Idex Pulsafeeder Pulsa Series Guide

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Bulletin #: IOM-680
Installation
Operation
Maintenance
Instruction
IOM-680 Rev B.

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Table of Contents
1. INTRODUCTION .....................................................................................................................................1
1.1 How Things Work ....................................................................................................................1
1.2 Hydraulically Balance Flat Diaphragm Design.....................................................................1
1.3 Pump Head Assemblies..........................................................................................................2
1.4 Make-up Hydraulic Bypass and Bleeder Valves within the Hydraulic System .................2
1.5 Hydraulic Bypass Valve ..........................................................................................................4
1.6 Pressure Relief Valve ..............................................................................................................4
1.7 Bleeder Valve ...........................................................................................................................4
1.8 Reagent Head Assemblies .....................................................................................................4
2. INSTALLATION ......................................................................................................................................5
2.1 Check the Shipment ................................................................................................................5
2.2 Locating the 680 Pumps .........................................................................................................5
2.3 Flooded Suction Desirable .....................................................................................................5
2.4 Discharge Pressure.................................................................................................................5
2.5 Piping........................................................................................................................................5
2.6 Strainers ...................................................................................................................................6
2.7 Flush Piping System ...............................................................................................................6
2.8 Metal Reagent Head Models ...................................................................................................7
2.9 Plastic Reagent Head ..............................................................................................................7
3. START-UP INSPECTION .........................................................................................................................7
3.1 Filling Gear and Oil Reservoirs..............................................................................................7
3.2 Final Inspection .......................................................................................................................7
3.3 Start-up .....................................................................................................................................8
3.4 Priming Process Head ............................................................................................................8
3.5 To Adjust Flow Rate ................................................................................................................9

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4. OPERATION AND MAINTENANCE ............................................................................................................9
4.1 Diaphragm Inspection.............................................................................................................10
4.2 Repriming Hydraulic ...............................................................................................................11
4.3 Piston and Diaphragm Alignment..........................................................................................11
4.4 Check Valves ...........................................................................................................................12
4.5 Hydraulic Make-up Valve ........................................................................................................12
4.6 Adjustable Valves....................................................................................................................13
4.7 Hydrualic Bypass Valve ..........................................................................................................13
4.8 Automatic Bleed Valve............................................................................................................14
4.9 Manual Bleed Valve .................................................................................................................15
4.10 Lubricating Instructions .........................................................................................................15
4.11 Oil Capacity..............................................................................................................................16
5. STORAGE INSTRUCTIONS.......................................................................................................................16
5.1 Short Term ...............................................................................................................................16
5.2 Long Term ................................................................................................................................16
5.3 Maintenance and KOPkits ......................................................................................................17
5.4 Ordering Parts .........................................................................................................................17
5.5 Additional Services .................................................................................................................17
6. TROUBLESHOOTING ..............................................................................................................................18
7. PULSATROL .......................................................................................................................................20
7.1 Installation................................................................................................................................20
7.2 Operation..................................................................................................................................21
8. DIAPHRAGM BACK PRESSURE VALVES..................................................................................................22
Revision History:
Rev A Release Date Sept 1997, first revision
Rev B Release Date January 2006

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1. Introduction
1.1 How it Works
A standard foot mounted motor drives a worm shaft at constant speed. Through worm gear reduction and
eccentric, a reciprocating power stroke is transferred to a plunger. The length of the plunger stroke
determines pump capacity and can be adjusted manually to provide pumping range from
0-100% of rating. However, this plunger does not pump chemicals, but an exceptionally stable oil*, having
excellent lubrication qualities. This makes a perfect pumping medium.
1.2 Hydraulically Balanced Flat Diaphragm Design (Figure 2)
Using this oil, the plunger hydraulically moves a diaphragm alternately forward and backward. A
displacement from this diaphragm movement in turn, takes in the liquid (chemical) being pumped through a
suction check valve on the suction stroke of the plunger and discharges a like amount of liquid (chemical)
through a discharge check valve on a forward or discharge stroke. The plunger operating in a sized cylinder
and at exact stroke length gives exact displacement and accurate pumping rate. The diaphragm isolates the
chemical being pumped within the reagent head and check valves. No other parts need to be of special
chemically stable material. This isolation of prompt eliminates the possibility of contamination. The plunger
handles only oil and no stuffing box is required.
*A special property petroleum oil tradenamed “PULSAlube” is generally used as hydraulic fluid. Continual reference to “Oil” as hydraulic medium
implies its general use rather than its use of necessity. Check with your representative or the factory if substitute oils must be used.
(Figure 2)

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1.3 Pump Head Assemblies
The hydraulic pump head assembly contains the plunger cylinder and various hydraulic components to
protect and maintain a precise hydraulic balance between the plunger and the diaphragm. Figure No. 3 and
Figure No. 4 shows various styles of pump head assemblies.
1.4 Make-Up, Hydraulic Bypass and Bleeder Valves within the
Hydraulic System
Figures No. 3 and Figure No. 4 show the locations of valves according to piston diameter and diaphragm style
selected.
Make-Up Valve
Any leakage past the plunger or
bleeder, however slight, is replaced
by the make-up valve which
permits flow of replacement oil
from the oil reservoir. This is an
automatic function. The oil loss
allows the diaphragm to get out of
phase with plunger thus creating a
vacuum ahead of the plunger during
the suction stroke. The make-up
valves are factory set.

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1.5 Hydraulic Bypass Valve
Any excess hydraulic pressure buildup within the pump compression chamber or chemical end due to
accidental valve closure or line stoppage is relieved through the hydraulic bypass valve. It blows off oil
under excess pressure ahead of the plunger back into the oil reservoir thus terminating the pumping action
and protecting the pump mechanism. Hydraulic bypass valves are factory set at full design pressure unless
specified differently by purchaser.
1.6 Pressure Relief Valve
A separate process relief valve should be installed in the process piping to protect piping and sensitive
process equipment.
1.7 Bleeder Valve
The function of this valve is to release any air or oil vapors from ahead of the piston and maintain a solid
hydraulic medium to transmit infinite movements of the piston to the diaphragm. In large piston models
where adequate oil movement exists, the bleed valve functions automatically weeping a minute quantity of
oil plus any air or vapor out of the hydraulic system. In small piston models where oil movement and
hydraulic instabilities are minimal a manual bleed valve is used.
Additional detail on the function of these valves will be given as applicable in the Operation, Maintenance
and Trouble Shooting Sections.
1.8 Reagent Head Assemblies
Flat diaphragm reagent head assemblies are available in several basic configurations. They are:
Figure No. 5 ¼” through 1 ½” piston metal reagent head and plastic diaphragm
Figure No. 6 ¼” through 5/8” metal reagent head and metal diaphragm
Figure No. 7 ½” through 1 ½”, plastic reagent head and plastic diaphragm

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2. Installation Tips
2.1 Check the Shipment
A standard Pulsafeeder shipment includes the pump, PULSAlube oil, wrenches, instruction and parts list
packet as well as replacement parts if ordered. Unpack carefully, check packing list and make sure all parts
are received. Check voltage of electric motor against the service to be used.
2.2 Locating the 680 Pumps
PULSAFEEDER pumps are designed to operate under indoor atmospheric conditions. It is desirable to
provide a hood or covering for outdoor service. Alternate oil or external heating is required if ambient
temperatures will be below 40◦F (4.4 ◦C). Check with factory if fluid temperatures entering the pump will be
below 40◦F (4.4 ◦C).
1. Check level of pump. Shim where necessary.
2. Securely bolt to foundation. Do not distort base.
3. Check motor alignment, reagent head, and valve bolt tightness before operation. Follow bolt torque
readings carefully.
NOTE: Most 680 models will operate without bolting down. However, it is important to have a solid
and level foundation so that a minimum of vibration is evident. Continual vibration can loosen
gaskets and pipe connections.
2.3 Flooded Suction Desirable
Installation will be simpler to operate if the liquid will flow to the pump by gravity. Wherever possible, the
pump should be located below the level of storage vessel.
2.4 Discharge Pressure
All 680 models are designed for continuous service at the rated discharge pressure. To prevent liquid flow
through, it is necessary that discharge pressure be at least 5 psi above suction pressure. When pumping
downhill, a back pressure valve should be placed in the discharge line.
2.5 Piping
Pipe size and length are critical to proper operation of any metering pump. A restricted discharge or starved
suction condition spells immediate failure to any metering pump installation. A separate brochure entitled
“Designing a Successful Metering Pump Installation” is provided to assist engineers responsible for piping
system design. Copies are available upon request (Technical Sheet 304). Inlet piping must be at least equal in
size to pump inlet connection.

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Figure A shows the preferred piping configuration for a good metering pump installation. A god piping
installation addresses present and future requirements of the metering system. Plan for shut off valves and
unions or flanges installed on both the suction and discharge lines. This allows inspection of the check valves
without draining long runs of pipe. Install a tee in the suction and discharge
piping between the pump and shut off valves. This permits easy installation of a calibration tube for
calibration of the pump at start up or any future date. A tee in the discharge piping is a must on a good
installation because it permits ease of mounting a pressure gauge to check discharge pressure at the pump
and setting the hydraulic bypass valve during start up and future maintenance functions. To prevent strain on
the pump fittings use pipe straps and braces. Do not allow the weight of the piping to be supported by a pipe
union, the valve fitting or other portion of the pump head or leaks will occur. An air leak at a union or other
fitting in the suction piping can severely affect metering accuracy and is extremely difficult to detect. In
assembly of piping, use pipe thread tape or a compound compatible with the product handled. If rigid piping
is used, we suggest bolting the pump to its foundation.
2.6 Strainers
Pump check valves are susceptible to dirt and other contaminates and any accumulation can cause
malfunction. Be sure to use a pipeline strainer in the suction line between the suction shut off valve and the
pump suction valve. 100 mesh screen is preferred.
2.7 Flush Piping System
Whether new or old piping is used, all lines should be flushed with a clean liquid or air before starting pump
to carry out pipe scale or other foreign material. Make sure flushing liquid is compatible with the chemical to
be pumped.

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2.8 Metal Reagent Head Models
The metal reagent head assembly is provided in several alloys. Piping of similar alloy should be selected.
Dissimilar materials can cause galvanic corrosion.
Do not backweld piping to the valve housings without first removing the valve housings from the pump as
excessive heat can damage the reagent head and other parts. Tie bars must be positioned on the valve
housing before welding.
2.9 Plastic Reagent Head Models
Care must be exercised when making connections on plastic reagent head models. Excessive tightening can
distort or break the plastic materials. Tubing should be rated for the highest discharge pressure expected. DO
NOT USE METAL PIPING.
3. Start-Up Inspection
Every 680 metering pump is tested for correct capacity at maximum pressure capability of the pressure relief
valve before shipment. The diaphragm cavity is fully primed and remains so for shipment. For shipping
purposes, the gear and hydraulic reservoir oil have been removed. Sufficient fresh PULSAlube oil is
included with the shipment for refilling the gear and hydraulic reservoirs.
WARNING
1. DO NOT run pump without oil.
2. DO NOT remove main gear box cover while pump is running.
3. DO NOT run pump with coupling guard removed.
4. DO NOT put hands or fingers in gear box or reservoir when pump is running.
3.1 Filling Gear and Oil Reservoirs
Remove the pump cover and fill both reservoirs with PULSAlube oil to the top of the gear box partition. Do
not overfill. PULSAlube oil is compounded to serve as both gear lubricant and hydraulic transfer fluid.
Check with factory if substitute oils must be used.
The cover assembly incorporates a free acting diaphragm to allow breathing of the reservoir and at the same
time seal the reservoir from the atmosphere. Be sure the diaphragm is properly positioned when replacing the
cover so that it will seal on the gear box.
3.2 Final Inspection
Because of the pump’s small size and light weight it sometimes receives severe handling during shipment.
Though physical damage may not occur, it is always possible for parts to move slightly in adjustment. This
situation might occur with motor or pneumatic control alignment. A quick visual check should be made to
assure that motor and control shafts have not shifted severely out of alignment or damage could occur from
starting the motor. If unusual vibration should occur after start up, realign the motor and coupling.