Pulsafeeder DC6 Manual

Installation, Operation, &
Maintenance Instruction
Models DC2, 3, 4, 5, and 6
Bulletin #: IOM-OM-1104- E
Manufacturers of Quality Pumps,
Controls, and Systems
STANDARD PUMP OPERATIONS
27101 Airport Road
Punta Gorda, FL 33982
[phone] Fax [phone]
www.pulsatron.com
®

ii
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. Solutions may include
purchase of replacement parts or returning the unit to the factory for inspection and repair. All returns
require a Return Authorization number to be issued by Pulsafeeder. Parts purchased to correct a warranty
issue may be credited after an examination of original parts by Pulsafeeder. Warranty parts returned as
defective which test good will be sent back freight collect. No credit will be issued on any replacement
electronic parts.
Any modifications or out-of-warranty repairs will be subject to bench fees and costs associated with
replacement parts.
Safety Considerations:
1. Read and understand all related instructions and documentation before attempting to install or maintain
this equipment
2. Observe all special instructions, notes, and cautions.
3. Act with care and exercise good common sense and judgment during all installation, adjustment, and
maintenance procedures.
4. 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 this equipment.
Revision History:
Rev B (3-1-05)
-Update diagram fig. 10
-Revise text step 11b page 11 diaphragm removal and replacement
- Update all parts diagrams and lists, Section 12
Rev C (9-1-06)
-Update for Kynar (PVDF) heads
-Add model string ID page
-Update KOPkit list with PVDF kits
-Update parts lists with PVDF parts
Rev E (2-2007)
-Update all for introduction of model DC6, SPO address only
-Update materials references to “PTFE”
Copyright ©2004, 2006, 2007 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, Inc.

iii
Table of Contents
1. INTRODUCTION .....................................................................................................................................1
2. PRINCIPLES OF OPERATION ..................................................................................................................1
2.1 Reagent Head Assembly ........................................................................................................2
2.2 Control Assembly....................................................................................................................2
2.3 Gear Ratio Assembly ..............................................................................................................2
3. EQUIPMENT INSPECTION .......................................................................................................................3
4. STORAGE ……………………………………………………………………………………………………...3
5. INSTALLATION ......................................................................................................................................3
5.1 Location....................................................................................................................................3
5.2 Piping System..........................................................................................................................4
5.3 Suction Pressure Requirements............................................................................................5
5.4 Discharge Pressure Requirements........................................................................................5
6. EQUIPMENT STARTUP ...........................................................................................................................6
6.1 Fastener Inspection.................................................................................................................6
6.2 Output Adjustment ..................................................................................................................6
6.3 Priming the Reagent Head......................................................................................................7
6.4 Calibration ................................................................................................................................8
7. MAINTENANCE ......................................................................................................................................9
7.1 Lubrication ...............................................................................................................................9
7.2 Wet End Removal, Inspection, & Reinstallation...................................................................10
7.3 Check Valves ...........................................................................................................................12
7.4 Motor Removal & Reinstallation ............................................................................................16
7.5 Gearset Removal .....................................................................................................................16
7.6 Gearset Replacement..............................................................................................................18
8. REPLACEMENT PARTS ..........................................................................................................................19
8.1 KOPkit Program.......................................................................................................................19
8.2 Ordering KOPkits or Parts......................................................................................................19

iv
8.3 KOPkit numbers by model: ....................................................................................................20
9. MODEL NUMBER IDENTIFICATION...........................................................................................................21
10. WET END MATERIALS REFERENCE ........................................................................................................22
11. TROUBLESHOOTING ..............................................................................................................................23
12. PIPING ACCESSORIES ...........................................................................................................................25
13. DIMENSIONAL DRAWING........................................................................................................................26
14. PARTS DIAGRAMS AND PARTS LISTS.....................................................................................................28
14.1 Parts diagram, DC2 and 3 .......................................................................................................28
14.2 Bill of Materials, DC2...............................................................................................................29
14.3 Bill of Materials, DC3...............................................................................................................31
14.4 Parts Diagram, DC4, 5, and 6..................................................................................................34
14.5 Bill of Materials, DC4...............................................................................................................35
14.6 Bill of Materials, DC5...............................................................................................................37
14.7 Bill of Materials, DC6...............................................................................................................39

1
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.
Diaphragm retraction causes the product to enter through the suction check valve. Diaphragm advance
causes the discharge of an equal amount of the product through the discharge check valve.

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 OMNI
®
pump incorporates a lost motion style of stroke length adjustment to limit diaphragm
travel during the suction portion of each stroke. The stroke length setting is indicated by a (0% –
100%) scale located on the stroke adjustment assembly.
Stroke length is changed by loosening the locking screw and turning the hand knob. This turns a
mechanism, which limits rearward travel of the diaphragm. Refer to Section 6.2 for further
information.
For automatic flow rate control, users can consider the Pulsafeeder MPC speed based control system,
please contact your local Pulsafeeder dealer or representative for more information.
2.3 Gear Ratio Assembly
OMNI
®
pumps are driven by an electric motor mounted on the motor adaptor input flange. The
motor drives a set of worm gears that convert rotational speed into torque. They, in turn, power the
eccentric shaft assembly that converts rotary motion into reciprocating motion.
Figure 2, isometric view

3
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.
b) If required by the operating environment, take precautions to prevent entry of water or humid air
into the eccentric enclosure.
c) Prior to startup, perform a complete inspection and then start up in accordance with instructions
in this manual.
4.1.2 Long Term
Every twelve months, in addition to the above short-term procedures, power up the motor and operate
the pump for a minimum of one hour. It is not necessary to have liquid in the reagent head during
this operation, but the suction and discharge ports must be open to atmosphere.
After twelve months of storage, Pulsafeeder’s warranty cannot cover items that are subject to
deterioration with age, such as seals, gaskets, and diaphragms. If the pump has been in storage longer
than 12 months it is recommended that these items be inspected and replaced as necessary prior to
startup. Materials and labor to replace this class of item under this circumstance are the purchaser’s
responsibility. Consult your local Pulsafeeder representative for assistance in obtaining parts and
service for your pump.
5. Installation
5.1 Location
When selecting an installation site or designing a chemical feed system, consideration should be given
to access for routine maintenance.
OMNI
®
pumps are 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 pumps are not in continuous duty. Check with the factory if concerned
with the suitability of the operating environment.
The pump must be rigidly bolted to a solid and flat foundation to minimize vibration, which can loosen
connections. When the pump is bolted down, care must be taken to avoid distorting the base and
affecting alignments. The pump must be level within 5°. This will assure that the check valves can
operate properly.

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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. This
permits check valve inspection without draining long runs of piping, making periodic maintenance
and inspection easier.
Shutoff valves should be of the same size as connecting pipe. Ball valves are preferred since they
offer minimum flow restriction.
3. Suction systems should include an inlet strainer, if appropriate for the product being pumped. Pump
check valves are susceptible to dirt and other solid contaminants, and any accumulation can cause
malfunction. The strainer should be located between the suction shutoff valve and the pump suction
valve. It must be sized to accommodate the flow rate and the anticipated level of contamination. A
100 mesh screen size is generally recommended.
4. Vacuum/pressure gauges in the suction and discharge lines are helpful in order to check system
operation. Gauges should be fitted with protective shutoff valves for isolation while not in use.
5. Piping weight must not be supported by valve housings or other portions of the reagent head, as the
resulting stresses can cause leaks. If appropriate, provide for thermal expansion and contraction so
that no excess force or moments are applied to the pump.
6. When making process connections, ensure that the check valve assemblies do not rotate as the
threaded connections are secured. It is critical, especially with plastic construction, that the check
valves not be too tight into the reagent head. The threaded connection between the check valve
assembly and the regent head uses on o-ring seal and does not require sealing tape or any other
sealant.
7. In piping assembly, use a sealing compound chemically compatible with the process material. Users
of sealing tape are cautioned to ensure that the entering pipe thread ends are not taped, and that tape is
removed from previously-used threads to the maximum practical extent prior to re-use. Both new and
existing piping should be cleaned, preferably by flushing with a clean liquid (compatible with process
material) and blown out with air, prior to connection to the pump. Debris from the piping system that
prevents proper check valve operation is a common startup issue.
8. Note that for pumps which utilize cartridge-type check valve assemblies, no thread tape or sealant is
required on the threads which secure the cartridge assembly to the pump reagent head. This area is
sealed with o-rings integral to the cartridge. Sealant on these threads can actually degrade sealing
capability.

5
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. If this requirement is not met, the pump will not provide reliable,
accurate flow. In suction lift conditions, the use of a foot valve is recommended at the lowest point of
the pickup tube or pipe. Pumps under suction lift conditions may require some liquid priming before
they will operate reliably.
5.4 Discharge Pressure Requirements
All OMNI
®
metering pumps are designed for continuous service at the rated discharge pressure. If
system suction pressure exceeds discharge pressure (a condition sometimes described as “pumping
downhill”), flow would be generated (siphoning) in addition to that caused by the pump. This results in
a reduction in accuracy and loss of control over the metering process. To prevent this flow-through
condition, the discharge pressure must exceed suction pressure by at least 0.35 Bar (5 psi). This can be
achieved where necessary by the installation of a backpressure valve in the discharge line. Conditions
where the actual discharge pressure exceeds the pump’s rating are to be avoided as they will cause
damage to the pump components.
Figure 3, sample system configuration

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Figure 4, stroke adjustment
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:
Reagent Head Bolt Torque
Model Material # Bolts and size N-m In. - Lbs
Plastic (4) M6 * 1.0 3.39 30
DC2 Metal (4) M6 * 1.0 3.39 30
Plastic (4) M8 * 1.25 6.77 60
DC3 and 4 Metal (4) M8 * 1.25 6.77 60
Plastic (6) M8 * 1.25 8.46 75
DC5 Metal (6) M8 * 1.25 8.46 75
Plastic (6) M8 * 1.25 8.46 75
DC6 Metal (6) M8 * 1.25 8.46 75
6.2 Output Adjustment
All OMNI
®
pumps have a hand wheel for manual stroke adjustment. The hand wheel can be adjusted to
any point from 0 to 100%. This value represents the stroke length setting and therefore the flow rate of
the pump relative to its maximum output.
1. Turn the red lock screw counterclockwise to release the
stroke lock. Making adjustments without releasing the
lock may damage the mechanism.
2. Adjust the hand wheel to the desired output.
a) The stroke barrel indicates stroke length in 20%
increments.
b) The hand wheel indicates stroke length in 1%
increments.
For example, to set the pump to 75% stroke length,
(starting from the factory default setting of 0%) turn the
hand wheel counter clockwise until he 60% indicator is
visible on the stroke barrel.
Continue the counter clockwise rotation until the hand
wheel indicator is at 15. Refer to Figure 4.
3. Turn the lock screw clockwise to lock the stroke adjustment
into position.
Adjustments can be made while the pump is at rest or
operating, although adjustments are easier to make
while the pump is in operation.