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Pulsafeeder DC6 Installation & Operating Instructions Manual

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Installation, Operation, &
Maintenance Instruction
Models DC2, 3, 4, 5, and 6
Bulletin #: IOM-OM-1104- E
Manufacturers of Quality Pumps,
Controls, and Systems
STANDARD PUMP OPERATIONS
27101 Airport Road
Punta Gorda,
FL
(941) 575-3800
Fax (941) 575-4085
www.pulsatron.com
33982
®

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Summary of Contents for Pulsafeeder DC6

  • Page 1 ® Installation, Operation, & Maintenance Instruction Models DC2, 3, 4, 5, and 6 Bulletin #: IOM-OM-1104- E STANDARD PUMP OPERATIONS 27101 Airport Road Punta Gorda, 33982 (941) 575-3800 Fax (941) 575-4085 Manufacturers of Quality Pumps, www.pulsatron.com Controls, and Systems...

  • Page 2: Safety Considerations

    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.

  • Page 3: Table Of Contents

    Table of Contents 1. I .............................1 NTRODUCTION 2. P ........................1 RINCIPLES PERATION Reagent Head Assembly ......................2 Control Assembly........................2 Gear Ratio Assembly ......................2 3. E ........................3 QUIPMENT NSPECTION 4. S ……………………………………………………………………………………………………...3 TORAGE 5. I ............................3 NSTALLATION Location............................3 Piping System ..........................4 Suction Pressure Requirements....................5 Discharge Pressure Requirements..................5 6.
  • Page 4 ISTS 14.1 Parts diagram, DC2 and 3 .......................28 14.2 Bill of Materials, DC2.......................29 14.3 Bill of Materials, DC3.......................31 14.4 Parts Diagram, DC4, 5, and 6....................34 14.5 Bill of Materials, DC4.......................35 14.6 Bill of Materials, DC5.......................37 14.7 Bill of Materials, DC6.......................39...

  • Page 5: Introduction

    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.

  • Page 6: Reagent Head Assembly

    Refer to Section 6.2 for further information. For automatic flow rate control, users can consider the Pulsafeeder MPC speed based control system, please contact your local Pulsafeeder dealer or representative for more information.

  • Page 7: Equipment Inspection

    After twelve months of storage, Pulsafeeder’s warranty cannot cover items that are subject to deterioration with age, such as seals, gaskets, and diaphragms. If the pump has been in storage longer than 12 months it is recommended that these items be inspected and replaced as necessary prior to startup.

  • Page 8: Piping System

    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.

  • Page 9: Suction Pressure Requirements

    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.

  • Page 10: Equipment Startup

    6. Equipment Startup 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...

  • Page 11: Priming The Reagent Head

    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.

  • Page 12: Calibration

    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).

  • Page 13: Maintenance

    7. Maintenance EFORE 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 EAR PROTECTIVE CLOTHING AND EQUIPMENT AS APPROPRIATE Accurate records from the early stages of pump operation will indicate the type and levels of required maintenance.

  • Page 14: Wet End Removal, Inspection, & Reinstallation

    Wet End Removal, Inspection, & Reinstallation F THE DIAPHRAGM HAS FAILED PROCESS FLUID MAY HAVE CONTAMINATED THE PUMP ECCENTRIC HOUSING ALTHOUGH NORMALLY ANY PROCESS FLUID BEHIND A FAILED ). H DIAPHRAGM WOULD PASS THROUGH THE BOTTOM DRAIN HOLE ANDLE WITH APPROPRIATE CARE Figure 8, wet end components ®...
  • Page 15 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.

  • Page 16: Check Valves

    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.
  • Page 17 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...
  • Page 18 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.
  • Page 19 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).

  • Page 20: Motor Removal & Reinstallation

    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.
  • Page 21 Figure 14, gearset components 7. Loosen the set screw (Item 9) on the worm gear (Item 8) and remove it along with its shaft key (Item 10). If you have the DC2 or 3 models go to step 8. If you have the DC4, 5, or 6 models go to step 9.

  • Page 22: Gearset Replacement

    Gearset Replacement 1. Apply PULSAlube grease # NP980006-000 to both sides of the thrust washer and install onto the eccentric shaft. On the DC4, 5, and 6 models, the washer fits into a shallow counter-bore. 2. Assemble Worm Gear (Item 8) and key (Item 10) to the eccentric shaft. Do not tighten the setscrew yet.

  • Page 23: Replacement Parts

    Pulsafeeder order documents. KOPkits can also be selected from the technical data sheet shipped with the pump or by a Pulsafeeder representative. A list of the OMNI KOPkit numbers can also be found on the next page. The kit is identified by the model number of the pump, the wetted end material, and the process connection thread type.

  • Page 24: Kopkit Numbers By Model

    Wetted Material Connection Type KOPkit number PVDF NLK020FP DC3 or DC4 PVDF NLK040FP DC3 or DC4 PVDF ISO 7-1 NLK040FB DC5 or DC6 PVDF NLK050FP DC5 or DC6 PVDF ISO 7-1 NLK050FB PVDF NLK070FX DC5 or DC6 Polypropylene NLK050PP DC5 or DC6...

  • Page 25: Model Number Identification

    9. Model Number Identification Position Sample Specifies Options 1 and 2 DC = OMNI model pump 3 and 4 2 / 3 / 4 / 5 / 6 – diaphragm diameter Size/Flow A / B / C / D – stroking rate See sales literature for flow/pressure ratings Motor frame 1 –...

  • Page 26: Wet End Materials Reference

    10. Wet End Materials Reference Wet End Sealing Seat O- Model Connection Head Guide Balls Seats Configuration O-rings ring 1/4" NPT 1/2" NPT or ISO 7-1 PTFE PVDF PVDF PVDF PVDF Ceramic 1" NPT or ISO 7-1 ® (Kynar 1 1/2" NPT & ANSI ®...

  • Page 27: Troubleshooting

    11. Troubleshooting Difficulty Probable Cause Remedy Pump does not start Faulty power source. Check power source. Blown fuse, circuit breaker. Replace - eliminate overload. Broken wire. Locate and repair. Wired improperly. Check diagram. Process piping blockage. Open valves, clear other obstructions. No delivery Motor not running.
  • Page 28 Difficulty Probable Cause Remedy Noisy gearing, Discharge pressure too high. Reduce pressure. knocking Water hammer. Install pulsation dampener. Stroke length at partial setting. Some operating noise is characteristic of lost motion pumps. Low grease level. Add or replace grease. Piping noisy. Pipe size too small.

  • Page 29: Piping Accessories

    12. Piping Accessories Pressure Relief Valves Pressure relief valves are designed to protect chemical feed systems from damage that may be caused by defective equipment or a blockage in the discharge line. These valves function to limit the pressure downstream of the pump. Field adjust the pressure relief valve to operate when the discharge pressure exceeds operating pressure by 10-15%.

  • Page 30: Dimensional Drawing

    13. Dimensional Drawing Letters reference dimensional table on next page...
  • Page 31 1.8 / 44.5 DC5 – SS 2.0 / 50.8 0.9 / 22.4 7.6 / 193.0 5.1 / 130.2 1.8 / 44.5 DC6 – PP/PVDF 2.0 / 50.8 0.9 / 22.4 7.6 / 193.0 5.1 / 130.2 1.8 / 44.5 DC6 - SS 2.0 / 50.8...

  • Page 32: Parts Diagrams And Parts Lists

    14. Parts Diagrams and Parts Lists 14.1 Parts diagram, DC2 and 3...

  • Page 33: Bill Of Materials, Dc2

    14.2 Bill of Materials, DC2 ITEM DESCRIPTION PART NUMBER SUPPORT PLATE N P 1 4 0 0 5 4 - B R S DIAPHRAGM N P 1 7 0 0 3 0 - T H Y REAGENT HEAD PVDF N P 1 6 0 0 7 6 - P V D REAGENT HEAD PVC (obsolete) N P 1 6 0 0 5 4 - P V C REAGENT HEAD 316...
  • Page 34 NAME TAG N P 5 5 0 1 3 0 - 0 0 0 NAME TAG SCREW W 7 7 1 0 0 0 - 1 8 8 SET SCREW W 7 7 1 0 0 4 - 0 2 2 NEEDLE BEARING N P 4 0 0 0 4 6 - 0 0 0 KEY-WORM GEAR...

  • Page 35: Bill Of Materials, Dc3

    14.3 Bill of Materials, DC3 ITEM DESCRIPTION PART NUMBER SUPPORT PLATE N P 1 4 0 0 5 5 - B R S DIAPHRAGM N P 1 7 0 0 3 1 - T H Y REAGENT HEAD PVDF N P 1 6 0 0 7 7 - P V D REAGENT HEAD PVC (obsolete) N P 1 6 0 0 5 5 - P V C REAGENT HEAD 316...
  • Page 36 WASHER W 7 7 1 0 0 6 - S T L MOTOR ADAPT ASSY 56C N P 4 9 0 0 3 0 - 0 0 0 MOTOR ADAPT ASSY 71 N P 4 9 0 0 2 9 - 0 0 0 WORM SHAFT ASSY 56C N P 0 6 0 0 3 1 - A 0 0 WORM SHAFT ASSY IEC71...
  • Page 37 This page intentionally left BLANK...

  • Page 38: Parts Diagram, Dc4, 5, And 6

    14.4 Parts Diagram, DC4, 5, and 6...

  • Page 39: Bill Of Materials, Dc4

    14.5 Bill of Materials, DC4 ITEM DESCRIPTION PART NUMBER SUPPORT PLATE N P 1 4 0 0 5 5 - B R S DIAPHRAGM N P 1 7 0 0 3 1 - T H Y REAGENT HEAD PVDF N P 1 6 0 0 7 7 - P V D REAGENT HEAD PVC (obsolete) N P 1 6 0 0 5 5 - P V C REAGENT HEAD 316...
  • Page 40 LABEL N P 5 5 0 0 8 4 - 0 0 0 WASHER W 7 7 1 0 0 6 - S T L MOTOR ADAPT ASSY 56C N P 4 9 0 0 3 0 - 0 0 0 MOTOR ADAPT ASSY 71 N P 4 9 0 0 2 9 - 0 0 0 WORM SHAFT ASSY 56C...

  • Page 41: Bill Of Materials, Dc5

    14.6 Bill of Materials, DC5 ITEM DESCRIPTION PART NUMBER SUPPORT PLATE N P 1 4 0 0 7 1 - B R S DIAPHRAGM N P 1 7 0 0 3 7 - T H Y REAGENT HEAD PVDF N P 1 6 0 0 2 2 - P V D REAGENT HEAD PP N P 1 6 0 0 2 2 - P P L REAGENT HEAD PVC...
  • Page 42 SCREW W 7 7 1 0 0 1 - 0 1 0 LABEL N P 5 5 0 0 8 4 - 0 0 0 WASHER W 7 7 1 0 0 6 - S T L MOTOR ADAPT ASSY 56C N P 4 9 0 0 3 0 - 0 0 0 MOTOR ADAPT ASSY 71 N P 4 9 0 0 2 9 - 0 0 0...

  • Page 43: Bill Of Materials, Dc6

    14.7 Bill of Materials, DC6 ITEM DESCRIPTION PART NUMBER SUPPORT PLATE N P 1 4 0 0 8 1 - S T L DIAPHRAGM N P 1 7 0 0 3 9 - T H Y REAGENT HEAD FPP N P 1 6 0 0 2 3 - F P P...
  • Page 44 DC4/5/6 GEARBOX N P 0 1 0 0 2 3 - A L U NAME TAG N P 5 5 0 1 3 0 - 0 0 0 NAME TAG SCREW W 7 7 1 0 0 0 - 1 8 8 SET SCREW W 7 7 1 0 0 4 - 0 3 2 KEY-WORM GEAR...
  • Page 46 STANDARD PUMP OPERATIONS 27101 Airport Road Punta Gorda, 33982 (941) 575-3800 Fax (941) 575-4085 Bulletin #: IOM-OM-1104- E www.pulsatron.com R e v E...

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