INSTALLATION

OPERATION
MAINTENANCE
INSTRUCTION

BULLETIN No. 9490-IOM-2000 Rev. C

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9490
Hydraulic Diaphragm Metering Pump
PULSA SERIES GUARANTEE
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 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.
In addition, Pulsafeeder guarantees its PULSA Series drive assemblies for a period of two years from
the date of shipment. All other material and workmanship are fully covered for a period of one year.
Any parts found to be defective within the above time span will be replaced free of charge, F.O.B.
factory.
Equipment or accessories manufactured by others but purchased through Pulsafeeder, such as electric
motors, are guaranteed only to the extent of the original manufacturer.
Damages incurred from misuse, abuse, and/or improper protection during storage will be cause to
void the guarantee. Erosion, corrosion, or improper application of the equipment or related piping by
the buyer or any third party is also excluded from the guarantee.
The above guarantee is in lieu of any other guarantee, either expressed or implied. We make no
warranty of fitness or merchantability. No agent of ours is authorized to make any warranty other
than the above.

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 ©2004 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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 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............................................................................................................... 2
2.2.1 Standard Reagent Head Assembly ................................................................................ 3
2.2.2 Pump Head/Piston assembly .......................................................................................... 4
2.2.3 Control Assembly ............................................................................................................ 5
2.2.4 Gear Reducer Assembly ................................................................................................. 6
3. EQUIPMENT INSPECTION ....................................................................................................................... 7
4. STORAGE INSTRUCTIONS ...................................................................................................................... 8
4.1 Short Term ............................................................................................................................... 8
4.2 Long Term ................................................................................................................................ 8
5. INSTALLATION ...................................................................................................................................... 8
5.1 Location .................................................................................................................................... 8
5.2 Piping System .......................................................................................................................... 9
5.2.1 Suction Pressure Requirements .................................................................................... 10
5.2.2 Discharge Pressure Requirements ................................................................................ 10
6. EQUIPMENT STARTUP ........................................................................................................................... 11
6.1 Lubrication ............................................................................................................................... 11
6.1.1 Oil Capacities ................................................................................................................... 11
6.1.2 Hydraulic Oil Fill ............................................................................................................... 12
6.1.3 Gear Oil Fill ....................................................................................................................... 12
6.1.4 Oil Changes ...................................................................................................................... 13
6.2 Startup ...................................................................................................................................... 14
6.2.1 Output Adjustment .......................................................................................................... 14
6.2.2 Priming the Pumphead .................................................................................................... 14
6.2.3 Priming the Reagent Head .............................................................................................. 15
6.2.4 Calibration ........................................................................................................................ 15
7. M AINTENANCE ...................................................................................................................................... 16
7.1 Wet End Removal, Inspection, And Reinstallation .............................................................. 17
7.2 Priming The Pump ................................................................................................................... 19
7.3 Check Valves ........................................................................................................................... 21
7.3.1 Check Valve Removal ...................................................................................................... 22
7.3.2 Ball Valve – Inspection and Repair ................................................................................ 22
7.3.3 Disk Valve – Inspection and Repair ............................................................................... 23
7.3.4 Check Valve Reinstallation ............................................................................................. 23
7.4 Hydraulic Performance Valve (HPV) ...................................................................................... 24
7.4.1 Check Valve Screen - Removal and Cleaning ............................................................... 24
7.4.2 HPV Removal and Replacement ..................................................................................... 25
7.5 Hydraulic Bypass Valve (HBV) ............................................................................................... 26
7.5.1 PTP (Automatic Bleed Valve) .......................................................................................... 27
7.5.2 PTP Removal, Cleaning, and Reinstallation.................................................................. 28
7.6 Piston Seal ............................................................................................................................... 29
7.6.1 General Description ......................................................................................................... 30
7.6.2 Piston Seal Removal (1 - 3" pistons) ............................................................................. 30
7.6.3 Piston Seal Reinstallation (1 - 3" pistons) ..................................................................... 31
7.6.4 Piston Seal Removal (4 - 5" pistons) ............................................................................. 32
7.6.5 Piston Seal Reinstallation (4 - 5" pistons) ..................................................................... 32
7.7 Oil Seals ................................................................................................................................... 33
7.7.1 General Description ......................................................................................................... 33
7.7.2 Oil Seal Removal and Replacement ............................................................................... 34
7.8 Cover Assembly ...................................................................................................................... 39
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 7.8.1 Cover Assembly Removal and Reinstallation .............................................................. 39
7.9 Motor Removal and Reinstallation ........................................................................................ 41
8. REPLACEMENT PARTS .......................................................................................................................... 42
8.1 PULSA Series KOPkit Program .............................................................................................. 42
8.2 Ordering KOPkits or Parts ...................................................................................................... 42
9. TROUBLESHOOTING CHART................................................................................................................... 43
10. APPENDIX I – PIPING CALCULATIONS ..................................................................................................... 45
Suction Head Requirements .............................................................................................................. 45
System Back Pressure ........................................................................................................................ 47
Nomenclature ....................................................................................................................................... 47
11. APPENDIX II – OIL SPECIFICATIONS ....................................................................................................... 48
PULSAlube #7H ................................................................................................................................... 48
PULSAlube #9M ................................................................................................................................... 48
12. APPENDIX III – BOLT TORQUE RECOMMENDATIONS ............................................................................... 49
Reagent Head and Tie-Bars ................................................................................................................ 49
Cylinder Bolts ...................................................................................................................................... 50
13. APPENDIX IV PULSALARM LEAK DETECTION ..................................................................................... 51
13.1 PULSAlarm Leak Detection Reagent Head Assembly ......................................................... 51
13.2 PULSAlarm Leak Detection Diaphragm ................................................................................ 51
13.3 Leak Detection Option – Setup for Vacuum ......................................................................... 52
13.4 Leak Detection Option – Setup for Pressure ........................................................................ 52
13.5 Pressure System Set-up and Priming ................................................................................... 53
13.6 Leak Detection System Maintenance .................................................................................... 55
13.6.1 Vacuum Setpoint Adjustment ......................................................................................... 55
13.7 PULSAlarm Leak Detection Diaphragm Maintenance ......................................................... 56
13.7.1 Leak Detection Diaphragm Removal ............................................................................. 56
13.7.2 Inspection ......................................................................................................................... 57
13.7.3 Leak Detection Diaphragm Reinstallation ..................................................................... 57
13.8 Leak Detection system conversion ....................................................................................... 57

Conventions
For the remainder of this bulletin, the following Conventions are in effect.
A WARNING 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.

Tips have been included within this bulletin to help the operator run the
equipment in the most efficient manner possible. These “Tips” are drawn from
the knowledge and experience of our staff engineers, and input from the field.

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1. Introduction
1.1 General Description
Metering pumps are positive displacement reciprocating pumps that 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 a hydraulic fluid.
The piston and associated mechanisms are enclosed in the pumphead and intermediate housing
which 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.
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

Figure 2

2
2.2.1 Standard Reagent Head Assembly

The typical reagent head assembly consists of the following:

a) Reagent Head
b) Diaphragm
c) Suction and Discharge Check valves

High flow pump models use disk valves.

Figure 3

This assembly is the only part of the pump to contact the process liquid; consequently,
maintenance is critical to pump performance.

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2.2.2 Pump Head/Piston assembly

Figure 4

The pump head/piston assembly is installed on the intermediate housing. This assembly
contains the hydraulic system which consists of the pump head, cylinder, piston assembly, and
three hydraulic valves:
− PTP (Push-To-Purge automatic bleed)
− HPV (Hydraulic Performance Valve)
− HBV (Hydraulic Bypass Valve).
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 valve
button overrides automatic operation to validate priming or to determine diaphragm integrity.
The HPV valve automatically maintains the required hydraulic oil volume by replacing any oil
lost over time past the piston or through the PTP valve. The HBV valve protects the pump
from over-pressurizing by relieving any excess pressure in the pump’s hydraulic system.

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2.2.3 Control Assembly
By changing the length of the piston stroke in a pump, the amount of product displaced can be
increased or decreased. The PULSA Series diaphragm metering pump Model 9490 contains an
adjustment mechanism which controls stroke length (Figure 5). The mechanism consists of an
oscillating housing, a slider block which fits inside the housing and a connecting rod attached to
the block. The housing pivots on horizontal bearing pins and oscillates through a fixed arc from
the action of the eccentric-driven rear connecting rod. The position of the block within the
housing is adjustable. Pushing in and rotating the external self-locking hand wheel causes a
threaded shaft in the housing to turn. This shaft is threaded through the block and raises or
lowers the block as the hand wheel is turned. When the block is centered on the pivot point of
the housing it is motionless. As it is lowered off center, it develops increasing reciprocating
movement (Figure 5) which is transmitted through the connecting rod. Side thrust on the
piston is eliminated by the use of a cross-head block that travels in a bore between the
connecting rod and piston assembly.

Figure 5

PULSA Series pumps incorporate a full motion style of stroke length adjustment to control
piston travel during each stroke. The stroke length setting is denoted by a (0 – 100%) scale with
one tenth increments. It is located on the top of the control gearbox.

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2.2.4 Gear Reducer Assembly

Figure 6

9490 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 that convert rotational speed into torque. They in
turn power the eccentric shaft assembly that converts rotary motion to reciprocating motion.
Optional construction gearboxes can also be provided.

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 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. Bases are optional and can be
provided per customer specification.

Figure 7

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.

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 PULSA Series
representative.

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4. Storage Instructions
4.1 Short Term
Storage of PULSA Series 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) Prior to startup, 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 in the Equipment Startup section.
c) Prior to startup, perform a complete inspection and then start up in accordance with
instructions in this manual.

4.2 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 all seals and gaskets 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 5 year warranty after extended storage,
equipment inspection and any required refurbishing must be done by a Pulsafeeder representative.

5. Installation
5.1 Location
When selecting an installation site or designing a skid package, consideration should be given to
access for routine maintenance.
PULSA Series pumps are designed to operate indoors and outdoors, but a hood or covering for
outdoor service is recommended. External heating or the use of synthetic lubricants for the
gearbox is recommended if ambient temperatures below 20°C (0°F) are anticipated. Check with
the factory if you are 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. 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.

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5.2 Piping System

Figure 8
All piping systems should include:
1. Shutoff valves and unions (or flanges) on suction and discharge piping.
a) This permits check valve inspection without draining long runs of piping.
b) Shutoff valves should be of the same size as connecting pipe.
c) Ball valves are preferred since they offer minimum flow restriction.
2. An inlet strainer, if the product is not a slurry.
a) Pump check valves are susceptible to dirt and other solid contaminants unless designed for
that service, and any accumulation can cause malfunction.
b) The strainer should be located between the suction shutoff valve and the pump suction
valve.
c) It must be sized to accommodate the flow rate and the anticipated level of contamination.
d) 100 mesh screen is recommended.
3. Vacuum/pressure gauges in the suction and discharge lines in order to check system operation.
a) Gauges should be fitted with protective shutoff valves for isolation while not in use.
4. A separate system relief valve to protect piping and process equipment, including the pump,
from excess process pressures.
a) The hydraulic bypass valve (HBV) in the pump is not intended to protect the system.
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 movement is 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 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.

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5.2.1 Suction Pressure Requirements

Although metering pumps have suction lift capability, all pump installations should have
minimum lift for optimum performance. A flooded suction (i.e., suction fluid level higher than
the centerline of the pump) is preferable whenever possible. The pump should be located as
close as possible to the suction side reservoir or other source.
If suction lift is required, the net positive suction pressure required (NPSH R ) is 5 psia
(or 0.35 bar). If this requirement is not met the process liquid may cavitate inside the pump,
degrading metering accuracy. In addition, suction pressure must be maintained at a minimum
absolute value of 5 psia (or 0.35 bar) to ensure proper hydraulic system and proper pump
operation.
The maximum inlet pressure is limited to 30 psig with composite TFE/elastomer diaphragms.

Higher pressures may be possible with optional alternate diaphragm materials.

Refer to Appendix I for procedures for the calculation of suction pressure.

5.2.2 Discharge Pressure Requirements

All PULSA Series 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” or “flow-through”), 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, discharge pressure must exceed suction
pressure by at least 25 psia (or 1.7 bar). This can be achieved where necessary by installing a
backpressure valve in the discharge line.
Discharge pressure must never exceed the maximum nameplate rating of the pump.

Refer to Appendix I for procedures for the calculation of discharge pressure.

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6. Equipment Startup

6.1 Lubrication
9490 PUMPS USE TWO SEPARATE OILS: PULSALUBE 7H, HYDRAULIC OIL FOR THE
ECCENTRIC BOX AND PULSALUBE 9M, GEAR OIL FOR THE GEARBOX. CONFUSION
BETWEEN THE TWO WILL IMPAIR PERFORMANCE AND COULD DAMAGE THE PUMP.

6.1.1 Oil Capacities

PULSAlube 7H hydraulic oil is available in 5 gallon (Part #: NP 980002-007), 15 Gallon

(Part #: NP980002-008) and 55 gallon (Part #: NP980002-006) containers.
PULSAlube 9M gear oil is available in 1 gallon (Part #: NP980003-001) or 5 gallon
(Part #: NP980003-007) 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 9490 pumps to specified levels are:

Hydraulic oil No. 7H (purple)

Eccentric Box 15-20 Gallons

Gear oil No. 9M (amber)

“A” Gearbox 14-15 Quarts

“B” Gearbox 4-5 Quarts

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6.1.2 Hydraulic Oil Fill
The pump is shipped with the proper level of hydraulic oil. The oil level is visible through the
sight glass on the back of the eccentric box.
The diagnostic window is also another place to check the oil level and to fill the pump with oil.

Figure 9

6.1.3 Gear Oil Fill

The pump is shipped with the proper level of gear oil. 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 9M (amber) gear oil to the level of the gear box side port (refer to
Figure 28). Replace both pipe plugs after filling.

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6.1.4 Oil Changes
The recommended oil change intervals are dependent upon the operating environment and level
of pump usage, classified as follows:
1. Normal service: clean/dry atmosphere, an ambient operating temperature of 0°C to 40°C
(32°F to 104°F) and up to 2,000 annual operating hours.
2. Severe Service: humid atmosphere, an ambient operating temperature below 0°C (32°F) or
above 40°C (104°F), and over 2,000 annual operating hours.

6.1.4.1 Hydraulic Oil Change:

The recommended hydraulic oil change interval is 2 years for normal service and 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 oil fill cap from the top of the eccentric box cover.
4. Drain the oil by removing the drain plug on the side, near the bottom of the eccentric box,
and the plug on the bottom of the intermediate housing
5. Remove and clean the HPV check valve screen (refer to Section 7.4.2 – Check Valve
Screen - Removal and Cleaning.)
6. Replace the drain plugs.
7. Fill the eccentric box with PULSAlube 7H (purple) hydraulic oil (refer to Hydraulic Oil
Fill).
8. Replace the oil fill cap.

6.1.4.2 Gear Oil Change:

The recommended gear oil change interval is two years for normal service and one 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 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 9M (amber) gear oil (refer to Gear Oil Fill).
7. Be sure to replace the top fill plug and side plug (if removed).

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6.2 Startup
6.2.1 Output Adjustment
Due to the possibility of piping leaks, it is best to start the pump at 0% output and then slowly
increase the setting to 100%.
The manually controlled PULSA Series 9490 has a hand wheel for manual stroke adjustment.
Mounted on the rear of the eccentric box cover, the hand wheel can be adjusted at any point
from 0 (0000 on the digital position indicator) to 100% (1000 on the digital indicator) by
pushing in and then rotating as required. Stroke length is locked during pump operation to
prevent drift. Pushing the hand wheel in temporarily disengages the lock for adjustment; release
after adjustment automatically resets the lock at the new setting.

Figure 10
The hand wheel gearbox can be removed and rotated through 45° increments if necessary to
improve operator access to the hand wheel.

6.2.2 Priming the Pumphead

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:
a) Fully depressing and holding the PTP valve while the pump is operating at any stroke rate
above 30%.
With the valve depressed, oil should begin to flow out of the small diagnostic port (refer to
Figure 9).
b) Hold the valve down for several seconds after the oil is clear of bubbles to ensure a good
prime.
If the pump fails to prime refer to Section 7.2.1, Priming the Pumphead.

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6.2.3 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, 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.
a) Remove the discharge valve by unscrewing the four tie bar bolts and removing the valve
as a unit.
b) Fill the head through the discharge valve port with process (or compatible) liquid
c) Reinstall the valve and retighten the tie bar bolts.
4. Start the pump at the 100% stroke length setting to prime the pump. If this does not work, it
will be necessary to fill the suction line.
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.
a) Remove the suction valve assembly.
b) Fill the line
c) Replace the valve.
d) Remove the discharge valve assembly and fill the reagent head as described in Step 3
above.

6.2.4 Calibration
All metering pumps must be calibrated to accurately specify stroke length settings for required
flow rates.

Figure 11

15
 A typical calibration chart is shown in Figure 11. 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. 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.
Allowing the pump to run for several hours prior to performing a calibration will provide
better results.

Procedure for constructing a calibration chart,

1. Measure the flow rate several times at three or more stroke settings (i.e., 25, 50, 75, and 100%).
2. Plot these values on linear graph paper.
3. Draw a best-fit line through the points.
For stable conditions, this line should predict stroke settings to attain required outputs.

7. Maintenance
BEFORE PERFORMING ANY MAINTENANCE REQUIRING REAGENT HEAD OR VALVE (WET
END) DISASSEMBLY, BE SURE TO RELIEVE PRESSURE FROM THE PIPING SYSTEM

WHERE HAZARDOUS PROCESS MATERIALS ARE INVOLVED, RENDER THE PUMP SAFE TO
PERSONNEL AND THE ENVIRONMENT BY CLEANING AND CHEMICALLY NEUTRALIZING AS
APPROPRIATE. WEAR PROTECTIVE CLOTHING AND EQUIPMENT AS APPROPRIATE.

Accurate records from the early stages of pump operation will indicate the type and levels of
required maintenance. A preventative maintenance program based on such records will minimize
operational problems. It is not possible to forecast the lives of wetted parts such as diaphragms and
check valves. Since corrosion rates and operational conditions affect functional material life, each
metering pump must be considered according to its particular service conditions.
PULSA Series KOPkits contain all replacement parts normally used in a preventative maintenance
program. It is recommended that KOPkits and PULSAlube hydraulic and gear oils be kept available
at all times.
Each PULSA Series pump is provided with an individual specification data sheet included in the
parts list package. The data sheet contains important information relating to the application along
with pump serial number, pump specifications (i.e., materials, piston size, stroking rate, etc.).

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7.1 Wet End Removal, Inspection, And Reinstallation
IF THE DIAPHRAGM HAS FAILED, PROCESS MATERIAL MAY HAVE CONTAMINATED THE
PUMP HYDRAULIC OIL. HANDLE WITH APPROPRIATE CARE, CLEAN AND REPLACE OIL IF
REQUIRED.

DUE TO THE SIZE AND WEIGHT OF WET END COMPONENTS, CARE MUST BE USED TO
SELECT THE PROPER TOOLS AND LIFTING EQUIPMENT FOR HEAVY LOADS.

Pump Head
Diaphragm

Reagent Head

Figure 12

PULSA Series diaphragms do not have a specific cycle life; however, the accumulation of
foreign material or the entrapment of sharp particles between the diaphragm and dish cavity can
eventually cause failure. Failure can also occur as a result of hydraulic system malfunction or
chemical attack. Periodic diaphragm inspection and replacement is recommended.

17
Take all precautions to prevent environmental and personnel exposure to hazardous materials.

Diaphragm Replacement procedure

1. Disconnect the power source to the drive motor.
2. Relieve all pressure from the piping system.
3. Close the inlet and outlet shutoff valves (refer to Figure 8).
4. Disconnect piping to the reagent head and drain any process liquid, following material safety
precautions from the process liquid manufacturer.
5. Place a pan underneath the pump head to catch any liquid leakage.
6. Remove the valving as in Section 7.3.2 and pour out any liquids retained by the check valves
into a suitable container, continuing to follow safety precautions as appropriate.
7. Remove all but two top reagent head bolts.
Oil will leak out between the pump head and reagent head as the bolts are loosened.
8. Install proper lifting devices to the tie bar holes, and remove the final bolts and rinse or clean the
reagent head with an appropriate material.
9. Remove and inspect the diaphragm. It may have taken a permanent convex/concave set as a
result of normal flexure and conformance to the dish plate. This condition is normal and is not
cause for replacement.

The diaphragm must be replaced if it is excessively deformed, dimpled, or obviously damaged.

10. To install a diaphragm, first ensure that the critical sealing areas of the diaphragm, reagent head,
and pump head are clean and free of debris.
When reinstalling a used diaphragm it is not necessary to maintain the previous orientation
relative to the reagent head or pump head hole pattern.
a) Apply a thin coat of O-Lube or silicon grease to the outer side of the back of the diaphragm
(approximately 1” wide from the edge of the diaphragm).
b) Place the diaphragm into the counter bore on the pump head and press firmly around the
outer edge.
11. Place the reagent head up to the diaphragm and install the head bolts finger tight (just in contact
with the reagent head front face).
12. Tighten the bolts in an alternating pattern as displayed in Appendix III, to ensure an even
seating force. Initially torque the nuts/bolts to one half the value recommended in Appendix III.
Tighten the nuts/bolts to the specified value the second time around.
13. Re-prime the pump following the procedure outlined in the next section.

18
7.2 Priming The Pump

Figure 13

Use the following procedure to prime the pumphead

1. Disconnect the power source to the drive motor.
2. Relieve all pressure from the piping system and where possible allow liquid to enter the reagent
head assembly.
3. Verify the eccentric box is filled with hydraulic fluid and fill with PULSAlube 7H hydraulic oil
if necessary.
4. Set the pump stroke length to a value between 0 and 20 %.
5. Connect power to the drive motor.
6. Turn on the pump and adjust the stroke length slowly to the maximum setting (100%).
7. Fully depress and hold the PTP valve for several seconds periodically as the stroke length is
adjusted. Within several minutes oil should begin to flow out of the small diagnostic port (refer
to Figure 13). Continue to press the valve periodically until the oil is clear of bubbles. The
pump is now primed. If oil fails to flow out of the diagnostic port after two minutes, proceed to
Step 8.

19
8. Turn off the pump.
9. Remove power from the pump.
10. Remove the PTP valve from the pumphead carefully.
11. Reset the stroke length to zero percent.
12. Using a small plastic funnel, slowly pour oil into the pumphead through the PTP valve port until
full.
13. Replace the PTP valve, ensuring that the flat copper gasket and o-ring are properly in place.
14. Connect power to the pump.
15. Turn on the pump and adjust the stroke length slowly to the maximum setting (100%).
16. Fully depress and hold the PTP valve for several seconds periodically as the stroke length is
adjusted. Within several minutes oil should begin to flow out of the small diagnostic port (refer
to Figure 13). Continue to press the valve periodically until the oil is clear of bubbles

20
7.3 Check Valves

Figure 14

Most fluid metering problems are related to check valves. Problems can be caused by solids
accumulation between valve and seat, corrosion of seating surfaces, erosion, or physical damage
due to wear or the presence of foreign objects.
Two types of check valves are used, the ball type for lower flows and the disk type for higher
flows.
The ball valve incorporates a ball, guide, and seat. Flow in the unchecked direction lifts the ball
off the seat, allowing liquid to pass through the guide. Reverse flow forces the ball down,
sealing it against the sharp edge of the seat. The guide permits the ball to rotate but restricts
vertical and lateral movement in order to minimize “slip” or reverse flow. Ball rotation
prolongs life by distributing wear over the entire surface of the ball. Since ball return is by
gravity, the valve must be in the vertical position in order to function properly. Parts are sealed
by o-rings.
The disk valve functions as does the ball valve, except that the ball is replaced by a spring-
loaded guided disk assembly. The seat may contain a captured o-ring to facilitate sealing,
unless process conditions require a metal to metal seal.

21
7.3.1 Check Valve Removal

Take all precautions to prevent environmental and personnel exposure to hazardous materials.

1. Disconnect the power source to the drive motor.

2. Relieve all pressure from the piping system.
3. Close the inlet and outlet shutoff valves (refer to Figure 8).
4. Loosen the suction valve tie-bar bolts and spring the suction piping slightly to drain any liquid
from the reagent head cavity. If the piping is closely connected it may be necessary to
disconnect a union or flange.
5. Remove the suction check valve assembly, holding it together as a unit.
6. Loosen the tie bar bolts on the discharge valve and spring the piping slightly to drain any liquid.
7. Remove the discharge check valve assembly, holding it together as a unit.

7.3.2 Ball Valve – Inspection and Repair

Ball Valve Inspection and Repair procedure

1. Disassemble both valves.
Seats should have sharp edges or a small chamfer, free from dents or nicks.
2. Examine components for wear by holding the ball firmly against its mating seat in front of a
bright light to inspect for fit.

Observation of light between ball and seat is cause for replacement of either or both
components.

3. Reassemble both valves using new parts as required. The o-rings should always be replaced.

22
7.3.3 Disk Valve – Inspection and Repair
Disk Valve Inspection and Repair procedure
1. Disassemble valves and inspect components for wear.
The seats and lower disk surfaces contacting the seats should remain flat and smooth. Although
it is normal for the o-ring in the seat to be flattened after significant use, replacement is
recommended as a part of valve maintenance.
2. The seat o-ring is captured by an internal lip in its groove in the seat, removal requires the
following destructive procedure.
a) Position a small blade type screwdriver against the outer edge of the o-ring at an angle of
approximately 45 degrees.
b) Taking care not to damage the sides of the seat, drive the screwdriver into the o-ring.
c) Using the screwdriver, pry one section of the o-ring out of the groove.
d) Grip the O-Ring with pliers, and remove it from the seat.
3. To install the replacement seat o-ring, place it on the seat above the groove.
a) Position a flat metal object over the o-ring
b) Apply uniform light pressure using a hand arbor press.
The slight movement that accompanies seating can be easily felt through the press handle.

DO NOT TRY TO INSTALL THE RING BY HAMMERING, AS THE SEATING WILL NOT BE UNIFORM.
THE RING MAY BE DAMAGED AND THE PUMP PERFORMANCE MAY BE IMPAIRED

4. Reassemble both valves using new parts as required. Sealing O-Rings should always be
replaced.

7.3.4 Check Valve Reinstallation

Use the following procedure to reinstall a Check Valve(s)

1. Reinstall both valve assemblies, taking care to ensure that they are correctly oriented with balls
or disks above seats. Refer to Figure 14.
2. Tighten the tie bar bolts evenly, making sure the valve assemblies are assembled squarely.
Refer to Appendix III for torque values.

For best results, always loosen the unions or flanges on either side of the system piping prior to
re tightening the check valve assemblies. Retighten the unions or flanges after the check
valves are securely tightened into position.

3. Check for leaks and retighten tie bar bolts as necessary.

23
7.4 Hydraulic Performance Valve (HPV)
During normal pump operation hydraulic fluid is continually discharged through the automatic
bleed valve and may also be lost past the piston seals. This causes the diaphragm to be drawn
further back on each successive suction stroke until it actuates the HPV. Once the valve is
actuated, oil is allowed to flow into the hydraulic system until the piston reaches the end of the
suction stroke. As the piston starts forward a check valve prevents oil from flowing back
through the HPV, thereby allowing the valve to close as the diaphragm moves forward. Through
this process the diaphragm is continually maintained in a proper operating position relative to
the pumphead dishplate. Since the HPV is unaffected by the vacuum level in the pumphead, oil
cannot be inadvertently brought into the hydraulic system which would result in over-extension
and damage to the diaphragm. This feature provides pump protection should the suction line
become restricted or closed for up to 1 – 2 hours.
PULSA 9490 pumps High Performance Valves (refer to Figure 16) are factory preset and
require no maintenance provided the hydraulic oil remains clean. The check valve in series with
the HPV includes a screen to trap contaminants (refer to Figure 18) and should be removed and
cleaned with each change of the hydraulic oil as indicated below. Should the HPV require
removal for cleaning or replacement follow the procedure below.

Figure 15

7.4.1 Check Valve Screen - Removal and Cleaning

Check Valve Screen - Removal and Cleaning procedure

1. Disconnect the power source to the drive motor
2. Relieve all pressure from the piping system.
3. Drain hydraulic fluid from the eccentric box.
4. Unscrew the check valve from the bottom of pump head.
5. Clean the valve and check valve screen in a solvent compatible with the nitrile seal material and
blow air through the valve to remove all contaminants.
6. Inspect the O-Rings for nicks or other damage and replace if necessary.
7. Lubricate the O-Rings with PULSAlube 7H and replace the valve, tightening securely.
8. Re-install the eccentric box drain plug and refill with PULSAlube 7H hydraulic oil.

24
7.4.2 HPV Removal and Replacement

HPV Removal and Replacement procedure

1. Drain hydraulic oil from the eccentric box and intermediate housing.
2. Remove the reagent head and diaphragm (refer to Section 7.1.1). Using PULSA Spanner
Wrench #NP660001-000 or suitable substitute, remove the HPV check valve assembly.
The HPV valve assembly may have been shimmed at the factory for proper valve placement.
The shims (if any) will be located in the back of the valve assembly hole of the pump head.
Locate these shims and ensure they are reinstalled with the valve (used or new).
3. If cleaning of the valve is required, use a solvent compatible with nitrile rubber and blow air
through the valve to remove all contaminants.
4. Inspect the O-Rings on the body of the valve for nicks or other damage and replace if required.
5. Lubricate the O-Rings with PULSAlube 7H and carefully insert the HPV into the dish side bore
of the pumphead.
6. Rotate the valve into the pumphead until it is fully seated.
7. Tighten into pump head with PULSA Spanner Wrench #NP660001-000 or suitable substitute.

Figure 16

8. Reinstall the diaphragm and reagent head.

9. Re-install the eccentric box drain plug and fill with PULSAlube 7H hydraulic oil.
10. Reprime the pump.

25
7.5 Hydraulic Bypass Valve (HBV)
All PULSA Series pumps incorporate a Hydraulic Bypass Valve which is an adjustable spring
loaded valve ported into the hydraulic cavity of the pumphead. The valve is designed to protect the
pump against excessive hydraulic pressure and will not limit or regulate system pressure. The
valve is factory-adjusted for pressure as originally specified, or at 10% above the rated pump
pressure.

Figure 17
The HBV is located at the top of the pumphead and any discharge, indicating over pressurization,
is visible at the outer diagnostics port (refer to figure 18)

Adjusting the HBV valve

1. Remove the valve cover.
2. Loosen the locknut.
3. Turn the adjustment screw clockwise (as seen facing the screw) to increase the bypass pressure
or counterclockwise to decrease it.
The locking nut must be tightened after adjustment.
Pump damage may occur during a system upset, if the hydraulic bypass pressure is set higher than
10% over the design pressure of the pump. Conversely, if the setting is too low the valve will
operate on each discharge stroke. This results in decreased pumping capacity and will eventually
affect the efficiency of the valve.
To check the hydraulic bypass pressure setting, install a gauge and a regulating valve in the pump
discharge line. The gauge must be between the pump and valve. For convenience, locate the two as
close to the pump as possible. With the pump operating at maximum stroke length, gradually
increase the discharge pressure and observe when the HBV starts to operate. The cracking pressure

26
 of the valve must be at least as high as the maximum pressure of the system but no more than 10%
over the pumps rated pressure. After adjustment tighten the lock nut and reinstall the metal cover.
Periodic inspection of the valve seat is recommended. If it becomes worn or damaged leakage will
occur regardless of how tightly the valve is adjusted.

7.5.1 PTP (Automatic Bleed Valve)

Figure 18

The PTP (automatic bleed valve) is a gravity-operated ball check valve which automatically
removes gases from the hydraulic system. On each discharge stroke of the pump, hydraulic
pressure drives the ball off the lower seat, expelling any accumulation of gases at the top of the
hydraulic system. An upper seat limits ball travel and flow during each actuation. On each
suction stroke, the ball is positioned (by gravity) against the lower seat to prevent reentry of gas
into the system. When all gas has been expelled, a small amount of oil will be displaced on
each discharge stroke. This oil is returned by gravity to the hydraulic reservoir.
Under normal operating conditions this ongoing process removes minute, invisible
accumulations of gas long before they are visible or detrimental to pump operation. To
accelerate hydraulic startup, pressing the spring-loaded button at the top of the valve holds the
valve momentarily open so that large amounts of gas can be instantly purged. When the button
is released, the valve reverts to normal automatic operation. Bleed valve operation can be
monitored by observing oil flow from the discharge port through the diagnostic window.

27
7.5.2 PTP Removal, Cleaning, and Reinstallation

Any accumulation of solids can cause the valve to malfunction.

1. Disconnect the power source to the drive motor.

2. Relieve all pressure from the piping system.
3. Slowly unscrew the valve to gradually relieve any residual hydraulic system pressure.
4. Remove the valve and clean it by soaking in compatible solvent.
Valve operation can be confirmed by blowing air through it in both directions and listening for
the “click” sound of ball-seat contact in both directions.
5. Verify that the copper gasket is installed at the bottom of the threaded hole in the pump head.
The copper gasket need not be replaced provided that it is sound and undamaged.
The elastomer gasket around the upper portion of the valve assembly may be likewise re-used.

This valve is not repairable and must be replaced if it continues to malfunction after cleaning.

28
7.6 Piston Seal

Figure 19

29
 Figure 20
7.6.1 General Description
The piston seals are of molded plastic or leather piston cup construction. Two different seal
arrangements are used. On the 1 - 3" pistons, refer to Figure 19. On the 4 – 5” pistons refer to
Figure 20. With oil changes at recommended intervals, piston seals should give years of
service.

7.6.2 Piston Seal Removal (1 - 3" pistons)

Piston Seal Removal Procedure
1. Remove the reagent head and diaphragm (refer to Section 7.1, Wet End Removal, Inspection
and Reinstallation).
2. Using proper hoisting techniques, support the pump head.
3. Remove the six nuts that secure the pumphead to the intermediate housing.
4. Carefully slide the pumphead/cylinder assembly straight off the piston assembly, taking care not
to damage the threaded studs.
5. Remove the piston retaining bolt and the piston assembly parts.
6. Wipe the piston end and the inside of the piston assembly parts clean.

30
7.6.3 Piston Seal Reinstallation (1 - 3" pistons)
Piston Seal Reinstallation
It is important to apply an anaerobic thread locking compound to the threads of the hex nut and
torque to 140 foot-pounds to prevent loosening during operation.

Figure 21

7. Apply PULSAlube 7H hydraulic oil to the piston seals, retainer, piston end, and the O-Ring.
8. Position and press the O-Ring into place in the Inner Retainer O-Ring groove.

There are two retainers in the piston assembly. These retainers are identical and have been
named “Inner” and “Outer” only for documentation purposes. Remember that the retainer
closest to the piston must have an O-Ring installed.

9. Place the Piston Seal on the Inner Retainer.

10. Slide the Inner Retainer / Piston Seal / O-Ring assembly onto the piston.
11. Slide the Spacer on the Piston.
12. Place the Piston Seal on the Outer Retainer.
13. Slide the Outer Retainer / Piston Seal assembly onto the piston.
14. Insert and tighten the bolt and washer assembly into the end of the piston.
15. Using proper lifting techniques, position and then connect the pump head assembly to the
Intermediate Housing.
16. Replace the reagent head and diaphragm (refer to Section 7.1, Wet End Removal, Inspection
and Reinstallation).
17. Fill the eccentric box with PULSAlube 7H hydraulic oil and prime the pump head (refer to
Section 6 – Equipment Startup).

31
7.6.4 Piston Seal Removal (4 - 5" pistons)
Piston Seal Removal Procedure
1. Remove the reagent head and diaphragm (refer to Section 7.1, Wet End Removal, Inspection
and Reinstallation).
2. Using proper hoisting techniques, support the pump head and intermediate housing.
3. Remove the eight nuts that secure the intermediate housing to the eccentric housing.
4. Carefully remove the intermediate housing / pumphead assembly, taking care not to damage the
threaded studs.
5. Remove the piston retaining nut and the piston seal assembly parts.
6. Wipe the piston end and the inside of the piston assembly parts clean.

7.6.5 Piston Seal Reinstallation (4 - 5" pistons)

Piston Seal Reinstallation

It is important to apply an anaerobic thread locking compound to the threads of the hex nut and
torque to 140 foot-pounds to prevent loosening during operation.

Figure 22
1. Apply PULSAlube 7H hydraulic oil to the piston seals, Expander, piston end, and Energizer.
2. Position and press the Cup Energizer into place on both of the Cup Expanders.
There are two retainers in the piston assembly. These retainers are identical and have been
named “Inner” and “Outer” only for documentation purposes. Remember that the retainer
closest to the piston must have an O-Ring installed.
3. Place the Piston Seal on one of the Cup Expander / Cup Energizer assembly’s.
4. Slide the Piston Seal / Cup Expander / Cup Energizer assembly onto the piston.
5. Slide the Spacer on the Piston.
6. Place the Piston Seal on the remaining Cup Expander / Cup Energizer assembly.
7. Slide this Piston Seal / Cup Expander / Cup Energizer assembly onto the piston..
8. Thread and then tighten the bolt into the end of the piston.
9. Using proper lifting techniques, position and then connect the intermediate housing / pump head
assembly to the eccentric box.
10. Replace the reagent head and diaphragm (refer to Section 7.1, Wet End Removal, Inspection
and Reinstallation).
11. Fill the eccentric box with PULSAlube 7H hydraulic oil and prime the pump head (refer to
Section 6 – Equipment Startup).

32
7.7 Oil Seals
7.7.1 General Description
The 9490 pump has three oil seals:
Motor Adaptor Seal Inside the motor adaptor, below the worm shaft coupling.
Gearbox Oil Seal Inside the mounting flange of the gearbox.
Eccentric Box Seal Side of the eccentric cap where the eccentric shaft protrudes.

Figure 23

33
7.7.2 Oil Seal Removal and Replacement
7.7.2.1 Motor Adaptor Oil Seal Removal and Replacement

1. Remove power from the 9490 pump assembly.

2. Attach required lifting device to the motor.
Do not put any tension on the pump motor at this time.
3. Remove the four Motor Attachment Bolts from the motor (refer to Figure 24).
4. Open the Access Panel by removing the four Access Panel Screws.

Motor Attachment Bolts (4)

Access Panel Screws (4)

Access Panel

Figure 24

34
5. Remove the Motor and Upper Coupling assembly by lifting straight up.
6. Rotate the Lower Coupling Assembly by hand until the Coupling Setscrew is visible.
7. Loosen the Lower Coupling Setscrew.

Upper Coupling Setscrew

Upper Coupling
Spider
Lower Coupling Setscrew
Lower Coupling

Figure 25

8. Remove the lower coupling and coupling spider.

9. Remove the four motor adapter bolts and lift the motor adapter from the gearbox.
Take care not to lose the shim(s) {if present} from between the motor adapter and gearbox.

Motor Adapter Oil Seal

Motor Adapter bolts (4)

Motor Adapter O-Ring

Figure 26

35
10. Remove the Motor Adaptor oil seal from the motor adapter.
11. Lubricate the replacement Motor Adaptor oil seal with silicone grease or PULSAlube 9M gear
oil.
12. Install the Motor Adaptor oil seal by pressing it into position.
13. Start the re-assembly process by inspecting the Motor Adaptor o-ring.
If there is no damage visible the o-ring can be reused.
14. Lightly coat the Motor Adaptor o-ring with silicone grease or PULSAlube 9M gear oil.
15. Verify that all shims (if there were any) are in place.
16. Install the Motor Adaptor over the gearbox worm shaft, taking care to not cut the seal and then
bolt in place.
The worm gear shaft is to have .003 max end play.
17. Slip the Lower Coupling and Spider over the worm gear shaft.
18. Position the coupling half flush to the end of the worm shaft.
19. Tighten the setscrew.
20. Lower the motor / Upper Coupling into position.
As you are positioning the motor, it may be necessary to rotate the Lower Coupling / Spider
assembly to facilitate proper alignment.
21. Once the coupling is aligned, lower the motor assembly until full contact has been made with
the lower coupling.
22. Insert and tighten the motor mounting bolts that were removed in Step 3.
23. Restore power to the 9490 pump assembly.

36
7.7.2.2 Gearbox Oil Seal Removal and Replacement

1. Remove all power from the 9490 assembly.

2. Attach required lifting device to the motor.
Do not put any tension on the pump motor at this time.
3. Remove the four Motor Attachment Bolts from the motor (refer to Figure 24).
4. Open the Access Panel by removing the four Access Panel Screws.
5. Remove the Motor and Upper Coupling assembly by lifting straight up.
Place the Motor and Upper Coupling assembly aside, taking care not to damage the Upper
Coupling assembly.

Gearbox Oil Level Port

Gearbox

Gearbox Drain

Eccentric Box Drain

Figure 27
6. Drain the gearbox.

While draining the gearbox, check the fluids for any sign of contamination. If the heavy gear oil
appears contaminated, replace it.

7. Connect the required lifting device to the gearbox. Lifting Eyebolt

8. Loosen the four gearbox mounting nuts.
9. Put a light amount of tension on the gearbox. Gearbox mounting nuts
(4)
10. Remove the four gearbox mounting nuts.
11. Remove the gearbox from the eccentric box,
sliding it off the eccentric shaft.
Support the gearbox appropriately to be able to pull
it off horizontally.

Figure 28

37
 Lifting Eye bolt

Mounting Bolt holes (4)

Guide Pin holes (4)

Gearbox Oil Seal

Figure 29
12. Remove the gearbox oil seal.
13. Lubricate the replacement with silicone grease or PULSAlube 9M gear oil.
14. Install the oil seal by pressing into position.
15. Reinstall by reversing the disassembly procedure.
Take care not to damage the seal when reinstalling the gearbox.
16. Refill the gearbox with PULSAlube 9M gear oil.

7.7.2.3 Eccentric Box Oil Seal Removal and Replacement

1. Remove the gearbox following the procedure defined in Section 7.7.2.2.

2. Drain the hydraulic fluid from the eccentric box

While draining the Eccentric, check the hydraulic fluid for any sign of contamination. If the
hydraulic fluid appears contaminated, replace it.

Hydraulic Fluid Fill Plug

Jacking Screws (2)

Eccentric Oil Seal

Eccentric Shaft
Eccentric Side Cap bolts (6)

Eccentric Drain Plug

Figure 30

38
 3. Remove the six bolts that retain the eccentric side cap to the eccentric box.
4. Insert the two 1/4 X 20 jacking screws into the eccentric side cap.
5. Use the Jacking screws to break the eccentric side cap free from the eccentric box.
6. Remove the eccentric side cap and support the eccentric shaft.
Keep track of any shims present for later reinstallation.

Once the side cap is free, remove and store the jacking screws for later use. Do not attempt to
reinstall the side cap with the jacking screws in place.

7. Remove the Eccentric Box Oil seal.

Jacking Screw O-Ring

Eccentric Box Oil Seal

Jacking Screw

Figure 31

8. Lubricate the replacement O-Ring with silicone grease, and install by pressing into position.
9. Lubricate the cap O-Ring with silicone or PULSAlube 7H oil before reinstallation.
10. Reinstall by reversing the disassembly procedure.
Maximum eccentric shaft endplay is .003 inches.
11. Refill the eccentric box with PULSAlube 7H hydraulic fluid.
12. Place the 9490 system in its normal operating condition.

7.8 Cover Assembly

7.8.1 Cover Assembly Removal and Reinstallation

The handwheel on manually controlled pumps is linked to the oscillating housing by universals,
and a telescoping slip joint (refer to Figure 33). When the cover is removed, the relationship
between the two halves of the joint must be maintained or pump calibration will be affected.

39
Cover Assembly Removal
1. Press and hold the handwheel in and then turn in a counter clockwise direction to adjust the
stroke length dial indicator to zero.

Dial Indicator

Hand wheel

Figure 32
Use caution when approaching the 0000 mark. It is possible for the dial indicator to go
beyond zero. Allow the handwheel locking mechanism to engage to the nearest detent.
2. Disconnect the power source to the drive motor.
3. Remove the 12 cover screws.
4. Pull the cover back away from the pump head and lift off. Use care not to rotate the adjustment
shaft. Slip the square shaft out of the square tube without turning the shafts.

Hand wheel

Upper Universal

Upper Adjustment Shaft

Telescoping slip joint

Lower Adjustment Shaft

Lower Universal

Figure 33

40
 Cover Assembly Reinstallation
If the lower adjustment shaft has been turned while the cover was removed from the pump, the
stroke control needs to be re-calibrated.
1. Turn the lower adjustment shaft counterclockwise until the slide block stops against the top of
the oscillating housing (refer to Figure 5).
2. Turn the adjustment shaft clockwise 2 full turns.
The stroke control is now at the zero position.
3. Coat all surfaces of the slip joint assembly with silicone grease.
4. Verify the dial indicator registers zero.
a) Angle the front of the cover up to expose the square tube.
b) While holding the tube, carefully move the cover forward to engage the shaft (refer to
Figure 34).
IMPORTANT!!! The shaft and tube must be reassembled with the same orientation as when the
cover was removed.
5. Place the cover on top of the gearbox and replace the screws.
The indicator should read zero within 0005. If it does not, then remove the cover, turn the
handle until it reads zero, and reinstall it as described in Step 2.
6. After re-assembly, turn the handle a few turns in both directions to check for proper operation.

7.9 Motor Removal and Reinstallation

1. Remove power from the 9490 pump assembly.
2. Disconnect the motor wiring from the motor.
3. Attach required lifting device to the motor.
Do not put any tension on the pump motor at this time.
4. Remove the four Motor Attachment Bolts from the motor (refer to Figure 24).
Some European motors will have eight bolts
5. Open the access panel by removing the four access panel screws to expose the coupling.

The coupling is an interlocking jaw design and uses an elastomer spider between the two
coupling halves. The upper half of the coupling remains on the motor shaft and the lower half
stays on the gear shaft.

6. Lift the motor from the mounting adaptor.

7. If the motor is to be replaced, position the “old” motor so that the upper coupling is accessible.
8. Loosen the upper coupling setscrew to allow removal of the upper coupling half, taking care to
not lose the shaft key.
9. Install the upper coupling half on the shaft of the replacement motor, ensuring that the shaft key
is in place.
10. Align the end of the shaft flush with the inner surface of the coupling and tighten the setscrew.
11. Reinstall the motor by reversing the steps above.

41
8. Replacement Parts
8.1 PULSA Series KOPkit Program
PULSA Series KOPkits contain all replacement parts normally used in a preventative maintenance
program. (PULSAlube 7H hydraulic and PULSAlube 9M gear oils are also available for
preventative maintenance programs. Refer to the Equipment Startup section).
There is a specific KOPkit for every PULSA Series pump model. When practical, each KOPkit is
vacuum-packed for extended storage.
All PULSA Series pumps will have the KOPkit number identified on:
a) the pump nameplate,
b) the specification data sheet,
c) the Pulsafeeder order documents.
KOPkits can also be selected from the technical data sheet shipped with the pump or by a
Pulsafeeder representative.

8.2 Ordering KOPkits or Parts

When ordering replacement parts always specify:
a) Pump model and serial number (stamped on pump nameplate), e.g., Model No.
NPH9490A0001 with Serial No. B216245.
b) Part number and description from the PULSA Series parts list. Include the three-character
suffix.
PULSA Series part numbers begin either with the letters “NP”, or the letter “W”, e.g.,
NP170001-TNR or W210221-001.

42
9. Troubleshooting Chart
Difficulty Probable Cause Remedy
Pump does not 1. Coupling disconnected Connect coupling
start 2. Faulty power source Check power source
3. Blown fuse, circuit breaker Replace - eliminate overload
4. Broken wire Locate and repair
5. Wired improperly Check wiring diagram
6. Closed line valves Open valves
No delivery 1. Motor not running Check power source. Check wiring diagram
2. Supply tank empty Fill tank
3. Lines clogged Clean and flush
4. Closed line valves Open valves
5. Check valves held open with Clean - inspect
solids
6. Vapor lock, cavitation Increase suction pressure
7. Prime lost Reprime, check for leak
8. Strainer clogged Remove and clean. Replace screen if necessary
9. Hydraulic system underprimed Refer to Repriming the Pump
Low delivery 1. Motor speed too low Check voltages, frequency, wiring, and Terminal
connections. Check nameplate vs. Specifications.
2. Check valves worn or dirty Clean, replace if damaged
3. Hydraulic bypass valve operating Refer to Hydraulic Bypass Valve
each stroke
4. Calibration system error Evaluate and correct
5. Product viscosity too high Lower viscosity by increasing product temperature.
Increase pump and/or piping size
6. Product cavitating Increase suction pressure. Cool product
as necessary
7. Piston seal worn or damaged by Inspect and replace if necessary, refer to Piston Seal.
contamination
Delivery gradually 1. Check valve leakage Clean, replace if damaged
drops 2. Leak in suction line Locate and correct
3. Strainer fouled Clean or replace screen
4. Product change Check viscosity
5. Bypass leakage Correct for bypass valve leakage
6. Piston seal worn or damaged by Inspect and replace if necessary refer to Piston Seal
contamination
7. Supply tank vent plugged Unplug vent
Delivery erratic 1. Leak in suction line Locate and correct
2. Product cavitating Increase suction pressure
3. Entrained air or gas in product Consult factory for suggested venting
4. Motor speed erratic Check voltage and frequency
5. Fouled check valves Clean, replace if necessary
Delivery higher 1. Suction pressure higher than Install back pressure valve or consult factory for piping
than rated discharge pressure recommendations
2. Discharge piping too small Increase pipe size - install pulsation dampener in
discharge line
3. Back pressure valve set too low Increase setting
4. Back pressure valve leaks Repair, clean, or replace

43
Difficulty Probable Cause Remedy
Pump loses 1. Diaphragm ruptured Replace
hydraulic oil 2. Leaky seal Replace
3. Cover gasket leaks Replace or retighten
4. Eccentric box overfilled Remove excess oil
Air bleeds 1. Hydraulic oil level low Refill to correct level
continuously from 2. Hydraulic bypass valve operating Refer to Hydraulic Bypass Valve
PTP (automatic each stroke
bleed valve) 3. Suction pressure too low Increase pressure
4. Oil breakdown. Temperature Change oil type, consult factory
high
5. Plugged hydraulic refill inlet Clean contamination screen
check
Noisy gearing, 1. Discharge pressure too high Reduce pressure
knocking 2. Water hammer Install pulsation dampener
3. Hydraulic bypass valve set too Readjust (refer to Hydraulic Bypass Valve)
high
4. Stroke length at partial setting Nondestructive knocking sometimes occurs at reduced
stroke lengths.
Piping noisy 1. Pipe size too small Increase size of piping – install pulsation dampener
2. Pipe runs too long Install pulsation dampener in line
3. Surge chamber flooded Replace with air or inert gas. If a pulsation dampener is
installed, replace diaphragm and recharge
4. No Pulsation Dampener used Install pulsation dampener
Motor overheats 1. Pump overloaded Check operating conditions against pump design
requirements
2. High or low voltage Check power source
3. Loose wire Trace and correct
Diaphragm 1. Diaphragm extruded into Check and clean oil contamination screen.
Damage pumphead holes Reduce discharge pressure to pump design limits.
Relieve discharge pressure before stopping pump.
2. Diaphragm extrudes into Verify PTP bleeder is bypassing oil. Increase dynamic
pumphead holes suction pressure to at least 5 psia. Replace or clean
hydraulic performance valve. Replace worn piston
seals.

44
10. Appendix I – Piping Calculations
Suction Head Requirements
All reciprocating metering pumps require a net positive suction head (NPSHR). Refer to Table 1
for the (NPSHR) required for PULSA Series pump models. The NPSHR is defined as the pressure
required above the absolute vapor pressure of the process fluid at the pumping temperature. This
pressure is required at the suction port of the pump throughout the entire pump stroking cycle in
order to prevent cavitation of the process fluid within the reagent head. The NPSHR is one of the
requirements necessary to assure metering accuracy.

NPSH R
English (psi) 5
Metric (bar) 0.35
Table 1. NPSH R values

The net positive suction head available (NPSH A ) must be greater than the NPSH R . The NPSH A of
any given system is calculated as follows for comparison to the NPSH R as shown in Table 1.

Equation 1 – For fluid viscosity below 50 centipoise.

Equation 2 – For fluid viscosity above 50 centipoise.

The variables used in Equations 1 through 5 must be in the units shown in Table 2 for the
constants listed below to be used correctly.

45
 Units Set
Variable
English Metric

NPSH psi bar

PA psia bar(a)
PH psi bar
PV psia bar(a)
LS feet meters
R strokes/min strokes/min
G no units no units
Q gallons/hr liters/hr
d inches millimeters
µ centipoise centipoise
LD feet meters
PT psi bar
PP psi bar
VP feet/sec meters/sec
C1 24,600 640
C2 45,700 1.84
C3 46.8 0.91

Table 2. Unit sets and constant values for use in Equations 1 through 5.

If piping sizes vary throughout the suction line, different additive values may be used for the
pressure losses attributed to the liquid’s acceleration and deceleration.

Use the last term of Equation 1 or 2 as many times as needed in the equation to adjust for
different lengths of different pipe diameters in the suction line. (Everything but the pipe length
and diameter will stay the same in the equation.)
All reciprocating metering pumps also require that a minimum absolute pressure, minimum
suction head (MSH), be maintained at the pump inlet throughout the pumping cycle to ensure
a stable hydraulic system and proper pump operation.

MSH
English, (psia) 5.0
Metric, (bar(a)) 0.35
Table 3. Minimum values for the sum of NPSHA and vapor pressure. (MSH)

The sum of the NPSHA and the vapor pressure (P V ) must be greater than the values shown in
Table 3.

46
System Back Pressure
The system back pressure must exceed the suction pressure by at least 25 psi (1.7 bar) in order to
prevent flowthrough, however it must not exceed the rated discharge pressure of the pump.
Flowthrough can be defined as the process liquid flowing from a higher pressure to a lower
pressure (downhill pumping), which attributes to pump failure and undesired flow at pump
shutdown.
If the system back pressure is not at least 25 psi (1.7 bar) greater than the suction pressure, a back
pressure valve must be installed in the discharge piping. To calculate the system’s total back
pressure use Equation 3 or 4 below.

Equation 3. For fluid viscosity below 50 centipoise.

Equation 4. For fluid viscosity above 50 centipoise.

Nomenclature
NPSH R = Net positive suction head required, [psi, bar]
NPSH A = Net positive suction head available, [psi, bar]
PA = Pressure at the surface of the liquid being pumped (atmospheric or supply tank
blanket pressure) [psi(a), bar(a)]
PH = Head pressure above (+) or below (-) the pump centerline, [psi, bar,] (convert
from ft or m)
PV = Absolute vapor pressure at pumping temperature of the process liquid at pump
inlet, [psi(a), bar(a)]
LS = Length of suction piping (actual, not equivalent), [ft, m]
R = Pump stroking rate, strokes/min [spm]
G = Specific gravity of process liquid, [no units]
Q = Pump average flow rate, [gph, lph]
d = Internal pipe diameter, [inches, mm]
C 1 ,C 2 ,C 3 = Numeric constants used in Equations 1- 5 [no units]
µ = Viscosity of process liquid at pumping temperature, centipoise [cp]
LD = Length of discharge piping (actual, not equivalent), [ft, m]
PP = System discharge pressure, [psi(g), bar(g)]
PT = Peak pump discharge pressure at the discharge port, [psi(g), bar(g)]
VP = Peak liquid velocity generated by the pump, (suction or discharge) [ft/s, m/s]

47
11. Appendix II – Oil Specifications

PULSAlube #7H
API Gravity (ASTM D 287) = 31
Viscosity (ASTM D 2161) 175 SSU @ 100°F (38°C)
Viscosity (ASTM D 2161) 51 SSU @ 210°F (99°C)
Viscosity Index (ASTM D 2270) = 193
Pour Point (ASTM D 97) – 60°F (–51°C)
Flash Point, COC (ASTM D 92) 367°F (186°C)
Fire Point, COC (ASTM D 92) 403°F (205°C)
Color = purple

PULSAlube #9M
AGMA Number = 7
ISO Viscosity Grade = 460
API Gravity = 28.7
Viscosity (ASTM D 2161) 2100 SSU @ 100°F (38°C)
Viscosity (ASTM D 2161) 141 SSU @ 210°F (99°C)
Viscosity Index (ASTM D 2270) = 159
Pour Point (ASTM D 67) – 10°F (– 24°C)
Flash Point, COC (ASTM D 92) 560°F (293°C)
Timken OK Load (ASTM D 2782) Lb (kg) = 100lb (45kg)
Four Ball EP Test (ASTM D 2783)
Weld Point kg = 255
Load Wear Index = 44
Rust Test (ASTM D 665A&B) = Pass
Oxidation Test (ASTM D 2893) = Pass
Demulsibility Test (ASTM D 2711) = Pass
Foam Test (ASTM D 892) = Pass
Copper Corrosion (ASTM D 130) = 1-A
Color = dark amber

48
12. Appendix III – Bolt Torque Recommendations
Reagent Head and Tie-Bars

Reagent Head Reagent Head Torque Tie Bar Bolt Torque Ft.
Number Bolt Size/(Qty) Ft. Lbs./N-m Size Lbs/N-m

NP-160083-XXX 1.50 - 6 (10) 1000/1360 1.36 - 6 335/460

NP-160043-XXX 1.00 - 8 (10) 246/330 1.25 - 7 190/260
NP-160044-XXX 1.38 - 6 (10) 656/890 1.50 - 6 190/260
NP-160045-XXX 1.00 - 8 (10) 185/250 1.00 - 8 100/135
NP-160046-XXX 1.00 - 8 (10) 155/210 1.00 - 8 100/135

When torquing bolts, make sure you start with bolts equally hand tight. Then torque to one half the
specified rating following the bolt patterns below. Once you have completed the first pass, then
torque to the final rating.

49
Cylinder Bolts

Piston Size Bolt Size Torque

Ft. Lbs/N-m
1.5 .75 - 10 250 / 340
2.0 .75 - 10 250 / 340
2.5 .75 - 10 150 / 205
3.0 .75 - 10 150 / 205
4.0 NR
5.5 NR

50
13. Appendix IV PULSAlarm Leak Detection

13.1 PULSAlarm Leak Detection Reagent Head Assembly

The PULSAlarm leak detection

reagent head assembly consists of
reagent head, leak detection
diaphragm, suction and discharge
check valves, vacuum bleed port,
and optional pressure/vacuum
switch and gauge. The reagent
head, diaphragm, suction and
discharge check valves are the only
parts of the pump to contact the
process liquid; consequently,
maintenance is critical to pump
performance
Figure 24

A sealed system must be maintained at all times during pump operation, whether leak
detection is required or not. If the proper level of vacuum, between 10 in and 26 in.
(250mm to 650mm) Hg, or a sealed pressure system is not present, decreased flow and/or
diaphragm damage will occur. Please note that the factory setpoint for actuation of the
vacuum switch is 6 in (152mm) Hg (vacuum) or 5 psig (pressure).

13.2 PULSAlarm Leak Detection Diaphragm

Double, or sandwiched, TFE diaphragms are sealed at their peripheries to an intermediate metal
spacer ring. The space between the diaphragms is sealed so that the diaphragm functions as
does a standard single diaphragm. For the vacuum system, the space between the diaphragms is
evacuated of air to produce a vacuum. For the pressure system, the space between the
diaphragms is filled with a small amount of fluid. At startup, any excess fluid in the system is
expelled through the check valve, and then the system is capped and sealed. The fluid as
supplied from the factory is a silicone-based oil, but an alternate fluid can be used if
compatibility with the materials of construction is verified. This space is connected to an
adjustable electrical switch (optional) that actuates in response to loss of vacuum or buildup of
pressure resulting from rupture of either or both diaphragms. Switch operation can be used to
perform any external function, typically to signal an alarm or turn off the pump. For component
location refer to Figure26.

PULSAlarm leak detection can utilize a vacuum or pressure detection system. Although both
systems are similar, they do utilize different parts and require specific set-up procedures.
Always ensure that you are following the procedure correct for your system.

51
13.3 Leak Detection Option – Setup for Vacuum

A vacuum must be maintained at all times during pump operation,

otherwise, the diaphragm halves may separate during the suction stroke of
the pump, reducing flow capacity and potentially damaging the diaphragm.
Pumps incorporating the leak detection option are shipped from the factory
with the system evacuated to the operating vacuum of 650 mm Hg (26 in.
Hg). Due to flexure of the TFE diaphragms during transit and storage, the
initial vacuum may not be present at startup. When this occurs, re-evacuate
the system to the operating vacuum of 650 mm Hg (26 in. Hg).
12. Apply power to the alarm circuit.
13. Connect a vacuum pump capable of generating 26 inches of vacuum to
the Vacuum port, open the needle valve, and evacuate the system. A
hand-operated vacuum pump is generally appropriate for this procedure.
14. If required, verify system operation.

Figure 25

13.4 Leak Detection Option – Setup for Pressure

Pumps incorporating pressure leak detection are shipped from the factory with the system fully set
up to work at full pump pressure. No further setup is required. The standard factory barrier fluid
is silicone oil, if any other customer-specified media is used it must be compatible with
construction materials. The system will require proper setup after maintenance or repairs, see
section 11.5 on the following page for the proper procedure.

Figure 26

52
13.5 Pressure System Set-up and Priming

If the pressurized leak detection system is opened to the atmosphere during maintenance or
inspection, the system must be re-primed properly to avoid diaphragm damage and ensure
proper leak detection operation and system performance.

The standard factory intermediate fluid is a Silicone oil. If any other customer-specified
media is used, it must be compatible with the materials of construction. Refer to the fluid
manufacturer’s literature for appropriate safety precautions.

Use the following procedure to set-up the pressurized leak-detection system:

1. Complete re-assembly of the diaphragm, reagent head, and external components. Ensure that
reagent head and tie-bar bolts are tightened according to the appropriate torque
specifications (consult Appendix III)
2. Remove the pressure gauge from the housing body and replace with the straight tubing
connection supplied with the pump or conversion kit. Connect a vacuum supply (hand vacuum
pump) to the tube fitting.

If the system was previously sealed, you may need to remove the plug and re-install the hose
fittings at the fill port. There should be a container in the vacuum line to trap excess barrier
fluid. An inexpensive automotive brake bleeding kit is appropriate for this purpose.

3. Connect the fill tube, supplied with the replacement diaphragm, to the fill valve tubing
connection. Any short length of the appropriate sized tubing may be used for this purpose.
4. Open the fill valve.
5. Place the fill tube into a container of the barrier fluid being used.
6. Apply vacuum, the fluid should rise into the fill tube and enter the system.
7. Observe the fluid at the exit (vacuum pump) side. When clear, air free fluid is observed, close
the fill valve, while maintaining the vacuum on the system to begin the process of drawing out
excess fluid.

If you a re-using a previous diaphragm, it will take time for the silicone fluid to migrate
through the system, be patient!

8. Release the vacuum, and remove both the fill tube and the vacuum pump from the fittings.

Continues next page…

53
9. Empty the fill tube of fluid, and place it on the fitting near the switch, extending upwards, open
to the atmosphere.
10. Ensure that the eccentric box of the pump has been filled to the appropriate level with the
correct hydraulic fluid.
11. Adjust the pump to the zero stroke (0%) position.
12. If the pump is not already hydraulically primed, remove the PTP valve from the top of the
pump head. Using a plastic funnel or similar, slowly pour hydraulic fluid into the pump head
cavity until full.
13. Inspect the PTP valve to ensure the sealing o-ring is still in position, and re-install the valve.
14. In order to fully balance and evacuate the leak detection system, the pump must now run at
normal discharge pressure for a period of one hour. This ensures that excess barrier fluid is
fully evacuated from the system.
15. Supply either process fluid, or test fluid (i.e. water) to the suction fitting and ensure that the
discharge system is configured for safe operation. The pump can be started with minimal
discharge pressure and then slowly brought up to full pressure, if the system allows for this.
16. Apply power and start the pump.
17. Adjust the pump slowly to full (100%) stroke.
18. Hold down the PTP valve momentarily and observe the middle port under the diagnostic cover.
If no fluid is coming from this port, stop the pump and return to step 11. If fluid is present,
continue to step 19.
19. Slowly increase the discharge pressure to full operating pressure, and continue to run the pump
for a period of one hour.
20. During this time, excess barrier fluid will be displaced from the system into the short length of
tubing attached to the exit port, balancing the system for proper operation. A small pen mark on
the tube can assist in observing this process visually.
21. After the one-hour startup period, remove the tubing and connection from the housing body and
reinstall the pressure gage. Remove the fitting from the fill port and replace with the supplied
pipe plug.
22. Reconnect the alarm switch to the external system if necessary.
23. The pump and pressure leak-detection system are now properly prepared and ready for normal
service. During normal operation, the gauge should indicate 0 (zero) pressure.

Under certain circumstances, the system may not completely evacuate excess barrier fluid
during the procedure as outlined above. In these cases, after several days run time, a small
amount of pressure may build in the system. If this occurs, simply loosen the pressure gauge
from the switch housing and relieve a small amount of barrier fluid, returning the system to
a zero-pressure state.

Once this startup procedure is completed, the pressure leak detection system should require
no further maintenance.

54
13.6 Leak Detection System Maintenance

Although the PULSAlarm leak detection system requires minimal maintenance, vacuum must
be maintained to prevent false alarms and diaphragm damage.

13.6.1 Vacuum Setpoint Adjustment

If the optional switch is purchased, it is factory preset at the specified vacuum setpoint, 150 mm
Hg (6 in. Hg), at which loss of vacuum causes the vacuum switch to actuate. The standard
pressure switch is set to actuate at 5 psig.

 Use the following procedure to perform a Vacuum setpoint adjustment:

15. Disconnect the alarm circuit from the vacuum switch.
16. Remove the switch enclosure cover and loosen the knurled locking ring on the switch.
17. Rotate the hex adjusting ring counterclockwise to increase or clockwise to decrease the setpoint.
18. Verify the new setpoint (refer to the next section).
19. Repeat steps (3) and (4) above until the required setpoint as attained.
20. Tighten the switch locking ring and replace the switch enclosure cover.
21. Reconnect the alarm circuit to the vacuum switch.

 Use the following procedure to perform a setpoint adjustment test

22. Evacuate the system to approximately 650 mm Hg (26 in. Hg) OR properly prime and prepare
the pressure system.
23. Remove the switch cover and connect ohmmeter leads across the common terminal and the
other terminal used in operation (NO or NC).
24. Record the status of the switch (open or closed).
25. a. Vacuum: Break the vacuum system at any point external to the pump to permit gradual loss of
vacuum.
b. Pressure: remove the pressure gauge, and install a hand pump or other means of producing a
small amount of pressure in the system.
26. Observe the ohmmeter to detect actuation.

The setpoint can be observed by reading the vacuum/pressure

gauge upon actuation.

55
13.7 PULSAlarm Leak Detection Diaphragm Maintenance

After diaphragm failure, pressurized process fluid can be present in any

part of the PULSAlarm leak detection vacuum system. Take appropriate
precautions and handle with care.

Figure 27

13.7.1 Leak Detection Diaphragm Removal

 Use the following procedure to remove the Leak Detection Diaphragm:

27. Disconnect the power source to the drive motor.
28. Relieve all pressure from the piping system, and close the inlet and outlet shutoff valves
29. Take all precautions to prevent environmental and personnel exposure to hazardous materials.
30. Place a suitable container underneath the pump head to catch any liquid leakage.
31. Disconnect process piping and drain any process liquid, following material safety precautions.
32. Remove all but one top reagent head bolt. Oil will leak out between the pump head and reagent
head as the bolts are loosened.
33. Tilt the head and pour out any liquids retained by the check valves into a suitable container,
continuing to follow safety precautions as appropriate.
34. Remove the alarm switch assembly or pressure gauge from the reagent head.
35. Remove the bleed valve assembly and flat gasket from the reagent head.
36. Rinse or clean the reagent head with an appropriate material.
37. Remove the diaphragm by running a blunt blade along the periphery and prying it out.

56
13.7.2 Inspection
Remove and inspect the diaphragm assembly. It may have taken a permanent convex/concave
set as a result of normal flexure and conformance to the dish-plate. This condition is normal and
is not cause for replacement. The diaphragm must be replaced if it is deformed, dimpled, or
obviously damaged.

If the diaphragms have been removed from the spacer ring, the entire assembly should be
replaced to ensure proper sealing of its components.

13.7.3 Leak Detection Diaphragm Reinstallation

38. Ensure that the critical sealing areas of diaphragm assembly, reagent head, and pump head are
clean and free from debris. Align the diaphragm assembly capillary tubes with mating holes in
the seal groove in the reagent head and position it in place against the reagent head. Ensure
seating of the diaphragm sealing ring into the mating groove in the reagent head.
39. Install the reagent head bolts and tighten in an alternating pattern to ensure an even seating
force. Torque to the values recommended in Appendix III.
40. Apply sealing compound to the gauge/pressure switch assembly and reinstall to the upper port
on the reagent head.
41. Apply sealing compound to the fill valve assembly and reinstall to the lower port on the reagent
head.
42. Open the needle valve
43. Connect a hand-held vacuum pump or other vacuum source to the vacuum port, which fits 6 mm
(1/4 in.) I.D. tubing.
44. For a vacuum system, evacuate to approximately 650 mm Hg (26 in. Hg) and securely
tighten the needle valve after evacuation. Diaphragm damage or decreased flow will occur if
a vacuum is not drawn before the pump is returned to service. Refer to section 13.3 “Setup for
Vacuum”.
45. Re-prime the pump head hydraulic system, see Section 7.2
46. For a pressure system, see section 13.5, “Pressure System Set-up and Priming”
47. If required, test vacuum or pressure system operation.
48. After diaphragm set-up and priming, the pump is ready to be returned to service.

13.8 Leak Detection system conversion

Leak detection system conversion information can be found in Bulletin CV-LD-0203 (vacuum to pressure
system). For further conversion information and kits, please contact your local Pulsafeeder sales
representative.

57
 3-23-2004
B u l l e t i n 9490-IOM-2000
Rev C