Installation Operation Maintenance Instruction MD Series Model#: Serial#: English Mechanical Diaphragm Metering Pump
Pulsafeeder Factory Service Policy Should you experience a problem with your Pulsafeeder pump, first consult the troubleshooting guide in your operation and maintenance manual. If the problem is not covered or cannot be solved, please contact your local Pulsafeeder Sales Representative or Distributor, or our Technical Services Department for further assistance. Trained technicians are available to diagnose your problem and arrange a solution.
Table of Contents 1. INTRODUCTION ..................................................................................................................................... 4 2. PRINCIPLES OF OPERATION .................................................................................................................. 4 2.1 Reagent Head Assembly ........................................................................................................ 5 2.2 Control Assembly .........................................
1. Introduction The BLACKLINE® 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. 2.
2.1 Reagent Head Assembly The typical reagent head assembly consists of reagent head, diaphragm, and suction and discharge cartridge check valves. This assembly is the only part of the pump to contact the process liquid; consequently, maintenance is critical to pump performance. 2.2 Control Assembly The BLACKLINE® pump incorporates a lost motion style of stroke length adjustment to limit diaphragm travel during the suction portion of each stroke.
3. Equipment Inspection Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damage must be reported immediately to the carrier and your authorized representative or distributor of BLACKLINE® pumps. 3.1 3.1.1 Storage Short Term Storage of your BLACKLINE® pump for up to 12 months is considered short-term. The recommended short-term storage procedures are: a) Store the pump indoors at room temperature in a dry environment.
4.2 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. 2. Shutoff valves and unions (or flanges) on suction and discharge piping are recommended.
Suction Pressure Requirements Although BLACKLINE® 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 (5) feet.
5. Equipment Startup 5.1 Check oil level All pumps are supplied filled with oil. The prevent oil spills during shipping, a temporary plug is provided. Before starting up the pump replace the temporary plug with the operational plug. Check the oil level daily. 5.2 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.
5.4 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. If the piping system design and the storage tank are such 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.
5.5 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).
6. Maintenance BEFORE PERFORMING ANY MAINTENANCE REQUIRING REAGENT HEAD OR VALVE (WET END) DISASSEMBLY, DISCONNECT POWER, 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. WEAR PROTECTIVE CLOTHING AND EQUIPMENT AS APPROPRIATE. Accurate records from the early stages of pump operation will indicate the type and levels of required maintenance.
Use lubricating oil different than suggested is permitted only if the characteristics are compatible/equivalent. Use mineral oil for gears with a ISO VG 320 viscosity index (320 cSt at 40 °C or 23 °E at 50 °C) The MD series holds 400mL of oil (approximately ½ quart) Suggested oils. OIL MAKE OIL TYPE/NAME SHELL OMALA OIL 320 ESSO SPARTAN EP 320 MOBIL MOBILGEAR 632 IP MELLANA OIL 320 AGIP BLASIA 320 6.
Clean inside the diaphragm chamber (item#33) and the head body (item#21), especially along the diaphragm pinching zone Before screwing on the new diaphragm, apply grease on diaphragm locking screw (threaded end of the slide item#102) Screw on the diaphragm (item#32) make sure it reaches the edge on the slide (item#102) Reassemble the pump head (item#21) following in reverse these instructions and refers to the figures about the type of pump Fix the pump head by means of the locking screws
6.3 Check Valves Most fluid metering service requirements are related to check valves. Service requirements 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. Flow in the unchecked direction lifts the ball off the seat, allowing liquid to pass through the guide. Reverse flow forces the ball down, sealing it against the sharp edge of the seat.
Figure 10, check valves, DC3 and DC 4 Figure 9, check valves to 137 GPH 16 72-001-02 Rev A
6.3.
6.3.2 Check Valve Removal & Reinstallation, Cartridge type Valving that is of the cartridge design is intended to be replaced as an assembly. 1. Disconnect the power source to the drive motor. 2. Relieve all pressure from the piping system. 3. Take all precautions necessary to prevent contamination to the environment and personnel exposure to hazardous materials. 4. Close the inlet and outlet shutoff valves. 5. Disconnect the suction piping at the installed union near the suction port. 6.
7. Replacement Parts 7.1 KOPkit Program BLACKLINE® KOPkits contain all replacement parts normally used in a preventative maintenance program. (Replacement oil is also available separately for preventative maintenance programs. Refer to Section 6 – Equipment Startup). There is a specific KOPkit for every BLACKLINE® pump model. Each KOPkit is packaged for extended storage. All BLACKLINE® pumps have the KOPkit number identified on the pump nameplate and Pulsafeeder order documents.
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9. TroubleShooting Difficulty Pump does not start No delivery Probable Cause Faulty power source. Blown fuse, circuit breaker. Broken wire. Wired improperly. Process piping blockage. Motor not running. Supply tank empty. Lines clogged. Closed line valves. Ball check valves held open with solids. Vapor lock, cavitation. Prime lost. Strainer clogged. Low delivery Stroke adjustment set at zero.
Difficulty Noisy gearing, knocking Probable Cause Discharge pressure too high. Water hammer. Stroke length at partial setting. Piping noisy. Low grease level. Pipe size too small. Motor overheats. Pipe runs too long. Pulsation dampener inoperative or flooded. No surge chamber or dampener used. Pump overloaded. High or low voltage. Loose wire. Incorrect motor wiring 22 72-001-02 Rev A Remedy Reduce pressure. Install pulsation dampener. Some operating noise is characteristic of lost motion pumps.
10. 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%. Pressure relief valve should always be adjusted to a setting below the maximum rated pressure of the pump.
USA European Union (EU) Pulsafeeder, Inc. 27101 Airport Road Punta Gorda, FL 33982 USA (941) 575-3800 www.pulsatron.
