®
Installation, Operation, &
Maintenance Instruction
Models DC2, 3, 4, 5, and 6
Bulletin #: IOM-OM-1104- E
STANDARD PUMP OPERATIONS
27101 Airport Road
Punta Gorda, FL
(941) 575-3800
33982
Fax (941) 575-4085
Manufacturers of Quality Pumps,
Controls, and Systems
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Table of Contents
1. INTRODUCTION .....................................................................................................................................1
2. PRINCIPLES
OF
OPERATION ..................................................................................................................1
2.1
2.2
2.3
Reagent Head Assembly ........................................................................................................2
Control Assembly....................................................................................................................2
Gear Ratio Assembly ..............................................................................................................2
3. EQUIPMENT INSPECTION .......................................................................................................................3
4. STORAGE ……………………………………………………………………………………………………...3
5. INSTALLATION ......................................................................................................................................3
5.1
5.2
5.3
5.4
Location....................................................................................................................................3
Piping System..........................................................................................................................4
Suction Pressure Requirements............................................................................................5
Discharge Pressure Requirements........................................................................................5
6. EQUIPMENT STARTUP ...........................................................................................................................6
6.1
6.2
6.3
6.4
Fastener Inspection.................................................................................................................6
Output Adjustment..................................................................................................................6
Priming the Reagent Head......................................................................................................7
Calibration................................................................................................................................8
7. MAINTENANCE......................................................................................................................................9
7.1
7.2
7.3
7.4
7.5
7.6
Lubrication...............................................................................................................................9
Wet End Removal, Inspection, & Reinstallation...................................................................10
Check Valves ...........................................................................................................................12
Motor Removal & Reinstallation ............................................................................................16
Gearset Removal .....................................................................................................................16
Gearset Replacement..............................................................................................................18
8. REPLACEMENT PARTS ..........................................................................................................................19
8.1
8.2
KOPkit Program.......................................................................................................................19
Ordering KOPkits or Parts......................................................................................................19
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8.3
KOPkit numbers by model: ....................................................................................................20
9. MODEL NUMBER IDENTIFICATION...........................................................................................................21
10. WET END MATERIALS REFERENCE........................................................................................................22
11. TROUBLESHOOTING..............................................................................................................................23
12. PIPING ACCESSORIES ...........................................................................................................................25
13. DIMENSIONAL DRAWING........................................................................................................................26
14. PARTS DIAGRAMS AND PARTS LISTS.....................................................................................................28
14.1 Parts diagram, DC2 and 3.......................................................................................................28
14.2 Bill of Materials, DC2...............................................................................................................29
14.3 Bill of Materials, DC3...............................................................................................................31
14.4 Parts Diagram, DC4, 5, and 6..................................................................................................34
14.5 Bill of Materials, DC4...............................................................................................................35
14.6 Bill of Materials, DC5...............................................................................................................37
14.7 Bill of Materials, DC6...............................................................................................................39
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1. Introduction
The OMNI® metering pump is positive displacement, mechanically operated reciprocating diaphragm
pump. Each pump consists of a power end and a process end separated by a PTFE faced diaphragm.
Individual pumps will vary in appearance due to various liquid ends and accessories; however, the basic
principles of operation remain the same.
2. Principles Of Operation
Figure 1, reagent head operation
A diaphragm reciprocates at a preset stroke length, displacing an exact volume of process fluid.
Diaphragm retraction causes the product to enter through the suction check valve. Diaphragm advance
causes the discharge of an equal amount of the product through the discharge check valve.
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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 Assembly
The OMNI® pump incorporates a lost motion style of stroke length adjustment to limit diaphragm
travel during the suction portion of each stroke. The stroke length setting is indicated by a (0% –
100%) scale located on the stroke adjustment assembly.
Stroke length is changed by loosening the locking screw and turning the hand knob. This turns a
mechanism, which limits rearward travel of the diaphragm. Refer to Section 6.2 for further
information.
For automatic flow rate control, users can consider the Pulsafeeder MPC speed based control system,
please contact your local Pulsafeeder dealer or representative for more information.
2.3 Gear Ratio Assembly
OMNI® pumps are driven by an electric motor mounted on the motor adaptor input flange. The
motor drives a set of worm gears that convert rotational speed into torque. They, in turn, power the
eccentric shaft assembly that converts rotary motion into reciprocating motion.
Figure 2, isometric view
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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 OMNI® pump for up to 12 months is considered short-term. The recommended
short-term storage procedures are:
a) Store the pump indoors at room temperature in a dry environment.
b) If required by the operating environment, take precautions to prevent entry of water or humid air
into the eccentric enclosure.
c) Prior to startup, perform a complete inspection and then start up in accordance with instructions
in this manual.
4.1.2
Long Term
Every twelve months, in addition to the above short-term procedures, power up the motor and operate
the pump for a minimum of one hour. It is not necessary to have liquid in the reagent head during
this operation, but the suction and discharge ports must be open to atmosphere.
After twelve months of storage, Pulsafeeder’s warranty cannot cover items that are subject to
deterioration with age, such as seals, gaskets, and diaphragms. If the pump has been in storage longer
than 12 months it is recommended that these items be inspected and replaced as necessary prior to
startup. Materials and labor to replace this class of item under this circumstance are the purchaser’s
responsibility. Consult your local Pulsafeeder representative for assistance in obtaining parts and
service for your pump.
5. Installation
5.1 Location
When selecting an installation site or designing a chemical feed system, consideration should be given
to access for routine maintenance.
OMNI® pumps are designed to operate indoors and outdoors, but it is desirable to provide a hood or
covering for outdoor service. External heating is required if ambient temperatures below 0° C (32° F)
are anticipated, especially if pumps are not in continuous duty. Check with the factory if concerned
with the suitability of the operating environment.
The pump must be rigidly bolted to a solid and flat foundation to minimize vibration, which can loosen
connections. When the pump is bolted down, care must be taken to avoid distorting the base and
affecting alignments. The pump must be level within 5°. This will assure that the check valves can
operate properly.
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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) located between
the pump and the relief device.
2. Shutoff valves and unions (or flanges) on suction and discharge piping are recommended. This
permits check valve inspection without draining long runs of piping, making periodic maintenance
and inspection easier.
Shutoff valves should be of the same size as connecting pipe. Ball valves are preferred since they
offer minimum flow restriction.
3. Suction systems should include an inlet strainer, if appropriate for the product being pumped. Pump
check valves are susceptible to dirt and other solid contaminants, and any accumulation can cause
malfunction. The strainer should be located between the suction shutoff valve and the pump suction
valve. It must be sized to accommodate the flow rate and the anticipated level of contamination. A
100 mesh screen size is generally recommended.
4. Vacuum/pressure gauges in the suction and discharge lines are helpful in order to check system
operation. Gauges should be fitted with protective shutoff valves for isolation while not in use.
5. Piping weight must not be supported by valve housings or other portions of the reagent head, as the
resulting stresses can cause leaks. If appropriate, provide for thermal expansion and contraction so
that no excess force or moments are applied to the pump.
6. When making process connections, ensure that the check valve assemblies do not rotate as the
threaded connections are secured. It is critical, especially with plastic construction, that the check
valves not be too tight into the reagent head. The threaded connection between the check valve
assembly and the regent head uses on o-ring seal and does not require sealing tape or any other
sealant.
7. In piping assembly, use a sealing compound chemically compatible with the process material. Users
of sealing tape are cautioned to ensure that the entering pipe thread ends are not taped, and that tape is
removed from previously-used threads to the maximum practical extent prior to re-use. Both new and
existing piping should be cleaned, preferably by flushing with a clean liquid (compatible with process
material) and blown out with air, prior to connection to the pump. Debris from the piping system that
prevents proper check valve operation is a common startup issue.
8. Note that for pumps which utilize cartridge-type check valve assemblies, no thread tape or sealant is
required on the threads which secure the cartridge assembly to the pump reagent head. This area is
sealed with o-rings integral to the cartridge. Sealant on these threads can actually degrade sealing
capability.
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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 supply source.
For fluid with a vapor pressure of 5 psia or less (at operating temperature) the wet suction lift capability
is approximately ten (10) feet. If this requirement is not met, the pump will not provide reliable,
accurate flow. In suction lift conditions, the use of a foot valve is recommended at the lowest point of
the pickup tube or pipe. Pumps under suction lift conditions may require some liquid priming before
they will operate reliably.
5.4 Discharge Pressure Requirements
All OMNI® metering pumps are designed for continuous service at the rated discharge pressure. If
system suction pressure exceeds discharge pressure (a condition sometimes described as “pumping
downhill”), flow would be generated (siphoning) in addition to that caused by the pump. This results in
a reduction in accuracy and loss of control over the metering process. To prevent this flow-through
condition, the discharge pressure must exceed suction pressure by at least 0.35 Bar (5 psi). This can be
achieved where necessary by the installation of a backpressure valve in the discharge line. Conditions
where the actual discharge pressure exceeds the pump’s rating are to be avoided as they will cause
damage to the pump components.
Figure 3, sample system configuration
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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 hardware can be checked simply to ensure it is not loose. However, utilize
the following values when checking reagent head bolt torque:
Reagent Head Bolt Torque
Model
DC2
Material
# Bolts and size
(4) M6 * 1.0
(4) M6 * 1.0
(4) M8 * 1.25
(4) M8 * 1.25
(6) M8 * 1.25
(6) M8 * 1.25
(6) M8 * 1.25
(6) M8 * 1.25
N-m
3.39
3.39
6.77
6.77
8.46
8.46
8.46
8.46
In. - Lbs
30
Plastic
Metal
Plastic
Metal
Plastic
Metal
Plastic
Metal
30
60
DC3 and 4
DC5
60
75
75
75
DC6
75
6.2 Output Adjustment
All OMNI® pumps have a hand wheel for manual stroke adjustment. The hand wheel can be adjusted to
any point from 0 to 100%. This value represents the stroke length setting and therefore the flow rate of
the pump relative to its maximum output.
1. Turn the red lock screw counterclockwise to release the
stroke lock. Making adjustments without releasing the
lock may damage the mechanism.
2. Adjust the hand wheel to the desired output.
a) The stroke barrel indicates stroke length in 20%
increments.
b) The hand wheel indicates stroke length in 1%
increments.
For example, to set the pump to 75% stroke length,
(starting from the factory default setting of 0%) turn the
hand wheel counter clockwise until he 60% indicator is
visible on the stroke barrel.
Continue the counter clockwise rotation until the hand
wheel indicator is at 15. Refer to Figure 4.
3. Turn the lock screw clockwise to lock the stroke adjustment
into position.
Figure 4, stroke adjustment
Adjustments can be made while the pump is at rest or
operating, although adjustments are easier to make
while the pump is in operation.
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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 design and the storage tank are such that the product flows due to gravity through
the pump, reduce the discharge pressure and the system will self prime when the pump is started. In
the event the discharge line contains a significant amount of pressurized air or other gas, it may be
necessary to lower the discharge pressure to enable the pump to self-prime.
5. If the installation involves a suction lift, it may be necessary to prime the reagent head and suction
line. Operate the pump as in step 4 above, many times the pump will be capable of self priming. If it
does not begin to pump, remove the discharge valve assembly. Carefully fill the reagent head
through the discharge valve port with process (or compatible) liquid, and then reinstall the check
valve.
6. Start the pump at the zero stroke length setting and slowly increase the setting to 100 to prime the
pump. If this does not work, it will be necessary to fill the suction line.
7. 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 suction valve, then remove the discharge valve assembly and fill
the reagent head as described in Step (3) above. The pump will now self-prime when started up per
step (4) above. Use appropriate precautions if handling process fluid. Ensure that any other fluid
used for priming is compatible with the product that will be pumped.
Figure 5, process flow
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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 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 discharge pressure is based on the displacement of the
diaphragm, stroke length and the stroking rate of the pump. With increasing discharge pressure there is
a corresponding decrease in output flow. Pumps are rated for a certain flow at a rated pressure (check
nameplate). Whenever possible, calibration should be performed under actual process conditions (i.e.,
the same or a similar process liquid at system operating pressure).
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.
All users are encouraged to test the flow rate of their pump once installed in their system, to
ensure best accuracy and reliable operation.
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7. Maintenance
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.
WEAR PROTECTIVE CLOTHING AND EQUIPMENT AS APPROPRIATE.
Accurate records from the early stages of pump operation will indicate the type and levels of required
maintenance. A preventative maintenance program based on such records will minimize operational
problems. It is not possible to forecast the lives of wetted parts such as diaphragms and check valves.
Since corrosion rates and operational conditions affect functional material life, each metering pump must
be considered according to its particular service conditions.
The OMNI® KOPkit will contain all replacement parts normally used in a preventative maintenance
program. It is recommended that KOPkits and PULSAlube grease be kept available at all times.
7.1 Lubrication
OMNI® pumps are supplied completely lubricated from the factory. For optimum pump performance
under normal conditions, gear grease should be redistributed every 1500 hours. For severe service in
extreme temperatures or very dirty environments, this interval may be shorter.
1. Disconnect the power source to the drive motor, and relieve all pressure from the piping system.
2. Remove the side cover from the pump. Refer to Figure 7.
3. Redistribute grease onto gear and worm teeth. On DC2 and 3 pumps, force grease into the hole in the
end of the gear shaft using a screwdriver or putty knife. Primary lubrication points are called out in
Figure 7, below.
4. Replace the side gasket and cover.
Figure 7, gearset lubrication points
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7.2 Wet End Removal, Inspection, & Reinstallation
IF THE DIAPHRAGM HAS FAILED, PROCESS FLUID MAY HAVE CONTAMINATED THE PUMP
ECCENTRIC HOUSING (ALTHOUGH NORMALLY, ANY PROCESS FLUID BEHIND A FAILED
DIAPHRAGM WOULD PASS THROUGH THE BOTTOM DRAIN HOLE). HANDLE WITH APPROPRIATE
CARE.
Figure 8, wet end components
OMNI® diaphragms do not have a specific cycle life; however, the accumulation of foreign material
or debris sufficient to deform the diaphragm can eventually cause failure. Failure can also occur as a
result of system over pressure or chemical attack. Periodic diaphragm inspection and replacement are
recommended. Each user should perform regular inspections to determine the replacement interval
that is appropriate to their system conditions.
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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.
Take all precautions described under the WARNING on page 9, Section 7 to prevent environmental
damage and exposure of personnel to hazardous materials.
3. Close the inlet and outlet shutoff valves.
4. Place a pan underneath the pump head adaptor to catch any liquid leakage.
5. Disconnect piping to the reagent head and drain any process liquid, following material safety
precautions described.
6. Remove all but one top reagent head bolt. Product will leak out between the pump head adaptor and
reagent head as the bolts are loosened.
7. Tilt the head and pour out any liquids retained by the check valves into a suitable container,
continuing to follow safety precautions as appropriate.
8. Remove the final bolt and rinse or clean the reagent head with an appropriate material.
9. Remove the diaphragm by turning it counter-clockwise.
10. Inspect the diaphragm. The diaphragm must be replaced if it is cracked, separated, or obviously
damaged.
11. Install the diaphragm.
a) Ensure that the critical sealing areas of diaphragm, reagent head, and pump head are clean and
free of debris.
b) Lubricate the elastomer side of the diaphragm liberally, where it is in contact against the pump
head and deflection plate. Use a silicone grease or silicone-based o-ring lubricant.
12. Thread the diaphragm (clockwise) fully onto the shaft.
When reinstalling a used diaphragm it is not necessary to maintain the previous orientation relative to
the reagent head or pump head hole pattern.
13. Install the reagent head bolts and tighten in an alternating pattern to ensure an even seating force.
Torque to the values recommended in Section 6.1.
14. Re-prime the pump following the procedure outlined in Section 6.3.
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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 incorporates a ball, guide, and seat. Flow in the unchecked direction lifts the ball off the
seat, allowing liquid to pass through the guide. Reverse flow forces the ball down, sealing it against
the sharp edge of the seat. The guide permits the ball to rotate but restricts vertical and lateral
movement in order to minimize “slip” or reverse flow. Ball rotation prolongs life by distributing
wear over the entire surface of the ball. Since ball return is by gravity, the valve must be in the
vertical position in order to function properly. Parts are sealed by “O”-rings.
All OMNI models with the exception of the DC5 and 6 in metal construction utilize a convenient
cartridge-type check valve. All check components are pre-assembled and the cartridge should be
replaced as a unit. When replacing, note that valves are marked with the flow direction, as the suction
and discharge configurations are different.
OMNI DC5 and 6 models supplied with metal (316ss) reagent head construction utilize a multi-part
check valve assembly, secured to the reagent head with a tie-bar clamping arrangement. These utilize
the same components (seat, ball, and guide) and operate in the same manner as the cartridge type.
Check Valve
Discharge Position
Check Valve
Suction Position
Figure 9, check valves DC2
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Check Valve
Suction Position
Check Valve
Discharge Position
Figure 10, check valves, DC3 and DC 4
Check Valve
Suction Position
Check Valve
Discharge Position
Figure 11, check valves, DC5 and DC6 plastic construction
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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 contamination to the environment and personnel exposure
to hazardous materials.
18. Close the inlet and outlet shutoff valves.
19. Disconnect the suction piping at the installed union near the suction port.
20. Loosen and remove the suction valve cartridge slowly to drain any liquid from the reagent head.
21. Disconnect the discharge piping at the installed union near the discharge port.
22. Loosen and remove the discharge valve cartridge slowly to drain any trapped liquid.
23. Reinstall both new valve assemblies, taking care to ensure that they are in the correct ports.
Lettering on the side of each valve should be right side up when assembled to the pump. Each valve
assembly should also have an arrow, which should indicate direction of flow (upwards). Do not coat
the threads of the cartridge vale with a pipe sealant. Each valve cartridge should be tightened only
until the o-ring seal makes good contact with the reagent head surface. Over-tightening will cause
damage and lead to leaks
24. Reinstall both suction and discharge piping. Secure the cartridge while making your external
connections to prevent rotating the cartridge and over-tightening it into the pump.
7.3.3
Check Valve Removal & Reinstallation, Tie-bar type
1. Disconnect the power source to the drive motor.
2. Relieve all pressure from the piping system.
3. Take all precautions necessary to prevent contamination to the environment and personnel exposure
to hazardous materials.
4. Close the inlet and outlet shutoff valves.
5. Loosen the suction valve tie-bar bolts (4) and spring the suction piping slightly away from the head,
allowing liquid to drain. It may be necessary to loosen a union or flange.
6. Remove the suction check valve assembly by sliding it towards you, holding it together as a unit.
Note carefully the position of the component parts, to assist in re-assembly.
7. Loosen the discharge valve tie-bar bolts (4) and spring the discharge piping slightly away from the
head, allowing liquid to drain. It may be necessary to loosen a union or flange.
8. Remove the discharge check valve assembly by sliding it towards you, holding it together as a unit.
Note carefully the position of the component parts, to assist in re-assembly.
9. Disassemble both valves and check components for wear or damage. The seats should have a sharp
edge and be free from dents or nicks. Hold a ball firmly against the seat in front of a bright light and
inspect for fit, observation of light between the ball and seat is cause for replacement.
10. Reassemble both valves using new parts as required. Sealing o-rings should always be replaced.
11. Replace both valve assemblies onto the pump, taking care to ensure they are oriented correctly, with
the balls above the seats, and the seats oriented with the sharp edge up and the chamfered edge down.
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Inserting the check valve assmbly into the pump in the wrong directiom, or having the check seat
upside down, will prevent proper seals at the o-rings, decrease pump performance, and can cause
damage to the diaphragm.
12. Carefully make sure that the check assemblies are in proper position, and tighten the four tie-bar
bolts, using a star pattern, to a torque of 6 Ft-lbs (8 N-m).
13. Retighten any unions, flanges, or other process connections that may have been loosened previously.
Figure 12, DC5 and 6 check valves, metal construction
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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 pump input shaft.
Be careful not to lift the pump input shaft up out of the pump.
5. Apply a lubricant such as Loctite™ Silver Grade® Anti-seize paste
(or similar) to the motor shaft and key before reassembling..
6. Reinstall the motor by sliding the motor shaft into the pump input
shaft.
7. Insert and tighten the four bolts removed in step 3.
8. Reconnect the motor wiring to the motor.
9. Connect power to the drive motor.
Figure 13, motor mounting
Motor rotation must be wired for CW rotation, as viewed from the top of the motor, as noted by the
arrow on the top of the pump housing.
7.5 Gearset Removal
Gearset diagram is on following page
1. Disconnect power source and wiring from the motor.
2. Set stroke adjustment to zero.
3. Remove motor from the pump (refer to Section 7.4).
4. Remove the four socket head screws (Item 1) that attach the motor adaptor (Item 2) to the
pump housing and remove the adaptor.
5. Loosen and remove the Hex Head Bolts (Item 5), and remove the pump side cover (Item 6)
and gasket (Item 7).
6. Remove the Worm Shaft Assembly (item 4) by carefully pulling it straight up out of the
pump housing. On DC2 and DC3 models, be careful not to lose the lower thrust bearing
and washers (items 11 and 12).
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Figure 14, gearset components
7. Loosen the set screw (Item 9) on the worm gear (Item 8) and remove it along with its
shaft key (Item 10).
If you have the DC2 or 3 models go to step 8. If you have the DC4, 5, or 6 models go to
step 9.
8. Remove the Thrust Washers and Bearing
(Item 11 & 12) from the housing.
If the Thrust Washers show signs of
excessive wear or scoring, replace them
during re-assembly.
9. Clean grease from the gear cavity.
10. Examine the Worm Shaft Grease Seal
(Item 3) in the pump housing on the DC
2 and 3 model or in the motor adaptor on
the DC 4, 5, and 6 models.
If the Grease Seal shows excessive wear
or damage, replace it during re-assembly.
Figure 15, worm shaft
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7.6 Gearset Replacement
1. Apply PULSAlube 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 tighten the setscrew
yet.
3. Thread the M6-1.0 screw into the threaded hole in the end of the eccentric shaft. Tighten the Worm
Gear set screw while simultaneously pulling on the screw in the end of the shaft in order to eliminate
any endplay in the eccentric shaft.
4. Rotate the Worm Gear
It should turn easily with no perceptible endplay.
5. Remove the screw that was inserted in the shaft in step 3.
6. Assemble and install the worm shaft assembly
a) If you have a DC2 or 3 model:
Apply PULSAlube grease # NP980006-000 to the two lips of the worm shaft seal.
Apply PULSAlube grease # NP980006-000 to the small end of the worm shaft.
Carefully insert the worm shaft into the pump housing.
Assemble the lower thrust bearing (with a washer on each side) into the shallow counter bore in
the bottom of the housing cavity.
Fit the shaft into the bearing in the housing.
b) If you have a DC4, 5, or 6 model:
Apply PULSAlube grease # NP980006-000 to the small end of the worm shaft.
Insert the worm shaft into the pump housing, fitting the end of the shaft into the bearing in the
housing.
Apply PULSAlube grease # NP980006-000 to the two lips of the seal.
Assemble the adapter to the pump housing while carefully slipping the seal over the worm shaft.
7. Fill the gear cavity completely with PULSAlube grease # NP980006-000 and reassemble the pump
side cover and gasket.
8. Reassemble the motor to the pump. Verify that motor rotation is clockwise when viewed from the
top.
9. Reinstall the pump in the system and restart the pump (refer to Section 6 – Startup).
18
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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 every OMNI® pump model. Each
KOPkit is vacuum-packed for extended storage. All OMNI® pumps have the KOPkit number identified
on the pump nameplate and Pulsafeeder order documents. KOPkits can also be selected from the
technical data sheet shipped with the pump or by a Pulsafeeder representative. A list of the OMNI
KOPkit numbers can also be found on the next page. The kit is identified by the model number of the
pump, the wetted end material, and the process connection thread type. For models with tie-bar type
check valves, the appropriate components (check valve balls, seats, and o-rings) are supplied instead of
the cartridges pictured.
Figure 16, KOPkit parts
8.2 Ordering KOPkits or Parts
When ordering replacement parts always specify:
•
•
Pump model and serial number (from pump nameplate), e.g., Model No. (DC-2) with Serial No.
F406365-3.
Part number and description from the OMNI® parts list. Include the three-character suffix. (Note:
OMNI part numbers begin either with the letters NP, or the letter W, e.g., NP170001-THY or
W210221-001.)
19
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8.3 KOPkit numbers by model:
Pump Model
DC2
Wetted Material
PVDF
Connection Type
NPT
KOPkit number
NLK020FP
NLK040FP
NLK040FB
NLK050FP
NLK050FB
NLK070FX
DC3 or DC4
DC3 or DC4
DC5 or DC6
DC5 or DC6
DC7
PVDF
NPT
PVDF
ISO 7-1
NPT
PVDF
PVDF
ISO 7-1
n/a
PVDF
DC5 or DC6
DC5 or DC6
DC7
Polypropylene
Polypropylene
Polypropylene
NPT
ISO 7-1
n/a
NLK050PP
NLK050PB
NLK070PX
DC2
316
316
316
316
316
NPT
NPT
NLK020AP
NLK040AP
NLK040AB
NLK050AP
NLK050AB
DC3 or DC4
DC3 or DC4
DC5 or DC6
DC5 or DC6
ISO 7-1
NPT
ISO 7-1
DC6
DC6
HSO(2)
HSO(2)
NPT
NLK060HX(1 )
NLK060HX(1 )
ISO 7-1
NOTES:
(1) “HSO” construction refers to the recommended materials for handling Sulfuric Acid at high
concentrations (above 95%). This configuration consists of 316ss for the reagent head, the
valve guide, and the process connection. Alloy-20 is supplied for the check valve seats,
and Hastelloy-C is supplied for the check valve balls. HS0 configuration is supplied only
as a KOPkit and not as an original pump configuration.
(2) PVC wet end material has been discontinued, use PVDF (Kynar®) parts as a direct
replacement for these pumps.
(3) DC7 model is covered in a separate publication
20
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9. Model Number Identification
Position
1 and 2
3 and 4
Sample
DC
Specifies
Options
DC = OMNI model pump
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
and size
1 – ½ Hp, 1 pH 115/230V, 71 frame
2 – ½ Hp, 1 pH, 115/230V, 56 frame
3 – ½ Hp, 3 pH, 230/380V, 71 frame
4 – ½ Hp, 3 pH, 230/380/460V, 56 frame
5 – MPC control with 56 frame motor
6 – MPC control, NO motor, 56 frame
7 – MPC control with 71 frame motor
8 – MPC control, NO motor, 71 frame
X – no motor, set up for 56 frame
Y – no motor, set up for 71 frame
6
7
F
P
Wetted materials F – PVDF, PTFE o-rings, ceramic ball
E – PVC (note - obsolete)
A – 316ss, PTFE o-rings
P - Polypropylene, DC 5 and 6 only
Connections
P – NPT
B – ISO 7-1 (not available on DC2)
8
9
- *
position 8 is a dash
Option *
Option *
MPC control
Input voltage
M – indicates supplied with MPC controller
10
1 – 115V 60 Hz
2 – 230V 60 Hz
3 – 110V 50 Hz
4 – 220V 50 Hz
11
12
Option *
Option *
Remote cable X – standard length remote at pump
C – extended cable length
Language
E – English
F - French
S - Spanish
G - German
* - If no MPC controller is ordered, the model string ends at position 7. Positions 8 through 12 are
not entered for a pump without the MPC.
21
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10. Wet End Materials Reference
Wet End
Configuration
Sealing
O-rings
Seat O-
ring
Model
Connection
1/4" NPT
Head
Guide
Balls
Seats
DC2
DC3
DC4
DC5
DC6
1/2" NPT or ISO 7-1
PTFE
Viton®
PVDF
n/a
PVDF
PVDF
PVDF
Ceramic
1" NPT or ISO 7-1
(Kynar®)
1 1/2" NPT & ANSI
Flange and
1 1/2" DIN40 Flange
PVDF (o-
ring seat)
Viton®
DC7
(1)
DC2
DC3
DC4
DC5
DC6
n/a
n/a
PP
(Polypropylene)
1" NPT or
I
ISO 7-1
PTFE
Viton
PP
n/a
PP
SS
PP
SS
Ceramic
PP (o-ring
seat)
Viton®
1 1/2" NPT & ANSI
Flange and
1 1/2" DIN40 Flange
DC7
(1)
1/4" NPT
DC2
DC3
DC4
DC5
DC6
DC7
Ceramic
SS
PTFE
1/2" NPT or ISO 7-1
PTFE
n/a
SS
(316)
SS
n/a
1" NPT or ISO 7-1
n/a
(1) DC7 check valve seats incorporate an o-ring seal
DC7 model is covered in a separate publication
n/a = materials not available in this pump size or component not used on this model
22
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11. Troubleshooting
Difficulty
Probable Cause
Remedy
Check power source.
Pump does not start
Faulty power source.
Blown fuse, circuit breaker.
Broken wire.
Replace - eliminate overload.
Locate and repair.
Check diagram.
Wired improperly.
Process piping blockage.
Motor not running.
Open valves, clear other obstructions.
No delivery
Check power source. Check wiring
diagram (see above).
Fill tank.
Supply tank empty.
Lines clogged.
Closed line valves.
Clean and flush.
Open valves.
Ball check valves held open with solids. Clean – inspect, flush with clear fluid.
Vapor lock, cavitation.
Prime lost.
Strainer clogged.
Increase suction pressure.
Re-prime, check for leak.
Remove and clean. Replace screen if
necessary.
Stroke adjustment set at zero.
Motor speed too low
Increase stroke length setting.
Low delivery
Check voltages, frequency, wiring, and
terminal connections. Check nameplate
vs. Specifications.
Check valves worn or dirty
Calibration system error
Product viscosity too high
Clean, replace if damaged
Evaluate and correct
Lower viscosity by increasing product
temperature or dilution. Increase pump
and/or piping size
Product cavitating
Increase suction pressure.
Delivery gradually
drops.
Check valve leakage.
Leak in suction line.
Strainer fouled.
Clean, replace if damaged.
Locate and correct.
Clean or replace screen.
Check viscosity and other variables.
Unplug vent.
Product change.
Supply tank vent plugged.
Leak in suction line.
Product cavitating.
Delivery erratic.
Locate and correct.
Increase suction pressure.
Entrained air or gas in product.
Motor speed erratic.
Fouled check valves.
Inadequate backpressure
Consult factory for suggested venting.
Check voltage and frequency.
Clean, replace if necessary.
Increase discharge pressure to obtain a
minimum pressure difference of 5 pis
from suction to discharge
Delivery higher than
rated.
Suction pressure higher than discharge
pressure.
Install backpressure valve or consult
factory for piping recommendations.
Increase setting.
Back pressure valve set too low.
Back pressure valve leaks.
Repair, clean, or replace.
23
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Difficulty
Probable Cause
Remedy
Reduce pressure.
Noisy gearing,
knocking
Discharge pressure too high.
Water hammer.
Stroke length at partial setting.
Install pulsation dampener.
Some operating noise is characteristic of
lost motion pumps.
Low grease level.
Pipe size too small.
Add or replace grease.
Piping noisy.
Increase size of piping - install pulsation
dampener.
Pipe runs too long.
Pulsation dampener inoperative or
flooded.
Install pulsation dampener in line.
Refill with air or inert gas. Inspect and
replace diaphragm and recharge.
Install pulsation dampeners.
Check operating conditions against pump
design. Verify discharge pressure
Check power source.
No surge chamber or dampener used.
Pump overloaded.
Motor overheats.
High or low voltage.
Loose wire.
Incorrect motor wiring
Trace and correct.
Verify and correct
24
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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 pressure relief valve to operate when the discharge pressure
exceeds operating pressure by 10-15%. Pressure relief valve should always be adjusted to a setting below
the maximum rated pressure of the pump. No potentially restrictive components, such as a valve, should
be installed between the pump discharge and the PRV.
Diaphragm Backpressure Valve
A diaphragm backpressure valve creates constant back pressure. A PTFE or PTFE-faced diaphragm
offers maximum chemical protection and service life, and seals spring and bonnet from product.
Be sure to install with fluid flow in direction of arrow on valve body.
Pulsation Dampener
A pulsation dampener is a pneumatically charged diaphragm-type chamber that intermittently stores
hydraulic energy. Used on the inlet, it can improve NPSHA (Net Positive Suction Head available)
characteristics of the suction piping system. On the discharge line it will reduce discharge pressure and
pulsating flow variations.
25
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13. Dimensional Drawing
Letters reference dimensional table on next page
26
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Dimension table in inches / mm
Letter references to diagram, previous page
“PP” = Polypropylene wetted material
“SS” = Stainless steel wetted material
Dimensions are with standard IEC 71 B14 frame motor
Dimension
C
Model
A
B
D
E
DC2
DC3
1.0 / 25.4
0.7 / 18.0
6.9 / 175.3
6.9 / 175.3
7.6 / 193.0
7.6 / 193.0
7.6 / 193.0
7.6 / 193.0
7.6 / 193.0
4.5 / 113.5
1.5 / 38.1
1.0 / 25.4
2.0 / 50.8
2.0 / 50.8
2.0 / 50.8
2.0 / 50.8
2.0 / 50.8
0.7 / 18.0
0.9 / 22.4
0.9 / 22.4
0.9 / 22.4
0.9 / 22.4
0.9 / 22.4
4.5 / 113.5
5.1 / 130.2
5.1 / 130.2
5.1 / 130.2
5.1 / 130.2
5.1 / 130.2
1.5 / 38.1
1.8 / 44.5
1.8 / 44.5
1.8 / 44.5
1.8 / 44.5
1.8 / 44.5
DC4
DC5 – PP/PVDF
DC5 – SS
DC6 – PP/PVDF
DC6 - SS
Dimension
H
Model
F
G
I
J
DC2
DC3
2.9 / 72.4
7.4 / 188.7
13.6 / 347.6
14.6 / 370.2
15.4 / 392.4
15.8 / 402.0
15.8 / 402.0
15.8 / 402.0
15.8 / 402.0
1.8 / 46.7
5.7 / 145.3
3.3 / 83.6
3.4 / 85.5
3.6 / 90.4
3.6 / 90.4
3.6 / 90.4
3.6 / 90.4
7.4 / 188.7
8.4 / 213.9
8.4 / 213.9
8.4 / 213.9
8.4 / 213.9
8.4 / 213.9
1.8 / 46.7
2.5 / 63.5
2.5 / 63.5
2.5 / 63.5
2.5 / 63.5
2.5 / 63.5
5.7 / 145.3
6.9 / 175.5
6.9 / 175.5
6.9 / 175.5
6.9 / 175.5
6.9 / 175.5
DC4
DC5 – PP/PVDF
DC5 – SS
DC6 – PP/PVDF
DC6 - SS
Dimension
M
Model
K
L
DC2
DC3
14.5 / 367.5
7.7 / 196.3
3.9 / 98.2
4.5 / 113.0
4.5 / 113.0
6.9 / 175.3
6.3 / 160.0
7.6 / 193.7
7.1 / 178.5
14.5 / 367.5
15.7 / 397.8
15.7 / 397.8
15.7 / 397.8
15.7 / 397.8
15.7 / 397.8
8.9 / 226.1
8.9 / 226.1
13.8 / 350.5
12.6 / 320.0
15.3 / 387.3
14.1 / 356.9
DC4
DC5 – PP/PVDF
DC5 – SS
DC6 – PP/PVDF
DC6 – SS
27
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14. Parts Diagrams and Parts Lists
14.1 Parts diagram, DC2 and 3
28
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14.2 Bill of Materials, DC2
ITEM
DESCRIPTION
QTY
PART NUMBER
1
SUPPORT PLATE
1
NP140054-BRS
2
DIAPHRAGM
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
4
1
1
1
1
2
1
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
NP170030-THY
NP160076-PVD
NP160054-PVC
NP160054-316
NP990420-188
NP991017-188
NP140067-ALU
L3200TC4-PVD
L3200TC4-PVC
L3200TC4-316
L3100TC4-PVD
L3100TC4-PVC
L3100TC4-316
NP430033-000
NP250084-000
NP992216-STL
NP410066-000
NP400037-000
NP070022-000
NP400041-000
NP470033-000
W206961-000
W056965-000
W047022-000
W770013-000
NP460045-000
NP250060-STL
NP990414-188
W206446-011
W206446-020
W206446-040
NP470029-000
NP410054-000
NP400039-000
NP260013-000
NP260001-GPC
NP250061-000
W771001-010
NP550084-000
W771006-STL
NP490030-000
NP490029-000
NP060031-A00
NP060031-D00
NP010024-ALU
3
REAGENT HEAD PVDF
REAGENT HEAD PVC (obsolete)
REAGENT HEAD 316
BOLT
3
3
4
5
FLT WASHER
6
DC2 SPOOL ADAPTOR
7
VLV ASSY PVDF NPT
DISCHARGE
7
VLV ASSY PVC
VLV ASSY 316
NPT
NPT
DISCHARGE (obs)
DISCHARGE
SUCTION
7
8
VLV ASSY PVDF NPT
8
VLV ASSY PVC
VLV ASSY 316
NPT
NPT
SUCTION (obs)
SUCTION
8
9
RETURN SPRING
BOTTOM COVER
10
11
12
13
14
15
16
17
17
17
18
19
20
21
22
22
22
23
24
25
26
27
28
29
30
31
32
32
33
33
34
BOTTOM COVER SCREW
STRADDLE ASSEMBLY
BEARING
ECCENTRIC
BEARING
THRUST WASHER
WORM
WORM
WORM
SCREW
GASKET
SIDE COVER
BOLT
11:1
20:1
40:1
GEAR
11:1
20:1
40:1
GEAR
GEAR
THRUST WASHER
ECCENTRIC SHAFT
BEARING
STRK ADJ ASSEMBLY
KNOB
KNOB COVER
SCREW
LABEL
WASHER
MOTOR ADAPT ASSY 56C
MOTOR ADAPT ASSY 71
WORM SHAFT ASSY 56C
WORM SHAFT ASSY IEC71
DC2/3 GEARBOX
29
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35
36
38
39
40
41
42
43
44
45
46
47
48
49
50
50
51
51
NAME TAG
1
4
2
1
1
1
1
2
1
1
1
4
4
1
1
1
1
1
NP550130-000
W771000-188
W771004-022
NP400046-000
W773097-004
NP470031-000
NP460047-000
NP990008-STA
NP450029-000
W772565-STL
W774034-STL
W770534-STL
NP991018-188
NP999041-000
NP470041-STL
NP410075-000
NP999042-000
NP999032-000
NAME TAG SCREW
SET SCREW
NEEDLE BEARING
KEY-WORM GEAR
ECCENTRIC SPACER
GASKET
SCREW
OIL SEAL
PIPE PLUG
WASHER
SPOOL ADAPTOR BOLT
SPOOL ADAPTOR WASHER
RETAINING RING 71 FRAME
RETAINER 71 FRAME
RETAINER 56C FRAME
RETAINING RING 71 FRAME
RETAINING RING 56C FRAME
30
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14.3 Bill of Materials, DC3
ITEM
DESCRIPTION
QTY
PART NUMBER
1
SUPPORT PLATE
1
NP140055-BRS
2
3
DIAPHRAGM
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
2
1
1
1
1
1
1
4
1
1
1
1
1
2
1
1
1
1
1
NP170031-THY
NP160077-PVD
NP160055-PVC
NP160055-316
NP990436-188
NP991018-188
NP140068-ALU
NP32BVC8-PVD
NP32BAA8-316
NP32BVC8-PVC
NP32PVD8-PVD
NP32PAA8-316
NP32PVC8-PVC
NP31BVC8-PVD
NP31BAA8-316
NP31BVC8-PVC
NP31PVD8-PVD
NP31PAA8-316
NP31PVC8-PVC
NP430033-000
NP250084-000
NP992216-STL
NP410066-000
NP400037-000
NP070022-000
NP400041-000
NP470033-000
W206961-000
W056965-000
W047022-000
W770013-000
NP460045-000
NP250060-STL
NP990414-188
W206446-011
W206446-020
W206446-040
NP470029-000
NP410054-000
NP400039-000
NP260013-000
NP260001-GPC
NP250061-000
W771001-010
NP550084-000
REAGENT HEAD PVDF
REAGENT HEAD PVC (obsolete)
REAGENT HEAD 316
BOLT
3
3
4
5
FLT WASHER
6
DC3 SPOOL ADAPTOR
VALVE DISCHARGE PVDF ISO 7-1
7
7
VALVE, DISCHARGE, 316,
VALVE, DISCHARGE, PVC,
ISO 7-1
7
ISO 7-1 (obs)
7
VALVE DISCHARGE PVDF NPT
VALVE, DISCHARGE, 316, NPT
VALVE, DISCHARGE, PVC, NPT (obs)
7
7
8
VALVE, SUCTION,
VALVE, SUCTION,
VALVE, SUCTION,
VALVE , SUCTION,
VALVE, SUCTION,
VALVE, SUCTION,
RETURN SPRING
BOTTOM COVER
PVDF ISO 7-1
316, ISO 7-1
8
8
PVC, ISO 7-1 (obs)
PVDF NPT
8
8
316,
NPT
8
PVC, NPT (obs)
9
10
11
12
13
14
15
16
17
17
17
18
19
20
21
22
22
22
23
24
25
26
27
28
29
30
BOTTOM COVER SCREW
STRADDLE ASSEMBLY
BEARING
ECCENTRIC
BEARING
THRUST WASHER
WORM
WORM
WORM
SCREW
GASKET
SIDE COVER
BOLT
11:1
20:1
40:1 (obsolete)
GEAR
11:1
GEAR
20:1
GEAR
40:1 (obsolete)
THRUST WASHER
ECCENTRIC SHAFT
BEARING
STRK ADJ ASSEMBLY
KNOB
KNOB COVER
SCREW
LABEL
31
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31
32
32
33
33
34
35
36
38
39
40
41
42
43
44
45
46
47
48
49
50
50
51
51
WASHER
1
1
1
1
1
1
1
4
2
1
1
1
1
2
1
1
1
4
4
1
1
1
1
1
W771006-STL
NP490030-000
NP490029-000
NP060031-A00
NP060031-D00
NP010024-ALU
NP550130-000
W771000-188
W771004-022
NP400046-000
W773097-004
NP470031-000
NP460047-000
NP990008-STA
NP450029-000
W772565-STL
W774034-STL
W770534-STL
NP991018-188
NP999041-000
NP470041-STL
NP410075-000
NP999042-000
NP999032-000
MOTOR ADAPT ASSY 56C
MOTOR ADAPT ASSY 71
WORM SHAFT ASSY 56C
WORM SHAFT ASSY IEC71
DC2/3 GEARBOX
NAME TAG
NAME TAG SCREW
SET SCREW
NEEDLE BEARING
KEY-WORM GEAR
ECCENTRIC SPACER
GASKET
SCREW
OIL SEAL
PIPE PLUG
WASHER
SPOOL ADAPTOR BOLT
SPOOL ADAPTOR WASHER
RETAINING RING 71 FRAME
RETAINER 71 FRAME
RETAINER 56C FRAME
RETAINING RING 71 FRAME
RETAINING RING 56C FRAME
32
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33
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14.4 Parts Diagram, DC4, 5, and 6
34
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14.5 Bill of Materials, DC4
ITEM
DESCRIPTION
QTY
PART NUMBER
1
SUPPORT PLATE
1
NP140055-BRS
2
3
DIAPHRAGM
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
2
1
1
1
1
NP170031-THY
NP160077-PVD
NP160055-PVC
NP160055-316
NP990436-188
NP991018-188
NP32BVC8-PVD
NP32BAA8-316
NP32BVC8-PVC
NP32PVD8-PVD
NP32PAA8-316
NP32PVC8-PVC
NP31BVC8-PVD
NP31BAA8-316
NP31BVC8-PVC
NP31PVD8-PVD
NP31PAA8-316
NP31PVC8-PVC
NP430034-000
NP250085-000
NP992216-STL
NP410067-000
NP400038-000
NP070023-000
NP400042-000
NP140068-ALU
W208764-008
W208764-010
W208764-015
W208764-030
W770010-000
NP460045-000
NP250060-STL
NP990414-188
W208765-008
W208765-010
W208765-015
W208765-030
NP470030-000
NP410055-000
NP400040-000
NP260013-000
NP260001-GPC
NP250061-000
W771001-010
REAGENT HEAD PVDF
REAGENT HEAD PVC (obsolete)
REAGENT HEAD 316
BOLT
3
3
4
5
FLT WASHER
7
VLV/CONN ISO 7-1 PVDF
VLV/CONN ISO 7-1 316
VLV/CONN ISO 7-1 PVC
VLV/CONN NPT PVDF
VLV/CONN NPT 316
VLV/CONN NPT PVC
VLV/CONN ISO 7-1 PVDF
VLV/CONN ISO 7-1 316
VLV/CONN ISO 7-1 PVC
VLV/CONN NPT PVDF
VLV/CONN NPT 316
VLV/CONN NPT PVC
RETURN SPRING
DISCHARGE
7
DISCHARGE
DISCHARGE (obs)
DISCHARGE
DISCHARGE
DISCHARGE (obs)
SUCTION
7
7
7
7
8
8
SUCTION
8
SUCTION (obs)
SUCTION
8
8
SUCT
8
SUCT (obs)
9
10
11
12
13
14
15
16
17
17
17
17
18
19
20
21
22
22
22
22
23
24
25
26
27
28
29
BOTTOM COVER
BOTTOM COVER SCREW
STRADLE ASSEMBLY
BEARING
ECCENTRIC
BEARING
DC4 SPOOL ADAPTOR
WORM
WORM
WORM
WORM
SCREW
GASKET
SIDE COVER
BOLT
8:1
10:1
15:1
30:1 (obsolete)
GEAR
8:1
GEAR
10:1
GEAR
15:1
GEAR
30:1 (obsolete)
THRUST WASHER
ECCENTRIC SHAFT
BEARING
STRK ADJ ASSEMBLY
KNOB
KNOB COVER
SCREW
35
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30
31
32
32
33
33
34
35
36
38
40
41
42
43
44
45
46
LABEL
1
1
1
1
1
1
1
1
4
2
1
1
1
2
1
4
4
NP550084-000
W771006-STL
NP490030-000
NP490029-000
NP060032-A00
NP060032-B00
NP010023-ALU
NP550130-000
W771000-188
W771004-032
W773098-004
NP999032-STL
NP460047-000
NP990008-STA
NP450029-000
W770534-STL
NP991018-188
WASHER
MOTOR ADAPT ASSY 56C
MOTOR ADAPT ASSY 71
WORM SHAFT ASSY 56C
WORM SHAFT ASSY IEC71
DC4/5 GEARBOX
NAME TAG
NAME TAG SCREW
SET SCREW
KEY-WORM GEAR
RETAINING RING
GASKET
SCREW
OIL SEAL
SPOOL ADAPTOR BOLT
SPOOL ADAPTOR WASHER
36
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14.6 Bill of Materials, DC5
ITEM
DESCRIPTION
QTY
PART NUMBER
1
SUPPORT PLATE
1
NP140071-BRS
2
3
DIAPHRAGM
1
1
1
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
2
1
1
1
NP170037-THY
NP160022-PVD
NP160022-PPL
NP160017-PVC
NP160004-316
NP990436-188
NP991018-188
NP87NLFUCJ-DISC
NP87NLFUCJ-BDIS
NP87AAAUCJ-DISC
NP87AAAUCJ-BDIS
NP87SLVUCJ-DISC
NP87SLVUCJ-BDIS
NP87NLFUCJ-SUCT
NP87NLFUCJ-BSUC
NP87AAAUCJ-SUCT
NP87AAAUCJ-BSUC
NP87SLVUCJ-SUCT
NP87SLVUCJ-BSUC
NP430034-000
NP250085-000
NP992216-STL
NP410067-000
NP400038-000
NP070023-000
NP400042-000
NP140069-ALU
W208764-008
REAGENT HEAD PVDF
REAGENT HEAD PP
REAGENT HEAD PVC
REAGENT HEAD 316
BOLT
3
3
3
4
5
FLT WASHER
7
VLV ASSY DISCHARGE PVDF NPT
VLV ASSY DISCHARGE PVDF ISO 7-1
7
7
VLV ASSY DISCHARGE 316
VLV ASSY DISCHARGE 316
VLV ASSY DISCHARGE PVC
VLV ASSY DISCHARGE PVC
NPT
7
ISO 7-1
7
NPT (obs)
ISO 7-1 (obs)
7
8
VLV ASSY SUCTION
VLV ASSY SUCTION
VLV ASSY SUCTION
VLV ASSY SUCTION
VLV ASSY SUCTION
VLV ASSY SUCTION
RETURN SPRING
BOTTOM COVER
BOTTOM COVER BOLT
STRADLE ASSEMBLY
BEARING
PVDF NPT
PVDF ISO 7-1
8
8
316
NPT
8
316
ISO 7-1
8
PVC
PVC
NPT (obs)
ISO 7-1 (obs)
8
9
10
11
12
13
14
15
16
17
17
17
17
18
19
20
21
22
22
22
22
23
24
25
26
27
28
ECCENTRIC
BEARING
DC5 SPOOL ADAPTOR
WORM
WORM
WORM
WORM
SCREW
GASKET
SIDE COVER
BOLT
8:1
10:1
W208764-010
15:1 (obsolete)
30:1 (obsolete)
W208764-015
W208764-030
W770010-000
NP460045-000
NP250060-STL
NP990414-188
W208765-008
GEAR
8:1
GEAR
10:1
W208765-010
GEAR
15:1 (obsolete)
30:1 (obsolete)
W208765-015
GEAR
W208765-030
THRUST WASHER
ECCENTRIC SHAFT
BEARING
NP470030-000
NP410055-000
NP400040-000
NP260013-000
NP260001-GPC
NP250061-000
STRK ADJ ASSEMBLY
KNOB
KNOB COVER
37
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29
30
31
32
32
33
33
34
35
36
38
40
41
42
43
44
45
46
47
48
49
SCREW
1
1
1
1
1
1
1
1
1
4
2
1
1
1
2
1
4
4
2
8
8
W771001-010
NP550084-000
W771006-STL
NP490030-000
NP490029-000
NP060032-A00
NP060032-B00
NP010023-ALU
NP550130-000
W771000-188
W771004-032
W773098-004
NP999032-STL
NP460047-000
NP990008-STA
NP450029-000
W770534-STL
NP991018-188
NP360004-000
NP990435-188
NP991018-188
LABEL
WASHER
MOTOR ADAPT ASSY 56C
MOTOR ADAPT ASSY 71
WORM SHAFT ASSY 56C
WORM SHAFT ASSY IEC71
DC4/5 GEARBOX
NAME TAG
NAME TAG SCREW
SET SCREW
KEY-WORM GEAR
RETAINING RING
GASKET
SCREW
OIL SEAL
SPOOL ADAPTOR BOLT
SPOOL ADAPTOR WASHER
TIEBAR
TIEBAR BOLT
TIEBAR WASHER
38
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14.7 Bill of Materials, DC6
ITEM
DESCRIPTION
QTY
PART NUMBER
1
SUPPORT PLATE
1
NP140081-STL
2
3
DIAPHRAGM
1
1
1
1
6
6
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
NP170039-THY
NP160023-FPP
NP160023-PVD
NP160031-316
NP990477-188
NP991018-188
NP87NLFUCJ-DISC
NP87NLFUCJ-BDIS
NP87AAAUCJ-DISC
NP87AAAUCJ-BDIS
NP87NLFUCJ-SUCT
NP87NLFUCJ-BSUC
NP87AAAUCJ-SUCT
NP87AAAUCJ-BSUC
NP430034-000
NP250085-000
NP992216-STL
NP410067-000
NP400038-000
NP070023-000
NP400042-000
NP140080-ALU
W208764-008
REAGENT HEAD FPP
REAGENT HEAD PVDF
REAGENT HEAD 316
BOLT
3
3
4
5
FLT WASHER
7
VLV ASSY DISCHARGE PVDF NPT
VLV ASSY DISCHARGE PVDF ISO 7-1
7
7
VLV ASSY DISCHARGE 316
VLV ASSY DISCHARGE 316
NPT
7
ISO 7-1
8
VLV ASSY SUCTION
VLV ASSY SUCTION
VLV ASSY SUCTION
VLV ASSY SUCTION
RETURN SPRING
BOTTOM COVER
BOTTOM COVER BOLT
STRADLE ASSEMBLY
BEARING
PVDF NPT
8
PVDF ISO 7-1
8
316
316
NPT
8
ISO 7-1
9
10
11
12
13
14
15
16
17
17
18
19
20
21
22
22
23
24
25
26
27
28
29
30
31
32
32
33
33
ECCENTRIC
BEARING
DC5 SPOOL ADAPTOR
WORM
WORM
SCREW
GASKET
SIDE COVER
BOLT
8:1
10:1
W208764-010
W770010-000
NP460045-000
NP250060-STL
NP990414-188
W208765-008
GEAR
8:1
GEAR
10:1
W208765-010
THRUST WASHER
ECCENTRIC SHAFT
BEARING
NP470030-000
NP410055-000
NP400040-000
NP260013-000
NP260001-GPC
NP250061-000
W771001-010
STRK ADJ ASSEMBLY
KNOB
KNOB COVER
SCREW
LABEL
NP550084-000
W771006-STL
WASHER
MOTOR ADAPT ASSY 56C
MOTOR ADAPT ASSY 71
WORM SHAFT ASSY 56C
WORM SHAFT ASSY IEC71
NP490030-000
NP490029-000
NP060032-A00
NP060032-B00
39
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34
35
36
38
40
41
42
43
44
45
46
47
48
49
DC4/5/6 GEARBOX
NAME TAG
1
1
4
2
1
1
1
2
1
4
4
2
8
8
NP010023-ALU
NP550130-000
W771000-188
W771004-032
W773098-004
NP999032-STL
NP460047-000
NP990008-STA
NP450029-000
W770534-STL
NP991018-188
NP360004-000
NP990435-188
NP991018-188
NAME TAG SCREW
SET SCREW
KEY-WORM GEAR
RETAINING RING
GASKET
SCREW
OIL SEAL
SPOOL ADAPTOR BOLT
SPOOL ADAPTOR WASHER
TIEBAR
TIEBAR BOLT
TIEBAR WASHER
40
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41
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STANDARD PUMP OPERATIONS
27101 Airport Road
Punta Gorda, FL
(941) 575-3800
33982
Fax (941) 575-4085
Bulletin #: IOM-OM-1104- E
Rev E
42
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