Pulsafeeder PULSAR Shadow Series, Installation, Operation & Maintenance Manual

Page 1: ...PULSAR Shadow MECHANICAL DIAPHRAGM METERING PUMP Bulletin IOM PSRM 1501 REV B Installation Operation Maintenance Manual ...

Page 2: ... fees and costs associated with replacement parts 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 wo...

Page 3: ... 3 Electrical 12 5 EQUIPMENT STARTUP 12 5 1 Oil Capacities 13 5 2 Eccentric Oil Fill 13 5 3 Gear Oil Fill 13 5 4 Oil Changes 14 5 4 1 Eccentric Oil Change 14 5 4 2 Gear Oil Change 14 6 STARTUP 15 6 1 Output Adjustment 15 6 2 Priming the Reagent Head 15 6 3 Calibration 16 6 4 Leak Detection 17 7 MAINTENANCE 18 7 1 Wet End Removal Inspection and Reinstallation 18 7 1 1 Standard Diaphragm 18 7 1 2 Le...

Page 4: ...S 30 10 1 Suction Head Requirements 30 10 2 System Backpressure 31 11 APPENDIX II OIL SPECIFICATIONS 32 12 APPENDIX III BOLT TORQUE TABLES 33 13 APPENDIX V PULSAFEEDER ACCESSORIES 34 13 1 Pulsation Dampeners 34 13 2 Dampener Installation 34 13 3 Pulsation Dampener Removal 36 13 4 Diaphragm Back Pressure and Pressure Relief Valves 36 ...

Page 5: ...GE TO BOTH THE EQUIPMENT AND THE PERSONNEL OPERATING IT PAY CLOSE ATTENTION TO ANY WARNING NOTES ARE GENERAL INFORMATION MEANT TO MAKE OPERATING THE EQUIPMENT EASIER Revision History REV A Release date February 2016 Branding and document number updated REV B Release date May 2016 Appendix III Bolt torque table updated ...

Page 6: ...ted diaphragm Individual pumps will vary in appearance due to various liquid ends accessories and multiplexing however the basic principles of operation remain the same 1 1 Overall Operation Figure 1 A diaphragm reciprocates at a preset stroke length displacing an exact volume of process fluid Diaphragm retraction causes the product to enter through the suction check valve Diaphragm advance causes...

Page 7: ...2 1 2 Component Layout Figure 2 A typical model with manual external stroke adjustment is shown ...

Page 8: ...sts 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 For most pump configurations suction and discharge check valve components are identical ...

Page 9: ...pump performance If there is a breach of the primary product side diaphragm process liquid will enter the space between the primary and leak detection diaphragms The liquid will be contained in this area and is prevented from contacting other components of the pump On the discharge stroke pressure will build in between the diaphragms This pressure will activate the pressure switch It is recommende...

Page 10: ...and turning the hand knob This turns a screw which locates a wedge shaped slider cam to position the follower pin which in turn limits rearward travel of the diaphragm To increase stroke length the slider cam is moved downwards This allows the follower pin to slide back increasing the distance the diaphragm can travel with each pump stroke To decrease stroke length the slider cam is moved upwards ...

Page 11: ...erred to as multiplexing The pumps are mounted to a common gearbox assembly and driven by a common motor Each pump is mounted on a 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 back in the same o...

Page 12: ... a complete inspection and then start up in accordance with instructions in this manual 3 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 After twelve months of st...

Page 13: ... down care must be taken to avoid distorting the base and affecting alignments The pump must be level within 5O This will assure that the eccentric and gear oils are maintained at the proper levels and that the check valves can operate properly 4 2 Piping System All piping systems should include A separate system relief valve to protect piping and process equipment including the pump from excess p...

Page 14: ...ure Requirements Although PULSAR Shadow metering pumps have 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 other source For fluid with a vapor pressure of 5 psia or less at operating temperature the wet suction lift capability is ten 10 f...

Page 15: ...rs are provided with separate instructions Refer to the latest Installation Operation and Maintenance Manual specific to your controller Follow all safety and operational information contained in those documents Perform and verify all controller installation procedures prior to pump startup Figure 9 ...

Page 16: ...ntacts 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 SINCE THE SWITCH IS OF THE MECHANICAL CONTACT TYPE IT CAN NEVER QUALIFY AS NON SPARKING NON INCENDIVE OR M FOR OCCASIONAL AND SHORT TERM HAZARDOUS AREA USE PROTECTION ...

Page 17: ...Final position can be achieved by slightly rotating the motor until the coupling jaws align 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 4 7 3 Electrical Wire the PULSAR Shadow drive motor according to the motor vendor s nameplates and instructions an...

Page 18: ... with the proper oil Pulsalube 9M to the upper edge of the crosshead assembly and return spring s or slightly above Replace the cover or controller Take care not to disturb the stroke length setting when reinstalling See figure 12 Figure 12 5 3 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 p...

Page 19: ...ieve all pressure from the piping system 3 Remove the top cover or controller from the pump 4 Drain the oil by removing the drain plug on the bottom of the eccentric box 5 Replace the drain plug 6 Fill the eccentric box with Pulsalube 9M oil as described under Eccentric Oil Fill 7 Replace the top cover or controller 5 4 2 Gear Oil Change The recommended gear oil change interval is five 5 years for...

Page 20: ...h 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 the discharge line contains a significant amount of pressurized air or other gas it may be necessary to lower the discharge pressure to enable the pump to self prime 3 If the installation involves a suction lift it may be necessary to prime the...

Page 21: ...nes one for each pressure only two are shown The theoretical output flow rate at atmospheric discharge pressure is based on the displacement of the diaphragm stroke length and the stroking rate of the pump With increasing discharge pressure there is a some corresponding decrease in output flow Pumps are rated at a certain flow at their rated pressure check nameplate Whenever possible calibration s...

Page 22: ...h the diaphragm leak detection system If the optional pressure switch has been supplied apply power to the alarm circuit It is recommended that this switch be integrated into the pump control system If a failure of the diaphragm is detected the pump should be shut down until a diagnosis of the fault can be made ...

Page 23: ...sible to forecast the lives of wetted parts such as diaphragms and check valves Since corrosion rates and operational conditions affect functional material life each metering pump must be considered according to its particular service conditions PULSAR Shadow KOPkits contain all replacement parts normally used in a preventative maintenance program It is recommended that KOPkits and PULSAlube eccen...

Page 24: ...ter clockwise and inspect the diaphragm The diaphragm must be replaced if any surface is cracked separated or obviously damaged 11 To install a diaphragm first ensure that the critical sealing areas of diaphragm reagent head and pump head are clean and free of debris Lubricate the elastomer back side of the diaphragm liberally where it is in contact against the pump head and deflection plate with ...

Page 25: ... all pressure from the piping system 3 Take all precautions to prevent environmental and personnel exposure to hazardous materials 4 Close the inlet and outlet shutoff valves 5 Loosen the suction valve tiebar 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 t...

Page 26: ...r to Appendix III for torque values 13 Check for leaks and retighten tiebar bolts as necessary Re check any piping connections that may have been disturbed Figure 18 7 3 Oil Seals General Description The pump has four oil seals as follows Seal Location Pump shaft Inside the pump head Motor adapter Inside the motor adapter below the worm shaft coupling Gearbox oil Inside the screwed end play adjust...

Page 27: ...il over time when running Reinstall by reversing the disassembly procedure Lubricate the ID of the seal liberally with silicone grease ex Parker Super O Lube Refill the eccentric box with Pulsalube Oil 9M per the Lubrication Section Figure 19 To replace the motor adapter seal First remove the motor per Motor Removal and Reinstallation Loosen the coupling setscrew through the access hole in the mot...

Page 28: ...arbox bolts and withdraw the gearbox from the eccentric box sliding it off the eccentric shaft Remove the seal Lubricate the replacement with Pulsalube 8G gear oil and install by pressing into position Reinstall by reversing the disassembly procedure Refill the gearbox with Pulsalube 8G gear oil per Lubrication ...

Page 29: ...cap to the eccentric box Remove the eccentric side cap and withdraw the eccentric shaft Remove the seal Lubricate the replacement with Pulsalube 8G gear oil and install by pressing it into position Reinstall by reversing the disassembly procedure Refill the gearbox with Pulsalube 8G gear oil per the lubrication instructions Figure 20 ...

Page 30: ...t be retained for reassembly so that pump calibration is retained 7 5 2 Removal 1 Adjust the stroke length until the dial indicator is set at the zero stroke setting Adjustment is easier with the drive motor running Allow the locking mechanism to engage to the nearest detent 2 Disconnect the power source to the drive motor 3 Remove the cover screws 4 Using care not to rotate the adjustment shaft r...

Page 31: ...the screw in the center of the dial cover 7 Adjust the dial cover to align the pointer with the zero mark 8 Retighten the screw in the center of the dial cover 7 6 Motor 7 6 1 Removal 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 and remove the motor 4 The coupling is an interlocking ja...

Page 32: ...kit is vacuum packed for extended storage All PULSAR Shadow pumps have the KOPkit number identified on the pump nameplate and Pulsafeeder order documents KOPkits can also be selected from the technical data sheet shipped with the pump or with the assistance of a Pulsafeeder representative 8 2 Ordering KOPkits or Parts When ordering replacement parts always specify Pump model and serial number stam...

Page 33: ...size Product cavitating Increase suction pressure Cool product as necessary Delivery gradually drops Check valve leakage Clean replace if damaged Leak in suction line Locate and correct Strainer fouled Clean or replace screen Product change Check viscosity Supply tank vent plugged Unplug vent Delivery erratic Leak in suction line Locate and correct Product cavitating Increase suction pressure Entr...

Page 34: ...ts Pump overloaded Check operating conditions against pump design High or low voltage Check power source Loose wire Trace and correct Excessive discharge pressure Correct conditions so ratings of pump are not exceeded Leak Detection False Alarm Vacuum pressure leak Find and correct Switch adjustment off Readjust switch Switch malfunction Replace switch Leak Detection Failure to Alarm Switch adjust...

Page 35: ...ow 50 centipoise Equation 2 For fluid viscosity at or above 50 centipoise The variables used in Equations 1 through 4 must be in the units shown in the table below for the constants listed below to be used correctly Variable Units Set English Metric NPSH 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 milli...

Page 36: ...on 4 For fluid viscosity at or above 50 centipoise P P d C Q L d C RGQ L P H P 2 4 2 D 2 2 1 D T µ NOMENCLATURE NPSHR Net positive 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 psia bar a PH Head pressure above or below the pump centerline psi bar PV Absolute vapor pr...

Page 37: ...STM D 2893 Pass Demulsibility Test ASTM D 2711 Pass Foam Test ASTM D 892 Pass Copper Corrosion ASTM D 130 1 A Color Amber PULSAlube 9M AGMA Number 7 ISO Viscosity Grade 460 API Gravity 28 7 Viscosity ASTM D 2161 SSU 100 F 2000 Viscosity ASTM D 2161 SSU 210 F 141 Viscosity Index ASTM D 2270 159 Pour Point ASTM D 67 Degrees F8 10 Flash Point COC ASTM D 92 Degrees F8 560 Timken OK Load ASTM D 2782 Lb...

Page 38: ...1 25 8 6 NP160002 B 6 M12 1 75 68 50 4 M8 1 25 8 6 NP160003 C 6 M10 1 5 39 29 4 M8 1 25 8 6 NP160004 D 6 M8 1 25 20 15 4 M8 1 25 8 6 Plastic Construction Reagent Head Part Number Head Size Head Bolts Tie Bars Bolts and Size Torque Bolts and Size Torque N m in lb N m in lb NP160012 A 6 M10 1 5 850 75 4 M8 1 25 250 22 NP160014 B 6 M12 1 75 850 75 4 M8 1 25 250 22 NP160011 C 6 M10 1 5 850 75 4 M8 1 2...

Page 39: ...sition horizontally vertically or at any angle Vertical orientation places the process connection at the bottom facilitating draining of the unit for maintenance or repair A shutoff valve should always be used between the piping system and pulsation dampener If the discharge line is open to atmospheric pressure a backpressure valve should also be incorporated in the system beyond the pulsation dam...

Page 40: ... 4 Apply precharge pressure additional liquid may drain as diaphragm moves 5 Close drain valve 6 Place the pulsation dampener in the process stream B Suction Setup Flooded Suction Charge the pulsation dampener with adequate pressure to overcome the static suction head Start up the pump Depress the stem on the charge valve but only during discharge strokes of the pump until the gauge indicates pres...

Page 41: ...bonnet from the product This diaphragm seals directly on a replaceable seat In most systems the setting of the backpressure valve will determine the overall system backpressure seen by the metering pump A diaphragm pressure relief valve protects system components from excessive pressure within the system The valve is normally set to some value slightly above normal process pressure If this pressur...

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Page 46: ...hadow MECHANICAL DIAPHRAGM METERING PUMP Bulletin IOM PSRM 1501 Pulsafeeder Inc A unit of IDEX Corporation 2883 Brighton Henrietta Town Line Road Rochester NY 14623 1 585 292 8000 www pulsa com pulsa idexcorp com ...