PulsaPro ®

HYDRAULIC DIAPHRAGM
METERING PUMPS
PP7440

Installation, Operation &

Maintenance Manual

Bulletin: IOM-PRO-003 Rev A

PULSAFEEDER FACTORY SERVICE POLICY
Should you experience a problem with your PulsaPro pump, consult the troubleshooting
guide in your operation and maintenance manual. If the issue is not covered or cannot be
solved, contact your Pulsafeeder Sales Representative; or contact the Pulsafeeder Service
department directly.
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. If the product requires
returning to the factory for inspection and/or repair, a Return Authorization Number (RMA) issued
by Pulsafeeder is mandatory. To request an RMA, contact your local sales representative for an
authorization form.

TRADEMARKS
®
PulsaPro is a registered trademark of Pulsafeeder, Inc.
®
Pulsafeeder is a registered trademark of Pulsafeeder, Inc.

SAFETY CONSIDERATIONS
• Read and understand all related instructions and documentation before
attempting to install or maintain this equipment
• Observe all special instructions, notes, and cautions.
• Act with care and exercise good common sense and judgment during
all installation, adjustment, and maintenance procedures.
• 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.
• Caution: Dependent on Ambient conditions external surfaces of the pump (e.g.,
gearbox) can exceed 40C (104F). Operating personnel shall be notified and
use caution with servicing pump.

REFER TO SECTION 9 for additional Safety Precautions/ Ignition Hazards and

Protective Means
Copyright ©2022 / 2020 Pulsafeeder, Inc. All rights reserved.
Information in this document is subject to change without notice. No part of this publication may be
reproduced, stored in a retrieval system; or transmitted in any form or any means electronic or
mechanical, including photocopying and recording for any purpose other than the purchaser’s
personal use without the written permission of Pulsafeeder, Inc.

CONVENTIONS
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.

REVISION HISTORY
Revision Level Date Description of Change
A 11/3/2023 Initial Release
Table of Contents

Pulsafeeder Factory Service Policy……………………………………...……...…… 1

Trademarks………………………………………………………………....…...……. 1
Safety Considerations…………………………………………………………....…… 1
1. Introduction………………………………………………………………………. 5
1.1 Receiving Inspection………………………………………………………………. 5
1.2 General Information………………………………………………………………… 5
1.3 Personnel Responsible for Pump Operation…………………………………. 5
1.4 Testing………………………………………………………………………………. 5
1.5 Warranty……………………………………………………………………………. 5
1.6 Requesting Spare Parts………………………………………………………… 5
1.7 Spare Parts…………………………………………………………………………. 6
1.8 Liability Exclusion…………………………………………………………………… 6
1.9 Restrictions Regarding this document…………………………………………. 6
2. Transport and Storage…………………………………………………………. 6
2.1 Consignment receipt and unpacking…………………………………………… 6
2.2 Handling……………………………………………………………………………… 6
3. Storage Instructions……………………………………………………………. 7
3.1 Short Term…………………………………………………………………………... 7
3.2 Long Term…………………………………………………………………………… 7
4. Principles of Operation………………………………………………………... 7
4.1 Overall Operation…………………………………………………………………… 7
4.2 Nameplate Identification………………………………………………………… 8
4.3 Flow Rate…………………………………………………………………………. 9
4.4 Intended Use……………………………………………………………….……… 9
4.5 Components and Operation…………………………………………………… 9
5. Installation………………………………………………………………………. 14
5.1 Location……………………………………………………………………………. 14
5.2 Ideal Metering Pump Installation……………………………………………… 14
5.3 Suction Pressure Requirements……………………………………………… 15
5.4 Discharge Pressure Requirements…………………………………………… 16
5.5 PULSAlarm Leak Detection Electrical Connections……………………… 16
6. Equipment Setup………………………………………………………………. 17
6.1 Hydraulic Oil Fill…………………………………………………………………… 17
6.2 Drive Motor Installation…………………………………………………………… 17
6.3 Drive Motor Wiring………………………………………………………………… 18
6.4 Motor Rotation………………………………………………………………….… 18
7. Startup Procedure………………………………………………………………… 18
7.1 Output Adjustment………………………………………………………………… 18
7.2 Suction System……………………………………………………………………. 18
7.3 Priming the Pump Head…………………………………………………………. 18
7.4 Priming the Reagent Head………………………………………………………. 18
7.5 Calibration…………………………………………………………………………. 18
8. Maintenance………………………………………………………………………... 20
8.1 Operating Precautions……………………………………………………………. 20
8.2 Consulting with Technical Documentation……………………………………… 20
8.3 Oil Changes………………………………………………………………………... 20
8.4 Wet End Removal, Inspection, and Reinstallation……………………………. 23
8.5 Priming……………………………………………………………………………… 26

Page 3 of 50
8.6 Check Valves……………………………………………………………………… 28
8.7 Hydraulic Performance Valve (HPV)………………………………………… 30
8.8 Hydraulic Bypass Valve (HBV)…………………………………………………. 31
8.9 Push to Purge (PTP)…………………………………………………………… 31
8.10 Piston Seals……………………………………………………………………… .32
8.11 Oil Seal……………………………………………………………………………. 34
8.12 Pump Motor Removal and Reinstallation……………………………………... 34
9. Safety Precautions/ Ignition Hazards and Protective Means
10. Troubleshooting………………………………………………………………. 34
11. Technical Service Support………………………………………………... 37
11.1 Authorized Service Centers……………………………………………………. 37
11.2 Local Sales Representatives………………………………………………… 37
11.3 Factory Service Support………………………………………………………… 37
12. APPENDIX I……………………………………………………………………. 38
12.1 PULSAlarm Leak Detection System………………………………………… 38
12.2 PULSAlarm Leak Detection Diaphragm……………………………………. 38
12.3 Priming of Leak Detection Diaphragm……………………………………… 42
13. APPENDIX II……………………………………………………………………. 43
13.1 Piping Calculations……………………………………………………………. 43
13.2 System Back Pressure………………………………………………………. 44
13.3 Nomenclature……………………………………………………………………. 45
14. APPENDIX III………………………………………………………………….... 46
14.1 Oil Specification………………………………………………………………. ….. 46
15. APPENDIX IV……………………………………………………………...……... 47
15.1 Bolt Torque Recommendations………………………………………………... 47
16. APPENDIX V……………………………………………………………...……... 48
16.1 Pulsatrol Pulsation Dampener…………………………………………………... 48
16.2 Back Pressure Valve………………………………………………………….... 49
16.3 Pressure Relief Valve…………………………………………………………… 49

Page 4 of 50
1. Introduction
THIS DOCUMENT CONTAINS INFORMATION TO BE USED BY QUALIFIED PERSONNEL ONLY

1.1 Receiving Inspection

All materials relative to supply are delivered to the shipper in perfect condition after thorough final
testing and packaging. Inspect goods immediately upon receipt and check:
o The goods received correspond to the order made
o The packaging has not undergone damage due to transport or has not been tampered with
o The actual condition of goods
If anomalies or damage are found immediately issue a complaint with the courier and inform
Pulsafeeder aftermarket service at [email protected] or call Pulsafeeder at 585-292-8000.
1.2 General Information
The purpose of these instructions is to refer information deemed necessary for understanding as
much as possible about and facilitating the installation, commissioning, use and maintenance of
hydraulic diaphragm metering pumps.
1.3 Personnel Responsible for Pump Operation
Anyone operating the pump should have read and understood the instructions set forth within this
manual. The employer must instruct all staff on the risks of accidents and on devices and clothing
to be used for individual safety.
1.4 Testing
Each Pulsafeeder metering pump is a reliable quality product, subject to careful final inspection to
ensure their proper functioning and found compliance with the specified performance. The final test
results, if specifically requested by contract, are registered and made available to the customer.
Pulsafeeder offers many different tests available with your PulsaPro pump.
1.5 Warranty
PulsaPro metering pumps are guaranteed for a period of eighteen (18) months from the date of
shipment. Drive assemblies (gearing, shafts, eccentric, and related components within gearbox)
are guaranteed for a period of sixty (60) months from the date of shipment. The guarantee covers
replacement, free of charge, of any component found to be defective in material or processing by
the Aftermarket Service Group at Pulsafeeder, Inc.
The Warranty is NOT valid in the following cases:
o Components subject to normal wear (gaskets, seals, O-rings)
o Installation and/or use do not meet the technical conditions of sale and instruction
o If the pump has been tampered with or disassembled
o Motor (drive) is covered by the motor manufacturer
1.6 Requesting Spare Parts
For preventative maintenance, Pulsafeeder recommends the installation of a KOPkit (Keep-On-
Pumping), which includes the recommended spare parts needed. The part number for this kit can
be located on the pump nameplate as well as the specification data sheet provided with your
metering pump.
For other needed components, find and study the sectional drawings of the pump in use, if
necessary, contact Pulsafeeder to obtain a copy. For drawings and bill of materials for your
pump(s) please send an email to [email protected]. Using the nomenclature of the sectional
drawing, make a list of the parts needed and send to your local Pulsafeeder sales representative,
always specify the pump serial number.

Page 5 of 50
 To find the local Pulsafeeder representative for parts pricing and availability log onto
www.pulsafeeder.com, select “Sales Contacts”. For assistance with determining the representative
then please contact us at 585-292-8000
1.7 Spare Parts
Modifications are not allowed. Original Pulsafeeder spare parts and accessories are to be used to
assure conformity with safety rules. Pulsafeeder declines any responsibility in case of use of non-
original parts and which results in the warranty being voided.
1.8 Liability Exclusion
Attempts to disassemble, modify, or tamper in general by unauthorized personnel will void the
warranty and will release Pulsafeeder from any liability for damage caused to persons or property
resulting from such actions.
Pulsafeeder is considered released from any liability in the following cases:
o Improper Installation
o Improper use of the machine by non-professional or inadequately trained operators
o Use not in compliance with regulations in the Country of use
o Lack of maintenance or improperly performed
o Use of non-original spare parts or incorrect parts for model in question
o Total or partial failure to observe the instructions
o Exception environmental events
1.9 Restrictions Regarding this Document
This document is the property of Pulsafeeder together with the technical information contained in it.
Modification, reproduction, or copying (in part or whole) without written permission is prohibited.

2. Transport and Storage

2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must be checked against the delivery/shipping
documents for its completeness and that there has been no damage in transportation.
Check any crates, boxes, or wrappings for any accessories or spare parts that may be packed
separately with the equipment or attached to side walls of the box.
Each product has a unique serial number, check that the number corresponds with that advised,
and always quote this number in correspondence as well as when ordering spare parts.
Shortages or damage should be reported immediately to the carrier and your Pulsafeeder
Representative.

2.2 Handling
Boxes, crates, pallets, or cartons may be unloaded using forklift vehicles or slings dependent on
their size and construction. Slings, ropes, and other lifting gear should be positioned where they
cannot slip and where a balanced lift is obtained. If lifting without equipment, follow safe practices
to avoid injury (i.e., lifting with two people).

Page 6 of 50
3. Storage Instructions
3.1 Short Term
Storage of PulsaPro pumps for up to twelve (12) months is considered short-term. The
recommended short-term storage procedures are:
o Store the pump indoors at room temperature in a dry environment
o Confirm or fill the eccentric box to its normal operating level with PULSAlube Premium 7H
Hydraulic Oil. If required by the operating environment, take steps to prevent entry of water
or humid air into the eccentric enclosure.
o Prior to startup, inspect the housing and gearbox. Replenish hydraulic oil as required to
maintain operating levels. If water or condensation is present, change oil as described
under Equipment Set-Up.
o Start up in accordance with instructions in this manual
3.2 Long Term
Every twelve months, in addition to the above short-term procedures, power up the motor and
operate the pump for a minimum of one hour. It is not necessary to have liquid in the reagent head
during this operation, but the suction and discharge ports must be open to atmosphere. If the pump
is equipped with a PULSAlarm leak detection system, ensure that a vacuum is drawn before
operating the pump. See Appendix I for more information.
After twelve months of storage, Pulsafeeder Warranty cannot cover such items which are subject to
deterioration with age such as seals and gaskets. If the pump has been in storage longer than
twelve (12) months, it is recommended that such items be inspected and replaced as necessary
prior to startup. Materials and labor to replace this class of items under these circumstances are the
purchaser’s responsibility. For continuance of the warranty after extended storage, equipment
inspection and any required refurbishing must be done by a Pulsafeeder Representative.

4. Principles of Operation
4.1 Overall Operation
A piston reciprocates within an accurately sized cylinder at a preset stroke length, displacing an
exact volume of fluid. The piston, however, does not pump various chemicals. The piston and
associated mechanisms are enclosed in a gearbox that also serves as a hydraulic oil reservoir. A
diaphragm separates the oil from the product pumped. The diaphragm moves in exact response to
piston displacement. The diaphragm does no work and acts only as a separator. Consequently,
the oil displacement is translated into equal product displacement. The piston retraction causes the
product to enter through the suction check valve. Piston advancement causes the discharge of an
equal amount of product through the discharge check valve.
Individual pumps may vary in appearance due to various liquid ends, accessories, and multiplexing.
The basic principles of operation, however, remain the same.
The maximum A-weighted sound pressure level of the Pulsa Pro 7440 series metering pump was
tested and determined to be 59 dBA.

Page 7 of 50
 Figure 1
4.2 Nameplate Identification
Each pump carries a nameplate for identification with the following information:
o Model Series
o Serial Number
o Rated Flow
o Rated Pressure
o KOPkit (recommended spare
parts)
o Piston Diameter
o Gear Ratio
o Motor Frame Size, RPM
Rating

Figure 2

Page 8 of 50
4.3 Flow Rate
PulsaPro has pulsating flow rates, generated by the alternating movement of the piston and the
action of the check valves on the pump head which determine flow direction. Pump flow rate is
adjustable and increases or decreases in direct proportion to the variation of the stroke adjustment.
The theoretical flow rate – corresponds exactly to the volume described by the movement of the
diaphragm.
The actual flow rate – is inevitably lower than the theoretical flow rate, due to the volumetric
efficiency of the pump. It varies depending on the type and size of the pump, the nature and
viscosity of the liquid to be pumped, working pressure, etc.
4.4 Intended Use
PulsaPro 7440 Pumps are designed for dosing liquid fluids (flammable, acids, alkaline, solvents,
etc.) at ambient temperature or heated, suitable for continuous service.
These pumps are used in the following markets:
- Chemical Processing, Petrochemical, Oil & Gas, Power & Energy, Water/Wastewater
treatments, and General Industries.
Applications may include but not limited to:
- Amines, Defoamers, Oxygen Scavengers, Disinfectants, Oil Additives, Acids, Demulsifiers,
Caustics, Methanol, Biocides, Corrosion Inhibitors, Ethylene Glycol, Anti-Scalants, and other
chemical feeds.
4.5 Components and Operation
Reagent Head (Wet End) – The typical reagent head assembly consists of the reagent head,
diaphragm, and the suction/discharge check valves. This assembly is the only part of the pump to
contact the process liquid; consequently, maintenance is critical to pump performance.

Figure 3

Page 9 of 50
Types of Diaphragms – PulsaPro 7440 offer the Flat Diaphragm and HYDRAtube. Additionally,
you can utilize our Double Diaphragm (Flat) with PULSAlarm Leak detection. (Figure 4 showing the
Flat diaphragm and HYDRAtube.

Figure 4

Flat Diaphragm – is the standard design ensuring high performance metering in a

leak-free operation. PulsaPro flat diaphragms are available in a variety of both
metal and plastic materials and can handle a wide range of chemicals. As with
PulsaPro diaphragm constructions, the flat diaphragm is hydraulically balanced
and operates stress free, providing exceptional life and accuracy.

Figure 5

HYDRAtube – is the best choice for sheer sensitive, high viscosity fluids and
slurries. It’s straight flow through design eliminates clogging and flow restrictions.
It offers double diaphragm safety as a standard as well as optional slurry valves.
Available in FKM, CSM, or PFA, it can be utilized with the most corrosive or acidic
chemicals. Optional ChemAlarm leak detection system monitors the electrical
conductivity of the intermediate liquid between the HYDRAtube and second
diaphragm to detect diaphragm failure and, can signal an alarm or stop the pump.

Figure 6

Page 10 of 50
 Double Diaphragm (Flat) with PULSAlarm Leak Detection – offers a rugged
sandwich style double diaphragm construction for increased protection against
leaks. PULSAlarm provides a pressurized leak detection technology to monitor
the diaphragm integrity and can signal an alarm or stop the pump at the first sign
of diaphragm failure. PULSAlarm is designed to contain full rated pressure up to
3,000 PSI (207 BAR), and is rated NEMA Type 7, EEMAC7 Class 1, Division 1,
Groups C&D, Class 1, Zone 1, Groups IIA&IIB; UL, cUL, CE, ATEX. An optional
pressure gauge is also available for visual indication of diaphragm integrity at the
pump.

Figure 7

Pump Head Assembly – attached to the intermediate head of the pump, it consists of the pump head,
cylinder, piston assembly, and three hydraulic valves.

Push-To-Purge (PTP) – situated at the top of the pump head

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.

Figure 8

Hydraulic Performance Valve (HPV) – integrated within the

dish plate this valve automatically maintains the required
hydraulic oil volume by replacing any oil lost past the piston or
through the PTP valve.

Figure 9

Page 11 of 50
 Hydraulic Bypass Valve (HBV) – this valve protects the pump
from over-pressurization by relieving any excess pressure in the
pump’s hydraulic system. The valve is preset based on
customer’s specification, typically adjusted to 10% above the
system pressure. The sight glass above the valve allows visual
aid to observe the operation.

Designed to protect the pump only, does not provide

an overall system protection.

Figure 10

Manual Control/Stroke Adjustment

The PulsaPro 7440 pump flow rate is adjusted by changing the stroke length utilizing a counter located
next to the handwheel which denotes the stroke position. The stroke is adjusted by turning the control
knob to the desired setting. The stroke length percentage is denoted by a counter.

NOTE: Stroke Adjustment is measured to the tenths. The below picture represents 100.0% stroke.

Figure 11

Page 12 of 50
Automatic Stroke Adjustment

If ordered with a controller you would have the XAE which is a microprocessor-based stroke length
control device. The unit is physically attached and integrated into the pumps design. This controller
allows for precise adjustment of output flow of a process media by means of stroke length position. For
additional information on your XAE please download or review a copy of the IOM.

Figure 12

Gear Ratio Assembly/Motor Adaptor

PulsaPro pumps are driven by a standard C-face electric motor mounted on the adaptor input flange.
The motor drives a set of worm gears located in the gearbox which will then convert rotational speed
into torque. They in turn power the eccentric shaft assembly that converts rotary motion into
reciprocating motion. The motor adaptor is available in a variety of sizes to accommodate different
motor frame specifications.

Figure 13

More than one pump can be driven through a single drive assembly, which is referred to as multiplexing.
The pumps are mounted on a common gear reducer assembly on the drive pump and the pump without
a gear reducer is called the driven pump. Each pump is mounted on its respective standard simplex
base. Each pump will have its own gear ratio.

Page 13 of 50
 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 reassemble in the same orientation.

5. Installation
5.1 Location

When selecting an installation site or designing a skid package, consideration should be given to access
for routine maintenance.

PulsaPro pumps are designed to operate indoors and outdoors, but it is desirable to provide a hood or
covering for outdoor service. External heating may be required if ambient temperatures are below -40°F
are anticipated. Check with the factory regarding suitability of the operating environment.

The pump must be rigidly bolted to a solid and flat foundation to minimize vibration, which can loosen
connections. When the pump is bolted down, care must be taken to avoid distorting the base and
affecting alignments, check for levelness when securing. This will assure that the hydraulic oil is
maintained at the proper levels and that the check valves can operate properly.

5.2 Ideal Metering Pump Installation

Figure 14

Page 14 of 50
 All piping systems should include:

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

Piping weight must not be supported by the valve housings or other portions of the reagent head, as the
resulting stresses can cause leaks. If appropriate, provide for thermal expansion and contraction so
that no excess force or moments are applied to the pump.

If piping assembly, use a sealing compound chemically compatible with the process material.

Users of sealing tape are cautioned to ensure that the pipe thread ends are not taped. Both new and
existing piping should be cleaned, preferably by flushing with a clean liquid (compatible with process
material) and blown out with air, prior to connection to the pump. Flow issues at pump startup are often
related to the check valves being fouled with piping and process debris.

5.3 Suction Pressure Requirements

Although PulsaPro metering pumps have suction lift capability, all pump installations should have
minimum lift for optimum performance. A flooded suction (i.e., suction pressure higher than
atmospheric pressure) is preferable whenever possible. The pump should be located as close as
possible to the suction side reservoir or other source.

Piping should be sized to allow for best possible NPIP conditions.

IT IS NOT RECOMMENDED TO INSTALL A PUMP EQUIPPED WITH A PULSALARM LEAK

DETECTION IN A SUCTION LIFT SYSTEM

If suction lift is required, the net positive suction pressure required (NPSHr) is 0.21 bar (or 3
psia). If this requirement is not met the process liquid may cavitate inside the pump, degrading
metering accuracy. To maintain prime on a suction installation, a foot valve is required. In
addition, suction pressure must be maintained at a minimum absolute value of 0.35 bar (or 5
psia) to ensure proper hydraulic system and proper pump operation.

IT IS CRITICAL THAT PULSAPRO PUMPS HAVE FREE FLOWING AND UNOBSTRUCTED

SUCTION CONDITIONS AT ALL TIMES. CLOSED VALVES, CLOGGED STRAINERS,
OBSTRUCTED PIPING, ETC. ARE TO BE AVOIDED. SUCTION RESTRICTIONS CAN PLACE
STRESS ON THE DIAPHRAGM THAT MAY RESULT IN PREMATURE FAILURE.

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

Page 15 of 50
5.4 Discharge Pressure Requirements

PulsaPro Metering Pumps are designed for continuous service at the rated discharge pressure. If
system suction pressure exceeds system discharge pressure, flow would be generated in addition
to that caused by the pump, resulting in a reduction in accuracy and loss of control over the
metering process. To prevent this condition, commonly referred to as “flow-through”, discharge
pressure must exceed suction pressure by at least 20 PSI (1.37 BAR). The installation of a back-
pressure valve can achieve this is necessary to achieve the differential pressure.

Discharge systems should be protected from excessive pressures by utilizing a pressure relief or
pressure limiting valve in the piping system. Operation of the pump at pressure above its rated
maximum (found on nameplate) may result in damage to the pump components and/or unsafe
system conditions.

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

5.5 PULSAlarm Leak Detection Electrical Connections

If equipped with an optional pressure switch, install electrical wiring and conduit in accordance with
local electrical codes.

Figure 15
The switch is rated as follows:

Voltage 115VAC
Phase Single
Load 1.0 Amp (Resistive)
Contacts NO/NC (SPDT)
Connection Flying Leads, 20AWG
Max Pressure 3000PSI

The switch is the SPDT (single pole, double throw) type and can therefore be connected to either
open or to close upon detection of a diaphragm leak condition. Contacts
or wires are identified as follows:

Normally Open (NO) Wire Color White

Normally Closed (NC) Wire Color Red
Common (COM) Wire Color Black

THE ENCLOSURE IS LABELED WITH APPLICABLE SAFETY

AGENCY RATINGS FOR HAZARDOUS AREA INSTALLATION. SINCE THE SWITCH IS OF
THE MECHANICAL CONTACT TYPE, IT CAN NEVER QUALIFY AS NON-SPARKING (NON-
INCENDIVE, OR “M”) FOR OCCASSIONAL AND SHORT-TERM HAZARDOUS AREA USE.
PROTECTION MUST BE PROVIDED BY THE ENCLOSURE.

Go to Section 11 Appendix I for further description and instructions for the PULSAlarm Leak
Detection System.

Page 16 of 50
6. Equipment Setup
6.1 Hydraulic Oil Fill

The PulsaPro ships from the factory pre-filled with oil after testing is completed. When starting up
you can verify the oil level from the provided sight glass on the gearbox as well as the Intermediate
Head.

Figure 16
Figure 17

Remove the oil fill cap on the rear of the gearbox to gain access to the gear oil reservoir and add
PULSAlube 8GS gear oil. For the hydraulic oil, remove the plastic cover on the top of the
intermediate chamber cover and add PULSAlube 7H hydraulic oil. High oil level will not affect the
operation of the pump; however, it can result in nuisance leakage of oil.

Oil Type Color Amount

Hydraulic Purple 3 Liters
Gear Amber 1.75 Liter

6.2 Drive Motor Installation

PulsaPro pumps may be shipped with the drive motor packed separately. This is done to avoid damage
during transport.
o Remove the unattached coupling half from the motor adaptor. Ensure that the elastomer
coupling spider remains in place, on the coupling half that remains attached to the worm shaft in
the pump.
o If applicable, remove any tape or retainer rings that hold the motor shaft key in place.
o Place the loose coupling half on the motor shaft. Align the face of the motor shaft flush with the
face of the coupling.
o Tighten the setscrew onto the shaft key
o Place the motor in a vertical position and align the coupling teeth
o Install the motor downwards onto the adaptor. Final position can be achieved by slightly
rotating the motor until the coupling jaws align
o Rotate the motor until the clearance holes in the adaptor and the tapped holes in the motor
align. Fasten the motor to the adaptor using the supplied bolts (4). Tighten bolts evenly to
secure motor.

Figure 18

Page 17 of 50
 6.3 Drive Motor Wiring

Wire the PulsaPro drive motor according to the motor vendor’s nameplates and instructions, and
according to any appropriate national and local electrical codes and regulations.

6.4 Motor Rotation

Verification of the motor direction is necessary at startup. The motor direction must be counterclockwise
as indicated on the gearbox by a directional arrow.

Figure 19

7. Startup Procedure
7.1 Output Adjustment

All PulsaPro pumps have a handwheel for manual stroke length

adjustment. Mounted on the top of the stroke adjustment housing,
the hand-knob can be adjusted at any point (from 0 to 100% stroke
setting) by rotating the hand wheel as required. A counter, located
next to the handwheel will denote the stroke position.

Adjustments can be made while the pump is at rest or operating,

although operating adjustments are easier to make.

Figure 20

NOTE: Stroke Adjustment is measured to the tenths. The below picture represents 100.0% stroke

IF THE PUMP IS EQUIPPED WITH A PRESSURE LEAK DETECTION SYSTEM, THE SYSTEM
MUST REMAIN SEALED AT ALL TIMES DURING PUMP OPERATION, WHETHER OR NOT LEAK
DETECTION IS REQUIRED. IF THE SEAL IS BROKEN, DECREASED FLOW AND/OR DIAPHRAGM
DAMAGE WILL OCCUR. SEE APPENDIX I FOR FURTHER INFORMATION

LEAK DETECTION DIAPHRAGM SYSTEMS REQUIRE SPECIAL HYDRAULIC PRIMING

CONSIDERATIONS TO PROTECT THE DIAPHRAGM FROM DAMAGE DURING INTIAL PUMP
STARTUP. SEE APPENDIX I FOR FURTHER INFORMATION.

Page 18 of 50
7.2 Suction System

Before operation of any PulsaPro pump, carefully ensure that all suction valves are in the open position.
Verify that all filters and strainers are clean and clear. Ensure that any other potential causes of
restriction have been addressed. Unrestricted flow of liquid to the suction side of the pump is critical to
proper operation.

7.3 Priming the Pump Head

All pumps are shipped with a fully primed hydraulic system. However, during shipping and handling
some air may enter the hydraulic system. Generally, this air will be automatically purged after a short
run-in period. If necessary, rapid purging may be accomplished by fully depressing and holding the
PTP valve for five to ten seconds, while the pump is operating. Repeat as necessary until the pump
stabilizes at rated flow.

7.4 Priming the Reagent Head

o Open the suction and discharge line shutoff valves

o If the piping system design and the storage tank are such that the product flow 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.
o If the installation involves a suction lift, it may be necessary to prime the reagent head and
suction line. Try priming the reagent headfirst. Remove the discharge valve by unscrewing the
four tie bar bolts and removing the valve as a unit. Fill the head through the discharge valve
port with process (or compatible) liquid, then reinstall the valve and retighten the tie bar bolts to
the recommended specification.
o Start the pump at the 0% stroke length setting and slowly increase the setting to 100% to prime
the pump. If this does not work, it will be necessary to fill the suction line.
o Filling of the suction line will necessitate the use of a foot valve or similar device at the end of
the suction line so that liquid can be maintained above the reservoir level. Remove the suction
valve assembly, fill the line, replace the valve, then remove the discharge valve assembly and
fill the reagent head as described in the third step above. The pump will now self-prime when
started up per step four above.

7.5 Calibration

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

A typical calibration charge is shown in figure 23. Although

output is linear with respect to stroke length setting, an
increase in discharge pressure decreases output uniformly,
describing a series of parallel lines, one for each pressure
(only two are shown).

The theoretical output flow rate at atmospheric output

pressure is based on the displacement of the hydraulic
piston (the product of piston cross-sectional area and
stroke length) and the stroking rate of the pump. With
increasing the discharge pressure there is a corresponding
decrease in output flow of approximately 1% per 100 PSI
(7 BAR) increase in output pressure. Whenever possible,
calibration should be performed under actual process
conditions (i.e., the same or a similar process liquid at
system operating pressure). Figure 21

Page 19 of 50
 To assure a sound hydraulic system, run the pump for ten to fifteen minutes prior to calibration. This will
allow the PTP valve to purge any air from the system.

To construct a calibration chart, measure the flow rate several times at three or more stroke settings
(i.e., 25, 50, 75, and 100), plot these values on linear graph paper, and draw a best fit line through the
points. For stable conditions, this line should predict settings to attain required outputs. See figure 2 for
example of a four-point test plotted onto a calibration chart.

Checking the actual flow rates is especially important in pumps producing low flow rates and operating
against high discharge pressures. In this type of system, normal losses of efficiency can result in lack of
measurable flow at shorter piston stroke lengths. This is a function of the system conditions and does
not indicate a problem with the pump. Careful measurement of actual pump flow at several test points
will allow for proper calibration over the complete flow range.

Figure 22

7.6 Stopping Mechanism

The PulsaPro 7440 pump shall be fitted with a local/clearly visible control device that will allow the pump
motor and accessories (e.g. stroke length actuator, hypovalve, PULSAlarm, etc.) to be brought to a
complete stop. This is commonly known as an emergency stop or E-Stop.

Any external drivers (e.g. motor) or controls (e.g. XAE) used with the pump shall be purchased as
accessories and installed in accordance with the manufacturer installation manual. Proper installation is
the responsibility of the customer.

8. Maintenance
Accurate records from 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 service conditions.

Each PulsaPro 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 the pump
serial number and pump specifications (i.e., materials, piston size, stroking rate, etc.).

PulsaPro KOPkits (Keep-On-Pumping) contains all the replacement parts normally used in preventative
maintenance program. It is always recommended that KOPkits and PULSAlube hydraulic oil be kept
available. A good instruction manual, parts list, and a good maintenance record are key to long trouble-
free metering pump operation.

Page 20 of 50
BEFORE PERFORMING ANY MAINTENANCE REQUIRING REAGENT HEAD OR VALVE (WET
END) DISASSEMBLY, BE SURE TO RELIEVE PRESSURE FROM THE PIPING SYSTEM AND,
WHERE HAZARDOUS PROCESS MATERIALS ARE INVOLVED, RENDER THE PUMP SAFE TO
PERSONNEL AND THE ENVIRONMENT BY CLEANING AND CHEMICALLY NEUTRALIZING AS
APPROPRIATE. FOLLOW SAFETY MEASURES BY WEARING YOUR PROTECTIVE CLOTHING
BASED ON THE HAZARDOUS.

8.1 Operating Precautions

All operations must be performed by qualified personnel. Prior to work:

o The power line is disconnected, and no parts are energized

o Any risk of accidental restart has been excluded
o Handled fluid, present in the pump head and pipelines is not pressurized
o With the pump off, suction and discharge valves are closed
o Pump has been adequately cleaned, when operating in aggressive chemical environments

THESE MAINTENANCE SUGGESTIONS ARE NOT INTENDED AS “DO IT YOURSELF” REPAIRS.

TO PERFORM SUCH WORK, SPECIALIZED TECHNICAL KNOWLEDGE IS REQUIRED, AND
OPERATIONS ARE TO BE PERFORMED BY QUALIFIED PERSONNEL.

8.2 Consulting with Technical Documentation

Before starting work, you should consult this maintenance manual, identify the correct sectional drawing
of the pump in use and get all the tools and equipment necessary to perform the maintenance or repair
work.

When the pump has been disassembled, waiting to be reassembled, it is necessary to protect the
various components to prevent damage caused by oxidation or accidental impact.

8.3 Oil Changes

It is recommended after six months of operation to replace the hydraulic oil within the PulsaPro pump.
To accomplish this, you will need to remove the drain on the gearbox as well as the drain plug on the
intermediate head. Oil changes thereafter would be on an annual basis for Normal Service, or every six
months for Severe Service as defined below.

Normal Service: Clean/Dry Atmosphere, an ambient operating temperature of 0°C to 40°C (32°F to
104°F) and/or up to 2,000 annual operating hours.

Severe Service: Humidity/Chemical/Dust laden atmospheres, and/or ambient operating temperatures

below 0°C or above 40°C (below 32°F, above 104°F), and/or over 2,000 annual operating hours.
Hydraulic/Gear Oil Change Procedure:

o Disconnect the power source to the drive motor

o Relieve all pressure from the piping system
o Drain the oil by removing both drain plugs on the back of the gearbox
o Drain the remaining oil in the pump head/intermediate head reservoir by removing the drain
plug located on the side of the intermediate head
o After drained, replace the plugs using thread sealant
o Fill the gear chamber from the black oil fill cap located just underneath the motor adapter on the
gearbox using PULSAlube 8GS.
o Fill the hydraulic chamber from the purple (or aluminum) cover affixed to the top cover of the
intermediate head using PULSAlube 7H.

8.4 Wet End Removal, Inspection, and Reinstallation

Page 21 of 50
IF THE DIAPHRAGM HAS FAILED, PROCESS MATERIAL MAY HAVE CONTAIMINATED THE
PUMP HYDRAULIC OIL. HANDLE WITH APPROPRIATE CARE; CLEAN AND REPLACE OIL.

Flat Diaphragm Replacement

PulsaPro diaphragms do not have a specific cycle life; however, the accumulation of foreign material or
the entrapment of sharp particles between the diaphragm and the dish cavity can eventually cause
failures. Failure can also occur because of hydraulic system malfunction or chemical attack.

Flat Diaphragm Replacement Procedure:

o Disconnect the power source to the drive motor.
o Relieve all pressure from the piping system.
o Take all precautions to prevent environmental and personnel exposure to hazardous materials.
o Close the inlet and outlet shutoff valves.
o Place a suitable container underneath the pump head to catch any liquid leakage.
o Disconnect piping to the reagent head and drain process liquid, following material safety
precautions described.
o Remove all but one top reagent head bolts. Oil will leak out between the pump head and
reagent head as the bolts are loosened. The HPV will hold the reservoir of oil in the
intermediate head but any oil between the diaphragm and dish plate will drain.
o Tilt the head and pour out any liquids retained by the
check valves into a suitable container, continue to follow
safety precautions.
o Remove the final bolt and rinse or clean the reagent head
with appropriate material.
o Remove the old diaphragm and replace it with the new one supplied in the KOPkit.
o 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. Set the diaphragm in place on the reagent
head and ensure the seat of the diaphragm sealing ring into mating groove in the reagent head.
o Install the reagent head bolts and tighten in an alternating pattern to ensure an even seating
force. Refer to torque values in torque table.
o Re-prime the pump head.

HYDRAtube Replacement

1. Remove all pressure from piping system.

2. Disconnect the power source to the drive motor.
3. Adequately flush the reagent head and associated piping with a neutralizing liquid to
remove all toxic or hazardous product.
4. Close the suction and discharge shut off valves.
5. Disconnect the unions or flanges on the piping and drain
off any liquid. Use extreme caution if the product is
hazardous.
6. Remove the top fill plug from the HYDRAtube housing.
Next place a pan under the housing and remove the
bottom pipe plug to drain the intermediate fluid. Note –
on models equipped with a CHEMALARM the bottom
pipe plug is replaced with a conduction probe. Refer to
separate instructions for removal and reinstallation of the
probe.

IF THE DIAPHRAGM HAS FAILED, INTERMEDIATE LIQUID COULD HAVE PROCESS LIQUID
MIXED INTO IT. IF THE PRIMARY DIAPHRAGM HAS ALSO FAILED, PRODUCT MAY HAVE
CONTAIMINATED THE PUMP OIL. HANDLE WITH PROPER CARE.

7. Remove the tie bars, valves, and valve adaptors from both suction and discharge.

Page 22 of 50
FOR ELASTOMER HYDRATUBES FOLLOW STEPS 8
THROUGH 20. FOR PFA HYDRATUBES FOLLOW STEPS 21
THROUGH 35.

8. Pick up on the edge of the HYDRAtube flange and push

that same edge down the throat of the HYDRAtube. The
balance of the flange will fold and follow.
9. Pull the HYDRAtube out from the bottom of the housing
by a combination of twisting and bending sideways.
10. Inspect for any damage (i.e. cuts, cracks, chemical
attack, or excessive deformation). Replace if necessary.

11. When installing a HYDRAtube do not use tools which may cut or damage the tube.
12. Obtain a rubber band
13. Fold a point on the edge of the flange upward. Push the
edge down the throat of the tube. Fold the sides of the
flange inward to form a compact 45° and wrap tightly
with a rubber band. This wrapped nose should be
reasonably compact and secure.
14. Work the wrapped nose of the tube up through the
bottom hole of the housing, rotating gently to work the
tube upward to the top of the housing.
15. With a slight push at the bottom flange of the tube, guide
the nose of the tube to the center and out of the top hole
in the housing.

16. If the HYDRAtube is one of the larger models, (inside is greater than 1 inch or 38.1mm) the
time required to fill the housing can be reduced by pouring the intermediate liquid past the
top flange while it is still folded.
17. Reinstall the bottom valve adaptor and drain plug and then
partially fill the housing with the appropriate liquid.
18. Remove the rubber band.
19. Unfold the top flange and center both the top and bottom of
the HYDRAtube
20. Reassemble the top and bottom adaptor parts, torque the
tie bar bolts to the recommended value.
21. If the HYDRAtube housing has been removed from the
pump head and the hydraulic prime lost, follow the flat
diaphragm re-priming procedure before re-priming the
intermediate/housing chamber.

The following steps apply to PFA HYDRATUBES

22. Pick up the edge of the HYDRAtube flange and bend it upwards so that it is even with the
body of the tube. Avoid creasing the tube material.
23. While keeping the flange bent up, lift and remove the HYDRAtube adaptor and any gaskets
beneath it.

Page 23 of 50
 24. Pull the HYDRAtube out from the bottom by a combination of twisting and bending. Also
remove any gaskets which were beneath the bottom
tube adaptor.
25. Inspect the tube for any damage (i.e.; cuts, cracks,
chemical attack). Replace if necessary.
26. When installing a tube do not use tools which may
cut or damage the tube
27. Obtain a rubber band.
28. Place one flat gaskets in the top recess of the
HYDRAtube housing.
29. Check the bottom HYDRAtube adaptor, it should
have one flat gasket on it. Carefully straighten the
flange on one end of the tube and work it through the
adaptor and gasket. Slide the adaptor and gasket to
the opposite end of the HYDRAtube.

30. Now tightly wrap the straightened end of the HYDRAtube with a rubber band.
31. Work the wrapped end of the HYDRAtube up through
the bottom hole of the housing, rotating gently to work
the HYDRAtube upward to the top of the housing.
32. With a slight push at the bottom flange of the tube, guide
the nose of the HYDRAtube to the center and out the top
hole in the housing.
33. Work the top tube adaptor over the top end of the tube.
It may be necessary to remove the rubber band first.

34. Unfold the top flange and center both the top and bottom of the HYDRAtube. Make certain
the HYDRAtube flanges are seated in the HYDRAtube adaptors.
35. Reassemble the top and bottom adaptor parts, torqueing the tie bar bolts to the
recommended value.
36. If the HYDRAtube housing has been removed from the pump and the hydraulic prime lost,
follow the flat diaphragm re-priming procedure before re-priming the intermediate/housing
chamber.

8.5 Priming

Flat Diaphragm Priming

1. Disconnect the power source to the drive motor.

2. Relieve all pressure from the piping system.
3. Remove the diagnostic window from the intermediate chamber cover. Pour the appropriate
amount of Pulsalube 7H hydraulic oil. Replace diagnostic window.
4. Remove the fill cap on the back of the gearbox and fill the gearbox with Pulsalube 8GS
gear oil to the proper level. Replace the fill cap after complete.
5. Turn on the pump and adjust the stroke length to the maximum setting of one hundred
percent stroke. Fully depress and hold the PTP valve. Oil should begin to flow out of the
center diagnostic port. Depress the PTP valve down for three to five seconds then release
and repeat until the oil is clear of bubbles. The pump is now primed. If oil fails to flow out of
the diagnostic port, re-check the oil levels.
6. If you continue to have issues, you can try to speed up the process. Set the stroke to Zero
and isolate the power from the pump.
7. Remove the PTP valve from the pump head. Using a plastic funnel, slowly pour oil into the
pump head through the PTP valve port until full.

Page 24 of 50
 8. Replace the PTP valve in the pump head, ensuring that the flat copper gasket and O-ring
are properly in place.
9. Restore power to the pump. Increase the stroke slowly to 100% depressing and holding
the PTP valve periodically. Oil should begin to flow out of the center diagnostic port.
Continue to hold the valve down until the oil is clear of bubbles.
10. If oil fails to flow out of the diagnostics port, then additional oil is required: repeat steps 7-9.
11. The pump is fully primed and ready to put into service.

HYDRAtube

Before filling the HYDRAtube chamber you must first have performed the hydraulic priming of the
flat diaphragm. If this has not been done, follow the instructions above for priming of a flat
diaphragm. You must have the flat diaphragm and the HYDRAtube diaphragm in sync for proper
operation. This process will place the flat diaphragm back with the tube diaphragm in a fully
relaxed and open state.

The HYDRAtube, when properly primed, should be in its neutral position (fully round) when the
diaphragm is in its rearmost position (as dictated by the piston, figure 33), and should begin to
close as the diaphragm moves forward (figure 34). Priming in this way assures stable
performance and protects the HYDRAtube from damage during system upsets. The priming
procedures is the same for elastomer and PFA HYDRAtubes.

Figure 30 Figure 31

• With the intermediate chamber fill plug removed and motor removed, manually rotate
the motor coupling until the pump piston assembly is in the full rearward position.
• Fill the intermediate chamber using a mixture of water and 1/3 propylene glycol by
volume or other liquid selected for the application.
• Check the seal on the fill plug and replace if necessary. Reinstall and tighten the fill
plug to the intermediate chamber.
• Reinstall the motor. Allow the pump to run for 5 to 10 minutes. Observe the action of
the HYDRAtube through the discharge port. It may be helpful to shine a light up
through the suction port. It should go from a complete round form at the end of the

Page 25 of 50
 suction stroke to an elliptical shape at full discharge stroke, but not closing off at the
middle. The pump now has a correct intermediate prime and is ready for service.
• Reinstall the suction and discharge valve assemblies.

Double Diaphragm Flat Leak Detection

Please refer to Appendix I for detailed information for priming of the Leak Detection Diaphragm.

8.6 Check Valves

Description of Check Valves

Most fluid metering problems are related to check valves. Problems usually stem from solids
accumulation between the valve and seat, corrosion of seating surfaces, erosion, or physical
damage due to wear or the presence of foreign objects.

The check valve incorporates a ball or disc, guide, and seat. Flow in the unchecked direction lifts
the ball or disc off the seat, allowing liquid to pass through the guide. Reverse flow forces the ball
or disc down, sealing it against the sharp edge of the seat. The guide permits the ball to rotate
but restricts vertical and lateral movement to minimize “slip” or reverse flow. Ball rotation prolongs
life by disturbing wear over the entire surface of the ball.

Since check return is by gravity, the valve must be in the vertical position to function properly.
The guide and seat are sealed by O-rings.

Figure 32

Removal, Inspection, and Reinstallation

With the removal of wet end components follow the recommended safety procedures in place and
use your Personal Protective Equipment (PPE).

o Disconnect the power source to the drive motor.

o Relieve all pressure from the piping system.
o Take all precautions to prevent environmental and personnel exposure to hazardous
materials.
o Close the inlet and outlet shutoff valves.
o 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

Page 26 of 50
 to disconnect a union or flange.
o Remove the suction check valve assembly (ball contained within guide and seat), holding
it together as a unit.

o Loosen the tie bar bolts on the discharge valve

and spring the piping slightly to drain any liquid.
o Remove the discharge valve assembly, holding
it together as a unit as before.
o Disassemble both valves and examine
components for wear. Seats should have sharp
edges or a small chamfer, free from dents or
nicks. Hold the ball firmly against its mating
seat in front of a bright light to inspect for fit.

Figure 33

OBSERVATION OF LIGHT BETWEEN THE BALL AND SEAT IS CAUSE FOR

REPLACEMENT OF EITHER OR BOTH COMPONENTS. FOR BEST RESULTS, ALWAYS
LOOSEN THE UNIONS OR FLANGES ON EITHER SIDE OF THE PIPING PRIOR TO RE-
TIGHTENING OF THE CHECK VALVE ASSEMBLIES. RE-TIGHTEN THE UNIONS OR
FLANGES AFTER THE CHECK VAVLES ARE TIGHTENED INTO POSITION.

Figure 34
o Reassemble both valves using new parts as required. Sealing O-rings should always
be replaced.
o Reinstall both valve assemblies, taking care to ensure that they are correctly orientated
with balls above seats.
o Tighten the tie bar bolts evenly.
o Torque the tie bar bolts according to the torque specification list in Appendix IV

Page 27 of 50
8.7 Hydraulic Performance Valve (HPV)

PulsaPro pumps utilize the high-performance valve which is integrated within the dish plate to
preserve hydraulic balance. The valve is factory preset and requires no maintenance provided the
hydraulic oil remains clean. When the valve is actuated, oil can 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 pump head dish plate. Since
the HPV is unaffected by the vacuum level in the
pump head, oil cannot be inadvertently brought into
the hydraulic system which would result in over
extension and damage to the diaphragm. This
feature provides the pump protection should the
suction line become restricted or closed.

The check valve (HPVC) in series with the HPV

includes a screen to trap contaminants and should
be removed and cleaned with each change of
hydraulic oil as indicated. A clogged filter screen will
impede the operation of the HPV and can lead to
diaphragm damage. If a diaphragm has failed, and
chemical has contaminated the pump head
assembly, both HPV and HPVC should be removed
and thoroughly cleaned.

Figure 35

Check Valve Screen (HPVC) – Removal and Cleaning

o Disconnect power, relieve all pressure, and drain the hydraulic fluid.
o Unscrew the check valve from the bottom of the pump.
o Clean the valve and screen in a solvent compatible with the nitrile seal material and blow
air through the valve to remove all contaminants.
o Inspect the copper gasket and O-ring for nicks or other damage and replace if necessary.
o Lubricate the O-ring with PULSAlube 7H and install the valve, tightening securely.
o Re-install the drain plug and refill the hydraulic oil.

Figure 36

Page 28 of 50
8.8 Hydraulic Bypass Valve (HBV)

All PulsaPro pumps incorporate a hydraulic bypass valve which is an adjustable spring-loaded
valve ported into the hydraulic cavity of the pump head. 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 pressure.

The HBV is located on the side of the pump head and any discharge, indicating over
pressurization, is visible through the diagnostic port via sight glass. If adjustments are necessary in
the field, remove the valve’s plastic cover and loosen the lock nut. When turning the adjustment
screw clockwise you will increase the bypass pressure, counterclockwise will decrease the bypass
pressure. 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 pressure 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 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.

Periodic inspection of the valve is recommended. If it becomes worn or damaged leakage will
occur.

Figure 37

Page 29 of 50
 Bypass Side PTP Port

Figure 38

8.9 Push to Purge (PTP)

The PTP is a gravity operated ball check valve that 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 pre-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.

Page 30 of 50
 Under normal operating conditions this ongoing process
removes accumulation 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. PTP operation can be monitored
by observing oil flow from the diagnostic port through the
sight glass. Any accumulation of solids can cause the
valve to malfunction.

Figure 39

Removal, Cleaning, and Reinstallation of PTP

o Disconnect the pump from the power source.

o Relieve all pressure from the piping system.
o Slowly unscrew the valve to gradually relieve any residual hydraulic system pressure.
o 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.
o Make sure that the copper gasket is installed at the bottom of the threaded hole in the pump
head. It does not need replacement if it is undamaged.
o The elastomer gasket around the upper portion of the valve assembly may be likewise re-
used.

THE VALVE IS NOT REPAIRABLE, AND MUST BE REPLACED IF IT CONTINUES TO

MALFUNCTION AFTER CLEANING.

8.10 Piston Seals

PulsaPro piston seals are a thermoplastic elastomer with an FKKM energizer seal. The seal is
mounted two different ways: on the piston (for larger piston sizes) or in the cylinder (for smaller
piston sizes). With oil changes at recommended intervals, piston assemblies should provide
years of service.

Figure 40

Page 31 of 50
Removal and Replacement of Piston Seals (small piston sizes 7/8” and under)

o With any maintenance performed, follow safety procedures in place. Lockout/Tagout,

relieve pressure, close valves, flush the reagent head, drain the hydraulic oil.
o Remove the reagent head from the pump head.
o Remove the four bolts that secure the pump head to the intermediate head.
o Loosen the nut at the end of the cylinder that holds the piston seals.
o With the nut removed from the cylinder, remove the piston seals. Install new piston seals
into cylinder, follow same direction as removal.
o With the new seals installed, apply Loctite #242 (blue) to the threads of the nut and tighten.
Torque nut to 50-foot pounds.

Figure 41 Figure 42 Figure 43

Removal and Replacement of Piston Seals (large piston sizes above 7/8”)

o With any maintenance performed, follow safety procedures in place. Lockout/Tagout,

relieve pressure, close valves, flush the reagent head, drain the hydraulic oil.
o Remove the reagent head from the pump head.
o Remove the dish plate from the pump head to have access to the piston.
o Remove top cover from intermediate chamber.
o Using ¾ inch box wrench, loosen piston rod from crosshead.
o Push/pull piston assembly from cylinder.
o Remove jam nut from piston rod. Remove all piston plates and seals. NOTE orientation
during disassembly, as this is important.
o Remove and replace O-rings (x2) from piston rod. Grease O-rings.
o Slide piston plate 1 into position.
o Attach piston seal 1 to piston plate 2 and slide into position.
o Attach piston seal 2 to plate 3 and slide into position.
o Apply Loctite 242 to jam nut and tighten to 35 ft.-lbs.
o Oil/grease piston seals and cylinder inner diameter.
o Reinstall piston assembly into cylinder.
o Apply Loctite 263 onto threaded end of rod and resecure to crosshead.
o Reassemble the pump in reverse order.

Figure 44

Page 32 of 50
8.11 Oil Seal

The PulsaPro pumps utilize an oil seal on the worm shaft (input shaft) like the Pulsa product line.
This seal is serviceable, but only necessary to replace if there is an oil leak.

Replacing the Oil Seal

o Power has been disconnected from the source; safety procedures are followed.
o Remove the four fasteners securing the motor to the motor adaptor and remove motor.
o Rotate the coupling on the worm shaft until you see the set screw through the slots on the
adaptor.
o Remove the four hex head cap screws securing the motor adaptor to the gearbox.
o With the motor adaptor removed, you have visibility of the tension nut and the oil seal,
using a marker or equivalent put a mark on both tension nut and gearbox. This will provide
a reference when reassembly is performed, ensuring that the nut is properly aligned.
o Remove the oil seal
o Place electrical tape or equivalent over the end of the worm shaft prior to installing new oil
seal to prevent damage.
o Use Loctite # 534 around the outer surface of the oil seal.
o Press the oil seal onto the worm shaft and slide in place.
o Gently tap the oil seal flush into the tension nut.

Figure 49 Figure 50 Figure 51

8.12 Pump Motor Removal & Reinstallation

o Disconnect the power source to the drive motor.

o Disconnect the motor wiring from the motor.
o Remove the four bolts retaining the motor to the motor adaptor and remove the motor.
o The coupling is an interlocking jaw design and uses an elastomer spider between two
coupling halves. One half of the coupling remains on the worm shaft and the other on
the motor shaft.
o Loosen the setscrew that retains the coupling half of the replacement motor, ensuring
that the shaft key is in place.
o Align the end of the shaft flush with the inner surface of the coupling and tighten the
setscrew.
o Reinstall the motor by reversing the steps.

Page 33 of 50
9.0 Safety Precautions/ Ignition Hazards and Protective Means

Potential Ignition Measures to take to prevent the source from

Source becoming effective
• Motor sizing is to be as approved by the factory.
Electric Motor • Motors must be nameplated for the environment.
• Heat • Motors must be compliant with IEC EN 60079-0.
• Sparking • Motors are to be wired/used in accordance with the manufacturer’s direction.
• Motor secondary earth (bond) to be used. Must be grounded.
• Motor alignment to be assured prior to securing with bolts.
• Shaft rotation direction to be verified in compliance with pump
• Motor case temperature under load to be verified and monitored.
• Do not tamper with Pump protective Bypass Valve
• Include External Back Pressure and Bypass Valve in discharge piping.
• Whenever possible first-time startup in non-hazardous environment
• Couplings to be supplied/approved by factory.
Couplings • Couplings to be installed flush with shaft end per Instruction Manual.
• Heat • Coupling set screw to be installed with thread locking compound.
• Impact • Motor alignment to be assured prior to securing with bolts.
• Sparking • Coupling to be monitored for noise/vibration/heat on startup.
• Couplings to be inspected quarterly for evidence of spider wear.
• Motor to be removed to inspect Spider annually and replaced if worn.
• Coupling guards used between multiplexed pumps shall not be removed during
operation. Care should be taken to avoid contact with guarded couplings.
Guards shall not be used as steps for personnel to climb over equipment.

• Do not operate pump beyond limits stated on nameplate (e.g. pressure, SPM).
Drivetrain • Immersive lubrication is required to prevent ignition due to friction.
• Heat • Use only factory authorized lubricants.
• Impact • Check oil level weekly. Repair leaks immediately.
• Sparking • Check external Pressure Relief valve quarterly.
• Check external Back Pressure valve gage daily. Adjust back pressure as
required.
• Use only factory authorized replacement parts.
• Do not run pump dry of both lubricant and process fluid.
• Oil drain plugs must be sealed with liquid thread sealant and tightened.
• Covers and/or sight glass elements are only to be removed when the pump is
Caps & Closures cool (at ambient) and/or the environment is safe.
• Heat • Adhere to instructive labeling “WARNING-AFTER DE-ENERGIZING, DELAY 30
• Impact MINUTES BEFORE OPENING ANY COVERS”
• Sparking • Pipe threaded fittings (i.e., sight glass, drain plugs) removed for maintenance are
to be replaced with liquid thread sealant in accordance with the thread sealant
instruction.
• The oil fill cap is to be replaced after opening and hand tightened so that the o-
ring seals against the housing.
• Protect sight glass elements from falling objects (e.g., dropped hand tools/flange
hardware). If breakage occurs repair immediately.
• At temperatures less than 20F, the Diagnostic Sight Glass may be prone to
cracking if impacted. If this occurs, replace immediately.

Page 34 of 50
 • Prevent dust deposits from accumulating to a thickness great enough to become
Dust an Ignition hazard.
• Accumulation • Clean pump regularly
• Tools/Methods • Apply methods and tools appropriate to the Hazardous Location.
• Use only a damp cloth to clean pump surfaces.

Potential Ignition Measures to take to prevent the source from

Source becoming effective
• Ground (bond) Pump all "Protective Earth Ground" marked locations.
Static Electricity / Stray • Ground (bond) all accessories (e.g., controls, motor) in accordance to
Currents
manufacturer instructions.
• Discharge • Ground (bond) terminals must not be modified.
• Arcing • Non-metallic parts in contact with the process fluid must be retained with all
supplied fasteners and fixtures. These components must be grounded (bonded).
• Thickness of protective coating (i.e., paint) must not exceed 2mm (0.080in) at any
location.
• Clean pump surfaces with a damp cloth only.
• Clean with methods prescribed for the area

Corrosion • Coating to be approved by Pulsafeeder.

• Coatings to be maintained by user
• Heat • Coatings to be as specified. Field additions are not allowed unless pre-
arranged with factory.
• Thickness of protective coating (i.e., paint) must not exceed 2mm (0.080in) at
any location.

• Controls/Accessories approved for the Hazardous Location.

• Controls/Accessories must be compliant with IEC EN 60079-0.
Equipment/Accessories
• Controls/Accessories must be used in accordance with manufacturer’s instructions.
• RF/EM Waves

• Pump Installed Protective Valves (i.e., Hydraulic Pressure By-Pass Valve [HBV],
Hydraulic System Hydraulic Make-up Valve [HPV/HPV-C], Automatic Bleed Valve [PTP]) are not to
• Adiabatic
be over-ridden or defeated.
Compression
• Shock Waves • Protective valves only to be adjusted by qualified personnel.
• Visual Diagnostics Windows to confirm proper Protective valve operation per
manual.
• Stroke adjustment mechanism not to be modified by user (excluding normal
adjustment).

• User is responsible for equipment maintenance including replacement of wet end

Pumped Fluid sealing components and torque of retaining bolts (Reagent Head and Valve Cap).
• Pyrophoric
• Protective measures must be taken against accidental release of pumped chemical
on equipment startup and whenever maintenance is performed.

Page 35 of 50
 9. Troubleshooting Chart
ISSUE POSSIBLE CAUSES REMEDY
Check voltages, frequency, wiring, and terminal
Motor Speed too low connections. Check nameplates vs.
specifications.
Check Valves worn or dirty Clean of any debris, replace if damaged or
worn
Flow Rate Lower Hydraulic bypass valve operating Refer to Hydraulic Bypass Valve
than Expected each stroke
Calibration system error Evaluate and correct
Product Viscosity too high Lower viscosity. Increase pump and/or piping
size
Product cavitation Increase suction pressure
Piston seal worn or damaged by Inspect and replace, if necessary, refer to
contamination Piston Seal (Section 8 Maintenance)
Process pressure relief valve leaking Repair, adjust or replace
or relieving
Check Valve Leakage Verify the tie bar bolts are properly torqued,
evaluate for any pipe stress placed on check
valve. Replace the O-Ring.
Delivery Leak in Suction Line Locate and correct
gradually drops Strainer Fouled Clean or replace screen
Product change Check viscosity
Bypass leakage Correct for bypass valve leakage
Piston seal worn or damaged by Inspect and replace, if necessary, refer to
contamination Piston seal
Supply tank vent plugged Unplug vent
Coupling Disconnected Connect Coupling
Faulty power source Check power source
Pump does not Blown fuse, and circuit breaker Replace – eliminate overload
start Broken Wire Locate and repair
Wired Improperly Check wiring diagram and correct
Pipeline blockage Open valves
Motor not running Check power source. Check wiring diagram
Supply tank empty Fill tank
Lines clogged Clean and flush
Closed line valves Open valves
Ball check valves held open with Clean and inspect
No Delivery solids
Vapor lock, cavitation Increase suction pressure
Prime lost Re-prime, and check for leak
Strainer clogged Remove and clean, replace screen if necessary

Hydraulic system under-primed Re-prime the pump

Leak in suction line Locate and correct
Product cavitation Increase suction pressure
Delivery Erratic Entrapped air or gas in product Ensure proper venting of system
Motor speed erratic Check voltage and frequency
Fouled check valves Clean, replace if necessary
Suction pressure higher than Install backpressure valve or consult factory for
Delivery higher discharge pressure piping recommendations
than rated Back pressure valve set too low Increase setting
Back pressure valve leaks Repair, clean, or replace
Calibration error Review calculations

Page 36 of 50
 Diaphragm ruptured Replace diaphragm
Pump loses Leaky seal Replace seal
hydraulic oil Cover gasket leaks Replace or retighten
Pump head O-ring leaks Replace – tighten pump head bolts. Apply
sealing compound
Pump head overfilled Remove excess oil
Noisy Discharge pressure too high Reduce pressure
gearing/knocking Water hammer Install dampener or dampener not charged
properly
Hydraulic bypass valve set too high Readjust bypass valve
Pipe size too small Increase size of piping
Pipe runs too long Install dampener in line
Piping Noisy Repair with air or inert gas. If dampener is
Surge chambers flooded installed, replace diaphragm and recharge
No surge chambers used Install dampener
Pump overloaded Check operating conditions against pump
Motor Overheats design
High or low voltage Check power source
Loose wire Trace and correct

Diagnosis of Diaphragm Failure

FAILURE OBSERVED POTENTIAL CAUSES
Puncture, surface wear, or physical damage Abrasives or solids in the process stream
Foreign object in process or hydraulic system
Extended time under poor suction conditions, can
Extrusion and/or failure to the front (towards the included inadequate NPIP, closed valves, clogged
process side) strainers or filters, obstructed piping
Malfunctioning High Performance Valve (HPV)
HPV filter screen clogged
Extrusion and/or failure to the rear (towards the High (excessive) suction pressure
hydraulic side) Discharge pressure above maximum limit
Leaking (damaged) discharge check valve
Change in surface characteristics, color Chemical incompatibility with the process fluid

10. Technical Service Support

10.1 Authorized Service Centers

Pulsafeeder has several Authorized Service Centers across the United States. Contact your local sales
representative for a service center near your location.

10.2 Local Sales Representative

Your local Pulsafeeder Sales Representative has knowledge of Pulsafeeder Products and can provide
technical service support. To find a representative, go to www.pulsafeeder.com and select the Sales
Contacts tab. Or contact Pulsafeeder directly to find a local representative.

10.3 Factory Service Support

Pulsafeeder 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 issued by Pulsafeeder through your local
representative. Pulsafeeder cannot accept any pump, part, or piping accessory that has pumped strong
odorants (such as mercaptan).

Page 37 of 50
11. APPENDIX I
11.1 PULSAlarm® Leak Detection System

The PULSAlarm® leak detection system utilizes a

two-layer PTFE diaphragm, coupled to a pressure
switch. The system is initially primed by filling the
void within the detection assembly and between
the diaphragm layers with a barrier fluid. The
setup process then bleeds excess fluid from
between the diaphragm layers until they are in
close contact.

During normal pump operation, the two layers of

the PTFE diaphragm bear directly against one
another, and there is no pressure generated
between the two layers. The sensing system
monitors the space between the layers, which will
remain at zero pressure if the diaphragm layers
remain undamaged.
Figure 52
In the event of a failure of either layer of the diaphragm, liquid will enter the space between the two
layers. This liquid will be either the hydraulic oil (if the rear layer fails) or the pumped fluid (if the front
layer fails). As the pump operates, this liquid will generate pressure between the layers of the
diaphragm that will then be transferred outwards by the barrier fluid. This fluid will create pressure
against the pressure switch. The switch has a trip point of 20 PSI (1.37 BAR). When this pressure is
reached the switch will operate.

The output of the switch (both normally closed, and normally open connections are available) can then
signal the failure of the diaphragm. It is recommended that the pump be stopped in the event a leak is
detected. Immediate attention to the problem, followed by cleanup and appropriate maintenance, will
avoid further damage to the pump.

11.2 PULSAlarm® Leak Detection Diaphragm

Double, or sandwiched, PTFE diaphragms are sealed at the 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. The space is filled with a small amount of barrier fluid (silicon oil is factory default
unless advised otherwise). This space is connected to an electrical switch that actuates in response to a
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.

Figure 53

Page 38 of 50
11.2.1 Reinstallation of Leak Detection Diaphragm

1. Ensure that the critical sealing areas of diaphragm assembly, reagent head, and
pump head are clean and free from debris.
2. Place a dab of grease on the back of the rear diaphragm. Note the rear diaphragm
has swirls on the face. Apply grease to the side that does not have swirls and set
in place on the pump head face as shown below.
3. Place the capillary tubes (2) into the holes located on the perimeter of the
diaphragm.

4. Once inserted, the capillary tubes should be orientated as shown below.

5. If possible, use compressed air to ensure the tubes are free of debris.
6. Push the capillary tubes down so that they are flush with the surface of the
diaphragm as shown below.

7. Turn the diaphragm over and place the O-Rings onto the capillary tubes. Push
them down until they meet the lip of the diaphragm.

Page 39 of 50
8. Place the diaphragm onto the reagent head; ensuring the capillary tubes are
seated into the pre-drilled holes in the reagent head.

9. Place the leak detection spacer onto the diaphragm. Ensure that the capillary
tubes are in the slots as shown.

10. Place two (2) clips onto the assembly to hold the spacer and diaphragm in place.

11. Place the two reagent head bolts into the reagent head.

12. Slide the reagent head forward onto the pump head and hand tighten the bolts until
the head of the bolt touches the reagent head.

Page 40 of 50
13. Once attached, remove the clips as shown

14. Install remaining head bolts. Torque the bolts per the recommended torque
settings.

Page 41 of 50
11.3 Priming of Leak Detection Diaphragm

IF THE 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 SILICON OIL. IF ANY OTHER

CUSTOMER SPECIFIED MEDIA IS USED, IT MUST BE COMPATIBLE WITH THE MATERIALS
OF CONSTRUCTION.

1. Complete re-assembly of the diaphragm, reagent

head, and external components. Ensure that the
reagent head and tie bar bolts are tightened
according to the appropriate torque specifications
(Appendix IV).
2. Remove the pressure gauge from the housing body
and replace with the straight tubing connection that
is supplied with the pump.
3. Install a short length of the appropriately sized tubing
to the fitting and connect a vacuum supply (either
handheld or electric vacuum pump).
4. Remove the pipe plug from the fill port and install the
90º fitting supplied with the pump.
5. Install a short length of the appropriately sized tubing to the fitting and place tube into the
container of the barrier fluid being used.
6. Apply a vacuum, the fluid should rise into the fill tube and enter through 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 for approximately 2 -3 minutes to
begin the process of drawing out excess fluid.
8. Remove the vacuum source and leave the tube on the outlet side (pressure gauge) open to
atmosphere.
9. 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.
10. Inspect the PTP valve to ensure the sealing O-ring is still in position and re-install the valve.
11. Adjust the pump to full (100%) stroke.
12. To fully balance and evacuate the leak detection system, the pump must now run at normal
discharge pressure for a period of about thirty minutes to one hour.
13. 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.
14. Apply power and start the pump. Hold down the PTP valve momentarily and observe the port
via sight glass. Continue to depress the PTP to release any entrapped air within the hydraulics
until you observe oil from the sight glass.
15. Slowly increase the discharge pressure to full operating pressure and continue to run the pump
for a period of one hour.
16. During this time, excess barrier fluid will be displaced from the system into the short length of
the 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.
17. After the one-hour startup period, remove the tubing and connection from the housing body and
reinstall the pressure gauge.
18. Reconnect the alarm to the external system if necessary.
19. The pump and pressure leak detection system are now properly prepared and ready for normal
service. During normal operation, the gauge should indicate zero (0) pressure.

Page 42 of 50
12. APPENDIX II
12.1 Piping Calculations

All reciprocating metering pumps require a net positive suction head (NPIPR). Refer to Table 1 for
the (NPIPR) required for PULSAPRO pump models. The NPIPR 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 to
prevent cavitation of the process fluid within the reagent head. The NPIPR is one of the
requirements necessary to assure metering accuracy.
NPIPR PULSAPRO 7440
English (psi) 3
Metric (bar) 0.21

Table 1

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

Equation # 1 – For fluid viscosity below 50 centipoises

Equation # 2 – For fluid viscosity above 50 centipoises

Refer to Section 12.3 Nomenclature, for the definitions of variables used in the equations above; follow the
units shown in Table 3B for the constants listed to be used correctly.

IF PIPING SIZES VARY THROUGHOUT THE SUCTION LINE, DIFFERENT ADDITIVE VALUES MAY BE
USED FOR 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 and minimum suction head
(msh), be maintained at the pump inlet throughout the pumping cycle to ensure a stable hydraulic system and
proper pump operation. The sum of the NPSHa and the vapor pressure (pv) must be greater than the values
shown in table 2.

MSP PULSAPRO 7440

English, (psia) 5.0
Metric, (bar(a)) 0.35

Table 2 - Minimum values for the sum of NPIPA and vapor pressure. (MSP)

Page 43 of 50
12.2 System Back Pressure
The system back pressure must exceed the suction pressure by at least five (5) psi (0.35bar) to prevent flow
through, however it must not exceed the rated discharge pressure of the pump. Flow through can be defined
as the process liquid flowing from a higher pressure to a lower pressure, which attributes to pump failure and
undesired flow at pump shutdown. If the system back pressure is not at least five (5) psi (0.35bar) greater
than the suction pressure, a back-pressure valve must be installed in the discharge piping. To calculate the
system’s total backpressure, use Equation 3 or 4.

Equation # 3 – For fluid viscosity below 50 centipoises

Equation # 4 – For fluid viscosity above 50 centipoises

Page 44 of 50
12.3 Nomenclature

Table 3A – Definitions of abbreviations used in NPIP Equations

NPIPR Net positive inlet pressure required, [psi, bar]

NPIPA Net positive inlet pressure 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]
C1, C2, Numeric constants used in Equations 1 - 4 [no units] see table 2 for
C3 values
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]

Table 3B – Unit sets and constant values for use in NPIP Equations

Variable Units Set

English Metric
NPIP 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

Page 45 of 50
13. APPENDIX III
13.1 Oil Specification

PULSALube Ultra 8GS Synthetic Gear Oil

PULSAlube Premium 7H Hydraulic Oil

Please visit our website at www.pulsafeeder.com to view and download any Safety Data
Sheet (SDS) under the Resources tab.

Page 46 of 50
 14. APPENDIX IV
14.1 Bolt Torque Recommendations

For Models with Metal Heads and PTFE Diaphragm:

REAGENT HEAD BOLTS TIEBAR BOLTS
# BOLTS AND TORQUE (2) # BOLTS AND TORQUE (2)
REAGENT HEAD THREAD SIZE FT-LBS N-M THREAD SIZE IN-LBS N-M
MW160078 (14) 5/8-11 75 101.7 (4) 1/4-20 45 5.1
MW160079 (12) 5/8-11 60 81.3 (4) 1/4-20 45 5.1
MW160080 (8) 3/8-16 30 40.1 (4) 5/16-18 50 5.6
MW160082 (6) 1/2-13 35 47.5 (4) 1/2-13 30 3.4
MW160083 (6) 3/4-10 95 128.8 (4) 1/2-13 30 3.4
MW160084 (14) 5/8-11 75 101.7 (4) 1/4-20 45 5.1
MW160085 (12) 5/8-11 60 81.3 (4) 1/4-20 45 5.1
MW160086 (8) 3/8-16 30 40.1 (4) 5/16-18 50 5.6
MW160088 (6) 1/2-13 35 47.5 (4) 1/2-13 30 3.4
MW160089 (6) 3/4-10 95 128.8 (4) 1/2-13 30 3.4
MW160098 (8) 3/8-16 30 40.1 (4) 5/16-18 50 5.6
MW160099 (6) 1/2-13 35 47.5 (4) 1/2-13 30 3.4
MW160100 (6) 3/4-10 95 128.8 (4) 1/2-13 30 3.4
MW160101 (8) 3/8-16 30 40.1 (4) 5/16-18 50 5.6
MW160102 (6) 1/2-13 35 47.5 (4) 1/2-13 30 3.4
MW160103 (6) 3/4-10 95 128.8 (4) 1/2-13 30 3.4

For Models with PTFE/PVC Heads and PTFE Diaphragm:

REAGENT HEAD BOLTS TIEBAR BOLTS
TORQUE (2) TORQUE (2)
# BOLTS AND # BOLTS AND
REAGENT HEAD THREAD SIZE FT-LBS N-M THREAD SIZE IN-LBS N-M
MW160090 (4) 5/8-11 50 67.8 (4) 1/4-20 45 5.1
MW160091 (4) 3/8-16 10 13.6 (4) 1/4-20 45 5.1
MW160092 (6) 1/2-13 15 20.3 (4) 5/16-18 50 5.6
MW160093 (6) 3/4-10 30 40.7 (4) 1/2-13 30 3.4
MW160094 (4) 5/8-11 50 67.8 (4) 1/4-20 45 5.1
MW160095 (4) 3/8-16 10 13.6 (4) 1/4-20 45 5.1
MW160096 (6) 1/2-13 15 20.3 (4) 5/16-18 50 5.6
MW160097 (6) 3/4-10 30 40.7 (4) 1/2-13 30 3.4

The torque valve is based on the reagent head part number which is stamped or cast on the
part itself. If assistance is needed in identifying your specific torque value for your pump
please contact the local representative or the Pulsafeeder Service Group at 585-292-8000 or
via email at [email protected]

Page 47 of 50
15. APPENDIX V – Accessories

15.1 PULSAtrol Pulsation Dampener

The PULSAtrol is a pneumatically charged diaphragm-type chamber that intermittently stores

energy. Used on the inlet, it will improve NPIPA (Net Positive Inlet Pressure available)
characteristics of the suction piping system. On the discharge line it will reduce peak pressures
and pulsating flow variations.

Installation
On both discharge and suction lines, it is desirable to mount the PULSAtrol as close to the pump
connection as possible. It can be mounted in any position: horizontally, vertically, or at any angle.
A shutoff valve should always be used between the piping system and PULSAtrol. If the discharge
line is open to atmospheric pressure, a backpressure valve should also be incorporated in the
system near the PULSAtrol to assure proper operation. Pulsation dampeners do require regular
maintenance and inspection. Charge pressure should be checked every 2 – 4 months and
renewed as needed. Temperature, pressure, and other variables will affect charge life and
diaphragm/bladder life.

Discharge Setup
The PULSAtrol may be pre-charged with air or nitrogen. When properly pre-charged the
diaphragm is positioned against the bottom liquid chamber. It is therefore necessary to drain all
liquid below the diaphragm and vent to atmospheric pressure when pre-charging.

Use the pre-charge pressure as determined from the PULSAtrol selection and sizing procedure.
This can vary from 50 to 80% of mean line pressure in accordance with fluctuation level selected.
The PULSAtrol is now ready for service and the diaphragm will move to a neutral position as liquid
enters the chamber.

Pre-Charge Procedure for Discharge Installation

1. Calculate the pre-charge pressure
a. Mean line pressure (psig) + Atmospheric Pressure = Absolute Pressure (psia)
b. Absolute Pressure (psia) x Pre-charge percentage (80% max) = Pressure Absolute
c. Pressure Absolute – Atmospheric Pressure = Pre-charge Pressure (psig)
2. Isolate PULSAtrol from line
3. Carefully drain off process fluid by open a drain valve
4. Apply pre-charge pressure (additional liquid may drain as diaphragm moves)
5. Close drain valve
6. Place PULSAtrol in stream

Suction Setup (Flooded Suction)

Charge the PULSAtrol with adequate pressure to overcome the static suction head. Start up the
pump. Depress the stem on the charge valve, but only during discharge strokes of the pump, until
the gauge indicates pressure pulses. The diaphragm has now centered allowing the PULSAtrol to
accumulate liquid while the pump is discharging. If too much air becomes released and the gauge
will not indicate pressure pulses, recharge the PULSAtrol and repeat the procedure.

Pre-Charge Procedure for Suction Installation

1. Isolate accumulator from line
2. Carefully drain off process fluid by opening a drain valve
3. Apply 5 – 10 psi pre-charge pressure (additional liquid may drain as diaphragm moves)
4. Close drain valve
5. Bleed off all pressure on the PULSAtrol
6. Open the valve to put PULSAtrol in stream
7. Push in on the stem of the charging valve during the discharge stroke of the pump and release
during the suction stroke
8. Continue this for about ten times and observe the compound gauge. As accumulator functions,
the needle will go from pressure to vacuum

Page 48 of 50
15.2 Back Pressure Valve
The Pulsafeeder diaphragm backpressure valve creates constant backpressure. A PTFE
diaphragm, offering maximum chemical protection and service life, seals the spring and bonnet
from process fluid. This diaphragm seals directly on a replaceable seat. Be sure to install with
fluid flow in direction of arrow on valve body. If arrow is missing from plastic valve body, install
with flow exiting out center hole of valve body.

15.3 Pressure Relief Valve

Pressure relief valves should be utilized in any system to protect the pump and other process
equipment and piping from potentially damaging or unsafe pressures. It is critical that the
pressure relief valve be mounted in the discharge piping system before any other devices that
can potentially block or impede flow, or it cannot perform its intended function. The pressure
relief valve must be set to a pressure high enough to prevent unwanted fluid relief during
normal process conditions. A setting that is approximately 10-20% above normal operating
pressures is generally enough. The valve must also be set below the maximum pressure
capability of the lowest rated device in the system. For example, if a PulsaPro pump is rated
with a maximum pressure capability of 150 psi (approx. 10bar) but the piping within the system
is rated only to a maximum of 100 psi (approx. 7 bar) then the pressure relief valve must be set
to a value lower than 100 psi.

Page 49 of 50
Pulsafeeder, Inc.
2883 Brighton Henrietta Town Line Road
Rochester NY 14623
+1 (585) 292-8000
www.pulsafeeder.com

Page 50 of 50