Pulsafeeder PULSAR 25HJ Installation, Operation & Maintenance Manual Download

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PULSAR

HYDRAULIC DIAPHRAGM

METERING PUMPS

Bulletin: IOM-PSR-1500-Rev.G

Installation, Operation &
Maintenance Manual

Summary of Contents for PULSAR 25HJ

Page 1: ...PULSAR HYDRAULIC DIAPHRAGM METERING PUMPS Bulletin IOM PSR 1500 Rev G Installation Operation Maintenance Manual...

Page 2: ...and costs associated with replacement parts TRADEMARKS PULSAR is a registered trademark of Pulsafeeder Inc Pulsafeeder is a registered trademark of Pulsafeeder Inc Pulsafeeder EPO is a registered tra...

Page 3: ...eshooting section Revised oil level recommendations Added suction condition cautions General text and formatting corrections Rev E Release 7 2015 Rebranding Formatting updates Rev F Release 9 2016 Bol...

Page 4: ...otation 12 5 2 2 Motor Installation 12 5 2 3 Electrical 13 6 STARTUP PROCEDURE 13 6 1 OUTPUT ADJUSTMENT 13 6 2 Suction System 14 6 3 Priming the Pump head Hydraulic System 14 6 4 Priming the Reagent H...

Page 5: ...ION OPTION SETUP FOR PRESSURE 34 11 4 PRESSURE SYSTEM SET UP AND PRIMING 34 11 5 LEAK DETECTION SYSTEM MAINTENANCE Error Bookmark not defined 11 5 1 Vacuum Setpoint Adjustment Error Bookmark not defin...

Page 6: ...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 associ...

Page 7: ...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 cons...

Page 8: ...t all times during pump operation whether leak detection is required or not 2 2 2 Pump Head Piston assembly The pump head piston assembly is installed on the eccentric box This assembly contains the h...

Page 9: ...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 lbs 225 270 N cm PULSAR pumps may also be equipped with the Pulsaf...

Page 10: ...t 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 dr...

Page 11: ...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 w...

Page 12: ...low 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 lo...

Page 13: ...he 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 comp...

Page 14: ...ive 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 compon...

Page 15: ...SAlube 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...

Page 16: ...on the label on the side of the eccentric box 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 Fig...

Page 17: ...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 retaine...

Page 18: ...00 stroke setting by pressing down and then rotating the hand wheel as required Stroke length is locked during operation to prevent drift pressing the hand wheel down temporarily disengages the lock f...

Page 19: ...if your pump is equipped with a PULSAlarm leak detection system 6 4 Priming the Reagent Head Product System 1 Open the suction and discharge line shutoff valves 2 If the piping system design and the s...

Page 20: ...henever possible calibration should be performed under actual process conditions i e the same or a similar process liquid at system operating pressure To assure a sound hydraulic system run the pump f...

Page 21: ...through this port when the pump is operating normally Small amount of oil will weep from port during operation flow increases if PTP button is depressed Abnormal operation Oil is seen flowing from the...

Page 22: ...AR pump is provided with an individual specification data sheet included in the parts list package The data sheet contains important information relating to the application along with pump serial numb...

Page 23: ...ve screen refer to Check Valve Screen Removal and Cleaning Section 7 4 2 6 Replace the drain plug 7 Fill the eccentric box with PULSAlube 7H purple hydraulic oil refer to Hydraulic Oil Fill Section 5...

Page 24: ...he bolts are loosened 8 Tilt the head and pour out any liquids retained by the check valves into a suitable container continuing to follow safety precautions as appropriate 9 Remove the final bolt and...

Page 25: ...hold the PTP valve After several minutes oil should begin to flow out of the center diagnostic port Continue to hold the valve down until the oil is clear of bubbles The pump is now primed If oil fail...

Page 26: ...bar bolts and spring the suction piping slightly to drain any liquid from the reagent head cavity If the piping is closely connected it may be necessary to disconnect a union or flange 6 Remove the su...

Page 27: ...set and require no maintenance provided the hydraulic oil remains clean The check valve in series with the HPV includes a screen to trap contaminants refer to Figure 15 and should be removed and clean...

Page 28: ...re of the pump head and also clears the rear poppet of the HPV refer to Figure 18 6 Exert pressure on the socket or spacer to press the HPV out of the pump head 7 If cleaning of the valve is required...

Page 29: ...flange which retain the pump head the piston return spring is under compression and should force the pump head cylinder away from the eccentric box as the bolts are removed If the cylinder separates f...

Page 30: ...usted for pressure as originally specified or at 10 above the rated pump pressure The HBV is located at the top of the pump head and any discharge indicating over pressurization is visible at the oute...

Page 31: ...p operation To accelerate hydraulic startup pressing the spring loaded button at the top of the valve holds the valve momentarily open so that large amounts of gas can be instantly purged When the but...

Page 32: ...the cylinder and withdraw the seal from the counterbore 7 7 3 Reinstallation Reinstallation is the reverse of removal In the case of the larger piston sizes seal installed on piston it is important t...

Page 33: ...SAlube 8G gear oil and install by pressing into position 5 Reinstall by reversing the disassembly procedure 6 Refill the gearbox with PULSAlube 8G gear oil Use the following procedure to remove and re...

Page 34: ...se until it stops Adjustment is easier with the drive motor running 6 Verify that the cover dial indicates the zero stroke setting as before if so reinstallation is complete and if not refer to step 7...

Page 35: ...R parts list Include the three character suffix Note PULSAR part numbers begin either with the letters NP or the letter W e g NP170001 TNR or W210221 001 10 TROUBLESHOOTING CHART DIFFICULTY PROBABLE C...

Page 36: ...ct Consult factory for suggested venting 4 Motor speed erratic Check voltage and frequency 5 Fouled check valves Clean replace if necessary Delivery higher than rated 1 Suction pressure higher than di...

Page 37: ...ded Check operating conditions against pump design 2 High or low voltage Check power source 3 Loose wire Trace and correct PULSAlarm Leak Detection False Alarm 1 Vacuum pressure leak Find and correct...

Page 38: ...damage Abrasives or solids in the process stream Foreign object in process or hydraulic system Extrusion and or failure to the front towards the process end Extended time under poor suction conditions...

Page 39: ...l spacer ring The space between the diaphragms is sealed so that the diaphragm functions as does a standard single diaphragm With the pressure system the space between the diaphragms is filled with a...

Page 40: ...factory intermediate fluid is a Silicone oil If any other customer specified media is used it must be compatible with the materials of construction Refer to the fluid manufacturer s literature for ap...

Page 41: ...ne hour This ensures that excess barrier fluid is fully evacuated from the system 16 Supply either process fluid or test fluid i e water to the suction fitting and ensure that the discharge system is...

Page 42: ...ng the system to a zero pressure state These switches are set to trip at 20 PSIG at the factory Once this startup procedure is completed the pressure leak detection system should require no further ma...

Page 43: ...ous materials 4 Place a suitable container underneath the pump head to catch any liquid leakage 5 Disconnect process piping and drain any process liquid following material safety precautions 6 Remove...

Page 44: ...g groove in the reagent head 2 Install the reagent head bolts and tighten in an alternating pattern to ensure an even seating force Torque to the values recommended in Appendix IV 3 Apply sealing comp...

Page 45: ...e in order to prevent cavitation of the process fluid within the reagent head The NPSHR is one of the requirements necessary to assure metering accuracy Table 1 NPSHR values NPSHR PULSAR English psi 3...

Page 46: ...ion Use the last term of Equation 1 or 2 as many times as needed in the equation to adjust for different lengths of different pipe diameters in the suction line Everything but the pipe length and diam...

Page 47: ...itive suction head required psi bar NPSHA Net positive suction head available psi bar PA Pressure at the surface of the liquid being pumped atmospheric or supply tank blanket pressure psi a bar a PH H...

Page 48: ...G AGMA Number 7 EP ISO Viscosity Grade 460 API Gravity ASTM D 287 34 1 Viscosity ASTM D 2161 SSU 100 F 2241 Viscosity ASTM D 2161 SSU 210 F 225 Viscosity Index ASTM D 2270 167 Pour Point ASTM D 97 Deg...

Page 49: ...25HJ 25HL 55HL 50mm D 6 M8 x 1 25 20 15 4 M8 x 1 25 8 6 Plastic Construction Please note that torque values for plastic heads are given in N centimeters and inch lbs Pump Model Piston Size Head Size...

Page 50: ...incorporated in the system near the PULSAtrol to assure proper operation Pulsation dampeners do require regular maintenance and inspection Charge pressure should be checked every 2 4 months and renew...

Page 51: ...much air becomes released and the gauge will not indicate pressure pulses recharge the PULSAtrol and repeat the procedure Use the following to complete a Pre Charge Procedure for Suction Installation...

Page 52: ...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 perform its intended f...

Page 53: ...47...

Page 54: ...DRAULIC DIAPHRAGM METERING PUMPS Bulletin IOM PSR 1500 Rev F Pulsafeeder Inc A unit of IDEX Corporation 2883 Brighton Henrietta Town Line Road Rochester NY 14623 1 585 292 8000 www pulsa com pulsa ide...

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