Pulsafeeder PulsaPro PP680 Installation, Operation & Maintenance Manual Download Page 1

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PulsaPro

HYDRAULIC DIAPHRAGM
METERING PUMPS

PP680, PP880, PP7120

Installation, Operation &
Maintenance Manual

Bulletin: IOM-PRO-001 Rev 1.2

Summary of Contents for PulsaPro PP680

Page 1: ...PulsaPro HYDRAULIC DIAPHRAGM METERING PUMPS PP680 PP880 PP7120 Installation Operation Maintenance Manual Bulletin IOM PRO 001 Rev 1 2...

Page 2: ...stall or maintain this equipment Observe all special instructions notes and cautions Act with care and exercise good common sense and judgment during all installation adjustment and maintenance proced...

Page 3: ...4 2 Nameplate Identification 8 4 3 Flow Rate 9 4 4 Intended Use 9 4 5 Components and Operation 9 5 Installation 14 5 1 Location 14 5 2 Ideal Metering Pump Installation 15 5 3 Suction Pressure Requirem...

Page 4: ...al Sales Representatives 36 10 3 Factory Service Support 36 11 APPENDIX I 37 11 1 PULSAlarm Leak Detection System 37 11 2 PULSAlarm Leak Detection Diaphragm 37 11 3 Priming of Leak Detection Diaphragm...

Page 5: ...g Each Pulsafeeder metering pump is a reliable quality product subject to careful final inspection to ensure their proper functioning and found compliance with the specified performance The final test...

Page 6: ...l will void the warranty and will release Pulsafeeder from any liability for damage caused to persons or property resulting from such actions Pulsafeeder is considered released from any liability in t...

Page 7: ...vacuum leak detection system ensure that a vacuum is drawn before operating the pump See Appendix I for more information After twelve months of storage Pulsafeeder Warranty cannot cover such items whi...

Page 8: ...on Each pump carries a nameplate for identification with the following information o Model Series o Serial Number o Rated Flow o Rated Pressure o KOPkit recommended spare parts o Piston Diameter o Gea...

Page 9: ...ntended Use PulsaPro 680 880 and 7120 pumps are designed for dosing liquid fluids flammable acids alkaline solvents etc at ambient temperature or heated suitable for continuous service These pumps are...

Page 10: ...aPro diaphragm constructions the flat diaphragm is hydraulically balanced and operates stress free providing exceptional life and accuracy Figure 5 HYDRAtube is the best choice for sheer sensitive hig...

Page 11: ...pressure up to 3 000 PSI 207 BAR and is rated NEMA Type 7 EEMAC7 Class 1 Division 1 Groups C D Class 1 Zone 1 Groups IIA IIB UL cUL CE ATEX An optional pressure gauge is also available for visual indi...

Page 12: ...e pump only does not provide an overall system protection Figure 11 Manual Control Stroke Adjustment The PulsaPro pump flow rate is adjusted by changing the stroke length on a scale from 0 100 The str...

Page 13: ...tional information on your XAE please download or review a copy of the IOM Figure 13 Gear Ratio Assembly Motor Adaptor PulsaPro pumps are driven by a standard C face electric motor mounted on the adap...

Page 14: ...stallation 5 1 Location When selecting an installation site or designing a skid package consideration should be given to access for routine maintenance PulsaPro pumps are designed to operate indoors a...

Page 15: ...ceptible 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 pum...

Page 16: ...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 m...

Page 17: ...connected to either open or to close upon detection of a diaphragm leak condition Contacts or wires are identified as follows Normally Open NO Wire Color White Normally Closed NC Wire Color Red Common...

Page 18: ...P680 Orange 19 23 oz PP880 PP7120 39 44 oz 6 2 Drive Motor Installation PulsaPro pumps may be shipped with the drive motor packed separately This is done to avoid damage during transport o Remove the...

Page 19: ...dor s nameplates and instructions and according to any appropriate national and local electrical codes and regulations 6 4 Motor Rotation Verification of the motor direction is necessary at startup Th...

Page 20: ...of the pump is critical to proper operation 7 3 Priming the Pump Head All pumps are shipped with a fully primed hydraulic system However during shipping and handling some air may enter the hydraulic s...

Page 21: ...per 100 PSI 7 BAR increase in output pressure Whenever possible calibration should be performed under actual process conditions i e the same or a similar process liquid at system operating pressure T...

Page 22: ...Y WEARING YOUR PROTECTIVE CLOTHING BASED ON THE HAZARDOUS 8 1 Operating Precautions All operations must be performed by qualified personnel Prior to work o The power line is disconnected and no parts...

Page 23: ...e to the drive motor o Relieve all pressure from the piping system o Take all precautions to prevent environmental and personnel exposure to hazardous materials o Close the inlet and outlet shutoff va...

Page 24: ...FA HYDRATUBES FOLLOW STEPS 21 THROUGH 35 8 Pick up on the edge of the HYDRAtube flange and push that same edge down the throat of the HYDRAtube The balance of the flange will fold and follow Figure 28...

Page 25: ...which may cut or damage the tube 27 Obtain a rubber band 28 Place one flat gaskets in the top recess of the HYDRAtube housing 29 Check the bottom HYDRAtube adaptor it should have one flat gasket on it...

Page 26: ...Flat Diaphragm Priming 1 Disconnect the power source to the drive motor 2 Relieve all pressure from the piping system 3 For the 680 880 models remove the sight glass on the intermediate head and pour...

Page 27: ...his way assures stable performance and protects the HYDRAtube from damage during system upsets The priming procedures is the same for elastomer and PFA HYDRAtubes Figure 33 Figure 34 With the intermed...

Page 28: ...veral hours again check for any last traces of air at the pressure relief valve Double Diaphragm Flat Leak Detection Please refer to Appendix I for detailed information for priming of the Leak Detecti...

Page 29: ...he piping slightly to drain any liquid o Remove the discharge valve assembly holding it together as a unit as before o Disassemble both valves and examine components for wear Seats should have sharp e...

Page 30: ...iaphragm This feature provides the pump protection should the suction line become restricted or closed The check valve HPVC in series with the HPV includes a screen to trap contaminants and should be...

Page 31: ...and will eventually affect the efficiency of the valve To check the hydraulic bypass pressure setting install a pressure gauge and a regulating valve in the pump discharge line The gauge must be betwe...

Page 32: ...alve to gradually relieve any residual hydraulic system pressure o Remove the valve and clean it by soaking in compatible solvent Valve operation can be confirmed by blowing air through it in both dir...

Page 33: ...gure 45 Figure 46 Removal and Replacement of Piston Seals large piston sizes above 7 8 o With any maintenance performed follow safety procedures in place Lockout Tagout relieve pressure close valves f...

Page 34: ...operly aligned o Remove the oil seal o Place electrical tape or equivalent over the end of the worm shaft prior to installing new oil seal to prevent damage o Use Loctite 534 around the outer surface...

Page 35: ...Connect Coupling Faulty power source Check power source Blown fuse and circuit breaker Replace eliminate overload Broken Wire Locate and repair Wired Improperly Check wiring diagram and correct Pipeli...

Page 36: ...ctioning High Performance Valve HPV Extrusion and or failure to the rear towards the hydraulic side HPV filter screen clogged High excessive suction pressure Discharge pressure above maximum limit Lea...

Page 37: ...of the diaphragm that will then be transferred outwards by the barrier fluid This fluid will create pressure against the pressure switch The switch has a trip point of 20 PSI 1 37 BAR When this pressu...

Page 38: ...ee from debris 2 Ensure O Ring is seated in the pump head as shown below 3 Place a dab of grease on the back of the rear diaphragm Note the rear diaphragm has swirls on the face Apply grease to the si...

Page 39: ...ush the capillary tubes down so that they are flush with the surface of the diaphragm as shown below 8 Turn the diaphragm over and place the O Rings onto the capillary tubes Push them down until they...

Page 40: ...phragm Note 1 5 thru 1 94 dish sizes require this O Ring 2 25 thru 6 dish sizes there is no O Ring 11 Place the leak detection spacer onto the diaphragm Ensure that the capillary tubes are in the slot...

Page 41: ...ad forward onto the pump head and hand tighten the bolts until the head of the bolt touches the reagent head 15 Once attached remove the clips as shown 16 Install remaining head bolts Torque the bolts...

Page 42: ...atmosphere 9 If the pump is not already hydraulically primed remove the PTP valve from the top of the pump head Using a plastic funnel or similar slowly pour hydraulic fluid into the pump head cavity...

Page 43: ...r to Section 12 3 Nomenclature for the definitions of variables used in the equations above follow the units shown in Table 3B for the constants listed to be used correctly IF PIPING SIZES VARY THROUG...

Page 44: ...uations NPIPR Net positive inlet pressure required psi bar NPIPA Net positive inlet pressure available psi bar PA Pressure at the surface of the liquid being pumped atmospheric or supply tank blanket...

Page 45: ...English Metric NPIP psi bar PA psia bar a PH psi bar PV psia bar a LS feet meters R strokes min strokes min G no units no units Q gallons hr liters hr d inches millimeters centipoise centipoise LD fe...

Page 46: ...Flash Point Method 210 C 410 F ASTM D 92 Flammable Limits Approx volume in air LEL 0 9 UEL 7 0 Autoignition Temperature N D Boiling Point Range 316 C 600 F Decomposition Temperature N D Vapor Density...

Page 47: ...23 31 4 1 4 20 18 2 MW160054 8 3 8 16 23 31 4 1 4 20 18 2 MW160013 8 3 8 16 29 39 4 1 4 20 18 2 MW160009 8 3 8 16 29 39 4 1 4 20 18 2 MW160014 8 5 16 18 17 23 4 1 4 20 42 5 MW160010 8 5 16 18 17 23 4...

Page 48: ...4 1 2 13 30 3 4 MW160026 6 1 2 13 15 0 20 4 1 2 13 30 3 4 MW160056 6 1 2 13 15 0 20 4 3 8 16 18 2 MW160058 6 1 2 13 15 0 20 4 3 8 16 18 2 MW160064 4 3 8 16 3 4 4 1 4 20 12 0 1 3 MW160065 8 5 16 18 2...

Page 49: ...E BAR BOLTS Reagent Head Bolts and Thread Size Torque 2 Bolts and Thread Size Torque 2 FT LBS N M IN LBS N M W094147 8 5 16 18 1 5 2 0 2 5 16 18 3 8 0 4 W094544 4 3 8 16 5 9 8 0 2 3 8 16 9 3 1 1 W0946...

Page 50: ...l selected The PULSAtrol is now ready for service and the diaphragm will move to a neutral position as liquid enters the chamber Pre Charge Procedure for Discharge Installation 1 Calculate the pre cha...

Page 51: ...y damaging or unsafe pressures It is critical that the pressure relief valve be mounted in the discharge piping system before any other devices that can potentially block or impede flow or it cannot p...

Page 52: ...Page 52 of 52 Pulsafeeder Inc 2883 Brighton Henrietta Town Line Road Rochester NY 14623 1 585 292 8000 www pulsa com...

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