Pulsafeeder DC6 Anleitung zur Fehlerbehebung

BULLETIN No.: PulsaPro 900-IOM-2009 Rev. J PulsaPro Control Addendum INSTALLATION OP

6 2.2.3 Control Assembly The output of the PulsaPro 900 can be controlled by changing how far the piston moves with each pump stroke. The Piston is

7 2.2.4 Gear Reducer Assembly PulsaPro 900 pumps are driven by a standard C-face electric motor mounted to an adaptor that completely encloses a cou

8 3. Equipment Inspection Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damage should

9 5. Installation 5.1 Location When selecting an installation site or designing a skid package, consideration should be given to access for routine m

105.3 Piping System Figure 8A All piping systems should include: 1. Shutoff valves and unions (or flanges) on suction and discharge piping. a)

114. A separate system relief valve to protect piping and process equipment, including the pump, from excess process pressures. a) The hydraulic by

12 6. Equipment Startup 6.1 Lubrication PULSAPRO 900 PUMPS USE PULSALUBE UNIVERSAL 1HG OIL AS STANDARD FOR THE PUMP HEAD AND GEARBOX. USE OF ALTERN

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146.1.2 Oil Fill The pump is shipped from the factory filled to the proper level with PULSAlube Universal or Ultra. The oil is held within two main

15 Figure 9B: Pump Head Oil Level – Maximum/Minimum Definition FRONT SIGHT GLASS Proper Oil Level with pump off

ii PulsaPro Series Guarantee Should you experience a problem with your Pulsafeeder pump, first consult the troubleshooting guide in your operation a

166.1.3 Oil Changes 6.1.3.1 Service Level Definition The recommended oil change intervals are dependent upon the operating environment and level of

176.2 Startup 6.2.1 Output Adjustment When starting up the pump for the first time, it is best to set the stroke adjustment to 0% output and then sl

186.2.2 Priming the Pump Head All pumps are shipped with a fully primed hydraulic system. However, during shipping, handling and storage some air

196.2.4 Motor Rotation Verifying the proper rotation of the motor a) To verify the correct shaft rotation of the motor you can remove the 3 screws

206.2.5 Calibration All metering pumps must be calibrated to accurately specify stroke length settings to achieve required flow rates.

217. Maintenance ALWAYS LOCKOUT/TAGOUT THE PUMP MOTOR BEFORE PERFORMING MAINTENANCE OF ANY KIND. BEFORE PERFORMING ANY MAINTENANCE REQUIRING REAGEN

227.1 Wet End Removal, Inspection, and Reinstallation IF THE DIAPHRAGM HAS FAILED, PROCESS FLUID MAY HAVE CONTAMINATED THE PUMP OIL. HANDLE WITH AP

23Diaphragm Replacement procedure 1. Disconnect the power source to the drive motor (e.g., lockout/tagout the motor disconnect). 2. Relieve all pr

24 7.2 Re-Priming the Pump Head The PulsaPro must maintain hydraulic prime to operate properly. While its Hydraulic System includes several compone

25 7.2.1 Re-Filling the Hydraulic System Use the following procedure to refill the Hydraulic System after Diaphragm/Piston service or extreme syste

iii Table of Contents 1. INTRODUCTION ...

26 7.3 Check Valves Most fluid metering problems are related to check valves. Problems can be caused by solids accumulation between the valve and

277.3.1 Check Valve Removal TAKE ALL PRECAUTIONS TO PREVENT ENVIRONMENTAL AND PERSONNEL EXPOSURE TO HAZARDOUS MATERIALS. 1. Disconnect the power s

287.3.4 Check Valve Reinstallation 1. Reinstall both valve assemblies, taking care to ensure that they are correctly oriented with balls or disks a

297.4 Hydraulic Performance Valve (HPV) During normal pump operation hydraulic fluid is continually discharged through the automatic bleed valve and

307.4.1 HPV Removal and Replacement 1. Disconnect the power source to the drive motor (e.g., lockout/tagout the motor disconnect). 2. Relieve all

31Figure 16 10. Reinstall the diaphragm and the reagent head using the procedure outlined in Section 7.1. 11. Close the Gearbox / Pump Head drain va

32the setting is too low the valve will operate on each discharge stroke. This results in decreased pumping capacity and will eventually affect the e

337.5.2 PTP Removal, Cleaning, and Reinstallation Any accumulation of solids can cause the valve to malfunction. 1. Disconnect the power sour

347.5.3 Piston Seal 7.5.3.1 General Description The piston assembly has 2 different design structures as shown in Figure 19. With proper maintenance,

35 7.5.4 Piston Removal Piston Removal Procedure: 1. Remove reagent head, and dish plate using the procedure defined in Section 7.4.1, HPV Remova

iv Conventions For the remainder of this bulletin, the following Conventions are in effect. A WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO

361. Apply PULSAlube Universal or Ultra hydraulic oil to all the piston assembly components. No matter which piston size you have. For 4 inch pisto

37 7.6 Oil Seals 7.6.1 General Description The PulsaPro 900 gear box has seven primary oil seals. Six of these are static o-ring seals. Only one

387.6.2 Motor Adaptor Oil Seal Removal and Replacement 7.6.2.1 Motor Adaptor Removal and Worm Oil Seal Replacement 1. Disconnect the power sou

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40 7.7 Stroke Control Assembly 7.7.1 Stroke Control Assembly Maintenance The stroke adjust housing has grease fittings that will need to be maintai

41 7.8 Motor Removal and Reinstallation 1. Disconnect the power source to the drive motor (e.g., lockout/tagout the motor disconnect). 2. Disco

428. Replacement Parts 8.1 PulsaPro Series KOPkit Program PulsaPro Series KOPkits contain all replacement parts normally used in a preventative main

439. PULSAlarm Leak Detection Assembly The PULSAlarm leak detection assembly consists of a reagent head, leak detection diaphragm, fill port, and p

44 9.1 PULSAlarm Leak Detection Diaphragm Double, or sandwiched, TFE diaphragms are sealed at their peripheries to an intermediate metal spacer rin

45Pressure System Set-up and Priming If the pressurized leak detection system is opened to the atmosphere during maintenance or inspection, the syst

1 1. Introduction 1.1 General Description Diaphragm Metering pumps are positive displacement reciprocating pumps that combine the high efficiency of

4612. 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

47 9.3 PULSAlarm Leak Detection Diaphragm Maintenance Figure 27 AFTER DIAPHRAGM FAILURE, PRESSURIZED PROCESS FLUID CAN BE PRESENT IN AN

489.3.1 Leak Detection Diaphragm Removal  Use the following procedure to remove the Leak Detection Diaphragm: 1. Disconnect the power source to t

4910. Troubleshooting Chart Difficulty Probable Cause Remedy Pump does not start 1. Coupling disconnected 2. Faulty power source 3. Blown fuse

50 Difficulty Probable Cause Remedy Pump loses hydraulic oil 1. Diaphragm ruptured 2. Leaky seal 3. Cover gasket leaks 4. Eccentric box ove

51Appendix I – Piping Calculations Suction Head Requirements All reciprocating metering pumps require a net positive suction head (NPSHR). Refer to

52Variable 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

53System Back Pressure The system back pressure must exceed the suction pressure by at least 25 psi (1.7 bar) in order to prevent flow through; howev

54Appendix II – Oil Specifications PULSAlube Universal 1HG MSDS Number: 775465 Appearance: Clear and bright Physical Form:

55Appendix III – Bolt Torque Recommendations/Nozzle Loads Reagent Head and Tie-Bar REAGENT HEAD SIZE RH PART NUMBER PISTON SIZE (in) DESCRIPTION TO

2 2.2 Component Location Figure 2

56 Nozzle Loads Load Type - Direction Load Load Force - X 150 lb 667 N Force - Y 150 lb 667 N Force – Z 250 lb 1,112 N Moment 1,600 in-lb

57Appendix IV Dimensional Drawings

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62Appendix V EC Declaration of Conformance

68 PulsaPro Control Rotork Actuator Installation, Operation & Maintenance Addendum USER NOTE: This addendum serves as addition

68 FACTORY SERVICE POLICY If you are experiencing a problem with your Pulsafeeder supplied pump controller, first review to the PulsaPro 900 IOM,

68 1. Scope of Supply This addendum covers the installation of a Rotork series IQ controller supplied with PulsaPro 900 series pump. This mounting

3 2.2.1 Reagent Head Assembly The term Reagent Head Assembly refers to the pump components that come into direct contact with the process fluid (or

68 3.1 The stroke control unit is supplied with 2 sealing O-rings; these o-rings must be installed prior to mounting of the stroke

An ISO 9001 and 14001 Certified Company Pulsafeeder, Inc. 2883 Brighton-Henrietta Town Line Ro

4 2.2.2 Pump Head/Piston Assembly The pump head/piston assembly is installed on the intermediate housing. This assembly contains the hydraulic syst

5 2.2.2.1 Push to Purge (PTP) The Push to Purge (PTP) valve is located at the top of the Pump Head. It automatically removes air entrained in the h