. Operation of the pump at pressure above its nameplate rated maximum may result in damage to the pump components and/or unsafe system conditions.

Refer to Appendix II for procedures for the calculation of discharge pressure.

4.5 Automatic Control (DLC, DLCM or MPC)

Pumps equipped with the electronic controllers are provided with separate instructions. Refer to DLC manual IOM-PS-DLC-1101, DLCM manual IOM-PS-DLCM-1101, or MPC manual IOM-MPC-0104. Perform all DLC, DLCM or MPC installation procedures prior to pump startup.

4.6 PULSAlarm Leak Detection Electrical Connections

Pressure Gauge

Figure 9

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

The switch is rated as follows:

30 VDC or 125 VAC 1 Amp er e R es is t iv e .

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

THE ENCLOSURE IS LABELED WITH APPLICABLE SAFETY AGENCY RATINGS FOR HAZARDOUS

AREA INSTALLATION NEVER QUALIFY AS NON

TERM HAZARDOUS AREA USE. PROTECTION MUST BE PROVIDED BY THE ENCLOSURE.

. SINCE THE SWITCH IS OF THE MECHANICAL CONTACT TYPE, IT CAN

-SPARKING (NON-INCENDIVE, OR “M”) FOR OCCASIONAL AND SHORT-

Oil

Color

Application

Amount (approx.)

PULSAlube 7H

Purple

Eccentric Housing

1000 ml (1 quart) NP980002-005

PULSAlube 8G

Amber

P25H Series Gearbox

150 ml (0.16 quart)

P55H Series Gearbox

200 ml (0.21 quart) NP980001-002

5. Equipment Setup

5.1 Lubrication

PULSAR pumps use two separate oils: PULSAlub e 7H, hyd raul ic oil for the e ccent ri c box and PULSAlube 8G, gear oil for the gearbox. Confusion between the two will impair performance and

damage the pump.

PULSAR pumps are shipped from the factory with the Eccent ric Hou sing d r ained, and th e Gear box full. The Installer should fill the Eccentric Housing. The external gearcase does not need to be checked.

5.1.1 Oil Capacities

PULSAlube 7H hydraulic oil is now available in 1 liter containers (previously 1.5 liters). PULSAlube 8G gear oil is available in 200 ml containers.

It is recommended that adequate supplies of both PULSAlube oils be on hand for periodic changes and emergency requirements. The approximate amounts of oil required to fill PULSAR pumps to specified levels are:

Please note that the eccentric box section of the pump is not completely full when the proper amount of oil is used, this is normal. Starting in production year 2007, Pulsafeeder will distribute PULSAlube 7H in 1 liter containers to facilitate proper oil fill.

5.1.2 Gear Oil Fill

In all pump configurations, one pipe plug is present at the top of the gearbox and one is on the side at the centerline level. Remove the top plug and fill with PULSAlube 8G (amber) gear oil through the top port to the level of the eccentric shaft centerline, which is level with the side port. If desired, the side plug can be removed so that leakage from the side port indicates attainment of the required level. Replace both pipe plugs after filling. Do not add oil through the port on the side of the motor adapter, as this port is for motor drive coupling access only.

5.1.3 Hydraulic Oil Fill

Remove the diagnostic window to gain access to the reservoir and add PULSAlube 7H hydraulic oil until the oil level is between the max and min as indicated on the new (flexible style) dipstick as illustrated below. For older pumps equipped with a solid dipstick, the oil level should be below the upper coils of the piston return spring, if the upper coils of the spring are submerged, the oil level is too high (ref. Figure 10). Adding 1 liter (approx. 1 quart) of oil to a fully drained pump will result in the correct fill level. High oil level will not affect the operation of the pump, however it can result in nuisance leakage of oil. Replace the window, making sure it is properly aligned and square before tightening the thumbscrew.

DIAGNOSTIC COVER

(FOR OIL FILL)

MAXIMUM

FILL

Figure 10

5.2 PULSAlarm Leak Detection

Refer to Appendix I, page 33 for startup instructions specific to pumps equipped with the PULSAlarm diaphragm leak detection system

Drive Motor Installation

5.2.1 Motor Rotation

Motor can be operated in either direction, clockwise or counterclockwise. Verification of motor direction is not necessary at startup.

5.2.2 Motor Installation

PULSAR pumps may be shipped with the drive motor packed separately. This is done to avoid damage during transport.

1. Remove the unattached coupling half from the motor adaptor. Ensure that the elastomer

coupling spider remains in place, on the coupling half that remains attached to the worm shaft.

2. If applicable, remove any tape or retainer rings that hold the motor shaft key in place.

3. Place the loose coupling half on the motor shaft. Align the keyway with the key and align shaft

end to inner coupling surface as shown in figure above.

4. Tighten the setscrew onto the shaft key.

5. Place the motor in a vertical position and align the coupling teeth.

6. Install the motor downwards onto the adaptor. The plastic guide will assist in aligning the

coupling halves. Final position can be achieved by slightly rotating the motor until the coupling jaws align.

7. Rotate the motor until the clearance holes in the adaptor and the tapped holes in the motor align.

Fasten the motor to the adaptor using the supplied bolts (4). Tighten bolts evenly to secure motor.

5.2.3 Electrical

Wire the PULSAR drive motor according to the motor vendor’s nameplates and instructions, and according to any appropriate national and local electrical codes and regulations.

If the motor is to be utilized with a Pulsafeeder controller, such as the DLC, DLCM, or MPC, consult the appropriate Pulsafeeder IOM for further motor wiring instructions.

Figure 11

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