Pulsafeeder PULSAlarm Pulsa Series Manual

DEMKO 12 ATEX 1204081X
II 2 G Ex db IIB T5 Gb
II 2 D Ex tb IIIC T100°C Db IP66
IECEx UL 14.0118X
Ex db IIB T5 Gb
Ex tb IIIC T100°C Db IP66
Bulletin: IOM-PUL-1007 Rev F
THIS DOCUMENT CONTAINS CHARACTERISTICS CONTROLLED BY U.L. FILE # E186527;
CHANGES REQUIRE AGENCY APPROVAL.
PULSAlarm®
LEAK DETECTION
SWITCH ASSEMBLY
Installation, Operation &
Maintenance Instruction
Models: Pulsa Series®, Pulsar®, PulsaPro®

3
PulsafeederFactoryService Policy
Should you experience a problem with your Pulsafeeder pump, first consult the
troubleshooting guide in your pump operation and maintenance manual. If the problem is
not covered or cannot be solved, please contact your local Pulsafeeder Sales
Representative or Pulsafeeder Technical Service Department for further assistance.
Trained individuals are available to diagnose your problem and arrange a solution.
Solutions may include purchasing a replacement unit or returning the PULSAlarm to the
factory for inspection and repair.
All returns require a Return Material Authorization (R.M.A.) number to be issued by
Pulsafeeder. Parts purchased to correct a warranty issue may be credited after
examination of the original parts by Pulsafeeder personnel. Parts returned for warranty
considerations which are good will be sent back freight collect.
Any field modifications will void the warranty. Out-of-warranty repairs will be subject to
Pulsafeeder's standard bench fees and testing costs associated with replacement
components.
This document describes product features controlled by IECEx / ATEX
requirements. Those features, and this document, cannot be changed without
notification or approval of the appropriate agency.
Copyright
Copyright © 2006 - 2019 Pulsafeeder, Inc. All rights reserved.
Information in this document is subject to change without notice. No part of this
publication may be reproduced, stored in a retrieval system or transmitted in any form or
any means electronic or mechanical, including photocopying and recording for any
purpose other than the purchaser’s personal use without the written permission of
Pulsafeeder.

4
SafetyConsiderations:
•Read and understand all related instructions and documentation before attempting to
install or maintain this equipment
•Observe all special instructions, notes, and cautions.
•Act with care and exercise good common sense and judgment during all installation,
adjustment, and maintenance procedures.
•Ensure that all safety and work procedures and standards that are applicable to your
company and facility are followed during the installation, maintenance, and operation of
thisequipment.
Notice Information and specifications in this document are subject to change without notice.
Trademarks
Pulsa Series®, PulsaPro®, and Pulsar®and PULSAlarm®are registered trademarks of
Pulsafeeder, Inc.
Revision History
Revision
Implemented
By
Revision
Date
Approved
By
Approval
Date
Reason
B
Engineering
04/27/2007
Technical
Service
04/27/2007
Material reference to
“PTFE”
C
Engineering,
Quality,
Compliance
04/07/2015
Technical
Service
04/07/2015
Remove references to
PULSAlarm® Vacuum
offering. Add ATEX and
IECEx information, general
updates.
D
Engineering
03/03/2016
Technical
Service
03/03/2016
Modify temperature and
code information on front
and back cover only
E
Technical
Service
05/31/2017
AM
Manager
06/02/2017
Modify switch trip point
settings and remove
paragraph 7.4 for vacuum
system priming.
F
Engineering
11/15/2019
Product
Line
Manger
12/15/2019
Corrected wording in
Introduction. ATEX and
IECEx updates

5
Table of Contents
Contents
Revision History.............................................................................................................. 4
Table of Contents ............................................................................................................ 5
1.0 Conventions ....................................................................................................... 6
2.0 Foreword............................................................................................................ 6
3.0 Introduction......................................................................................................... 7
4.0 ATEX / IECEx Nameplate and Marking.............................................................. 8
5.0 Theory of Operation ........................................................................................... 9
6.0 Setup –Pump with Leak Detection .................................................................... 9
7.0 Setup - Switch Assembly.................................................................................... 9
8.0 PULSAlarm® Reagent Head............................................................................ 11
9.0 PULSAlarm® Leak Detection Diaphragm......................................................... 11
10.0 Diaphragm Construction................................................................................... 12
11.0 PULSAlarm® Diaphragm Maintenance............................................................ 13
11.1 PULSAlarm® Diaphragm Removal................................................................................13
11.2 Inspection ......................................................................................................................14
11.3 PULSAlarm® Diaphragm Reinstallation.........................................................................14
12.0 Barrier Fluid Setup ........................................................................................... 14

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1.0 Conventions
For the remainder of this bulletin, the following conventions are in effect.
AWARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH
THE EQUIPMENT AND THE PERSONNEL OPERATING IT.THIS MANUAL MUST
BE CONSULTED IN ALL CASES WHERE THE WARNING SYMBOL IS MARKED IN
ORDER TO FIND OUT THE NATURE OF THE POTENTIAL HAZARDS AND ANY
ACTIONS WHICH HAVE TO BE TAKEN TO AVOID THEM.
CAUTION, POSSIBILITY OF ELECTRIC SHOCK
Notes are general information meant to make operating the equipment
easier. For information on overall pump operation and maintenance, refer to
the Installation, Operation, and Maintenance manual specific to the model
of pump in question. The information in this bulletin pertains only to the
PULSAlarm® leak detection system supplied as an option on Pulsafeeder
PULSA/PULSAPRO/PULSAR Series pumps
Tips have been included within this bulletin to help the operator run the
equipment in the most efficient manner possible. These “Tips” are drawn
from the knowledge and experience of our staff engineers, and input from
the field.
2.0 Foreword
The equipment to which these instructions refer is designed for use in industrial areas
and therefore cannot be treated as retail products. The present documentation gives
instructions to be used by qualified personnel only. It must be used in compliance with
the regulations, laws and technical standards in force and cannot, under any
circumstances, take the place of plant standard or additional regulations, including any
which are not legally enforceable, which have been issued with the scope of ensuring
safety.
Equipment with special manufacturing or constructive variances may differ in detail with
respect to this description.
In case of any difficulty, please contact Pulsafeeder, Inc. Technical Service, email at
[e-mail].
The PULSAlarm® Switch Assembly is rated for NEMA 7 locations as identified on the
nameplate. The PULSAlarm® Switch Assembly complies with both ATEX and IEC IECEx
standards.

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The following standards apply to this product:
IEC 60079-0 6th Edition
IEC 60079-1 7th Edition
IEC 60079-31 2nd Edition
EN 60079-0:2012+A11:2013
EN 60079-1:2014
EN 60079-31:2014
3.0 Introduction
Reciprocating diaphragm metering pumps require a flexible diaphragm to separate the fluid
that is being pumped from the hydraulic fluid that is moving diaphragm back and forth
causing its pumping action. To be certain that the diaphragm is properly sealed the
PULSAlarm® Leak Detection System can be included. It uses a special dual layer
diaphragm. When one layer of this diaphragm fails, it passes system pressure to an
indicating pressure switch known as the PULSAlarm® Leak Detection Switch Assembly. It
has been designed to operate in a variety of industrial environments including hazardous
locations.

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4.0 ATEX / IECEx Nameplate and Marking
PULSAlarm® Leak Detection Switch Assembly has a standard rating nameplate which
includes Hazardous Location data, Markings, Ratings, and universal identification
information as required by the applied directives.
ATEX Marking
IECEx Marking
Ex
db
IIC
T6
Gb
I
II
III
IV
V
I –Notified body for Quality System
I –Explosive atmosphere
II –Explosive Protection
II –Protection Methods –flameproof
enclosure
III –Gas Group
III –Gas Group
IV –Equipment Category
IV –Temperature Code or Temperature
Rating (max surface temp = T85°)
V –Combustible Dust Environment
V –Equipment Protection Level –Equipment
suitable for Zones 1,2
VI –Explosive Atmosphere
VII –Protection Method
VIII –Combustible Dust Group
IX –Temperature Class –max surface temp
X –Equipment Protection Level
Agency certificate
number and ratings
Manufacturer name and
address

9
Design ambient temperature range “Ta”
Unless differently agreed with the customer, can be:
-20°C ≤ Ta ≤ +40°C: standard temperature range for all type of pumps
5.0 Theory of Operation
The PULSAlarm® leak detection system utilizes a two-layer PTFE diaphragm, coupled
to the PULSAlarm® Leak Detection Switch Assembly by a contained barrier fluid –
typically silicone oil.
During normal pump operation, the two layers of the PTFE diaphragm bear directly
against one another, and there is no fluid pressure generated between the two layers.
The attached pressure gage reads 0 and the pressure switch does not operate.
In the event of a failure of either layer of the diaphragm, liquid will enter the space
between the two layers. This liquid will be either the hydraulic oil (if the rear layer fails) or
the pumped fluid (if the front layer fails). As the pump operates with a failed diaphragm,
liquid will be pulled into the space between the diaphragm layers. As the pump
continues to operate it will generate a pulsating pressure that will be transferred by the
barrier fluid to the gage and PULSAlarm® pressure switch.
When the fluid pressure is greater than 20 psi (1.37 bar) the switch will operate signaling
a failure. The output of the switch can signal the failure of the diaphragm - both normally
open and normally closed contacts are standard.
It is recommended that the pump be stopped in the event such a leak is detected.
Immediate attention to the problem, followed by cleanup and appropriate maintenance,
will avoid further damage to the pump.
6.0 Setup –Pump with Leak Detection
Pumps incorporating leak detection are shipped from the factory with the system fully set
up to work at full pump pressure. No further setup is required. The standard factory barrier
fluid is silicone oil. Installed pressure gages will indicate 0 pressure during normal
operation and greater than 1 bar (15 psi) when a failure has occurred. When the
PULSAlarm® switch assembly is provided it must be installed and wired properly to comply
with its hazardous location ratings.
7.0 Setup - Switch Assembly
Conduit connections can carry fluids and vapors into the PULSAlarm®
causing damage and void the warranty. Care should be taken when
installing conduit to protect against fluid/vapor entry. In accordance
with any applicable codes provide sealed entries and conduit drains
near the point of entry as required. For installation purposes, the conduit
glands on the PULSAlarm® are .50-14 NPT.
To reduce the risk of ignition of hazardous atmospheres, conduit runs
must have a sealing fitting connected within 18 inches of the enclosure
for Division I applications (NEMA 7). For Zone 1,2 applications, a seal
shall be installed within 50 mm of the enclosure (IECEx/ATEX).

10
The enclosure is labeled with applicable safety agency ratings for
hazardous area installation. Since the switch is of the mechanical
contact type, it can never qualify as non-sparking (non-incendive, or
“M”) for occasional and short-term hazardous area use. Protection
must be provided by the enclosure.
In North America installations, the external supplemental ground is not
to be used. Rigid metal conduit (RMC) will act as the supplementary
ground.
If equipped with an optional pressure switch (shown in LD FIG 4), install electrical
wiring and conduit in accordance with local electrical codes.
The PULSAlarm® switch is rated as follows:
Voltage
115 VAC
Phase
Single
Load
1.0 Amp (Resistive)
Contacts
NO/NC (SPDT)
Connection
Flying Leads,
20AWG
Max. Press.
3000PSI
Electrical Connections
The switch is the SPDT (single pole, double throw) type and can therefore be setup to
either open or to close upon detection of diaphragm leak condition. Contacts or wires
are identified as follows:
Normally Open(NO) Wire color WHITE
Normally Closed (NC) Wire color RED
Common(Com) Wire color BLACK

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8.0 PULSAlarm® Reagent Head
The PULSAlarm® leak detection reagent head assembly consists of reagent head,
leak detection diaphragm, suction and discharge check valves, bleed port, and
optional switch and gauge. The reagent head, diaphragm, suction and discharge
check valves are the only parts of the pump to contact the process liquid;
consequently, maintenance is critical to pump performance.
9.0 PULSAlarm® Leak Detection Diaphragm
Double, or sandwiched, PTFE diaphragms are sealed at their peripheries to an
intermediate metal spacer ring. The space between the diaphragms is sealed so that the
diaphragm functions like a standard single diaphragm. The space between the
diaphragms is filled with a small amount of fluid. This space is connected to an electrical
switch (optional) that actuates in response to a buildup of pressure resulting from rupture
of either or both diaphragms.
Switch operation can be used to perform any external function, typically to signal an
alarm or turn off the pump.
During installation, ensure that adequate space is available around the reagent
head assembly to allow for service of both the pressure switch and the diaphragm
assembly.

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10.0 Diaphragm Construction
In some cases, diaphragm components are retained with adhesive. It is not present for
sealing purposes.
Diaphragm construction

13
11.0 PULSAlarm® Diaphragm Maintenance
After diaphragm failure, pressurized process fluid can be present in
any part of the PULSAlarm® Leak Detection System. Take
appropriate precautions and handle with care.
Diaphragm and head orientation
11.1 PULSAlarm® Diaphragm Removal
BE SAFE –FOLLOW ALL APPLICABLE SAFETY PROCEDURES
BEFORE MAINTENANCE. ASSURE THE ENVIRONMENT IS
SAFE, USE PERSONAL PROTECTIVE EQUIPMENT
APPROPRIATE TO THE JOB, RELEAVE ANY STORED ENERGY
(E.G., PRESSURE IN SYSTEM PIPING AND PUMP
HYDRAULICS) AND CONTROL UNINTENDED OPERATION
(E.G., APPLY LOCK-OUT/TAG-OUT PROCEDURES
Use the following procedure to remove the Leak Detection Diaphragm:
1. Disconnect the power source to the drive motor (apply all necessary engineering
controls –e.g., lockout-tagout).
2. Relieve all pressure from the piping system, and close the inlet and outlet shutoff
valves
3. Take all precautions to prevent environmental and personnel exposure to
hazardous materials.
4. Place a suitable container underneath the pump head to catch any liquid leakage.
5. Disconnect process piping and drain any process liquid, following
material safety precautions.
6. Remove all but one top reagent head bolt. Oil will leak out between the
pump head and reagent head as the bolts are loosened.
7. Tilt the head and pour out any liquids retained by the check valves into a
suitable container, continuing to follow safety precautions as appropriate.
8. Remove the alarm switch assembly or pressure gauge from the reagent head.

14
9. Rinse or clean the reagent head with an appropriate material.
10. Remove the diaphragm by running a blunt blade along the periphery and prying it
out.
11.2 Inspection
Remove and inspect the diaphragm assembly. It may have taken a permanent
convex/concave set as a result of normal flexure and conformance to the dish-
plate. This condition is normal and is not cause for replacement. The diaphragm
must be replaced if it is deformed, dimpled, or obviously damaged.
If the diaphragms have been removed from the support ring, the entire
assembly should be replaced to ensure proper sealing of its components.
11.3 PULSAlarm® Diaphragm Reinstallation
1. Ensure that the critical sealing areas of diaphragm assembly, reagent head,
and pump head are clean and free from debris. Align the diaphragm
assembly capillary tubes with mating holes in the seal groove in the reagent
head and position it in place against the reagent head. Ensure seating of the
diaphragm sealing ring into the mating groove in the reagent head.
2. Install the reagent head bolts and tighten in an alternating pattern to ensure an
even seating force. Torque to the values recommended in the Installation,
Operation, and Maintenance manual appropriate to the pump.
3. Apply sealing compound to the gauge/pressure switch assembly threads and
reinstall to the upper port on the reagent head.
4. Apply sealing compound to the fill valve assembly pipe plug and reinstall to the
lower port on the reagent head.
5. Connect a hand-held vacuum pump or other vacuum source to the vacuum
port, which fits 6 mm (1/4 in.) I.D. tubing.
Diaphragm damage or decreased flow will occur if a vacuum is not drawn
before the pump is returned to service.
6. Re-prime the pump head hydraulic system
7. If required, test operation
8. After diaphragm set-up and priming, the pump is ready to be returned to
service.
12.0Barrier Fluid Setup
The barrier fluid should be chosen for compatibility with the process and
environmental conditions. The fluid chosen should have as low a viscosity as
possible to aid in priming the system. Water can be used, and ethylene or
propylene glycol can be added for corrosion and temperature protection. Thin oils
such as silicone oil or mineral oil can also be used. Liquids of higher viscosity will
extend the time required to properly prime the system. Thinner liquids will allow for
faster setup.
Pulsafeeder supplies low viscosity silicone oil standardly.

15
System identification is noted on the switch cover nameplate, and on your
Pulsa Series pump nameplate.
The barrier fluid used to prime the system will vary with the
application. The fluid selection must be compatible with the
materials of construction used in the diaphragm and detection
assembly. It should also be compatible with the process fluid
and the process conditions.
BE SAFE –FOLLOW ALL APPLICABLE SAFETY PROCEDURES
BEFORE MAINTENANCE. Assure the environment is safe, use
personal protective equipment appropriate to the job, relieve
any stored energy (e.g., pressure in system piping and pump
hydraulics) and control unintended operation (e.g., apply lock-
out/tag-out procedures).
1. Assure the equipment is safe to work on by following established rules and
using good common sense (e.g., be sure the air surrounding the work is not
hazardous, use the proper Personal Protective Equipment, relieve
pressure/drain fluid from piping, and lockout the pump motor).
2. Follow complete re-assembly of the diaphragm, reagent head, and external
components. Ensure that reagent head and tie-bar bolts are tightened evenly
according to the appropriate torque specifications. Refer to the pump
operating manual for further information.
3. Remove the pressure gauge from the housing body and replace it with a
straight tubing adaptor fitting with a short piece of clear tubing as shown. This
will be referred to in this document as the “outlet side”.
Fitting for priming “outlet side”
4. Remove the plug from the elbow on the front of the reagent head and install a
hose adaptor fitting. Attach a length of clear tubing that will be long enough to
go to the bottom of the container of barrier fluid. This will be referred to in
this document as the “inlet side”.
5. Connect a hand vacuum pump to the tubing on the outlet side. This will be

16
used to pull the barrier fluid into the system.
6. Open the bottle of barrier fluid and run the tubing on the inlet side so the end
near the bottom. Try to hold the bottle so that the bottom is at the same
level as the inlet side fitting.
7. Squeeze the handle of the vacuum pump several times. You should see the
fluid start to move from the bottle through the clear tubing into the inlet fitting.
Be patient because the fluid needs to travel through several small capillary
tubes in the assembly and past a check valve.
8. Keep working the vacuum pump to keep vacuum on the system until you see
the barrier fluid in the tubing on the outlet side.
9. Watch the fluid at the outlet (vacuum pump) side. The fluid may appear to
bubble. Large bubbles are usually due to leakage of the fitting you are using
to attach the tubing on the outlet side fitting. Small bubbles (foaming) can
happen when the vacuum is too high –causing the fluid to boil at room
temperature. If bubbles occur, keep pumping the vacuum pump slowly. Stop
when you can see a level of fluid in the outlet side tubing (not just bubbles)
without any vacuum pressure.
10. Release the vacuum to check for a clear level of fluid in the outlet side tubing.
If there is no level restore the vacuum by pumping the pump and return to the
previous step.
11. With the vacuum released, remove the fitting with tubing from the inlet side
connection.
12. Be sure the elbow on the inlet side won’t trap any air bubbles when you put
the pipe plug back in the fitting. To be sure you should refill the elbow with
barrier fluid by pouring fluid into the fitting opening until it is overflowing. Use
another container to catch any fluid that might spill.
13. Apply pipe dope to the pipe plug threads and tighten it into the inlet side
elbow. Remove any drips on the fitting with a rag.
14. Squeeze the handle of the vacuum pump again and allow the vacuum to
remain on the outlet side of the system for approx. 2-3 minutes, this will aid in
the evacuation of excess fluid. Once complete, release the vacuum and
remove the hand pump from the tubing (leaving the outlet side tubing in
place).
Bleed tubing placement
15. Check the pump to be sure that all the oil levels show full. Some pumps have
more than one type of oil (for example gear oil in one part and hydraulic oil in

17
another). Refer to the Pump manual for further instruction.
16. If the pump is not already hydraulically primed, re-prime it now using the
procedure found in the Pump Operating Manual. If the diaphragm was never
removed, this step should not be necessary. If a new diaphragm is being
installed, the pump will need to be re-primed.
17. In order to fully balance and remove air from the leak detection system the
pump must now run at normal discharge pressure for a period of about 30
minutes to one hour. This ensures that excess barrier fluid and air is fully
evacuated from the system.
18. Remake any process connections that were broken to the suction and
discharge of the pump. Check that the system is safe for operation.
19. Restore/replace any convers to the pump that may have been removed.
20. In hazardous locations the PULSAlarm cover must be threaded onto the fitting
and locked using the lock screw.
21. Remove any safety related engineering controls (lockout/tagout).
22. If possible, adjust any discharge pressure devices to their lowest settings.
23. Adjust the pump stroke length to its 0% setting.
24. Apply power to the pump motor and start the pump.
25. Slowly increase the pump stroke length from 0% to 100%.
26. Slowly increase the discharge pressure to full operating pressure.
27. Continue to run the pump. During this time, excess barrier fluid will be
displaced from the system into the length of tubing attached to the outlet side,
balancing the system for proper operation. A small pen mark on the tube can
assist in observing this process visually. Once the liquid in the tube no longer
rises, the evacuation should be complete.
28. After 30 minutes of operation, stop the pump motor.
29. Remove the tubing and connection from the housing body and reinstall the
pressure gauge. Use thread sealing pipe dope to seal the fitting.
30. Verify the connections to the alarm switch if they were disturbed during
maintenance.
31. The pump and pressure leak-detection system are now properly prepared and
ready for normal service.
During normal operation, the gauge should indicate 0 (zero) pressure.
Under certain circumstances, the system may not completely evacuate excess
barrier fluid during the procedure as outlined above. In these cases, after
several days run time, a small amount of pressure may build in the system. If
this occurs, simply loosen the pressure gauge from the switch housing and
relieve a small amount of barrier fluid, returning the system to a zero-pressure
state.
Once this startup procedure is completed, the pressure leak detection system
should require no further maintenance.

18

Bulletin: IOM-PUL-1007 Rev F
PULSAlarm®
LEAK DETECTION
SYSTEM
A unit of IDEX Corporation
2883 Brighton Henrietta Town Line Road
Rochester NY 14623
[phone]
pulsa.com
[email protected]m