Installation Operation Maintenance Instruction Models DC2, 3, 4, 5, and 6 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 ..................................................................................................................................... 1 2. PRINCIPLES OF OPERATION .................................................................................................................. 1 2.1 Reagent Head Assembly ........................................................................................................ 2 2.2 Control Assembly .........................................
8.3 KOPkit numbers by model: .................................................................................................... 20 9. MODEL NUMBER IDENTIFICATION........................................................................................................... 21 10. WET END M ATERIALS REFERENCE ........................................................................................................ 22 11. TROUBLESHOOTING ...........................................................................
1. Introduction The OMNI® 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. Principles Of Operation Figure 1, reagent head operation A diaphragm reciprocates at a preset stroke length, displacing an exact volume of process fluid.
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 OMNI® 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 OMNI® pumps. 4. Storage 4.1.1 Short Term Storage of your OMNI® 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.
5.2 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.
5.3 Suction Pressure Requirements Although OMNI® 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 (10) feet.
6. Equipment Startup 6.1 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. Most hardware can be checked simply to ensure it is not loose. However, utilize the following values when checking reagent head bolt torque: Model DC2 DC3 and 4 DC5 DC6 6.
6.3 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.
6.4 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).
7. Maintenance BEFORE PERFORMING ANY MAINTENANCE REQUIRING REAGENT HEAD OR VALVE (WET END) DISASSEMBLY, 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.
Figure 7, gearset lubrication points 7.2 Wet End Removal, Inspection, & Reinstallation IF THE DIAPHRAGM HAS FAILED, PROCESS FLUID MAY HAVE CONTAMINATED THE PUMP ECCENTRIC HOUSING (ALTHOUGH NORMALLY, ANY PROCESS FLUID BEHIND A FAILED DIAPHRAGM WOULD PASS THROUGH THE BOTTOM DRAIN HOLE). HANDLE WITH APPROPRIATE CARE.
7.2.1 Diaphragm Removal & Reinstallation 1. Adjust the stroke setting to 50% and disconnect the power source to the drive motor. 2. Relieve all pressure from the piping system. Take all precautions described under the WARNING on page 9, Section 7 to prevent environmental damage and exposure of personnel to hazardous materials. 3. Close the inlet and outlet shutoff valves. 4. Place a pan underneath the pump head adaptor to catch any liquid leakage. 5.
7.3 7.3.1 Check Valves General Description Most fluid metering problems are related to check valves. Problems 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.
Check Valve Suction Position Check Valve Discharge Position Figure 10, check valves, DC3 and DC 4 Check Valve Suction Position Check Valve Discharge Position Figure 11, check valves, DC5 and DC6 plastic construction 13
7.3.2 Check Valve Removal & Reinstallation, Cartridge type Valving that is of the cartridge design is intended to be replaced as an assembly. 15. Disconnect the power source to the drive motor. 16. Relieve all pressure from the piping system. 17. Take all precautions necessary to prevent contamination to the environment and personnel exposure to hazardous materials. 18. Close the inlet and outlet shutoff valves. 19. Disconnect the suction piping at the installed union near the suction port. 20.
Inserting the check valve assmbly into the pump in the wrong directiom, or having the check seat upside down, will prevent proper seals at the o-rings, decrease pump performance, and can cause damage to the diaphragm. 12. Carefully make sure that the check assemblies are in proper position, and tighten the four tie-bar bolts, using a star pattern, to a torque of 6 Ft-lbs (8 N-m). 13. Retighten any unions, flanges, or other process connections that may have been loosened previously.
7.4 Motor Removal & Reinstallation 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. The motor shaft fits into a bore on the pump input shaft. 4. Slide the motor shaft out of the pump input shaft. Be careful not to lift the pump input shaft up out of the pump. 5. Apply a lubricant such as Loctite™ Silver Grade® Anti-seize paste (or similar) to the motor shaft and key before reassembling.. 6.
Figure 14, gearset components 7. Loosen the set screw (Item 9) on the worm gear (Item 8) and remove it along with its shaft key (Item 10). If you have the DC2 or 3 models go to step 8. If you have the DC4, 5, or 6 models go to step 9. 8. Remove the Thrust Washers and Bearing (Item 11 & 12) from the housing. If the Thrust Washers show signs of excessive wear or scoring, replace them during re-assembly. 9. Clean grease from the gear cavity. 10.
7.6 Gearset Replacement 1. Apply PULSAlube grease # NP980006-000 to both sides of the thrust washer and install onto the eccentric shaft. On the DC4, 5, and 6 models, the washer fits into a shallow counter-bore. 2. Assemble Worm Gear (Item 8) and key (Item 10) to the eccentric shaft. Do not tighten the setscrew yet. 3. Thread the M6-1.0 screw into the threaded hole in the end of the eccentric shaft.
8. Replacement Parts 8.1 KOPkit Program OMNI® KOPkits contain all replacement parts normally used in a preventative maintenance program. (PULSAlube grease is also available separately for preventative maintenance programs. Refer to Section 6 – Equipment Startup). There is a specific KOPkit for every OMNI® pump model. Each KOPkit is vacuum-packed for extended storage. All OMNI® pumps have the KOPkit number identified on the pump nameplate and Pulsafeeder order documents.
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11. 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 24 Remedy Reduce pressure. Install pulsation dampener. Some operating noise is characteristic of lost motion pumps.
12. 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.
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Dimension table in inches / mm Letter references to diagram, previous page “PP” = Polypropylene wetted material “SS” = Stainless steel wetted material Dimensions are with standard IEC 71 B14 frame motor DC2 A 1.0 / 25.4 B 0.7 / 18.0 Dimension C 6.9 / 175.3 D 4.5 / 113.5 E 1.5 / 38.1 DC3 1.0 / 25.4 0.7 / 18.0 6.9 / 175.3 4.5 / 113.5 1.5 / 38.1 DC4 2.0 / 50.8 0.9 / 22.4 7.6 / 193.0 5.1 / 130.2 1.8 / 44.5 DC5 – PP/PVDF 2.0 / 50.8 0.9 / 22.4 7.6 / 193.0 5.1 / 130.2 1.8 / 44.
14. Parts Diagrams and Parts Lists 14.
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DC2/3 GEARBOX 1 NP010024-ALU 35 NAME TAG 1 NP550130-000 36 NAME TAG SCREW 4 W771000-188 38 SET SCREW 2 W771004-022 39 NEEDLE BEARING 1 NP400046-000 40 KEY-WORM GEAR 1 W773097-004 41 ECCENTRIC SPACER 1 NP470031-000 42 GASKET 1 NP460047-000 43 SCREW 2 NP990008-STA 44 OIL SEAL 1 NP450029-000 45 PIPE PLUG 1 W772565-STL 46 WASHER 1 W774034-STL 47 SPOOL ADAPTOR BOLT 4 W770534-STL 48 SPOOL ADAPTOR WASHER 4 NP991018-188 49 RETAINING RING 71 FRAME 1 NP999
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30 LABEL 1 31 WASHER 1 W 771006-STL 32 MOTOR ADAPT ASSY 56C 1 NP490030-000 32 MOTOR ADAPT ASSY 71 1 NP490029-000 33 WORM SHAFT ASSY 56C 1 NP060031-A00 33 WORM SHAFT ASSY IEC71 1 NP060031-D00 34 DC2/3 GEARBOX 1 NP010024-ALU 35 NAME TAG 1 NP550130-000 36 NAME TAG SCREW 4 W771000-188 38 SET SCREW 2 W771004-022 39 NEEDLE BEARING 1 NP400046-000 40 KEY-WORM GEAR 1 W773097-004 41 ECCENTRIC SPACER 1 NP470031-000 42 GASKET 1 NP460047-000 43 SCREW 2 NP990008-S
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29 SCREW 1 W771001-010 30 31 LABEL 1 NP550084-000 WASHER 1 W771006-STL 32 MOTOR ADAPT ASSY 56C 1 NP490030-000 32 MOTOR ADAPT ASSY 71 1 NP490029-000 33 WORM SHAFT ASSY 56C 1 NP060032-A00 33 WORM SHAFT ASSY IEC71 1 NP060032-B00 34 DC4/5 GEARBOX 1 NP010023-ALU 35 NAME TAG 1 NP550130-000 36 NAME TAG SCREW 4 W771000-188 38 SET SCREW 2 W771004-032 40 KEY-WORM GEAR 1 W773098-004 41 RETAINING RING 1 NP999032-STL 42 GASKET 1 NP460047-000 43 SCREW 2 NP990008-S
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28 KNOB COVER 1 NP250061-000 29 SCREW 1 W771001-010 30 LABEL 1 NP550084-000 31 WASHER 1 W771006-STL 32 MOTOR ADAPT ASSY 56C 1 NP490030-000 32 MOTOR ADAPT ASSY 71 1 NP490029-000 33 WORM SHAFT ASSY 56C 1 NP060032-A00 33 WORM SHAFT ASSY IEC71 1 NP060032-B00 34 DC4/5 GEARBOX 1 NP010023-ALU 35 NAME TAG 1 NP550130-000 36 NAME TAG SCREW 4 W771000-188 38 SET SCREW 2 W771004-032 40 KEY-WORM GEAR 1 W773098-004 41 RETAINING RING 1 NP999032-STL 42 GASKET 1 NP46
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34 DC4/5/6 GEARBOX 1 NP010023-ALU 35 NAME TAG 1 NP550130-000 36 NAME TAG SCREW 4 W771000-188 38 SET SCREW 2 W771004-032 40 KEY-WORM GEAR 1 W773098-004 41 RETAINING RING 1 NP999032-STL 42 GASKET 1 NP460047-000 43 SCREW 2 NP990008-STA 44 OIL SEAL 1 NP450029-000 45 SPOOL ADAPTOR BOLT 4 W770534-STL 46 SPOOL ADAPTOR WASHER 4 NP991018-188 47 TIEBAR 2 NP360004-000 48 TIEBAR BOLT 8 NP990435-188 49 TIEBAR WASHER 8 NP991018-188 41
Bulletin #: IOM-OM-1104- E 42 Rev G
