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®
Installation, Operation, &
Maintenance Instruction
Models DC2, 3, 4, 5, and 6
Bulletin #: IOM-OM-1104- E
STANDARD PUMP OPERATIONS
27101 Airport Road
Punta Gorda, FL 33982
(941) 575-3800 Fax (941) 575-4085
Manufacturers of Quality Pumps,
www.pulsatron.com
Controls, and Systems
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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 Distributor, 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 replaceme
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Table of Contents 1. INTRODUCTION .....................................................................................................................................1 2. PRINCIPLES OF OPERATION ..................................................................................................................1 2.1 Reagent Head Assembly ........................................................................................................2 2.2 Control Assembly..............................
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8.3 KOPkit numbers by model: ....................................................................................................20 9. MODEL NUMBER IDENTIFICATION...........................................................................................................21 10. WET END MATERIALS REFERENCE........................................................................................................22 11. TROUBLESHOOTING....................................................................
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1. Introduction ® The OMNI metering pump is positive displacement, mechanically operated reciprocating diaphragm pump. Each pump consists of a power end and a process end separated by a PTFE faced diaphragm. Individual pumps will vary in appearance due to various liquid ends and accessories; however, the basic principles of operation remain the same. 2. Principles Of Operation Figure 1, reagent head operation A diaphragm reciprocates at a preset stroke length, displacing an
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2.1 Reagent Head Assembly The typical reagent head assembly consists of reagent head, diaphragm, and suction and discharge cartridge check valves. This assembly is the only part of the pump to contact the process liquid; consequently, maintenance is critical to pump performance. 2.2 Control Assembly ® The OMNI pump incorporates a lost motion style of stroke length adjustment to limit diaphragm travel during the suction portion of each stroke. The stroke length setting is indicated by a
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3. Equipment Inspection Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damage must be reported immediately to the carrier and your authorized representative or ® distributor of OMNI pumps. 4. Storage 4.1.1 Short Term ® Storage of your OMNI pump for up to 12 months is considered short-term. The recommended short-term storage procedures are: a) Store the pump indoors at room temperature in a dry environment. b) If requi
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5.2 Piping System 1. All systems should include a pressure relief valve on the discharge side, to protect piping and process equipment, including the pump, from excess process pressures. An external relief valve is required! There should be no devices capable of restricting flow (such as a valve) located between the pump and the relief device. 2. Shutoff valves and unions (or flanges) on suction and discharge piping are recommended. This permits check valve inspection without draining
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5.3 Suction Pressure Requirements ® Although OMNI metering pumps have some suction lift capability, 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 fluid supply source. For fluid with a vapor pressure of 5 psia or less (at operating temperature) the wet suction lift capability is approximately ten (10) feet. If this requirement is not met, the pump
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6. Equipment Startup 6.1 Fastener Inspection All pump fasteners should be checked prior to pump operation, and occasionally during use. This would include reagent head mounting bolts, motor mounting bolts, and the hardware that secures the pump to its foundation. Most hardware can be checked simply to ensure it is not loose. However, utilize the following values when checking reagent head bolt torque: Reagent Head Bolt Torque Model Material # Bolts and size N-m In. - Lbs Plastic (4
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6.3 Priming the Reagent Head 1. When handling process liquids, follow all applicable personal and facility safety guidelines. 2. Ensure that the pump is ready for operation and that all process connections are secure. 3. Open the suction and discharge line shutoff valves. 4. If the piping system design and the storage tank are such that the product flows due to gravity through the pump, reduce the discharge pressure and the system will self prime when the pump is started. In the event
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6.4 Calibration Figure 6, sample flow calibration curve All metering pumps must be calibrated to accurately specify stroke length settings for required flow rates. A typical calibration chart is shown above. Although output is linear with respect to stroke length setting, an increase in discharge pressure decreases output uniformly, describing a series of parallel lines, one for each pressure (only two are shown). The theoretical output flow rate at atmospheric discharge pressure is bas
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7. Maintenance BEFORE PERFORMING ANY MAINTENANCE REQUIRING REAGENT HEAD OR VALVE (WET END) DISASSEMBLY, BE SURE TO RELIEVE PRESSURE FROM THE PIPING SYSTEM AND, WHERE HAZARDOUS PROCESS MATERIALS ARE INVOLVED, RENDER THE PUMP SAFE TO PERSONNEL AND THE ENVIRONMENT BY CLEANING AND CHEMICALLY NEUTRALIZING AS APPROPRIATE. WEAR PROTECTIVE CLOTHING AND EQUIPMENT AS APPROPRIATE. Accurate records from the early stages of pump operation will indicate the type and levels of required maintenance.
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7.2 Wet End Removal, Inspection, & Reinstallation IF THE DIAPHRAGM HAS FAILED, PROCESS FLUID MAY HAVE CONTAMINATED THE PUMP ECCENTRIC HOUSING (ALTHOUGH NORMALLY, ANY PROCESS FLUID BEHIND A FAILED DIAPHRAGM WOULD PASS THROUGH THE BOTTOM DRAIN HOLE). HANDLE WITH APPROPRIATE CARE. Figure 8, wet end components ® OMNI diaphragms do not have a specific cycle life; however, the accumulation of foreign material or debris sufficient to deform the diaphragm can eventually cause failure.
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7.2.1 Diaphragm Removal & Reinstallation 1. Adjust the stroke setting to 50% and disconnect the power source to the drive motor. 2. Relieve all pressure from the piping system. Take all precautions described under the WARNING on page 9, Section 7 to prevent environmental damage and exposure of personnel to hazardous materials. 3. Close the inlet and outlet shutoff valves. 4. Place a pan underneath the pump head adaptor to catch any liquid leakage. 5. Disconnect piping to the reagen
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7.3 Check Valves 7.3.1 General Description Most fluid metering problems are related to check valves. Problems usually stem from solids accumulation between valve and seat, corrosion of seating surfaces, erosion, or physical damage due to wear or the presence of foreign objects. The valve incorporates a ball, guide, and seat. Flow in the unchecked direction lifts the ball off the seat, allowing liquid to pass through the guide. Reverse flow forces the ball down, sealing it against the s
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Check Valve Suction Position Check Valve Discharge Position Figure 10, check valves, DC3 and DC 4 Check Valve Suction Position Check Valve Discharge Position Figure 11, check valves, DC5 and DC6 plastic construction 13
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7.3.2 Check Valve Removal & Reinstallation, Cartridge type Valving that is of the cartridge design is intended to be replaced as an assembly. 15. Disconnect the power source to the drive motor. 16. Relieve all pressure from the piping system. 17. Take all precautions necessary to prevent contamination to the environment and personnel exposure to hazardous materials. 18. Close the inlet and outlet shutoff valves. 19. Disconnect the suction piping at the installed union near the suction
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Inserting the check valve assmbly into the pump in the wrong directiom, or having the check seat upside down, will prevent proper seals at the o-rings, decrease pump performance, and can cause damage to the diaphragm. 12. Carefully make sure that the check assemblies are in proper position, and tighten the four tie-bar bolts, using a star pattern, to a torque of 6 Ft-lbs (8 N-m). 13. Retighten any unions, flanges, or other process connections that may have been loosened previously.
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7.4 Motor Removal & Reinstallation 1. Disconnect the power source to the drive motor. 2. Disconnect the motor wiring from the motor. 3. Remove the four bolts retaining the motor to the motor adaptor. The motor shaft fits into a bore on the pump input shaft. 4. Slide the motor shaft out of the pump input shaft. Be careful not to lift the pump input shaft up out of the pump. 5. Apply a lubricant such as Loctite™ Silver Grade® Anti-seize paste (or similar) to the motor shaft and key befor
