Honeywell DC4 manual

Installatio n, Oper ation, & Maintenan ce Instruc tion Models DC2, 3, 4, 5, and 6 Bulletin #: IO M-OM-1104- E Manufacturers of Quality Pumps, Controls, and Systems STANDARD PUMP OPERATIONS 27101 Airport Road Punta Gorda, FL 33982 (941) 575-3800 Fax (941) 575 -4085 www.pulsatron.com ®[...]

ii Pulsafeeder F actory Ser vice Policy Should you experience a problem with your Pulsafeeder pum p, first consult the troubleshooting g uide in your operation and maintenance manual. I f the problem is not covered or cannot be solved, please contact your local Pulsafeeder Sale s Representative or D istributor, or our Technical Services Departm ent[...]

iii Table of Contents 1. I NTRODUCT ION ....................................................................... ..............................................................1 2. P RINCIPLES O F O PERATION ....................................................................... ...........................................1 2.1 Reagent He ad Assembly [...]

i v 8.3 KOPkit numb ers by m odel: ....................................................................................................20 9. M ODEL N UMBER I DENTIFICATION ....................................................................... ....................................21 10. W ET E ND M A TERIALS R EFERENCE ..............................[...]

1 1. Introduction The OMNI ® metering pump is positive displacem ent, mechanically operated reci procating diaphragm pump. Each pump consists of a power end an d a process end separated by a PTFE faced diaphragm . Individual pumps will vary in appearance due to various liquid end s and accessories; however, the basic principles of operation rem ai[...]

2 2.1 Reagent H ead Assembl y The typical reagent head assem bly consists of reagent head, diaphragm , and suction and discharge cartridge check valves. This assem bly is the only part of the pump to contact the process liquid; consequently, maintenance is critical to pum p performance. 2.2 Control Assembl y The OMNI ® pump incorporates a lost mot[...]

3 3. Equipment Inspection Check all equipment for com pleteness against the order and for any ev idence of shipping dam age. Shortages or damag e must be reported immediately to the carrier and y our 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 [...]

4 5.2 Piping S ystem 1. All systems should include a pressu re relief valve on the discharg e side, to protect piping and process equipment, including the pum p, from excess process pressures . A n external relief valve is required! There should be no devic es capable of restricting flow (such as a valve) loca ted between the pump and the relief de[...]

5 5.3 Suction Pr essur e Requir ements Although OMNI ® metering pumps have some suction lift capability, a flood ed suction (i.e., suction pressure higher than atm ospheric pressure) is preferable whenev er possible. The pum p should be located as close as possible to the suct ion side reservoir or fluid supply source. For fluid with a vapor press[...]

6 Figure 4, stroke adjustment 6. Equipment Startup 6.1 Fastener In spection All pump fasteners should be check ed prior to pump operation, and occasiona lly during use. This would include reagent head m ounting bolts, motor mounting bolts, and the hardware that secures the pump to its foundation. Most hardware c an be checked simply to ensure it is[...]

7 6.3 Priming the Reage nt Hea d 1. When handling process liquids, fo llow all applicable personal and fac ility safety guidelines. 2. Ensure that the pump is rea dy for operation and that all process conne ctions are secure. 3. Open the suction and discharge line shuto ff valves. 4. If the piping system design and the storag e tank are such that t[...]

8 6.4 Calibration Figure 6, sample flow calibration curve All metering pumps must be ca librated to accurately specify stroke length settings for requir ed flow rates. A typical calibration chart is shown abov e. Although output is linear with respect to stroke leng th setting, an increase in discharge pressure decr eases output uniform ly, describ[...]

9 7. Maintenance B EFORE PERF ORMING ANY MAINTENANCE RE QUIRING RE AGENT HE AD OR V AL VE ( WET E ND ) DISASSEM BLY , BE SURE T O RELIEVE PRE SSURE FROM THE PIP ING SYSTEM AND , WHERE HAZARDOUS PRO CESS MATE RIALS ARE INV OLVED , RENDER T HE PUMP SAFE TO PERSONNE L AND THE E NVIRONMENT BY CLEANING AND CHEMIC ALLY NEUTRALIZING AS APPROPRI ATE . W EA[...]

10 7.2 Wet End Remo val, Inspecti on, & Reins tallation I F THE DI APHRAGM HAS F AILED , PROCESS F LUID M AY HAVE CONT AMINATED THE PUMP ECCENTRIC HOUSING ( ALTHOUGH NORM ALLY , ANY P ROCESS FLUID BEHIN D A FAILED DIAPHRAGM W OULD PASS THROUGH THE BOT TOM DRAIN HOLE ). H ANDLE W ITH APPROPRIATE CARE . Figure 8, wet end components OMNI ® diaphr[...]

11 7.2.1 Diaphragm Removal & Reinstallation 1. Adjust the stroke setting to 50% and disconnec t the power source to the dr ive motor. 2. Relieve all pressure from the piping system. 3. Close the inlet and outlet shutoff valv es. 4. Place a pan underneath the pump head adaptor to catch any liquid leakage. 5. Disconnect piping to the reag ent hea[...]

12 7.3 Check Val ves 7.3.1 General Description Most fluid metering proble ms are related to check v alves. Problems usually stem from solids accumulation between valve and sea t, corrosion of seating surfaces, e rosion, or physical dam age due to wear or the presence of foreign objects. The valve incorporates a ball, guide, and seat. Flow in the un[...]

13 Figure 10, check valves, DC3 and DC 4 Figure 11, check valves, DC5 and DC6 plastic construction Check Valve Suction Position Check Valve Suction Position Check Valve Discharge Position Check Valve Discharge Position[...]

14 7.3.2 Check Valve Removal & Reinstallation , Cartridge type Valving that is of the cartridge design is intended to be replaced as an assemb ly. 15. Disconnect the power source to the drive m otor. 16. Relieve all pressure from th e piping system. 17. Take all precautions necess ary to prevent contamination to the env ironment and personnel e[...]

15 Inserting the check valve assmbly into the pump in the wrong dir ectiom, or having the check seat upside down, will prevent proper seals at the o-rings, decrease pump p erformance, and can cau se damage to the diaphragm. 12. Carefully m ake sure that the check assemblies are in proper position, and tighten the four tie- bar bolts, using a star p[...]

16 7.4 Motor Rem o val & Reinstalla tion 1. Disconnect the power source to the drive m otor. 2. Disconnect the motor wiring from the motor. 3. Remove the four bolts retaining the m otor to the motor adaptor. The motor shaft fits into a b ore on the pump input shaft. 4. Slide the motor shaft out of the pump input s haft. Be careful not to lift t[...]

17 Figure 14, gearset components 7. Loosen the set screw (Item 9) on the worm gear (Item 8) and remov e it along with its shaft key (I tem 10). If you have the DC2 or 3 models go to step 8. I f you have the DC4, 5, or 6 m odels go to step 9. 8. Remove the Thrust Washers and Bearing (Item 11 & 12) from the housing. If the Thrust Washers show sig[...]

18 7.6 Gearset Re plac ement 1. Apply PULSA lube grease # NP980006- 000 to both sides of the thrust washer and install onto the eccentric shaft. On the DC4, 5, and 6 models, the washer fits into a shallow counter- bore. 2. Assemble Worm Gear (Item 8) and key (Item 10) to the eccentric shaf t. Do not tighten the setscrew yet. 3. Thread the M6-1.0 sc[...]

19 8. Replacement Parts 8.1 KOPkit Pr ogram OMNI ® KOPkits contain all replacement parts norm ally used in a preven tative maintenance program . ( PULSAlube grease is also available separately for prev entative maintenance program s. Refer to Section 6 – Equipment Sta rtup ). There is a specific KOPk it for every OMNI ® pump model. Each KOPkit [...]

20 8.3 KOPkit n umber s b y model: Pump Model Wet ted Material Connection Type KOPkit number D C 2 P V D F N P T N L K 0 2 0 F P D C 3 o r D C 4 P V D F N P T N L K 0 4 0 F P D C 3 o r D C 4 P V D F I S O 7 - 1 N L K 0 4 0 F B D C 5 o r D C 6 P V D F N P T N L K 0 5 0 F P D C 5 o r D C 6 P V D F I S O 7 - 1 N L K 0 5 0 F B D C 7 P V D F n / a N L K[...]

21 9. Model Number Identification Position Sample Specifies Option s 1 and 2 DC DC = OMNI m odel pum p 3 and 4 3B Size/Flow 2 / 3 / 4 / 5 / 6 – diaphra gm diam eter A / B / C / D – strok ing rate See s ales literature for flow/pressure ratings 5 X Motor fram e 1 – ½ Hp, 1 pH 11 5/230 V, 71 fram e and size 2 – ½ Hp, 1 pH, 1 15/230 V, 56 fr[...]

22 10. Wet End Materials Reference Wet End Configu ration Model Connection Head Gu ide Sealing O-rings Balls Seats Seat O- ring DC2 1/4" NPT DC3 DC4 1/2" NPT or ISO 7 -1 DC5 DC6 1" NPT or ISO 7-1 PTFE PVDF n/a PVDF (Kynar ® ) DC7 1 1/2" NPT & ANSI Flange and 1 1/2" DIN40 Flange PVDF PVDF Viton ® Ceram ic PVDF (o- ring[...]

23 11. Troubleshooting Difficulty Probable Cause Remedy Faulty power source. Check power source. Blown fuse, circuit breaker. Replace - eliminate overloa d. Broken wire. Locate and repair. Wired improperly. Check diagram. Pump does not start Process piping blockage. Open v alves, clear other obstruction s. Motor not running. Check power source. Che[...]

24 Difficulty Probable Cause Remedy Discharge pressure too high. Reduce pressure. Water hammer. Install pulsation dampener. Stroke length at partial setti ng. Some operating noise is characterist ic of lost motion pumps. Noisy gearing, knocking Low grease level. Add or replace grease. Pipe size too small. Increase size of piping - install pulsation[...]

25 12. Piping Accessories Pressure Relief Valves Pressure relief valves are designed to protect chemical feed sy stems from damag e that may be caused by defective equipment or a block age in the discharge line. These valves function to lim it the pressure downstream of the pump. Field adjust the pr essure relief valve to opera te when the discharg[...]

26 13. Dimensional Dra w ing Letters refe rence dimensiona l table on next page[...]

27 Dimens ion table in inc hes / m m Letter referenc es to d iagram , previous page “PP” = Pol ypropylene wetted m aterial “SS” = Stai nless steel wetted m aterial Dimens ions are with st andard IEC 71 B14 f ram e motor Dimension Model A B C D E DC2 1.0 / 25.4 0.7 / 18.0 6.9 / 175.3 4.5 / 113.5 1.5 / 38.1 DC3 1.0 / 25.4 0.7 / 18.0 6.9 / 175[...]

28 14. Parts Diagrams and Parts Lists 14.1 Parts dia gram, DC2 and 3[...]

29 14.2 Bill of Mater ials, DC2 ITEM DESCRIPTION QTY P ART NUMBER 1 SUPPORT PLATE 1 N P 1 4 0 0 5 4 - B R S 2 DIAPHRAGM 1 N P 1 7 0 0 3 0 - T H Y 3 REAGENT HEAD PVDF 1 N P 1 6 0 0 7 6 - P V D 3 REAGENT HEAD PVC (obsole te) 1 N P 1 6 0 0 5 4 - P V C 3 REAGENT HEAD 316 1 N P 1 6 0 0 5 4 - 3 1 6 4 BOLT 4 N P 9 9 0 4 2 0 - 1 8 8 5 FLT WASHER 4 N P 9 9 [...]

30 35 NAME TAG 1 N P 5 5 0 1 3 0 - 0 0 0 36 NAME TAG SCRE W 4 W 7 7 1 0 0 0 - 1 8 8 38 SET SCRE W 2 W 7 7 1 0 0 4 - 0 2 2 39 NEEDLE BEARING 1 N P 4 0 0 0 4 6 - 0 0 0 40 KEY-WORM GEAR 1 W 7 7 3 0 9 7 - 0 0 4 41 ECCENTRIC SPAC ER 1 N P 4 7 0 0 3 1 - 0 0 0 42 GASKET 1 N P 4 6 0 0 4 7 - 0 0 0 43 SCRE W 2 N P 9 9 0 0 0 8 - S T A 44 OIL SEAL 1 N P 4 5 0 [...]

31 14.3 Bill of Mater ials, DC3 ITEM DESCRIPTION QTY P ART NUMBER 1 SUPPORT PLATE 1 N P 1 4 0 0 5 5 - B R S 2 DIAPHRAGM 1 N P 1 7 0 0 3 1 - T H Y 3 REAGENT HEAD PVDF 1 N P 1 6 0 0 7 7 - P V D 3 REAGENT HEAD PVC (obsole te) 1 N P 1 6 0 0 5 5 - P V C 3 REAGENT HEAD 316 1 N P 1 6 0 0 5 5 - 3 1 6 4 BOLT 4 N P 9 9 0 4 3 6 - 1 8 8 5 FLT WASHER 4 N P 9 9 [...]

32 31 WASHER 1 W 7 7 1 0 0 6 - S T L 32 MOTOR ADAPT ASSY 56C 1 N P 4 9 0 0 3 0 - 0 0 0 32 MOTOR ADAPT A SSY 71 1 N P 4 9 0 0 2 9 - 0 0 0 33 W ORM SHAFT ASSY 56C 1 N P 0 6 0 0 3 1 - A 0 0 33 W ORM SHAFT ASSY IEC71 1 N P 0 6 0 0 3 1 - D 0 0 34 DC2/3 GEARBOX 1 N P 0 1 0 0 2 4 - A L U 35 NAME TAG 1 N P 5 5 0 1 3 0 - 0 0 0 36 NAME TAG SCRE W 4 W 7 7 1 0[...]

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34 14.4 Parts Dia gram, DC 4, 5, and 6[...]

35 14.5 Bill of Mater ials, DC4 ITEM DESCRIPTION QTY P ART NUMBER 1 SUPPORT PLATE 1 N P 1 4 0 0 5 5 - B R S 2 DIAPHRAGM 1 N P 1 7 0 0 3 1 - T H Y 3 REAGENT HEAD PVDF 1 N P 1 6 0 0 7 7 - P V D 3 REAGENT HEAD PVC (obsole te) 1 N P 1 6 0 0 5 5 - P V C 3 REAGENT HEAD 316 1 N P 1 6 0 0 5 5 - 3 1 6 4 BOLT 4 N P 9 9 0 4 3 6 - 1 8 8 5 FLT WASHER 4 N P 9 9 [...]

36 30 LABEL 1 N P 5 5 0 0 8 4 - 0 0 0 31 WASHER 1 W 7 7 1 0 0 6 - S T L 32 MOTOR ADAPT ASSY 56C 1 N P 4 9 0 0 3 0 - 0 0 0 32 MOTOR ADAPT ASSY 71 1 N P 4 9 0 0 2 9 - 0 0 0 33 W ORM SHAFT ASSY 56C 1 N P 0 6 0 0 3 2 - A 0 0 33 W ORM SHAFT ASSY IEC71 1 N P 0 6 0 0 3 2 - B 0 0 34 DC4/5 GEARBOX 1 N P 0 1 0 0 2 3 - A L U 35 NAME TAG 1 N P 5 5 0 1 3 0 - 0 [...]

37 14.6 Bill of Mater ials, DC5 ITEM DESCRIPTION QTY P ART NUMBER 1 SUPPORT PLATE 1 N P 1 4 0 0 7 1 - B R S 2 DIAPHRAGM 1 N P 1 7 0 0 3 7 - T H Y 3 REAGENT HEAD PVDF 1 N P 1 6 0 0 2 2 - P V D 3 REAGENT HEAD PP 1 N P 1 6 0 0 2 2 - P P L 3 REAGENT HEAD PVC 1 N P 1 6 0 0 1 7 - P V C 3 REAGENT HEAD 316 1 N P 1 6 0 0 0 4 - 3 1 6 4 BOLT 6 N P 9 9 0 4 3 6[...]

38 29 SCREW 1 W 7 7 1 0 0 1 - 0 1 0 30 LABEL 1 N P 5 5 0 0 8 4 - 0 0 0 31 WASHER 1 W 7 7 1 0 0 6 - S T L 32 MOTOR ADAPT ASSY 56C 1 N P 4 9 0 0 3 0 - 0 0 0 32 MOTOR ADAPT A SSY 71 1 N P 4 9 0 0 2 9 - 0 0 0 33 W ORM SHAFT ASSY 56C 1 N P 0 6 0 0 3 2 - A 0 0 33 W ORM SHAFT ASSY IEC71 1 N P 0 6 0 0 3 2 - B 0 0 34 DC4/5 GEARBOX 1 N P 0 1 0 0 2 3 - A L U [...]

39 14.7 Bill of Mater ials, DC6 ITEM DESCRIPTION QTY P ART NUMBER 1 SUPPORT PLATE 1 N P 1 4 0 0 8 1 - S T L 2 DIAPHRAGM 1 N P 1 7 0 0 3 9 - T H Y 3 REAGENT HEAD FPP 1 N P 1 6 0 0 2 3 - F P P 3 REAGENT HEAD PVDF 1 N P 1 6 0 0 2 3 - P V D 3 REAGENT HEAD 316 1 N P 1 6 0 0 3 1 - 3 1 6 4 BOLT 6 N P 9 9 0 4 7 7 - 1 8 8 5 FLT WASHER 6 N P 9 9 1 0 1 8 - 1 [...]

40 34 DC4/5/6 GEARBOX 1 N P 0 1 0 0 2 3 - A L U 35 NAME TAG 1 N P 5 5 0 1 3 0 - 0 0 0 36 NAME TAG SCRE W 4 W 7 7 1 0 0 0 - 1 8 8 38 SET SCREW 2 W 7 7 1 0 0 4 - 0 3 2 40 KEY-WORM GEAR 1 W 7 7 3 0 9 8 - 0 0 4 41 RETAINING RING 1 N P 9 9 9 0 3 2 - S T L 42 GASKET 1 N P 4 6 0 0 4 7 - 0 0 0 43 SCREW 2 N P 9 9 0 0 0 8 - S T A 44 OIL SEAL 1 N P 4 5 0 0 2 [...]

41[...]

42 STANDARD PUMP O PERAT IONS 27101 Airport Road Punta Gord a, FL 33 982 (941) 575-38 00 Fax ( 941) 575-4085 Bullet in #: IOM- OM-1104- E www.pulsatro n.com R e v E[...]