Pulsafeeder PULSAR 25HJ Instruction manual

PULSAR®
HYDRAULIC DIAPHRAGM
METERING PUMPS
Bulletin: IOM-PSR-1500-Rev.G
Installation, Operation &
Maintenance Manual

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PULSARFACTORY SERVICE POLICY
Should you experience a problem with your PULSAR 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 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.
TRADEMARKS
PULSAR®is a registered trademark of Pulsafeeder, Inc.
Pulsafeeder®is a registered trademark of Pulsafeeder, Inc.
Pulsafeeder EPO®is a registered trademark of Pulsafeeder, Inc.
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.
Copyright ©2003/2006/2015/2020 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.

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CONVENTIONS
AWARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH THE EQUIPMENT AND
THE PERSONNEL OPERATING IT.PAY CLOSE ATTENTION TO ANY WARNING.
Notes are general information meant to make operating the equipment easier.
REVISION HISTORY
Rev D:Release 12-2006
•Added information on use of diagnostic window
•Added diaphragm failure information to troubleshooting section
•Revised oil level recommendations
•Added suction condition cautions
•General text and formatting corrections
Rev E: Release 7-2015
•Rebranding
•Formatting updates
Rev F: Release 9-2016
•Bolt torque recommendation update
Rev G: Release 7-2020 Michael Groth
•General review update
•Remove Vacuum Leak Detection
Additional information regarding your pump can be found by going to our Pulsafeeder
website WWW.Pulsa.com If you need further assistance, you can contact our service
department by calling 585-292-8000, or by emailing us at [e-mail]

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Table of Contents
1. INTRODUCTION................................................................................................................................1
1.1 GENERAL DESCRIPTION.......................................................................................................1
2. PRINCIPLES OF OPERATION..........................................................................................................1
2.1 OVERALL OPERATION ..........................................................................................................1
2.2 COMPONENT LOCATION AND OPERATION .......................................................................2
2.2.1 Reagent Head Assembly ................................................................................................2
PULSAlarm LEAK DETECTION .....................................................................................................3
2.2.2 Pump Head/Piston assembly.........................................................................................3
2.2.3 Control Assembly ...........................................................................................................4
3. EQUIPMENT INSPECTION...............................................................................................................6
3.1 STORAGE INSTRUCTIONS ....................................................................................................6
3.1.1 Short Term.......................................................................................................................6
3.1.2 Long Term........................................................................................................................6
4. INSTALLATION.................................................................................................................................7
4.1 LOCATION ...............................................................................................................................7
4.2 PIPING SYSTEM......................................................................................................................7
4.3 SUCTION PRESSURE REQUIREMENTS...............................................................................8
4.4 DISCHARGE PRESSURE REQUIREMENTS .........................................................................9
4.5 AUTOMATIC CONTROL (DLC, DLCM OR MPC)...................................................................9
4.6 PULSALARM LEAK DETECTION ELECTRICAL CONNECTIONS.......................................9
5. EQUIPMENT SETUP.........................................................................................................................10
5.1 LUBRICATION .........................................................................................................................10
5.1.1 Oil Capacities...................................................................................................................10
5.1.2 Gear Oil Fill ......................................................................................................................10
5.1.3 Hydraulic Oil Fill..............................................................................................................11
5.2 PULSAlarm LEAK DETECTION..............................................................................................12
DRIVE MOTOR INSTALLATION .........................................................................................................12
5.2.1 Motor Rotation.................................................................................................................12
5.2.2 Motor Installation ............................................................................................................12
5.2.3 Electrical ..........................................................................................................................13
6. STARTUP PROCEDURE ..................................................................................................................13
6.1 OUTPUT ADJUSTMENT..........................................................................................................13
6.2 Suction System.......................................................................................................................14
6.3 Priming the Pump head (Hydraulic System)........................................................................14
6.4 Priming the Reagent Head (Product System) ......................................................................14
6.5 Calibration ...............................................................................................................................15
6.6 CHECKING THE DIAGNOSTIC WINDOW..............................................................................16
7. MAINTENANCE.................................................................................................................................17
7.1 Oil Changes .............................................................................................................................17
7.1.1 Gear Oil Change:.............................................................................................................17
7.1.2 Hydraulic Oil Change:.....................................................................................................18
7.2 WET END REMOVAL, INSPECTION, AND REINSTALLATION............................................18
PULSALARM LEAK DETECTION SYSTEM...................................................................................18
7.2.1 Standard Diaphragm Replacement ...............................................................................19
7.2.2 Re-Priming the Pump head ............................................................................................20
7.3 CHECK VALVES......................................................................................................................20
7.3.1 General Description........................................................................................................20
7.3.2 Removal, Inspection, and Reinstallation......................................................................20
7.4 HYDRAULIC PERFORMANCE VALVE (HPV)........................................................................21
7.4.1General Description........................................................................................................21
7.4.2 Check Valve Screen - Removal and Cleaning..............................................................21
7.4.3 HPV Removal and Replacement - A & B Pump head Style.........................................22
7.4.4 HPV Removal and Replacement - C & D Pump head Style.........................................23
7.5 HYDRAULIC BYPASS VALVE (HBV).....................................................................................24
7.6 PTP (PUSH TO PURGE / AUTOMATIC BLEED VALVE).......................................................25
7.6.1 General Description........................................................................................................25

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7.6.2 Removal, Cleaning, & Reinstallation.............................................................................25
7.7 PISTON SEAL..........................................................................................................................25
7.7.1 General Description........................................................................................................26
7.7.2 Removal ...........................................................................................................................26
7.7.3 Reinstallation...................................................................................................................26
7.8 OIL SEALS ...............................................................................................................................26
7.8.1 General Description........................................................................................................26
7.8.2 Removal and Replacement ............................................................................................26
7.9 COVER ASSEMBLY ................................................................................................................27
7.9.1 Removal & Reinstallation...............................................................................................27
8. PUMP MOTOR...................................................................................................................................28
8.1 REMOVAL & REINSTALLATION............................................................................................28
9. REPLACEMENT PARTS...................................................................................................................29
9.1 PULSAR KOPKIT PROGRAM.................................................................................................29
9.2 ORDERING KOPKITS OR PARTS..........................................................................................29
10. TROUBLESHOOTING CHART.........................................................................................................29
10.1 DIAGNOSIS OF DIAPHRAGM FAILURE................................................................................32
11. APPENDIX I.......................................................................................................................................33
PULSALARM LEAK DETECTION SYSTEM...........................................................................................33
11.1 PULSALARM LEAK DETECTION REAGENT HEAD ASSEMBLY........................................33
11.2 PULSAlarm Leak Detection Diaphragm................................................................................33
11.3LEAK DETECTION OPTION –SETUP FOR PRESSURE......................................................34
11.4PRESSURE SYSTEM SET-UP AND PRIMING.......................................................................34
11.5LEAK DETECTION SYSTEM MAINTENANCE.......................................................................Error!
Bookmark not defined.
11.5.1 Vacuum Setpoint Adjustment........................................................................................Error!
Bookmark not defined.
11.6PULSALARM LEAK DETECTION DIAPHRAGM MAINTENANCE........................................37
11.6.1 Leak Detection Diaphragm Removal.............................................................................37
11.6.2 Inspection ........................................................................................................................38
11.6.3 Leak Detection Diaphragm Reinstallation....................................................................38
11.7Leak Detection system conversion.......................................................................................38
12. APPENDIX II......................................................................................................................................39
PIPING CALCULATIONS ........................................................................................................................39
SUCTION HEAD REQUIREMENTS.....................................................................................................39
SYSTEM BACK PRESSURE...............................................................................................................41
NOMENCLATURE................................................................................................................................41
13. APPENDIX III.....................................................................................................................................42
OIL SPECIFICATIONS.............................................................................................................................42
PULSAlube # 7H..................................................................................................................................42
PULSAlube # 8G..................................................................................................................................42
14. APPENDIX IV.....................................................................................................................................43
BOLT TORQUE RECOMMENDATIONS.................................................................................................43
15. APPENDIX V......................................................................................................................................44
PULSAFEEDER ACCESSORIES............................................................................................................44
PULSATROL INSTALLATION, OPERATION, & REMOVAL INSTRUCTIONS.................................44
INSTALLATION................................................................................................................................44
PULSATROL REMOVAL.................................................................................................................45
BACK PRESSURE VALVE..................................................................................................................46
PRESSURE RELIEF VALVE ...............................................................................................................46

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1. INTRODUCTION
1.1 GENERAL DESCRIPTION
PULSAR metering pumps are positive displacement reciprocating pumps. They combine the
high efficiency of the plunger pump with diaphragm sealing to prevent product leakage. Each
pump consists of a power end and a process end separated by a hydraulically operated
diaphragm. Individual pumps will vary in appearance due to various liquid ends, accessories,
and multiplexing; however, the basic principles of operation remain the same.
2. PRINCIPLES OF OPERATION
2.1 OVERALL OPERATION
Figure 1
A piston reciprocates within an accurately sized cylinder at a preset stroke length, displacing an
exact volume of fluid. This piston does not pump chemicals: it pumps hydraulic oil. The piston
and associated mechanisms are enclosed in the eccentric box that also serves as a hydraulic oil
reservoir. A diaphragm separates the oil from the product pumped. The diaphragm moves in
exact response to piston displacement. The diaphragm does no work and acts only as a
separator. Consequently, oil displacement is translated into equal product displacement.
Piston retraction causes the product to enter through the suction check valve. Piston advance
causes the discharge of an equal amount of the product through the discharge check valve.

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2.2 COMPONENT LOCATION AND OPERATION
Figure 2
2.2.1 Reagent Head Assembly
The typical reagent head assembly consists of reagent
head, diaphragm, and suction and discharge check
valves. This assembly is the only part of the pump to
contact the process liquid; consequently, maintenance
is critical to pump performance.
Figure 3

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PULSAlarm LEAK DETECTION
The PULSAlarm Pressure leak detection reagent head assembly consists of a leak detection
reagent head, leak detection diaphragm, suction and discharge check valves, and optional
pressure switch and gauge. If your pump is equipped with this option, refer to Appendix I on
page 33 for further information.
A sealed system must be maintained at all times during pump operation, whether leak
detection is required or not.
2.2.2 Pump Head/Piston assembly
The pump head/piston assembly is installed on the eccentric box. This assembly contains
the hydraulic system consisting of the pump head, cylinder, piston assembly, and three
hydraulic valves:
PTP (Push-To-Purge)
HPV (Hydraulic Performance Valve)
HBV (Hydraulic Bypass Valve).
Figure 4
The PTP valve is situated at the top of the pump head and automatically removes gases from
the hydraulic system during normal operation. Momentary manual actuation of the external

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valve button overrides automatic operation to validate priming or to determine diaphragm
integrity.
The HPV automatically maintains the required hydraulic oil volume by replacing any oil lost past
the piston or through the PTP valve.
The HBV protects the pump from over-pressurizing by relieving any excess pressure in the
pump’s hydraulic system.
2.2.3 Control Assembly
Figure 5
PULSAR pumps incorporate a lost motion style of stroke length adjustment to limit piston travel
during the suction portion of each stroke. The stroke length setting is denoted by a (0 - 100)
scale located on the top of the unit.
Stroke is changed by depressing and turning the hand knob. This turns a screw which locates a
slider cam to position the follower pin as to limit the rearward travel of the piston. If the control
cover is removed and replaced, the bolts should be tightened to 20-24 In-lbs. (225 –270 N-cm).
PULSAR pumps may also be equipped with the Pulsafeeder DLC or DLCM electronic stroke
length controllers. These allow for local and/or remote automatic control over stroke length
(DLC) or stroke length and motor speed (DLCM). Pumps equipped with the DLC or DLCM
controllers are provided with separate instructions for the controller. Refer to the appropriate
Installation, Operation and Maintenance Manual (IOM-CTL-DLC-2005 or IOM-CTL-DLCM-
2004).
Some PULSAR pumps may also be equipped with the MPC control which allows for pump flow
control over a wide range via a specially designed variable speed drive. The MPC Installation,
Operation and Maintenance manual IOM-MPC-0104 covers information specific to this type of
control and should be consulted prior to operating the pump or the controller.

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2.2.5 Gear Ratio Assembly
Figure 6
PULSAR pumps are driven by a standard C-face electric motor mounted on the motor
adaptor input flange. The motor drives a set of worm gears which convert rotational speed
into torque. They in turn power the eccentric shaft assembly that converts rotary motion to
reciprocating motion. The motor adaptor is available in a variety of configurations to
accommodate different motor frame specifications.
Figure 7
More than one pump can be driven through a single drive assembly. This is referred to as
multiplexing. The pumps are mounted on a common gear reducer assembly on the driver pump
and the pump without a gear reducer is called the driven pump. Each pump is mounted on its
respective standard simplex base.

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Whenever pumps are multiplexed, the eccentric shafts are positioned to place a uniform load on
the driver. Before full disassembly always note the relative positions of the eccentric shafts to
each other so they can be reassembled in the same orientation.
3. EQUIPMENT INSPECTION
Check all equipment for completeness against the order and for any evidence of shipping
damage. Shortages or damage should be reported immediately to the carrier and your
Pulsafeeder representative.
3.1 STORAGE INSTRUCTIONS
3.1.1 Short Term
Storage of PULSAR pumps 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) Within two months after date of shipment, fill the eccentric box to its normal operating level
with PULSAlube 7H (purple) hydraulic oil. If required by the operating environment, take
steps to prevent entry of water or humid air into the eccentric enclosure.
c) Prior to start up, inspect housing, and gearbox. Replenish hydraulic and gearbox oils as
required to maintain operating levels. If water or condensation is present, change oil as
described under Equipment Startup.
d) Start up in accordance with instructions in this manual.
3.1.2 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. If
the pump is equipped with a PULSAlarm pressure leak detection system, See Appendix I on
page 33 for more information.
After twelve months of storage, Pulsafeeder’s warranty cannot cover such items which are
subject to deterioration with age such as seals and gaskets. If the pump has been in storage
longer than 12 months, it is recommended that such 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. For a continuance of the warranty after
extended storage, equipment inspection and any required refurbishing must be done by a
Pulsafeeder representative.

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4. INSTALLATION
4.1 LOCATION
When selecting an installation site or designing a skid package, consideration should be
given to access for routine maintenance.
PULSAR pumps are designed to operate indoors and outdoors, but it is desirable to
provide a hood or covering for outdoor service. External heating may be required if
ambient temperatures below -18C (0F) are anticipated. Check with the factory
regarding 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 2.
This will assure that the hydraulic and gear oils are maintained at the proper levels and
that the check valves can operate properly.
4.2 PIPING SYSTEM
All piping systems should include:
Figure 8

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1. Shutoff valves and unions (or flanges) on suction and discharge piping. This permits check
valve inspection without draining long runs of piping. Shutoff valves should be of the same
size as connecting pipe. Ball valves are preferred since they offer minimum flow restriction.
2. An inlet strainer, if the product is not a slurry. Pump check valves are susceptible to dirt and
other solid contaminants unless designed for that service, and any accumulation can cause
a 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. 100-mesh screen is recommended.
3. Vacuum/pressure gauges in the suction and discharge lines in order to check system
operation. Gauges should be fitted with protective shutoff valves for isolation while not in
use.
4. A back-pressure valve (BPV) on the discharge piping to create an established pressure
upon the pump valving to ensure proper seating of the check balls.
5. A separate system pressure relief valve (PRV) to protect piping and process equipment,
including the pump, from excess process pressures.
The hydraulic bypass valve (HBV) in the pump is not intended to protect the system!
Piping weight must not be supported by the 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.
In piping assembly, use a sealing compound chemically compatible with the process material.
Users of sealing tape are cautioned to ensure that the pipe thread ends are not taped. 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. Flow issues at
pump startup are often related to the check valves being fouled with piping and process debris.
4.3 SUCTION PRESSURE REQUIREMENTS
Although PULSAR metering pumps have suction lift capability, all pump installations should
have minimum lift for optimum performance. 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 other source. Piping should be sized to allow
for best possible NPSH conditions. (Preferably the same size as the pumps check valving size
at a minimum or larger)
It is not recommended to install a PULSAlarm equipped pump in a suction lift system.
If suction lift is required, the net positive suction pressure required (NPSHr) is 0.21 bar (or 3
psia). If this requirement is not met the process liquid may cavitate inside the pump, degrading
metering accuracy. To maintain prime on a suction installation, a foot valve is required. In
addition, suction pressure must be maintained at a minimum absolute value of 0.35 bar (or 5
psia) to ensure proper hydraulic system and proper pump operation.
The maximum inlet pressure is limited to 30 psig with the standard composite diaphragm.
Higher suction pressures may be accommodated with optional diaphragm configurations.
It is critical that PULSAR pumps have free flowing and unobstructed suction conditions
at all times. Closed valves, clogged strainers, obstructed piping, etc., are to be avoided.

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Suction restrictions can place stress on the diaphragm that may result in premature
failure.
Refer to Appendix II for procedures for the calculation of suction pressure.
4.4 DISCHARGE PRESSURE REQUIREMENTS
All PULSAR Metering Pumps are designed for continuous service at the rated discharge
pressure. If system suction pressure were to exceed system discharge pressure (a condition
sometimes described as “pumping downhill”), flow would be generated in addition to that
caused by the pump, resulting in a reduction in accuracy and loss of control over the metering
process. To prevent this condition, commonly referred to as “flow-through”, discharge pressure
must exceed suction pressure by at least 0.35 Bar (or 5 psi). This can be achieved where
necessary by the installation of a backpressure valve in the discharge line.
Discharge systems should be protected from excessive pressures by utilizing a pressure relief
or pressure limiting valve in the piping system. Operation of the pump at pressure above its
nameplate rated maximum may result in damage to the pump components and/or unsafe
system conditions.
Refer to Appendix II for procedures for the calculation of discharge pressure.
4.5 AUTOMATIC CONTROL (DLC, DLCM OR MPC)
Pumps equipped with the electronic controllers are provided with separate instructions. Refer to
DLC manual IOM-CTL-DLC-2005, DLCM manual IOM-CTL-DLCM-2004, or MPC manual IOM-
MPC-0104. Perform all DLC, DLCM or MPC installation procedures prior to pump startup.
4.6 PULSALARM LEAK DETECTION ELECTRICAL
CONNECTIONS
Figure 9
If equipped with an optional pressure switch, install electrical wiring and conduit in accordance
with local electrical codes.
The switch is rated as follows:
30 VDC or 125 VAC 1 Ampere Resistive.
The switch is the SPDT (single pole, double throw) type and can therefore be connected to
either open or to close upon detection of diaphragm leak condition. Contacts or wires are
identified as follows:

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Normally Open (NO) wire color WHITE
Normally Closed (NC) wire color RED
Common (Com) wire color BLACK
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.
5. EQUIPMENT SETUP
5.1 LUBRICATION
PULSAR pumps use two separate oils: PULSAlube 7H, hydraulic oil for the eccentric box
and PULSAlube 8G, gear oil for the gearbox. Confusion between the two will impair
performance and damage the pump.
PULSAR pumps are shipped from the factory with the Eccentric Housing drained, and
the Gearbox full. The Installer should fill the Eccentric Housing. The external gearcase
does not need to be checked.
5.1.1 Oil Capacities
PULSAlube 7H hydraulic oil is now available in 1-liter containers (previously 1.5 liters).
PULSAlube 8G gear oil is available in 200 ml containers.
It is recommended that adequate supplies of both PULSAlube oils be on hand for periodic
changes and emergency requirements. The approximate amounts of oil required to fill PULSAR
pumps to specified levels are:
Oil
Color
Application
Amount (approx.)
PULSAlube 7H
Purple
Eccentric Housing
1000 ml (1 quart) NP980002-005
PULSAlube 8G
Amber
P25H Series Gearbox
150 ml (0.16 quart)
P55H Series Gearbox
200 ml (0.21 quart) NP980001-002
Please note that the eccentric box section of the pump is not completely full when the proper
amount of oil is used, this is normal. Starting in production year 2007, Pulsafeeder will distribute
PULSAlube 7H in 1-liter containers to facilitate proper oil fill.
5.1.2 Gear Oil Fill
In all pump configurations, one pipe plug is present at the top of the gearbox and one is on the
side at the centerline level. Remove the top plug and fill with PULSAlube 8G (amber) gear oil
through the top port to the level of the eccentric shaft centerline, which is level with the side port.
If desired, the side plug can be removed so that leakage from the side port indicates attainment

11
of the required level. Replace both pipe plugs after filling. Do not add oil through the port on
the side of the motor adapter, as this port is for motor drive coupling access only.
5.1.3 Hydraulic Oil Fill
Remove the diagnostic window to gain access to the reservoir and add PULSAlube 7H
hydraulic oil until the oil level is between the max and min as indicated on the label on the side
of the eccentric box. The oil level should be below the upper coils of the piston return spring, if
the upper coils of the spring are submerged, the oil level is too high (ref. Figure 10). Adding 1
liter (approx. 1 quart) of oil to a fully drained pump will result in the correct fill level. High oil
level will not affect the operation of the pump; however, it can result in nuisance leakage of oil.
Replace the window, making sure it is properly aligned and square before tightening the
thumbscrew.
Figure 10
DIAGNOSTIC COVER
(FOR OIL FILL)
MAXIMUM
FILL

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5.2 PULSAlarm LEAK DETECTION
Refer to Appendix I, page 33 for startup instructions specific to pumps equipped with the
PULSAlarm diaphragm leak detection system
DRIVE MOTOR INSTALLATION
5.2.1 Motor Rotation
Motor can be operated in either direction, clockwise or counterclockwise. Verification of motor
direction is not necessary at startup.
5.2.2 Motor Installation
PULSAR pumps may be shipped with the drive motor packed separately. This is done to avoid
damage during transport.
Figure 11
1. Remove the unattached coupling half from the motor adaptor. Ensure that the elastomer
coupling spider remains in place, on the coupling half that remains attached to the worm
shaft.
2. If applicable, remove any tape or retainer rings that hold the motor shaft key in place.
3. Place the loose coupling half on the motor shaft. Align the keyway with the key and align
shaft end to inner coupling surface as shown in figure above.
4. Tighten the setscrew onto the shaft key.
5. Place the motor in a vertical position and align the coupling teeth.
6. Install the motor downwards onto the adaptor. The plastic guide will assist in aligning the
coupling halves. Final position can be achieved by slightly rotating the motor until the
coupling jaws align.

13
7. Rotate the motor until the clearance holes in the adaptor and the tapped holes in the motor
align. Fasten the motor to the adaptor using the supplied bolts (4). Tighten bolts evenly to
secure motor.
5.2.3 Electrical
Wire the PULSAR drive motor according to the motor vendor’s nameplates and instructions, and
according to any appropriate national and local electrical codes and regulations.
If the motor is to be utilized with a Pulsafeeder controller, such as the DLC, DLCM, or
MPC, consult the appropriate Pulsafeeder IOM for further motor wiring instructions.
6. STARTUP PROCEDURE
6.1 OUTPUT ADJUSTMENT
Figure 12
All PULSAR pumps have a hand-wheel for manual stroke length adjustment. Mounted atop the
eccentric box, the hand-wheel can be adjusted at any point (from 0 to 100% stroke setting) by
pressing down and then rotating the hand wheel as required. Stroke length is locked during
operation to prevent drift: pressing the hand-wheel down temporarily disengages the lock for
adjustment; release after adjustment automatically resets the lock at the new setting. An
indicator adjacent to the hand-wheel displays the output setting. Adjustments can be made
while the pump is at rest or operating, although operating adjustments are easier to make.
Manual adjustment serves as a backup for pumps provided with an optional DLC stroke length
controller. If the control cover is removed and replaced, the bolts should be tightened to 20-24
In-lb (225 –270 N-cm).
If the pump is equipped with a pressure leak detection system, the system must
remain sealed at all times during pump operation, whether or not leak detection is
required. If the seal is broken, decreased flow and/or diaphragm damage will occur.
See Appendix I on page 33 for further information.

14
Leak Detection Diaphragm systems require special hydraulic priming considerations
to protect the diaphragm from damage during initial pump startup. See Appendix I on
page 33 for further information.
6.2 Suction System
Before operation of any PULSAR pump, carefully ensure that all suction valves are in the open
position. Verify that all filters and strainers are clean and clear. Ensure that any other potential
causes of restriction have been addressed. Unrestricted flow of liquid to the suction side of the
pump is critical to proper operation.
6.3 Priming the Pump head (Hydraulic System)
All pumps are shipped with a fully primed hydraulic system. However, during shipping and
handling some air may enter the hydraulic system. Generally, this air will be automatically
purged after a short run-in period. If necessary, rapid purging may be accomplished by fully
depressing and holding the PTP valve while the pump is operating. With the valve depressed,
oil should begin to flow out of the center diagnostic port. Continue to hold the valve down until
the oil is clear of bubbles.
If the pump fails to prime, go to the next section and follow the Priming the Pump head
procedure (Section 7.2.2). See Appendix I on page 33 for further information if your pump is
equipped with a PULSAlarm leak detection system.
6.4 Priming the Reagent Head (Product System)
1. Open the suction and discharge line shutoff valves.
2. If the piping system design and the storage tank are such that the product flows due to
gravity through the pump, no priming is required. In the event the discharge line contains a
significant amount of pressurized air or other gas, it may be necessary to lower the
discharge pressure to enable the pump to self-prime.
3. If the installation involves a suction lift, it may be necessary to prime the reagent head and
suction line. Try priming the reagent head first. Remove the discharge valve by unscrewing
the four tie bar bolts and removing the valve as a unit. Fill the head through the discharge
valve port with process (or compatible) liquid, then reinstall the valve and retighten the tie
bar bolts.
4. Start the pump at the 0% stroke length setting and slowly increase the setting to 100% to
prime the pump. If this does not work, it will be necessary to fill the suction line.
5. Filling of the suction line will necessitate the use of a foot valve or similar device at the end
of the suction line so that liquid can be maintained above the reservoir level. Remove the
suction valve assembly, fill the line, replace the valve, then remove the discharge valve
assembly and fill the reagent head as described in Step (3) above. The pump will now self-
prime when started up per step (4) above.

15
6.5 Calibration
Figure 13
All metering pumps must be calibrated in order to accurately specify stroke length settings for
required flow rates. For pumps provided with DLC or DLCM electronic stoke length control, refer to
separate instructions as noted on page 8.
A typical calibration chart is shown in Figure 13. 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).
The theoretical output flow rate at atmospheric output pressure is based on the displacement of the
hydraulic piston (the product of piston cross-sectional area and stroke length) and the stroking rate
of the pump. With increasing discharge pressure there is a corresponding decrease in output flow of
approximately 1% per 7 bar (100 psig) increase in output pressure. Whenever possible, calibration
should be performed under actual process conditions (i.e., the same or a similar process liquid at
system operating pressure).
To assure a sound hydraulic system, run the pump for 10-15 minutes prior to calibration. This will
allow the PTP (automatic bleed) valve to purge any air from the system.
To construct a calibration chart, measure the flow rate several times at three or more stroke settings
(i.e., 25, 50, 75, and 100), plot these values on linear graph paper, and draw a best-fit line through
the points. For stable conditions, this line should predict settings to attain required outputs.
Checking the actual flow rates is especially important in pumps producing low flow rates and
operating against high discharge pressures. In this type of system, normal losses of efficiency can
result in lack of measurable flow at shorter piston stroke lengths. This is a function of the system
conditions and does not indicate a problem with the pump. Careful measurement of actual pump
flow at several test points will allow for proper calibration over the complete flow range.