Honeywell DC4 - Manual

2 2.1 Reagent Head Assembly The typical reagent head assembly consists of reagent head, diaphragm, and suction and discharge cartridge check valves. This assembly is the only part of the pump to contact the process liquid; consequently, maintenance is critical to pump performance. 2.2 Control Assemb...

3 3. Equipment Inspection Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damage must be reported immediately to the carrier and your authorized representative or distributor of OMNI ® pumps. 4. Storage 4.1.1 Short Term Storage of your OMN...

4 5.2 Piping System 1. All systems should include a pressure relief valve on the discharge side, to protect piping and process equipment, including the pump, from excess process pressures . An external relief valve is required! There should be no devices capable of restricting flow (such as a valve)...

5 5.3 Suction Pressure Requirements Although OMNI ® metering pumps have some suction lift capability, a flooded suction (i.e., suction pressure higher than atmospheric pressure) is preferable whenever possible. The pump should be located as close as possible to the suction side reservoir or fluid su...

6 Figure 4, stroke adjustment 6. Equipment Startup 6.1 Fastener Inspection All pump fasteners should be checked prior to pump operation, and occasionally during use. This would include reagent head mounting bolts, motor mounting bolts, and the hardware that secures the pump to its foundation. Most h...

7 6.3 Priming the Reagent Head 1. When handling process liquids, follow all applicable personal and facility safety guidelines. 2. Ensure that the pump is ready for operation and that all process connections are secure. 3. Open the suction and discharge line shutoff valves. 4. If the piping system d...

8 6.4 Calibration Figure 6, sample flow calibration curve All metering pumps must be calibrated to accurately specify stroke length settings for required flow rates. A typical calibration chart is shown above. Although output is linear with respect to stroke length setting, an increase in discharge ...

9 7. Maintenance B EFORE 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 NEU...

11 7.2.1 Diaphragm Removal & Reinstallation 1. Adjust the stroke setting to 50% and disconnect the power source to the drive motor. 2. Relieve all pressure from the piping system. 3. Close the inlet and outlet shutoff valves. 4. Place a pan underneath the pump head adaptor to catch any liquid le...

12 7.3 Check Valves 7.3.1 General Description Most fluid metering problems are related to check valves. Problems usually stem from solids accumulation between valve and seat, corrosion of seating surfaces, erosion, or physical damage due to wear or the presence of foreign objects. The valve incorpor...

14 7.3.2 Check Valve Removal & Reinstallation, Cartridge type Valving that is of the cartridge design is intended to be replaced as an assembly. 15. Disconnect the power source to the drive motor. 16. Relieve all pressure from the piping system. 17. Take all precautions necessary to prevent cont...

16 7.4 Motor Removal & Reinstallation 1. Disconnect the power source to the drive motor. 2. Disconnect the motor wiring from the motor. 3. Remove the four bolts retaining the motor to the motor adaptor. The motor shaft fits into a bore on the pump input shaft. 4. Slide the motor shaft out of the...

18 7.6 Gearset Replacement 1. Apply PULSA lube grease # NP980006-000 to both sides of the thrust washer and install onto the eccentric shaft. On the DC4, 5, and 6 models, the washer fits into a shallow counter-bore. 2. Assemble Worm Gear (Item 8) and key (Item 10) to the eccentric shaft. Do not tigh...

19 8. Replacement Parts 8.1 KOPkit Program OMNI ® KOPkits contain all replacement parts normally used in a preventative maintenance program. ( PULSAlube grease is also available separately for preventative maintenance programs. Refer to Section 6 – Equipment Startup ). There is a specific KOPkit for...

20 8.3 KOPkit numbers by model: Pump Model Wetted Material Connection Type KOPkit number D C 2 P V D F N P T N L K 0 2 0 F P D C 3 o r D C 4 P V D F N P T N L K 0 4 0 F P D C 3 o r D C 4 P V D F I S O 7 - 1 N L K 0 4 0 F B D C 5 o r D C 6 P V D F N P T N L K 0 5 0 F P D C 5 o r D C 6 P V D F I S O 7...

21 9. Model Number Identification Position Sample Specifies Options 1 and 2 DC DC = OMNI model pump 3 and 4 3B Size/Flow 2 / 3 / 4 / 5 / 6 – diaphragm diameter A / B / C / D – stroking rate See sales literature for flow/pressure ratings 5 X Motor frame 1 – ½ Hp, 1 pH 115/230V, 71 frame and size 2 – ...

22 10. Wet End Materials Reference Wet End Configuration Model Connection Head Guide Sealing O-rings Balls Seats Seat O- ring DC2 1/4" NPT DC3 DC4 1/2" NPT or ISO 7-1 DC5 DC6 1" NPT or ISO 7-1 PTFE PVDF n/a PVDF (Kynar ® ) DC7 1 1/2" NPT & ANSI Flange and 1 1/2" DIN40 Flange ...

23 11. Troubleshooting Difficulty Probable Cause Remedy Faulty power source. Check power source. Blown fuse, circuit breaker. Replace - eliminate overload. Broken wire. Locate and repair. Wired improperly. Check diagram. Pump does not start Process piping blockage. Open valves, clear other obstructi...

25 12. Piping Accessories Pressure Relief Valves Pressure relief valves are designed to protect chemical feed systems from damage that may be caused by defective equipment or a blockage in the discharge line. These valves function to limit the pressure downstream of the pump. Field adjust the pressu...

26 13. Dimensional Drawing Letters reference dimensional table on next page

28 14. Parts Diagrams and Parts Lists 14.1 Parts diagram, DC2 and 3