Installlation, Operati O on, & Mainttenance Instrucction Bulletin #: IOM-PF FDR-1112-D D Manufactu urer of Qualitty Pumps, Contrrols, and Systtems ENGINEE ERED PUMP OPERATION NS 2883 Brighhton-Henriettta Townline R Road Rochester,, New York USA 144623 (585) 292--8000 Faxx (585) 424-5619 www.pulsaa.
Pulsafeeder Factory Service Policy © Should you experience a problem with your POLYFEEDER system, refer to the troubleshooting guide in your operation and maintenance manual, as well as the information in the separate manual for your neat polymer feed pump. If the problem is not covered or cannot be solved, please contact your local Pulsafeeder Sales Representative, Distributor, or our Technical Services Department for further assistance.
Table of Contents PULSAFEEDER FACTORY SERVICE POLICY ...................................................................................................2 1. INTRODUCTION ....................................................................................................................................4 2. PRINCIPLES OF OPERATION ..................................................................................................................4 2.1 Dilution Water Supply....................................
14.1 B-Series Polyfeeder Control Panel l .................................................................................46 Introduction © The POLYFEEDER is a reliable, efficient system for the make-down of polymer solutions. Versions are available with a variety of neat polymer feed equipment to suit the individual application, including solenoid, gear, and progressing cavity pump technology. Several control options are available as well, to best integrate the system into the user’s facility. 2.
The activated solution exits the system for immediate use or aging, depending on the needs of the user and/or process. 2.1 Dilution Water Supply Dilution water must be supplied from a water supply system capable of meeting the maximum flow requirements of the system. For pipe connection sizes, see the table in Section 5.4. Supply water must be in the temperature range of 40F – 104F (4.4C - 40C).
Figure 2-3 Polymer Mixing Chamber 2.4 System Controller options 2.4.1 Manual The simplest option for small systems: make down on/off controlled at the system, polymer blend concentration adjusted manually via neat polymer pump control, dilution water adjusted with globe valves. Once setup and calibrated, the system operates continuously supplying a constant flow of emulsified polymer solution at the desired concentration.
established, the controller will attempt to provide a polymer flow rate that will provide the user a desired “solution” concentration. B-series controllers, upon the user entering primary and secondary water flows, will automatically adjust the pump speed to provide the current and future user requested solution concentration. If water flows change concentration errors will occur. B++ Series B++ Series controllers come equipped with both primary and secondary water flow rate monitoring.
d) If required by the operating environment, take precautions to prevent entry of water, humid air, or chemical vapors into the system and control enclosures. e) Prior to startup, perform a complete inspection and then start up in accordance with instructions in this manual. 5.2 Long Term After twelve months of storage, Pulsafeeder’s warranty cannot cover items that are subject to deterioration with age, such as seals, gaskets, and diaphragms.
6. Installation/Start Up 6.1 Locating the Polyfeeder System When selecting an installation site or designing a chemical feed system, consideration should be given to access for routine maintenance. The PolyFeeder system is designed to operate indoors and outdoors, but it is desirable to provide a hood or covering for outdoor service. External heating is required if ambient temperatures below 0 C (32 F) are anticipated, especially if system will not be in continuous duty.
Supply water must be in the temperature range of 40 – 104 F (4.4 C to 40 C). Water should be filtered as required to ensure that any particulate present is less than 5 microns in size, typically a 100 mesh screen is recommended. It should also be noted that extremely hard water with adversely affect polymer solution quality and increase usage of neat polymer. 6.3.
6.4 Fastener and Fitting Inspection All system fasteners should be checked prior to pump operation, and occasionally during use. This would include: The mix chamber tie-rods Motor mounting bolts Hardware that secures the pipe clamps to the frame All piping unions and connection points Most hardware can be checked simply to ensure it is not loose.
6.5 CONNECTING, PRIMING, AND CALIBRATING THE POLYFEEDER SYSTEM Figure 6-5 Polyfeeder(Solenoid Version) Showing Process Connection and Valving NOTE: Do not run the system dry for any length of time as this will cause excessive wear of the polymer feed pump components and the Mixing chamber motor shaft seal. Momentary operation to verify power and shaft rotation is acceptable. CAUTION! The Mixing chamber is rated for 150 PSI.
Tools Required: Pipe Wrenches (for inlet/outlet connections) Flat Bladed Screwdriver (for adjusting backpressure / relief valves) Tools Recommended: Pocket Calculator & Stopwatch (for calibrating polymer flow rate) 6.5.1 Connecting Inlet and Outlet Piping 6.5.1.1 Initial Valve Settings It is highly recommended at this point that the system be electrically wired and power applied. Elements of startup require startups of the system. First, close all inlet, outlet, bleed and isolation valves.
6.5.1.3 Water Inlet Connection Connect the pressurized water source to the dilution water inlet of the system. The water source must be able to support a minimum of the capacity that you wish to make of dilute polymer at 30 psig. If water pressure varies, installation of a water pressure regulator may be necessary to have reasonable control over the water flow. 6.5.1.4 Polymer Inlet Connection Connect the neat polymer tote bin or bulk tank to the neat polymer inlet. 6.5.1.
NOTE: Depending on the level of neat polymer in the tote/ supply tank, the neat polymer suction side piping can fill very rapidly! Be prepared to close valves quickly! Carefully open the neat polymer inlet valve. The suction piping will begin to fill with neat polymer. Once polymer is observed coming out the suction side drain valve, close the drain valve. Polymer will then start to fill the calibration column and the rest of the suction side pipeline.
NOTE: N While setting neat polymer p backp pressure, the ppressure relieef valve may oopen. Adjust the pressure reelief valve if this t occurs. Set S the pressurre relief valvee to open at 1220% of system m pressure (ee.g. 96 psi if neeat polymer is at 80 psi, etcc.) Congratulation C ns your system m is primed an nd ready for ccalibration. S See section 6.6 Electrical E l Installa ation 6.6.
6.6.2 Control Input Requirements and Wiring Details 6.6.2.1 Remote Start Input Contact Requirements The Polyfeeder may be started remotely via a PLC/SCADA system or a remote located start/stop switch. The user must provide a dry contact closure signaling the Polyfeeder to start (contact closed) or stop (contact open). The contact or switch must be rated for 24 VDC and 1 amp. 6.6.2.
6.6.2.5 Programmable Contact Output Controller Wiring Signal Terminal Block Location Programmable Relay 1 (N.O.) TB2-2640 Programmable Relay 1 (COM) TB2-2660 Programmable Relay 2 (N.O.) TB2-2600 Programmable Relay 2 (COM) TB2-2620 Programmable Relay 3 (N.O.) TB2-2560 Programmable Relay 3 (COM) TB2-2580 Table 6-6-2-5 Programmable Relay Outputs Wiring (B-Series Only) 6.6.2.
6.6.
Water Solenoid Valve Starter Contact System Output Line Neutral Table 6-6-4 Field Connection Terminal Mapping 1 Optional for Solenoid Pump Only 2 Wiring dependent on system options ordered 20 TB2-2760 TB2-1050N
6.7 In nitial Pow wer Up and a Systeem Operation Upon U initial po ower applicatiion to the poly ymer mixing system the coontroller LCD D will report thhe basic sttart-up screen n sequence. The T sequence show s is whenn the system m mode selectorr switch is in tthe local po osition. Oncee the start-up sequence hass been compleeted and electr trical installatiion completedd, system co onfigurability y via the progrramming interface can occcur.
Starts and d Stops the P Polymer Mixing System System m Alarm Indicato or and Reset 2 S System Mode of O Operation 10 1 12 6 M ODE: ST TATUS: LOCAL OFF 8 D Displays in a alternating order: S System Mode, S System State W Water Flow P Primary and S Secondary M MakeDown and S Solution C Concentration P Polymer Flow R Rate 11 Polymer Pum mp Status Adjustment and Programmability Interface 9 3 Water Vallve Status 4 5 7 Figu ure 6-7-2 Poly lyfeeder Contrroller User Innterface Diagram m Key# 1 2
Programming Parameter the parameter being edited or moves to the next selection. In program mode this key decreases the parameter being edited. 4 Down Key Decrease or Select Programming Parameter 5 Enter Key Enter key button that saves the parameter being edited or moves to next step. 6 LCD Liquid Crystal Display (2 line by 16 character) Displays current operational mode, operational parameters, or programming mode parameter.
6.7.2.1 LCD Displa ay - Operational Mode The T following four screens,, that alternatiively cycle, teell the user thhe mode of opperation (the diagram beelow shows the t system op perating in loccal mode), thee system statuus, the mixing concentratiion to be prrovided, and the t water & polymer p flow rates. Figu ure 6-7-2-1 Operational O M Mode Screen D Display 6.7.2.1.
Starts and d Stops the P Polymer System Mixing S System m Alarm Indicato or and Reset 2 S System Mode of O Operation 10 1 12 6 M ODE: ST TATUS: LOCAL OFF 8 D Displays in a alternating order: S System Mode, S System State W Water Flow P Primary and S Secondary M MakeDown and S Solution C Concentration P Polymer Flow R Rate 11 Polymer Pum mp Status Adjustment and Programmability Interface 9 3 Water Vallve Status 7 25 4 5
6.7.2.2 6.7.2.2.1 Operating the Polymer Mixing System Starting/Stopping the Polymer Mixing System The Polymer Mixing system has a fully programmable start up and shutdown sequence. System delays may be put into the system to provide for system start lags and system self flushing timings. -- in the case of emergency the system provides for a fast stop mode that will de-energize the system components simultaneously by placing the operational mode switch into the pump off position. 6.7.2.2.
6.7.2.2.3 Stopping the Polymer Mixing System The polymer mixing stop sequence is initiated by pushing the “SYSTEM START/STOP” button or upon opening of the remote start/stop contact, while in the run state. Upon receiving either signal, the system will proceed through a fixed series of actions with programmable delays. The shutdown sequence provided by the controller is as follows: 1. 2. 3. 4. 5. Stops the polymer delivery pump. Waits a user adjustable delivery pump off wait time (provides flushing).
6.7.2.3 Programmin P ng the Polym mer Mixing System In n order to chaange any of th he systems setttings or param meter values tthe user must enter program mming mode. m To enteer into program mming mode, the operatorr must press thhe UP and DO OWN keys siimultaneously y until the disp play reads “PROGRAMM MING MODE””. The system m will ask the user to co onfirm entry into i programm ming mode. Press P ENTER R to confirm aand enter the m menu system..
POLYMER MENU POLY START DELAY NUMBER FROM 0 TO 255 USING UP AND DOWN ARROWS. ENTER TO FINISH NUMBER FROM 0 TO 255 USING UP AND DOWN ARROWS. ENTER TO FINISH NUMBER FROM 0 TO 255 USING UP AND DOWN ARROWS. ENTER TO FINISH NUMBER FROM 0 TO 255 USING UP AND DOWN ARROWS. ENTER TO FINISH TIME THE SYSTEM WILL OPERATE PRIOR TO RECOGNIZING A PENDING ALARM. NUMBER FROM 0 TO 255 USING UP AND DOWN ARROWS.
ANALOG OUT 0%, 25% %, 50%, 75%, 100%, Cu ustom SETS THE ANALOG A OUTPUT TO O THE PRESCRIBE ED VALUE ENTER TO SET S FACTORY Y DEFAULT PROGRAMM MING RESET DEFAULT?? NA NA ENT ENT Tablee 6-7-2-3-1 1 Controlleer Parameeter Descripption and D Defaults 6.7.2.3.2 6.7.2.3.2.1 Parameter P Description D Configurin ng Polyfeederr Sensors Polyfeedeer systems can n be provided d with two sysstem monitoriing sensors, one for water fflow, and onee for polymer flow.
6.7.2.3.2.2 Setting th he Water Flo ow (BSeries only) o The Polyffeeder B-seriees must be pro ogrammed wiith the currentt primary andd secondary (total dilution sstreams) system waater flow. Th hese flows aree read from the system’s rootameters in orrder to providde pump pacinng for Bseries con ntrollers. Setting the water flow rate maay be accompllished by presssing the DOW WN ARROW W while running. 6.7.2.3.2.
6.7.2.3.2.6 6 Setting th he Low Polym mer Alarm Threshold T and d Recognitioon Time The Polyffeeder Low Po olymer thresh hold is factory y set based uppon the maxim mum and miniimum flows oof your polymer pump p and neeeds no thresho old adjustmen nt. The threshhold recognitioon time is thee time that thee polymer flow switcch is active, prior p to recogn nizing an alarrm.
Figure 6-1 Program mming the Anaalog Concenttration Input As an exaample supposee you are usin ng a 4-20mA signal s to reprresent system concentrationn range of 0.11 and 3.0% respectiveely. Apply 4.0mA from yo ou calibration source 6.7.2.3.2.9 9 Setting th he Polyfeederr System Starrt-up/Shut-d down Delays Your Poly yfeeder system m provides sy ystem elementt delays to suiit individual ssystem needs..
6.7.2.3.2.9 9.2 MIXER DELAYS D The mixerr start delay iss the time bettween the watter valve openning and the A AC mixer mottor being activated. This can be con nsidered as paart of the pre--flush sequencce without miixer agitation. The mixer sstop time, occcurring during thee shutdown seequence, is thee timeframe after a the polym mer pump stoops. During thhis timeframee the mixer remains on with water flow providin ng mixing chaamber post-fluush agitation..
6.7.2.3.2.10 Calibra ating the Poly yfeeder Pum mp Flow Your Poly yfeeder system m requires a 4-point 4 calibraation at 25, 500, 75, and 1000% pump speeed. This caliibration is required in order for th he polymer miixing system to t provide co ncentration coontrol. 6.7.2.3.2.11 Calibra ating the Poly yfeeder Anallog Output 6.7.2.3.2.
6.7.2.3.3 Polymer Mixing M System m Alarms The Polyffeeder Polymeer Mixing Sysstem will notiify the user viia an alarm w when a system m condition exists that does not allow maintaining of o user requessted concentraation levels. T The system ddisplays the syystem alarm ccondition by energizing g the YELLO OW Alarm ind dicator continu uously. Thesse conditions aare continuouusly monitoredd after the programm mable alarm delay timeout has occurred d on a start seqquence.
6.7.2.3.3.2 CALIBRATING THE POLYFEEDER SYSTEM Calibrating the Polymer Mixing System SYSTEM WILL OPERATE IN THE NEXT STEPS...MAKE SURE ALL PROCESS VALVES ARE OPEN. PRESS ENTER TO CONTINUE" ENSURE CALIBRATION COLUMN FULL. SELECT MOTOR SPEED FOR DRAWDOWN. PRESS ENTER TO CONTINUE" PROCEED WITH NEXT CALIBRATION POINT TO CONTINUE or TO TERMINATE S TTING DOWN...
7. MAINT M TENAN NCE BEFORE PERFORMING ANY A MAINTE ENANCE REQ QUIRING DISA ASSEMBLY O OF THE WETT TED PARTS, O RELIEVE PR RESSURE FROM THE PIPIING SYSTEM M AND, WHER RE HAZARDO OUS PROCESS S BE SURE TO MATERIALS S ARE INVOL LVED, RENDE ER THE PUMP P SAFE TO PE ERSONNEL A AND THE ENV VIRONMENT BY CLEANIN NG AND CHE EMICALLY NE EUTRALIZIN NG AS APPRO OPRIATE. WEAR PROTEC CTIVE CLOTHING AND EQUIPM MENT AS APP PROPRIATE.
Figure 7-1, Common Maintenance Points 39
7.1 Neat Polymer Feed Pump Refer to the attached manual for the neat polymer feed pump supplied with your PolyFeeder system. Follow the operation and maintenance guidelines within. 7.2 Pump Technology Flow Rate Range Manufacturer Model(s) Available Solenoid Diaphragm 0.
Figure 7-2, Mix chamber motor shaft seal replacement 41
7.3 Polymer Injector w/ Integrated Valve The Pulsafeeder polymer activation system utilizes a special injector with integrated membrane valve (patent pending). This revolutionary, yet simplistic valve does not have springs or seats to foul. In fact there is only one elastomeric moving part that is easily replaceable and requires no tools. Simply slide the old sleeve off the end of the quill and slide on a new one (some lubricant will help with this).
8. Replacement Parts 8.1 Ordering Parts When ordering replacement parts always specify: 9. System model number System serial number Part number if identified Model Number Identification Position Sample Specifies 1 and 2 P3 Polyfeeder 3S Type 4S Pump Type 5,6 & 7 100 Options S – standard C – custom S – Solenoid P – Progressive Cavity G – Gear M - Magnetic Max Neat Polymer 7th position is tenths of a gallon capacity (GPH) (e.g. 10.0 GPH = 100, 0.
10.
12. Troubleshooting Difficulty Mixing chamber motor does not run No water flow No neat polymer flow Finished polymer concentration incorrect Abnormal noise Probable Cause Remedy Faulty power source Check power source Blown fuse, circuit breaker Replace - eliminate overload Broken wire Locate and repair Wired improperly Check diagram Lines clogged Clean and flush Closed line valves Open valves Strainer clogged Remove and clean.
13. Drawings System assembly and electrical drawings insert here.
EN NGINEERED PUMP OPER RATIONS 28 883 Brighton-H Henrietta Town nline Road 14623 Rochester, R New York USA (4 484) 292-8000 Fax (585) 424-5619 www.pulsa.
