Pulsafeeder PULSAR Shadow Series Instruction manual

PULSAR®Shadow
MECHANICAL DIAPHRAGM
METERING PUMP
Bulletin: IOM-PSRM-1501 REV B
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. You may
also visit our website at www.pulsa.com
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.
Notice
Information and specifications in this document are subject to change without notice.
Copyright
Copyright © 2003 Pulsafeeder, Inc. All rights reserved.
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.
Trademarks
PULSAR® is a registered trademark of Pulsafeeder, Inc.
PULSAR Shadow® is a registered trademark of Pulsafeeder, Inc.
Cruise Control®, ECA®, DLC®, and DLCM®are registered trademarks of Pulsafeeder,
Inc.

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Table of Contents
1. INTRODUCTION .....................................................................................................................................1
1.1 Overall Operation ....................................................................................................................1
1.2 Component Layout..................................................................................................................2
1.3 Standard Reagent Head Assembly........................................................................................3
1.4 Leak Detection Assembly.......................................................................................................4
1.5 Control Assembly....................................................................................................................5
1.6 Gear Ratio Assembly ..............................................................................................................6
2. EQUIPMENT INSPECTION .......................................................................................................................6
3. STORAGE INSTRUCTIONS ......................................................................................................................7
3.1 Short Term ...............................................................................................................................7
3.2 Long Term................................................................................................................................7
4. INSTALLATION ......................................................................................................................................8
4.1 Location....................................................................................................................................8
4.2 Piping System..........................................................................................................................8
4.3 Suction Pressure Requirements............................................................................................9
4.4 Discharge Pressure Requirements........................................................................................9
4.5 Automatic Control ...................................................................................................................10
4.6 Leak Detection Assembly.......................................................................................................11
4.7 Drive Motor Installation...........................................................................................................11
4.7.1 Motor Rotation.................................................................................................................11
4.7.2 Motor Installation.............................................................................................................11
4.7.3 Electrical...........................................................................................................................12
5. EQUIPMENT STARTUP ...........................................................................................................................12
5.1 Oil Capacities...........................................................................................................................13
5.2 Eccentric Oil Fill ......................................................................................................................13
5.3 Gear Oil Fill ..............................................................................................................................13
5.4 Oil Changes..............................................................................................................................14
5.4.1 Eccentric Oil Change: .....................................................................................................14
5.4.2 Gear Oil Change: .............................................................................................................14
6. STARTUP..............................................................................................................................................15
6.1 Output Adjustment..................................................................................................................15
6.2 Priming the Reagent Head......................................................................................................15
6.3 Calibration................................................................................................................................16
6.4 Leak Detection.........................................................................................................................17
7. MAINTENANCE......................................................................................................................................18
7.1 Wet End Removal, Inspection and Reinstallation................................................................18
7.1.1 Standard Diaphragm .......................................................................................................18
7.1.2 Leak Detection .................................................................................................................19
7.2Check Valves ...........................................................................................................................20
7.2.1 General Description.........................................................................................................20
7.2.2 Removal, Inspection, and Reinstallation ......................................................................20
7.3 Oil Seals - General Description..............................................................................................21
7.4 Removal and Replacement.....................................................................................................22
7.5 Cover Assembly ......................................................................................................................25
7.5.1 Removal and Reinstallation............................................................................................25
7.5.2 Removal............................................................................................................................25
7.5.3 Reinstallation ...................................................................................................................26
7.6 Motor.........................................................................................................................................26
7.6.1 Removal............................................................................................................................26
7.6.2 Reinstallation ...................................................................................................................26
8. REPLACEMENT PARTS ..........................................................................................................................27

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8.1 PULSAR Shadow® KOPkit Program .....................................................................................27
8.2 Ordering KOPkits or Parts......................................................................................................27
9. TROUBLESHOOTING CHART...................................................................................................................28
10. APPENDIX IPIPING CALCULATIONS..................................................................................................30
10.1 Suction Head Requirements ..................................................................................................30
10.2 System Backpressure.............................................................................................................31
11. APPENDIX II OIL SPECIFICATIONS....................................................................................................32
12. APPENDIX III BOLT TORQUE TABLES..............................................................................................33
13. APPENDIX VPULSAFEEDER ACCESSORIES..........................................................................................34
13.1 Pulsation Dampeners..............................................................................................................34
13.2 Dampener Installation.............................................................................................................34
13.3 Pulsation Dampener Removal................................................................................................36
13.4 Diaphragm Back Pressure and Pressure Relief Valves ......................................................36

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Conventions
The following Conventions are used in this document.
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 A Release date February, 2016
Branding and document number updated
REV B Release date May, 2016
Appendix III, Bolt torque table updated

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1. Introduction
PULSAR Shadow® 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
mechanically 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.
1.1 Overall Operation
Figure 1
Adiaphragm 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.

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1.2 Component Layout
Figure 2
A typical model with manual external stroke adjustment is shown.

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1.3 Standard Reagent Head Assembly
Figure 3
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. For most
pump configurations, suction and discharge check valve components are identical.

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1.4 Leak Detection Assembly
Figure 4
The Leak Detection Assembly (LDA) consists of a reagent head, suction and discharge check valves,
primary diaphragm, leak detection diaphragm assembly, pressure switch port, and optional pressure
switch and gauge. The reagent head, suction and discharge check valves, and primary diaphragm are
the only parts of the pump to contact the process liquid; consequently, maintenance is critical to pump
performance.
If there is a breach of the primary (product side) diaphragm, process liquid will enter the space between
the primary and leak detection diaphragms. The liquid will be contained in this area and is prevented from
contacting other components of the pump. On the discharge stroke, pressure will build in between the
diaphragms. This pressure will activate the pressure switch. It is recommended that the pressure switch
be integrated into a control system that will shut the pump off if a leak is detected. The pressure switch
may be wired directly to a Pulsafeeder DLC or DLCM controller if the pump is so equipped.

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1.5 Control Assembly
Figure 5
PULSAR Shadow® pumps incorporate 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 top of the unit.
Stroke length is changed by depressing and turning the hand knob. This turns a screw, which locates a
wedge-shaped slider cam to position the follower pin, which in turn limits rearward travel of the
diaphragm.
To increase stroke length, the slider cam is moved downwards. This allows the follower pin to slide
back, increasing the distance the diaphragm can travel with each pump stroke.
To decrease stroke length, the slider cam is moved upwards. This moves the follower pin forwards,
decreasing the diaphragm travel, and therefore the flow rate of the pump.

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1.6 Gear Ratio Assembly
Figure 6
PULSAR Shadow® 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 into reciprocating motion.
The drive motor can be wired to rotate in either direction.
More than one pump can be driven through a single
drive assembly. This is referred to as multiplexing. The
pumps are mounted to a common gearbox assembly,
and driven by a common motor. Each pump is
mounted on a standard simplex base.
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 back in the same orientation.
Figure 7
2. 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 authorized representative
for PULSAR Shadow® pumps.

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3. Storage Instructions
3.1 Short Term
Storage of PULSAR Shadow® pumps for up to 12 months is considered short-term. The
recommended short-term storage procedures are:
1. Store the pump indoors at room temperature in a dry environment.
2. Within two months after date of shipment, fill the eccentric box to its normal operating
level with Pulsalube 9M oil. If required by the operating environment, take any steps
required to prevent entry of water or humid air into the eccentric enclosure.
3. Prior to start up, inspect housing, and gearbox. Replenish eccentric and gearbox oils
as required to maintain operating levels. If water or condensation is present, change
oil as described under Equipment Startup, Section 5.
4. Prior to startup, perform a complete inspection and then start up in accordance with
instructions in this manual.
3.2 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 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 these circumstance are the purchaser’s responsibility. For a continuance of the
initial 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 Shadow® 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 0O C (32O F) are anticipated. 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 5O.
This will assure that the eccentric 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:
A separate system relief valve to
protect piping and process equipment,
including the pump, from excess
process pressures. *An external relief
valve is required, as a mechanical
diaphragm pump does not incorporate
an internal relief.
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.
Figure 8

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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 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 recommended.
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.
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.
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.
4.3 Suction Pressure Requirements
Although PULSAR Shadow® metering pumps have 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 other source.
For fluid with a vapor pressure of 5 psia or less (at operating temperature) the wet
suction lift capability is ten (10) feet. If this requirement is not met, the pump will not
provide reliable, accurate flow. The Net Positive Suction Head Required (NPSHR) is
0.35 bar (5 psi).
The maximum inlet pressure is limited to 0.35 bar (5 psi) below the operating discharge
pressure.
Refer to Appendix I for procedures for the calculation of suction pressure.
4.4 Discharge Pressure Requirements
All PULSAR Shadow® 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 (siphoning) 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 “flowthrough”, the 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.
Damage to the pump will occur if operated at pressures beyond the maximum rating.
Refer to Appendix I for procedures for the calculation of discharge pressure.

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4.5 Automatic Control
Pumps equipped with the DLC, DLCM, or ECA electronic stroke length controllers are
provided with separate instructions. Refer to the latest Installation, Operation and
Maintenance Manual specific to your controller. Follow all safety and operational
information contained in those documents. Perform and verify all controller installation
procedures prior to pump startup.
Figure 9

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4.6 Leak Detection Assembly
Figure 10
If the diaphragm leak detection system was specified with an optional pressure switch,
install electrical wiring and conduit in accordance with local electrical codes. The switch
is rated as follows:
The switch is rated as follows:
30 VDC or 125 VAC 1 Ampere Resistive.
The switch should be wired such that if a leak condition is detected, the pump will be
shut down. 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:
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.
4.7 Drive Motor Installation
4.7.1 Motor Rotation
Motor can be operated in either direction, clockwise or counterclockwise. Verification of
motor direction is not necessary at startup.
4.7.2 Motor Installation
PULSAR Shadow® pumps may be shipped with the drive motor packed separately.
This is done to avoid damage during transport.

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Figure 11
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.
If applicable, remove any tape or retainer rings that hold the motor shaft key in place.
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.
Tighten the setscrew onto the shaft key.
Place the motor in a vertical position and align the coupling teeth.
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.
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.
4.7.3 Electrical
Wire the PULSAR Shadow® 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 or DLCM,
consult the appropriate Pulsafeeder IOM for further motor wiring instructions.
5. Equipment Startup
PULSAR SHADOW®PUMP USE TWO SEPARATE OILS:PULSALUBE 9M OIL FOR THE
ECCENTRIC BOX AND PULSALUBE 8G, GEAR OIL FOR THE GEARBOX.CONFUSION
BETWEEN THE TWO REDUCES PERFORMANCE OF THE PUMP.

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5.1 Oil Capacities
Pulsalube 9M lubricating oil is available in 950 ml (1 quart) containers.
Pulsalube 8G gear oil is available in 200 ml (.21 quarts) or 950 ml (1 quart) 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 Shadow® pumps to specified levels are:
Eccentric Box, all Gearbox, Model 25B Gearbox, Model 55B
Eccentric Oil, No. 9M 950 ml (1 Qt) -- --
Gear Oil, No. 8G -- 150 ml (0.16 Qt) 200 ml (0.21 Qt)
5.2 Eccentric Oil Fill
Fill the eccentric box with oil by removing the manual cover assembly or DLC/M or ECA
controller if so equipped. Fill with the proper oil (Pulsalube 9M) to the upper edge of the
crosshead assembly and return spring(s) or slightly above. Replace the cover or
controller. Take care not to disturb the stroke length setting when reinstalling. See
figure 12.
Figure 12
5.3 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 gear
oil through the top port to the level of the eccentric shaft centerline, which is level with
the side port. The side plug should be removed so that leakage from the side port
indicates attainment of the required level. Replace both pipe plugs after filling.
GEAR OIL IS FILLED AT THE FACTORY, AND THE GEARBOX IS SHIPPED FULL.
DO NOT ADD OIL THROUGH THE PORT ON THE SIDE OF THE MOTOR ADAPTOR.
THIS PORT IS FOR MOTOR COUPLING ACCESS ONLY.

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5.4 Oil Changes
The recommended oil change intervals are dependent upon the operating environment
and level of pump usage, classified as follows:
Normal service: Clean/dry atmosphere, an ambient operating temperature of 00˚C to
400˚C (320˚F to 1040˚F) and up to 2,000 annual operating hours.
Severe Service:Humid atmosphere, an ambient operating temperature below 00˚C
(320˚F) or above 400˚C (1040˚F), and over 2,000 annual operating hours.
5.4.1 Eccentric Oil Change:
The recommended eccentric oil change interval is two (2) years for normal service and
one (1) year for severe service. The procedure is as follows:
1. Disconnect the power source to the drive motor
2. Relieve all pressure from the piping system.
3. Remove the top cover or controller from the pump.
4. Drain the oil by removing the drain plug on the bottom of the eccentric box.
5. Replace the drain plug.
6. Fill the eccentric box with Pulsalube 9M oil as described under Eccentric Oil Fill.
7. Replace the top cover or controller.
5.4.2 Gear Oil Change:
The recommended gear oil change interval is five (5) years for normal service and two
(2) years for severe service. The procedure is as follows:
1. Disconnect the power source to the drive motor
2. Relieve all pressure from the piping system.
3. Remove the fill plug from the top of the gearbox.
4. Drain the oil by removing the drain plug on the bottom of the gearbox.
5. Replace the drain plug.
6. Refill with fresh Pulsalube 8G (amber) gear oil as described under Gear Oil Fill.
7. Be sure to replace the top fill plug and side plug.

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6. Startup
6.1 Output Adjustment
Figure 13
PULSAR Shadow® pumps have a handwheel for manual stroke length adjustment.
Mounted atop the eccentric box, the handwheel can be adjusted at any point from (0 to
100%) stroke setting by pressing down and then rotating as required. Stroke length is
locked during operation to prevent drift: pressing the handwheel down temporarily
disengages the lock for adjustment; release after adjustment automatically resets the
lock at the new setting. An indicator adjacent to the handwheel displays the output
setting. Adjustments can be made while the pump is at rest or operating, although
adjustments are easier to make while the pump is in operation. Manual adjustment
serves as a backup for pumps provided with DLC/M controllers.
6.2 Priming the Reagent Head
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, reduce the discharge pressure and the system will self
prime when the pump is started. 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. Refer to the Maintenance
Section on Check Valves. Remove the discharge valve assembly. Fill the head
through the discharge valve port with process (or compatible) liquid, and then
reinstall the valve.
4. Start the pump at the zero 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